CONSTRUCTIONAL

DETAILS OF
GAS TURBINES
AT KAWAS
Introduction
 The session will deal with the
constructional aspects of Frame 9E
Gas Turbine along with our working
experience with these machines.
Introduction
 MAKE : GE USA
 MODEL : 9001 E (PG 9161 E)
 PACKEGED GENERATOR, SINGLE SHAFT
MACHINE, RATED CAP. 116.4 MW AT ISO
CONDITIONS
 AIR FLOW : 1450 T/Hr
 GAS CONS. : 39722 NM3/Hr
 L/F CONS. : 29206 KG/Hr
 TIT : 1104O C
 EXH. TEMP : 529O C
THERMAL CYCLES DIAGRAM FOR
COMBINED CYCLE POWER PLANT
HEAT FLOW DIAGRAM FOR
COMBINED CYCLE POWER PLANT
Agenda
 The topic on Gas Turbine
construction is broken up as under :-
I. Gas turbine auxiliaries
II. Inlet – air system.
III. Axial flow compressor.
IV. Combustion system.
V. Impulse gas turbine
VI. Turbine supports.
VII. Turbine bearings.
VIII. Turbine cooling.
 GT fin fan cooler
Compressor wash skid
Naptha skid
Gen. fin fan cooler

Gas skid Water injection skid

Gen. CW pump skid

Accessories Turbine Exhaust Load Generator

Compartment Compartment Compt. Compt. Compt.
Inlet air duct

Pulse Local Control room Exhaust plenum fan Jacking oil skid
cleaning air
receiver

Battery room
GAS TURBINE LAYOUT
GAS TURBINE AUXILIARIES
 Liquid fuel pump.
 Main lub oil pump hydraulic oil pumps.
 Atomising air compressor.
 Auxiliary lub oil and hydraulic oil pumps.
 Cooling water pumps.
 Liquid fuel flow divider.
 Ventilation fans for all gas turbine
compartments
 GAS TURBINE AUXILIARIES
 All the major auxiliaries are mounted on the lubricating oil
tank of 12450 L capacity.
 Major auxiliaries are driven by the gas turbine main shaft
through accessory gear box.
 The accessory gear box in turn is connected to the turbine
main shaft by accessory shaft / auxiliary shaft.
 The auxiliary shaft is a gear coupling between the turbine
main shaft and the gear box.
 Because the turbine main shaft expands towards the gear box
the float provided in the accessory shaft is between 22 to 25
mm.
GAS TURBINE AUXILIARIES LAYOUT
ARRANGEMENT OF AUXILIARIES
 STARTING MEANS
 For initial starting of the gas turbine a 6.6 KV starting
motor is provided.
 The starting motor / cranking motor is connected to the
main shaft through gear box and a hydraulic torque
converter.
 The hydraulic torque converter is a fluid coupling which
operates by the lub oil itself.
 It is a pump and turbine combination to transmit
maximum torque for starting.
 Turning gear motor is provided to run the turbine on
turbine speed for start up and cool down.
 The turning gear motor is coupled to the same shaft as
the cranking motor.
 ACCESSORY GEAR BOX
MAIN
ELECTROMEGNATIC OIL
CLUTCH PUMP

MAIN
SHAFT

MECHANICAL
TRIP BOLT
 FLOW DIVIDER
 Flow divider is used to divide the fuel coming from the
single discharge of the high pressure fuel pump in to 14
equal streams of fuel to be fed to the individual nozzle.
 Flow divider works on the principle of a gear pump, which
says that flow through a gear pump is proportional to the
speed of the rotating member.
 It has 14 individual gear pumps taking suction from the fuel
pump discharge and their out let is connected to the
individual nozzles.
 All the gears are joined by means of a single sun gear
thereby maintaining same speed of all the gears.
FLOW DIVIDER
GAS TURBINE
ARRANGEMENTS
INLET SYSTEM
 INLET SYSTEM

