Gas Turbine Part Manufactured with 3D Printer
Siemens engineers have successfully 3D-printed a pre-mixer for the SGT-A05 aeroderivative gas turbine. According the company's press release the part was tested with impressive results showing a good potential for significant reductions in CO (carbon monoxide) emissions.
‘This is another excellent example of how additive manufacturing is revolutionizing our industry, delivering measurable benefits and real value to our customers, particularly as they look to further reduce emissions to meet environmental targets," said Vladimir Navrotsky, Chief Technology Officer for Siemens Power Generation Services, Distributed Generation. He added that Siemens's achievements in using AM are ‘paving the way for greater agility in the design, manufacturing and maintenance of power generation components’.
Additive manufacturing technologies [in the media more commonly referred to as 3D-printing] make it possible to build any object by adding layer-upon-layer of material based on a digital 3D-model. As Siemens spokesperson stated, the use of AM in building this component of the gas turbine has proved to be efficient. The entire development process, from concept to engine test, took only seven months.
By utilizing Siemens-qualified nickel super alloys as the AM printing material, the 3D-printed component requires only two parts. As a result, the lead time is decreased by approximately 70%. This Siemens solution for the SGT-A05 gas turbine can reduce pollutant emissions and cut operating costs associated with water treatment.
In 2017, Siemens finished its first full-load engine tests for gas turbine blades completely designed and produced using AM technology. Earlier this year, the company’s customer got an industrial steam turbine part replaced with a 3D-printed one for the first time. In early 2017, Siemens achieved the first successful commercial installation and continuing safe operation of a 3D-printed part in a nuclear power plant – an impeller for a fire protection pump that is in commercial operation.
Siemens has accumulated over 30,000 hours of successful commercial operation for equipment repaired and manufactured using AM. These are SGT-800 burners (repaired with AM) and SGT-750 burner swirls (manufactured with AM). All these combustor components are running in a very high load and temperature environment.
Siemens is a business programme partner at the 'Russian Energy Week' International Forum which will be held on 3–6 October in Moscow. A number of events within the business program will be dedicated to environmental safety and security and reduction of harmful emissions. In particular, during the discussion on 'Building Cooperation between Russia and the EU in Energy Efficiency and Energy Development' experts from the energy sector will be discussing the necessary conditions for reducing energy intensity in the region by 2030, the role of businesses in expanding Russia–EU cooperation as well as European innovations which could be particularly in demand in Russia and the potential of scientific and technical cooperation in energy and energy efficiency.
As for new technologies in equipment production in the energy sector, these aspects were discussed at the REW 2017. Nico Paetzold, CEO of Siemens Gas Turbine Technologies, noted that integrating modern equipment into existing infrastructures is a very complex task in terms of engineering. One possible solution is digitalization of the industry.
'This year, the number of turbines manufactured in St. Petersburg is close to that of Berlin. Using new technologies, we can monitor each of our gas turbines,' said Nico Paetzold at a round table on 'The Best Management Models and Practice for Major Construction Work in the Fuel and Energy Industry' at the REW 2017.
