BHEL-INTRODUCTION

•Bharat Heavy Electricals Limited one of the top engineering companies in India
ranks among the top 12 Power Equipment manufacturers in the world. Setup in mid
fifties, BHEL has diversified its product base over the years and today every key sector
of the economy is served by BHEL.
•BHEL’s products cater to a wide spectrum of customers in various fields like power
generation and transmission, oil exploration and production, transportation, steel &
metals, fertilizer, petro-chemicals, refineries, cement plants, engineering industries, non
conventional energy sources, defense etc.
•More than 65% of installed capacity for electrical power in India is contributed by
BHEL. With 14 manufacturing units and over 63,000 skilled manpower, BHEL has built
up tremendous engineering strength.

BHEL-Hyderabad manufactures almost all critical high technology products requires for
Power Sector viz. Gas Turbine, Steam Turbine, Generator, Steam Generator, Heat
Recovery Steam Generators, Pumps & Compressors, Heat Exchangers, Control
equipment etc. IN the factory area of BHEL there are altogether broadly 8 workshops in
which all the major work is done. They are:
1.ELECTRICAL MACHINES-Electrical equipment like generators, transformers are
produced and tested here.
2.TC &GT-Turbines, compressors and gas turbines are produced here. This work area is
further divided into sub sections for undertaking different operations like Heavy Machine
shop, light machine shop, rotor shop, blade shop, testing and assembly area.
 Radial compressors are also produced and tested here. Several other operations like
forging, welding (small scale) are done. GT components are also done and assembled
separately. This project was done in this workshop.
Basic workshop operations like tapping, drilling etc. are done on the vertical drilling
machine. For different materials different coolants are used. Various specifications for processes are
1. Reaming-shell type or normal type reamers are the tools used.M-10,M-20…denote the
type of thread. They have their own characteristics like pitch ,drill dia, etc.
2. Drilling-According to requirement, the size of drill tool is selected. Radial drilling is used
to drill holes sideways.
3. Tapping-this operation is used for threading. There are many types of threads like gas
threads, NPT (National Pipe Taper), BSW, BSF etc. one example is shown below.

Thread size Major dia. Pitch dia. Drill dia. TPI(TEETH

BSW thread PER INCH
characteristics
1/4 6.35 5.53 4.72 20

1 25.4 22.36 21.33 8

•The use of taper pins in assembling two parts is that it does not allow their
separation.
 There is a design section adjoining the work area where analysis of the process is
done. Actual drawing sheets for various components are made here.
3.FOUNDRY - Input to this shop are details like drawing, temp. of boring,
allowances etc. Here the moulding process takes place. Exhaust roots, bearing
pedestal ,guide wheels are manufactured.
4. FORGING – the various welding operations are shielded metal arc welding, termite
welding etc. Closely related to this workshop is the metallurgical testing lab where the
composition of the metal is monitored. This is done by UV (ultraviolet) testing and
chemical analysis.
Mechanical testing lab is used for determining the properties of the metals. Here the
various tests done on are UTM (Universal testing machine), various hardness tests
like Brinnell, vicker etc.
5. SURFACE TREATMENT WORKSHOP- In most of the cases heat treatment is done here. Tempering ,nitriding and
other processes are made here.
 Steam turbines-introduction
• The steam turbine is a prime mover in which the potential energy of the steam is
transformed into kinetic energy, and later in turn transformed into mechanical energy of
rotation of the turbine shaft

•Transformation of potential energy of the steam into mechanical energy of rotation of

the shaft is brought about by different means.

• The steam passes through the main steam connection, the steam strainer and
the emergency stop valve before the servo valves into the inlet part of the
outer casing. After opening of the servo valves, the steam flows into the
steam chamber, to pass through the jet groups into the expansion area of the
turbine, by giving off its energy capacity and expanding up to the final pressure
in the exhaust part.

•In a steam turbine the force exerted by the blades is due to the velocity of the steam.
This is due to fact that the curved blades by changing the direction of the steam receive a
force of impulse. The action of steam in this case is said to be dynamic in a steam
turbine.
 General layout of a steam turbine plant TURBINE

STEAM

BOILER CONDENSER
HEAT
SUPPLIED
HEAT
REJECTED

FEED HOT
WELL EXTRACTION
PUMP
PUMP

1.3 STEAM TURBINE POWER PLANT CYCLE

Steam turbine power plants are based on the Rankine cycle investigated by a Scotch
Engineer and Scientist William Rankine (1820 -1872). Rankine cycle for Steam turbine
power plant with ideal turbines and pumps is shown below.
 OPERATION PRINCIPLES

