MAN Turbo

Product Training

Gas Generator /
Power Turbine

MAN Turbo AG

GF14

16-Jun-09

< 1 >

THM 1304
Gas generator / Power turbine

Core components
z gas generator and
z power turbine
(LP turbine).
Combined = bare turbine
Mounted on a baseframe

MAN Turbo AG

GF14

16-Jun-09

< 2 >

THM gas turbine

Principle of function

Two shaft gas turbine

Operation
z with combustion at
constant pressure
z adiabatic
compression of air in
an axial-centrifugal
compressor.
z combustion in two
combustion
chambers
z mixture of air and
fuel
(liquid fuel or gas)

MAN Turbo AG

GF14

16-Jun-09

< 3 >

THM gas turbine

Principle of function

Operation
z first expansion of the
pressurized hot gases
coming in
two-stage backpressure
turbine: high-pressure
turbine (HP turbine)
to drive the axialcentrifugal compressor
z second expansion in a

second backpressure
turbine: low-pressure
turbine (LP turbine).
to drive a processing
machine (e.g. pipeline
compressor or electric
generator)
MAN Turbo AG

GF14

16-Jun-09

< 4 >

THM gas turbine

Pressure and temperature curve
inside gas turbine
2
1

pressure curve

1 GG compressor
4 LP turbine

temperature curve

2 combustion chamber
5 processing machine

3 HP turbine
MAN Turbo AG

GF14

16-Jun-09

< 5 >

Gas generator
GG: modular structure

Modular structure of THM 1304 with

standard combustion chambers
Allows to exchange all modules inside
the sound cover without the request for
much equipment.

Main components of the gas generator

z compressor
z combustion chamber area
z HP turbine.

1..Gas Generator
2..combustion chamber
3..burner can
4 HP1 stator blade carrier
5 HP turbine rotor
6 HP2 stator blade carrier

MAN Turbo AG

GF14

16-Jun-09

< 6 >

Gas generator
Functional description

GG generates the energy required for

driving the power turbine
z Compression
z combustion chambers V shaped
mixed up and burnt with the fuel
with water in units with water
injection
z gas collector ducts the waste gases

get into the

z two-stage HP turbine driving the
compressor of the gas generator.
z surplus waste gas energy is
transferred further to the power
turbine (LP turbine).

MAN Turbo AG

GF14

16-Jun-09

< 7 >

Gas generator
Functional description

z part of the compressed air

used for cooling of the

combustion chambers and
turbines.
z Ignition by two igniters
operating independently
from each other.
z Subsequently, combustion is

self-sustaining.
z Fuel supply via fuel control
valve with regard to the
required power

MAN Turbo AG

GF14

16-Jun-09

< 8 >

Gas generator
Compressor inlet case

Single-part casing with

Four hollow struts
connecting the inner and
outer casing
Accommodates the GG
front bearing for
supporting the rotor.
18 inlet guide vanes (IGV)
and
Corresponding mechanism
for their adjustment

MAN Turbo AG

GF14

16-Jun-09

< 9 >

Gas generator
Compressor inlet case

Compressor inlet case

1 strut
2 stator blade
positioning mechanism
3 bore for passage
of the instrument cables
4 adjustable stator blades
5 front GG bearing

MAN Turbo AG

GF14

16-Jun-09

< 10 >

Gas generator
IGV

First stator blade row

adjustable
To allow control of the
air volume
z startup
z rundown
z turndown
For optimum efficiency
over the total speed
range.

Stator blade positioning

1 actuating ring

2 inlet case

MAN Turbo AG

3 lifting rod

GF14

Closing direction of blades

16-Jun-09

< 11 >

Gas generator
IGV

Actuation
z by the GT
control system
and depending
on the GG
speed
z by means of an
electrically
operated
stepping motor.

Warning
z This adjustment
shall only be
changed by
MAN Turbo AG.

Stator blade positioning

1 actuating ring

2 inlet case

MAN Turbo AG

3 lifting rod

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Closing direction of blades

16-Jun-09

< 12 >

Gas generator
Planetary gear unit

Installed in the compressor inlet

case
Description
z positive locking planetary gear
unit
z not engaging and disengaging
z provides two transmissions
z step-down ratio of 4.1.

Function
z to transfer torque to auxiliary
gear unit required for mechanical
drive of a lubricating oil pump.
z high speed of the GG rotor max.
11,800 1/min-1 is reduced to
approx. 2,850 1/min-1 .
1..gear shaft (82 teeth)

MAN Turbo AG

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2..gear wheels (3 off)

3 gear shaft (20 teeth)

16-Jun-09

< 13 >

Gas generator
Compressor description

Supplies air for

combustion and/or
Cooling
10-stage axial
compressor with
smoothing chamber

One centrifugal
stage.

