elally cl eS 5 Lig yr ill Ja) ya p bill 3 lal Gas Turbines Design & Operation Training Course Over 100 Question & answer Over 200 Pictures **FULLY ILLUSTURATED** OPERATION ENGINEER: ABDULLAH ZAMAN ALMERZA 20-24/10/2007TABLE OF GONTENT Page GAS TURBINES GENERAL NOTES 10 GAS TURBINE AIR INTAKE SYSTEM 34 GAS TURBINE COMPRESSOR GAS TURBINE COMBUSTION CHAMBERS. GAS TURBINE — TURBINE SECTION. 94 GAS TURBINE BLADE COOLING TECHNIQUE. 108 GENERAL NOTES IN SHAFT DESIGN.. 121 GAS TURBINE = START UP UNIT. GAS TURBINE OPERATION, CONTROL & PROTECTIONS. GAS TURBINE EFFICIENCY & OPTIMIZATION. 158 APPENDIX - A REFERENCES « 187 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobi 9656492894LIST OF QUESTIONS -4#—InY! Jyos Sand BS 5 4 jal) Aig) gill pale Whaat is the operating principal of gas turbine? How could weather conditions affect gas turbines? SA FAM Ay sll 5 yb daly ale | 2 Gas turbine history & stages of development? oI GS SY ELT al [3 What are the main types of intemal combustion engine? Se All i pg Ga GS How can gas turbine classified? Ce nt EG GS GS] 5 How aircraft gas turbines is classified? SH eS ASSIS BLY CY Csi jal Sl gl Gnas GS 6 How can land base gas turbines classified? {2 GS, ES GRY go ea, pl] 7 What is the difference between Internal & external combustion engine? FAM Sl ally Aj) Gly ps Go lid aas wale | 8 What is the difference between gas turbines & steam turbines? {el GRY SY Ce GT Al] 9 What are most common examples of external combustion engines? on Al AS, 4G) Gl Al Ga aS, wl) 10 What is the difference between gas turbines & reciprocating engines? SASS) BU CY Laskin! Hy jlall bigs gl p25 GSI | 11 Where are land base gas turbines used? Fla 28, Fal Cli gl ps Y Gal] 12 Why gas turbine doesn't used as car engine? a lead GU hy Lal! lig gil) jl 3a | 13. Why gas turbines are more expensive than reciprocating engines? ok ea Leal ge SLD) Sig 9 il Lg gins all) Gell Gul Ge Ryas al GiLS gins YD 14 § (GAGS Jae GI ia! 5 La) Sd 5) pa) Why reciprocating engines are not made from same materials that gas turbine is made although they are suffer from very high temperature just like gas turbines? RI yy al dee Ae CW Vly UGLISy GS | 15 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804What are the types of air effects during compression process in axial compressor? BL CY Lea A Gy yl, Gl pa al 2) i ol Qe SEY aT aL] 16 PL gS What is the main deference between land base gas turbines & gas turbine used in aircrafts? jal Si a) Sel SL 17 Explain air intake filter house in details? Tab y ah, Lele) wi) 18 What is the main purpose ofa compressor? ig MW Soa GL Ge TSU cyl Les WM ca LI 19 Why do we need to compress air before it is enter to the combustion chamber? TA AN Gli 5 gl 8 ol ygll Lele elit a | 20 What are the main types of compressors which are used in gas turbine engines? A SG a Fa wD bel all p85 YI] 21 Why reciprocating compressors are not used in gas turbine engines? $Centrifugal Compressor -~j 8 4)! 2 hil 3 Letal ple | 22 What are the operating principals of Centrifugal Compressor? fAxial compressor- Goss) LeLal al | 23 What are the operating principals of axial compressor? SEelal due She al 24 | What is compressor washing process? thital Loa Gay Gohl al | 25 What are the alternative methods used for compressor cleaning? Goad Béla, gS pall syhl PLELAI Go fellas, ple | 26 What is the difference between axial & centrifugal compressors? *Axial Compressor Design = ssl tLe prea cot | 27 Explain Axial Compressor in details? SUS yaa ale y Guidi Le glad Anas als | 28) What are the advantages of using blow off lines in axial compressor? TAxial Compressong jy L8LaN wanat sie USN Gaye all Col I am al | 29 What are the main design considerations in axial compressor? * Axial Compressor goa L2Lal Ge LEN tle GT -gl GEE aL | 30 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804List OF QUESTIONS - 4#—L-Y/ J jas What are the stages of the air during combustion? Axial Compressor gs) LLall 4 cl sell Gi pha! yale ge | 31 What is the definition of compressor surge? Axial Compressor gy edi betall i eiygl Go) LT ab | 32 What are the main reasons of compressor surge? $ Axial Compressor cs ys) Lee Lal) gio) gall ol plata! le Senet G phy Ge S33 How can compressor surge be avoided by improving compressor design? *Compressor Surge Protection 335d) Le ball 3 ely) Gaal U8, aL | 34 What is compressor surge protection? TAS Ge al [35 What are the main principals for combustion? Saal GLieyl oh he al | 36 What is the requirement for a good combustion? $a BY) cade yall al | 37 What are the important factors for combustion to start? t% BO yl gi Lael SETI Ge CIs al 38 What are the main types of combustion chamber which are used in gas turbines SG ASV AGY clei al] 39 What are the main parts of combustion chamber? 