Quality Assurance for
Gas & Steam Turbines

ZEISS Power & Energy Solutions

Steam turbine efficiency

Maximize efficiency

Gas and steam turbines require meticulous attention to detail in design and operation. Even the slightest quality issues can lead to operational hazards, reduced efficiency, and shorter service life. ZEISS offers solutions, enabling customers to achieve the highest quality standards and accelerate production, ensuring the turbines' safety, efficiency, and longevity.

Understanding steam turbine components

Ensuring performance

Steam turbine components must be stable under a wide range of load conditions. Such turbines can be integrated with gas turbines that use waste heat for steam generation, or they can be an integral part of nuclear and coal-fired power plants that rely on steam for energy production.

Providing part quality control for optimum performance of gas turbines

Compressor component quality control: Providing part quality control for optimum performance

A compressor is the crucial component for compressing air by a defined ratio to achieve efficient combustion and provide air for the cooling of the blades in the hot zone. As a result, it is subject to strict quality controls to ensure the compressor proper functioning and optimum performance. Discover how ZEISS Metrology can support you here.

Hot zone blades and components: Solutions for coated parts in production and maintenance

The fuel is ignited in the combustion chamber to produce high-pressure hot gases. These gases expand through the blades and vanes of the turbine stages and drive a shaft. The high temperature along this process requires proper air cooling and a special coating for all components. Proper design, coating of the parts as well the integrated cooling holes are essential for efficient operation and to prevent breakdowns. Discover the solutions of ZEISS.

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Additive Manufacturing: Quality assurance is key

Additive manufacturing processes, such as 3D printing, open up new opportunities for the design of components and, at the same time, more efficient production. Being able to simultaneously manufacture multiple components in one batch speeds up production, which contributes to improved process efficiency. Moreover, the material properties reach a level that is comparable to conventional production technologies such as casting or forging.

To guarantee consistent quality during the production process, in-process quality assurance is carried out. This includes material analysis, technical cleanliness and complete 3D scanning of free-form surfaces and special structures. You want to improve your processes? Then take a look at the solutions from ZEISS.

Gain insights into quality assurance at Materials Solutions

Steam turbine: Enhancing efficiency with quality control

Steam generation can have several sources, such as exhaust gas from gas turbines, iron casting, nuclear power, or other high-temperature sources. The available steam pressure and volume define the turbine design to include high-pressure, a medium-pressure, and a low-pressure turbine section. The pressurized steam flows through the blades and vanes to produce mechanical energy to run a generator. ZEISS metrology solutions ensure performance at the highest level and increase efficiency based on various data. Design and performance improvements are the key factors for power generation.

Gearbox for speed reduction

For power generation, gas and steam turbines run at a specific speed that is optimized based on the turbine design and efficiency. This speed level can deviate from the input needed at the generator side. In this case, a speed reduction gearbox is built into the power generation setup to align the speed level and torque of the turbine shaft through the gearbox to the generator. ZEISS Quality Solutions can increase reliability and longevity for the gearbox and its components, reducing costly downtime and repairs.

Generator: Maximizing efficiency with quality control

The generator consists out of the rotor, stator and stator housing, and converts mechanical energy into electrical energy. The generator can be mounted directly on the shaft of the gas and steam turbine or can be driven by the speed reduction gearbox.

Tight tolerances and a small air gap between the stator and rotor are crucial for the overall performance. ZEISS solutions help to enable high efficiency based on accuracy. From blades and injectors to metallurgical and other inspections, ZEISS provides the appropriate solution for your application.

Housing and casted parts

Inspection of gas and steam turbine housings and castings focuses on surface analysis and defect detection, which are crucial for ensuring reliability and longevity. ZEISS Power & Energy Solutions address quality challenges by detecting geometrical issues, accelerating measuring times, and enabling detailed high-resolution inspections. By acquiring complete 3D surface data, component analysis is significantly enhanced, leading to greater production efficiency and quality. ZEISS metrology enables optimum turbine performance while ensuring stringent quality standards throughout the manufacturing process.

Powerful software for efficient analysis

One software for advanced metrology

ZEISS INSPECT

Discover the strength of ZEISS INSPECT, a software solution that allows you to analyze a variety of data types, including optical 3D data, volume data, blades and airfoils, and moving image data. The software's powerful features ensure your specific needs can be met, regardless of the system you use. Easy drag-and-drop data import and user-friendly templates ensure efficient workflows and accurate results.

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All-purpose software for dimensional metrology

ZEISS CALYPSO

Coordinate measuring machine software: ZEISS CALYPSO measures geometric elements - accurately, fast and efficiently. Select the required measurement features to configure your inspection plans. When used in connection with ZEISS measuring systems and sensors, ZEISS CALYPSO provides you with a powerful system from a single source. The software also adapts to your needs: With numerous optional add-ons, ZEISS CALYPSO also provides the perfect solution for demanding applications.

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Intelligent inspection software for high demands

ZEISS PiWeb

ZEISS PiWeb supports decision making on the shopfloor with measurement results, values for temperature and other input data from various sources and equipment. This allows you to efficiently track your production quality across all machines along the production. ZEISS PiWeb can capture and analyze results from tactile, optical, manual or CT measurements from other parties as well as other machines such as CNC milling and more.

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From blades and injectors to metallurgical and other inspections, Zeiss provides the appropriate solution for your application.

ZEISS Solutions for Power & Energy

ZEISS ATOS LRX

ZEISS ATOS LRX is the specialist for large-volume parts as housings or casting parts.

ZEISS MMZ

High-precision CMM solution for multiple applications as housings, shafts, discs, and machining.

ZEISS AXIO and ZEISS EVO

The microscopy solutions from ZEISS support you in the inspection of blades as well as in metallurgy and technical cleanliness.

ZEISS ATOS 5

ZEISS ATOS 5 for Airfoil is used in manufacturing and MRO for blade and vane inspection as well as to measure the coating thickness

ZEISS PRISMO and ZEISS ScanBox

ZEISS PRISMO – High-precision tactile measurement of geometries and injectors. ZEISS ScanBox delivers full 3D data for your digital twin of additive manufactured parts.

ZEISS PRISMO for Airfoil

Accurate airfoil for high-precision blade inspection with ZEISS PRISMO for Airfoil.

ZEISS DuraMax

Zeiss DuraMax is designed to provide versatile inspection for blades, shopfloor grinding and preset option for EDM.

ZEISS T-Scan Hawk 2

Advanced MRO and other laser scanning applications in the power and energy industry.

ZEISS ScanBox

ZEISS ScanBoxes for measurement of blades, vanes, and coating thickness