IT CONSISTS OF
FOLLOWING PARTS

1. FILTER COMPARTMENT.
2. DUCT.
3. SILENCER.
4. LINED ELBOW.
5. TRANSISTION PIECE.
6. INLET PLENUM.
7. EXPANSION JOINTS.
a is
r FILTER HOUSE
 There are 1104
f number of filters
e. arranged in 3 tiers of
the filter house.
The filters are hanging
vertically downward and
fixed by means of a
central rod handle.
COMPRESSOR SECTION
COMPRESSOR SECTION
 VARIABLE INLET GUIDE VANES
 COMPRESSOR ROTOR
 COMPRESSOR STATOR
VARIABLE INLET GUIDE VANES
 Variable inlet guide vanes are located at the inlet of the
compressor
 VARIABLE INLET GUIDE VANE
The movement of the
guide vanes is accomplished
by the control ring that in
turn drives the individual
pinion gears attached to
each end of the vanes. The
control ring is positioned
by the hydraulic actuator
and linkage arm assembly.
COMPRESSOR
 The compressor is an 17 stages axial flow
compressor.
 The inlet guide vane constitutes the first
stage stationary blade of the compressor
 The compressor has air bleed off points at
various locations for bearing cooling and
sealing, bleed off to the exhaust for surge
suppression, for turbine cooling etc.
 COMPRESSOR ROTOR
 Compressor rotor is an assembly of 17 wheels.
 It consists of two stub shafts with integral wheel on each
side and 15 individual wheels in between which are held
together by tie rods.
 Forward stub shaft is machined to provided forward and aft
thrust faces and journal for bearing # 1 as well as sealing
surfaces for bearing # 1 oil seals and compressor low
pressure air seals.
 The wheels portion of each stage has a slot broached
around its periphery and rotor blades and spacers are
inserted in these slots.
COMPRESSOR & TURBINE
ROTORS
COMPRESSOR STATOR
 The stator of the compressor consists of four
major sections
 Inlet casing
 Forward compressor casing
 Aft compressor casing
 Compressor discharge casing.
 INLET COMPRESSOR
CASING
 Inlet casing is located at the forward end of the gas
turbine.
 Its function is to uniformly direct air into the
compressor.
 It consists of two casings, outer casing and inner casing
which is positioned to outer casing by 8 airfoil shaped
radial struts. The radial struts are cast into the casing
 Annular area between the two casing forms a bell
mouth entrance for air.
 Inner casing supports the housing of bearing # 1.
 VIGV is installed in this casing.
COMPRESSOR FORWARD
CASING
 Forward casing is bolted to the compressor
inlet casing and compressor aft casing.
 It houses first four compressor stator stages.
 It also transfers the structure load of adjoining
casings to the forward support.
COMPRESSOR AFT CASING
 The aft casing is bolted to the forward casing and
compressor discharge casing.
 It houses fifth to tenth stator stages of compressor.
 Extraction ports are provided in this casing for
cooling & sealing air and bleed off from fifth stage
and eleventh stage respectively.
 COMPRESSOR DISCHARGE
CASING
 It consists of two cylinders, one being the
continuation of compressor casing and the other
being inner cylinder that surrounds the compressor
rotor.
 Two cylinders are positioned by twelve redial struts.
 The compressor discharge casing contains the final
seven stages of compressor stator.
 The inner cylinder provides support for bearing # 2.
 The diffuser formed by the annular area between
outer cylinder and inner cylinder converts some of the
compressed air velocity to added pressure.
 COMPRESSOR BLADING
 Compressor Rotor blades are airfoil shape and are
attached to the wheels by dovetail arrangement.
 Compressor Stator blades (first eight) are airfoil shaped
and are mounted by similar dovetails into the ring
segments. And these ring segments are inserted into
circumferential grooves in the casing.
 Last nine stages and two exit guide vanes have a square
base dovetail that are inserted directly into the
circumferential groove into the casing.
COMPRESSOR BLADING
GAS FUEL SYSTEM
 Gas fuel system has stop ratio valve and
control valve for regulating pressure and flow
to the nozzle.
 When the turbine runs on liquid fuel the gas
line gets purged by compressor discharge air.
LIQUID FUEL SYSTEM
 Liquid fuel system has two check valves namely 1)
liquid fuel check valve and 2) purge air check valve.
 The opening pressure in the forward direction is 8
bar for liquid fuel check valve. This is to avoid the
fuel flow to the nozzle when not required.
 The liquid fuel lines from fuel check valve to the
nozzle gets purged when the turbine runs on gas
fuel through purge air check valve.
LIQUID FUEL SYSTEM
FUEL SYSTEM PIPINGS
COMBUSION SECTION
COMBUSION SECTION
 COMBUSTER CASING
 COMBUSTER HARDWARES
 SPARK PLUG
 FLAME SCANNER
 FUEL NOZZLE
 COMBUSTION LINER
 CROSS FIRE TUBE
 FLOW SLEEVE
 TRANSITION PIECE
 COMBUSTION CHAMBER
There are 14 combustion chambers arranged around
the periphery of compressor discharge casing in a
casing called combustor wrapper.
ARRANGEMENTS OF
COMBUSTION SECTION
The combustion system is a reverse
flow type system in which high
pressure air from compressor
discharge is directed around the
transition piece into the combustion
liner. The air enters to the combustion
zone, mix with fuel and is burned
inside the combustion liners.
SPARK PLUG
 The combustion is initiated by means of discharge
from two high voltage retractable electrodes
installed in the combustion chamber # 12 & # 13.
 These spring injected plugs receive there energy
from the ignition transformers. As the rotor speed
increases, chamber pressure causes the spark plug to
retract and the electrodes are removed from the
combustion chamber.
FLAME DETECTOR
 Flame detectors are installed in four adjacent
combustion chambers (3, 4, 10 & 11).
 A UV flame sensor consists of flame sensor
containing the gas filled detector which detects the
UV radiation emitted by the hydrocarbon
combustion. Presence of flame leads to ionization of
the gas which allows conduction in the circuit which
activates the signal to give an output defining flame.
ns
d DUEL FUEL NOZZLE
hat
Each combustion
on
chamber has
individual nozzle
which is capable of
firing both liquid and
the natural Gas fuels.
 COMBUSTION LINERS
 Combustion of fuel takes place inside the combustion
liners.
 It is the part which is severely subjected to thermal
stresses. The fuel injected into the combustion reaction
zone, burns with a portion of available air entering the
head end of the liner. The hot combustion gases are then
mixed with the secondary air entering through the
downstream holes of the liners to dilute the gas and lower
its temperature before it enters the transition piece.
 The liners are also provided with thermal barrier coating
on the inside.
 COMBUSTION LINERS
Cap Assembly Fuel Nozzle
LINER SUPPORT Collar