8 GIFS Y the cl a8 oly lel ge Lyi aval al | 40) What is the importance of good mixing between fuel & air during combustion process? Gavitle GLEE an pl ai What are the important points to be considered in a combustion process? £GLey e 5F Al Liallal at [42 What are the factors that affect combustion process? Sal SaY) LE Aa asd TSE al | 43 What are the different configurations of the flame during combustion process? Sdiffusion Flame - 4st) 283) 442 Premix Flame sisal 385) dat oe Gall ale 44 What is the difference between Premix flame & diffusion flame? ‘Hybrid Bumer-case! G) yall ala US ale) 45 What is the general configuration of the hybrid burner? Teed Gold Leg 1 Flame Humming - U2) 3 das gill Gabi al | 46 What is flame humming & why it is important to measure it? TG _AY cll yall Uap al | 47 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++965692804IST OF QUESTIONS - *—LY! Jja > | SNOx emission ssl) 3 3) Ss 9 he Go Ap Oey ll lsh Silas! Gl Gob al | 48 What are the various methods used to educe NOx emission form gas turbines? {SOx emission- iz 3 5 8 GI As YI GF ye ASW Sy SN atST Glas] Juli Gok al | 49 What are the various methods used to reduce SOx emission from gas turbines? Gye Cling) pil ais S| 50 How can turbines in general are classified? _ _ ‘Radial 458 pals) Axial 45 yall Ay pl JST SRY) AE Sali) Ge g sgl] 51 Which types of turbines is most common radial or axial turbine? £ Reaction turbine daill 3) 44x) Impulse turbine 5 3! x j¢ GUAT ale 52 What are the main principals of impulse &reaction turbines? $A SD ppenet aie Seidl Segall ul pl Gas ale | 53 What are the main considerations that used in turbine design? $Reaction Turbine Jaall 354x585 Impulse turbine Sj AF Ge Baas wl | 54 What is the main difference between impulse & reaction turbines? TB Ay) aad S29) a] 55 What are the different configurations of impulse turbine? TH Ll Lig ol FB pe Clin gl Gag gi gl) 56 Which type of turbines is used in gas turbines? SA Fall i A pene od) 57 Explain gas turbine design? ay AAS, 4S a Ob ad Gob al | 58 What are the methods used to cool turbine fixed & moving blades? Tey galls ely yall Gh ad Ga el aay ale | 59 What is the main deference between air cooled blades & water cooled blades? Aja i A AE pally yl AU LS Gul GS | 60 How blade cooling effectiveness is measured”? FH Sal Ai sl) A AS pally LI! GU LSD pill Gd al | 61 What is the definition of Corrosion & Erosion for gas turbine blades? $i sl GF a! le Y Ga wk All pall ale | 62 Which part in gas turbine is suffered from the highest thermal stress? £4 ANN Aig a BAS jaa, AU OM LS, all LT a | 63 What are the main causes of Erosion & Corrosion on turbine blades? Faia Ri si Sy Glas y USL) Juli Jt) als | 64 What are the methods used to reduce Corrosion & protect turbine blades? "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804What are the methods used to reduce vibrations at last stage of turbine? Siggy il BAS paiall Gy I Lg) ue pa ald ASUS! Slag gh sl ga Le | 65 What are the types of loads that exerted on rotating turbine blades? $ Ais sll 56S gle te I gh il pl Shs yy HS | 66 How does deposits formation on turbine blade affect turbine efficiency? Ads sl SelGS (cle Ady 8 Cony gall ocala | 67 How does the damage to turbine-blades tell upon the efficiency of the unit? hagas HL GS GS; Shall Alignment — yl pau) sldae dle Gags BLS | 68 Why shaft alignment process is important & how can we perform this process correctly? _ _ Sly sll JE xe 452 Journal Bearings said! GIS Jyeadll pul $ pass Ld | 69 PALA y Atal Why Journal bearings are used in large turbines? AY) aad Gag YG: lal ayeall G5 Gj A Gl a ae TLD] 70 Why lifting oil is used in some turbines to lift their shafts? ined Seed atl S phi Leg Laid al y 5 pee Sand pee 9S Sih gill cas of pain Ll | 7] Foatade 4 ld Why we use only one axial bearing in turbine shaft instead of multiple bearings? Shy AAS Ai lly Sy Ua Sig gl) gall 2 pall Gay ALAN SUDA pw Le | 72 What are the main deference between gas turbine shaft & steam turbine shaft? Sq gS pel JS Ais 79 poe Oe SIE Jal) Lin i po GSI] 73 Why gas turbine is larger than steam turbine for the same power output? Teele Gay WL, i a aya al le a a | 74 What is critical speed for turbine rotor & why do we have to avoid it? $ 5g sill 2 yd Sagging - +8291; hogging - sill Syl sD GLY a 75 What are the main reasons for shaft Hogging & Sagging? Pag ysl a yee FSI iI SY! Soya us DM GLY ge | 76 What are the main reasons of shaft vibration in turbine $A all iy yl Ball Gini ys pall Gines Gly sll pje Ge GS GS) 77 How is the torque, pressure & temperature distribution on gas turbine iy wd AS aid EG a ll GA Sie Ud pd Ga al | 78, "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804What are some of the factors that may determine the service life of gas turbine components? ISLS chy all ing ll ce SST Ay LM Sig ytd Dalya ase | 79 Why the number of steam turbine stages is larger than gas turbines stages? © iy Hl 3 yal Abad Yl Auaal gale | BO What is the importance of turning gear operation for turbine rotor? taVlex eal S jal Ge yall CELI BT Why are gas turbines needs start up unit? FS fobll gF eastiall 4, Clay pgs Jay) ey Eel Ela aedl gal | 82 What are the most common starters which are used in aircraft gas turbine engines __ Ag, pgSIl ABU) cABY Lead jal) Gly sls LY cay Beal EL sl gal | 83 What are the most common starters which are used land base gas turbines? aSatlls jes AL an ll Sal | 84 What is the main purpose of control system? ed oly df Lalas all Sal Gai TEL al | 5 What are the main types of speed/load controller that used in steam turbines? Fhe jl Jeall Salat Jeli als | 86 What are the main types of speed/load controllers? CaS | Lage Saal Sey Metall Gli 5 gi quand agile Ze yall GELS Aas GS Gf Guay LD] 87 S gile Why it is preferred to make speed droop setting same for all turbines which are connected to the same network? Bly aD PUR Salicisl al | 88 What are the types of governors which are used in gas turbine? TA ja) iy) a A dal 5 he GSS | 89 Describe the process of increasing gas turbine load? Tay ¢ fey BELA © patel Gis NGI Ge pé SM gle Gall aa gh Daa Ba) GL a | (90 £%100 Could we increase the gas turbine load even if compressor inlet guide vanes are fully open? TGS 6 Rd pe ES AEE Gas al | 91 