Case Study

Gas turbine build stations

Hyde completed the full design, manufacture and assembly of two aero engine build stations, installed and commissioned on site. The two stations were fully CE marked and are in daily use, supporting the engine build and test for the next two decades.

The engine build stations allow the client to perform engine build and strip activities in a single location, previously performed separately. Each build station therefore combines the functionality of two facilities and was consequently novel and complex in design. 

The build stations are identical but independent and are suspended from the building superstructure, providing full access around and under the engine. Each consists of two, four point screw-jack lift systems capable of safely lifting a maximum of 50 tonnes.

One of the structures provides the lift and support of engine accessories whilst the other supports the engine and working gantries. Both can be lifted and lowered independently via computer control. This also provides feedback from over thirty sensors monitoring the machine to ensure it’s in a safe configuration at all times, protecting both the operators and the engine. This allows the client to work on engines of all sizes at any height, up to a maximum of three meters from ground level, giving a high degree of flexibility and providing a safe and efficient working environment.  

Major technical challenges were to design each build structure with the capacity and strength to lift an engine and provide all client functionality, but also to work within the load limitations of the building superstructure. Hyde Group’s diverse manufacturing capability, technical experience and expertise proved vital in the management and realisation of the project and was key in securing the contract award.  The work covered the complete design of the mechanical structure, control systems, the manufacture and procurement of all hardware and the full management of the project.