GT6B Foundamental

GE Energy Products – Europe
Rev. : A
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OPERATION AND MAINTENANCE MANUAL
DESCRIPTION
GAS TURBINE
1. GAS TURBINE ......................................................................................................................2
1.1. GENERAL, FUNCTIONAL DESCRIPTION..............................................................................2
1.1.1. INTRODUCTION ......................................................................................................................2
1.1.2. GAS TURBINE FUNCTIONAL DESCRIPTION........................................................................4
1.2. TURBINE BASE AND SUPPORTS..........................................................................................6
1.2.1. TURBINE BASE .......................................................................................................................6
1.2.2. TURBINE SUPPORTS .............................................................................................................7
1.2.3. GIB KEY AND GUIDE BLOCK .................................................................................................9
1.3. COMPRESSOR SECTION.....................................................................................................10
1.3.1. GENERAL ..............................................................................................................................10
1.3.2. COMPRESSOR ROTOR........................................................................................................11
1.3.3. COMPRESSOR STATOR ......................................................................................................13
1.4. COMBUSTION SYSTEM .......................................................................................................22
1.4.1. GENERAL ..............................................................................................................................22
1.4.2. COMBUSTION CHAMBERS AND CROSSFIRE TUBES ......................................................24
1.4.3. SPARK PLUGS AND FLAME DETECTORS .........................................................................25
1.4.4. FUEL NOZZLES.....................................................................................................................27
1.4.5. TRANSITION PIECES............................................................................................................28
1.4.6. FALSE START DRAIN ...........................................................................................................30
1.5. TURBINE SECTION...............................................................................................................31
1.5.1. GENERAL ..............................................................................................................................31
1.5.2. TURBINE ROTOR..................................................................................................................32
1.5.3. TURBINE STATOR ................................................................................................................36
1.5.4. EXHAUST FRAME AND DIFFUSER .....................................................................................41
1.6. BEARINGS.............................................................................................................................42
1.6.1. GENERAL ..............................................................................................................................42
1.6.2. N° 1 BEARING .......................................................................................................................43
1.6.3. N° 2 BEARING .......................................................................................................................49
1.7. COUPLING.............................................................................................................................50
1.7.1. GENERAL ..............................................................................................................................50
1.7.2. ACCESSORY GEAR AND LOAD COUPLING.......................................................................51
1.7.3. EACH END OF THE COUPLING IS BOLTED AT THE FLANGE ..........................................51
1.8. ENCLOSURES.......................................................................................................................52
1.9. INLET AND EXHAUST SECTIONS .......................................................................................53
1.9.1. AIR INLET SYSTEM ..............................................................................................................53
1.9.2. EXHAUST SYSTEM...............................................................................................................53
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OMMD_GT_6B_EN Revision: A Date: 11/2007
Rev. : A
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DESCRIPTION
1. GAS TURBINE
1.1. GENERAL, FUNCTIONAL DESCRIPTION
1.1.1. INTRODUCTION
A heavy duty gas turbine unit is a mechanical power engine installed in a plant :
• In most application to drive a generator to supply an electrical network.
• Or sometimes to drive a compressor for gas treatment plan.
The gas turbine power engine includes an axial airflow compressor, a multi chamber
combustion system and a three stages turbine. Main components of the gas turbine are
listed here below.
The axial airflow compressor is a 17 stages compressor with :

• Adjustable inlet guide vanes (IGV) to control the airflow during starting and loading
sequences.
• Bleed valves to bypass part of the air flow for starting and shut down to escape from
surging.
The combustion system comprises :

• Fuel nozzles fitted on the combustion chamber’s cover.
• Ten combustion chambers where the fuel burns permanently from firing speed to full load.
• Ten cross fire tubes connecting the combustion chamber.
• Ten transition pieces downstream the combustion chamber connected to the first turbine
stage nozzle.
• Two spark plugs for the fuel ignition.
• A set of flame detectors.
The three stages turbine includes first, second and third stage nozzle and first, second and
third wheel.
The turbine and the axial flow compressor belong to the same shaft connected to :
• The auxiliary gear box and the starting means at the front end.
• The generator at the rear end through a load gear box.
The gas turbine components and function are detailed in the text here after.

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DESCRIPTION
NOTE : the design convention for gas turbine orientation is :

• Front / forward : the air inlet side of the gas turbine is the front/forward end.
• After / rear : the gas turbine exhaust side is the after/rear end.
• Left / right : the left and right sides of the turbine or of a particular component are
determined by standing forward/front and looking after/rear.
The forward and aft ends of each component are determined in like manner with respect to
its orientation within the complete unit.

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DESCRIPTION
1.1.2. GAS TURBINE FUNCTIONAL DESCRIPTION
(Refer to gas turbine simplified flow diagram here below)

