6FA user conference Lisbon

Presentation 6FA conference 8th April 2014

Introduction & Agenda

■ Sulzer team present:

■ Luc Gooren (Design Manager New Parts)
■ Peter van Neerven (Regional Sales Manager ME & ASA)
■ Ervin Mom (Product Manager Parts)
■ Anton Wesselman (Product Manager TS&O)
■ Howard Peeters (Regional Sales Manager Europe & Africa)

■ Agenda
■ Sulzer introduction and overview of 6FA service capabilies (Howard Peeters)
■ 6FA new parts development program update (Luc Gooren)
■ 6FA repair capabilities (Ervin Mom)
■ Questions & answers (open discussion)

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Sulzer Rotating Equipment Services

Services for rotating equipment

Mechanical Electromechanical Pump services
Turbines and compressors Generators and motors Pumps

Service integration

■ Complete service offering for all rotating equipment and global presence
■ Increase customer benefits through one access point
■ Leverage existing assets and capabilities
■ Technology leadership and deep technical expertise

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Sulzer Service portfolio for the 6FA (+e)

■ New part supply for 6FA (+e)

■ Refurbishment and life time extension of all 6FA (+e) components
■ Field Services
■ CI, HGP, MO
■ Sulzer can perform all these types of outages fully by its own
■ Long Term Service agreements
■ Two LTSA contracts for 12 years covering 5 units including generators
■ 6FA +e DLN 2.6, Mark VIe

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 Transition piece
 Liner
 Liner cap
 Fuel nozzles
 Stage 1 bucket
 Stage 2 bucket
 Stage 3 bucket
 Stage 1 nozzle
 Stage 2 nozzle
 Stage 3 nozzle
 Stage 1 shroud
 Stage 2 shroud
 Stage 3 shroud

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Re-design

Quality Assurance

Re-design Machining
Manufacturing
Coating Delivery

Product Project Data Modeling &

IPR Final review
enquiry definition collection engineering

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Manufacturing

Quality Assurance

Re-design Machining
Manufacturing
Coating Delivery

Casting Machining Coating Delivery

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DLN 2.6 combustion
Transition piece

• Nimonic 263
• Impingement cooled
• TBC coating system

Liner

• Nimonic 263
• Turbulated outer wall cooling
• Advanced cooling outlet liner
• TBC coating system

Liner cap

• Hastelloy X effusion plate

• Effusion cooled

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DLN 2.6 combustion
Bull horn

• AISI 304
• Haynes 25 Wear covers

Cross-fire tubes

• Haynes 188

DLN 2.6 Fuel nozzles

• Austenitic steel
• Cast faired swirler
• Gas only & dual fuel

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6FA+e buckets
S1 bucket

• DS EEQ110
• Platform undercut
• LE and tip cooling holes
• TE exit cooling holes
• TBC coating system
• Int. Al diffusion coating
• Installation hardware included

S2 bucket

• EEQ111
• 10 cooling hole design
• Turbulated radial cooling holes
• TBC coating system
• Int. Al diffusion coating
• Cutter teeth
• Installation hardware included

S3 bucket

• EEQ110
• Non cooled
• Cutter teeth
• Installation hardware included

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6FA+e nozzles
S1 nozzle

• FSX414
• TBC coating system
• Film cooling
• Installation hardware included

S2 nozzle

• EEQ220
• Enhanced cooling
• Optimised TE cooling
• Al diffusion coated
• Installation hardware included

S3 nozzle

• EEQ220
• Impingment cooled OS
• Installation hardware included

| slide 11
6FA+e shrouds
S1 shroud

• IN738LC
• Duo piece design
• Impingment cooling
• Abradable coating
• Installation hardware included

S2 shroud

• IN738LC
• Honeycomb sealing
• Installation hardware included

S3 shroud

• AISI 310
• Honeycomb sealing
• Installation hardware included

| slide 12
Parts in process

| slide 13
Parts in process

| slide 14
Parts in process

| slide 15
First set ready
 First two sets of stage 3 buckets delivered to customer
Part Q1 2014 Q2 2014 Q3 2014 Q4 2014 Q1 2015 Q2 2015

Compressor

DLN 2.6 Transition piece

DLN 2.6 Liner

DLN 2.6 Liner cap

DLN 2.6 Fuel nozzle

Crossfire tubes

Stage 1 bucket

Stage 2 bucket

Stage 3 bucket

Stage 1 nozzle

Stage 2 nozzle

Stage 3 nozzle

Stage 1 shroud

Stage 2 shroud

Stage 3 shroud

Stage 1 turbine disc

12 pad thrust bearing upgrade

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6FA / 6FA+e HGP interchangeability
 Sulzer 6FA+e parts are interchangeable with 6FA parts

Replacement Replacement
Part Remarks
6FA Sulzer 6FA+e

Stage 1 bucket 2 3 Upgrade of 12 pad thrust bearing and oil supply orifice required.

