Gas Turbine Construction

Feature
Leelananda
Pilanawithana

1
Gas Turbine Details

2
Specification

3
Gas Turbine Layout

4
Cross Sectional
View

5
Introduction

Introduction
Turbine assembly
consists of
• Air inlet
• Compressor
• Combustion system
• Turbine
• Exhaust
• Support system

6
Gas path

• Flow path of gases from the air inlet through the compressor,
combustion section and turbine, to the turbine exhaust.

7
Compressor

• It is a axial flow compressor consists of

– Variable inlet guide vanes
– Compressor rotor
– Compressor stator
• It has 17 stages
• The inlet guide vane constitutes the first stage stationary blade
of the compressor

8
• Variable inlet guide vanes
– Located at the inlet of the compressor
– Can rotate open & close to 900 (adjust the position) on its
axis. (When it fully closed it position is 340 and when it
fully open it position is 840 degrees.)
– The position of these vanes has an effect on the quantity of
air pass through the compressor.
– The Movement of the guide vanes is accomplished by the
control ring that in tern drives the individual pinion gears
attached to the to the each end of the vanes . The control
ring which drives the pinion gears is positioned by the
hydraulic actuator and a linkage arm assembly.
• Compressor Rotor
– The compressor rotor is an assembly of 15 individual
wheels, two stub shafts (each with an integral wheel) a
speed ring, tie bolts, and the compressor rotor blades 9
• Compressor Starter
Consists of 4 major sections
• Inlet casing
• Forward compressor casing
• Aft compressor casing
• Compressor discharge casing

Compressor Stator-Cutaway View Back 10

Inlet Casing

Struts
Inner Bellmouth

Outer Bellmouth

– It is located at the forward end.

– It uniformly directs air into the compressor.
– It supports the No. l bearing housing, a separate casting that
contains the No. 1 bearing.
– Bearing housing maintain axial and radial alignment with
the compressor rotor shaft.
– Contains inlet guide vane assembly. 11
• Forward Casing
– It contains the first four compressor stator stages.
– It also transfers the structural loads from the adjoining
casings to the forward support.
– It equipped with two large integrally cast trunnions one on
each side which are used to lift the gas turbine.
• Aft Casing
– It contains the 5th through 10th compressor stages.
– Extraction ports in the casing permit removal of 5th and
11th-stage compressor air.
– 5th stage extracted air is used for cooling and sealing
functions and 11th stage extracted air is used for starting
and shutdown pulsation control.
• Discharge Casing
– Final portion of the compressor section.
12
– The functions of the compressor discharge casing are
– To contain the final seven compressor stages,
– Again at 17th stage air is extracted for rotor and turbine
wheel space cooling. This air travel through inside rotor.
– To form both the inner and outer walls of the compressor
diffuser,
– To join the compressor and turbine stators.
– Provide support for the No. 2 bearing, the forward end of
the combustion wrapper, and the inner support of the first-
stage turbine nozzle.

Comp disch case inner cylinder

radial struts
Back13
 – This casing consists of two cylinders,
• One being a continuation of the compressor casings,
• the other an inner cylinder that surrounds the
compressor rotor.
– The two cylinders are concentrically positioned by twelve
radial struts.
• Compressor Blading
– The compressor rotor and stator blades are airfoil shaped and designed
to compress air efficiently at high blade tip velocities.

14
 COMBUSTION SYSTEM
• It is a reverse-flow type with 14 combustion chambers
arranged around the periphery of the compressor discharge
casing
• System includes
– fuel nozzles,
– spark plug ,
– ignition system,
– flame detectors,
– and crossfire tubes.
• Combustion Wrapper
– It is a fabricated
casing that encloses
the combustion area.
15
Combustion wrapper….
– Provides a supporting surface for the combustion chamber
assemblies.
– Forms a plenum like area, receives and fill with compressor
discharge air.
– Facilitates discharge air to flow into the combustion
chambers.
– The forward face of the wrapper is slanted at a 13° angle
from the vertical and contains the machined openings for
mounting the 14 covers of the combustion chamber
assemblies

16
 Back

• Combustion Chambers
Compressor discharge air flows into each combustion flow
17
sleeve from the combustion wrapper.
• The air flows upstream in between the flow sleeve and the
combustion liner.
• Part of the air enters through line cap metering hole to the
combustion chamber reaction zone through the fuel nozzle
swirl tip.
• Air is mixed thoroughly with the fuel due to atomizing and
nozzle swirl action of the tip and burn at reaction zone .
• Another part of compressed air enters through metering hole to
the thermal soaking zone to dilute the hot flue gas to reduce
its temperature.
• Along the length of the combustion liner and in the liner cap
are openings (slots) whose function is to provide a film of air
for cooling the walls of the liner and cap.
• Transition pieces direct the hot gases from the liners to the
turbine nozzles.
18
 Back 19
Line cap metering hole
 Back