Functional description at nominal speed :
While the gas turbine is running, filtered ambient air is drawn through the inlet plenum
assembly, then compressed in the 17th-stage axial flow compressor. Compressed air from
the compressor flows into the annular space surrounding the ten combustion chambers, from
which it flows into the spaces between the outer combustion casings and the combustion
liners, and enters the combustion zone through metering holes in each of the combustion
liners.
The fuel nozzles introduce the fuel into each of the ten combustion chambers where it mixes
with the combustion air and burns.
The hot gases from the combustion chambers expand into the ten separate transition pieces
attached to the downstream end of the combustion chamber liners and flows from there to
the three-stage turbine section of the machine. Each stage consists of a row of fixed nozzles
followed by a row of turbine buckets. In each nozzle row, the kinetic energy of the jet is
increased, with an associated pressure drop, and in each following row of moving buckets, a
portion of the kinetic energy of the jet is absorbed as useful work on the turbine rotor.
After passing through the 3rd-stage buckets, the exhaust gases are directed into the exhaust
casing and diffuser which contains a series of turning vanes to turn the gases from an axial
direction to a radial direction, thereby minimizing exhaust hood losses. Then, the gases pass
into the exhaust plenum and are introduced to atmosphere through the exhaust stack.
Resultant shaft rotation turns the generator rotor to generate electrical power or to drive a
centrifugal compressor in industrial power applications and drives the auxiliaries through the
accessory gearbox.
Starting sequence :
The gas turbine cannot run itself from zero speed. A starting means bring the shaft line up to
the self-sustaining speed.
When the starting means is actuated, the IGV are in the closed shut down position and the
compressor bleed valves are open. The cranking torque from the ratchet system breaks
away the turbine shaft through the mechanical clutch, the cranking motor brings the gas
turbine to firing speed. Fuel is injected in the combustion chamber, spark plug provide
ignition in two combustion chambers and the flame spreads to the other combustion
chambers through the crossfire tubes. Flame detectors confirm full ignition to the control
panel.
Starting means remain actuated to accelerate the unit to self-sustaining speed. When the
turbine torque is higher than the cranking torque at clutch level, the clutch opens and stops
the starting means function. The gas turbine reaches nominal speed, the IGV move to full
speed no load (FSNL) operating position and the bleed valve closes.
Main shaft driven lube oil pump provides lubricating oil for the shaft line bearings. During
starting sequence the auxiliary lube oil pump feeds the header.

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DESCRIPTION
Cool down sequence :

Due to the high temperature within the gas path, the gas turbine must follow a 24 hours
ratchet sequence, after shut down, to provide cool down cycle to the shaft line by turning a
eighth turn every three minutes.
GAS TURBINE SIMPLIFIED FLOW DIAGRAM
Filtered
Inlet
air Exhaust
Fuel Combustion
Torque output Torque

to drive output
Axial flow Turbine
accessories to drive
Compressor
and from the load
starting
means

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DESCRIPTION
1.2. TURBINE BASE AND SUPPORTS
1.2.1. TURBINE BASE
Description :
The base upon which the gas turbine and its accessories are mounted is a structural-steel
fabrication. It forms a single platform which supports the basic gas turbine unit and the
accessory equipment.
In addition, the base supports the gas turbine inlet and exhaust plenums.
The forward end of the base, under the accessory compartment, also functions as a lube oil
storage tank. An oil drain channel is constructed along the web of the left longitudinal I-beam.
The channel extends from the oil tank to the aft end of the base, providing a passage for the
lube oil header.
Lube oil feed and drain connections are made at the aft end of this drain channel.
Finished pads on the bottom of the base facilitate its mounting on the site foundation.
TURBINE BASE

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DESCRIPTION
1.2.2. TURBINE SUPPORTS
Description :
The gas turbine is mounted to its base by vertical supports at three locations. The forward
support is located at the lower half of the vertical flange of the forward compressor casing,
and the aft two support-legs are located on either side of the turbine shell.
The forward support is a flexible plate that rests on two machined pads attached to the
forward cross frame beam of the turbine base. The support plate is bolted and doweled to
these pads and to the forward flanges of the forward compressor casing.
The aft supports are leg-type supports, located one on each side of the turbine shell. Both
vertical support legs rest on machined pads on the base and attach snugly to the turbine
exhaust-frame-mounted support pads. The legs provide centerline support to supply casing
alignment.
On the inner surface of each support leg a water jacket is provided, through which cooling
water is circulated to minimize thermal expansion and to assist in maintaining alignment
between the turbine and the generator.
The leg-type supports maintain the axial and vertical position of the turbine, while a gib key
coupled with the support legs maintains its lateral position.
FORWARD TURBINE SUPPORT

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DESCRIPTION
AFTER TURBINE
SUPPORT LEG (one
on each side)

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DESCRIPTION
1.2.3. GIB KEY AND GUIDE BLOCK
Description :
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 turbine base aft cross beam. The key is held securely in place in the guide block with
bolts that bear against the key on each side.
This key-and-block arrangement prevents lateral or rotational movement of the turbine while
permitting axial and radial movement resulting from thermal expansion.
GIB KEY
GUIDE BLOCK

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DESCRIPTION
1.3. COMPRESSOR SECTION
1.3.1. GENERAL
Description :
The axial-flow compressor section consists of the compressor rotor and the enclosing casing.
Included within the compressor casing are the inlet guide vanes, the 17 stages of rotor and stator
blades, and the 2 exit guide vanes rows.
In the compressor, air is confined to the space between the rotor and stator blades where it is
compressed in stages by a series of alternate rotating (rotor) and stationary (stator) airfoil-shaped
blades.
The rotor blades supply the force needed to compress the air in each stage and the stator blades
guide the air so that it enters the following rotor stage at the proper angle. The compressed air exits
through the compressor discharge casing to the combustion chambers. Air is extracted from the
compressor for turbine cooling, for bearing sealing, and during start-up for pulsation control.
Since minimum clearance between rotor and stator provides best performance in a compressor,
parts are made and assembled very accurately.
COMPRESSOR

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DESCRIPTION
1.3.2. COMPRESSOR ROTOR
Description :
The compressor rotor is an assembly of 15 wheels, 2 stubshafts and wheels assemblies, through
bolts, and the rotor blades.
Each wheel and the wheel portion of each stubshaft has slots broached around its periphery. The
rotor blades are inserted into these slots and they are held in axial position by staking at each end
of the slot. The wheels and stubshafts are assembled to each other with mating rabbets for
concentricity control and are held together with tie bolts.
The forward stubshaft is machined to provide the active and inactive thrust faces and the journal for
the n° 1 bearing, as well as the sealing surfaces for the n° 1 bearing oil seals and the compressor
low pressure air seal.
After assembly, the rotor is dynamically balanced to a fine limit.
COMPRESSOR ROTOR LOCATION

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DESCRIPTION
COMPRESSOR ROTOR BLADE

