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NATIONAL COMPETENCE INMARINE GAS TURBINE PROPULSION

CDR CHV SUDHAKARGTTT (V)

ON THE ANVIL

INTRODUCTION

CHALLENGES – DESIGN, METALLURGY & MANUFACTURING PROCESSES

CURRENT INDIGENOUS COMPETENCE

WAY AHEAD

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INTRODUCTION

M2 – 10000 HP

M3 – 13750 HP

M15 – 9000 HP

M36 – 19540 HP

LM2500 – 33000 HP

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INTRODUCTION

156 GTs

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INTRODUCTION

• THREE MAJOR COMPONENTS

• DESIGN OF EACH COMPONENT VERY COMPLEX

• R & D AND INNOVATION

• NEW MATERIALS & COATINGS

• IMPROVED ENGINEERING AND MANUFACTURING

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COMPRESSOR

CC

TURBINE

CHALLENGES6

DESIGN CHALLENGES

HIGHLY SOPHISTICATED AERODYNAMICS

ABILITY TO MANAGE STALL

INLET GUIDE VANES AND BLEEDING AIR FROM COMPRESSOR

STAGES

COMPRESSOR

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DESIGN CHALLENGES

• COMBUSTION AT HIGHTEMPERATURES WITH AMINIMUM PRESSUREDROP AND EMISSION

• COOLING TECHNOLOGY

• MATERIALS TOWITHSTAND HIGHTEMPERATURES

CC

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TURBINE

METALLURGICAL CHALLENGES

* HIGH STRENGTH TO WEIGHT RATIO

* TITANIUM ALLOYS

* HT CREEP RUPTURE STRENGTH

* OXIDATION RESISTANCE

* EMISSION CONTROL

* NICKEL BASE SUPERALLOYS

* HIGHER FIRING TEMP & HOT CORROSION

* NI BASE SAs WITH SPECIAL PROCESSING

* TBCs

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COMPRESSOR

COMBUSTION CHAMBER

TURBINE

MANUFACTURING CHALLENGES

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• CASTING FOR STATICCOMPONENTS

• FORGING FOR ROTATINGCOMPONENTS

• POWDER METALLURGY

• EQUIAXED INVESTMENT CASTING

• DIRECTIONALLY SOLIDIFIEDCASTING

• SINGLE CRYSTAL CASTING

CURRENT COMPETENCE

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MATERIALS

MANUFACTURING PROCESSES

DESIGN

GAS TURBINE DESIGN

• CONCERTED EFFORTS OVER THE LAST 50 YRS PUT INTODESIGNING A GAS TURBINE

• PREMIER ORGANISATIONS - GTRE, HAL AND BHEL

• SUCCESSFUL DESIGNS INCLUDE GTX37-14U AFTER-BURNING TURBOJET AND TURBOFAN DERIVATIVE,GTX37-14UB

• ‘KAVERI’ GAS TURBINE (GTX-35VS) FOR TEJAS & KMGT

GTRE

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KAVERI GAS TURBINE

•INDIGENOUS GAS TURBINE ENGINEFOR LCA OR TEJAS FIGHTER

•INTEGRATED WITH IL-76 AIRCRAFTAT GROMOV FLIGHT RESEARCHINSTITUTE (GFRI), RUSSIA

•82 KN THRUST ACHIEVED AGAINSTDESIRED THRUST OF 90 – 95 KN

LACK OF TECHNICALLY SPECIALISED MANPOWER, NON-AVAILABILITY OFTEST FACILITIES, DENIAL OF TECHNOLOGIES BY FOEMs ANDTECHNOLOGICAL COMPLEXITIES

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KAVERI MARINE GAS TURBINE (KMGT)