Transition piece

1st stage turbine

Nozzles

20
Forward face

Back

21
• Spark Plugs
– Use for the ignition air-fuel mixture.
– Ignition transformer connected to it feed the required high
voltage.
– Has a spring loaded electrode.
– Electrode is inside the combustion zone when the
combustion zone pressure is low.
– After ignition and with building-up of pressure in the
combustion zone electrode retracts or move outward
direction.
– Two of this is fixed at two of adjacent combustion
chambers. 13th &14th.
– All other chambers receive ignition by propagation of
flame through Cross-Fire-Tubes
22
23
• Ultraviolet Flame Detectors
– Monitor flame condition (present, intensity).
– Installed at two adjacent combustion chamber of either side
of the turbine, and away from the spark plugs.
– Signal is rooted to turbine control panel.
– Successful firing indicates 2/4 flames present, allows
turbine operation to continue if not stop the operation by
the control system.
• Fuel Nozzles
– Each combustion chamber is equipped one.
– Emits a metered amount of fuel into the combustion liner.
– Liquid fuel is atomized in the nozzle swirl chamber by
means of high pressure air (atomizing air).
– Atomized fuel/air mixture is then sprayed into the
combustion zone. 24
– Action of the tip imparts a swirl to the combustion air.
– Results complete combustion with smoke free operation.

Back
25
 TURBINE SECTION
• This is the area where energy, in the form of high-temperature
pressurized gas is converted to mechanical energy.
Type
• Impulse turbine
• Reaction turbine

26
 Turbine Rotor
• It consists of the following.
• Balancing of the rotating parts
is achieved with mating
Buckets
rabbets on the turbine
wheels, wheel shafts,
and spacers.
• The
wheels
are held
together
with
through bolts.
• #2 bearing comes here

Spacer 27Back
Back
28
• #3 bearing takes the load of the aft wheel shaft that enters to
the load tunnel where bearing is located.
• Spacer carry the diaphragm sealing glands. Buckets

Back
Buckets
• Increase in size from the
first to the third-stage.
• 1St and 2nd stage bucket are
internally cooled but not 3rd
stage bucket.
• Gas pressure drops across the
buckets.
• 2nd and 3rd stage buckets tips
are sealed to prevent gas leak through bucket tip. Tips are
enclosed by a shroud which is a part of the tip seal.
• Buckets are attached to their wheels by straight, axial-entry,
multiple-tang dovetails that fit into matching cutouts in the
turbine wheel rims.
Cooling
• The turbine rotor must be cooled to maintain reasonable
operating temperatures. (discuss more with Sealing and 30
Cooling Air scheme)
1st stage bucket cooling arrangement
Air flows through cooling holes

Structure
of the 2nd-stage
Bucket bucket blades
are cooled by
span-wise air
passages. No
shank cooling.

Back
31
Back

32
 Air from off-
base cooling
fan

Back

Turbine Section-
Cutaway View 33
34
 Turbine Stator
• Constitutes
– Turbine shell
– Exhaust frame
• These internally support
– turbine nozzles,
– shrouds,
– #3 bearing,
– turbine exhaust diffuser.
Turbine Casing (Shell)
• It controls the axial and radial positions of the shrouds and
nozzles. Both of these are fixed to the shell.
• It determines turbine clearances and the relative positions of
the nozzles to the turbine buckets.
• External surface of the shell has cooling air passages. Flow
through these passages is generated by an external fans.
Turbine Cooling

Back 36
Turbine Nozzles
• Consists of three
____ stages.
• Stationary, fixed to turbine shell
____ .
• Direct high velocity expanding hot gas against turbine buckets
______
at proper angle
____ .
• Gas press
____ drop
___ across the nozzles is very high. It is more than
in the buckets.
• This pressure drop requires seals at bucket tips
___ and nozzle
____
ends .
• Bucket tip seals – shroud
• Nozzle end seals – diaphragm
• These seals prevents loss of system energy by leakage.
_________________
1st stage nozzles
• 18 cast nozzle segments, each with two partitions or airfoils,
• Receive gas via transition piece .
____________
• Two retaining rings fix the nozzles to turbine shell
____ . 37
2nd stage Nozzles
• 16 cast nozzle segments each with three partitions or airfoils.
• Nozzles are internally
cooled by compressor
discharge air.
3rd Stage nozzles
• Again 16 cast segments each
with four partitions or airfoils
• No cooling of nozzles
Nozzle Diaphragm
• Attached to the inside diameters
of both the second and third-stage
nozzle segments
Shrouds
• Provide a cylindrical surface for
minimizing bucket tip clearance
leakage. 39
Shroud ….
• Provide a high thermal resistance between the hot gases and
the comparatively cool shell.
• They also subjected to internal cooling.
Exhaust Frame Assembly
• Consists of the exhaust frame and the exhaust diffuser.
• Exhaust Frame consists of
– An outer cylinder
– An inner cylinder
two interconnected by ten radial struts.
• Exhaust diffuser consist of inner and outer diffusers.
Diffuser gas path has turning vanes at the exit end.
At diffuser gas velocity is reduced by diffusion and pressure is
recovered.
From there gas enters into the exhaust plenum. 40
 Back