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DESCRIPTION
1.3.3. COMPRESSOR STATOR
General :
The stator (casing) area of the compressor section is composed of three major sections :
• Inlet casing.
• Compressor casing.
• Compressor discharge casing.
These sections, in conjunction with the turbine shell and exhaust frame 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.
COMPRESSOR STATOR (IN BLACK)

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DESCRIPTION
Inlet casing :
The inlet casing is located at the forward end of the gas turbine, in the inlet plenum.
Its prime function is to uniformly direct air to the compressor. The inlet casing also supports the n°1
bearing assembly. The n° 1 bearing lower half is cast integral with the inner bellmouth. The upper
half bearing housing is a separate casting, flanged and bolted to the lower half. The inner bellmouth
is positioned to the outer bellmouth by seven airfoil-shaped radial struts and seven axial tiebars.
Both the struts and tiebars are cast into the bellmouth walls.
INLET CASING

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DESCRIPTION
Variable inlet guide vanes :

Variable inlet guide vanes are located at the aft end of the inlet casing.
The position of these vanes has an effect on the quantity of compressor air flow. Movement of the
inlet guide vanes is actuated by a hydraulic cylinder connected to the inlet guide vane control ring
that turns the individual pinion gears mounted on the end of each vane. The gears, the ring and the
vanes are shown next page.
VARIABLE INLET GUIDE VANES
HYDRAULIC
CYLINDER FOR
I.G.V. SYSTEM

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DESCRIPTION
INLET GUIDE VANES SYSTEM
PINION GEAR
VANES

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DESCRIPTION
INLET GUIDE VANES
PINION GEAR
RING GEAR

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DESCRIPTION
Compressor casing :
The forward compressor casing contains the first- through tenth- compressor stages. It also
transfers the structural loads from the adjoining casing to the forward support which is bolted and
doweled to this compressor casing’s forward flange.
Extraction ports in the casing permit removal of fifth- eleventh- and thirteenth-stage compressor air.
Air from fifth and eleventh-stages is used for cooling and sealing functions and is also used for
starting and shutdown pulsation control. Air from therteenth-stage is used for the cooling of the
second-stage nozzle.
COMPRESSOR CASING

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DESCRIPTION
Discharge casing :
The compressor discharge casing is the final portion of the compressor section.
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 casing are to contain the final seven compressor
stages, to form both the inner and outer walls of the compressor diffuser, provide inner support for
the first-stage nozzle and join the compressor and turbine stators, and support the outer
combustion cans.
The compressor discharge casing consists of two cylinders, one being a continuation of the
compressor casings and the other being an inner cylinder that surrounds the compressor rotor. The
two cylinders are concentrically positioned by ten radial struts. These struts extend from the inner
cylinder outward to a vertical bulkhead.
The bulkhead has ten circular openings permitting air flow to enter the combustion system. This
bulkhead also provides support to the ten combustion chamber assemblies.
A diffuser is formed by the tapered annulus between the outer cylinder and inner cylinder of the
discharge casing. The diffuser converts some of the compressor exit velocity into added pressure.
DISCHARGE CASING

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DESCRIPTION
Blading :
The compressor rotor and stator blades are airfoil shaped and were designed to compress air
efficiently at high blade tip velocities. The blades are attached to their wheels by dovetails
arrangements.
The dovetail is very precise in size and position so as to maintain each blade in the desired position
and location on the wheel.
The stator blades for stages 1 through 4 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. In stages 5 through 17, the stator blades and exit guide vanes 1 and 2 have a square
base dovetail and are inserted directly into circumferential grooves in the casing. Locking keys are
used as with the blade ring design.

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DESCRIPTION
COMPRESSOR STATOR BLADE

(Stage 5 trough 17)
COMPRESSOR STATOR BLADE

(Stage 1 trough 4)

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DESCRIPTION
1.4. COMBUSTION SYSTEM
1.4.1. GENERAL
The combustion system is the reverse flow type which includes 10 combustion chambers having
the following components :
• Liners.
• flow sleeves.
• Transition pieces.
• Crossfire tubes.
Flame detectors, crossfire tubes, fuel nozzles and spark plugs igniters are also part of the total
system.
Hot gases, generated from burning fuel in the combustion chambers, are used to drive the turbine.
In the reverse flow system high pressure air from the compressor discharge is directed around the
transition pieces and into the annular spaces that surround each of the 10 combustion chamber
liners.
Compressor discharge air which surrounds the liner, flows radially inward through small holes in the
liner wall and impinges against rings that are brazed to the liner wall. This air then flows right
toward the liner discharge end and forms a film of air that shields the liner wall from the hot
combustion gases. Fuel is supplied to each combustion chamber through a nozzle.
Combustion chambers are numbered counterclockwise when viewed looking down stream and
starting from the top of the machine.
The ten combustion chambers are interconnected by means of crossfire tubes. These tubes enable
flame from the fired chambers containing spark plugs to propagate to the unfired chambers.

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DESCRIPTION
COMBUSTION CHAMBER ARRANGEMENT
VUE LOOKING DOWNSTREAM

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DESCRIPTION
1.4.2. COMBUSTION CHAMBERS AND CROSSFIRE TUBES
Description :
Discharge air from the axial flow compressor enters the combustion chamber from the cavity at the
center of the unit. The air flows up-stream along the outside of the combustion liner toward the liner
cap. A part of this air enters the combustion chamber reaction zone through the fuel nozzle swirl tip
and through metering holes in both the cap and liner.
The hot combustion gases from the reaction zone pass through a thermal soaking zone and then
into a dilution zone where additional air is mixed with the combustion gases. Metering holes in the
dilution zone allow the correct amount of air to enter and cool the gases to the desired temperature.
Along the length of the combustion liner and in the liner cap are openings whose function is to
provide a film of air for cooling the walls of the liner and cap.
The 10 combustion chamber casings are identical with the exception of those fitted with spark plugs
or flame detectors.
COMBUSTION LINER

