Industrial Gas Turbines Aftermarket Parts, Repairs & Services
Industrial Gas Turbine New Parts
Industrial Gas Turbine Repair
Aftermarket Field Services
About Us
Industrial Gas Turbine New Parts
Industrial Gas Turbine Repair
Aftermarket Field Services
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About UsPW Power Systems is a world leader in developing and manufacturing energysolutions for power generation offering products for aero-derivative andindustrial gas turbines. PWPS offers a full range of maintenance, overhaul, repairand spare parts for other manufacturers’ gas turbines with specificconcentration on the high-temperature “F”-class industrial machines. PWPSalso offers quick turnaround for parts and repair services utilizing the latest incomponent repair technology integrated from Pratt & Whitney® GlobalAftermarket Service expertise.
PW Power Systems is committed to providing high-quality solutions for thedistributed energy market that increase energy productivity, energy reliability,and operational savings for our customers.
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PW Power Systems designs, reengineers and manufacturescomponents for use in land-based Industrial Gas Turbine(IGT) applications. As part of the portfolio of componentsand services available, PWPS produces and repairsreplacement parts for the hot gas path (HGP) from otherOEMs of large-frame gas turbines.
The PWPS™ components are manufactured using Pratt & Whitney® proprietary alloys and coatings. Thesematerials, coupled with aerospace and industrial designtechnology and quality systems, enable users to install these components and operate their equipment with no degradation in machine performance while realizingimproved durability of the hot gas path components.
PWPS™ solutions allow customers to develop a degree ofconfidence that is unparalleled in the industry. PWPSexperience with HGP parts and repairs is based oncomparisons of distress modes observed in the fleet.
At PW Power Systems, it is our goal to provide value- basedgas turbine solutions for our customers by incorporatingcustomer feedback, component optimization and theadvantage of over 80 years of technology developmentfrom our extensive high-temperature aviation heritage.
PWPS is leveraging Pratt & Whitney® world-renowned hotsection engineering to address the needs of the industrialgas turbine customer.
PWPS has an extensive proven history of producingindustry-leading technological solutions. We utilize thisadvantage by applying our proprietary technology to createnew and innovative solutions for our industrial customers.
Industrial Gas Turbine New Parts
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OEM Part
ScanningScanned Data
Initial CAD Model Systems & Aero Analysis
Design/Analysis Multidisciplinary Optimization
BaselineNew
Final Definition
New PWPS™ Part
Engineering Standard WorkThe Foundation for Quality
“PWPS has surpassed over 1.5 millionhours of accumulated run time on itsFrame 7FA.03 (7FA+e) HGP components.”
Industrial Gas Turbine Enhanced New PartsAdvanced Proprietary Technology includes:
• High-Temperature Technology
• Proprietary Alloys
• Metallic Coatings
• Ceramic Coatings
• Film Cooling
• Multidisciplinary Optimization
• Tip Clearance Material Systems
• Advanced Computational Modeling Techniques
60 HZ Portfolio offering
• Frame 7FA.03 1st, 2nd and 3rd Stage Buckets, Nozzles & Shroud Blocks
• 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
• STG5-4000F (V94.3A4x) Hot Gas Path Components
• 1st, 2nd, 3rd, 4th stage Blades & Vanes
• Blade outer air seals (BOAS)
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ProjectLaunch Metrology Detailed
DesignPreliminary
DesignProduction
Final IPClearance
PatentApplications
Valid Claims
ClearedFeatures
EngineeringAnalysis
Prelim IPAssessment
Features List
IP RiskIdentification
Product Development ProcessRobust intellectual property strategy integrated into reengineering design
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PW Power Systems™ Experience and Technology Differentiating from the Competition
Market Data & Sourcefor Parts
Reverse Engineer
Existing Parts & Engine
Equipment
Enhance Design / System
IntegrationManufacturingDevelopment Validation Manufacturing
& Sourcing
PWPS™
Sales ProductionCMM
TechnologyComputationalFluid Dynamics
ProductionQualificationProcessing
Testing &Producibility
OpticalTechnology
DurabilityAnalysis
Wax Molding StructuralAnalysis
SOAPPAnalysis
Finite ElementHeat Distribution
Analysis
Materials &Coatings
Copying vs Redesigning
• Multiple Disciplinary Optimization allows for extensive exploration of design options while monitoring many design constraints
• Iterations effectiveness maximized
PW Power Systems Design Toolbox:
ID RiskAnalysis
Industrial Gas Turbine RepairOverview
PW Power Systems™ IGT repair activities are directed from our San Antonio Centerof Excellence. Originally installed as an aero engine repair facility supportingmilitary and commercial customers, this facility is now solely dedicated to IGTrepair. The same level of rigor and competency has been extended into theefficient repair of industrial gas turbine components. Each component repair isdriven by documented repair procedures, process control and inspectionmethods, ensuring the highest quality levels.
A significant investment in equipment and facility improvements has been madeover the last several years as we have transformed this facility into a dedicatedindustrial gas turbine facility. With that investment in our facility, it will continueto expand our capabilities and retain the best technical talent in the industry.
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The vast majority of all repair processing required isperformed in-house with minimal vendor-supportedoperations. This helps ensure the highest levels of qualityand schedule control. On-site process capabilities includebut 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 andexecute advanced IGT repairs resides on-site inour San Antonio facility, fortified by the depth and technical resources of over 80 years of turbine engine expertise.
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ENGINEERING GATE
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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
Gated Repair Process
INDUCT STRIP & INSPECT
COAT & FINISHREPAIR PACK & SHIP
“PWPS has successfully repaired over 500 sets of F-class HGP components.”
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Engine Types with Repair Experience
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
Standardized Repair Methodology
TWP – Technical Work Package
Technical requirements
Defines key characteristics
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 WorkInstruction group unique to a specific operation/part
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Turnkey Outage Services
Project Management
Gas/Steam Turbine Minor and Major Inspections
Generator Inspections
Rotor Life Assessments
Failure and Root Cause Analysis
Outage Parts Kits
Balance, Tuning and NDE
Turbine Control Troubleshootingand Upgrade
Remote Monitoring andDiagnostics
Aftermarket Field ServicesPW Power Systems has strategic alliances with best-in-class service providers todeliver the entire portfolio of power plant services, enabling PWPS to deliver thehighest 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 cost-effective manner. PWPS supports a wide range of power generation equipmentincluding gas turbine, steam turbine, generator and auxiliary equipment.
PWPS is ready to provide a highly experienced team to investigate, plan andexecute solutions to meet your turbine generator requirements.
The PWPS™ objective is to provide total service and support throughout theAmericas, Europe, Asia and the Middle East, helping power producers achieve thehighest levels of availability, reliability and profit.
Contracted Service Agreements
PWPS offers flexible, customizable maintenance agreements to fit your specific requirements.
Maintenance objectives have moved from preservation and protection to costreduction and optimization. Power producers need optimized maintenancesolutions 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.
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PW Power Systems, Inc.628 Hebron Avenue, Suite 400Glastonbury, CT 06033
www.pwps.comPS-S00365/2013
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.