1. Turbine Services Ltd, Group
Engineering Presentation

2. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
OVERVIEW
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
Our product development 3 axis – Reverse Engineering, R&D, Product Manufacturing
With this synergy – bullet 1, bullet 2
And what makes TSL different from our competittors
In the next sections- discuss how we conduct each axis

3. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
REVERSE ENGINEERING
DATA COLLECTION
REVERSE ENGINEERING
VALIDATION OF DESIGN
Start with RE
Flow

4. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
DATA COLLECTION
REVERSE ENGINEERING
VALIDATION OF DESIGN
REVERSE ENGINEERING
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
Show in tour

5. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
DATA COLLECTION
REVERSE ENGINEERING
VALIDATION OF DESIGN
REVERSE ENGINEERING
REVERSE ENGINEERING
3D Modeling and Design
2D Drawing
Material Specification
Process Specification
Inspection Report

6. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
DATA COLLECTION
REVERSE ENGINEERING
VALIDATION OF DESIGN
REVERSE ENGINEERING
VALIDATION OF DESIGN
Prototyping
Stereo Lithography Model (SLA)
Finite Element Analysis

7. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
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
2nd axis – RnD
In the last 2 years -

8. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
RESEARCH & DEVELOPMENT
Technology
The 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

9. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
MANUFACTURING
CASTING
MACHINING
COATING
ASSEMBLY
Finally, product manufacturing
Classic flow point

10. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
MANUFACTURING
CASTING
MACHINING
COATING
THE CASTING PROCESS

11. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
MANUFACTURING
CASTING
MACHINING
COATING
THE CASTING PROCESS

12. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
MANUFACTURING
CASTING
MACHINING
COATING
ALLOYS
All TSL blades and vanes are manufactured with Super alloys
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

13. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
MANUFACTURING
CASTING
MACHINING
COATING
TSL TOOLING
All capital parts tooling are owned by TSL
Each capital part has a complete set of tooling
Wax injection tooling
Assembly fixture
Checking gauges
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

14. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
MANUFACTURING
CASTING
MACHINING
COATING
CONVENTIONAL MACHINING
Parts are machined to finished dimensions using
Stress free grinding, Turning, Milling
TSL owns all machining tooling
NON 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
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

15. Turbine Services Limited
Replacement Parts for GE Design Large Frame Gas Turbine Parts
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.

16. Turbine Services Ltd, Group
Delivering Quality Anywhere In The World
Conclusion
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. Group 41 Old Gick Road, Saratoga Springs, NY Phone: – Fax:
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