Extend the life of your gas turbine rotors with EthosEnergy’s proven solutions
- Date
- February 06, 2025
- Category
- Impact
Extend the life of your gas turbine rotors with EthosEnergy’s proven solutions
In the world of gas turbine operation, rotors are a critical component that directly influences performance, reliability, and cost.
The issue is that, over time, these rotors wear down and stop operating at peak efficiency. This is mainly due to the extreme temperature variations, operational stress, and environmental factors that these rotors face in their daily operation. On top of this, they also have a defined end of life.
When a rotor isn’t at its best, it can often lead to costly downtime or even catastrophic failure if not managed properly.
At EthosEnergy, we understand the importance of extending rotor life to maximize efficiency and minimize costs for operators. Our comprehensive rotor life extension offerings are designed to make sure your rotors continue to perform at their best, even as they age.
Backed by our EcoLife™ warranty, all of our rotor solutions deliver peace of mind and operational longevity.
Let’s take a closer look at what we have to offer here at EthosEnergy to keep your rotors in tip-top shape.
Our tailored solutions for your rotors' long-term performance
1. Lifetime Assessment (LTA)
The foundation of rotor life extension begins with having a good understanding of the current condition of your equipment.
EthosEnergy’s Lifetime Assessment (LTA) involves a thorough, industry-standard inspection. We evaluate your rotor’s condition after significant operational milestones to see how it has been affected, and how much of a life extension is possible.
Following the guidelines of safety-critical technical information letter (TIL 1576), we disassemble the rotor, inspect every critical component, and perform non-destructive testing.
This assessment helps to pinpoint any areas of concern, providing a detailed report that gives operators insight into the potential areas where rotor life extension can be applied.
With this data, you can avoid costly unplanned downtime by making informed, data-based decisions about necessary repairs or component replacements.
2. Condition Based Life Extension (CBLE)
Building on the findings of an LTA, our Condition Based Life Extension (CBLE) solution focuses on extending the rotor’s operational life by addressing specific areas of wear and tear.
EthosEnergy’s engineers develop a tailored plan to repair or replace only the critical components that can limit your rotor’s lifespan, allowing for up to 200,000 factory fired-hour extension. Our tailored approach is designed specifically for each rotor’s projected operating profile.
We take this data-driven approach to make sure your turbine continues to operate safely and efficiently – all while keeping downtime and repair costs to a minimum.
By managing risk and optimizing performance, CBLE is a cost-effective solution for extending rotor life without the need for full replacement.
3. Certified Previously Operated (CPO™) rotor
For operators looking for a more budget-conscious solution, EthosEnergy’s Certified Previously Operated (CPO™) rotors offer a reliable, cost-effective alternative.
Each CPO™ rotor undergoes rigorous testing and refurbishment, ensuring each and every unit that leaves our facility meets the highest quality standards.
Certified for up to 150,000 factory fired hours, CPO™ rotors provide operators with a dependable option.
4. Phoenix Rotor™
Our Phoenix Rotor™ is a unique hybrid solution.
It combines new and Certified Previously Operated (CPO™) components – creating a rotor with the same life expectancy as a brand-new one but at a lower cost point.
This innovative hybrid offering is the perfect choice for operators who want to maximize rotor life while minimizing their capital expenditure.
Our expertise and intricate understanding of rotor design and material performance have allowed us to create the Phoenix Rotor™, which offers up to 200,000 factory fired hours of reliable operation.
It’s an ideal balance between performance and cost efficiency, allowing operators to keep their rotors running longer without compromising on quality.
5. New rotor solutions
In cases where extending rotor life isn’t a viable option due to excessive wear or damage, EthosEnergy offers complete new rotor replacements.
These new rotors are manufactured at our own facility in Torino, Italy, using advanced materials and techniques that address known weaknesses in the original rotor designs.
These new rotors are fully compatible with your existing turbine systems and offer up to 200,000 factory fired hours of operational life for GE Frame B, E, and F class units.
Our new rotor solutions give you a fresh clean slate if you’re looking to restore your equipment to peak performance.
Maximizing your rotor life with EthosEnergy
EthosEnergy’s rotor life extension offerings are designed to provide flexible, cost-effective solutions for operators looking to extend the life of their gas turbine rotors.
From detailed inspections and tailored repairs to full rotor replacements and hybrid solutions like the Phoenix Rotor™, we’re here to make sure your turbines remain reliable and efficient throughout their operational life.
With our industry-leading expertise and commitment to quality, EthosEnergy is your trusted partner in keeping your rotors running longer, reducing costs, and enhancing performance.
Free guide to GE rotor life extension
In our eGuide, we cover:
1. the implications of TIL 1576 on GE gas turbine rotor life extension;
2. what you need to do to comply with the TIL and reduce your risk;
3. how to arrive at an accurate evaluation of the remaining life of your rotor; and
4. your options for gas turbine rotor life extension
...and much more!
Benefits of rotor life extension
There are significant advantages to staying in your current technology and choosing a rotor life extension over a change in frame type or technology, most notably cost efficiency and the carbon-friendly decision to reuse versus manufacture new.
EthosEnergy is the only non-OEM rotor option available for B/E/F class that uses OEM technology and materials. Key benefits include:
- Fully compatible and interchangeable to minimize downtime
- Improved design on new manufacture rotors to address known weaknesses of original design
- Minimal turnaround time - no need for new permitting
- Carbon-friendly (ESG friendly) by reusing existing assets vs new manufacture
- Flexible, tailored solution from a partner to guide you through rotor replacement
Lifetime assessment (LTA)
- TIL 1576 allows for a potential one-time extension beyond the FFH/FFS limits based on the results of an LTA. EthosEnergy’s qualified craftsmen and engineers can perform the LTA and determine the possible life extension based on results
Condition Based Life Extension (CBLE)
- Our qualified engineers perform a detailed evaluation of the rotor condition, associated risks, and recommendations for component replacement with a possible 50k-200k FFH and 2,500 FFS extension
New Rotor
- Our manufacturing facility in Torino, Italy can manufacture EthosEnergy's upgraded rotor design that is interchangable with your current rotor.
Phoenix Rotor™
- A hybrid rotor with new and Certified Previously Operated (CPO)™ components certified for the equivalent of the life of a new rotor. Proven OEM design and materials are used for EthosEnergy Phoenix Rotor™ compressor and turbine rotor discs.
Certified Previously Operated (CPO)™
- A rotor with a known pedigree that has been thoroughly inspected and tested at one of our centers of excellence. Certified for possible life up to 150k FFH and 2,500 FFS.
Run your rotor for longer
There are more options than you might think when it comes to addressing GE gas turbine rotor life extension. Options beyond purchasing a new rotor from the OEM, moving to a new technology, or replacing your rotor with risky used and grey market options.
You need a trusted partner to navigate these options. We have a dual advantage - the ability to offer both the capability/quality/standards of an OEM (as the OEM for Fiat and Mature Westinghouse gas turibnes) and the commercial flexibility of an ISP.
Over the last 15 years, we have focused on the rotor market and gained extensive experience in engineering, repair, and manufacturing of components for B, E, and F-class units.
This means that we can offer both rotor replacement and life extensions on existing rotors; this includes new rotors that are manufactured in-house.