VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI-590018

INTERNSHIP/PROFESSIONAL PRACTICE REPORT

Submitted in the partial fulfillment of the requirements for the award of degree
BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
Submitted by
S VISHAL KASYAP USN:1BI15ME168
Internship Carried Out at
Hindustan Aeronautics Limited, IMGT Division, Bangalore.

Internal Guide External Guide

Dr. N. SATISH, M.E., Ph.D. Mr. P.S. MAHESH KUMAR
Associate Professor Chief Manager
Bangalore Institute of Technology IMGT Division, HAL

DEPARTMENT OF MECHANICAL ENGINEERING

BANGALORE INSTITUTE OF TECHNOLOGY
K.R. Road, V.V. Puram, Bengaluru – 560004
2018-19
BANGALORE INSTITUTE OF TECHNOLOGY
K.R. Road, V.V. Puram, Bengaluru - 560 004
Department of Mechanical Engineering

CERTIFICATE

This is to certify that the “Internship/Professional Practice Report” submitted by

Mr. S Vishal Kasyap (1BI15ME168), a bonafide student of Bangalore Institute of
Technology in the partial fulfillment for the award of Bachelor of Engineering in
Mechanical Engineering of the Visvesvaraya Technological University, Belagavi during
the year 2018-2019. It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report. The report of the internship/professional
practice has been approved as it satisfies the academic requirements in respect of
internship/professional practice prescribed for the said degree

Dr. N. Satish M.E., Ph.D. Dr. B. Gurudatt

Associate Professor Professor and Head
Guide

Name of the examiner Signature

1.

2.
 DECLARATION

I, S Vishal Kasyap bearing the USN 1BI15ME168 of 8th semester B. E in Mechanical

Engineering, Bangalore Institute of Technology, Bengaluru, hereby declare that the work
being presented in this Internship/Professional Practice Report is an authentic record of the
work that has been carried out by me during the course under the supervision of guide
Dr. N. Satish M.E., Ph.D. Associate Professor, Department of Mechanical Engineering,
Bangalore Institute of Technology, Bangalore. The work contained in this report has not
been submitted in part or full to any other university or Institution or Professional body for
the award of any degree or diploma or any fellowship.

Place: Bangalore
Date: 06/05/2019

Name: S Vishal Kasyap

USN: 1BI15ME168 Signature
 ACKNOWLEDGEMENT

It is my pride, privilege and duty to acknowledge the kind of help and guidance received
from several people in preparation of this report. It would not have been possible to prepare
this report in this form without their valuable help, cooperation and guidance.

I would like to thank my guide Dr. N. Satish M.E., Ph.D. Associate Professor, Department
of Mechanical Engineering, Bangalore Institute of Technology, Bangalore for guiding me
throughout the program.

My sincere thanks to Dr. B. Gurudatt, Professor and Head of Department, Mechanical

Engineering, Bangalore Institute of Technology, Bangalore for his valuable suggestions
and guidance throughout the period of this report.

I wish to record my sincere gratitude to Management of Bangalore Institute of Technology

and Dr. M.U. Aswath, Principal, Bangalore Institute of Technology, Bangalore for his
constant support and encouragement in academic performance and for making available
library facilities needed to prepare this report.

I would like to thank IMGT Division, HAL for giving me the permission to commence my
Internship to gain necessary technical knowledge and its work. I consider this opportunity
as a proud privilege and express my heartfelt gratitude towards Mr. K. Ramesh, the AGM
of IMGT division, HAL. I would not forget to remember Mr. P.S. Mahesh Kumar,
(Chief Manager, Shop & Test-bed, IMGT Division) for his encouragement and for his
timely support and guidance till the completion of our Internship.

Finally, I take this opportunity to extend my deep gratitude to my family and friends, for
all that they meant to me during the crucial times of completion of my report.

[i]
 EXECUTIVE SUMMARY

HAL India is the country’s leading manufacturer of Aircrafts, components, precision

instruments and so on. This is the primary supplier to the Indian Military, the Air force and
HAL India are interlinked to an elementary level. The better the production in this facility
is, the stronger and more advanced is our air force.

