The large installed base of large frame industrial gas turbines has prompted a number of replacement part offerings, in addition to the replacement parts offered by the OEM. The quality and rigor of the offerings varies considerably. The replacement parts can be broken down into three categories: replicated parts, reverse-engineered parts, and re-engineered parts. The processes of replication, reverse engineering, and re-engineering are examined in detail. Specific differences between the three approaches are identified and discussed. The economic model presented by Willett and Pothier [2003] is used to examine the potential economic benefits of replacement parts and quantify differences in potential benefits as a function of engineering approach. The benefits of each approach depend not only on the engineering process, but also on the customer (power plant operator) profile. Base load, cyclic duty, and peaking operation, along with risk tolerance, influence the predicted benefit and determine the most effective engineering approach.

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