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Ay A ye Gal Ld BI al | 92 What is the method used to calculate gas turbine service life? taal gle Ain sil Lele 1 Jalal el yell 8 ylja da po 8G ole | 93 What he effect of compressor inlet temperature on gas turbine output power? Jul Lip sl Ge lsh Gale | 94 What is the start up sequence of land base gas turbine? $4ab gL) CY Lest GD Slay sll GF SUE pal al 95 What are the most important protections used in land base gas turbines? TA jal Ai oll 8 opal al 9G What are the losses in gas turbine? Eee) al Aili Gy Gy al | 97 What are the methods used to improve /and base gas turbine efficiency? Axial Compressor g 9 sali Lela ud cll) gle pall ay pall 4 ph 9 SS GL | 98 Why compressor intercooling is not wildly used in axial compressors? Ses Lal gM SSN ol ygll 9 pc ass eall GES AIG ybll G pe y Gi jane gale | 99 What are the main advantages & disadvantages of cooling systems which are used for compressor inlet cooling? Sad SS EGS 100 How combined cycles are classified? AS Bhd) lhe Gail) 5 | all ela ph) AG Mill 1ST a 101 What are the main Configurations of heat recovery steam generator? "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804GAS TURBINE GENERAL NOTES 44 jell Cian y gill ge ale Pmt Te es ene a ad me MS6001B-G.E, "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804fda GS 5% Jali iy sl gale] 1-What is the operating principal of gas turbine’ to produce a reactive thrust to propel an object or to produce mechanical power to tum a load, the principal of operation of the gas turbine can be explained by the following examples: *-Example (1) Figure (1)1500AD-Old Style Gas Turbine for BARB-Q not for Power generation! (The sketch is drawn by Leonardo de Vinci) Cold air is enter from the hole at bottom of the oven, as its mix with the hot gases that released from the combustion its temperature will increase & hence its density will drop, then it will move up word & another cold air will replace hot air with continues action, due to the movement of hot air to the top, it will create a natural draft that pass through a series of blades that tumed the roasting spit so provide power to the attached mechanism, *-Example (2): Figure (2.A) shows a cylinder cross section with a fan on each end, now if the left hand fan is started via an limited speed electric motor, will draw air inside the cylinder which will cause the right hand fan to ul "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804losses rotate at the same speed of the other fan (if we neglect air pressure losses yet velo cylinder). If we drill a hole in the cylinder surface between both fans & we ignite a continues flame Figure Z.B), the temperature of the air that passes through the flame will increase & also its specific volume, this will cause the right hand fan to rotate even faster than the left hand fan (because the air occupied a larger area than before after being heated since its specific volume increased & hence its volumetric flow rate will increase). Now, if we disconnect the electric motor that rotates the left hand fan & we connect the left hand fan with right hand fan by a shaft & we insure a continuous flam Figure (2.C), the right hand fan will produce a mechanical power that is sufficient to rotate the left hand fan & another applied load. = => => => => => a += _— —_— a SS a — (©) = = = ~~ = = | Figure (2) Simplified gas turbine Now the idea of gas turbine is clear: 1. The left hand fan represents the COMPRESSOR 2. The right hand fan represents the TURBINE, 3- The flame represents the COMBUSTION CHAMBER 4- The electric motor represents the START UP UNIT of the gas turbine 12 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804raft .. 5+ Another applied load could be an electric generator, pump, or thrust propulsion as in 6- There is additional part of the gas turbine which is the AIR FILTER to insure clean air entrance. Now ifwe look to Figure (3) we can realize real gas turbine configuration Fuel intet Extioust Combustion Chamber Compressor ee € A Turbine = A Air Filter Figure(3) open cycle gas turbine ae bp a2 2- Gas turbine history & stages of development? a- First successful design for a gas turbine is done by a lot of pioneers at the same time, one of them is Sir Frank Whittle (England); he make painting for first gas turbine on 1930 but similar patent record in Germany & Italy on the same year. Whittle developed a working gas turbine engine in April 1937 which was used to drive the ful turbojet airplane in Britain; His early work on the theory of gas propulsion was based on the contributions of most of the earlier pioneers of this field, first succes b-After the Second World War, the jet engine became the most popular method of powering aero planes and consequently the gas turbine rapidly developed to generate electric power. e-The reason why the gas turbine appeared so much later than other types of intemal combustion engines was because of the difficulty of finding materials for the working parts, especially the turbine blades, as they would have to With stand extremely high temperatures of the buming gas without melting or weakening. Figure(4) Sir Frank Whittle 9656492894 Eng, Abdullah Zaman Al merza 20/10/2007 Mobil jas Turbines design & Operation+The following table summarizes the history of the gas turbines: @ 1935, 1936 1939 1939-41 1940 1942 1948 1948 @ 1949 1949 @ 1950 1952 1954 1954 1958-59 1963-68 1963 1979 Jendzassik, Hungary: first regenerative gas