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EDITORIAL

Sulzer’s technology— key for transportation

Dear technology experts, customers, and partners,

Did you know that a quarter of the worldwide annual primary energy consumption is needed for transportation alone? Economic globalization has led to an increasing need for the transportation of goods over longer distances from the producer to the consumer. In addition, people now travel increased distances to work and in their spare time. These requirements have risen substantially in the last few decades.

This issue of the Sulzer Technical Review (STR) focuses on Sulzer’s solutions for current and future requirements concerning fuel consumption, pollutant emissions, durability, maintenance, and renewable fuel production. Sulzer products are present at many levels—both visible and invisible to the end user.

You will learn, for example, how specialists at Sulzer Metco develop and produce innovative honeycomb seals to increase the efficiency of aircraft engines. A further article surveys Sulzer Metco’s surface refinement of individual automotive components. This treatment increases durability, lowers friction, and is environment friendly. Contrary to first-generation biofuels, second-generation biofuels are made from waste biomass. Sulzer Pumps’ and Sulzer Chemtech’s solutions are crucial for the future production of these environmental friendly fuels. Further, Sulzer Turbo Services presents its high-speed balancing facilities in Houston and Winterthur.

I hope you enjoy reading about these and other innovative developments of the Sulzer divisions and Sulzer Innotec.

Sincerely yours,

Ton Büchner

CEO Sulzer

Sulzer today

The Sulzer brothers laid the foundations of today's company 175 year ago in Winterthur, Switzerland. Sulzer is active in the fields of machinery, plant construction, and surface technology in more than 120 locations around the world. Its divisions are global leaders in their respective markets, including the oil and gas sector, the hydrocarbon processing industry, power generation, pulp and paper, aviation, and the automotive industry. Sulzer employs a total of 12,500 professionals who develop innovative new technical solutions. These products and services enable Sulzer's customers to achieve sustained improvements in their competitive positions.

www.sulzer.com

Sulzer Pumps

Sulzer Pumps offers a variety of centrifugal pumps, ranging from custom-built models to standardized series. The division's marketleading position reflects its research and development activities relating to processoriented materials as well as its reliable service. It serves customers in the oil and gas, hydrocarbon processing, pulp and paper, power generation, water distribution and treatment sectors, as well as other specialized areas. www.sulzerpumps.com

Sulzer Metco

Sulzer Metco specializes in thermal-spray and thin-film processes for surface technology applications. The division coats and enhances surfaces, produces materials and equipment, and develops machining processes for special components. Its customers are active in the aviation and automotive industries, the power generation segment, and other specialized markets.

www.sulzermetco.com

Sulzer Chemtech

Sulzer Chemtech is the market leader in the fields of process technology, separation columns, static mixing, and cartridge technologies. The division has sales, engineering, production, and customer service facilities throughout the world that enable it to meet the needs of its customers in the oil and gas, chemical, petrochemical and plastics industries. www.sulzerchemtech.com

Sulzer Turbo Services

Sulzer Turbo Services is the largest independent provider of repair and maintenance services for thermal turbomachinery and other rotating equipment. The division also manufactures and sells replacement parts for gas and steam turbines and compressors. Its customers operate in the oil and gas, power generation, and other specialized industrial sectors. www.sulzerts.com

Sulzer Innotec

The research and development unit supports the development projects of Sulzer's own divisions as well as projects of industrial companies around the world by providing contract research and special technical services. Sulzer Innotec has considerable expertise in materials engineering, surface engineering, fluid technology and medical technology, as well as in the field of mechanics. Its core competencies in the area of contract research also focus on these traditional disciplines. www.sulzerinnotec.com

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Requested by the airlines

Manufacturing environmentally friendly aero engines

High tech for transportation

Optimized surfaces for a more efficient transport

Emissions reduction

How coatings make a difference

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Sulzer world

Welcome to Sulzer Pumps in Brazil

Interview

Darayus Pardivala, Sulzer Turbo Services

Exhibitions, Events

December 8–10, 2009, Las Vegas, USA

Power-Gen International 09 www.power-gen.com

Information for Sulzer Turbo Service: Ashley Englebert Phone +1 713 567 2702

ashley.englebert@sulzer.com Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com

December 8–10, 2009, Las Vegas, USA

Nuclear Power International 09 www.nuclearpowerinternational.com Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com

December 10–13, 2009, New Orleans, USA

NGWA 09 www.ngwa.org

Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com

January 26–28, 2010, Bismark, USA

EGC Energy Generation Conference 2010 www.bismarckstate.edu

Information for Sulzer Pumps: Jim Willis Phone +1 318 742 9617 jim.willis@sulzer.com

