Extended parts life solution Alstom GT11D gas turbine
A fleet of Alstom GT11D liquid fuel gas turbines showed severe issues with premature erosion of the leading edge section of blades, causing them to prematurely fail.
Increase Power Output
A customer operating a fleet of Alstom GT11D liquid fuel gas turbines showed severe issues with premature erosion of the leading edge section of blades, causing them to prematurely fail. The erosion was limited to the row 1 blades and vanes.
Erosion was caused by a combination of operating on heavy fuel oil (HFO), the build-up of contaminants in the fuel adhering to the leading edge, & the increased temperature of the base material causing accelerated oxidation & premature failure.
The components were failing around the 5,000 Equivalent Operating Hours (EOH) mark. Primary factors effecting the damage of the components were fuel, contaminants & overheating
The EthosEnergy Solution
Through a root cause analysis, a corrective action plan was developed to repair the part
Wire eroded out the full leading edge section & replaced it with a machined section of upgraded cast base material
Directionally Solidified Rene 142 (DSR 142) alloy was used & is seen as a significant upgrade over manufactured alloy of equiaxed IN738
The replaced section had a higher oxidation resistance & was held in place by a high temperature braze
The key highlights of the project.
Significant parts life extension
Repairs allowed operation for a full life cycle of 24,000 EOH or almost 500% longer than previous run time
Reduced capital expenditure using a repair versus buying new
A significant extension in component life was achieved
Reduced capital expenditure without the need to buy new parts, opting to go with a repair instead of component replacement due to fallout