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Power Turbine Major Components

This section describes the power turbine, how it operates and major components.

Major Components

General
The RollsRoyce Energy Systems Inc. power turbine is a two stage impulse reaction turbine. It
extracts energy from the exhaust gases of the gas generator. The exhaust gases have high heat,
pressure, and velocity. The power turbine changes the energy from the exhaust gases
to rotating mechanical energy to drive the machines coupled to it.

Description
As hot gases flow from the gas generator through the free power turbine, velocity energy is
converted into mechanical energy rotating the power turbine shaft assembly. The power turbine
rotates any machinery coupled to its shaft at the output end .
The turbine inlet diffusers guide the exhaust gases to the first stage nozzle vanes. The first stage
nozzle vanes direct the hot gases into the first stage turbine wheel. The nozzle vanes cause the hot
gases to strike the first stage blades at an optimum angle and velocity. Once through the first
stage blades, the hot gases encounter the second stage nozzle vanes that guide them to the second
stage turbine wheel. After passing the second stage blades, the hot gas pressure de-creases
to slightly less than the normal atmospheric pressure. The exhaust diffusers direct the hot gases
into the exhaust hood and out to the atmosphere.

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The power turbine includes the following major components:

Exhaust Diffusers

Exhaust Hood

Turbine Wheels
Upper & Lower
Bearing Housings
Rear Support

Bearing
Assemblies
Inlet Diffuser
Front Support

TYPICAL GAS TURBINE ARRANGEMENT

[POWER TURBINE COMPONENTS INDICATED]

Bearing assemblies
There are three sets of bearings: two journal bearings (one at the coupling
end and one at the disc end) and a thrust bearing.
Journal bearings
The disc end journal bearings are selfaligning, tilting pads in a housing. The coupling end
journal bearing is a fluid pivot type bearing with high damping capability. Both bearings support
the rotor shaft and absorb the vertical and radial vibration. The selfadjusting action of these
bearings has high dampening properties in the individual bearing pads. The bearings consist of a
steel housing and babbitt faced pads.
Thrust bearing
The thrust bearing is an assembly of selfaligning pads in a housing and a babbitt surfaced split
ring, on the counterthrust side, surrounding the thrust collar. The thrust bearing absorbs the rotor
shaft axial thrust. The thrust side of the bearing consists of pads, leveling discs, and
lower links in a base ring. Setscrews retain the babbitt faced pads. Dowel pins retain the lower
links. The counterthrust bearing has a flat split plate. The halves are bolted to the bearing
housing. Shaft thrust is normally in one direction, toward the coupling end. So the self-leveling

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bearing pads are on the coupling side of the thrust collar. The pads equally divide the thrust load
and compensate for slight misalignment.

Bearing case and covers

Bearing case is a cast iron housing with three removable covers. It houses the rotor shaft, the
bearing assemblies, the vibration detectors, and oil lines. It is overhung from rear support and
extends through the center of the support toward the inlet end of the turbine. The bearing case is
visible from behind the rear support.

Detectors and pickups

Detectors and pickups are probes with lead wires. They measure position, speed, temperature, and
vibration and relay the information to the UCP. The UCP displays all detector and pickup
readings. The UCP signals an alarm or shuts down the gas turbine if any readings are out of
range.
Axial position detectors
Axial position detectors measure the amount of rotor axial movement. These detectors are
located near the thrust collar.
Resistance temperature detectors
RTDs measure bearing pad temperatures. There are RTDs in both journal bearings and the thrust
bearing.
Speed and fuel control pickups
The speed monitor and fuel control pickup control the GG speed by measuring turbine speed.
They protect the turbine from overspeed. These pickups are mounted on the bearing case covers.
Vibration detectors
Vibration detectors monitor the horizontal and vertical movement of the rotor shaft near both
journal bearings. These detectors are mounted on the journal bearing caps.

Inlet diffuser assembly

Honeycomb seals
Honeycomb seals are strips of steel with a honeycomb pattern on one side. The honeycomb seals
are installed inside the nozzle casing and second stage blade casing. The seals and shrouds, on the
ends of the turbine blades, limit exhaust gas from escaping around the ends of the turbine blades.
They have a specified radial clearance with the shrouds.
Inlet diffusers
Inner and outer inlet diffusers are circular casings fixed at the inlet to the power turbine. They
guide the exhaust gas between the GG and the power turbine.
Nozzle vanes
The nozzle vanes are stationary, angled vanes in the gas path. They direct and accelerate the hot
exhaust gas onto the turbine wheels. Drilled vanes provide an air circulating system to cool the
wheels. First stage nozzle vanes are secured in the inlet diffusers. The first stage vanes are
fastened to and support the inner inlet diffuser. Second stage nozzle vanes are secured to the
nozzle casing. They support the diaphragm that is between the turbine wheels.

