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A European power generation major wanted to upgrade the existing fleet with a new Heavy duty class capacity and capability milestone using a new Hot Gas Path design.

The primary requirement was to increase efficiency at the high-power output and flexibility.

Key Challenges

  • New combustion technologies to handle fuel alternatives aiming to reduce carbon emissions
  • Higher firing temperatures, lower emissions and increased operational with fuel flexibility
  • Product needed to be developed and deployed in a record time of under one year to meet client requirements

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The Solution

Delivering state of the art complex engineering

  • Redesigning of new blading rows for compressor and turbine stages including head shields
  • Extensive R&D support with full-scale CAE for the development of the next-generation combustor
  • New cooling schemes that reduce the total cooling air even with increased hot gas temperature
  • Optimized engineering solutions using the novel additive manufacturing against conventional casting

Proven depth and scale of technology at work

More than 180 engineers worked seamlessly over 12 months across five locations to achieve one goal

Benefits

Improved stage efficiency up to 1.5%

Increased lifetime of some Hot Gas Path parts by two times

Reduced overall cooling flow by 20%

40% complex fabrication converted to single integral part

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