THE IMPULSE PRINCIPLE

If steam at high pressure is allowed to expand through a stationary nozzle, the result
will be a drop in the steam pressure and an increase in steam velocity. The effect of this
change in direction of the steam flow will be to produce an impulse force, on the blade
causing it to move.
REACTION TURBINE PRINCIPLE
A reaction turbine has rows of fixed blades alternating with rows of moving
blades. The steam expands first in the stationary or fixed blades where it gains some
velocity as it drops in pressure. It then enters the moving blades where its direction of
flow is changed thus producing an impulse force on the moving blades. In addition,
however, the steam upon passing through the moving blades again expands and further
drops in pressure giving a reaction force to the blades.

Special Aspects of Reaction Turbines

1. There is a difference in pressure across the moving blades. The steam will therefore
tend to leak around the periphery of the blades instead of passing through them.
Blade clearances therefore must be kept to a minimum.
2. Also, due to pressure drop across the moving blades, an unbalanced thrust will be
developed upon the rotor and some arrangement must be made to balance this.
 MAJOR PARTS OF STEAM TURBINE
• The major parts of impulse-reaction turbines are as follows—
1.NOZZLE: The nozzle expands steam of comparatively low velocity and high static
pressure within considerable increase in velocity
2. DIFFUSER: It is a mechanical device that is designed to control the characteristics of
steam at the entrance to a thermodynamic open system. Diffusers are used to slow the
steam's velocity and to enhance its mixing into the surrounding steam
3. BLADES OR BUCKETS: The blades or buckets form the rotor flow passage and
serves to change the direction and hence the momentum of the steam received in the
stationary nozzles.
4. GUIDEBLADES: Often a turbine is arranged with a series of rotor flow passages.
Intervening between the blades comprising the rotor passages are rows of stationary
guide blades.
5.CASING:The turbine enclosure is called the casing. The nozzle and guide blades are
fixed on the casing.
6.ROTOR:The rotor is the rotating part in the turbine on which the moving blades fixed.
7.BLADE CARRIER: The carrier carries fixed blades. It is rested on the casing.
8.TURBINE BEARINGS AND JOURNAL BEARINGS: The main purpose of bearings is
to keep the rotor in the exact position in the casing. It is also used to absorb the axial
thrust.
9.GOVERNORS:They are used to regulate the steam inflow into the turbine.
10.EXHAUST HOOD: The exhaust hood is the portion of the casing which collects and
delivers the exhaust steam to exhaust pipe or condenser.
11.THROTTLE OR STOP VALVES: The throttle and stop valves are located in the
steam supply line to the turbine. The stop valve is hydraulically operated quick opening
and shutting valves designed to be either fully opened or shut.

.
 Machining of casing:
• STEAM CHAMBER: The steam chamber represents the connection
between the control valve bores in the outer casing and the nozzle groups of the
control stage.
• The steam chamber contains the nozzle groups for the control stage(3),provision
for stem flow(2),inner shaft gland(5).
•Movable L-rings seal the steam path between the steam chamber and the
outer casing so as to permit thermal movement.
•The detailed design is as shown below---
 •OUTER CASING:

• The turbine casing is divided into an admission and exhaust section. Back
pressures as well as condensing turbines have admission sections of
identical design. Depending on the inlet steam conditions, the admission
sections of comparable size are designed with casings of different wall
thickness. The admission section will be completed by an exhaust section of
adequate size.
1. Outer casing
2. Exhaust steam part sealing shells
3. Support blocks
9. Webs to accommodate the blade
carriers
11 Mounts for rear bearing
6 Main steam line connection
12 Exhaust steam flange
 Initial machining operations:
•The overall length is adjusted by cylindrical or conical spacer rings. The outer diameter
at the inlet and exhaust are measured.
•It is general practice to let the thickness of walls and flanges decrease from inlet- to
exhaust-end.
•Rough machining by a Gantry machine is done. Shoulder milling operation is done for
machining circular surfaces.
•On the inside, the outer casing has surrounding webs and contact cams to
accommodate blade carriers, the inner case or the steam chamber. By means of these
webs, the outer case is split into several sectors of differing pressure, out of which
tappings can be obtained to suit requirements

•The casing of a condensation turbine

essentially consists of an outer case with
steam inflow and the exhaust steam part
bolted on via a ring flange .Flanges are
projecting rims or edges used for guidance,
strength and attachment to other components
like the blade carrier.
•By using drill tool for boring operation directly holes are drilled if required or using
reaming operation the holes are machined according to specifications.
•Now by using CNC operated machining( for small capacity turbines), blade groove
roughing is done to get approximate shape of blade groove on blade slot machine.