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DESCRIPTION
1.4.3. SPARK PLUGS AND FLAME DETECTORS
Spark plugs :
Combustion is initiated by means of the discharge from two high-voltage, retractable-electrode
spark plugs installed in adjacent combustion chambers (N° 1 and 10).
These spring-injected and pressure-retractable plugs receive their energy from ignition
transformers. At the time of firing, a spark at one or both of these plugs ignites the combustion
gases in the chambers. The gases in the remaining chambers are ignited by crossfire through the
tubes that interconnect the reaction zones of the remaining chambers. As rotor speed increases,
chamber pressure causes the spark plugs to retract and the electrodes are removed from the
combustion zone.
SPARK PLUG (TYPICAL)

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DESCRIPTION
Flame detectors :
During the starting sequence, it is essential that an indication of the presence or absence of flame
be transmitted to the control system. For this reason, a primary flame monitoring system is used
consisting of four sensors which are installed on four adjacent combustion chambers (N° 2 and 3, 7
and 8) and an electronic amplifier which is mounted in the turbine control panel.
The ultraviolet flame sensor consists of a flame sensor, containing a gas filled detector. The gas
within this flame sensor detector is sensitive to the presence of ultraviolet radiation which is emitted
by a hydrocarbon flame. A d.c voltage, supplied by the amplifier, is impressed across the detector
terminals. If flame is present, the ionization of the gas in the detector allows conduction in the circuit
which activates the electronics to give an output defining flame. Conversely, the absence of flame
will generate an opposite output defining ”no flame”.
FLAME DETECTOR (TYPICAL)

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DESCRIPTION
1.4.4. FUEL NOZZLES
Description :
Each combustion chamber is equipped with a fuel nozzle that emits a metered amount of the
required fuel into the combustion liner. Fuel nozzles are used in gas turbine burning gas. The fuel
nozzle functions to distribute the gas fuel into the reaction zone of the combustion liner, in a manner
which promotes uniform, rapid and complete combustion.
Gas fuel enters the fuel nozzle assembly through the fuel gas connection flange and is routed
through nozzle internal passages to orifices located in the gas tip.
PRIMARY
NOZZLE
SECONDARY
NOZZLE

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DESCRIPTION
1.4.5. TRANSITION PIECES
Description :
Transition pieces direct the hot gases from the liners to the turbine first-stage nozzle. Thus, the first
nozzle area is divided into ten equal areas receiving the hot gas flow.
The transition pieces are sealed to both the outer and inner sidewalls on the entrance side of the
nozzle, so minimizing leakage of compressor discharge air into the nozzle.

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DESCRIPTION

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DESCRIPTION
1.4.6. FALSE START DRAIN
False start drain valve shown on the washing diagram are opened for washing purpose. Air
pressure from the discharge of the unit’s axial-flow compressor is used to actuate these valve.
Valve drain excessive water from the combustion chambers.

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DESCRIPTION
1.5. TURBINE SECTION
1.5.1. GENERAL
Description :
The three-stage turbine section is the area in which energy in the form of high energy, pressured
gas produced by the compressor and combustion sections is converted to mechanical energy.
Each turbine stage is comprised of a nozzle and the corresponding wheel with its buckets. Turbine
section components include the turbine rotor (wheels, buckets), turbine shell, (nozzles, shrouds),
exhaust frame and exhaust diffuser.
TURBINE SECTION

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DESCRIPTION
1.5.2. TURBINE ROTOR
Description :
The turbine rotor is of through-bolted construction, consisting of the distance piece, first-stage
wheel, first- and second-stage spacer, second-stage wheel, second- and third-stage spacer, third-
stage wheel and the aft wheel shaft.
It is mated to the compressor rotor by the bolted flange connection of the compressor seventeenth-
stage wheel, thus connecting the distance piece to the wheel.
Concentricity control is achieved with mating rabbets on the turbine wheels, wheel shafts and
spacers. The wheels are held together with through-bolt. Selective positioning of rotor members is
performed to minimize balance corrections.
The aft wheel shaft connects from the third-stage turbine wheel to the load coupling. It includes the
n° 2 bearing journal.
Spacers between the first- and second-stage turbine wheels and between the second- and third-
stage turbine wheels provide the axial position of the individual wheels. These spacers carry the
diaphragm sealing bands. The spacer forward faces include radial slots for cooling air passages.
TURBINE ROTOR

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DESCRIPTION
Buckets :
The turbine buckets 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, the increasing size of the buckets.
The first-stage buckets are the first rotating surfaces encountered by the extremely hot gases
leaving the first-stage nozzle. Each first-stage bucket contains a series of longitudinal air passages
for bucket cooling. Air is introduced into each first-stage bucket through a cavity between the wheel
and the base of the bucket dovetail (pine-tree shaped). The air flows through a series of cooling
holes spanning the bucket lengthwise and exits from these holes at each recessed bucket tip. The
holes are spaced and sized to obtain optimum cooling of the airfoil with a minimum of compressor
extraction air.
The second-stage buckets also contains a series of longitudinal air passages for bucket cooling. Air
is introduced through four cooling holes in the bucket dovetail and it flows towards the bucket tip
where it exits. The tips of these buckets are enclosed by a shroud which is a part of the tip seal
(integral shroud). The shroud interlock from bucket to bucket to dampen vibration.
The third-stage buckets are not internally air cooled. The tips of these buckets, like the second-
stage buckets, are enclosed by a shroud which is a part of the tip seal. The shrouds interlock from
bucket to bucket to dampen vibration.
The three-stages of turbine buckets are attached to their wheels by straight, axial entry, multiple-
tang dovetails that fit into matching cutouts in the rims of the turbine wheels. The dovetails are a
significant distance from the hot gases to reduce the temperature at the dovetail.
The turbine rotor assembly is arranged so that the buckets can be replaced without unstacking the
wheels, spacers, and wheel shaft assemblies.

