V84 (2000E) Combustion Turbines

Now that there is a basic understanding of the underlying principles behind the operation of a
combustion turbine, it's easy to take a closer look at the major components of the Siemens V84
combustion turbine. In this segment, the rotor, the 17-stage axial flow compressor, the 4-
stage turbine, the turbine bearings, and the two combustion chambers are examined.

This figure shows the major components of the V-84 combustion turbine, including the 17-stage
axial compressor, the rotor, the connections to the two combustion chambers, and the 4-stage
turbine. It is important to know the location of the major components. It is vital to future
discussions that you recognize each major part of the combustion turbine.
Rotor
The combustion turbine rotor carries the compressor blades and turbine blades. A cross-
section of the combustion turbine rotor is shown below. The rotor combines the compressor
and turbine sections on a single shaft.

The rotor is built up of individual discs and three hollow shaft sections, one at the front end, one
at the central region, and one at the rear region. Each disc carries one row of blades. All discs
and the three hollow shaft sections are held together by a central tie bolt (as shown here).
There are six separate locations used to dynamically balance
the rotor. A typical location with balance weights inserted is
shown to the right.

Compressor
The V-84's compressor is a 17-stage axial flow unit that achieves up to a 10.33 to 1
compression ratio when firing fuel gas, and a compression ratio of 9.33 to 1 when firing No. 2
fuel oil. A nominal compressor discharge pressure, at rated speed (3,600 RPM), is 150
psia (10.3 bar).

There are three compressor stator blade carriers.

Stator blade carrier No. 1 is attached to the center casing of the combustion turbine (not
shown). This forms the outer casing.
Stator blade carrier No. 2 and No. 3 are suspended in the center casing, allowing for thermal
expansion (as shown).
Located between the stator blade carriers are annular gaps. These gaps are used for sealing
and cooling of the turbine inner and outer casings. Bleed air from the compressor is the source
of cooling air.

The compressor rotor blades are made of stainless steel

and are shaped in an airfoil design. The airfoil design
improves the flow characteristics of the air and also
improves the blade strength. A typical compressor stage
disk is shown here. As shown, the blade root consists of a
dovetail with a short parallel guide to prevent axial
movement.

Combustor
The V-84 combustion engine has two external combustors, one on each side of the turbine.
The two combustion chambers are flanged to the opposite sides of the unit between the
compressor and turbine sections. A top view of the combustion chambers (showing burner
assemblies) is shown to the right.

The inner surface of each combustion chamber (flame tube) is coated with ceramic tiles that are
fixed to the sheet metal liner. Compressed air is admitted through the liner to the rear side of
the tiles through bore holes to prevent overheating. Each combustor has six burner assemblies
(as seen here).
A spark plug is the initial ignition source for most combustion turbines. Once ignited, the turbine
is self sustaining, requiring the absence of the correct mixture of fuel and air to quit burning.
The V-84 is capable of both multi-fuel and dual-fuel operation.

Each combustion chamber has two (2) flame scanners

mounted to it as shown here. The flame scanners provide
flame verification for the turbine supervisory control
system.
During operation, the turbine combustion chambers
achieve temperatures of approximately 1900°F
(1038°C). The final, or exhaust gas temperature is
1000°F (538°C), at or near atmospheric pressure. The
turbine exhaust still contains sufficient oxygen to sustain
proper combustion for the use of duct burners in the
HRSG (heat recovery steam generator).

Air bled from the compressor enters the combustion

chambers through an annular space between the
pressure jacket and the inner liner. This air is referred
to as primary air and is directed to the burner
assemblies.

Compressor air also enters the combustion chamber, at the lower part of the flame tube, as
secondary air. Secondary air is admitted into the flame tube through openings that are covered
by an electrically actuated adjusting ring. As load increases, secondary air decreases, and as
load decreases, secondary air increases.
The roles of air supplied to the combustion chambers will become more apparent later with the
explanation of burner operation.
Specially conditioned superheated steam is supplied to the combustion chambers. It is treated
beforehand to remove all moisture and entrained solids.
The steam is injected to limit NOx emissions and for the purpose of power augmentation.

Burner
There are five modes of burner operation. They are:
1. Ignition Gas
2. Pilot Gas
3. Fuel Oil
4. Diffusion Gas
5. Premix Gas
Ignition Gas
Ignition gas is used for establishing a main flame during initial start-up of the combustion
turbine.

