iffco_report

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Vocational Training Report

IFFCO AONLA UNIT
Submitted to: Submitted by:
Mr. R.R Seth Kartik Sati
(DY.GM(TRG.)) V.T - 72

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Certificate

I hereby certified that the trainee is being presented in Bachelor of technology
Cooperative industrial training project report in title Indian Farmers Fertiliser
Cooperative Ltd. (IFFCO) is an authentic record of my own work carried out
during a period from 16-May-2016 to 15-June-2016 under the supervision of Mr.
R.R Seth (DY.GM (TRG.)).
The matter presented in this report hasn’t been submitted by me elsewhere.
DATE: 10/06/2016
PLACE: Aonla
(Sign of student)
(Kartik Sati)
This is to certify that the above statement made by the student is correct to the best
of my knowledge.
(Sign of the project guide)
(Mr. R.R Seth)

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Acknowledgement
I would like to thank my respected project guide Mr. R.R Seth (DY.GM (TRG.))
IFFCO Aonla Unit, for his valuable guidance and support under whom I have been
able to complete my industrial training project. He has been a constant help
throughout.
I would also like to thank to other plant Supervisors and Different Department Heads
of IFFCO Aonla who always found out time in answering my unending queries.

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Contents of the Report
S.NO. TOPIC PAGE
1. Introduction 5
2. Industry Profile of Fertilisers 6
3. Company Profile of IFFCO 10
4. Product Profile 24
5. Steam Generator 27
6. Gas Turbine Generator 31
7. Compressors 34
8. References 36

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Introduction
The Indian fertilizer industry has been supplying a substantial portion of the growing
demand of fertilizers within the country. India is the third largest producer of
fertilizers in the world. There are 60 large size fertilizer plants in the country,
manufacturing a wide range of nitrogenous, phosphates and complex fertilizers.
Besides, there are 81 medium and small scale single superphosphate units. The
cooperative sector has come to play a significant role in the Indian fertilizer industry.
In terms of nutrients, the share of cooperative sector in the installed capacity is 19.7
% for nitrogen and 10.2 %for phosphate. Indian Farmers Fertilizer Cooperative
Limited (IFFCO), a Multi-Unit Co-operative Society established on November 3,
1967 accounts for 64% of the installed capacity of Nitrogen and the total of the
Phosphate capacity in the cooperative sector.
In the last 41 years IFFCO has emerged as the pioneer venture in the cooperative
sector. It has witnessed a meteoric rise and has blossomed into the largest
manufacturer and marketer of fertilizers in the country. The success of IFFCO has
encouraged the growth of the cooperative movement in INDIA.

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INDUSTRY PROFILE OF
FERTILISERS

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Global Industry
The International Fertilizer Industry Association or IFA is a not-for-profit trade
association that represents the global fertilizer industry, on issues related to the
promotion of plant nutrients, improvement of the operating environment of the
member companies and the collection and compilation of industry information. IFA
has some 540 members in about 85 countries. About half of the membership is based
in developing countries.
IFA member companies represent all activities related to the production, trade,
transport and distribution of every type of fertilizer, their raw materials and
intermediates. The global fertilizer industry produces some 170 million tonnes of
fertilizer nutrients annually. These are used in every corner of the globe to support
agricultural production.
There is no substitute for the nutrients absorbed by crops. As a major source of these,
fertilizers therefore represent an essential ingredient in the drive towards sustainable
agriculture and world food security. IFA's membership also includes organizations
involved in construction, engineering, consulting, agronomic research and training.