Stage

000

00

rotor blade

stator blade

1 annular channel stage 3

MAN Turbo AG

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2 annular channel stage 6

16-Jun-09

< 14 >

Gas generator
Compressor components

Main casing
(2 parts)

Stator blade
carrier (2 parts)
Axial rotor

1 centrifugal stage

2 HP turbine

3 axial compressor

GG rotor

MAN Turbo AG

GF14

16-Jun-09

< 15 >

Compressor
Function

Compression also
increases temperature.

Radial flow impeller

z deflects the air jet by
90 and
z directs it over a diffuser
into the smoothing
chamber
Diffuser initiates a
reduction of the flow speed

1 centrifugal stage

2 HP turbine

3 axial compressor

GG rotor

Smoothing chamber
between
z compressor stator blade
carrier casing and
z GG main casing.
MAN Turbo AG

GF14

16-Jun-09

< 16 >

Compressor
Function

Larger part of the air is transferred

via two elbows into the combustion
chambers.
Remaining air is passed on via
channels and bores for cooling of
the HP turbine that drives the
compressor rotor.

MAN Turbo AG

GF14

16-Jun-09

< 17 >

Compressor
Blades design

Stages 000, 00 and 0

added through increase
of THM 1304 capacity
Coating on all
compressor blades as
protection against
corrosion,

smoothing chamber

Stage

000

00

rotor blade
1 annular channel stage 3

MAN Turbo AG

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stator blade
2 annular channel stage 6

16-Jun-09

< 18 >

Compressor
Rotor design

Teflon segments are screwed to

the tips of the stator blades of
stages 000, 00, 0, 1 and 2.
z labyrinth strips at the rotor
discs of the compressor rotor
penetrate the Teflon in the
first operating hours.
z This kind of sealing keeps
the clearances and thus the
performance and/or
efficiency losses low.

smoothing chamber

Discs with dovetail slots

00

MAN Turbo AG

GF14

16-Jun-09

< 19 >

Compressor
Rotor design

13 tie rods keep

together
z rotor discs,
z radial flow impeller
z shaft ends of the
rotor

smoothing chamber

Stage

000

00

rotor blade

stator blade

1 annular channel stage 3

MAN Turbo AG

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2 annular channel stage 6

16-Jun-09

< 20 >

Compressor
Number of Blades

smoothing chamber

Stage

000

00

rotor blade
1 annular channel stage 3

MAN Turbo AG

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stator blade
2 annular channel stage 6

16-Jun-09

< 21 >

Compressor
Blow-off and cooling air system.

To avoid surging of the compressor during

certain operating situations.
Radially running grooves at compressor
stator blade carrier
z between 2nd and 3rd and
z between 5th and 6th stage

smoothing chamber

Through which compressor air is routed

into two annular channels
Blow-off valves of lower stages
z two or three depending on the type of
machine
z installed on top of the GG main casing.

Stage

000

00

rotor blade
1 annular channel stage 3

stator blade
2 annular channel stage 6

Blow-off valves of last stage

z one or two, depending on the machine
type
z installed on the lower GG main casing
half
MAN Turbo AG

GF14

16-Jun-09

< 22 >

Combustion Chamber
Components

Two combustion chambers

V-shaped on the upper GG
main casing half

Components
z casing with inlet elbow
z burner
z igniter
z injector nozzle

1 fuel nozzle
3 elbow 4 burner can

MAN Turbo AG

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2 igniter

16-Jun-09

< 23 >

Combustion Chamber
Function

Compressed air gets into

the combustion chamber
casing via
z smoothing chamber
and
z elbow.

Through slots and bores

in the burner can the
compressed air gets into
the combustion
compartment where it is
Mixed up with fuel and

1 fuel nozzle
3 elbow 4 burner can

Ignited via an igniter.

MAN Turbo AG

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2 igniter

16-Jun-09

< 24 >

Gas collector
Function

Guides the hot waste

gases
z from combustion
chamber
z into HP turbine.
Cooled from outside
with air
z routed before
over smoothing
chamber
z into combustion
chambers for
cooling of burner
cans.

1 Gas collector

2 Drainage connection

Lower section with

drainage connection
MAN Turbo AG

GF14

16-Jun-09

< 25 >

HP Turbine
Components

Axial-flow two-stage
backpressure turbine

HP1 stator blade carrier

HP turbine rotor
HP2 stator blade carrier
z in 2 parts,
z vertical split joint

rotor blade
1 HP2 stator blade carrier casing
3 HP2 stator blade

MAN Turbo AG

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stator blade
2 HP1 stator blade carrier
4 HP turbine rotor

16-Jun-09

< 26 >

HP Turbine
HP1 stator blade carrier

Single-part

Centered via 8 pins on the

GG main casing
Components
z one inner and
z one outer carrier ring
z 32 stator blades

Location
z inner ring is screwed to
the gas collector
z outer ring to the GG
main casing

rotor blade
1 HP2 stator blade carrier casing
3 HP2 stator blade

MAN Turbo AG

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stator blade
2 HP1 stator blade carrier
4 HP turbine rotor

16-Jun-09

< 27 >

HP Turbine
HP turbine rotor

Components
z two discs with
z 70 rotor blades each,
z inserted in fir-treeshaped grooves.

