Engineered for High-Temperature Performance
- GT13E2 vanes and nozzle guide vanes are exposed to extreme thermal cycling and gas loads in the hot gas path.
- ZURN Power manufactures vanes using directionally solidified and equiaxed nickel-based superalloys to match OEM life expectations.
- Internal cooling configurations are replicated to protect against oxidation and thermal fatigue.
Materials & Cooling Configurations
- We use cobalt and nickel-based superalloys equivalent to Alstom specifications.
- Thermal barrier coatings (TBC) and aluminide diffusion coatings are applied to extend service intervals.
- Material certifications and heat treatment records are supplied with each batch.
Inspection, Repair & Replacement
- Incoming vanes are inspected for erosion, cracking, and coating degradation using penetrant testing and dimensional checks.
- Repair options include tip restoration, coating refurbishment, and crack repair where technically feasible.
- Replacement vanes are delivered ready for installation with full traceability documentation.
Request a Quote
- Share your part number, quantity, and required delivery timeline for a fast quotation.
- Our engineering team can cross-reference obsolete or modified vane designs.
- Email sales@zurnpower.com for GT13E2 vane pricing and availability.
GT13E2 Nozzle Guide Vane (NGV) Design
The GT13E2 turbine section uses 5 stages of nozzle guide vanes (stationary blades) that direct hot gas onto the rotating turbine blades at the optimal angle and velocity. NGVs operate at the highest metal temperatures in the engine, as they are stationary (no centrifugal cooling from rotation) and directly exposed to combustion gas. Stage 1 NGVs see gas temperatures exceeding 1,100 C and require advanced cooling and thermal barrier coating (TBC) systems.
| Parameter | Specification |
|---|---|
| NGV stages | 5 (matching 5 turbine stages) |
| Vaners per stage | ~40-80 (varies by stage) |
| Stage 1 gas temperature | 1,100-1,140 C |
| Cooling type | Internal convection + film cooling |
| Cooling hole count (S1) | ~200-400 holes per vane segment |
| TBC thickness | 150-300 microns (YSZ) |
| Primary materials | CMSX-4, DS GTD-222, Inconel 939, Nimonic 263 |
NGV Materials & Manufacturing
Nozzle guide vanes are investment-cast using advanced superalloy chemistries tailored to each stage operating environment:
| Stage | Material | Casting Type | Max Metal Temp |
|---|---|---|---|
| Stage 1 | CMSX-4 (single crystal) | Directional solidification | 1,050 C |
| Stage 2 | GTD-222 (DS) | Directional solidification | 950 C |
| Stage 3 | Inconel 939 | Equiaxed investment cast | 850 C |
| Stage 4 | Nimonic 263 | Equiaxed investment cast | 750 C |
| Stage 5 | Nimonic 263 | Equiaxed investment cast | 650 C |
ZURN Power sources investment-cast NGV segments from qualified foundries with vacuum induction melting (VIM) and vacuum arc remelting (VAR) capabilities. Each casting undergoes 100% radiographic inspection per ASTM E192 for internal soundness. Cooling hole patterns are produced by EDM (electrical discharge machining) or laser drilling, with hole diameter tolerance of 0.05 mm.
Common NGV Failure Modes
- TBC spallation: Thermal barrier coating delaminates from bond coat due to thermal cycling and oxidation. Exposes base metal to gas path temperatures, accelerating material loss. Inspect at every combustion inspection (8,000-12,000 hours).
- Cooling hole blockage: Combustion deposits and particulate matter plug film cooling holes, reducing cooling effectiveness. Blocked holes increase local metal temperature by 50-100 C. Clean or re-drill at major inspection.
- Trailing edge cracking: Thermal fatigue cracks initiate at thin trailing edge sections where stress concentrations are highest. Monitor crack length; repair if under 3 mm, replace if exceeding limits.
- Leading edge oxidation: High-temperature oxidation erodes leading edge material, changing gas turning angle and reducing stage efficiency. Measure leading edge profile at each inspection.
- Vane segment shifting: NGV segments may shift in the casing groove, changing throat area distribution. Measure throat areas at each major overhaul; re-shim or replace segments as needed.
NGV Repair & Refurbishment
NGV refurbishment can extend component life at 30-50% of new cost. ZURN Power's NGV repair scope includes:
- TBC strip and recoat: Chemical stripping of damaged TBC, surface reconditioning, bond coat (NiCoCrAlY) reapplication via HVOF or PVD, and top coat (YSZ) reapplication via EB-PVD or plasma spray
- Cooling hole restoration: EDM or laser re-drilling of blocked or eroded cooling holes to original diameter and angle
- Weld repair: GTAW (TIG) welding of trailing edge cracks using matching filler metal; stress relief heat treatment post-weld
- Leading edge buildup: Weld buildup on eroded leading edges, followed by profile restoration machining
- Throat area adjustment: Shimming or machining to restore correct throat area distribution within 2% of design
- Final inspection: Dimensional CMM check, airflow verification, and FPI on all repaired surfaces
Quality Assurance & Lead Time
All NGV segments and refurbishment services are delivered under ISO 9001:2015 and AS9100D. Quality controls:
- Casting inspection: 100% radiographic per ASTM E192; fluorescent penetrant per ASTM E1417
- Dimensional verification: CMM inspection of airfoil profile, throat area, and mounting interfaces
- Coating verification: Metallographic cross-section for TBC thickness and bond integrity; eddy current for thickness measurement
- Documentation: Material certs, NDT reports, coating records, dimensional report, and conformity certificate per shipment
Lead times: Stocked Stage 1 NGV segments ship in 5-7 business days. New castings: 20-28 weeks. Refurbishment: 6-10 weeks from receipt. For NGV inquiries, provide GT13E2 serial number, affected stage(s), and vane segment part numbers. Contact sales@zurnpower.com for availability and pricing.