Preventing catastrophic failures: Lessons from real-world turbine maintenance
EthosEnergy helps industrial asset owners avoid catastrophic failures
- Goals
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- Avoid catastrophic rotor failures
- Extend the life and reliability of steam turbines
- Shift from reactive to predictive maintenance
- Optimize total cost of ownership
- Sectors
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- Power generation
- Asset
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- Steam turbines
- Location
- Global
Aging turbines under changing conditions
Industrial steam turbines are often decades old, running well beyond their original design scope.
And, over time, the conditions of plants shift – feedstock changes, pressure drops, loads vary – and turbines can often be pushed beyond their limits. Without targeted maintenance or system updates, damage can start to accumulate and take its toll.
Common issues can include worn seals, blade erosion, casing material degradation, and degraded diaphragms. In some cases, backup rotors that are assumed to be ready for use are then found to be unfit – which presents a major risk if the primary unit fails.
Without regular inspection, these problems can go unnoticed until they lead to extended outages or even catastrophic failure.
Advanced machine components diagnostics and their lifetime evaluation
EthosEnergy is considered a world leader in the development and application of advanced diagnostics technology.
This includes unique phased array techniques for complex blade attachment configurations, allowing for detailed inspections without needing to disassemble the blades.
Rotor shaft material can be examined across its entire material volume to detect any operational or manufacturing defects. Reliable diagnostics also form the foundation for assessing the lifespan of key machine components, including:
- Valve casings (Emergency stop valves, control valves)
- Intermediate pipelines
- Turbine casings
- Rotor shaft
- Rotating blades
- Stationary blades, carriers, and diaphragms
Key Points
- Advanced diagnostics and lifetime evaluation of critical machine components.
- Deep engineering expertise and smart design thinking help detect and correct failures before they cascade.
- Re-rates, rotor repairs, and component redesigns offer dramatic reliability improvements and output gains.
- Real-world case studies show how early intervention – and asking the right questions – prevents catastrophic downtime.
Engineering upgrades that match real-world conditions
EthosEnergy works closely with customers to carry out detailed turbine assessments – guided by expert engineering insight with a focus on long-term performance goals.
We start by asking key operational questions that get to the root of the issue:
- Has your process changed since the turbine was installed?
- Are you pressure-reducing inefficiently?
- Is the machine operating significantly below or above its original design point?
- Is your spare rotor fit for duty?
In one instance, a customer in Thailand discovered that their backup rotors, which were swapped in during a past outage, had never been cleaned or inspected.
EthosEnergy carried out a full analysis, revealing that the rotors were unfit for use. We then restored and reversed them, preventing future failure.
In another case, a geothermal plant faced ongoing blade damage. We replaced the parts and re-engineered the entire steam path – an upgrade that delivered an additional 2.5 MW of output, with zero increase in steam consumption.
Across all projects, EthosEnergy’s focus is on long-term reliability, not one-off repairs.
Data-driven review of risks and upgrade options
Every engagement begins with a technical evaluation based on the machine’s operating data and mechanical configuration.
Where data or drawings aren’t available, our expert team applies reverse engineering to recreate a full picture of the turbine’s condition, so they can have as good an idea as possible as to what is needed.
Using performance modelling, rotordynamics simulations, and stress analysis tools, we identify loss points and potential failure modes.
We assess:
- Flow rates vs. original design
- Blade loading and vibratory stress
- Steam chemistry and its impact on seals and blades
- The structural integrity of rotors, diaphragms, and other key parts
This process allows us to build a clear, credible value proposition for every upgrade or repair.
In-house execution from inspection to installation
EthosEnergy delivers complete turnkey solutions using in-house engineering, manufacturing, and testing capabilities.
We inspect, scan, and reverse rotors. We redesign blades and diaphragms. And we execute upgrades with precision – applying lessons from over 40 years of experience across GE, Siemens, and other OEM platforms.
When needed, our Houston high-speed balancing facility is used to verify rotor integrity and reduce startup time in the field.
Every solution is tailored to the site’s operational needs, budget, and schedule.
Improved output, lower risk, and long-term reliability
EthosEnergy’s solutions have helped customers:
- Increase output by up to 2.5 MW through re-rate engineerig
- Extend rotor life from 2 years to 24+ years
- Avoid catastrophic outages by identifying hidden rotor and blade faults
- Shift to predictable, proactive maintenance models
- Reduce unplanned downtime and operational risk
Our approach delivers measurable value – from improved turbine availability to lower cost of ownership.
Find out more
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Upgrades
Whether your process has changed or is undergoing a life cycle extension project, EthosEnergy can redesign your unit to run more efficiently and more reliably, providing optimal performance for years to come.
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Shop and field services
Global steam turbine repair facilities and field service teams with advanced technologies and engineering capabilities
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