turbine engine. Allis Chalmers Manufacturing Co. U.S.: built 600 kW Brown-Boveri gas turbine sets for U.S. oil fields. Brown-Boveri installed the first marine gas turbine in the French ship Athos. First flights of jet aircraft: 1939 in Germany, 1940 in Italy, and on May 14, 1941 in England in a Gloster E/28 experimental plane with the first Whittle flight engine. Escher-Wyss Co., Switzerland built first closed-cycle powerplant; air as working fluid, 2000 kw, with intercooling and regeneration. Brown-Boveri Co., Switzerland built first gas turbine locomtive with zegenerator. Boeing Company, U.S., built first mini-gas-turbine engine, 175 hp. Brown-Soweri built the Beznau 13,000 kW powerplant, the first gas turbine plant with intercooling and regeneration; then added a 27,000 kw unit with coal-fired indirect heating in 1949. Huey Station, Oklahoma Gas & Electric Co., operated the first combined cycle plant with a general Electric gas turbine and steam turbine and 3500 kW output. Alco/Elliott/General Electric team built the first U.S. locomotive gas turbine, producing 4800 hp. Rover Co., England: first gas-turbine powered automobile. General Electric/El Paso Natural Gas: first gas turbine powered compressor on a natural gas pipeline. General Electric teamed with the Esso Company to build the first ga turbine powered refinery using cogeneration. Westinghouse Electric Co. builds first U.S. gas turbine powerplant with intercooling and regeneration. Rolls-Royce DART turbo-propeller engine in VISCOUNT; first commercial flight. Dehavilland GHOST jet engine in COMET; first flight for commercial jet propulsion. General Motors GT-302 engine, 370 hp, powered Firebird I, the first U.S. gas turbine automobile: G. M. Allison engines GT 304-305, with first rotary regenerators. Ford operated a 300 hp vehicle gas turbine, and Chrysler developed its 140 hp model CR-2A engine. First gas turbine powered hovercraft over the English Channel. First highway use of a gas turbine powered Greyhound bus, and gas turbine ‘powered tractor-trailer, using the Allison GT 404-4 regenerative 300 hp engine, sponsored by U.S. Department of Energy. Tablet) History of gas turbine development "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894 14¥ la GL ay) YT gly pale 3 3-What are the main types of internal combustion engine? Most popular internal combustion engines: 1-Reiprocating engines There are two ways in which reciprocating engines classified which are: a-spark ignition engines (that burn kerosene) b-compression ignition engines (that burn diesel) other way of reciprocating engines classification is: a-Two stroke engines gs NOUETION Fig. 2 COMPRESSION Fig. 2 EXPANSION OR rowen fig 4 ExnausT igure(5) 4-stroke Reciprocating Engine 15 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894ae ie Sa {2 we Bay ey be pom ue PALA ob oer ey yen Ae AS 80H PR a os sas Se Figure(6) 2-Stroke Reciprocating En, b- Four stroke engines stroke Reciprocatins igure 2-Rotary Pistons Engine(Wankel Engine} In wankel engine, the piston has triangular shape & it produce rotating motion rather than reciprocal motion as in reciprocating engines. Main advantages of Wankel engine are its extremely lower weight compare to its power output & its low noise & vibration level. Its main disadvantages is higher fuel consumption & higher pollution level compare to reciprocating engines 16 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894ope Figure(§) Wankel Engine + Typically, it is more difficult (but not impossible) to make a rotary engine meet U.S. emissions regulations. + The manufacturing costs can be higher, mostly because the number of these engines produced is not as high as the number of piston engines. + They typically consume more fuel than a piston engine because the thermodynamic efficiency of the engine is reduced by the long combustion-chamber shape and low compression ratio. 3-Gas turbines 17 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894Layer 4 Lal Gig gh WG Sg 4-How can gas turbine is classified? Gas turbines can be classified as: a- Gas turbine that produce mechanical power to drive a load (land base). b- Gas turhine that produces thrust (propulsion) which is used to move an air planes c- Open cycle or closed cycle or combined cycle. Shp a asl) A fla Ss id Gad SS 5-How can aircraft gas turbine is classified? Dimmer | Comrewar | Bumeracton Tut Nose Figure (9) Turbojet Engine ‘Most common gas turbines that used in turbojet aero plane are: 1-Turbojet Engin The original concept, the turbojet, is the simplest form of gas turbine and relies on the high velocity hot gas exhaust to provide the thrust, Its disadvantages today are its relatively high noise levels and fuel consumption. turbine compressor air intake — combustion chamber Figure (10) Turbojet Engine 18, "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++96564928942-Turbofan Engine: ‘A turbo fan engine is based on the principal that for the same power, a larger volume of slower moving air will produce more thrust than a small volume of fast moving air. Turbofan engine is the most widely used in aircraft propulsion, ‘There are two main types of Turbofan engines: First type: Low bypass turbofan Engines. Hohpressae Ha pressue Hohoressue — Hghoressire Fan composer tine Fn compressor oie Lowpressure _Combutton Nore owes Comtuston Lowressue Nozze campeon” chante congress chamber tine Figure(11) Low bypass turbofan Engine Figure(12) High-bypass turbofan engine a-In the