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DESCRIPTION
BUCKETS
1ST-STAGE 2ND-STAGE 3RD-STAGE

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DESCRIPTION
Turbine rotor cooling :

The turbine rotor must be cooled to maintain reasonable operating temperatures and therefore,
assure a longer turbine service life.
Cooling is accomplished by means of a positive flow of cool air radially outward through a space
between the wheel and buckets and the stator into the main gas stream. This area is called the
wheelspace.
• The first-stage forward wheelspace is cooled by compressor discharge air. At the aft end of the
compressor rotor is a high pressure packing between the rotor and the inner barrel of the
compressor discharge casing. Part of the leakage through this labyrinth furnishes the air flow
through the first-stage forward wheelspace. This cooling air flow discharges into the main gas
stream aft of the first nozzle.
• The first-stage aft wheelspace is cooled by second-stage nozzle cooling air.
• The second-stage forward wheelspace is cooled by leakage from the first-stage aft wheelspace
through the interstage labyrinth. This air returns to the gas path at the entrance of the second-
stage buckets.
• The second-stage aft wheelspace is cooled by air from the internal extraction system (from the
sixteenth-stage of compression, more exactly). This air enters the wheelspace through slots in
the forward face of the spacer. Air from this wheelspace returns to the gas path at the third-stage
nozzle entrance.
• The third-stage forward wheelspace is cooled by leakage from the second-stage aft wheelspace
through the interstage labyrinth. This air reenters the gas path at the third-stage bucket entrance.
• The third-stage aft wheelspace is cooled by air from externally mounted blowers. This cooling air
is piped to the turbine shell where it flows through holes in the shell and enters the exhaust
frame where it is first used for cooling the struts and then the majority is finally directed to the
third-stage aft wheelspace cavity.

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DESCRIPTION
1.5.3. TURBINE STATOR
Structure :
The turbine shell and the exhaust frame complete the major portion of the gas turbine stator
structure. The turbine nozzles, shrouds, n° 2 bearing and turbine exhaust diffuser are internally
supported from these components.
TURBINE SHELL TURBINE STATOR

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DESCRIPTION
Turbine shell :
The turbine shell controls the axial and radial position of the shrouds and nozzles. Resultantly, it
controls turbine clearances and the relative positions of the nozzles to the turbine buckets. This
positioning is critical to the turbine performance.
Hot gases contained by the turbine shell are a source of heat flow into the shell. To control the shell
diameter, it is important to reduce the heat flow into the shell by design and to cool it to limit its
temperature. Heat flow limitations incorporate insulation, cooling, and multilayered structures. The
cylindrical portion of the shell is cooled by cooling air produced from an external device with
blowers. This air flows axially through the shell and out through holes in the aft vertical flange into
the exhaust frame. Then, air is used for further cooling of the exhaust frame struts and turbine third-
stage aft wheelspace.
The shell forward flange is bolted to the bulkhead at the aft end of the compressor discharge
casing. The shell aft flange is bolted to the exhaust frame. Trunnions cast onto the sides of the shell
are used to aid in lifting the gas turbine when it is separated from its base, should this ever be
necessary.

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DESCRIPTION
Turbine 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 the rotor to rotate.
Because of the high pressure drop across these nozzles, there are seals at both the inside
diameters and the outside diameters to prevent loss of system energy by leakage. Since these
nozzles operate in the hot combustion gas flow, they are subjected to thermal stresses in addition
to gas pressure loadings.
• First-stage nozzle :
The first-stage nozzle receives the hot combustion gases from the combustion system via the
transition pieces. The transition pieces are sealed to both the outer and inner sidewalls on the
entrance side of the nozzle minimizing leakage of compressor discharge air into the nozzle. The
18 cast nozzle segments, each with two partitions (or airfoils) are contained by a horizontally
split retaining ring which is centre-line supported to the turbine shell on lugs at the sides and
guided by pins at the top and bottom vertical centre-lines. This permits radial growth of the
retaining ring, resulting from changes in temperature while the ring remains centred in the shell.
The aft outer diameter of the retaining ring is loaded against the forward face of the first-stage
turbine shroud and acts an the air seal to prevent leakage of compressor discharge air between
the nozzle and shell. On the inner sidewall, the nozzle is sealed by U-shaped seal segments
installed between the nozzle and the first-stage nozzle support ring bolted to the compressor
discharge casing. The nozzle is prevented from moving forward by four lugs welded to the aft
outside diameter of the retaining ring at 45 degrees from vertical and horizontal centre-lines.
These lugs fit in a groove machined in the turbine shell just forward of the first-stage shroud T-
hook. By removing the horizontal joint support block and the bottom centre-line guide pine, the
lower half of the nozzle can be rolled out with the turbine rotor in place.
The first-stage nozzle partitions are internally cooled by compressor discharge air.
• Second-stage nozzle :
Combustion gas exiting from the first-stage buckets is again expanded and redirected against
the second-stage turbine buckets by the second-stage nozzle.
The second-stage nozzle is made of 16 cast segments, each with three partitions (or airfoils).
The male hooks on the entrance and exit sides of the sidewall fit into female grooves on the aft
side of the first-stage shrouds and on the forward side of the second-stage shrouds to maintain
the nozzle concentric with the turbine shell and rotor. This close fitting tongue-and-groove fit
between nozzle and shrouds acts as an outside diameter air seal. The nozzle segments are held
in a circumferential position by radial pins from the shell into axial slots in the nozzle outer
sidewall.
The second-stage nozzle partitions are cooled with compressor discharge air of thirteenth-
stage.
• Third-stage nozzle :
The third-stage nozzle receives the hot gas as it leaves the second-stage buckets, increases its
velocity by pressure drop and directs this flow to impinge against the third-stage buckets.
The nozzle consists of 16 cast segments, each with four partitions (or airfoils). It is held at the
outer sidewall forward and aft sides in grooves in the turbine shrouds in a manner identical to
that used on the second-stage nozzle. The third-stage nozzle is circumferentially positioned by
radial pins from the shell.