The programs underway at HAL are production of SU-30 MKI, LCA & DO-228 Aircraft:
Dhruv-ALH, Chetak & Cheetah Helicopters, and repair overhaul of Jaguar, Kiran Mk
I/IA/II, Mirage, HS-748, AN-32, MiG21, Su-30MKi & ALH, Cheetah, Cheetah and Chetak
helicopters.

The Company takes up maintenance and overhaul services to cover the life cycle
requirement of all the old and new products. Presently, 13 types of aircraft/ helicopters and
17 types of engines are being overhauled. In addition, facilities exist for repair/ overhaul of
various accessories and avionics fitted on aircraft of Russian, western and Indigenous
designs.

HAL is meeting the requirements of structures for Satellite Launch Vehicles and Satellites
of ISRO through its dedicated Aerospace Division (ASD). HAL(ASD) has been the
mainstay partner of ISRO for five decades and has supported throughout in the journey by
providing hardware for satellites, SLV, ASLV, PSLV, Chandrayan-1, Chandrayan-2 &
Mars Orbiter Mission. The division also integrates the L-40 booster rockets of GSLV MKII
and delivers it directly to the launch facility. HAL(ASD) is establishing a comprehensive
manufacturing facility for cryogenic & semi cryogenic engines and for carrying out total
Integration of the PS2/GS2 stage of PSLV/GSLV MKII vehicle for ISRO.

Industrial and Marine Gas Turbines: The LM-2500 marine gas turbine engine is being
produced and overhauled from the production line in the Industrial and Marine Gas Turbine
Division, Bangalore. The Division also undertakes Repair and overhaul of Industrial Avon
and Industrial 501K engines.

[ii]
 CONTENTS
Page No.
ACKNOWLEDGEMENT i
EXECUTIVE SUMMARY ii
CONTENTS iii
LIST OF FIGURES iv
LIST OF TABLES iv
CHAPTER DESCRIPTION
1. ABOUT HAL 1
1.1. HAL Bangalore 2
1.1.1. Manufacture 2
1.1.2. International Deals 2
1.1.3. Products 3
2. ABOUT THE DEPARTMENTS 3
2.1. IMGT Division 3
2.2. Engine Division 4
2.3. AERDC 5
3. OBJECTIVES 5
4. TASKS AND ACTIVITIES 6
4.1. Spin Test 6
4.1.1. Cyclic Testing 6
4.1.2. Over speed testing 6
4.1.2.1. Construction of Over speed tester 6
4.1.2.2. Over speed testing procedure 7
4.2. LM2500 8
4.2.1. Gas Turbine 8
4.2.2. Brayton Cycle 9
4.2.3. Dimensions of LM2500 10
4.2.4. Components of LM2500 10
4.2.4.1. Compressor 10
4.2.4.2. Combustor 11
4.2.4.3. High Pressure Turbines 12
4.2.4.4. Low Pressure Turbines 12
4.2.5. Construction and Testing 12
4.2.6. Working of LM2500 13
4.2.7. Performance of LM2500 13
4.2.8. Advantages of LM2500 14
4.2.9. Applications of LM2500 15
5. REFLECTION NOTES 15
6. CONCLUSION 16
7. REFERENCES 16
[iii]
 LIST OF FIGURES

Description of Figures Page No.

Figure 4.1. LM2500 Engine 8

Figure 4.2. Brayton Cycle 9
Figure 4.3. Compressor 10
Figure 4.4. Combustor 11
Figure 4.5. Working of LM2500 13
Figure 4.6. LM2500 Engine 15

LIST OF TABLES

Description of Tables Page No.

Table 4.1. Dimensions of LM2500 Engine 10

Table 4.2. Performance Characteristics of LM2500 Engine 14

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HAL, IMGT Division Internship Report 2018-19

1. ABOUT HAL:
Hindustan Aeronautic Limited [HAL] a premier Aerospace Company in Asia is engaged
in design, development and manufacture of military and civil aircraft for over 75 years.
Hindustan Aeronautic Limited is an organization where integrated air borne weapons
platforms are conceived, developed, manufactured and serviced. It is one of the few
corporate giants in Asia whose capabilities span the entire range of activities from
product conception to after sale support. HAL is also involved in the manufacture and
assembly of structures required for India's space programs. The Company which had its
origin as the Hindustan Aircraft Company was incorporated on 23 Dec 1940 at Bangalore
by the late Shri Walchand Hirachand a farsighted visionary in association with the
Government of Mysore with an Authorized Capital of Rs.4crores (Paid up capital Rs.40
lakhs) and with the aim of manufacturing aircraft in India. In March 1941, the
Government of India became one of the shareholders in the Company holding one-third
of its paid-up capital and subsequently took over its management in 1942.