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Indian Industry
Fertilizers have played a vital role in the success of India’s green revolution and
consequent self-reliance in food grains production. The increase in fertilizer
consumption has contributed significantly to sustainable production in food grains
in the country. Fertilizer is generally defined as “any material, organic or inorganic,
one or more of the chemical elements required for plant growth”.
India is the third largest fertilizer producer in the world. Fertilizer is a crucial input
contributing to about 40 per cent of the productivity of the crop. With expanding
agricultural production, improvement in technology and growing awareness among
farmer, the consumption of agrochemicals has been on the upswing. The
agrochemicals industry is made up of insecticides (74%), herbicides (20%) and
fungicides (6%). India is one among the most dynamic generic pesticides
manufacturing countries with a total market size of Rs 89 billion per annum. And
yet, India’s own average consumption of pesticides is very low at 480gms per
hectare which results in crops worth about Rs 120 billion being annually destroyed
by pests. Crop protection has assumed special importance since food grains demand
in the country is supposed to reach an estimated 343 million tonnes by 2020.
The agrochemical industry is spread over around 20 large manufacturers and 600
formulators. While the organized sector contributes 55% to the industry’s output,
the small scale sector makes up for the balance. The Indian industry has been
focusing sharply on integrated crop management (ICM), increasing exports of
genuine pesticides and concentrating on farmer friendly activities.
The pesticide industry is targeting a 10% share of global pesticides market and has
been working on the ICM programmed to introduce safer applications, spray devices
and crop protection through balanced use of biological and chemical pesticide. The
exports cover pesticide intermediates. Pesticides export from India was growing at
the rate of 15% and is expected to witness a more accelerated growth. Spurious
chemicals are growing at rates varying from 10% to 12% and have cornered a large
chunk of the market.
The generic pesticide players include Excel Industries, Cheminova India, United
Phosphorus, Rallis India, Aimco Pesticides, Bharat Rasayan, Bayer (India), Aventis,
Meghmain Organics etc. producing a range of products like urea, DAP, MOP,
Nitrogenous fertilizer(N), Phosphatic fertilizer(P), Potassic fertilizer(K) and NPK
etc.

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To conclude, fertilizer is a key ingredient in ensuring the food security of the
country, as it increases the production and productivity of the soil. The domestic
food grain production target has been set at 320 million tonnes by 2011-2012. This
target can be achieved by higher productivity through improved farming practices,
expansion of irrigation, better seeds and extensive and balanced use of fertilizers.
Towards this end, the government of India is now planning to raise the production
of urea by the end of 11th Five Year Plan by taking concrete steps to boost
production and productivity. All these things show the definite growth of fertilizer
industry in India.

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COMPANY PROFILE OF IFFCO

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Introduction of IFFCO
The fertilizer industry in India consists of three major players; The Government
owned Public Sector undertakings, Cooperative Societies like IFFCO, KRIBHCO
and units from Private sector. There are about 33 major producers producing N and
NP/NPK fertilizers in the country at present. The fertilizer industry of India had
made constructive use of the fertilizer provided by the Government of India to ensure
that the country achieved reasonable self-sufficiency in food grain production. The
fertilizer industry has organized itself through S Fertilizer Association of India (FAI)
to coordinate with the Government of India to achieve the macro-economic objective
related to agriculture sector and to provide other services.
During mid- sixties the co-operative sector in India was responsible for distribution
of 70 per cent of fertilizers consumed in the country. This sector had adequate
infrastructure to distribute fertilizers but had no production facilities of its own and
hence dependent on public/private sectors for supplies. To overcome this lacuna and
to bridge the demand - supply gap in the country, a new cooperative society was
conceived to specifically cater to the requirements of farmers. Thus was born
IFFCO, the world’s largest fertilizer cooperative.
It was a unique venture in which the farmers of the country through their own co-
operative societies created this new institution to safeguard their interests.
Indian Farmers Fertilizer Cooperative limited, a multistate Cooperative has
emerged as a role model for cooperatives Over 44 years of its inception; IFFCO has
turned into a true Cooperative – Of the Farmers, By the Farmers and for the Farmers.
IFFCO has steadily grown in strength and stature from a modest membership of 57
societies in 1967 - 68 to 39564 societies a s on 31 St March,2011. The initial equity
capital of Rs.6 lakh contributed by the cooperatives in 1967-68 has also gone up to
a paid-up capital of Rs.42616. crore.
Indian Farmers Fertilizer Co-operative Limited (IFFCO) was registered on
November 3, 1967 as a Multi-Unit Co-operative Society. On the enactment of the
Multistate Cooperative Societies Act 1984 which was amended in 2002, the Society
is deemed to be registered as a Multistate Cooperative Society. The Society is
primarily engaged in production and distribution of fertilizers. The bye laws of the
Society provide a broad framework for the activities of IFFCO as a Cooperative
Society. A pioneer in this field, IFFCO’s growth reflects its belief in the strength of
the farmer. Several prestigious awards stand testimony to the fact that IFFCO is

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driven by its values and the dedication of its people. This is an organization that
believes in fair play and has always followed transparent and professional practices
in corporate governance.