Exhaust Frame Assembly

41
Exhaust Diffuser

Back

42
Exhaust frame radial struts
• Located across in the gas path .
_______
• It positions Inner
____ cylinder
_______ and the ___ #3
bearing.
• Struts must be maintained at a uniform
temperature to control the center position
__________
of the rotor in relation to the stator.
• Struts has to be protected from exhaust gas heat
______ ___ ___.
• Hence, it need cooling
______ .
• _______
Exhaust Frame
_____ Blowers’
_______ air does this.

43
 Turbine Bearings

• No. Class Type

• 1 Loaded Tilting Pad–Thrust Equalizing
Unloaded Tilting Pad-Non-Thrust Equalizing
• 1 Journal Elliptical
• 2 Journal Elliptical
• 3 Journal Tilting Pad
Elliptical Journal Bearings
• Non-cylindrical bore, improve the stability of the shafts at high
speeds.
Tilting Pad Journal Bearings
• Used where a shaft may exhibit susceptibility to whirl or
misalignment.
44
 Elliptical Journal (Bottom Lobe) and
Thrust Bearings (Lower Half) Installed

Elliptical Journal Bearing

Schematic Diagram

45
Typical Tilting Pad Tilting Pad Journal
Journal Bearing Bearing Schematic
Diagram

46
Typical Tilting Pad Equalizing Thrust Bearing

47
Tilting-Pad
Equalizing Thrust
Bearing
Tilting-Pad
Non-Equalizing
Thrust Bearing

48
Tilting Pad Journal Bearing-Section Through Pad

49
No. 1 Bearing In Inlet Casing 50
#2 Bearing Assembly
51
Turbine Base
• IT is a structural steel fabrication of welded steel beams and
plate.
• Which is mounted on foundation that support turbine and has
lifting trunnions.
Turbine Supports
• Turbine is mounted to its base by vertical supports at three
locations.
• Forward support is a flexible plate that is bolted and doweled
to the turbine base.
• vertical support legs are fixed to the turbine exhaust-frame-
mounted support pads.
Gib Key and Guide Block
• A gib key is machined on the lower half of the turbine shell.
• The key fits into a guide block which is welded to the aft cross
beam of the turbine base.
• Arrangement prevents lateral or rotational movement of the
52
turbine but allow thermal expansion movements.
 Accessory Gear Compartment
Support System

Back

54
 Guide vane compressor casings
12-Inner cylinder

6 Orig

Next
55
1. Speed Ring 19. Support Ring
2. Thrust Bearing 20. Turbine Casing & Shrouds
3. No. 1 Bearing 21. Second-Stage Nozzle & Diaphragm
4. Journal Bearing 22. Shroud
5. Inlet Casing 23. Third-Stage Nozzle & Diaphragm
6. Compressor Rotor 24. Exhaust Air Cone
7. Forward Compressor Casing 25. Turbine Rotor Assembly
8. Aft Compressor Casing 26. No. 3 Bearing
9. Compressor Discharge Casing 27. Exhaust Hood
10. Fuel Nozzle 28. Exhaust Diffuser
11. Spark Plug 29. Load Coupling
12. Inner Compressor Discharge Casing 30. Turning Valves
13. Combustion Liner 31. Third-Stage Turbine Wheel &
14. Rotor Tie Bolt Bucket Assembly
15. Combustion Wrapper 32. Second-Stage Turbine Wheel &
16. Transition Piece Bucket Assembly
17. No. 2 Bearing 33. First-Stage Turbine Wheel & Bucket
Prev Assembly
18. First-Stage Nozzle
34. Rotor Unit 56
GAS TURBINE ARRANGEMENTS
Guide
vane

4 Orig 57
Fwd Leg support

one on each side

Back

58
Guide vanes

59
Guide vanes Rotate (Open position)

control ring

Back
60
Inlet Guide Vane
Control Ring and
Pinion Gears

61
62
 63
6 Back
64
Back

65
 Bolt to
Key secure Key

Guide Block
Back

66