turbofan or ‘bypass’ engine the partly compressed airflow is divided, some into a central part - the gas generator or core - and some into a surrounding casing - the bypass duct. b-The gas generator acts like a turbojet whilst the larger mass of bypass air is accelerated relatively slowly down the duct to provide ‘cold stream’ thrust. The cold and hot streams mix to give better propulsive efficiency. lower noise levels, and improved fuel consumption, Second type: High-bypass turbofan engines. a-In the high bypass ratio turbofan, as much as seven or eight times through b-A low bypass ratio turbofan, where the air is divided approximately equally between the gas generator and the much air bypasses the core as passes It achieves around 75% of thrust from the bypass air and is ideal for subsonic transport aircraft. bypass duct, is well suited to high-speed mi 3-Turboprop Engine: As its name implies, a turboprop uses a propeller to transmit the power it produces. The propeller is driven ary usage. through # reduction gear by a shaft from a power turbine, using the gas energy which would provide the thrust in a turbojet. Turboprop engines are generally used on small or slow subsonic aircraft. 19 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Figure(13) Turboprop Engine TURBOPROP and TURBOJET: same concept GAS TURBINE > / > al / ¥ if > > i> > > TuBoPROP TURBOFAN Le Figure(14) Turboprop & Turbofan Engines comparison 4- Ramjet Engine: Inlet Fuel injection Nozzle 0) (M=1) Compression Combustion Exhaust (M1) % Figure(15) Ramjet Engine 20 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894A ramjet, is a type of jet engine. It contains no (major) moving parts and can be particularly useful in applications requiring a small and simple engine for high speed use: such as missiles. Ina ramjet, due to the high flight speed, the ram compression of air is sufficient to provide the compressed air need for thrust. 4- Scramjet Engine: A scramjet (supersonic combustion ramjet) is a variation of a ramjet where the flow of the air and combustion of the fuel air mixture through the engine happen at supersonic speeds, This allows the scramjet to achieve greater speeds than a conventional ramjet which slows the incoming air to subsonic speeds before entering the combustion chamber. Inlet body Fuel injection Nozzle Supersonic Combustion ‘Supersonic Compression Exhaust Figure(16) Scramjet Engine 5-Pulse jet engine: A pulse jet engine is an engine where its combustion occurs in pulses and the propulsive effort is a jet. A typical pulsejet comprises an air intake fitted with a one-way valve, a combustion chamber, and an exhaust pipe. = ° 4 L =—— Figure(17) Pulse jet schematic. First part of the cycle: air intake (1), mixed with fuel (2). Second part: the valve (3) is closed and the ignited fuel-air mix (4) propels the craft. n Eng, Abdullah Zaman Al merza 2 "Gas Turbines design & Operation" (10/2007 Mobile: ++96564928940 05 10 15 20 25 30 Mach number My Fig (18) Mach number for various aircraft engines a eS SIS ANALY CY La A Jal) Cy A Gas GS -G 6-How can land base gas turbines classified? a-Open cycle gas turbines: 1-Single shaft gas turbine It's the simplest form of land base gas turbines where compressor & turbine are connected via the e shaft yet they have the same speed of rotation, Figure(19) Land Base - G.E. Gas turbine 2 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++96564928942-Twin spool gas turbine More complex configuration of gas turbine, in this engine there are two concentric shafts the first shaft is low pressure shaft & the other is high pressure shaft & both shafts are rotating with different speeds, the main advantages of this configuration is that the star up torque required to turn the machine is minimized compare to single shaft with the same load since only high pressure shaft needed to be turned, also compressor surge is minimized in this configuration, also its is shorter smaller & lighter than single shaft engine & has less number of blow off lines ,the main disadvantage of this configuration is additional complexity to the design & added cost. 23 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804b-Gas generator & power tu In this configuration, the gas turbine is used as GAS GENERATOR, the gas turbine provide stream of hot gases which tums the power turbine on the left & the power turbine tums the load. Enea ale Fut FUEL CONTROL eLecraowe unit To 2=-F) “contrat ic iie | cepteation parveo ur Pot Compressor ‘voter WP Tobine LP Taine os gematr Power ubine Eigure(21) Gas generator with power turbine configuration ¢-Combined cycle gas turbine 1. Single shaft combined eycle (Steam & gas turbines are on the same shaft via synchro self shifting clutch. Figure(22) Single shaft combined cycle 24 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++96564928942-Two shafi combined cycle Condensor Electric exchanger generators Figure(23) Two shaft combined cycle d-Closed cycle gas turbines: Closed cycle gas turbines are not so common like open cycles, on these engines the working fluid that is exit from turbine is goes through heat rejection process & recycled a gain as input for compressor, examples of working fluid used in this cycles are hydrogen, helium. tote \n@ Eat} le ® | —— c A T Output CREO) ® oe conpronar | wm o ol er |, H ® iano Fig (24) Closed gas turbine cycle $e! GVA, EIS YA Ge Bay ale 7 7-What is the difference between Internal & external combustion engine? 