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IFFCO-Aonla Unit
The Indian Farmers Fertilizer Co-operative Limited (IFFCO) is a national level
multi-unit cooperative society engaged in manufacturing and marketing of chemical
fertilizers.
The Society was registered in 1987 and presently having a membership of over
37,000 cooperatives as shareholders. IFFCO is presently operating four factories
located at Aonla and Phulpur in Uttar Pradesh and Kalol and Kandla in Gujarat.
IFFCO produced over 6 million tonnes of fertilizers in 2004-05 and contributed
about 18% to the total Nitrogen and 24% to the total P205 produced in India. IFFCO
markets its fertilizers through Cooperative Agencies and Member Cooperative
Societies.
Aonla project of IFFCO is one of the six natural gas based fertilizer plants set up in
the country on the H.J.B. pipe line which runs through four statuses. This project has
been designed to produce 7.26 lake tons of Urea per year with plant capacity of 1350
TPD Ammonia and 2200 TPD of urea.
The site is 28 km south west of Bareilly on Bareilly Aonla Road. The total land
acquired by IFFCO Aonla unit is 1273 acres for factory and township. The project
consists of main plants, Ammonia plant, urea plant, steam generator & power
generator plant, other offsite facilities like water supply and treatment system storage
for spares consumables & products, bagging plant laboratory, Inert gas plant,
instrument air compressor etc. In addition to these infrastructures facilities such a
railway station siding etc. are also created.

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(IFFCO AONLA)

PLANTS OF AONLA UNIT

There are mainly four units of productions:
AMMONIA PLANT:
There are two streams of Ammonia Plant having the capacity to produce 2x1520
MTPD of liquid ammonia. The technology is based on Holder Topside, Denmark
process with natural gas and naphtha as main raw material.

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UREA PLANT:
There are four streams of Urea Plant having the capacity to produce 2x1310 MTPD
of urea fertilizers. The technology is based on Snamprogetti, Italyon ammonia
stripping process.
PRODUCT HANDLING PLANT:
Product handling plant is composed of Urea storage known as Silo and packing and
transport activities. Two silos of 45,000 and 30,000 MT capacity have been
provided to Urea product to ensure continuous urea production even if it
is not taken off due to non‐ availability of rail wagons or seasonal demand
fluctuations.

STEAM AND POWER GENERATION PLANT:
To meet the continuous power supply needs of the main plants, captive power plant
and stem generation facilities have been provided. In this plant, two gas turbines
each having the capacity of 18MW along with heat recovery steam generation unit
has been provided to cater to the plant needs of power and steam. Additionally, HRU
unit of Ammonia –II add to the steam supply of the complex.

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OBJECTIVES OF IFFCO
The main objectives of the Society are as follows:
 IFFCO is a cooperative institution of the farmers by the farmers.
 Strengthening cooperation distribution system. o Educating and guiding the
farmers.
 Promoting nations growth through modern farming techniques.
 Improving agriculture productivity, through balance fertilizer applications.
 To promote the activity for enriching the life of rural.
 To achieve self-reliant and self-generated economy.