Location
z pair of discs is
connected to the rear
shaft end of the
compressor rotor
z by four centering pins
and four screws

rotor blade
1 HP2 stator blade carrier casing
3 HP2 stator blade

MAN Turbo AG

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stator blade
2 HP1 stator blade carrier
4 HP turbine rotor

16-Jun-09

< 28 >

HP Turbine
HP turbine Sealing

By honeycomb seals.

Labyrinth strips mounted

z on the rotor blades and
z on the turbine disc
Penetrate into the
honeycomb seals.

Keeps the clearances

Very low performance and
efficiency losses.

rotor blade
1 HP2 stator blade carrier casing
3 HP2 stator blade

MAN Turbo AG

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stator blade
2 HP1 stator blade carrier
4 HP turbine rotor

16-Jun-09

< 29 >

HP Turbine
HP turbine inspection

Inspection of the hot gas parts,

z one carrier half can be
removed
z after having shifted apart the
gas generator and the power
turbine

MAN Turbo AG

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16-Jun-09

< 30 >

HP Turbine
Number of blades

MAN Turbo AG

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16-Jun-09

< 31 >

Bearings of the GG rotor

Function

Two bearings
z hydrodynamic
z tilting pad sleeve.

Rotary movement of the GG rotor

generates required lubricating oil
pressure

With increasing speed, more and

more oil is transferred from the
contact surface of the shaft into
the lubricating gap.

Oil pressure in the lubricating

gap increases
Until the shaft floats on the
lubricating oil film.

1
4
7
10

thrust bearing
stop
oil return
backpressure bearing

MAN Turbo AG

GF14

2 oil supply
5 GG shaft
8 bearing support

3 carrier for labyrinth / floating ring seal

6 contact face for a sealing ring
9 sleeve bearing

16-Jun-09

< 32 >

Front bearing GG rotor

Function

Axial thrust,
Axial backpressure and

Radial bearing.

Function
z absorbs during startup the
axial force
z at higher speeds rotor is
pressed against the thrust
bearing in flow direction

1
4
7
10

thrust bearing
stop
oil return
backpressure bearing

MAN Turbo AG

2 oil supply
5 GG shaft
8 bearing support

GF14

3 carrier for labyrinth / floating ring seal

6 contact face for a sealing ring
9 sleeve bearing

16-Jun-09

< 33 >

Front bearing GG rotor

Sealing

To the compressor room on

the rear side
z via a floating ring sliding
on the shaft end of the
GG rotor and
z via a labyrinth seal.

Seal air required

z routed from the inner
area of the compressor
rotor
z to the labyrinth seal
through bores.

1
4
7
10

thrust bearing
stop
oil return
backpressure bearing

MAN Turbo AG

2 oil supply
5 GG shaft
8 bearing support

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3 carrier for labyrinth / floating ring seal

6 contact face for a sealing ring
9 sleeve bearing

16-Jun-09

< 34 >

Front bearing GG rotor

Tilting pads

12 tilting pads each

supported on bearings for
z thrust and
z backpressure bearing

5 tilting pads for

z sleeve bearing serving
for absorption of the
radially acting forces

1
4
7
10

thrust bearing
stop
oil return
backpressure bearing

MAN Turbo AG

2 oil supply
5 GG shaft
8 bearing support

GF14

3 carrier for labyrinth / floating ring seal

6 contact face for a sealing ring
9 sleeve bearing

16-Jun-09

< 35 >

Rear bearing GG rotor

Function

In two parts,
Sleeve bearing
Sealing
z on both sides of the bearing
z via floating rings and
z labyrinth seals.
Seal air is
z routed through the inner area
of the compressor rotor and
z through bores to the labyrinth
seals.

MAN Turbo AG

GF14

16-Jun-09

< 36 >

Front bearing GG rotor

Lube oil supply

Through line connected to

the GG inlet casing.
Through internal channels
and lines,
Into the annulus of the
bearing and
Injected through five
bores located between the
tilting pads of the radial
bearing.

oil supply

oil return

Return by gravitational
force
z over the lower strut of
the GG inlet casing
z into the oil tank.
MAN Turbo AG

GF14

16-Jun-09

< 37 >

Rear bearing GG rotor

Lube oil supply

Through line connected to

the lower GG main casing
half in the rear area.
Injected just like on the GG
front bearing
z through a hose and
z inner channels inside
the gas generator.
Return by gravitational
force
z into a collecting
chamber and
z through a internal hose
z back into oil tank

oil supply

MAN Turbo AG

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oil return

16-Jun-09

< 38 >

Power turbine
Design, Function

Axial-flow
Two-stage
Backpressure turbine
Transforms the waste
gas energy into a rotary
movement and
Transfers it to the
processing machine
with the drive coupling

