Industrial Gas Turbines Aftermarket Parts, Repairs & Services. Industrial Gas Turbine New Parts. Industrial Gas Turbine Repair

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1 Industrial Gas Turbine New Parts Industrial Gas Turbine Repair Aftermarket Field Services Industrial Gas Turbines Aftermarket Parts, Repairs & Services

2 About Us Industrial Gas Turbine New Parts Industrial Gas Turbine Repair Aftermarket Field Services

3 About Us PW Power Systems is a world leader in developing and manufacturing energy solutions for power generation offering products for aero-derivative and industrial gas turbines. PWPS offers a full range of maintenance, overhaul, repair and spare parts for other manufacturers gas turbines with specific concentration on the high-temperature F -class industrial machines. PWPS also offers quick turnaround for parts and repair services utilizing the latest in component repair technology integrated from Pratt & Whitney Global Aftermarket Service expertise. PW Power Systems is committed to providing high-quality solutions for the distributed energy market that increase energy productivity, energy reliability, and operational savings for our customers. 1

4 Industrial Gas Turbine New Parts PW Power Systems designs, reengineers and manufactures components for use in land-based Industrial Gas Turbine (IGT) applications. As part of the portfolio of components and services available, PWPS produces and repairs replacement parts for the hot gas path (HGP) from other OEMs of large-frame gas turbines. The PWPS components are manufactured using Pratt & Whitney proprietary alloys and coatings. These materials, coupled with aerospace and industrial design technology and quality systems, enable users to install these components and operate their equipment with no degradation in machine performance while realizing improved durability of the hot gas path components. At PW Power Systems, it is our goal to provide value- based gas turbine solutions for our customers by incorporating customer feedback, component optimization and the advantage of over 80 years of technology development from our extensive high-temperature aviation heritage. PWPS is leveraging Pratt & Whitney world-renowned hot section engineering to address the needs of the industrial gas turbine customer. PWPS has an extensive proven history of producing industry-leading technological solutions. We utilize this advantage by applying our proprietary technology to create new and innovative solutions for our industrial customers. PWPS solutions allow customers to develop a degree of confidence that is unparalleled in the industry. PWPS experience with HGP parts and repairs is based on comparisons of distress modes observed in the fleet. 2

5 Engineering Standard Work The Foundation for Quality OEM Part Industrial Gas Turbine Enhanced New Parts Advanced Proprietary Technology includes: High-Temperature Technology Proprietary Alloys Metallic Coatings Ceramic Coatings Film Cooling Multidisciplinary Optimization Tip Clearance Material Systems Advanced Computational Modeling Techniques Scanned Data Initial CAD Model New Scanning Systems & Aero Analysis Baseline 60 HZ Portfolio offering Frame 7FA.03 1st, 2nd and 3rd Stage Buckets, Nozzles & Shroud Blocks Design/Analysis Multidisciplinary Optimization Frame 7FA.03 DLN 2.6 Transition Pieces, Liners, Flowsleeves, Liner End Cap, Fuel Nozzles Frame 6B 1st Stage Bucket Frame 7EA 1st Stage Bucket 50 HZ Portfolio offering High-Temperature-Class hardware Final Definition STG5-4000F (V94.3A4x) Hot Gas Path Components 1st, 2nd, 3rd, 4th stage Blades & Vanes Blade outer air seals (BOAS) PWPS has surpassed over 1.5 million hours of accumulated run time on its Frame 7FA.03 (7FA+e) HGP components. New PWPS Part 3

6 Product Development Process Robust intellectual property strategy integrated into reengineering design Project Launch Metrology Preliminary Design Detailed Design Production Engineering Analysis Features List Final IP Clearance Prelim IP Assessment IP Risk Identification Valid Claims Cleared Features Patent Applications 4

7 PW Power Systems Experience and Technology Differentiating from the Competition Copying vs Redesigning Market Data & Source for Parts Reverse Engineer Existing Parts & Engine Equipment Enhance Design / System Integration Manufacturing Development Validation Manufacturing & Sourcing PWPS Sales CMM Technology Computational Fluid Dynamics Production Qualification Processing Testing & Producibility Production Optical Technology Durability Analysis Wax Molding Structural Analysis SOAPP Analysis ID Risk Analysis Finite Element Heat Distribution Analysis Materials & Coatings PW Power Systems Design Toolbox: Multiple Disciplinary Optimization allows for extensive exploration of design options while monitoring many design constraints Iterations effectiveness maximized 5

8 Industrial Gas Turbine Repair Overview PW Power Systems IGT repair activities are directed from our San Antonio Center of Excellence. Originally installed as an aero engine repair facility supporting military and commercial customers, this facility is now solely dedicated to IGT repair. The same level of rigor and competency has been extended into the efficient repair of industrial gas turbine components. Each component repair is driven by documented repair procedures, process control and inspection methods, ensuring the highest quality levels. A significant investment in equipment and facility improvements has been made over the last several years as we have transformed this facility into a dedicated industrial gas turbine facility. With that investment in our facility, it will continue to expand our capabilities and retain the best technical talent in the industry. 6