•As shown, the drilling

and boring operations as
well as spot facing
operations being done
on the casing
 Operation characteristics of horizontal milling and
boring machine type
Boring spindle diameter 200mm Corners 50*45`
chamfering
Longitudinal travel 125000mm
(column on bed), x axis Feeds in all O-10000mm/min
directions
Vertical travel, y axis 5000mm
Head stock 600*600mm
Head stock cross travel, 1400mm section
w axis
Table size 4500*4500mm
Boring spindle travel (z 1250mm
axis)
Max. reach on spindle 2650mm(w+z The CNC (Computer numerical
) control) system is
D.C spindle motor power 100 KW
SIEMENS SINUMERIC 840c
Max. Spindle rotation 1160rpm
speed
Max nominal torque 14101NM
Loading capacity 10^5kg
CNC COMMANDS AND CONTROL
G CODES
GO Rapid travels when
machining is not done.
• G -CODES & M- CODES are used for
writing the program. For different G01 Linear interpolation
operations different codes are given.
G02 Circular interpolation
• Some commands used are:
G04 Dwell time

M05 Spindle shaft G90 Absolute position

G91 Incremental position
M17 Program end
G95 Feed per revolution
M04,M03 Table rotation G58 Programmable offset
G59
M30 End of main program

M01 Program start

unconditional
G53 TO Work offset
G56
Overview of guide blade carrier:
 Blades manufacture:
manufacture
• The different operations involved in the
manufacture of blades are enumerated below::
1. RAW PIECE CUTTING: Using a power saw machine the lengthy bars are first
cut into small 20cm pieces. The material used for blades is heat resistant
alloyed steel having the composition X22CrMoV12.Here the use of chromium
is to get a good finish, Mo is a heat resistant metal.
2. SIZE MILLING: According to the required specification, the depth and
width of the w/p’s are set and machined on lathe using Angle cutter.
3. SIZE GRINDING: Horizontal grinding operation is done to set the w/p to
required tolerance.
4. RHOMBOIDAL MILLING: The cubical w/p’s are now milled to obtain a
rhomboidal shape whose edge angles are set.
5. RHOMBOIDAL GRINDING: According to the required tolerance grinding
operation is done (on many w/p’s) to get accurate edges.
6. BLADE LENGTH CUTTING: Now, according to required length of blade
the w/p’s are cut, leaving some tolerance limit.
7. ROOT MILLING: A T-root is now machined on to the base part of the
w/p using a T-max cutter. Simultaneously three cutters are in
operation on three sides of the w/p.
Blade profile after rhomboidal milling
8. WIDTH MILLING: For decreasing the side area for blade, width milling is used.
Two stages are involved.-outlet WM & inlet WM. Outlet and inlet are determined
according to the direction of steam flow.
9. BACK PROFILE USING COPYING MILLING: The back side of the w/p is now
milled
according to dimensions of a standard blade using the cam arrangement. The
cutter employed is convex cutter.
10. CHANNEL MILLING: The front portion of the blade is now machined using pre-
determined values to obtain an aerofoil shape.
11. CHANNEL AND BACK PROFILE WIDENING: To Meet the exact stipulations
this is done.
12. ROOT RADIUS: In order that the blade is assembled perfectly on the circular
rotor, a slight indent is made on the T-Root as shown.
13. TAPER MILLING: For all the blades to get perfectly fitted beside one another it
is now machined to get a taper, length-wise.
14. TAPER GRINDING: For smooth finishing the blades are now grinded.
15. POLISHING: To ensure meeting perfect specifications, polishing is done.
A-Wheel blade is made by cutting into small pieces a wheel, which has
grooves. This acts like a fork and later the usual operations are done on the A-
Wheel blades.
Root radius operation enables blades to fit round
circular rotor.

After polishing blades are fit onto rotor.

 Rotor machining:
• Blades are assembled on the rotor and thus when steam makes impact it
rotates. It is connected to the generator shaft to convert rotational energy
to electrical energy.
• The actual turbine shaft comprises of a monoblock forging.
• A 4-check lathe is used for man grooves on the rotor.
• The grooves have dimensions which allow exact fitting of blades.
• Based on the steam inflow pressure the rotor is divided into primarily five
sections:
1. Inlet section: It consists of A-Wheel which first receives
the high pressure steam and guides it onto the rotor.
2. HP (High pressure) section: This section intercepts steam of high
pressure and hence the blades, grooves are small in size.
3. IP (intermediate pressure) section: Due to the stationary stages, pressure
of steam is considerably reduced.
4. LP (low pressure) section: to intercept steam of low pressure the profile
and the size of the blades are considerably altered. Now the blade root is
of fork type.
5. EXHAUST section: It consists of the pinion for rotating the generator
shaft, journal bearing and other auxiliary equipment.