Hindustan Aeronautics Limited (HAL) came into existence on 1st October 1964. The
Company was formed by the merger of Hindustan Aircraft Limited with Aeronautics
India Limited and Aircraft Manufacturing Depot, Kanpur. HAL is a fully owned
Government of India undertaking under the administrative control of Ministry of
Defence, Department of Defence Production. H.A.L is the largest Public-Sector Unit
(PSU) under the department of Defence production and is a Navaratna Company. The
Company takes up maintenance and overhaul services to cover the life cycle requirement
of all the old and new products. Currently, 13 types of aircraft/ helicopters and 17 types
of engines are being overhauled. In addition, facilities exist for repair/ overhaul of
various accessories and avionics fitted on aircraft of Russian, western and Indigenous
designs.

HAL is currently meeting the requirements of structures for aerospace launch vehicles
and satellites of ISRO through its dedicated Aerospace Division. Infrastructure has also
been set up to undertake completed assembly of the strap-on L-40 stage booster.
Structures for GSLV Mk III have been productionised. HAL has also contributed to Mars
mission by supplying riveted structural assemblies and welded propellant tankages for the
Polar Satellite Launch Vehicle (PSLV-C25).

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Today, HAL has 20 Production Units and 11 Research and Design Centres in 7 locations
in India. The Company has impressive product track record-12 types of aircraft
manufactured with in-house R&D and 14 types produced under license. HAL has
manufactured 3550 aircraft (which includes 11 types designed indigenously), 3600
engines and overhauled over 8150 aircraft and 27300 engines.

1.1. HAL BANGALORE:

Aircraft Division was established in the year 1940. Since inception, the Division has
manufactured a variety of Aircraft both licence as Ill as indigenously designed and
developed. Apart from 1st of Hawk Mk 132 Aircraft, the division has signed contract
with Indian Air Force and Indian Navy to supply additional 57 Hawk Aircraft (40 Hawk
for Indian Air force and 17 Hawk for Indian Navy).

The HAL Bangalore complex deals with the following.

1.1.1. The manufacture of:

 Structural sub-assemblies such as Doors, Pylons, Fairings, Drop

Tanks, Control Structures, etc.
 Precision sheet metal forming (Cold or Hot Forming) of Aircraft
components out of Light alloys,
 Steel and Titanium
 Precision machined components
 Honeycomb Sand witch bonded structures, metal-to-metal bonded
components, Composite components in Carbon, Kevlar etc.
 Glass Fibre Reinforced Plastic components like Fairings, Ducts, Pipes etc.
 Aircraft Transparencies like Windshields, Canopies, Helicopters Panel,
etc.
 Electrical Cable Looms (Harnesses)
 Landing Gears

1.1.2. International deals with:

 Airbus, France.
 Boeing, USA.

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 BAE System, UK.

 IAI, Bedek Aviation Group, Israel.
 IAI, Commercial Aircraft Group, Israel.

1.1.3. Manufacturing products like:

 Hawk Mk 132- Advanced Jet Trainer
 HJT-Kiran Mk I, Mk II (IJT)
 Jaguar
 HJT-36 Sitara - Intermediate Jet Trainer (IJT)
 LCA- Tejas

2. ABOUT THE DEPARTMENTS:

2.1. IMGT Division:

IMGT Division, HAL, Bangalore, India provides the most comprehensive service by
offering support in areas of Inspection, Spare Parts, Maintenance, Equipment Overhauls
& Assembly for Industrial & Marine Gas Turbines under license from reputed
manufacturers.

IMGT activities which were earlier part of HAL, Engine Division became an independent
entity from 1st April 1998 to manufacture and support on Industrial & Marine Gas
Turbine under license from reputed manufacturers as given below:

2.1.1. Products of IMGT:

1. Industrial Avon
• IMGT repairs, overhauls & provides on-site support for industrial Avon
Engines.
• Current Collaborators: ITC, UK
• Customer: ONGC - Mumbai.
2. Industrial 501K (Allison)
• IMGT repairs, overhauls & provides on-site support of Industrial 501K
Engines.

