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