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MAJOR AWARDS RECEIVED BY IFFCO
KALOL:
 Seven awards for all performance from FAI.
 Two awards for industrial safety from GOI.
 Awards technical innovation from FAI.
 Two Rajya Bhasha shields for promoting Hindi.
 Awards for safety from National safety council, Chicago.
PHULPUR:
 Four awards for productivity from NPC.
 Six national safety awards for GOI.
 Two awards for overall performance from FAI.
 Two awards for technical innovation from FAI.
 Three national energy conservation awards.
 There awards for west environment protection from FAI.
AONLA:
 Awards for west implemented project (II prize) from GOI.
 Awards for conservation of energy from GOI.
 Aonla wins CII Environmental Best PracticesAward-2011.
 IFFCO Aonla Unit has been awarded the 'EDGE' winner prize.
 IFFCO Aonla & Paradeep Unit have won the prestigious FAI awards
presented on 3rd Dec.'2009.
 IFFCO Aonla Wins “Gold Award”10th Annual Green Tech Environment
Excellence Award 2009.
 IFFCO Aonla Unit Wins National Safety Council of India Safety Award-
2004.
KANDLA:
 Ten safety awards from National Council, Bombay GOI.
 Twenty-one safety awards from Gujarat Safety Council, Baroda.
 Nineteen awards for safety from National safety council, USA.
 Five awards for overall performance from FAI.
 Rajya Sabha awards for promoting Hindi.
 Best productivity awards from NPC.

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LOGO OF IFFCO
The Logo any organizations is very important by which the company is known to
everyone or that is identity of the company. After one year of establishment in 1968
the organization has decided to make Logo of IFFCO. The executive of the company
said that which can be easily fit any place or easily changeable according to the place
& made by simple geometrical method. So the Logo is made by at last Mr. M.R
Gupta chief visualize developer is like that…

Logo’s green color shows the faith of the farmers, they believe that after Using the
urea their fields will always be green, the remaining white color shows that the
quality of the IFFCO’s product is very good & oval shape is meant for prosperity.

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BUSINESS PRINCIPLES OF THE COMPANY
The principles of the company are as follows:
 Appreciation of national need of generation up to optimum return of
investment.
 To fair price of the product manufactured by the company is subsidy to the
farmers.
 Total consumer satisfaction as a quality of product, price of the product and
better service after selling the product.
 Effective management information system.
 To increase the efficiency to maintain better human relation and discipline
among all the employees.
 To maintain better human relation and discipline among all the employees.
 To develop good relation with customers.

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KEY RESULT AREAS OF IFFCO
1. FERTILIZER PRODUCTION:
The main aim of IFFCO is to remove the dependence of the Indian Fertilizer
sector on Foreign Imports. For achieving this goal IFFCO runs and maintains its
Five Production plants and also aims to increase its production capacity by
adopting new technology and acquiring new plants.
2. PROMOTION OF AGRICULTURAL AND RURAL
DEVELOPMENT:
To achieve this target IFFCO undertakes production, processing and manufacture
of insecticides, pesticides, seeds, agriculture machinery and implements and
other agricultural production requisites by setting up or taking on lease
manufacturing units either directly or in collaboration with or as a joint venture
with other Cooperative Institution. Also IFFCO’s CORDET is a major endeavor
in this direction.
3. DEVELOPMENT OF AGRICULTURAL COOPERATIVES:
IFFCO aims to undertake, promote, assist and encourage development of
cooperatives with special thrust on sustainable agriculture and tries to provide for
social, economic and culture development of the members through cooperative
bodies, voluntary institutions and other entities. IFFCO also promotes research
and training on the application of modern management, technology and global
experience for cooperative development.

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VISION & MISSION OF THE IFFCO
VISION – 2015
In pursuit of its growth and development, IFFCO had embarked upon and
successfully implemented its Corporate Plans, ‘Mission 2005’ and ‘Vision 2010’.
These plans have resulted in IFFCO becoming one of the largest producer and
marketer of Chemical Fertilizers by expansion of its existing Units, setting up
Joint Venture Companies Overseas and Diversification into new Sectors.
IFFCO has now visualized a comprehensive plan titled ‘Vision-2015’
which will be guided by the following objectives:
a) Production of fertilizers through expansion of existing units.
b) Setting up of fertilizer production facilities in India and outside the country
through joint ventures.
c) Diversification into other Profitable Sectors.
d) Strengthening its raw material sourcing through Strategic Joint Ventures in
India and abroad.
e) Strategic Alliances through IFFCO Consortium.
The salient features of the ‘Vision-2015’ document are as under:
a) To stand as a Global Leader in Fertilizers Production to cater to the food
security need of the nation.
b) Maximizing the synergies of the Core Business through Downstream Value
Additions and Forward/ Backward Integrations.
c) Enhancing presence in International Markets through Strategic Joint Ventures
and Synergistic Acquisitions.
d) Diversification into other profitable businesses to maximize returns to our
stakeholders.

