Parts & Repairs
With more than 40 years’ experience our aftermarket blade design engineering and manufacturing team provide engineered solutions fast, from replacement in-kind to enhancing the efficiency and reliability of your units.
EthosEnergy is one of the only aftermarket blade suppliers offering complete solutions regardless of your turbines OEM – devoted to quickly returning you to service while enhancing reliability and efficiency improvements for your steam turbines. EthosEnergy strives to provide short delivery times and improved value to you with none of the risks associated with using multiple suppliers. With more than 25,000 blade designs and a multi-million dollar on-premises blade-specific material inventory, we have the ability to quickly, reverse-engineer and manufacture the blades and buckets you need for your forced or planned outage.
Our complete manufacturing capabilities include: forging and casting; advanced CNC multi-axis machining, grinding and EDM processes; advanced in-house coatings; and round-the-clock 24/7 coverage. These all seamlessly integrate to help us meet your specific requirements – from parts supply to complete project management. Our blade manufacturing quality management systems are ISO 9001:2000 certified and we provide competitive pricing with full warranties on long-term service and maintenance support.
CASE STUDY: Longshanking Saves the Cost of a New Rotor for 110 MW Nuclear Unit
Stress corrosion cracking in the dovetail can cause extensive damage in large steam turbines. Most fixes require removing blades and derating the turbine or replacing the entire rotor. But EthosEnergy’s “longshanking” fix can save the rotor – plus millions of dollars and years of lead time – for turbines as large as 1150 MW.
CASE STUDY: Blade Redesign Solves Reliability Problems in 13,000-HP Industrial Unit
A refinery suffered blade failures every 18 months to two years in a six-stage, 13,300-HP mechanical drive steam turbine. EthosEnergy discovered that the failure was due to high-cycle fatigue initiating in the dovetail root attachment. To fix the problem, we designed more robust blades with improved aerodynamics, added z-shrouds, changed the dovetail attachment to reduce stress by a factor of 25:1, altered the diaphragms to fit the redesigned rotors and machined the case to accommodate all the changes. Not only did the unit run for years without failure – it has been running with greater efficiency.