Stage 2 bucket 1 3 Life improved part

Stage 3 bucket 3 3 Outside of TIL 1708 scope

Stage 1 nozzle 3 3 TE cutback required, improved cooling, TBC coated (under investigation)

Stage 2 nozzle 3 3 Enhanced core plug cooling

Stage 3 nozzle 3 3

Stage 1 shroud 2 2 Abradable coating

Stage 2 shroud 2 2

Stage 3 shroud 3 3 6FA (20 pc), 6FA+e (24 pc), turbine casing machining optional

| slide 17
GE 6FA & FA+e Inspection and Repair

| slide 18
 6FA & 6FA+e Inspection and Repair

• Compressor section

• Combustion system DLN 2.0&2.6

- Endcovers
- Fuel Nozzles
- Combustion Chamber
- Transition Piece
- Cross fire tubes

• Turbine Buckets

• Turbine Nozzles

• Turbine shrouds

• Turbine rotor and casing

| slide 19
6FA & 6FA+e DLN 2.0 & 2.6 combustion repair
Transition piece

• Inspection / 360º Simulation Fixture

• Weld Repair
• H-block re-alignment
• Picture Frame Replacement
• Hardware Replacement
• Vacuum heat treatment
• Class-B/C TBC Coatings
• Hard-Face Coatings
• Impingement sleeve repair

Liner

• Inspection / Flow Testing

• Weld Repair/CNC Machining
• Patch repairs
• Hardware replacement
• Vacuum heat treatment
• Class-C TBC Coatings
• Hardface coating
• Assembly checking by fixture

Liner cap

• Inspection
• Disassembly
• Weld Repair
• Hardware Replacement
• Perforated Plate Repair/Replacement
• Laser Drilling / EDM Machining
• Assembly / Installation

| slide 20
6FA & 6FA+e DLN 2.0 & 2.6 combustion repair
Bull horn

• AISI 304
• Haynes 25 Wear covers
• Inspection
• Weld repair within economical
limits

Cross-fire tubes

• Haynes 188 – AISI 310

• Inspection
• Weld repair

DLN 2.0 & 2.6 Fuel nozzles

• Inspection
• Flow Testing
• Disassembly
• Weld/Braze repair
• Sectional replacements
• Field Installation/Borescope
• Bellow replacement
• Hardware Replacement
• Upgrade

Endcovers

• Inspection
• Flow Testing
• Disassembly
• Weld/braze repair
• Inert replacement
• Leak testing
• Hardware replacement
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6FA & 6FA+e bucket repair
S1 bucket

• Inspection / Fluorescent NDT / flow measurement

• Weld Repair
• Laser Weld Repairs
• Squealer Tip Repair / Tip Grinding
• Tip cap repair/replacement
• EDM cooling holes/TE cut back
• Vacuum Heat Treatment
• TBC Airfoil Coating
• Internal Aluminide Coatings
• Aluminium root seal coating
• Moment Weighing and Computer Charting

S2 bucket

• Inspection / Dimensional Verification

• Weld Repair
• Laser Weld Repairs
• Z-Notch Repair
• Shroud Modifications
• Cutter teeth repair
• Vacuum Heat Treatment
• Assembly Fixtures
• Internal Aluminide Coatings
• Aluminium root seal coating
• Moment Weighing and Computer Charting

S3 bucket

• Inspection / Dimensional Verification

• Weld Repair
• Laser Weld Repairs
• Z-Notch Repair
• Shroud Modifications
• TIL affected blades refurbishment
• Assembly Fixtures
• Vacuum Heat Treatment
• Moment Weighing and Computer Charting

| slide 22
6FA & 6FA+e nozzle repair
S1 nozzle
• Inspection / Flow Testing
• Weld repair
• EDM cooling holes
• Vacuum heat treatment
• TBC coating
• Assembly Checking Fixtures
• Inserts repair/renewal
• Cover plates repair/renewal
• Retaining ring repair

S2 nozzle
• Inspection /flow testing /disassembly
• Weld Repair
• Shroud seal repair
• Honeycomb replacement
• Cover plates repair/renewal
• Vacuum heat treatment
• Aluminide Coatings
• Assembly Checking Fixtures
• Inserts repair/renewal

S3 nozzle
• Inspection /flow testing /disassembly
• Weld repair
• Shroud seal repair
• Honeycomb replacement
• Cover plates repair/renewal
• Vacuum heat treatment
• Aluminide Coatings
• Assembly Checking Fixtures
• Inserts repair/renewal

| slide 23
6FA & 6FA+e shroud block repair

S1 shroud

• Inspection / Disassembly
• Weld Repair
• EDM Machining / Cooling holes
• Vacuum heat treatment
• TBC Coating
• Coverplate repair/replacement
• Locking pin replacement
• Assembly Checking Fixtures

S2 shroud

• Inspection
• Honeycomb Removal/Installation
• Weld Repair / Rebuild
• EDM Machining
• Assembly Checking Fixtures

S3 shroud

• Inspection
• Honeycomb removal / Installation
• Weld Repair / Rebuild
• EDM Machining
• Assembly Checking Fixtures

| slide 24
Question & Answers

 Partnership with users to take developments to the next stage

 Questionnaire to validate our business case (technical & economicaly):

 Demand for 6FA versus 6FA +e parts
 Consideration for 6FA to +e upgrade program
 Consideration Upgrade DLN 2.0 to DLN 2.6
 Compressor modification

 First point of contact for further questions:

Ervin.mom@sulzer.com

| slide 25
Invitation for informal dinner
Where:
Cervejaria Trindade Chiado
 Rua Nova da Trindade 20 C
 2715-311 Lisboa, Portugal
 351 21 342 3506
 www.cervejariatrindade.pt

When
18:45 Bus in front of the hotel
Bus leaving 19:00 to restaurant
Return 22:30 from restaurant to Hotel

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