MAN Turbo AG

GF14

16-Jun-09

< 39 >

Power turbine
Components

LP1 stator blade carrier

LP2 stator blade carrier
z in 2 parts
z vertical split joint
LP turbine rotor
Main casing
Exhaust gas bend

1
2
3
4
5

MAN Turbo AG

LP1 stator blade carrier

LP2 stator blade carrier
LP turbine rotor
LP turbine shaft
LP main casing

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16-Jun-09

< 40 >

Power turbine
Number of blades

MAN Turbo AG

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16-Jun-09

< 41 >

LP1 Stator blade carrier casing

Number

Connection between
GG and power
turbine

Accommodates 8 T4
thermocouples for
power turbine inlet
temperature

42 stator blades.

1 T4 thermocouple
2 LP1 stator blade carrier casing
3 LP1 stator blade

MAN Turbo AG

GF14

16-Jun-09

< 42 >

LP2 Stator blade carrier casing

Description

Two-part LP2 stator blade

carrier.
54 stator blades
For inspection of the hot gas
parts, one carrier half can be
removed
z after having shifted apart
the GG and the power
turbine

MAN Turbo AG

GF14

16-Jun-09

< 43 >

LP Turbine rotor
Description

Two discs with

58 rotor blades each,

Inserted in fir-treeshaped grooves.

Connected to the LP
shaft via 4 stud bolts and
four screws.

Connected to the output

coupling that transfers
the torque to the
processing machine.

1 LP2 stator blade carrier

MAN Turbo AG

2 LP turbine rotor with shaft

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3 LP2 stator blade

16-Jun-09

< 44 >

LP Turbine rotor
Sealing

Honeycomb seals.

In the first operating hours

the labyrinth strips
mounted
z on the rotor blades and
z on turbine disc

Penetrate into the

honeycomb seals.
Keeps the clearances

Very low performance and

efficiency losses.

1 LP2 stator blade carrier

MAN Turbo AG

2 LP turbine rotor with shaft

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3 LP2 stator blade

16-Jun-09

< 45 >

LP Main casing
Description

Conical design
Internal and external
casing
z connected to each
other via four struts.
Internal casing: two
bearings

External casing:
connection to baseframe
z three bottom mount
pins

1 front bearing
4 LP shaft

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2 strut
5 LP main casing

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3 rear bearing
6 exhaust gas bend

16-Jun-09

< 46 >

LP Main casing
Function

Acts like a diffuser and

Reduces velocity of the
waste gas nearly
without losses.
Directs the waste
gases through the
waste gas elbow to
z the waste gas
stack or
z directly to heat
recovery system.

1 front bearing
4 LP shaft

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2 strut
5 LP main casing

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3 rear bearing
6 exhaust gas bend

16-Jun-09

< 47 >

Bearings LP turbine rotor

Description

Two hydrodynamic
Tilting pad
Sleeve bearings
Design and
functioning similar to
GG bearings
Contrary to GG rotor,
z the axial thrust,
axial backpressure
and radial bearing
arranged at rear
shaft end

oil supply

MAN Turbo AG

oil return

GF14

16-Jun-09

< 48 >

Bearings LP turbine rotor

Sealing

LP front bearing
z on the front side floating
ring sliding on the shaft
end and
z via a labyrinth seal.
z no sealing on the rear
side
z seal air for the labyrinth
seal: cooling air from the
space between the two
LP turbine discs is.
LP rear bearing
z No floating ring and
z no labyrinth seal
installed

Rear Bearing Power Turbine

1 Bearing casing
2 Oil supply
3Trust bearing
4 Backpressure bearing 5 Sleeve type radial
bearing
6 LP shaft
7oil supply
connection
8 Oil supply line to LP front bearing
MAN Turbo AG

GF14

16-Jun-09

< 49 >

Bearings LP turbine rotor

Lube oil supply

Through line
connected to the LP
rear bearing casing.
Part of the oil flows
directly into the LP
rear bearing
Part to the LP front
bearing through an
internal line
connecting the two
bearings

oil supply

oil return

Injection into the

bearing like on the
GG bearings.

MAN Turbo AG

GF14

16-Jun-09

< 50 >

Bearings LP turbine rotor

Lube oil return

By gravitational
force into the
internal casing of
the LP main casing.
Approx. half of the
oil from the LP rear
bearing flows into
the internal casing
Rest into the
coupling guard.

oil supply

oil return

Through the line

connected to the
internal casing or
To the coupling
guard into the
lubricating oil tank.
MAN Turbo AG

GF14

16-Jun-09

< 51 >