•CLOSEST TO PRODUCE A MARINE GT

•CORE OF THE KAVERI ENGINEAUGMENTED WITH LP SPOOL AND PT

•TESTED AT VISAKHAPATNAM UPTO12 MW SUITABLE FOR SNFs

•ACHIEVED RATED POWER BUT COULDNOT SUSTAIN

SHORTCOMINGS ON METALLURGY OF HOT SECTION COMPONENTSAND COOLING TECHNOLOGY

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GAS TURBINE DESIGN

• AERO ENGINE RESEARCH & DESIGN CENTRE (AERDC).SUCCESSFULLY DESIGNED & DEVELOPED AEROENGINES

• PTAE-7 ENGINE FOR LAKSHYA AIRCRAFT, GTSU-110STARTER ENGINE FOR LCA (TEJAS) & 25 kN HTFE

HAL

• HUGE CLIENTELE IN INDUSTRIAL GTs IN POWER ANDPROCESS SECTORS

• 100 MACHINES AND ACCUMULATED EXPERIENCE OFOVER FOUR MILLION FIRED HOURS

BHEL

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MATERIALS

• DEDICATED METALLURGY R & DCENTRES

• MIDHANI DEVELOPED OVER 100GRADES OF SPECIAL ALLOYS FORSTRATEGIC AND COMMERCIALSECTORS

• TITANIUM ALLOYS BT 14, TI 15 FORCOMPRESSOR

• NICKEL BASED SUPERALLOYSHASTELLOY X, NIMONIC 263,NIMONIC 90 & INCONEL 601 FORHOT SECTION COMPONENTS

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MANUFACTURING PROCESSES

• CASTING

• FORGING

• POWDER METALLURGY

• EQUIAXED INVESTMENT CASTING

• DIRECTIONALLY SOLIDIFIED CASTING

• SINGLE CRYSTAL CASTING

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BOTTOMLINE

DD

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• DESIGNING CAPABILITY

• MANUFACTURING TECHNOLOGY

• ADVANCED MATERIALS

LESSON FROM HISTORY

RESTRUCTURE OF THE POWER SECTOR

REDUCE THE NOxEMISSIONS

ABUNDANCE OF NATURAL

GAS FOR POWER

GENERATION

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RESEARCH & DEVELOPMENT

• CONSISTENT EFFORTS IN R&D OFSUPERALLOYS AND TBCs WHICH CANWITHSTAND HIGHER TEMPERATURES

• UNSTINTED SUPPORT FROM GOVTBOTH IN TERMS OF MONEY & TIME

• TIME TESTED CONCEPT OF‘BUILDING BLOCK’ APPROACH

• COMPRESSOR, COMBUSTOR &TURBINE AS INDIVIDUAL UNITS

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JOINT VENTURES

• COLLABORATIONBETWEEN FOEMs &PSUs ALREADYINVOLVED IN GASTURBINES

• COLLABORATIONBETWEEN FOEMs WITHINDIAN PRIVATEINDUSTRY

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INDUSTRY - ACADEMIA

• TECHNOLOGICAL SHORTCOMINGS AREBEYOND THE REACH OF INDIVIDUALORGANISATIONS

• CONSORTIUM TO PROVIDE IMPETUS INSPECIALISED AREAS OF GT TECHNOLOGY

• PARTICIPATION FROM IITs/ TECHUNIVERSITIES, PSUs & POTENTIALCANDIDATES FROM PVT INDUSTRY

• STEERED BY THE INDIAN NAVY

• BREAKDOWN MULTI-DISCIPLINARYPROBLEM INTO KEY RESEARCH AREAS

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ROLE OF GOVERNMENT

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• INDUSTRY OF CIVIL AVIATION –THE MOST LUCRATIVE MARKET

• ENCOURAGING BUSINESSMODEL FOR THE ENTHUSIASTICFIRMS

ROLE OF GOVERNMENT

POWER

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• EXTREME SHORTAGE OF COAL &NATURAL GAS RESERVES

• MIGRATION FROM COAL BASEDTHERMAL POWER PLANTS TONATURAL GAS BASED GT POWERPLANTS

• TAP THE TALENT AT AN EARLYSTAGE

• THRUST NEEDS TO BE GIVEN ONGAS TURBINE TECHNOLOGY ATUG/ PG LEVEL

TECHNICAL EDUCATION

CROSS LEVERAGING

NUCLEAR ENERGY SPACE

DEFENCE 26

*BE A FACILITATOR IN ALLCOLLABORATIONS

*SOTRs, SELECTING PROSPECTIVE OEMs &STARTING THE VENTURE

OVERSEEING TEAMS DURING THE PROCESSOF DEVELOPMENT AND MANUFACTURING

ROLE OF INDIAN NAVY

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AUGMENT EXISTING TEST FACILITY &ENHANCE INTO AN UNIVERSAL MARINE GASTURBINE TEST BED

TO CO-ORDINATE & DEVELOP INDIGENOUSSOLUTIONS, SET UP NAVAL RESEARCHORGANIZATION (NRO)

ROLE OF INDIAN NAVY

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CONCLUSION

• R & D ON ADVANCED MATERIALS

• JOINT VENTURES WITH ToT

• ENCOURAGING BUSINESS ATMOSPHERE

• ORIENTATION TOWARDS GT TECHNOLOGY AT HIGHER TECHNICAL EDUCATION LEVEL

• SETTING UP OF A NAVAL RESEARCH ORGANISATION

• LEVERAGE EXPERTISE FROM NUCLEAR & SPACE SPHERES

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