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e) Leveraging State of the Art Technologies and Global best practices to retain
its global competitiveness.
f) Promoting Integrated Nutrient Management to improve efficiency of Fertilizer
use and promoting location specific research on efficient fertilizer practices.
g) To bring in Sustainability and Strategies to prevent Climate Change by
reducing Energy Consumption, better Resources Management and promoting
Renewable Energy sources.
h) To help the Cooperative Societies become economically strong, professionally
managed and to equip the Farming Community with advanced agricultural
practices for improved Productivity, to ensure an Empowered Rural India.
i) Achieve Fertilizers Production / Marketing target of 15 million Tonne per
annum with an annual turnover of Rs. 30,000 crores.

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MISSION
 To provide to farmers high quality fertilizers in right time and in adequate
qualities with an objective to increase crop productivity.
 To make plants energy efficient and continually review various schemes
to conserve energy.
 Commitment to health, safety, environment and forestry development to
enrich the quality of community life.
 Commitment to social responsibility for a strong social fabric.
 To institutionalize core values and create a culture of team building,
empowerment and innovation which would help in incremental growth of
employees and enable achievement of strategic objectives.
 Foster a culture of trust, openness and mutual concern to make working a
stimulating and challenging experience for stake holders.
 Building a value driven organization with an improved and responsive
customer focus.
 A true commitment to transparency, accountability and integrity in
principle and practice.
 To acquire, assimilate and adopt reliable, efficient and cost effective
technologies.
 Sourcing raw material for production of phosphates fertilizers at
economical cost by entering into joint ventures outside India.
 To ensure growth in core and non-core sectors.

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PRODUCT PROFILE OF IFFCO

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IFFCO's NPK/DAP
As far as Indian farmer is concerned, IFFCO's NPK/DAP is not just a source of
crucial nutrients N, P, K for the crops, but is an integral part of his/her quest for
nurturing mother earth. The bountiful crop that results from this care is an enough
reason for the graceful bags of IFFCO NPK/DAP bags to be an integral part of the
farmer’s family. The two grades of NPK produced by IFFCO, 10:26:26 and
12:32:16, indicating the content of N, P, K proportion, is tailor made to supply the
exact composition required for replenishment of the soil. The Indian farmer's
confidence and trust stems from the fact that IFFCO's NPK/DAP are merely a part
of a complete package of services, ably supported by a dedicated team of qualified
personnel. More importantly, they are aware, IFFCO is a cooperative society owned
by farmer’s cooperatives.
ABOUT DAP/NPK
DI-AMMONIUM PHOSPHATE
It is the most popular phosphate fertilizer because of its high
analysis and good physical properties. The composition of pure
salt of DAP is N-21.19% and P210 -53.76%. Fertilizer grade DAP
is 18:46:0.
NPK COMPLEX GRADES
NPK complex fertilizers produced at Kandla are DAP based
grades. At present two grades Grade I - 10:26:26 and Grade II -
12:32:16 are produced. Granular NPK complexes are free flowing
and do not pose any problem during handling and storage.
However, exposure of material for long period to very high
humidity may cause caking. Therefore, NPK complexes are
bagged in quality tested HDPE bags to prevent ingress of
moisture.

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IFFCO's UREA
IFFCO's Urea is not merely a source of 46% of nutrient nitrogen
for crops, but it is an integral part of millions of farmers in India.
A bag of IFFCO's urea is a constant source of confidence and is a
trusted companion for Indian farmer.
When farmers buy IFFCO's urea, they know that what they get is
not just a product but a complete package of services, ably
supported by a dedicated team of qualified personnel.
ABOUT UREA
Urea is the most important nitrogenous fertilizer in the country because of its high
N content (46%N). Besides its use in the crops, it is used as a cattle feed supplement
to replace a part of protein requirements.
It has also numerous industrial uses notably for production of plastics. Hat it is their
own urea produced and supplied by a cooperative society owned by the IFFCO.