Scaling fins which are used for arresting the steam leakage ,and create more back
pressure so that the steam enters the guide vanes in the right way, are embedded
into the portion of the rotor between the grooves.
 ROTOR ASSEMBLY.
•Actual assembly consists of individually inserting the blades into the grooves and
locking their positions using a small metal piece between the base of blade and the
rotor groove.
•This is done for all the stages except LP blades which have fork-root base.
•For the last blade in assembling a row of the blades, the base part remains
. solid (no root milling is done). It is marked and used for conducting some of the
performance tests like rotor insensitivity test etc
•Shrouding operation is done on the projecting side of all the rows of moving blades.
This is done so that steam does not escape out of the blades (rotor part).
•The moving blades have integral shrouding, with the moving blades of one row forming
a closed, tightly fitting blade assembly at the shrouds.

Drum stage moving

blades with shrouds.
•The rotor is supported in two pressure lubricated journal bearings (4 and 12).
•The axial position of the rotor is fixed by the thrust bearing collars (2).
•Grooves for the electric speed measurement are provided in the right collar
(3). The mechanical overspeed trip (1) and the trip cams for the axial position
trips are arranged upstream of the thrust bearing (3).

1 Overspeed trip 9 HP nozzle group

2 Thrust bearing
3 Thrust bearing collar with grooves
4 Front bearing support point
5 Front shaft gland region
6 Balancing planes
7 Inner shaft gland region
8 Control Stage
10 LP nozzle group
11 Rear shaft gland region
12 Rear point of bearing support
13 Gear for manual turning gear
14 Coupling
15 Shaft nut
 Assembly of casing
•As we know for small capacity turbines, the guide blades are embedded in the
blade carriers whereas for the larger capacity ones, grooves are machined on the
inner casing using CNC operated vertical boring machine.
STEAM CHAMBER:
•The steam chamber is split axially. The two halves are bolted together by high-
temperature bolts. Axial fixation in the outer casing is effected using a circumferential
groove; the steam chamber is supported vertically by prepared supports on both
sides. The transverse axial fixation is provided by an eccentric bolt installed in the
outer casing bottom half.
•The blade carriers are axially split and are bolted together steam tight by partial
area screws. In the axial direction, the blade carriers are held in the outer
casing by a slot-web connection.
•Vertical support is provided via adjustment elements that are screwed into the
pads of the blade carrier bottom. Radial mounting and guidance are ensured
by an axial bolt guide in the bottom of the blade carrier and the outer casing

•The turbine case is axially split; the top and bottom of the case are held together by
reduced-shaft or solid shaft bolts. The outer faces of the casing parts possess webs to
accommodate the sealing shells and cast-in channels with affiliated flange connections
to remove leaking steam or to supply sealing
• A closed, tightly fitting blade assembly is obtained at the shrouds when the
stationary blade carrier halves are bolted together during final assembly.
The stationary blade carriers are suspended in the outer casing (5) so as to
allow for thermal expansion. If required, a stage drain can be provided
upstream of the last stationary blade stage to draw off any water that may
accumulate on the blade vanes into the condenser.
•Now the rotor is placed onto the one half of casing.
 Final assembly operations
SEALING:
Task
• The sealing shells serve the purpose of sealing between the outer casing and rotor
on the steam end. Besides sealing against internal excess pressures, the ingress of
ambient air in the event of an internal partial vacuum must be reliably prevented.

Structure
•The sealing shell is axially split, and the halves are bolted to one another. On
the outer circumference of the sealing shell body, there is a surrounding slot
with which the shell is fixed radially and axially in the outer casing.

1 Sealing shell 6 Turbine rotor

2 Caulking material
3 Sealing tip
4 Steam extraction (steam feed)
D Steam from turbine casing
5 Vapour chimney
 TURBINE BEARINGS AND JOURNAL BEARINGS
• The bearings for small turbines are often self-aligning spherical ball
or roller-bearings or they may be ring lubricated sleeve bearings
with bronze or Babbit lining.
• Thrust Bearings:
• The main purposes of the thrust bearing are:
To keep the rotor in an exact position in the casing.
To absorb any axial thrust on the rotor.