25 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804eg awe External Combustion Engine (eal GLY al Internal Combustion Engine Heat addition take place outside the engine ‘Heat addition take place inside the engine 2 | Ability to burn any fuel Liquid or gaseous fuel are required 3 | Complete combustion is insured ‘Cannot utilize all of fuel energy 4 _ | Less pollution since complete combustion ‘More pollution since incomplete combustion 5 | Mostly closed eyele (better to fix & control | Mostly open eycle the properties of the working fluid) 6 Lower heat rate ( more efficient) Higher heat rate (less efficient) ea 4ie 8-What is the difference between gas turbines & steam turbines? oi Se ll Go Fadl aay ale 8 Figure(25) Installation cost of ‘gas turbine, steam turbine & combined cycle stations Figure(26) Requirements for water in various power station "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894 26Sas ‘Steam Turbines way Gas Turbines: T_| External combustion engine Tntemal combustion engine More complex & required more auxiliaries ‘Simple & has much less auxiliaries ‘Start up time is long. ‘Startup time is much Tess Higher efficiency (less heat rate) Lower elficiency (larger heat rate) Inslallation costs very expensive Tnstallation cost is cheap in comparison Required large arca (more civil work) ‘Can be build any where & less civil work Cannot be portable Portable gas turbine is available Strongly depen! on water (cannot build far away from large water source) ‘Some configurations does not use water atall | Weather condition has small effect on unit performance (condenser vacuum in winter) ‘Strongly affected by weather condition TO | Required long time for installation ‘Shovter installation time TT | Lower noise level Tligher noise level 12 | Steam turbines are not as flexible as gas turbines {additional cycles cannot be added), ‘More flexible & has different configurations 13 | Long life if good maintenance is applied ‘Shorter life 14 | Much larger capacity per unit up to 1800 MW single unit ‘Smaller in capacity up t 340 MW open cycle 15 | Lower operating cost since lower heat rate Higher operating cost since higher heat rate 16 | Lower operating temperature Higher operating temperature 17 | Can utilize any fuel ‘Mosily depend on natural gas or diesel TS | Load changing is slow in comparison Load changing is very fast Tera afene Figure(27)Compare the efficiency of various cycles Spa) GRY OY! ple LEY) Gal 9 9-What are the examples of external combustion engines? "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Most famous example of external combustion engine is: steam turbine 2-Stirling engine SAS ll ASA, Ay FLAN) Cy ol ay A fll aa gL 10 10-What is the difference between gas turbines & reciprocating engines? Taw oe TaN Sia Reciprocating engines Gas Turbines 1 | Larger size & wei ‘Much smaller in size & weight 2 Higher efficiency for medium range Lower efficiency in medium range but higher Only (1-10 MW) efficiency for range of power >10 MW 3 | The engine put in operation very fast ‘Siartup time is longer 4 | Notaffecied by weather condition Extremely affected by weather condition 3 __| Cheap in comparison Very expensive 6 | Required reinforced foundation to counter | Lower vibration energy because of its direct unbalance force produced from reciprocating | rotary motion motion 7 | Produce higher vibration level & noise ‘More smooth (lower vibration level & noise) 8 | Practical for low speed - high torque preferred for high speed - low torque applications (cannot used in high speed) applications 9 | Lower fuel consumption Higher fuel consumption 10__| Useful in application which need higher Useful in application which need lower power power to heat ratio to heat ratio 11 | Supplied fuel pressure is lower ‘Supplied fuel pressure is higher 12 | Ability to burn even heavy fuels Gas turbines firing heavy fuels is uncommon 13 _| Fuel consumption is proportional to the power | Consume more fuel when they are idling output (compressor work) 14 | Can be operated with variable load but with | Better fuel consumption in a constant load good fuel consumption rather than a fluctuating load 15 | Required higher maintenance cost Required lower maintenance cost (more moving parts) 16 | Limited power output (up to 15 MW) Much higher power output (up to 258 MW as land base) "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804 28Seal GSAT Bia Shs Reciprocating engines Gas Turbines 17 | Engine exhaust temperature is relatively low | Higher turbine exhaust temperature can be & hence additional firing is required to utilizes to produce higher quality steam produce higher quality steam 18 | In reciprocating engine, all 4-processes Each process has a separate section (intake-compression-power-exhaust) are ‘occur in one section (the piston) 19 | Igniters are needed at all time of operation __| Igniter used only one time during speed up Eficney (LAV), % wer Output, MW Fig(28-a) Compare between internal combustion engines SS Sea ABUEN CUBY Aardtocall Ay LN) Shins 5 gl a5 Gl 11 11-Where are land base gas turbines used? Gas turbine is used as prime mover in powers stations, marine propulsion, Helicopters & Tanks. *-Gas turbines are used for electric power generation in several different ways: L-used during peak load time 2- Provide stand-by power 3-to provide a power source for black starts 4-to act as base load generating units (Recently only due to the improvement on their design which result in higher efficiency & also when they are used in combined cycles). 