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Description
The Steam Generator is a water tube double drum, natural circulation. Oil (LSHS)
or natural gas fired boiler manufactured by M/S Mitsuit engineering C/o Japan. The
capacity of the steam generator is 150 ton/hr. of superheated steam at a pressure of
1/6 atm. and temperature 515o
C.
The Steam Generator is designed to use natural gas to produce the electricity. The
basic step is first to fire HSD LSHS/FO and natural gas with four sets of oil and gas
combination burners.
The Steam generators comprises a water cooled furnaces, a convection bank, steam
and water drums, headers for collecting and distributing water and steam. Primary
and secondary super-heaters, frames casing insulation.
Drums and Internals
The MD type boiler is provided with steam drum and water drum. Both of the drums
have a man-hole for maintenance and inspection. The steam drum is equipped with
sets of steam purifiers inside to obtain the required steam purify.
The drum is equipped with internal pipes for feed water, chemical and continues
flow down as well as a steam purifier. The internal pipes are arranged so as to ensure
good distribution of feed water and chemical in the drum and to collect relatively
highly concentrated boiler water for blow down. The nozzle for feed water and
chemicals are of double pipe so as to reduce thermal stresses due to temperature
difference.
The mixture flows under the baffle plate and the water and steam are separated when
they turn into center space. The separated water flows back to the drum water and
steam flows upward to the demister. The demister comprises a number of layers of
expanded metal as shown when the steam passes the demister. Most of the water
droplets in the steam are caught by expanded metal and are separated from steam.
Finally, the steam passes through the scrubbers. The scrubbers comprise a number
of corrugated metal plate when the steam flows through the scrubber any remaining
water particles are efficiently removed. The film of the water adhering to the
scrubber surface flow down to the bottom of the scrubber by gravity and then
becomes a certain size of water drops which fall back to the drum water surface since

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these drops are much larger than the water particle itself which are being suspended
in the steam like flowing upward they are not entrained.
The moisture content present in the stream at the outlet of the drum safety depends
upon many contagious factor which can be mainly illustrated as the drum size which
determines the steam velocity. The drum pressure which broadly determines the
various thermal characteristics and properties of the steam and water etc.
Furnace
Furnace has an ample volume to secure complete combustion of the specified fuel.
The furnace wall is of welded longitudinal tin tube panels to form a completely gas
tight enclosure. For parts where tin tubes cannot be used the furnace floor is
converted with a layer of refractory bricks so as to shield the tubes from radiant heat
to secure a good water circulation.
Front wall is equipped with burners in two rows. The rear wall forms a partition wall
dividing the convection section from furnace. Side walls are provided with
connecting pipes.
Super Heaters
Boiler is provided with two stages of super-heaters i.e. primary and secondary super-
heaters. Both of them are of convection and pendent type. The primary super-heater
is located at lower gas temperature part while secondary is at higher temperature
part. The steam flows counter to gas in primary super-heater and parallel in
secondary super-heater.
Retractable root blower and an access door is provided in these super-heaters for
cleaning and maintenance.
De- Super Heaters
A De Super-heater is also provided on the connecting pipe between primary and
secondary super-heater to control the final steam temperature.

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Feed water is sprayed into the steam flow through a spray nozzle which reduces the
steam temperature.
Economizer
An economizer is furnished downstream the convection band to recover waste heat
from the gases.
The economizer comprises a number of spiral wound fine tubes inlet and outlet
headers and sufficient frames and casing. It is supported by the steel structure using
slide shoes to control with horizontal thermal expansion.
A reciprocating type root blower with nozzles is furnished to effectively clean the
heating surface.
Heat recovery Steam Generator
The main components of HRSG are:
Steam Drum: It is fabricated from
carbon steel material and equipped with
steam purifier and necessary nozzle and
connections.
Evaporator: Evaporator section is
composed of several components which
consists of number of tubes with spiral tin
and each inlet and outlet header each component is made up water circulation circuit
separately.
Water circulating system: It consists of steam drum down coming pipes. Down
comer heater supply pipes steam generating tubes and riser pipes.
Super-heater: It is of convection type counter flow drainable, inverted 0-100 ped
with spiral tin. It is located in the higher gas temperature zone.
Economizer: It is of counter flow, drainer with vertical tubes with spiral tins. It
consists of number of tubes, inlet and outlet header air vent and drain valve is
provided on outlet and inlet header respectively.