1 Turbine Casing 8 Stud bolt

2 Turbine support paw
3 Pedestal support
4 Stud bolt
5 Bearing housing
6 Adjusting element: Bearing
housing (vertical)
 GAS TURBINES
• The gas turbine is a rotating internal combustion engine, which takes air
from the atmosphere and compresses it to a higher pressure in a axial
compressor (compressor section) and the compressed air flows into
combustion chamber where fuel is admitted and ignited with the help of a
spark plug. The products of combustion are used as a working fluid for
developing power in the turbine section of the Gas Turbine
•The flow diagram of a simple gas turbine is as shown. The gas undergoes isentropic
compression before undergoing combustion, followed by expansion in the turbine
stage.

•The thermodynamic cycle upon which a gas

turbine works is called the Brayton Cycle.
 1-2:isentropic compression in compressor.
2-3:isobaric heat addition.
3-4:isentropic expansion in turbine.
4-1:exhaust.

• Work input to the turbine is needed to start rotating the shaft. During start-ups
50-60% of energy is consumed by the compressor. The self-sustaining speed
is taken as 40-45% of max. speed. The motor is cutoff from rotating the shaft.
• A Brayton Cycle is characterized by two very significant parameters: pressure
ratio and firing temperature. The pressure ratio of the cycle is the pressure at
point 2 divided by the pressure at point 1. The firing temperature point 3 on
the fig., is the highest temperature reached in the cycle. The thermodynamic
cycle efficiency and Power output of a Gas Turbine depends on these two
parameters
• The efficiency of gas turbine is in the range of 40-46% which is low compared
to a steam power plant. But, further refinement to the cycle is at the cost of
simplicity and not feasible. The high temperature of the exhaust gases can be
used to heat steam for steam turbine application.
 • The advantages of gas turbine are:
Efficient
 Compact
 Reliable
 Eco-Friendly
…Rotary Internal Combustion Engine
• Self contained
• Light weight
• High Power Density
• Low installation time
• Quick start
• Black Start Capability
NOTES: 1)Though the Otto cycle is more efficient it has many inherent disadvantages
like knocking, not practicable for high output applications.
2)As it is an IC engine it does not require any external inputs as in the case
of steam turbine. Hence the installation is quite easy
3)Hence it occupies very less space. In steam turbines for generating the
same 125 MW of power coupled system is used.
4)Since air fuel mixture is 30:1 the exhaust gases do not contain high
concentration of pollutants.
 COMPONENTS OF TURBINE.
The major components of a Gas Turbine are the compressor, combustion system and
turbine section. CDC stands for (compressor discharge casing). The various parts that
compose each individual section is dealt herewith.

Ancillary
base.
COMPRESSOR SECTION
• The axial-flow compressor section consists of the compressor rotor and the
enclosing casing, as also CDC.
• Within the compressor casing are the inlet guide vanes, 17 stages of rotor
and stator blading, and the exit guide vanes.
• Each compressor stage consists of a rotating row of blades (aerofoil) that
increases the velocity of the incoming air there by increasing its kinetic energy, followed
by stationary row of blades that act as diffusers, converting the kinetic energy to
pressure increase.
• The number of stages used for a particular gas turbine compressor depends
upon the design pressure ratio for that turbine. Typical pressure ratio ranges from 6:1 to
14.9:1.
• The compression efficiency is 85% that of the ideal isentropic process but handling
is easy. From stage to stage, the compressor ratio is n*o.85.(n approx 1.4)
NOTE:1) during startups ,50-60% of energy is consumed by compressor.
2)Some air is extracted from the intermediate stages to enable the rotor to rotate freely.
AT 95% of the full speed we close breed valve. Then compressor operates at full
efficiency.
 PARTS OF COMPRESSOR:
• INLET GUIDE VANES (IGV’s):

•At the compressor inlet there is a row of stationary blades, called inlet guide
vanes (IGV's) that direct the incoming air on to the first rotating stage in a
smooth way. The flow angle of the IGV's can be changed to control the
volume of air being drawn into the compressor. The variable inlet guide vanes
(VIGV's) are used to ensure aerodynamically smooth operating compressor
throughout a large operating range.