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• Current Collaborators: Siemens Inc., USA

• Customer: GAIL/ONGC - Assam.
3. LM2500
• IMGT Assembles, Tests, Repairs & Overhauls LM2500 Gas Turbine.
• Current Collaborators: GE, USA
• Customer: Indian Navy.

2.2. ENGINE DIVISION:

The Engine Division, which is ISO-9002 certified, was set up in 1957 to manufacture
Orpheus turbo jet engines under licence from Rolls Royce. In 1959, another licence
agreement was signed with Rolls Royce to manufacture Dart engines to power HS-748
passenger aircraft and overhaul Avon engines fitted on Canberra & Hunter aircraft. Since
then, the division has grown from strength to strength. It is now engaged in the
manufacture of Artouste engines for Chetak/Cheetah helicopters, Adour engines for
Jaguar aircraft and Garrett engines for Dornier aircraft. Engine division also undertakes
repair and overhaul of various aero engines operated by Indian Air force, Indian Navy,
Indian Army, Coast Guard, Border Security Force, Corporate sector, State Government
and other civil customers. The division has manufactured more than 2,100 aero engines
and overhauled & repaired 11,000 engines.

The division, during four decades of its existence, has acquired state-of-art-technologies
for manufacture, repair and overhaul of engines. It has an Ill-equipped CNC shop
comprising over 25 machine tools. Facilities also include Electron Beam welding,
vacuum Brazing, Electric Discharge / Chemical forming machines and others. The
division has also set up shops for special coating processes to combat high temperature
and atmospheric corrosion conditions, protection against surface erosions, such as
Plasma Spray, Aluminium Silicon diffusion coating, Sermetal coating.

Engine and Test Bed R & D centre, which is part of the Engine Division, has specialised
in the development of small Gas Turbines & Engine Test Beds. The AERDC is
equipped with necessary modern infrastructures. The R&D centre has developed a gas
turbine engine for Pilotless Target Aircraft and jet Fuel Starter for starting the engine of

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Light Combat Aircraft. The R & D centre has also designed and installed engine test
beds for Russian and western origin aero engines on turnkey basis.

The large facility is divided into different CNC shops for different engines, repair and
overhauls, manufacturing inspection, General inspection, Traditional machining centres,
Process shops, Chemical Units, Raw material loading, Tools inventory, Dispatch
section, Cafeterias, Auditorium and so on. They layout of the plant is scientific, well
planned and in a way as to minimize any harmful effects on the environment.

2.3. AERDC:

Aero Engines Research and Design Centre (AERDC) established in 1960 carries out
design and development of Gas Turbine Engines. It has successfully designed and
developed small aero engines in operation with the defence services. Centre holds
patents and copyrights for certain critical technologies.

Centre completed design and development of a Hindustan Jet Engine (HJE-2500) as

first jet engine project in 1965 which was proposed for the HJT-16 aircraft. Later,
piston engine and other engine accessories including a pneumatic starter and hydraulic
pump Ire developed. The centre is the only design house which has developed test
beds for Engines of western as Ill as Russian origin engines.

3. OBJECTIVES:

The main purpose of visiting this organization is to have an exposure to the field of
practical knowledge.
It involves in knowing what is being assembled, why to assemble, where it is being
assembled and how it is assembled.
The main purpose of being an intern in a reputed organization is to observe the working
of that particular organization as a whole. The objective of this internship was to gain first
hand industry knowledge by observing, interacting and being instructed by various levels
of employee hierarchy.

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4. TASKS AND ACTIVIES:

Had an exposure to different types of Jet Engines. I’ve learnt the types of tests done on
rotary components and mainly the assembly of LM2500 Gas Turbine Engine.

I’ve also learnt about the types of Jet Engine. Jet Engine is a reaction engine discharging
a fast-moving jet that generates thrust by jet propulsion in accordance with Newton’s
Laws of Motion.

