Tag Archives: gas turbines

Delivery of First New Generation GE Power HA.02 Gas Turbine

General Electric Power and Water have recently delivered the first HA.02 unit to the Exelon Wolf Hollow site in Granbury, Texas.   Groundbreaking for the new power generating station was held on July 9, 2015.  The new CCGT (combined-cycle gas turbine) will provide an additional 1,000 megawatts to the existing 704 megawatt natural gas power plant.  The new unit is to be one of the most environmentally friendly and efficient CCGTs in the state and nation. It utilizes GE Power’s most advanced gas turbine technology and an air cooling system, which eliminates the use of water to cool the unit.

HA.02 unit

The HA.02 unit is seen being positioned at the facility.

Hi-Tek Manufacturing, Inc. worked to develop the manufacturing of several critical components for the HA.02 hot gas path engine section.  The components include stage 1 and stage 2 vanes, baffles, and near flow path seals, and were developed with an extremely fast track New Product Introduction (NPI).  Hi-Tek Manufacturing’s engineering, quality, and manufacturing team developed the processing of these critical hot gas path components in the shortest time frame in the company’s history.  Utilizing the latest developed technology in laser, CBN grinding, fast hole EDM machining, and in-house braze and heat treat was the key to Hi-Tek’s success.

“It was a collaborative effort,” stated Barry Nehls, Sales and Marketing Manager.  “The General Electric Power and Water need dates for qualified, finished components was critical to the engine assembly and test schedules. Working with the GE team from engineering, sourcing, quality, and production required constant detailed communication in order to achieve our common goals.”

The HA.02 gas turbine power generation turbine is the first of two to be installed at the Wolf Hollow facility.  An additional 1,000 megawatt CCGT is being constructed at Exelon’s existing Colorado Bend Generating Station in Wharton, Texas, approximately 60 miles outside of Houston.  Both sites are expected to achieve commercial operation in 2017.  Hi-Tek Manufacturing, Inc. is pleased to be a GE Power and Water global supply chain partner to provide manufactured components for this exciting new HA.02 engine program.

The Name in Electrical Discharge Machining (EDM) is Hi-Tek!

EDM, an extraordinary technology, alternatively referred to as “spark machining” or “wire burning”, is a manufacturing process in which innumerable kinds of shapes are obtained utilizing electrical discharges or, what laypeople might call, sparks. In this seemingly magical process, material is removed from the piece being worked by a series of rapidly repeating current discharges between two electrodes that are separated by a dielectric liquid,  which is basically an electrical insulator in liquid form that can be polarized when an electric field is applied.

Electric Discharge Machining is surprisingly quite simple to explain when broken down:  An electrical spark is initiated between an electrode and the piece that is being shaped. The spark that is visibly emitted produces extreme heat that melts almost anything it contacts. This electrical spark is highly controlled and localized so that only the surface of the material being worked is affected. The liquid medium serves to cool and flush away any eroded metal particles eventually leaving behind a finished product.

Hi-Tek Manufacturing’s state-of-the-art electrical discharge machining services offer over 100 EDM machines that perform a wide variety of processes from the most staggeringly complex to simple, one-off operations. Hi-Tek’s equipment list consists of in-house designed and built fast hole machines, multi-axis CNC sinker machines, 3-axis sinker machines, a variety of EDM plunge equipment, and wire EDM machines. Holes can be produced as small as 0.001” and hold the true position to +/- 0.0005” and diameter tolerance to +/- 0.0002”.

The electrode manufacturing capabilities at Hi-Tek can produce stamped copper, brass tubes and rods, graphite, and tungsten rod electrodes and process holes in various forms such as cooling, round, shaped, pin seal, tip and non-line of sight, as well as non-hole features like slots, grooves, pockets, and notches. In other words, Hi-Tek is a one-stop shop!

To learn more about Hi-Tek’s cutting-edge electrical discharge machining (EDM) services, call today and discover why Hi-Tek lives up to its name.

Learning More about How Gas Turbines Work

Hi Tek Mfg gas turbineGas turbine engines are versatile and trustworthy engines, as they are used for a number of different industries, such as helicopters, ships, locomotives, tanks and small power plants. There are, of course, many different types of turbines, such as steam, wind and water turbines. Specifically, a gas turbine uses a pressurized gas to spin the turbine.

In all modern gas turbines, the engine produces its own pressurized gas by burning fuel such as propane, natural gas, kerosene or jet fuel. The heat produced by the burning the fuel expands in the air, and the rush of this hot air is what spins the turbine.

Gas turbines are made up of three basic parts:

  1. Compressor – Compresses the air to high pressure
  2. Combustion area – Burns the fuel and produces high-velocity gas
  3. Turbine – Extracts the energy from the gas flowing from the combustion chamber

In an axial-flow gas turbine engine, air is sucked in by the compressor, which is a cone-shaped cylinder with small fan blades attached. As the air is pushed through the compression stage, its pressure rises significantly.

One major advantage of gas turbines is that they have an excellent power-to-weight ratio compared to other engines. In other words, the amount of power you receive from the engine is good compared to the engine’s weight. On another positive note, gas turbine engines are much smaller than their reciprocating counterparts of the same power, saving space and energy.