29 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894Soh Ladd bA FLAD Sali ll a Y LD 1. 12-Why gas turbine doesn't used as car engine? Gas turbine is not used in ears because: 1 They are very expensive. 2-The gas turbine consume a lot of fuel if idling because of added compressor work. 3-Gas turbine are not suitable for variable load application, if the gas turbine is running with 60% of its load, it consume around 80% of fuel that used in full load, 4-Start up time for gas turbine is larger that start up time of reciprocating engines. faa fil AR Gs a al py a CA, gl LT 73 13-Why gas turbines are more expensive than reciprocating engines? 1- Gas turbine are manufactured by forming process which is much expensive than machining. 2-Gas turbines are subjected to very high temperature, so they are made from nickel & cobalt alloy which are much expensive than steel Solel oa a pe A Ge FAN Sly 9g Ge kes Gale Gadd Ga ag GIR gas YI $ (GAS! Jala GI a 5 y)ya) Adal 14-Why reciprocating engines are not made from the same materials that gas turbine is made although they are suffer from very high temperature just like gas turbines a-Because the way that the reciprocating engine operates provide better cooling, when fuel air mixture is enter the hot pistons afer the exhaust stroke, they will cool down the piston since they have much lower temperature than the piston & engine block although combustion process is complete & all air drawn into the piston is completely utilized (yet highest temperature form fuel is achieved). b-Also, the piston & engine block are subjected to heat at small intervals (pulse heating) due to engine excursive strokes (Intake Compression .Power ,Exhaust),Furthermore, reciprocating engines are cooled by air . water & lubricated by oil (relatively cold) which improve overall cooling process & make the average temperature of the engine around 440°C. While in gas turbines ,the turbine are subjected to very high temperature through entire period of operation & cooling techniques use to cool down turbine blades are 30 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804depend on air only since water cooled blades design are much expensive & additional cost must be considered (convection heat transfer coefficient for liquids much larger than it for gases) PA jal Aig sl) Gee gle 1 YN Gall ys GS-15 15-How could weather conditions affect gas turbines? Ideal gas equation of state: P=p*R*T P is temperature in ( Kelvin =°C +273 ) ; R=Gas constant (KJ/KgK) ; is pressure in (KPa) ; T= p=Gas density(Kg/m') Gas turbine is open cycle, it uses the ambient air as a working fluid, but it strongly affected by ambient conditions which are: 1-Ambinet temperature: *-Ambient temperature is representing compressor inlet temperature for the gas turbine, if the temperature drops, the air density will increase & hence heaver air will be compressed by the compressor which will increase mass flow rate, note that compressor work requirements will increase also. *-As heavy compressed air enter turbine section, it will create extra expansion & more work from turbine will produced, now to put general statement we can say: As compre Wr inlet temperature drop, air density increase, turbine output power will inerease but compressor work will increase, also fuel mass flow to the turbine will increase to handle the increase in air mass flow & extra turbine work. heat rate output Fig@8) Effect of ambient temperature on gas turbine performance 31 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++96564928042-Ambient pressure: As ambient pressure increase, air density will inerease & the same result in the above point will follows. 3-Relative humidity. Most people who haven't studied physics or chemistry find it hard to believe that humid air is lighter, or I dense, than dry air, how can the air become lighter if we add water vapor to it? *-To see why humid air is less dense than dry air, we need to tum to one of the laws of nature the Italian physicist Amadeo Avogadro discovered in the early 1800s. He found that a fixed volume of gas, say one cubie meter, at the same temperature and pressure, would always have the same number of molecules no matter what gas is in the container. *magine a cubic meter of perfectly dry air. It contains about 78% nitrogen molecules, which each have a molecular weight of 28 (2 atoms with atomic weight 14), Another 21% of the air is oxygen, with each molecule having a molecular weight of 32 (2 atoms with atomic weight 16). The final one percent is a mixture of other gases, which we would not worry about, *Molecules are free to move in and out of our cubic meter of air, What Avogadro discovered leads us to conclude that if we added water vapor molecules to our cubic meter of air, some of the nitrogen and oxygen molecules would leave Remember that the total number of molecules in our cubie meter of air stays the same. +The water molecules, which replace nitrogen or oxygen, have a molecular weight of 18.(One oxygen atom ith atomic weight of 16, and two hydrogen atoms each with atomic weight of 1). This is lighter than both nitrogen and oxygen. In other words, replacing nitrogen and oxygen with water vapor decreases the weight of the air in the cubic meter; that is, it’s density decreases. * You might say, "I know water's heavier than air.” True, liquid water is heavier, or denser, than air. But, the water that makes the air humid isn't Liquid. It’s water vapor, which isa gas that is lighter than nitrogen or oxygen. 