Jet Engines include,

1. Turbojet
2. Turbofan
3. Turboshaft and Turboprop
4. Ramjet and
5. Scramjet.

4.1. Spin Test:

The major rotary components of an aircraft are tested if they can withstand extreme
conditions. There are mainly two types of tests. They are,

1. Cyclic testing and

2. Over speed testing.
4.1.1. Cyclic testing:

This test is used to find component life i.e., TBO (Time between overhaul). The test is
conducted by setting maximum and minimum speeds and a number of Cycles are tested.
It is also done to determine structural integrity of the component being tested.
4.1.2. Over speed testing:

The aim of Over speed testing is to find the structural integrity of the component that
is being tested.

4.1.2.1. Construction of Over speed tester:

An Over speed tester contains the following parts.

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1. Prime Mover – Air Turbine (manufactured in U.S).

2. Oil pump for damper / bearings (oil mist).
3. Vacuum pressure pump.
4. Control system – PLC (Programming Logic Control).
5. Vacuum chamber surrounded by lead blocks and covered with strong steel
concrete.
6. Pneumatic and hydraulic actuators.

4.1.2.2. Over speed testing procedure:

The following steps are considered in the procedure of Over speed testing.

1. Firstly, a dummy disc is placed inside the chamber to check if the Over speed
rig is working properly.
2. Before placing the specimen, it is checked for surface defects. The surface
defects are tested using NDT methods. The component is further processed if
there are no surface defects.
3. The dimensions of the component are noted before testing so as to compare
after the test is conducted.
4. The component to be tested is attached to the spindle and held vertically hanged.
5. The pit is covered by a lid which is held tightly by a slider which is actuated by
pneumatic means.
6. An external compressor supplies air which rotates the specimen at higher rpm.
7. The pressure of the air supplied is based on the size of the component being tested.
a. For small sized component – 1.5 bar.
b. For comparatively bigger sized component – 3 to 5 bar.
8. A Vacuum pressure pump crates a vacuum inside the pit.
9. The use of bearings helps in smooth rotation of spindle.
10. A Damper is used to reduce the vibrations of the spindle to which the test specimen
is attached.
11. Controller regulates pressure (inlet and outlet), speed and the direction of air
flow (drive and brake).

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12. The controller is INTERLOCKED i.e.; The series of operations are fixed using
PLC.
13. This centre note the readings and plot a graph of speed vs time.
14. The speed is fixed more than what is required according to Integration Protection
System.
15. The component is made to rotate at a constant speed for some time before reducing
its speed.
16. A maximum of 60000 rpm is reached and gradually decreased by applying brake
(air is made to flow in opposite direction).
17. After Over speed testing, the component is again checked for dimensions.
18. If the obtained dimensions are same as that of the previous one before
testing with a minimum tolerance, then the component is further processed
for delivery.
19. If the obtained dimensions vary from the previous one, then it indicates that the
component has undergone plastic deformation and the component is rejected.

4.2. LM2500:

LM2500 is a gas turbine with two shafts of higher reliability and availability, delivers
high thermal efficiency. It consists of a gas generator, a power turbine, fuel pumps, fuel
control and speed governing system, inlet and exhaust sections and devices for starting
and monitoring engine operation.

LM2500 Engine is shown in Fig. 4.1.

Fig. 4.1. LM2500 Engine

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4.2.1. Gas Turbine:

A gas turbine is also known as combustion turbine. It is used to make mechanical

energy from a combustible fuel, this energy then drives a generator that produces
electrical energy. There are mainly three components of a gas turbine. They are,

a. An upstream rotating gas COMPRESSOR

b. A downstream TURBINE and
c. A combustion chamber known as COMBUSTOR.
The Brayton Cycle is the ideal cycle for gas turbine engines. The actual jet engine
components like compressor, combustor and turbine work in accordance to the curves of
Brayton cycle. It best describes the actual working.

4.2.2. Brayton Cycle:

Fig. 4.2. Brayton Cycle

An Ideal Brayton cycle consist of following four processes as shown in Fig. 4.2.

1. Isentropic Process – Undergoes a compression of ambient air (1-2).

2. Isobaric Process – The compressed air then runs through a combustion chamber (2-3).
3. Isentropic process – The heated, pressurized air then gives up its energy, and
undergoes an Expansion through a turbine (3-4).
4. Isobaric process – Heat rejection at constant pressure (4-1).