Cooling Holes Cross fire

tube collar
The combustion liners are
of slot cooled design,
which helps in removal of
heat by air sweeping over
the inside and the outside Body
of the liners, which
provides more uniform
and effective cooling.
Spring Seal
 kvaasa
KAWAS

COATED COMBUSTION LINERS

CROSS FIRE TUBES
 Cross fire tubes are used to interconnect all
the combustion liners. Ignition in one of the
chambers produces pressure rise which forces
hot gases through cross fire tubes, thereby
propagating rapid ignition to all other
combustion chambers.
CROSS FIRE TUBES
FLOW SLEEVE
 Flow sleeve surrounds the combustion liner
and forms annular space for air to go for
combustion.
 The flow sleeve enhances liner cooling by
increasing the cooling air velocity near the
liner.
FLOW SLEEVE
FLOW SLEEVE
TRANSITION PIECE
 The function of Transition Piece is to direct the hot
gases from liners to turbine first stage nozzle.
 One end is connected to the combustion liner and
the other end is connected to the first stage nozzle.
 Transition piece is positioned in place with the help
of Bull-Horns.
 Thermal barrier coating is provided on the inside of
the Transition Pieces.
 TRANSITION PIECE
FORWARD MOUNTS

FORWARD FRAME

AFT MOUNT

FLOATING SEALS
TRANSITION PIECE
 SILO TYPE
COMBUSTION CHAMBERS
TURBINE SECTION
TURBINE
 Gas Turbine is 3 stage impulse turbine where
high energy from Gas is converted to
mechanical energy.
 The turbine consists of the following
 Turbine rotor
 Turbine stator
 TURBINE ROTOR
 It consists of 2 stub wheel shaft and 3 stage turbine
wheels & spacers. All these are bolted together with
through bolts.
 Forward wheel shaft houses Brg. # 2 journal.
 Aft wheel shaft have Brg. # 3 journal.
 Forward wheel is shaft coupled to compressor rotor.
 Aft wheel shaft is coupled to load shaft.
 First stage and second stage buckets are air cooled.
 Third stage buckets are not internally cooled. Tips of
these buckets are enclosed by tip seal shrouds.
TURBINE ROTOR
TURBINE BUCKETS
TURBINE FIRST STAGE
BUCKET TIP
TURBINE FIRST STAGE
BUCKET SECTIONAL VIEW
TURBINE THIRD STAGE BUCKET
 TURBINE STATOR

 Major constituents are

 Turbine shell
 Stationary blades or nozzles
 Shrouds
 Exhaust frame and diffuser
 TURBINE SHELL

 One end of the shell is bolted to the aft end

of compressor discharge casing & combustor
wrapper and other end is bolted to exhaust
frame.
 Turbine shell is cooled by exhaust frame
cooling fans.
TURBINE SHELL
les
ents,
foils. TURBINE NOZZLES
e not
First stage nozzle are 18
led.cast segments, each with
two airfoils. These nozzles
are air cooled. Nine nozzle
segments are assembled in
les a semicircular frame and
two such frames form one
ts,
complete set of nozzles
.
also
ssor
SHROUDS
 Turbine blades do not run directly against
integral machine surfaces but against annular
curved segments called shrouds.
 Primary function of shroud is to provide a
cylindrical surface for minimising tip clearance
leakages.
 Secondary function of shrouds is to provide high
thermal resistance between hot gases and
comparatively cool shell.
SHROUDS
TURBINE
 Second stage
TURBINE ASSEMBLY
bucket

Third stage
First stage bucket
nozzle

First stage
bucket
Third stage
First stage nozzle
shroud
Third stage
shroud
Second stage
nozzle
Second stage
shroud
 EXHAUST FRAME AND DIFFUSER

