Documente Academic
Documente Profesional
Documente Cultură
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN
FUNDAMENTALS
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Learning goals
This unit is dedicated to gas turbines and
students are expected to gain knowledge and
understanding of:
Gas turbine theory,
Design fundamentals;
Practical considerations of gas turbines;
Gas turbine comparison.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Gas turbines have been gradually evolved on
the dominant main propulsion and ship-service
prime movers for destroyers, frigates, cruisers
as well as the foil-borne engines for hydrofoil
crafts.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
A gas turbine is a rotodynamic machine which
uses a gas compression combustion
expansion cycle. It differs from a reciprocating
internal combustion engine in that:
1 - The compression and expansion is
performed using rotodynamic components
2 - The combustion takes place at constant
pressure
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
GT are characterised by:
High power to weigth ratios;
Lower thermal efficiency;
High output shaft speed;
Better quality fuels;
High air to fuel ratios;
High power to volume ratios;
High availability;
Lower exhaust gas emissions;
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Centrifugal
Turbine and
centrifugal
compressor
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
The Centrifugal Compressor
The centrifugal compressor consists of an
impeller enclosed in a casing which contains the
diffuser.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
(Illustration Rolls-Royce Ltd., 1969)
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
compressors
(Reprinted with permission of copyright owner, United Technologies Corporation)
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
compressors
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Burners
About 15-20% of the air from the compressor passes over swirl vanes as it enters the primary zone of the burner. Here
also the fuel is introduced through nozzles as a fine spray of droplets. The swirling air causes the good mixing
necessary to support rapid, high temperature combustion.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Burners
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Burners
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Burners
The annular burner is well-suited for an axial
flow compressor. It is shown in the air
distribution pattern in this type may involve
introduction of the compressor air in only the first
two zones. The tertiary zone may involve final
mixing only. The advantage of this type of
burner is that it minimizes size and weight
with a sound aerodynamic design.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbines
There are two basic types of turbines,
comparable to the two types of compressors.
Due to the sizable stresses involved, the radial
turbine is generally not suitable for the high
temperatures necessary in a gas turbine engine.
Therefore, the axial flow turbine is the only type
that will be discussed here. (See slide n7)
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbines
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbines
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbines
Turbines may be of the impulse or reaction type
depending on rotor blade design.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbines
(a) Impulse turbine rotor blades -
The flow passages are of constant
cross--sectional area resulting in
essentially no flow speed,
pressure, or temperature change.
Those changes occur in the
stationary blades (nozzles). The
turning of the flow causes the
rotor to move.
(b) Reaction turbine rotor blades -
The blades act as nozzles to
accelerate the flow as pressure
and temperature decrease. These
processes take place in both the
stationary and moving blades.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
GT PTO
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
complex power system
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Calculations exercises
Example 1
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
Example 1
A gas turbine unit has a pressure ratio of 10:1 and a
maximum cycle temperature of 700C. The isentropic
efficiencies of the compressor and turbine are 0.82 and 0.85
respectively.
Calculate the power output of an electric alternator geared to
the gas turbine when the air enters the compressor at 15C
at a rate of 15kg/s.
Take Cp=1.005 kJ/kgK and = 1.4 for the compression
Take Cp=1.110 kJ/kgK and = 1.333 for expansion
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
2
2
0
v
h h + =
02 , 23 , 23 01
h W Q h
IN IN
= + +
( )
1 2 01 02 12
T T C h h W
p
= =
( )
2 3 23
T T C Q
p
=
( ) ( )
( )
2 3
1 2 4 3
23
34 12
) (
input heat
net work
T T C
T T C T T C
Q
W W
p
p p
=
+
= =
The steady flow energy equation applies to each component of the turbine. Defining
stagnation enthalpy
one can analyse the compressor, for instance, using:
In the idealised cycle there is no heat transfer during compression and
expansion so (for instance) the specific work (per kg of fluid)
Similarly there is no work done in the combustion chamber so
The efficiency can then be calculated using
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
3
4
2
1
1
2
1
T
T
T
T
P
P
k = =
( ) ( ) ( )( )
= =
1
2 3
2 3
2 3
2 3
1 1
1 1 1
r k
T T
k T T
T T
k T k T
1
2
P
P
r =
1
3
T
T
t =
( ) ( )
1 2 4 3
T T C T T C W
p p
=
1 1
1 1
1
r r t
T C
W
p
Let us assume the compressor and turbine are 100% efficient (no entropy rise) and define the temperature ratio using isentropic formulae as
Substituting in equation 4.3 we have
(4.4)
where r is the pressure ratio,
The specific work output can be calculated as a function of pressure ratio r and the non-dimensional peak temperature,
i.e. turbine inlet to compressor inlet temperature.