Pilot Gas
It is necessary to burn a certain amount of fuel in the diffusion flame zone during the premix
mode of operation. This is made possible by the pilot burner tubes, where gas and air are
mixed with the smaller part of the primary air supply. It is then burned in the flame tube.
Fuel Oil
Fuel oil is injected into the axial swirl zone of the fuel nozzle only. A fuel oil control valve
maintains the proper backpressure, allowing the correct amount of fuel oil into the burner
assemblies based on demand from the control system. Excess fuel oil is returned back to the
fuel oil tank via a return line.
Maintaining system fuel oil pressure is essential to proper atomization.

Diffusion Gas
At lower loads, the fuel gas is fed to the diffusion burner nozzles, where it is mixed with the
smaller part of the primary air in the axial swirler and is then burned in the flame tube.
Premix Gas
At higher loads when burning fuel gas, the fuel gas flows through the premix burner nozzles.
There it is mixed with the airflow from the diagonal swirler and is burned in the flame tube.

The combustion chambers are designed to operate

in either the diffusion mode or premix mode.
Startup is always performed in the diffusion mode
using natural gas up to 40-50% base load and when
firing No. 2 fuel oil (all loads). At 40-50% base load,
natural gas is mixed with primary air for automatic
switchover to premix mode. The premix mode can
be used up to a steam to fuel ratio of 2:1. In the
premix mode, steam is injected through the burners
up to a ratio of 1.2:1 to achieve maximum power
augmentation. This limitation prevents flame out in
the combustion chambers.

When the combustion turbine generator is operating

in the diffusion mode, steam flows through a motor-
operated shutoff valve into the combustors.
When the combustion turbine generator is operating in the
premix mode, steam flows through a different motor-
operated shutoff valve into the compressor discharge at a
steam to fuel ratio up to 1.2:1.

Bearings
There are two bearings used to support the rotor, the turbine end bearing and the compressor
end bearing. Each is located within its respective bearing housing. The turbine bearing housing
supports the rotor at the turbine end and is installed in the inner cylinder of the exhaust casing
to allow for thermal expansion. The bearing casing is cooled by sealing air supplied from the
No. 1 compressor bleed. The turbine-end bearing consists of two bearing sleeves lined with
white metal (or babbitt).

The compressor-end bearing is a combined journal and thrust bearing that supports the rotor
and compensates for axial thrust. The journal bearing consists of two bearing sleeves lined with
white metal. The thrust bearing consists of individual thrust pads, the active surfaces of these
pads are lined with white metal. The thrust pads are secured to the bearing sleeves by
cylindrical pins and supported by shims. The shims ensure uniform load distribution.
The compressor bearing housing forms part of the outer casing, and
connects the central outer casing with the air intake casing. The
compressor bearing housing consists of an outer and inner shell.
Oil is supplied to the thrust bearing from the laterally open oil pockets of
the journal bearing.

The temperature of both the compressor and turbine-end bearings are monitored by
thermocouples (seen here) inserted into the bearing metal on both sides. The thermocouples
provide input for routine logging, alarm, and supervisory protection.

Turbine
The turbine rotor blades (shown here) are
constructed of high temperature alloys to protect
them from thermal stress. Temperatures at the
turbine first stage normally reach as high as
1200°F (649°C). The blades are of the airfoil
design and are twisted from the root of the blade to
the tip in order to compensate for the different
circumferential speeds along the blade length.

The first two stages of rotor blades are internally cooled. The first blade row is cast with internal
channels. These channels allow cooling air to enter the blade at the root and exit the blade at
the trailing edge. The second stage blades are cast with radial bores. The cooling air enters
the blade at the root and exits the blade at the tips. The third and fourth stage blades are solid.
The only cooling for these blades is at their roots.

The blade root (seen here) is of the fir tree shape. As the blade size and centrifugal force
increase, the number of teeth used to attach the rotor blade to the rotor disk increases. The
blades are inserted into grooves in the rotor disk and keyed to prevent axial movement.

The turbine stator blades consist of the combustion turbine outer shroud, the airfoil section, and
the inner shroud. The outer shroud forms one boundary of the hot gas exhaust path and is
used to attach the stator blades to the stator blade carrier. The inner shroud forms the second
exhaust path boundary and directs the flow of hot gas from the combustion chambers against
the turbine blades.

The turbine stator blades are constructed of high temperature alloy castings. The turbine stator
blades for stages 1 through 3 are hollow for cooling purposes.