Case study
EthosEnergy completed a blade replacement using a patented titanium blade refurbishment process on the L-0 blades of a GE D-11 steam turbine rotor (double flow LP, 300 MW) for a 500+ MW combined cycle power plant.
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We are the only service provider offering a complete package of customized solutions for your GE A10 and D11 steam turbines. Whatever the issue, we have the answer.
Have you been told there is a problem with your A10 or D11 steam turbine?
Perhaps you’re in the middle of a major outage and an issue has cropped up, putting your critical path in jeopardy.
Or maybe you’ve received a technical information letter (TIL) recommending the replacement of L-0 blades, or alerting you to issues with the N2 casing or diaphragms.
Not to mention rotor vibration or bowing which can have serious consequences.
Suddenly, you’re looking at significant expenditure and the potential for extensive lead times. That’s if you go with the OEM.
But there’s a better way. You have options to repair, rather than replace, at a fraction of the cost and with much shorter lead times.
We offer an extensive range of engineered solutions for issues affecting A10/D11 steam turbines, including:
Our unique in-situ welding and titanium blade refurbishment processes extend the life of your blades by up to four times compared to the OEM design.
More cost-effective than replacing your steam turbine blades, our specialist repairs reduce the risk of catastrophic failure.
Our redesigned N2 box repair upgrades your joint hardware and reduces peak stresses by as much as 43%.
Removing reliance on casing material to maintain sealing, it secures sealing for 10 years. And leads to an efficiency (heat rate) improvement of approximately 1.4%.
You can expect to experience casing joint leaks on A10 and D11 steam turbines.
We address this troublesome issue through our outer casing joint machining and hardware upgrade.
Our proven steam turbine rotor straightening method is considered a permanent fix.
We’ve straightened dozens of rotors using our horizontal rotor straightening method and hundreds using our vertical method.
We’ve developed a seal that is an upgrade on OEM seals and avoids wear during startup and shutdown.
Our SMART Seals® for turbines result in a 1.4% efficiency (heat rate) improvement on D11 steam turbines.
Steam turbine diaphragm degradation can lead to a significant loss in heat rate and output of your unit.
We carry out a specialized weld repair with a straightener. We also repair vane trailing edges if required.
Specialist weld repair of a D11 L-0 turbine blade
When carrying out a major outage for a municipal combined-cycle power plant, our steam turbine application engineer detected a small crack on the L-0 blade tip of the LP rotor.
One of our specialist welders carried out an in-situ weld repair. As a result, we helped our client:
- Slash capital expenditure
- Keep a major outage on schedule
- Avoid a production loss costing millions of dollars
Reduced outage and costs on a D11 steam turbine
We performed our patented titanium blade refurbishment process on the L-0 blades of a D11 steam turbine rotor at a combined-cycle power plant belonging to a large utility in the US.
Restoring the blades to their original aerodynamic profile, our effective solution:
- Extended the life of the blades
- Reduced costs by over 60%
- Cut the outage time frame by 1/4
See our titanium blade refurbishment in action
When the wet steam environment in the last stages of a condensing steam turbine combines with very high tip speeds on long, last-stage blades, it leads to erosion damage at the leading edge of low-pressure (LP) blades.
Our expert team of skilled engineers and craftsmen has developed an innovative solution. We restore your 40-inch titanium blades by machining the eroded area and then – depending on the extent of the erosion damage – either welding a titanium insert or weld-building with titanium.
After this process is completed, we carry out a full inspection to ensure the integrity of the repair. And we guarantee 3,000 cycles on your repaired 40-inch titanium blades.
Ready to get much more out of your A10/D11 steam turbine?
Book a call with one of our experts today.
Discover how we can help you maximize your steam turbine performance and reliability.
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