Sulzer Turbo Services

W501F / SGT6 - 5000F Repair

Turbine Section
• Vane repair and full coupon
replacement
• Blade repair, including R1
modifications
• TBC and hot corrosion coatings
Manufacturing
• Compressor blades (Rotor)
• Rotor bolting

Compressor Diaphragm Repair

Outer sidewall spigot surfaces are subjected
to severe fretting and premature wear due
to excessive vibration in the compressor
case. The worn surfaces are a result of
airfoil motion being transmitted to the hook
fits. Sulzer Turbo Services has developed
specific procedures to repair the fretting
which are then fit to 360º, heavy wall fixtures to insure correct spigot
This 200 MW class gas turbine fleet has logged more than 3 million fit geometry. In all, airfoil repair, spigot fit welding, recontouring,
hours of operational time with many of the units now into their second rounding and flattening of the compressor diaphragms and coatings
major inspection cycles. To meet the demands of this maturing fleet, are all completed at Sulzer Turbo Services.
Sulzer Turbo Services has invested significant resources in capital,
tooling and repair procedures with extraordinary standards.

SGT6-5000F Capabilities
On-Site Work
• Combustion and hot gas path inspections
• “In situ Belly Band” replacement
• Major inspection and overhauls

Rotor Repair
• Class IIA inspection
• Compressor blade removal and installation
• Class IIB inspection
• Air baffle replacement
• Curvic clutch contact pattern analysis

Combustion System Repair

• Transition repair
• Combustor basket repair
• Fuel nozzle flow testing and repair
• TBC and hard face coatings
S1 Vane Repair, Fixture Check
R1 Vane Repair R1 Vane Fixture Check

Vane Repair via Foil Coupon the sonic nozzles, sets the proper pressure at the circuit being
Intricate cooling passages and complex geometries throughout the tested and calculates the mass flow through the sonic nozzles.
W501F vanes present significant challenges in Additionally, the system monitors the airflow
the restoration process. With the advancement conditions to insure the sonic nozzles are in
of full foil coupon replacement, Sulzer Turbo a “choked” state and that flow is stable within
Services can now repair vane segments that +/- 0.1% of the set pressure ratio.
would have been scrapped. This level of repair
is only achieved through state-of-the-art EDM, Liquid System
highly specialized tooling and world class The System Controller handles the operation
technicians. Sulzer Turbo Services facilities of the prime movers, sets the proper pressure
are equipped with the latest in technological at the Unit Under Test (UUT) and calculates the
advancements and continually train each flow number through the UUT. The controller
craftsman. also monitors the liquid flow conditions to
insure that the flow is stable within +/- 0.1% of
Flow Test - Air and Liquid the pressure ratio set point.
Air
Sulzer Turbo Services utilizes state-of-the- Blade Repair and TBC Coating
art sonic nozzle flow testing technology. The Sulzer Turbo Services has developed and
fuel nozzle flow bench is comprised of an air qualified repair procedures to fully repair
flow metering system that utilizes ten sonic R1 – R4 turbine blades. All coating removal,
nozzles housed in a common inlet and exit heat treatment repairs and new coatings are
manifold designed to meter the flow through completed at Sulzer Turbo Services, which are
the fuel nozzle circuits. Each fuel nozzle strictly monitored by on-site lab analysis.
assembly is visually and non-destructively Flow Testing Area

tested for deviations and failures in efforts to achieve the most Solving the R1 problem with severe “pressure side” platform
reliable, repeatable and accurate fuel nozzle system possible. Each cracking, Sulzer Turbo Services developed a patented procedure,
flow circuit has specially designed fixtures that allow accurate flow where the cracking is excavated and fully repaired.
measurements. The flow test system automatically opens and closes

W501F R1 Turbine Blade W501F R1 Blade, Fully Reconditioned and Coated with Advanced TBC
 Digital X-Ray
Digital X-Ray has opened
a window into the most
vulnerable areas of gas turbine
components. Turbine blades,
vanes, fuel nozzle components,
transitions and inlet guide vane
shafts are regularly inspected
for plugged cooling holes
and indications in cooling
passages. Real-time, digital
imagery enables Sulzer Turbo
Services to view and document
indications and irregularities well
into the cooling cavities and
Digital X-Ray of R1 Blade Cavity Digital X-Ray
across the length of the material
wall. Precision manipulation of the components while digitally
enhancing the image allows the operator to pin-point previously 501F Transition Repair
undetected irregularities. Sulzer Turbo Services repairs the original design transitions, as
well as the PSM design transitions. Full 360º fixtures are utilized
Blade Manufacturing to check all critical fit up and picture frame dimensions. Routine
Sulzer Turbo Services manufactures and stocks W501FD rotor repairs include picture frame replacement, panel replacement,
compressor blades. Via precision air foil machine with advanced vacuum heat treatment and where necessary, full digital X-Ray of
CNC mills, all blades are manufactured and coated at the La Porte the cooling hole passages.
facility. Strict QC inspections verify machining accuracy.

Compressor Blades Manufactured by Sulzer Turbo Services W501F Transition Repair in Full 360º Simulator Fixture

501F Rotor Repair

For the last 25 years, Sulzer Turbo Services has lead the 3rd
party repair facilities in gas turbine rotor repair. Specialized tooling,
engineering, heavy balancing and machining capabilities have
allowed for a smooth transition from mature frame W501 rotors to
the advanced 501F rotors. Sulzer Turbo Services has successfully
repaired 501F rotors, including machining, turbine and compressor
deblading / reblading, air baffle replacement and precision dynamic
balancing. All rotor coatings, including compressor coating and
turbine blade coatings are completed on-site in the Sulzer Turbo
Services coating facility.

W501F Rotor