Nowadays environmental impact assessment of a new product is necessary to meet rising sustainability requirements also in the Oil & Gas and Power Generation markets, especially for industrial gas turbines. From the conceptual phase to the detailed design, engineer’s work is supported by a wide range of tools aimed to define and evaluate typical parameters such as performances, life and costs, etc. However, considering environmental impact aspects from the early stages of product development may not be easy if the involved engineers are not provided by a specific Life Cycle Assessment (LCA) knowledge. Scope of this paper is to introduce and explain the development of a methodology aimed to define and evaluate the Key Environmental Performance Factors (KEPF) during the whole design process. The proposed methodology enables easy and fast eco-design evaluations and supports sustainable design assessments. Preliminary analysis of the entire processes involved in gas turbine (GT) design and production as well as testing and commissioning phases were performed to evaluate which factors affect mostly the Carbon Footprint of each process, referred to their specific functional unit. Extrapolating the KEPF from Cradle-to-Gate LCA they can be combined with case-specific qualitative and quantitative information such as material selection, manufacturing processes, mass quantity, presence of coatings etc. to provide environmental assessments. A case study of LCA applied to a heavy-duty GT is presented to outline the relative weight of each KEPF.

Nowadays the Energy Industry and Industrial Power Plants are committed to support sustainable development balancing environmental, social and economic benefits. Turbomachinery products, in particular gas turbines design, have to overcome the barriers imposed by: performance, lifetime and costs requirements. A new approach based on Life Cycle Assessment (LCA) is needed to define the correlation between carbon footprint and costs for different materials, manufacturing processes and production regions. To develop a decision-making tool to design sustainable products in the gas turbine sector high quality data are needed to model what is the impact of: materials and operations. Manufacturing operations (like forging and casting) and machining operations (like drilling, milling, turning, together with coating operations) are taken into account in this study. These processes have been customized to model the processes of the real supply chains used in Baker Hughes to build up a database, which is more focused on gas turbines, respect to the ones which can be found in the commercial LCA databases.

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Nowadays a preliminary evaluation of environmental impact of a new product becomes more and more important, especially when the case study refers to an industrial gas turbine both for power generation and mechanical drive applications. The environmental impact evaluation, as well as the preliminary lifecycle cost analysis, will represent a critical driver to develop a competitive product during the conceptual design phase where the engine architecture is an outcome of different alternatives trade-offs. Scope of the following paper is the presentation of a set of Design-for-Environment considerations obtained through gas turbine functional decomposition in modules, identification of the most critical, assessment of their contribution compared to the whole engine in terms of environmental impact as well as the effect on the engine use depending on ambient and operating conditions. The outcome of this study is an approach to preliminarily evaluate the engine life-cycle impact as well as a set of indications to drive machine architecture, material selection and production processes towards the sustainability during manufacturing and operational phases.