February 4–7, 2010, Istanbul, Turkey

WIN World of Industry 2010 www.win-fair.com

Information for Sulzer Metco: Karin Gehrig Phone +41 56 618 81 61 karin.gehrig@sulzer.com

March 8–10, 2010, Brisbane, Australia

Ozwater 2010 www.ozwater10.com.au

Information for Sulzer Pumps: Jonathan Fullford Phone +61 3 9826 3472 jonathan.fullford@sulzer.com

March 9–12, 2010, Gothenburg, Sweden

International Industrial Maintenance 2010 www.maintain-europe.com

Information for Sulzer Pumps: Kerstin Sallermo Phone +46 11 24 99 06 kerstin.sallermo@sulzer.com

March 23–26, 2010, Beijing, China

Nuclear Industry China NIC 2010 www.nic-expo.net

Information for Sulzer Pumps: Hongyi Liu Phone +86 10 6510 1777 hongyi.liu@sulzer.com

March 24–26, 2010, Perth, Australia

Australasian Oil & Gas Exhibition and Conference 2010 www.aogexpo.com.au

Information for Sulzer Pumps: Bob Beckett Phone +61 8 9309 1171 robert.beckett@sulzer.com

For this year's celebration of “175 years Experience Sulzer”, a special event—the Sulzer Idea Lab for the Future—was organized in cooperation with the Swiss Federal Institute of Technology (ETH) in Zurich. This idea generation event took place on November 4, 2009, and focused on alternative energy technologies, such as concentrated solar thermal power, wind power, second-generation biofuels, and carbon capture and storage. Twenty participants from Sulzer and about 15

professors and scientific talents held an intensive brainstorming session on possible opportunities for Sulzer. The most attractive ideas will be pursued in the near future. This event further strengthens the partnership between the ETH Zurich and Sulzer, and further dialog will be held on a regular basis.

Being close to its customers is key to Sulzer Pumps’ commitment to service. With more than 60 service centers worldwide, Sulzer Pumps operates one of the industry’s most extensive service networks, which supports operators of Sulzer and non-Sulzer pumping equipment. It continually adapts this network to provide a complete range of customer support services that draw on Sulzer Pumps’ technical expertise and industry experience. Services include field service, repairs, spare parts, and retrofits, as well as maintenance and operation agreements. Sulzer Pumps actively seeks and assesses new opportunities to increase its customer support services

worldwide. In recent years, Sulzer Pumps has opened new service centers that expand its service capabilities in strategic markets:

•The flagship project is the new facility in Abu Dhabi, UAE, where the focus is on serving customers engaged in the oil, power, and water segments in the Gulf states. The facility also houses Sulzer Pumps’ regional sales and project management teams.

•In the industrial city of Bitterfeld, Germany, Sulzer Pumps opened a service center to support the heavy use of pumps by the local chemicals, plastics, and aluminum industries.

•The new service center in Volta Redonda, Brazil, is located at a customer site to service the needs of approximately 900 pumps operating in this major steel-manufacturing region.

•Sulzer Pumps has successfully expanded its service engineering presence in Cape Town, South Africa, to include workshop facilities.

•A new service center has also been opened in Shanghai, China, to serve the Chinese power, oil and gas, and HPI markets.

Sulzer Innotec has expanded its accreditations to plastic analytics and asbestos analytics. The assessors of the Swiss Accreditation Service (SAS)— the federal accreditation office for laboratories, inspection bodies, and certification bodies according to international standards—carefully examined the laboratories, confronted the employees with fictive situations, tested the efficiency of the processes, and audited the reliability of the equipment. This certification guarantees customers standardized and comprehensible operational processes as

well as reliable, prime-quality, and on-time results.

With the expansion of the accreditation of the plastic analytics laboratory—for which recently significant investments were made—Sulzer Innotec is actively seeking seals of quality accreditations for all relevant activities. These measures help Sulzer to offer its customers a wide range of accredited measurement services from one source.

ll original equipment manufacturing (OEM) companies like GE, Rolls Royce, Snecma, and Pratt

& Whitney are responding to this challenge by developing state-of-the art engines. They are employing advanced light materials and coatings, thin wall castings, and other complex technologies in order to improve thermal efficiency, increase propulsive efficiency, and reduce weight and noise.

A supplier to most OEMs

As a supplier to almost all engine OEMs, Sulzer Metco contributes to this challenge by offering and adapting its expertise and manufacturing capabilities. Currently, Sulzer Metco is involved in several high-tech civil aero engine programs, such as the Trent 900, GP7000, Trent 1000, Trent XWB, BR725, PW1200, PW1500, and SaM146/TP400. These engines power different classes of civil airplanes.

