Turbo expanders are used to retrieve gas energy in reducing gas stations which convert the retrieved energy to electrical one or mechanical work. Different types of turbo expanders are available among which the power generator type is the most important and valuable. Mechanical components have to be very specific and accurate so that the device retrieves energy with ultimate output. In turbo expanders gas heats the blades (propeller) and causes them to rotate and so is the gas energy taken. The gas with reduced pressure is then flowed out and the propeller transfers its rotational movement to the rest of the system. The retrieved energy is used in different ways. In this thesis, the design of a turbo expander’s individual parts such as the shaft, wheels, bearings, and propeller as well as study of the seal is mentioned. Bending tension analysis of the propeller shell and shaft by ABAQUS application using Von Mises theory follows. In the end, manufacturing and machining of parts like the shaft and blades as well as sequence and assembly of such mechanical elements on the shaft is described. The design, analysis, manufacture, and assembly of a laboratory sample power generator turbo expander with generation capability of 10KW to be installed in a 5000m3/h reducing gas station is mentioned finally.