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DESCRIPTION

Rev. : A
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DESCRIPTION
Diaphragms :
Attached to the inside diameters of both the second- and third-stage nozzle segments are the
nozzle diaphragms.
These diaphragms prevent air leakage past the inner sidewall of the nozzles and the turbine rotor.
The high/low, labyrinth-type seal teeth are machined into the inside diameter of the diaphragm.
They mate with opposing sealing lands on the turbine rotor. Minimal radial clearance between
stationary parts (diaphragm and nozzles) and the moving rotor are essential for maintaining low
interstage leakage. This result in higher turbine efficiency.
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 primary function of the shrouds is to provide a cylindrical surface for minimizing tip clearance
leakage.
The secondary function is to provide a high thermal resistance between the hot gases and the
comparatively cool shell. By accomplishing this function, the shell cooling load is drastically
reduced, the shell diameter is controlled, the shell roundness is maintained, and important turbine
clearances are assured.
The shroud segments are maintained in the circumferential position by radial pins from the shell.
Joints between shroud segments are sealed by interconnecting tongues and grooves.
DIAPHRAGMS
SHROUD

Rev. : A
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DESCRIPTION
1.5.4. EXHAUST FRAME AND DIFFUSER
The exhaust frame is bolted to the aft flange of the turbine shell.
Structurally, the frame consists of an outer cylinder and an inner cylinder interconnected by the
radial struts.
Exhaust frame radial struts cross the exhaust gas stream. The struts must be maintained at a
uniform temperature in order to control the central position of the rotor in relation to the stator. This
temperature stabilization is accomplished by protecting the struts from exhaust gases with a metal
wrapper fabricated into the diffuser. This wrapper also provides a circuit for cooling air ; turbine
shell cooling air flows towards the exhaust frame holes facing the turbine shell holes, and then
through the space between the struts and the wrapper to maintain uniform temperature of the
struts.
The exhaust diffuser is located between the inner and outer cylinders. Gases exhaust from the
third- turbine stage enter the diffuser where velocity is reduced by diffusion and pressure is
recovered. At the exit of the diffuser, turning vanes assist in directing the gases into the exhaust
plenum.
EXHAUST FRAME AND DIFFUSER

Rev. : A
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DESCRIPTION
1.6. BEARINGS
1.6.1. GENERAL
Introduction :
The gas turbine unit contains two main journal bearings used to support the gas turbine rotor.
The unit also includes thrust bearings to maintain the rotor-to-stator axial position.
These bearings and seals are incorporated in two housings : one at the inlet and one in the exhaust
frame.
These two bearings are pressure-lubricated by fluid supplied from the main lubricating system. The
lubricating oil flows through branch lines to an inlet in each bearing housing.
The N° 1 bearing contains 3 bearings ; among these, there is a journal bearing, elliptical type.
The N° 2 bearing is a journal bearing, elliptical type.
Journal bearings, elliptical type are characterized by their non-cylindrical bores and are designed to
improve the stability of the shafts at high speeds.
An elliptical bearing is made up of two cylindrical halves brought together so that their centers are
displaced several mils from the bearing center (1 mil = 0.0254 mm).
It is manufactured by placing shims at the horizontal split and then machining a cylindrical bore.
The shims are then removed and the two halves are brought together to form the elliptical bearing.
Lubrication and lubricant seals (General) :
The two main bearings are pressure-lubricated with lubricating oil supplied from the lube reservoir
in the turbine base. When lubricating oil enters the bearing housing inlet, it flows into an annulus
around the bearing liner. From the annulus, the fluid flows through machined holes in the liner to
the bearing face. The lube oil is prevented from escaping along the turbine shaft by the use of seals
in each of the bearing housings.
These labyrinth packings of deflectors, or teeth, are assembled at the bearing assemblies where
fluid control is required. A smooth surface is machined on the shaft and the seals are assembled so
that only a small clearance exists between the seal deflector and the shaft.
The seals are designed with double rows of packing and an annular space between them.
Pressurized sealing air is admitted into this space and prevents lube oil from spreading along the
shaft. Some of this air returns with the lube oil to the reservoir and is vented through a vent.

Rev. : A
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DESCRIPTION
1.6.2. N° 1 BEARING
Description :
The N° 1 bearing subassembly is located in the center of the inlet casing assembly and contains
three bearings :
• Active (loaded) thrust bearing ;
• Inactive (unloaded) thrust bearing ;
• Journal bearing.
Additionally, it contains one ”running type” ring seal , two labyrinth seals, and a housing in which the
components are installed.
The components are keyed to the housing to prevent rotation. The bottom part of the housing is a
part of the inlet casing.
The top of the housing is a separate casting, flanged and bolted to the bottom half.
The labyrinth seals at each end of the housing are pressurized with air extracted from the
compressor’s fifth-stage. The ”running type” ring seal at the forward end of the thrust bearing cavity
contains the lubricant and limits entrance of air into the cavity.
A thrust bearing unit is made up of a shaft member called the ”thrust runner” and a stationary
member, called the ”bearing”. Thrust bearings are provided to support the thrust loads developed
on the rotor surfaces of a gas turbine unit. The thrust load imposed on such a bearing is the
algebraic sum of the forces that act on the rotor assembly in a direction along the rotor axis. For
example, the thrust forces of an axial-flow type compressor, such as used in this gas turbine, are
only partially compensated for by the anti-thrust forces of the turbine that drives it, and the resultant
thrust load will tend to move the rotor assembly in a direction opposite to that of the air flow through
the compressor.
During normal operation of the gas turbine unit, the thrust load of the rotor assembly is
unidirectional ; however, during start-up and shut-down of the unit, the direction of the thrust load
will generally reverse. Thus, two thrust bearings are assembled on a rotor shaft in order to support
the thrust loads imposed in either direction. The bearing which takes the thrust load during normal
operation is called the ”active” or ”loaded” thrust bearing, and that which takes the thrust load
during start-up or shut-down of the unit, is called the ”inactive” or ”unloaded” thrust bearing.
1 Active (loaded) thrust bearing