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Description
It is a device used for
converting fuels chemical
energy into mechanical
energy air drawn into the
compressor where it is
compressed to the desired
value. This compressed air is fed to the combustion chamber where it burns with the
fuel it adds energy to the air. The hot high pressure gas mixture is then ducted to the
turbine section where it is allowed to expand down to exhaust temperature. In
expansion process energy is removed from the gas which is used to run an alternator.
The used gas is then allowed to exhaust stack system. Since there is still much heat
energy in this gas, it can be put to use in some various ways such as air or water
heating process drying or as hot air feed supply to a separately fired boiler, waste
heat recovery boiler.
Two main types of turbine design are:
1. Reaction Turbine
2. Impulsive Turbine
Here we have used impulsive turbine. In the impulse turbine pressure drop occurs in
stationary elements with only a small percentage drop taking place in stating parts.
Higher overall efficiency may be achieved by addition of regenerator. In this,
exhaust gas is allowed to give up some of its heat to discharge air.
Turbine Section
It is the area in which energy contained in the hot pressurized gas produces by
compressor and combustion section is converted into mechanical work.
Major turbine components include:
Turbine Rotor: It consist of distance piece, the first and second stage turbine
wheels, buckets, one turbine spaces and after turbine wheel shaft, it is held together
by belt spacers provide axial separation between individual wheels.

33

Turbine Stator: The turbine shell and exhaust frame complete the major portion
of the gas turbine stator. Turbine nozzle, shrouds, turbine exhaust are internally
supported from these components.
1. Turbine Shell: It controls the axial and radial position of shrouds and nozzles
and thus control turbine clearance and location of nozzle relative to the turbine
buckets. The positioning is critical to gas turbine performance six hand holes
will be provided in the turbine shell forward of stage nozzle for access to the
transition piece mounting bots.
2. Nozzle: There are stages of stationary nozzles because of high pressure drop
across these nozzles there are seals at both inside and outside diameter to
prevent loss of the system energy by leakage.
3. Diaphragm: It is attached to the second largest stage nozzle segment which
prevent air leakage from the nozzle and turbine rotor.
4. Shrouds: It is the stationary curved segments under which turbine bucket tips
run. Its primary function is to provide cylindrical surface for minimizing
bucket tip clearance leakage. Its secondary function is to provide a high
thermal resistance between the hot gases and comparatively cool shell.
5. Exhaust Frame: It is bolted to the half flange of the turbine shell. It consists
of outer and inner cylinder inter connected by struts.
6. Bearings: There are two main bearing used to support the turbine. Gas turbine
also has thrust bearing to maintain rotor to stator axial position.

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Compressor
Different types of compressors are:
 Centrifugal
 Axial
 Intermeshing lobes type
Axial flow type is used for all major compression because of its ability to pump large
volume of air at better efficiency. The axial flow compressor consists of compressor
rotor and enclosing stator casing.
Air is compressed by a series of alternator rotating and stationary air foiled blades.
Compressed air is extracted for turbine, turbine shell and exhaust frame cooling.
Compressor Rotor
Compressor rotor consist of a forward shaft on which mounted the 1st
stage rotor
blades.
Sixteen Blades and Wheel Assembler
Compressor Discharge Casing
It contains 17 compressor stages, two shows of exit group vanes and the discharge
diffuses. Its function is to support the stator blading and combustion cans to provide
the inner and outer side walls to diffuser and to join the compressor and turbine
stator. It enclosed the compressor portion of the rotor and is divided into four section.
Inlet forward half and discharge.

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References
 Vocational Training Lectures
 Training Manual

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