Sulzer Eldim, part of the Sulzer Metco division, consists of three entities located in three European countries. Sulzer

Engine and corresponding airplane

Neomet products: typical honeycombs.

Eldim (NL), in Lomm, Netherlands, is specialized in the manufacturing of labyrinth air seals and industrial gas turbine (IGT) airfoil drilling; Neomet Ltd, in Stockport, United Kingdom, is specialized in the manufacturing of honeycombs , an essential component of a labyrinth air seal; and Sulzer Eldim (HU), in Debrecen, Hungary, is specialized in manufacturing sheet metal details, nozzle guide vane inserts, and baffles and offers a best-cost supplier option to our

customers. Currently, Sulzer Eldim (HU) is involved in the production of the V2500 nozzle guide vane inserts.

Know-how and manufacturing experience

Labyrinth air seals are used in aero gas turbines to reduce airflow leakage at stator/rotor tips. The ability to design and manufacture seals with less weight and tighter tolerances will significantly contribute to the overall performance of

Seal test rig.

the engine. Weight restrictions and tighter tolerance schemes are driving the manufacturability of a part to its limits. For example, machining a thin wall casting cost-effectively without deforming the shape of the component is a challenge for any supplier and, consequently, also for the customer. For that reason, the OEMs frequently use Sulzer Eldim’s accumulated know-how and manufacturing experience in the predesign phase of their products. In this co-design phase, customers can still adjust their final definition of the labyrinth seal to favor any of the above-mentioned requirements. During any development and engineering phase, it may become evident that the first design does not meet the required performance targets, and thus, changes may be needed to overcome this deficiency. Sulzer Eldim has often proven that know-how and manufacturing experience contributes to a more favorable approach in the design phase and therefore, ultimately, to a more successful solution.

Developing a new labyrinth seal

In addition to its direct work with OEMs, Sulzer Eldim has participated in a joint collaboration and initiative of the Dutch Aero Engine Cluster (DAEC) to develop a new labyrinth seal concept that will improve gas turbine efficiency. This development was undertaken in cooperation with DutchAero, Atkins Nedtech,

als that are adapted to the high loads by an appropriate combination treatment of plasma-nitriding and PVD coating. The customer profits from improved performance combined with lower costs. Diamond-like carbon coatings (DLC coatings), which have a wide application area thanks to their low coefficient of friction and their extraordinary range of variants, play a special role in transportation.

If we consider the “heart” of every vehicle, the engine, a wide variety of coating applications can be found. Crankshafts are nitrided to improve their endurance. Camshafts and tappets are also nitrided, and are provided with lowwear coating for further optimization. The use of DLC-coated hydro-tappets has provided a performance increase of 4% for a well-known motorcycle manu- facturer—without any further modifications, i.e., purely as a result of the reduced friction. Piston rings receive wearand friction-reducing PVD coatings that last longer than the life of the car. Plasma sprayed coatings enable cylinders to run for longer and, in some cases, make it possible to operate without cylinder liners. Valves are nitrided and coated in order to minimize the friction between the

Starter gear with diamond-like carbon coating.

valve shaft and guide. Valve springs can withstand higher speeds thanks to the residual compressive stresses induced by the nitriding. The nitriding of cylinder linings, crankshafts, piston heads and valves has already become standard in many areas of the large diesel engine sector.

Without coating—unrealizable

If we extend our consideration to ancillary units, it is the components of the modern common-rail injection systems that especially profit from high-tech coatings, or would not be able to be realized at all without coatings.As a result of alternative fuels, injection pump covers that were previously electroplated are now successfully protected against corrosion with IONIT OX. DLC coatings of Type a-C:H-Me bring unimagined benefits, for example, for starter gears . Through their microductile behavior, they not only successfully prevent the formation of pitting, but also significantly reduce the electric power consumption through the reduced friction. As a result, not only smaller and lighter starter motors will be possible in the future, butsmaller batteries can also be fitted. In addition to the required durability, vehicle gearboxes

Overview of vehicle components coated by Sulzer.

ments. Together with the OEMs or their suppliers, a team of experts develops a suitable coating system, so that our mobility can also be retained in the future.

Thomas Auf dem Brinke

Sulzer Metaplas GmbH

Am Böttcherberg 30–38

51427 Bergisch Gladbach Germany

Phone +49 2204 299 293 thomas.aufdembrinke@sulzer.com