The action thrust bearing is a tilting pad equalizing type. This type of bearing is capable of
sustaining high loads and is very tolerant of shaft and housing misalignment. The principal parts
of the tilting pad equalizing thrust bearing include the rotating ”collar” or ”thrust runner” which is
an integral part of the rotor shaft, the stationary pivoted segments or bearing members called
”pads”, two rows of hardened steel equalizing levers called ”levelling plates” and the supporting
member called the ”base ring”. The pads and the levelling plates are assembled in the base ring
and the assembled in the base ring and the complete assembly is supported in the bearing
housing where it is keyed to prevent rotation.

Rev. : A
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DESCRIPTION
• Pads :
The bearing pad is shaped like the sector of a ring. Its bearing surface is faced with babitt, and
each pad has a hardened steel button, called a ”pad support”, set into its back which allows the
pad to tilt slightly in any direction on its levelling plate.
• Levelling plates :
The levelling plates are short levers with center fulcrums. Their functions is to align the bearing
pads with the thrust runner and to equalize the load amongst the pads despite possible slight
misalignment of the shaft axis from the normal, a condition that might result from small
deflections in the turbine structure during operation. The levelling plates are located in the base
ring by dowels or screws such that the plates are free to tilt on their fulcrums. The load
transmitted by the thrust runner to any one pad causes the pad to press against the upper
levelling plate immediately behind it. Each levelling plate, in turn, is supported upon one edge of
each of the two adjacent lower levelling plates, the other edges of which take part in supporting
the next upper levelling plates on either side.
As a result of this arrangement, any incipient excess of thrust on one pad is immediately shared,
through the interaction of the levelling plates, by the adjacent pads, and this interaction and load
sharing is distributed all around the circle so that all the pads automatically receive equal
loading.
• Base ring :
The base ring provides the support for all the parts of the bearing assembly and keeps the parts
in their proper location.
Lubrication :
The tilting pad thrust bearing is classified as a hydrodynamically lubricated bearing which means
that the bearing surfaces are separated from the thrust runner by a thin film of lubricating oil
which is formed and maintained by the relative motion of the bearing surfaces. This oil film
supports the thrust load and prevents metal-to-metal contact of the bearing surfaces. In addition
to acting as a load-supporting medium, the oil also serves to carry away the heat generated by
the shearing action of the oil film.
The pads of the tilting pad thrust bearing are free to assume the position which will provide for
the optimum wedge-shaped oil film required by each different combination of load, speed, oil
viscosity and temperature to which the bearing is subjected.
The tilting pad thrust bearing is lubricated by oil which is admitted under pressure through ports
in the bearing housing to an annulus behind the base ring. The lube oil then flows through ports
in the base ring to the thrust bearing cavity where it is picked up by the rotating thrust runner and
carried around the entire bearing surface. Oil circulation through the tilting pad thrust bearing is
assisted by the natural pumping action of the rotating thrust collar.
Oil leaves the bearing at the outer periphery of the pads and thrust collar where it is gathered in
a large annular cavity and drained. The drain annulus and exit ports are cast or machined into
the bearing housing.

Rev. : A
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DESCRIPTION
N° 1 BEARING ASSEMBLY

Rev. : A
Page : 46/53
DESCRIPTION
2 Inactive (unloaded) thrust bearing

The inactive (unloaded) thrust bearing is a taper-land type.
The taper-land thrust bearing consists of a steel ring faced with babitt. The bearing derives its
name from the fact that the bearing surface is divided by radial oil grooves into a number of
individual pads, each surface of which is tapered. A portion of the surface near the trailing edge
of the pad is generally left untapered.
Lubrication :
The taper-land thrust bearing also is classified as a hydrodynamically lubricated bearing.
It is lubricated by oil admitted under pressure through the oil passages in the bearing housing to
the inner diameter of the bearing. The lube oil flows along the shaft into radial oil grooves. The
radial oil grooves do not fully extend to the outer periphery of the bearing, but instead, are
partially dammed to prevent the bearing from being starved of lubricating oil under the action of
the high centrifugal forces generated by the high shaft speed of the gas turbine rotor assembly.
From the radial oil grooves, the oil is carried over the surfaces of the lands by the rotating thrust
collar. An oil film is formed between the thrust collar and the bearing and provides for
hydrodynamic lubrication.

Rev. : A
Page : 47/53
DESCRIPTION
SCHEMATIC DIAGRAM OF THE EQUALIZING MEANS
LEVELING PLATES PADS
LOADED THRUST
UNLOADED THRUST

Rev. : A
Page : 48/53
DESCRIPTION
THRUST BEARING ARRANGEMENT

Rev. : A
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DESCRIPTION
1.6.3. N° 2 BEARING
Description :
The N° 2 bearing subassembly is centre-line supported and located inside the exhaust frame inner
tunnel. This support includes ears at the horizontal centre-line and a gib key at the bottom center
line. This permits relative growth resulting from temperature differences while the bearing remains
centred in the exhaust frame.
The assembly includes an elliptical liner, labyrinth seals and a bearing housing with separate
bearing liner retaining strap bolted to the lower half of the housing. The labyrinth seals at each end
of the housing are pressurized with air extracted from the compressor fifth-stage.
The elliptical bearings, characterized by their non-cylindrical bores, improve the stability of the
shafts at high speed. In the design of these bearings, convergent clearance regions exist even at a
concentric shaft position, and the convergence increases with an increase in shaft eccentricity. This
convergency creates high-pressure regions which, in effect, puts an additional load on the bearing,
a factor which tends to improve the shaft stability. The extra-clearance space, as compared with a
cylindrical bearing of a diameter equal to the inscribed circle in these bearings, increases the oil
flow and also reduces the power losses, resulting in lower temperature rises in the bearing.