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4.2.3. Dimensions of LM2500:

The Dimensions of LM2500 Engine is shown in Table 4.1.
BASE PLATE WIDTH 104 in (2.64 m)
BASE PLATE LENGTH 549 in (13.94 m)
ENCLOSURE HEIGHT 157 in (3.98 m)
BASE PLATE WEIGHT 90,000 Kg
INLET DUCT FLOW AREA 48 sq. ft.
EXHAUST DUCT FLOW AREA 30 sq. ft.

Table 4.1. Dimensions of LM2500 Engine

4.2.4. Components of LM2500:

Since it is a gas turbine it has four major components. They are,

1. Compressor
2. Combustor
3. High pressure turbine and
4. Low pressure turbine

4.2.4.1. Compressor:

Fig. 4.3. Compressor

LM2500 Gas Turbine Engine has a 16-stage axial flow compressor made up of a 16
stage Compressor rotor of moving blades driven by the high-pressure turbine. There are
two types of vanes in a compressor. They are Stator and Rotor Vanes. The Compressor
stator casing contains one stage of Inlet Guide Vanes, six stages of Variable Stator

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Vanes and 10 stages of stator vanes. The Stator Vanes as the name suggest remains
stationary. But the rotor vanes which are placed in between the stator vanes rotates and
suck the air from atmosphere. The size of the blades varies from stage to stage. The
compression ratio for LM2500 is 18:1. The main problem lies with balancing the blades.

4.2.4.1.1. Balancing:

Balancing means reducing uneven or unbalanced forces from the rotating component.
There are two types of balancing. They are,

a. Static Balancing.
b. Dynamic Balancing.
a. Static Balancing:

In Static Balancing, the part remains stationary. The force used to check the balance is
Centrifugal Force.

b. Dynamic Balancing:

The force used to check the balance is a combination of Centrifugal Force and Couple
Force. The compressor is divided into two sections. Then it is made to rotate at 600
rpm. The necessary inputs are added (radius, distance between sections etc.,). If there
are any unbalanced forces, then weights are added or subtracted accordingly to balance.

The blades are perfectly balanced (both statically and dynamically balanced)
allowing minimum tolerance. These blades are made up of Inconel (an alloy of
Nickel containing chromium and iron).

4.2.4.2. Combustor:

Fig. 4.4. Combustor

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The Combustor as shown in Fig. 4.4., is an annular type with fuel nozzles and spark
ignitors. Thermal energy is obtained in this component. 30% of the air from compressor
is mixed with fuel to support combustion. The remaining 70% is used to cool the flame
within the combustion liner. The fuel is sprayed from fuel nozzles which are externally
mounted with a swirling effect so that a proper air-fuel mixture is obtained. The above
figure shows the inlet of fuel into the combustion chamber. The fuel used is Diesel. The
ignition system produces a high intensity spark to ignite the air-fuel mixture during the
start sequence. Once the engine is started the ignitors are no longer needed and will be
de-energized.

4.2.4.3. High Pressure Turbines:

It is a two stage, air cooled turbine which drives the compressor and gear box. It is
mechanically coupled to the compressor rotor. An electrical starter is used to start the
compressor initially. After the rotor reaches a self-sustaining speed, the starter is cut-off.
For further rotation of compressor these high-pressure turbines are used. Also, gearbox is
driven by HPT. These gearboxes reduce the high speed to required low speed.

4.2.4.4. Low Pressure Turbines:

It is a 6 stage, aerodynamically coupled turbine. It is driven by the gas generator’s high-

energy exhaust gas flow. The power turbine extracts the useable energy from the obtained
thermal energy and uses this to drive the main reduction gear.

4.2.5. Construction and Testing:

It takes around 20 days to construct and inspect an LM2500 gas turbine. The construction
is started from compressor. The outer casing of the compressor has two semi cylindrical
shapes which are joined together with suitable bolts. Care is taken for not allowing air gap
since it reduces the efficiency of the turbine and in few cases leads to the damage of the
entire unit while testing. After construction, the unit is tested in a testbed. In a test bed,
different parameters are measured and are compared to that of ideal ones. If the obtained
results are satisfactory, then they are sent for delivery. If the obtained results do not match
or if any constructional errors are observed, then the gas turbine is rechecked and
rectified.