9 The vast majority of all repair processing required is performed in-house with minimal vendor-supported operations. This helps ensure the highest levels of quality and schedule control. On-site process capabilities include but are not limited to: Elevated Temperature Welding Manual TIG Welding Laser Welding Vacuum Heat Treat Braze Crack Repair CNC Shot Peen Robotic HVOF Plasma Robotic APS Plasma Grit Blast Blending Airflow; Water Flow Digital 450kv X-Ray Heat Tint FPI CMM Bridgeport Machining EDM Plunge and Hole Drill CNC Machining Center Submerged Ultra-sonic Inspection System FSET (Frequency Scanning Eddy Current Test) System 5-axis CNG Grinding The technical expertise required to develop and execute advanced IGT repairs resides on-site in our San Antonio facility, fortified by the depth and technical resources of over 80 years of turbine engine expertise. 7

10 PWPS has successfully repaired over 500 sets of F-class HGP components. Gated Repair Process INDUCT STRIP & INSPECT REPAIR COAT & FINISH PACK & SHIP ENGINEERING GATE Strip & Inspect Process Steps Mark ID and Incoming VIS Photo-Document Incoming Metallurgical Assessment Disassembly X-ray Airflow Grit Remove TBC Chemical or Water-Jet Strip Heat Tint Blend Residual Coating FPI, Dimensional Photo-Document Post Strip Generate Report Engineering Gate Repair Process Steps Machine/Rout Defects Solution Vacuum Heat Treat FPI Weld Repair Blend Repairs Hot Isostatic Press (HIP) if reqd FPI/Rework Machine/CNC Vacuum Heat Treat EDM Cooling Holes Blend/De-burr Grit Blast Clean FPI Heat Tint X-ray Airflow Water Flow Dimensional Pre-Coat VIS Engineering Gate Coat & Finish Heat Tint Al Coat Internals (if applicable) Mask for Coat HVOF (if applicable) Diffusion Vacuum HT APS TBC Coat (if applicable) Diffusion and Age Vacuum HT De-burr Cooling Holes Heat Tint Shot Peen Rail Coat Cosmetic Clean Airflow; Water Flow X-ray Dimensional Inspect Final Inspect Visual Moment Weigh & Sequence Engineering Gate 8

11 Standardized Repair Methodology Engine Types with Repair Experience TWP Technical Work Package Technical requirements Defines key characteristics Frame 6B Frame 7B/7EA Frame 6FA Frame 7FA.03 F rame 9FA+e F rame 9E V84.2 V94.2 V84.3A V94.3A2/A4 W501F W501D5/D5A Router (Traveler) Sequenced operational process steps Piece-by-piece traceability Work Instructions Instructions for performing a specific type of operation (blending, welding, moment weight, airflow, etc.) Technique Sheet Detailed parameters and specific instructions within a Work Instruction group unique to a specific operation/part 9

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13 Aftermarket Field Services PW Power Systems has strategic alliances with best-in-class service providers to deliver the entire portfolio of power plant services, enabling PWPS to deliver the highest quality and most cost-effective maintenance solutions to our customers. Field Service PWPS offers fully integrated outage services capable of completing emergency, unplanned or scheduled maintenance in a timely, safe, high-quality and costeffective manner. PWPS supports a wide range of power generation equipment including gas turbine, steam turbine, generator and auxiliary equipment. PWPS is ready to provide a highly experienced team to investigate, plan and execute solutions to meet your turbine generator requirements. The PWPS objective is to provide total service and support throughout the Americas, Europe, Asia and the Middle East, helping power producers achieve the highest levels of availability, reliability and profit. Turnkey Outage Services Project Management Gas/Steam Turbine Minor and Major Inspections Generator Inspections Rotor Life Assessments Contracted Service Agreements Failure and Root Cause Analysis Outage Parts Kits Balance, Tuning and NDE Turbine Control Troubleshooting and Upgrade Remote Monitoring and Diagnostics PWPS offers flexible, customizable maintenance agreements to fit your specific requirements. Maintenance objectives have moved from preservation and protection to cost reduction and optimization. Power producers need optimized maintenance solutions to cover the life cycle of the power plant, allowing for: Risk Management Control Operational Costs Guarantee Performance Technology Advancements PWPS is an integral part of an ever-changing market continually offering advanced service solutions. 11

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16 The export is made under the authority of No License Required (NLR). ECCN EAR99 No SED required per 30.55(h) FTSR. These commodities, technology, or software were exported from the United States in accordance with the Export Administration Regulations. Diversion contrary to U.S. Law prohibited. Copyright 2013 PW Power Systems, Inc. PW is a trademark of United Technologies Corporation. Used with permission. Pratt & Whitney is a trademark of United Technologies Corporation. Used with permission. PW Power Systems, Inc. 628 Hebron Avenue, Suite 400 Glastonbury, CT PS-S0036 5/2013