Rev. : A
Page : 50/53
DESCRIPTION
1.7. COUPLING
1.7.1. GENERAL
Introduction :
Couplings are used to transmit starting torque from the accessory gear to the gas turbine axial
compressor and to transmit shaft power from the turbine to the driven reduction gear.
Simplified cutaway view.
ACCESSORY GEAR COUPLING LOAD COUPLING

Rev. : A
Page : 51/53
DESCRIPTION
1.7.2. ACCESSORY GEAR AND LOAD COUPLING
Accessory gear coupling :

A flexible dry coupling is used to connect the accessory drive to the gas turbine shaft at the
compressor end.
Load coupling :
A rigid hollow coupling connects the turbine rotor shaft to the reduction gear.
1.7.3. EACH END OF THE COUPLING IS BOLTED AT THE FLANGE
TOWARDS TOWARDS
ACCESSORY GAS
GEAR TURBINE
ACCESSORY GEAR COUPLING

Rev. : A
Page : 52/53
DESCRIPTION
1.8. ENCLOSURES
The gas turbine and the relevant auxiliaries are installed on site within enclosures. The aim of those
enclosures is :
• To provide weather protection for the equipment.
• To detect and extinguish the fire and to contain fire fighting medium.
• To provide proper cooling and ventilation for the equipment.
• To dilute gas leak to avoid hazardous area.
• To provide attenuation of the noise generated by the equipment.
• To protect personnel from high temperature and fire risks.
• To heat the enclosure during cold period.

Rev. : A
Page : 53/53
DESCRIPTION
1.9. INLET AND EXHAUST SECTIONS
General :
It is necessary to treat incoming atmospheric air before it enters the turbine in order to adapt to the
environment and realize the desired machine performance. Specially designed equipment is
installed to modify the quality of the incoming air to make it suitable for use in the unit. It is
necessary also to attenuate the high frequency noise in the air inlet, caused by the rotating
compressor blades.
At the exhaust end of the gas turbine, gases produced as the result of combustion in the turbine
require specific equipment according to their exhaust to atmosphere or towards heat recovery
boilers.
1.9.1. AIR INLET SYSTEM
The air inlet system, down-stream of the air filtering installation, consists of an air duct, followed by
sections of parallel baffles silencers, then a screen system located in an inlet elbow, after which
airflow reaches the gas turbine air inlet plenum. To avoid freezing air there is an exchanger to warm
up the cold air, this system constitutes the anti-icing system (if used). For more details refer to
environment volumes. The gas turbine inlet plenum contains the compressor inlet casing.
The silencers are baffle-type construction to attenuate the high frequency noise in the air inlet,
caused by the rotating compressor blades.
More details about air inlet system and filtration are given in the Subcontractor’s Literature.
1.9.2. EXHAUST SYSTEM
In the exhaust section, the gases which have been used to power the turbine wheels are redirected
to be either released to atmosphere, or towards a heat recovery boiler in some cases.
After leaving the exhaust frame, the hot gases reach the diffuser, located in the exhaust plenum.
On the exhaust plenum wall facing the exhaust diffuser, a circular arrangement of thermocouples
permits exhaust gas temperature measurement. The thermocouples send their signals to the gas
turbine temperature control and protection system. The exhaust plenum configuration is that of a
box open at the top and welded to an extension of the turbine base. Insulation in the plenum
fabrication provides thermal and acoustical protection. A flow path from the exhaust plenum open
side to a duct is provided by an extension plenum and an expansion joint. A silencer is installed in
the duct after which there is another expansion joint, before exhaust either to atmosphere, upwards,
or to a recovery boiler.


GT6B Foundamental

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1.1. GENERAL, FUNCTIONAL DESCRIPTION

The axial airflow compressor is a 17 stages compressor with :

The combustion system comprises :

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NOTE : the design convention for gas turbine orientation is :

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1.1.2. GAS TURBINE FUNCTIONAL DESCRIPTION

(Refer to gas turbine simplified flow diagram here below)

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Cool down sequence :

GAS TURBINE SIMPLIFIED FLOW DIAGRAM

Torque output Torque

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1.2. TURBINE BASE AND SUPPORTS

1.2.1. TURBINE BASE

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1.2.2. TURBINE SUPPORTS

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1.2.3. GIB KEY AND GUIDE BLOCK

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1.3. COMPRESSOR SECTION

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1.3.2. COMPRESSOR ROTOR

COMPRESSOR ROTOR LOCATION

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COMPRESSOR ROTOR BLADE

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1.3.3. COMPRESSOR STATOR

COMPRESSOR STATOR (IN BLACK)

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Variable inlet guide vanes :

VARIABLE INLET GUIDE VANES

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INLET GUIDE VANES SYSTEM

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INLET GUIDE VANES

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COMPRESSOR STATOR BLADE

COMPRESSOR STATOR BLADE

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1.4. COMBUSTION SYSTEM

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COMBUSTION CHAMBER ARRANGEMENT

VUE LOOKING DOWNSTREAM

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1.4.2. COMBUSTION CHAMBERS AND CROSSFIRE TUBES

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1.4.3. SPARK PLUGS AND FLAME DETECTORS

SPARK PLUG (TYPICAL)

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FLAME DETECTOR (TYPICAL)

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1.4.4. FUEL NOZZLES

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1.4.5. TRANSITION PIECES

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