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Rim cool manifolds

The rim cool manifolds are two semicircular manifolds with drilled holes and attached flexible
hoses. They supply cooling air to control heat from the exhaust gases. Pressurized air from the
GG enters the air manifolds and flexible hoses. Air spreads through the rim cool manifolds
to a series of vane connectors around the outer inlet diffuser and nozzle casing. Then, the air
passes through holes in the nozzle vanes to cool the first stage turbine disc. Two thermocouples
extend through drilled passages in two of the first stage nozzle vanes to monitor the temperature
in front of the first stage disc.

Rotor assembly
The rotor assembly consists of a long steel shaft with a thrust collar, helical gear, and two stages
of turbine wheels. The rotor assembly converts the GG exhaust gas velocity energy to rotating
mechanical energy.
Diaphragm and labyrinth seal
The diaphragm and labyrinth seal are steel rings between the turbine wheels. The diaphragm
limits any hot gases that escape the gas path and controls the cooling air flow. The labyrinth seal
impedes the flow of any gas that escapes the gas path and flows around the diaphragm. The
labyrinth seal is doweled to the turbine disc. Second stage nozzle vanes hold the diaphragm in
place.
Helical gear
The helical gear is a heavy steel gear. It is interference fit and keyed to the rotor shaft on the
coupling side of the thrust collar.
Labyrinth seal ring
The labyrinth seal ring is a ring with annealed stainless steel strips inserted into it. It prevents any
hot gases and bearing oil from mixing. The seal works using air tapped from the GG. The air is
applied to the center of the seal. It flows evenly in both directions, keeping lubricating oil in the
bearing case and hot gases in the gas path. The labyrinth seal ring is bolted to the rotor shaft
behind the second stage turbine disc.
Turbine blades
The turbine blades are individually machined blades set in the gas path. They cause the rotor
assembly to rotate when the hot gas strikes them. The turbine blades are attached to each turbine
disc. At the base of each blade is a fir tree design that matches the design in each disc. Retainers
hold each blade securely in position. At the top of each blade is a shroud. The shroud matches
with honeycomb seals to limit the amount of hot gas escaping around the blade tips.
Thrust collar
The thrust collar is a hardened, precision lapped disc. It transfers shaft axial thrust to the thrust
bearing. It is keyed and interference fit to the rotor shaft. A spacer and spanner nut help hold it in
position. The thrust collar is located between the thrust bearing halves.
Turbine discs
The turbine discs are two large circular discs. They retain each turbine blade using a retainer and
fir tree design. The turbine discs along with the turbine blades make the turbine wheels. Twelve
tiebolts and nuts secure the two turbine discs to the end of the rotor shaft.

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Rotor shaft
The rotor shaft is a long steel shaft. All components of the rotor assembly are mounted on it. The
drive end is tapered to mate with a hydraulic fit coupling hub. The rotor assembly, shaft and
turbine discs, is dynamically balanced as a unit before it is installed. This reduces vibration and
bearing wear.

Supports
The turbine is held in position by a cast iron main turbine support and a spring support.
Rear turbine support
Rear turbine support is an upright stand positioning some of the stationary and rotating turbine
elements. Pivot pins, on the circular exhaust diffuser, are bolted on each side of the support. They
allow the turbine to move slightly. Eight radial pin and ball joints, with spherical bearings on the
circumference of the exhaust diffuser, permit thermal expansion. This design allows expansion
without overstressing the growing parts while keeping the rotor shaft and bearing case concentric.
Front turbine supports
The front turbine support has two parts: a one piece front support and a mounting ring spring
support. The one piece front support is bolted to the GG/RT base. It is secured to the mounting
ring by two spherical bushings and pins. It holds the turbine mounting ring and other inlet
diffuser components in place. The mounting ring spring support is a heavy duty horizontal
spring. It applies a load on the turbine mounting ring to maintain its correct loading
and concentricity while the turbine operates. This support is located on the GG and turbine base
under the turbine inlet.

Turbine exhaust
Exhaust diffusers
Exhaust diffusers are large curved steel cones. They reduce gas exit velocity and regain parts of
velocity energy. The inner exhaust diffuser is bolted to the main turbine support. The outer
exhaust diffuser is bolted to the expansion joint.
Exhaust hood
The exhaust hood is the insulated housing containing the exhaust diffuser. It collects the exhaust
gases and directs them to the exhaust stack. Also, it reduces thermal stress in the turbine
components by heating the outer surface of the turbine casing during warmup.