Lower casing
 • Movement of these guide vanes is accomplished by the
inlet guide vane control ring that turns individual pinion
gears attached to the end of each vane. The control ring
is positioned by a hydraulic actuator and linkage arm
assembly

ASSEMBLY

The inlet casing is located at the forward end

of the gas turbine. The inlet casing also
supports the No.-1 bearing housing, a separate
casting that contains the No.-1 bearing. The
No.-1 bearing housing is supported in the inlet
casing on machined surfaces on either side of
RADIAL
the inner bellmouth of the lower half casing. To STRUTS

maintain axial and radial alignment with

the compressor rotor shaft, the bearing
housing is shimmed, doweled and bolted DOWEL

in place at assembly. The inner bellmouth is PINS

positioned to the outer bellmouth by eight

airfoil-shaped radial struts that provide
structural integrity for the inlet casing. The
struts are cast into the bellmouth walls. BEARING HOUSING
 • ROTOR OF COMPRESSOR
•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.
•Unlike the steam turbine rotor here in GT the rotor is not a single block forge.

MACHINING:
Each wheel and the wheel portion of each stub shaft has slots machined
around its circumference. The rotor blades and spacers are inserted into these slots
and are held in axial position by staking at each end of the slot.
The blades are manufactured using the same process as in the case of a steam
turbine described earlier except that here the base profile is not a T-Root but an
inverted U.
STAKING is the process of inserting a thin metal piece between the compressor groove
and the sides of the blade base.

•The blades are not of the same size for all the stages,
but differ according to their position. Small size blades
are to be assembled at the front end of the rotor where COMPRESSOR
the pressure is more and large size blades are to be BLADES
assembled at the rear end of the rotor where pressure
is minimum.
ASSEMBLY:
• The wheels and stub shafts are assembled to each other with
mating rabbets for concentricity control and are held together with
tie bolts. Stub shaft is the protruding part of the connecting rod of
wheels of the compressor. They are two in number.
• Selective positioning of the wheels is made during assembly to
reduce balance correction. After assembly, the rotor is dynamically
balanced to a fine limit
 CASING:
•The stator (casing) area of the compressor section is composed of four major
sections. They are inlet casing, forward compressor casing, aft compressor casing,
compressor discharge casing.
•These sections, in conjunction with the turbine shell, form the primary structure
of the gas turbine. They support the rotor at the bearing points and constitute the
outer wall of the gas path annulus. The casing bore is maintained to close
tolerances with respect to the rotor blade tips for maximum efficiency.
FORWARD CASING
FORWARD CASING
•The forward compressor casing contains
the first four compressor stator stages. It
also transfers the structural loads from the
adjoining casing to the forward support RING
SEGMENTS
which is bolted and doweled to this
compressor casing’s forward flange.
Note: The forward compressor casing is
equipped with two large integrally cast
trunnions which are used to lift the gas
turbine when it is separated from its base.
Bleed air from the fourth rotor stage can be
extracted through four ports which are
located at the aft section of the compressor
casing
 BLADING ARRANGEMENT
The compressor stator blades are airfoil shape and are mounted by similar dovetails
into ring segments. The ring segments are inserted into circumferential grooves in
the casing and are held in place with locking keys.
AFT CASING
The aft compressor casing contains the 5 through 10 compressor stages. Extraction
ports in the casing permit removal of 5 and 11th-stage compressor air. This air is used
for cooling and sealing functions and is also for starting and shutdown pulsation control.
BLADING DESCRIPTION

The stator blades of the last nine

stages and two exit guide vanes
have a square base dovetail that
are inserted directly into
circumferential grooves
in the casing. Locking key holds
them in place
 COMPRESSOR DISCHARGE CASING
• The compressor discharge casing is the final portion of the compressor stages. It
is the longest single casting. It is situated at the midpoint—between the forward
and aft supports and is, in effect, the keystone of the gas turbine structure.
• The functions of the compressor discharge casings are:
1. to contain the final seven compressor stages,
2. to form both the inner and outer walls of the compressor diffuser, and
3. to join the compressor and turbine stators.
4. They also provide support for the No. 2 bearing, the forward end of the
combustion wrapper, and the inner support of the first-stage turbine nozzle.
INSIDE VIEW
OF CDC

NOTE:
As shown the grooves for fitting the blades
are of square dovetail shape
 ASSEMBLY
•The compressor discharge casing consists of two cylinders, one being a continuation
of the compressor casings and the other an inner cylinder that surrounds the
compressor rotor.
•The two cylinders are concentrically positioned by twelve radial struts.
These struts flair out to meet the larger diameter of the turbine shell, and are the
primary load bearing members in this portion of the gas turbine stator.
•The supporting structure for the No. 2 bearing is contained within the inner cylinder.

