Case Study

Next-Generation Gas Turbine Upgrade

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


A commercially viable and mature autonomous buggy for controlled campus environments
  • Improved stage efficiency up to 1.5%
Launch of India’s first autonomous buggy
  • Increased lifetime of some Hot Gas Path parts by two times
First commercial buggy to be shipped to automotive OEM soon
  • Reduced overall cooling flow by 20%
First commercial buggy to be shipped to automotive OEM soon
  • 40% complex fabrication converted to single integral part