(4.5)
so
(4.6)
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Plotting these efficiency and work relationships with
pressure ratio from equations 4.4 and 4.6, we see that
efficiency rises with pressure ratio (figure 4.4)
for any given peak temperature t there will be some
pressure ratio that produces the peak specific power
(figure 4.5).
At any given pressure ratio, increasing the peak
temperature (by injecting more fuel) increases the work
output.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
In practice only the simplest gas turbines, driving electrical
generators at constant speed, extract power directly from the gas
generator shaft as in Figure 4.2. When driving any other load a
separate power turbine is desirable:
Increases in load do not slow down the compressor
and cause a drop in pressure ratio
The speed:torque characteristic, for a given fuel flow,
is much more stable (see figure 4.6)
The starter can rotate the gas generator spool without
turning the load
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Calculations exercises
Example 2
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
Example 2
A gas turbine takes air at 17C and 1.01bar and has a compression ratio of 8:1. The
compressor is driven by the HP turbine and the LP turbine drives a CPP via a gear
box.
The isentropic efficiencies of the compressor and turbines are respectively 0.80,
0.85 and 0.83.
Determine the pressure and temperature of the gases entering the power turbine,
the net power developed by the unit per kg/s mass flow rate, the net work ratio and
the cycle efficiency of the unit.
The maximum cycle temperature is 650C
For the compression process take Cp= 1.005 kJ/kgK and gamma=1.4
For the expansion process take Cp=1.15 kJ/kgK and gamma=1.333
Neglect the fuel mass flow rate.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
The efficiency of an ideal simple cycle gas turbine is
purely a function of its pressure ratio. This has two
implications:
Efficiency is poor at part-load, when the shaft speed
and pressure ratio is lower and one is closer to the
self-sustaining point where all the fuel is used purely
to overcome component losses
When the effect of component losses is considered,
we find that for any peak temperature there is some
pressure ratio at which the efficiency peaks: adding
further compressor stages will then reduce rather
than increase the efficiency.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
The heat exchange cycle overcomes some of these
difficulties. The main result of inefficiency in a simple
cycle is that the exhaust is hot. Providing it is hotter than
the compressor exit temperature one can use a heat
exchanger to transfer heat from the exhaust to the air
before it enters the combustion chamber: a given turbine
entry temperature can thus be achieved with a lower fuel
flow than in the equivalent simple cycle
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
recuperated cycle
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Efficiency increases with temperature ratio
so the provision of sophisticated turbine
cooling systems is beneficial. Efficiency
also rises as pressure ratio is reduced but this
is at the expense of a drop in specific work so
some compromise must be found. Typically
heat exchange cycles operate with a pressure
ratio of 4 to 5 (compared with 11 to 30 for a
large simple cycle engine).
1
3
T
T
t =
The ideal cycle efficiency is then a
function of both pressure ratio and the
temperature ratio
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
As a further refinement the WR-21 includes an intercooler to cool the air
between the LP and HP compressor stages. This leads to a rise in specific
power, since less turbine work is required to drive the HP compressor. By
itself the intercooler would lead to a drop in efficiency (heat is being wasted);
in a recuperated cycle, however, the lower HP compressor exit temperature
means that the exhaust gases passing through the recuperator can be cooled
further and there is a corresponding rise in efficiency.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
The final WR-21 novelty is that the power turbine has
variable throat area nozzle guide vanes. At low powers
in a conventional engine the combustor exit temperature
must be reduced to limit the power; with a variable area
nozzle the power can be reduced by lowering the mass
flow whilst maintaining the temperature. Compressor
surge is avoided because the gas generator turbine,
seeing a higher back pressure, generates less power so
the shaft speed and compressor pressure ratio are
reduced (which does not have a severe adverse effect
on the efficiency since this is a recuperated cycle).