CDC-upper portion:

A diffuser is formed by the tapered

annulus between the outer cylinder and
inner cylinder of the discharge casing
.This diffuser converts some of the
compressor exit velocity into added
pressure. There are also stationary
diffuser blades which give maximum
pressure
 COMBUSTION CHAMBER
•The combustion system is a reverse flow type with 14 combustion chambers
arranged around the periphery of the compressor discharge casing. This system
also includes fuel nozzles, spark plug ignition system, flame detectors, and
crossfire tubes. Hot gases, generated from burning fuel in the combustion
chambers, are used to drive the turbine.
SPARK PLUGS
Combustion is initiated by means of the discharge from two high-voltage
retractable-electrode spark plugs installed in adjacent combustion chambers.
FUEL NOZZLES
Each combustion chamber is equipped with a fuel nozzle that emits a metered
amount of fuel into the combustion liner. Gaseous fuel is admitted directly into
each chamber through metering holes located in the outer wall of the gas swirl tip.
CROSSFIRE TUBES
All fourteen combustion chambers are interconnected by means of crossfire
tubes. These tubes allow flame from the fired chambers to propagate to the
unfired chamber
 Combustion flow diagram.

Spark plug
Arrangement of Combustion
chambers.
 • TURBINE SECTION
•The three-stage turbine section is the area where energy, in the form of
high-temperature pressurized gas produced by the compressor and combustion
sections, is converted to mechanical energy.
•The major components of Gas turbine are the turbine rotor, turbine casing
exhaust frame, exhaust diffuser, nozzles and shrouds.
ROTOR
•The turbine rotor consists of two wheel shafts; the first, second, and third-stage turbine
wheels with buckets; and two turbine spacers.
•The 3-stage turbine wheels are manufactured in the following way:
The outer rim part consists of grooves for assembling the buckets. These rims are
forged onto a supporting circular shaft by heat treatment, forging.
•These wheels are held together with through bolts.
• The turbine rotor must be cooled to maintain reasonable operating temperatures and,
therefore, assure a longer turbine service life. Cooling is accomplished by a positive
flow of cool air radially outward through a space between the turbine wheel with
buckets and the stator, into the main gas stream. This area is called the wheelspace.
WHEELSPACE: There are three stages of wheelspaces according to their positions.
1. FIRST STAGE: The first –stage forward wheelspace is cooled by compressor discharge
air. High-pressure packing is installed at the end of the compressor rotor between the
rotor and the inner barrel of the compressor discharge casing.
 2. SECOND-STAGE WHEELSPACES
The second-stage aft wheel space is cooled by air from the internal extraction
system. The air enters the wheel space through slots in the forward face of the spacer
3. THIRD-STAGE WHEELSPACES
The third-stage forward wheel space is cooled by leakage from the second-stage aft
wheel space through the inter stage labyrinth.

The third-stage aft wheel space obtains its

cooling air from the exhaust frame
cooling system. This air enters the wheel
space at the rear of the third-stage turbine
wheel and then flows into the gas path at
the entrance to the exhaust diffuser.
• NOZZLES
• In the turbine section, there are three stages of stationary nozzles which direct the
high velocity flow of the expanded hot combustion gas against the turbine buckets
causing rotor to rotate.
NOTE :These nozzles are not machined using the regular practices but by using
sophisticated procedures like EDM (Electrode dynamic machine) ,profile projector
etc.
ASSEMBLY
The 18 cast nozzle segments, each with two partitions or airfoils, are contained by a
horizontally-split retaining ring which is centerline supported to the turbine shell on
lugs at the sides and guided by pins at the top and bottom vertical centerlines. This
permits radial growth of the retaining ring, resulting from changes in temperature,
while the ring remains centered in the shell
• BUCKETS: The turbine bucket increase in size from the first to the third-stage.
Because of the pressure reduction resulting from energy conversion in each stage,
an increased annulus area is required to accommodate the gas flow; thus
necessitating increasing the size of the buckets.
•Turbine buckets for each stage are attached to their wheels by straight, axial-entry,
multiple-tang dovetails that fit into matching cutouts in the turbine wheel rims.
Bucket vanes are connected to their dovetails by means of shanks.
•These shanks locate the bucket-to-wheel attachment at a significant distance from
contact with hot gases so that they are at low temperature.
•Air is introduced into each first-stage bucket through a plenum at the base of the
bucket dovetail. It flows through cooling holes extending the length of the bucket
and exits at the recessed bucket tip.

