Turbine Services Ltd, Group Engineering Presentation

Turbine Services Ltd, GroupEngineering Presentation

Turbine Services LimitedReplacement Parts for GE Design Large Frame Gas Turbine Parts

Engineered more than700 turbine parts including 50 rotating blades 30 stationary vanes

Developed 7 complete product lines namely MS 3002, MS 5001, MS 5002, MS 5001NT, MS 6001, MS 7001, MS

9001

Product-to-market development cycle as low as 14 months for capital parts and even lower for other turbine parts

State Of The Art Equipment To Design & Analyze Turbine Components

OVERVIEW

Turbine Services Limited

REVERSE ENGINEERING

Replacement Parts for GE Design Large Frame Gas Turbine Parts

DATA COLLECTION

REVERSE

ENGINEERING

VALIDATION

OF DESIGN


REVERSE ENGINEERING


DATA COLLECTION

REVERSE

ENGINEERIN

G

VALIDATION

OF DESIG

N

TECHNIQUES/ METHODS• Point Cloud Data Collection

• White Light Scanner – GOM• Laser Scanner- Nvision

• Conventional Data Collection• Coordinate Measuring Machine (CMM)• Verniers, Calipers, Height Gauge

• Material• Xray Material Analyzer

• Thicknesses, Hardness etc• Ultrasonic probe• Hardness Tester

• Extra/ Hidden Features• XRAY• Boroscope Analysis


REVERSE ENGINEERING


DATA COLLECTION

REVERSE

ENGINEERIN

G

VALIDATION

OF DESIG

NREVERSE ENGINEERING

• 3D Modeling and Design• 2D Drawing• Material Specification• Process Specification• Inspection Report


REVERSE ENGINEERING


DATA COLLECTION

REVERSE

ENGINEERIN

G

VALIDATION

OF DESIG

NVALIDATION OF DESIGN

• Prototyping• Stereo Lithography Model (SLA)

• Finite Element Analysis


RESEARCH & DEVELOPMENT

BRUSH SEAL Direct replacement to OEM Brush Seal

Technology Improves Efficiency with advanced sealing

1.0% output 0.5% heat rate

Improved Durability Increased Efficiency Reduced Leakage



RESEARCH & DEVELOPMENT

TechnologyThe SL+™ package, engineered and manufactured by TSL® includes newly designed combustion parts with improved features including:

• Improved clearance• Addition of wear resistant materials • Thermal Barrier Coating (TBC)

Advantages• Extension of gas turbine Combustion Inspection interval• Reduction in Maintenance and Refurbishment Costs• Increase service life of parts



MANUFACTURING


CASTING


MANUFACTURING


CASTING MACHINING COATING

THE CASTING PROCESS


MANUFACTURING



THE CASTING PROCESS


MANUFACTURING


• All TSL blades and vanes are manufactured with Super alloyso Super Alloys are a class of material that represent the highest level of alloy chemistry and process

metallurgy in current aerospace and land based power generation industry. Super alloys run at 90% of their melting point.

• All hot section part manufactured by TSL are prepared from controlled virgin/remelt ratios using Vacuum Slag Remelt (VSR) or Electro Slag Remelt (ESR) to ensure cleanliness of alloy

• TSL requires certified chemical/mechanical properties of sample coupons or test bars for each master melt lot to ensure the integrity of the alloy.

• Manufactures both Equiax and Directionally Solidified parts

ALLOYS



MANUFACTURING


• All capital parts tooling are owned by TSL • Each capital part has a complete set of tooling

• Wax injection tooling• Assembly fixture• Checking gauges

TSL TOOLING

HEAT TREATMENT

• Castings are thermally processes for optimum strength

QUALITY CONTROL PLAN• TSL requires first article sample piece to validate suppliers’

casting process• Supplier submit process demonstration report • Independent testing of first article to validate supplier’s

process• Regular on site audit to ensure uniformity of processes



MANUFACTURING


CASTING

MACHINING

COATING

• Parts are machined to finished dimensions using• Stress free grinding, Turning, Milling

• TSL owns all machining tooling

CONVENTIONAL MACHINING

• Internal Cooling holes and other features are inserted by• Electric discharge machining (EDM)• Shaped Tube Electrochemical Machining (STEM)• Electrochemical Machining (ECM)

Internal Cooling holes are used to keep the core material of the blades and vanes cool at running temperatures

NON CONVENTIONAL MACHINING

QUALITY CONTROL PLAN• TSL requires first article sample piece to validate supplier’s process• Supplier submit manufacturing process plan• TSL conduct internal dimensional inspection to validate part• Regular on site audit to ensure uniformity of processes


MANUFACTURING


CASTING

MACHINING

COATING

TSL applies all the updated coating to our turbine parts namely:• Thermal Barrier Coating TBC

• For enhanced heat resistance• Chemical Vapor Deposition (CVD) Aluminide

• In cooling passages to resist corrosion and oxidation• Stellite strips inserts by High Velocity Oxy Fuel (HVOF)

• Increases wear resistance of parts by acting as sacrificial wear agent• Duplex Coating Systems (MCrAlY, NiCoCrAlY, CoNiCrAlY)

• Applied to allow blades and vanes to operate at high temperatures by resisting oxidation and corrosion

• Preserves the strengthening mechanisms of the base material• Plasma Coating

• Increases corrosion resistance.

TSL also Shot Peen blades to add compressive surface stress the structure and HIP (Hot Isostatic Pressing) to eliminate microporosity.

Turbine Services Ltd, GroupDelivering Quality Anywhere In The

World

Largest Non-OEM Manufacturer In The World Highly Experienced Engineering Personnel Unequaled product-to-market development cycles State of The Art Engineering Capabilities Manufacture parts with the latest turbine manufacturing technology Stringent Quality Control

Turbine Services, Ltd. Group41 Old Gick Road, Saratoga Springs, NY 12866

Phone: 518-583-6191 – Fax: 518-583-4094Email: [email protected]

Web: http://www.turbineservices.com

Conclusion

Documents

Turbine Services Ltd, Group Engineering Presentation