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Compressor theory
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Compressor theory
There are basically two ways to analyse how
turbomachinery (compressors or turbines) works.
1 - Trace the changes in temperature and pressure from
one blade row to the next using velocity triangles, in
which we consider flow within each frame of reference
(stationary or rotating) to have constant total
temperature and pressure along a streamline
2 - By consideration of the overall power input (Euler
equation) resulting from the change in angular
momentum across the rotor.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Compressor theory
( )
2 2
1 1
01, 01 01 1 1
2 tan
2 2 2
rel a
p p p
C V U
T T T U C
C C C
= + = +
1
01
, 01
01
, 01
T
T
P
P
rel rel
The rel suffix indicates that this is a stagnation
quantity in the rotating frame. (The total temperature as measured
by a thermocouple mounted on the rotor would be different to that
measured by a stationary one).
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Compressor theory
rel rel
T T
, 01 , 02
=
( )
2 2
2 2
02 02, 02, 2 2
2 tan
2 2 2
rel rel a
p p p
V C U
T T T U C
C C C
= + = +
( )
02 01 1 1 2 2
tan tan
a a
p
U
T T U C C
C
= +
rel rel
P P
, 01 , 02
=
1
02 02
01 01
P T
P T
=
In the absence of heat transfer
.
(4.8)
If we neglect frictional losses and changes in radius
and we can apply an isentropic relationship across the whole stage:
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Compressor theory
V
1
Air relative velocity
C
a1
Axial velocity component
C
1
Axial velocity component
U Blade velocity
, fluid angles
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Compressor theory
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Combustor
The calculation is based on the following assumptions
(figure 4.19):
No pressure drop takes place across the combustor
i.e. burner pressure ratio P4/P5.
Heat addition takes place under constant pressure
with no work output
The specific heat capacity of flue gas leaving the
combustor is equal to that of hot air at the exit
temperature.
Fuel used has got a calorific value of 42.7 MJ/kg
Use of the steady flow energy equation with no heat
loss to the surrounding and neglecting velocity and
potential heads.
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Combustor
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Combustor
)
2
( )
2
( 5
2
5
5 5
. . .
4
2
4
4 4
.
z
v
h m W Q z
v
h m + + = + + + +
5 5
. .
4 4
.
h m Q h m = +
05 05 5
.
04 04 4
.
T C m h m T C m p f f b p = +
05 05 4
.
4 04 04 4
.
) 1 ( T C m f h m f T C m p f b p + = +
05 05 04 04 ) 1 ( T C f h f T C p f b p + = +
Based on the following assumptions the general steady flow energy equation
Can be re-written as
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Combustor
04
05
04 04
04
05
) 1 (
1
p
p
p
f b
C
C
f
T C
h f
T
T
+
+
=
b
= Adiabatic efficiency
h
f
= Calorific value of fuel
C
p04
= Specific stagnation heat
capacity at inlet
C
p05
= Specific stagnation heat
capacity at outlet
f = Fuel air ratio
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Combustor
Graph for estimating
the gases
temperature at the
combustor outlet for
a variety of fuels
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbines
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbine
As with the compressor, we can trace the
variation of temperature through the turbine
using velocity triangles.
( )
2 02
2
2
2
2
02 , 02
tan 2
2 2 2
ax
p p p
rel
C U
C
U
T
C
V
C
C
T T + = + =
1
02
, 02
02
, 02
T
T
P
P
rel rel
rel rel
T T
, 02 , 03
= if uncooled
12/2006
School of Marine Science and Technology School of Marine Science and Technology
University of Newcastle University of Newcastle
GAS TURBINE DESIGN FUNDAMENTALS
Turbine
( )
3 , 03
2
3
2
3
, 03 03
tan 2
2 2 2
ax
p
rel
p p
rel
C U
C
U
T
C
C
C
V
T T + = + =
( )
3 2 01 03
tan tan
ax ax
p
C C U
C
U
T T + =
Neglecting frictional losses and changes in radius
rel rel
P P
, 02 , 03
=
and we can apply an isentropic relationship across the whole stage:
1
01
03
01
03
T
T
P
P
02 01
,
02 01
is T
isen s
T T W
W T T
= =