•The material used for these blades is high temperature

steel. At the site they are mostly imported. Since they
require highly precisioned measurements devices like
Co-ordinate Measuring Machine (CMM) is used.
Machining is done further on highly sophisticated
equipment like EDM, electronic enabled CNC machines
etc.
CASING:
• The turbine shell and the exhaust frame constitute the major portion of the gas
turbine stator structure. The turbine nozzles, shrouds, #2 bearing and turbine
exhaust diffuser and internally supported from these components.
• The turbine shell controls the axial and radial positions of the shrouds and
nozzles. It determines turbine clearances and the relative positions of the nozzles to
the turbine buckets
SHROUDS
•Unlike the compressor blading, the turbine bucket tips do not run directly against an
integral machined surface of the casing but against annular curved segments called
turbine shrouds. The shrouds’ primary function is to provide a cylindrical surface for
minimizing bucket tip clearance leakage.
•The turbine shrouds’ secondary function is to provide
a high thermal resistance
between the hot gases and the comparatively cool
shell. In doing this, shell cooling load is drastically
reduced, the shell diameter is controlled, the shell
roundness is maintained, and important turbine
clearances are assured SHROUDS
 • The shroud segments are maintained in the circumferential position by
radial pins from the shell. Joints between shroud segment are sealed by
interconnecting tongues and grooves
DESIGN:
•Hot gases contained by the turbine shell
are a source of heat flow into the shell. To
control the shell diameter, it is important
that the shell design reduces the heat flow
into the shell and limits its temperature.
Heat flow limitations incorporate insulation,
cooling, and multi-layered structures. The
external surface of the shell incorporates
cooling air passages.
shrouds
ASSEMBLY: nozzles
Structurally, the shell forward flange is bolted to flanges at the aft end of the
compressor discharge casing and combustion wrapper. The shell aft flange is bolted
to the forward flange of the exhaust frame. Trunnions cast onto the sides of the shell
are used with similar trunnions on the forward compressor casing to lift the gas
turbine when it is separated from its base.
 Turbine Shell

Inner Barrel
ALIGNMENT OF TURBINE CASE AND EXHAUST FRAME:

1. Pick up turbine case & shroud assembly and assemble on the height blocks with its
AFT face upwards. Clean AFT face free of burrs & high spots
2. Pick up exhaust frame. Clean the FWD face and assemble the exhaust frame on to
turbine case AFT face, aligning the horizontal parting plane of both frame and
turbine case.
3. Assemble the Frame to turbine case loosely with the above screws. They are
inserted into the holes drilled on the outer casing of turbine and exhaust.
4. Align the exhaust frame to turbine case by taking drop checks at 6 points.
5. Tighten the vertical flange bolting and recheck the alignment.
6. Using the quacken-bush drilling equipment and fixture drill and ream dia19H7
dowel pin holes.
7. Assemble correctly the dowel pins into the holes. Match mark the pins and holes.
8. Remove the pins and screws from vertical flanges and preserve. Dismantle the
exhaust frame from turbine case.
9. Reverse the turbine case and assemble it on height block such that FWD face is
up wards and repeat the operations.
Thus the exhaust frame is aligned with the turbine casing.
ALIGNMENT OF CDC WITH TURBINE:
1. Bring the compressor discharge casing assy. Loosen the support ring bolts all
around & tighten to a snug condition.
2. Assemble the C.D.C assy. on turbine casing. Rotate the casing to align the parting
planes closely
3.Assemble the two casings loosely with bolts move the alignment pole within 0.05,
maintaining horizontal joint alignment to turbine case.
4.
4.Bring the casing tube to horizontal position. Attach the FWD support fixture to FWD
COMP. casing.
5. Position the FWD & AFT support blocks. Lower the tube and rest it on the support
blocks. Ensure the tube is supported properly on blocks. Level the tube and release the
crane.
6. Bring the inlet casing including IGV assembly. Assemble the inlet casing to comp.
casing with bolts as before.
7. Assemble exhaust frame to turbine casing with sock screws, we should not tighten
the bolts.
ASSEMBLY OF ROTATING PARTS INTO CASING:
1. Before removing the top half of casing match mark all dowel pins and body bound
studs to matching holes in casing.
2. Remove the upper cover from variable I G V & control ring.
3. Remove the vertical bolting from combined compressor casing upper half. Remove
the
horizontal joint bolting.
4.Similarly unbolt the vertical and horizontal flange bolting of exhaust frame and remove
the upper half
5.These bolts and their order should be clearly demarcated. Now the rotating parts are
ready to be assembled into the corresponding stator parts.
ASSEMBLY OF EXHAUST
DIFFUSER INTO EXHAUST
FRAME