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4.2.6. Working of LM2500:

Fig. 4.5. Working of LM2500

The LM2500 gas turbines drives controllable pitch propellers through a conventional
main reduction gear, shaft and clutch. The outline of LM2500 is shown in Fig. 4.5. A 16
stage axial flow (air travel is parallel to the shaft) compressor increases the pressure and
temperature of the working mass (air). In the combustor section, fuel is added through
fuel nozzles and combustion occurs. A two stage high pressure turbine on the exhaust end
of the combustor drives the compressor. The combination of the compressor, combustor,
and high pressure turbine are often called the gas generator. The exhaust from the high
pressure turbine passes through a low pressure turbine which extracts the work required
to drive the main reduction gear and ultimately the ship's propeller. The LM2500 module
totally encloses the LM2500 to provide thermal and acoustic insulation. A top hatch and a
side door or two side doors provide access to and viewing of the engine. The module is
shock mounted to reduce hull-borne noise transmission.

4.2.7. Performance of LM2500:

LM2500 is best suited because of its performance. The performance characteristics of

LM2500 engine is shown in Table 4.2

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OUTPUT POWER 25060 KW

HEAT RATE 9421 Btu/kw-hr
THERMAL EFFICIENCY 36%
EXHAUST TEMPERATURE 566°C
EXHAUST GAS FLOW 155 lb/sec
EXHAUST ENERGY 141 MMBtu/hr
COMBUSTOR TECHNOLOGY SAC
POWER TURBINE SPEED 3600rpm
SFC 227 g/kw-hr

Table 4.2. Performance Characteristics of LM2500 Engine

4.2.8. Advantages of LM2500:

LM2500 Engine is the top selling gas turbine globally. It is an ideal gas turbine because
of the following reasons.

a. Capability:

It is ideal for combined cycle, onshore and offshore power generation, mechanical drive
and cogeneration.

b. Versatility:

It accommodates a wide variety of fuels including Coke oven gas, naphtha, propane,
diesel, ethanol and LNG.

c. Sustainability:

There are multiple technology options available to lower NOX and other emissions.

An advantage of a gas turbine engine is its ability to be removed from the ship for repair
in a short period of time (approximately 72 hours). A set of rails is permanently installed
in the intakes of each engine and a set of temporarily installed transition rails allow the
disconnected engine to transit from its mounting attachments in the module onto the rails
in the intakes. Crane service capable of extending over the soft patches in the intakes is

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required to pull the engine up the rails and out of the ship. Also, apart from these, the
efficiency of LM2500 Engine is greater than 85 percent. It helps in reducing Plant
Operation Costs, Plant Emissions and Reliance on the local grid. A lightweight and
compact modular design complements the universal packaging, which improves
accessibility for maintenance. The LM2500 Engine delivers power with reliability greater
than 99 percent and availability greater than 98 percent.

4.2.9. Applications of LM2500:

LM2500 Engines are primarily used in Ships. Indian Navy is the customer for HAL,
IMGT Division. LM2500 Engine is shown in Fig. 4.6.

Fig. 4.6. LM2500 Engine

5. REFLECTION NOTES:
Over the duration of the “In-plant training”, I visited a large number of machining
processes, test rigs and assembly shops and I’ve observed and studied their
various operations.

The theoretical knowledge obtained were backed up by hands on approach with

practical exposure which made the learning process very effective during the in-
plant training.

Also, this internship helped us to bridge a gap of communication with the senior
most faculties of Hindustan Aeronautics Limited, IMGT and ENGINE Division.

Dept. of Mechanical Engineering, BIT Page 15

HAL, IMGT Division Internship Report 2018-19

6. CONCLUSION:
During this internship I have understood that the administration and management of
an industry ensures to reach their desired goals within specified time without any
delay with proper time management.

A large amount of precision and hard work is insured by employees of HAL to ensure all
safety standards and quality checks of various products being developed by them.
Multiple iterations and test are constantly being conducted on various engines to ensure
no future failure would be possible. Re-work and overhauling operations are being
carried out to ensure maximum operating life without the risk of failure of system.

This has helped me in gaining better understanding of how an industry works and
maintains its standard.

7. REFERENCES:
1. www.hal-india.co.in
2. www.ge.com
3. www.google.com
4. www.wikipedia.org

Dept. of Mechanical Engineering, BIT Page 16