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Sulzer Turbo Services Venlo B.V.

Spikweien 36
NL-5943 AD Lomm, The Netherlands
Phone +31 77 473 8666
Fax +31 77 473 2785
www.sulzerts.com

To Whom it my concern Our ref.


Phone direct +31 77 473 8666
Fax direct +41 77 473 2785
E-Mail direct Peter.vanNeerven@sulzer.com
Document
Date

SULZER TURBO SERVICES VENLO Capabilities: REPAIR, NOT SCRAP !!

Rescued from scrap

Sulzer Turbo Services Venlo (TS Venlo) has always pushed the boundaries and is a pioneer in
the search for new techniques to repair even the worst condition parts. For this we have
successfully developed repairs using laser welding and other special processes. We have
attached a few examples were we have rescued components from SCRAP were other
competitors, including the OEM, were not able to repair. These parts are now running safely in
turbines.

Lowest price suppliers in many cases scrap or reject many components since these companies
are both financially as well as technically not able to effectively refurbish gas turbine hot section
parts. TS Venlo however is recognized in the Industry for the low scrap rates and high quality
and therefore we have rescued/repaired a lot of parts for customers and prevented the
customer to buy very expensive NEW parts from the OEM. If orders would have been evaluated
afterwards and not only at the tender opening, TS Venlo would have been the better
alternative, taking into account that NO replacement of scrap parts by NEW parts would have
been necessary.

We at TS Venlo have invested a lot of efforts in the Research & Development for new repair
techniques to RESCUE customers parts from being scrapped. We are successfully offering
these special repairs to our customers.

On the following pages several of many examples are showed to emphasize which parts &
developments (processes) we have used to rescue components from scrap. In addition, TS
Venlo is able to provide non-OEM new manufacturing of gas turbine components instead of our
existing refurbishment technology, if customer wishes.

For more information, Please do not hesitate to contact us.

Yours sincerely,

Peter van Neerven


Regional Sales Manager
Sulzer TS Venlo

Sulzer Turbo Services


RESCUED FROM SCRAP
(Few examples out of many repairs)

ABB13E2 stage 1 vane NEW Version A ABB13E2 stage 1 vane NEW Version A
(Meishi , China) (Meishi , China)

scrapped by OEM and UK repair company Rescued by coupon repair using laser welding
because of extensive airfoil & platform cracks

ABB13E2 stage 1 vane Version 96 (Indonesia / other)


Scrapped by OEM and non-OEM

Rescued by (several shapes of) coupon repairs using laser welding

Sulzer Turbo Services


X: Area of
concern in case
of cracks

ABB13E2 stage 1 blade Version 96 (various customers)

Scrapped by OEM and non-OEM

Rescued by special repair using laser welding

Sulzer Turbo Services


ABB11D/13D3 stage 1 blades Before and after coupon repair

(Saudia, Bahrain-ALBA/other)

Scrapped by OEM and non-OEM


Rescued by coupon repair using laser welding

Sulzer Turbo Services


Siemens V64.3 stage 1 vanes (Amata, Thailand)
Scrapped by others and rescued by coupon repair using laser welding

GE F6 stage 1 nozzle (Oman)


Scrapped by OEM and other local repair companies
Rescued by heavy coupon repair

Sulzer Turbo Services


GE F9E stage 1 buckets set (SEWA, Sharjah UAE)
Scrapped by OEM and others for heavy FOD
Rescued by special welding processes and running for > 2 years in GT

We also delivered NEW F9E components to SEWA which are fitted in a GT and started up
early June 2005 (stage 1-2-3 buckets, stage 2 nozzle, shroud blocks, TPs and C/L)

GE F6B stage 1 buckets set (JinHua P/S China)


Scrapped by UK repair company for heavy FOD
Rescued by laser welding (April 2005)

Sulzer Turbo Services


GE F9E stage 1 buckets (Iran/other)
LE cracks, scrapped by OEM and UK repair company

several sets rescued by Powder laser welding

Sulzer Turbo Services


GE F9E stage 2 Nozzle (Shenzhen Nanshan P/S, China)
Scrapped by OEM and others for heavy FOD and overheating
Rescued by inserting casted Leading Edge sections and special welding & brazing processes
Alternatively we are able to deliver NEW F9E stage 1-2-3 nozzles when necessary

GE F6B stage 1 nozzel (Shaoxing P/S China)


Scrapped by OEM and non-OEM repair company for heavy FOD
Rescued by inserting new casted trailing edge patches (2005)

Sulzer Turbo Services


GE F9E complete rotor overhaul AES Elsta The Netherlands

(Rescued from GE Scrap by machining & powder welding of heavily


cracked shaft: Bearing did not get oil for 3 minutes)

ABB13D3 complete rotor overhaul Pakka Malaysia

(Rescued from OEM Scrap :


rotor was heavily damaged and bent as result of a failure)

Sulzer Turbo Services


GE F9FA complete rotor overhaul UK customer

(Rescued from GE Scrap ; compressor rotor failed 4 times and Sulzer TS Venlo reverse engineered all
compressor blades & vanes and made some modifications to prevent shim migration)

GE F9FA complete rotor overhaul & casing repair UK customer

(Rescued from OEM Scrap : GE F-casings suffer from heavy deformations causing compressor blade tip
rubbing and finally causing catastrophic failure. Sulzer TS Venlo repaired the casings and bring back to
original shape)

Sulzer Turbo Services