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.