 It directs the hot gases from turbine to exhaust duct

 Exhaust frame assembly consists of exhaust frame and exhaust
diffuser and the complete assembly is bolted to the turbine
casing.
 Exhaust frame consists of two cylinders. The inner cylinder is
supported to outer cylinder by 10 radial struts. Inner cylinder
provides support to Brg. # 3.
 Exhaust diffuser is located at extreme end of the turbine and is
bolted to the exhaust frame. It has also two cylinders, one inner
cylinder and other outer divergent cylinder. The annular area
between the two helps in reducing the velocity by diffusion and
recovering the pressure.
EXHAUST FRAME AND DIFFUSER
TURBINE COOLING
 TURBINE COOLING
 Air for cooling turbine rotor is extracted after
16th stage and made to pass through hollow rotor
of the compressor to turbine.
 This air is used to cool first stage and second
stage turbine buckets and second stage aft and
third stage forward wheel space.
 First forward wheel space is cooled by the air
that passes through high pressure packing seal at
the aft end of the compressor rotor.
 TURBINE COOLING
 First stage aft and second stage forward wheel-
space is cooled by the air that passes through
first stage shroud than radially inward through
the second stage nozzle vanes.
 Third stage aft wheel-space is cooled by the air
from exhaust frame cooling fans.
 TURBINE SUPPORTS

FORWARD
SUPPORT
BASE FRAME GIB KEY AFT SUPPORT
 TURBINE BEARINGS

BEARING
BEARING #3
#2

BEARING
#1
COMBUSTION INSPECTION

 Short duration shutdown inspection. Carried

out at 8000 EOH.
 Involves inspection of parts which are more
maintenance prone and require replacement
to contribute to a longer life for the
downstream parts.
 These are Fuel Nozzles, Combustion Liners,
Transition Pieces, Cross Fire Tubes and their
Retainers etc.
COMBUSTION INSPECTION
KEY HARDWARE INSPECT FOR POTENTIAL
ACTIONS
Combustion liners Foreign Objects Repair/ Refurbishment
Combustion covers Abnormal Wear Liners
Fuel Nozzles Cracking Repair by welding
Transition Pieces Liner Cooling Hole TBC Repair
Cross Fire Tubes Plugging Transition Pieces

Flow Sleeves TBC Coating Condition

Repair by welding
Purge Valves Oxidation/corrosion/
TBC Repair
Check Valves Erosion
Distortion repair
Hot Spots/Burning
L/F Tubings Fuel Nozzles
Missing Hardware
Cleaning, decarbonising,
Clearance Limits.
replace worn TP
Cross Fire Tubes
HOT GAS PATH INSPECTION

 Carried out at about 16,000-24,000 EOH,

depending upon condition of first stage
nozzle.
 Purpose is to examine the parts exposed to
high temperature of hot gases discharged
from the combustion process.
 It includes apart from the full scope of the
combustion inspection, detailed inspection
of turbine nozzles, shrouds and turbine
buckets.
 HOT GAS PATH INSPECTION
KEY HARDWARE INSPECT FOR POTENTIAL
ACTIONS
Nozzle (1, 2, 3) Foreign Objects damage Repair/
Oxidation/corrosion/ Refurbishment
Buckets (1, 2, 3) Erosion Nozzles
Cracking Weld Repair
Cooling Hole Plugging
Stator Shrouds Reposition
Remaining coating life
Recoat
Nozzle
IGVs and Bushings Buckets
deflection/distortion
Strip and Recoat
Abnormal
Compressor Blading deflection/distortion Weld Repair
(Boroscope) Abnormal Wear Creep Life Limit
Missing Hardware Top Shroud deflection
Clearance Limits.
MAJOR INSPECTION

 Carried out at 40,000-48,000 EOH.

 Purpose is to examine all internal rotating and
stationary components from inlet of the
machine to exhaust section of the machine.
 It includes all elements of the CI and HGPI
and additionally laying open the complete
flange to flange of the Gas Turbine from the
horizontal joints.
MAJOR INSPECTION
KEY HARDWARE INSPECT FOR POTENTIAL ACTIONS
Compressor Blading Foreign Objects Repair/ Refurbishment
damage Stator Shrouds

Oxidation/corrosion/ Cracking/Oxidation/ Erosion

Turbine Wheels
Erosion Buckets
Dovetails
Cracking Coating deterioration
Leaks FOD/Cracking
Journals and Seal
Abnormal Wear Creep Life Limit
Surfaces
Missing Hardware Top Shroud deflection
Clearance Limits. Nozzles
Bearing, Seals
Severe deterioration
IGV Blading
Inlet System Wear
Bearings/ Seals

Exhaust System Scouring Wear

Compressor Blades

Corrosion/Erosion/ flubs/FOD