4-air density: +-As air density increases, compressor mass flow will increases & same concept in the first point will follows. *-The air's density depends on its temperature, its pressure and how much water vapor is in the air. 32 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804*-More dense, or "heavier" air will slow down objects moving through it more because the object has to, in effect, move aside more or heavier molecules Such air resistance is called "drag," which increases with air density. * Cool, dense air slows a race car because drag force increases, but some race cars gain from dense air, Cars designed from the wheels up for racing are really like upside down airplane wings that the air pushes down on the track, increasing their grip going around curves. Denser air pushes them down harder. Effect of air density on Aircraft engines: *- Lower air density effect aircraft engine in three ways: The lifting force on an airplane's wings or helicopter's rotor decreases(I), the power produced by the engine decreases(2), and the thrust of a propeller, rotor or jet engine decreases(3).These performance losses more than offset of reduced drag on the aircraft in less dense air. *- Pilots use charts or calculators to find out how temperature and air pressure at a particular time and place will affect the air’s density and therefore aircraft performance. In general, these calculations don't take humidity into account since its affects are so much less than the others. *.When the airs density is low, airplanes need longer runways to take off and land and they don‘ climb as quickly as when the air's density is high. 5-Elevation: Each 100 meter increase in altitude, 1% of gas turbine power will drop since as elevation increase, air density drops. Ay gS ABUL CUB Aaa call Ay HAN Rig gy Gh pall Maal Ay aN i 9 ll Gye SUDERY) gal ale -16 16-What is the main deference between land base gas turbines & gas turbine used in aircrafts? Refer to the table in the next pages. 33 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804lea he A as GT for Aireraft ha Cw GT for power generation Must have aerodynamic shape to reduce drag, Can have any shape 7 2 (0 aii mn (to avoid blockage) Ail ion is required 3 _| Use only can type combustion chamber Flexible for any type 4 | Must be designed to withstand high vibration | Casing & frame are will fixed to the ground level 5 Weight & size is very important in design Weight & size is not important © | Cannot bum any fuel (liquid fuel only) Can bum natural gas or fuel ofl 7 | Turbine is designed to handle fan & Turbine is design to handle Compressor work compressor work only where part of energy is | & extra mechanical power to the load(shaft accelerated in nozzle to provide thrust power, electric power) ¥_| The aim is to produce thrust The aim is to produce mechanical power 9 | Turbine & compressor size is much smaller | Turbine & compressor size is larger 10 | cycle modification cannot be added (weight) ‘Any cycle modification can be added "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804 34Rolls Royce Gas turbine used in jet aircraft "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804GAS TURBINE AIR INTAKE SYSTEM 4g Lal) Aan) gill cl pgll Sb ales M6001B-G.E. "Gas Turbines design & Operation”: Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804$A FM ii 5 gD ol yell SAL 17-Explain air intake filter house in detail: Air Intake system in gas turbines: Gas turbines consume large mass of air (a 125 MW machine has compressor inlet flow of 438 kilograms of air per second for 50°C ambient temperature), thus careful design of the intake system is needed to ensure that frictional losses are a minimum, and that the noise of the air entering the machine is kept to an acceptable limit. Figure (30) Air intake filter house from inside showing air filter elements before & after installation & the hole behind each filter is for filtered air exit) 37 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804intake main parts: a: Air intake filter house Filler house normally designed to have large shape so to make sure that the pressure drop across it will minimized (each 10 mbar pressure drop will reduce turbine power by 1%), it contains air filters, air entrance guide vanes & the implosion doors. jer element Air entering compressor must be filtered from any dust or residues that may enter & cause fouling to the which reduce compressor blades efficiency, the use of series of filters in stead of one big fi (er is more practical because design & erection complexity are reduced, also if pressure drop in air intake increases, a set of small filters can easily be removed in stead of removing the hall big filter. Fig2) Compressed air lines for filters purging & pulse air outlet can be seen Pulse air header pressure is 7.5 bar & each pulse has a pressure of 3 bar "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804¢- Air intake silencer, Due to the high speed of air entering air intake filter house, a large noise level will produced & silencer must be used to reduce noise level. The silencer contain sound absorbent baffles & these baffles are covered with perforated sheets & filled with high quality heat & moisture resistance mineral wool, this mineral wool is covered by a glass fiber which gives an additional mechanical protection for the absorbent material d- Filter element purging system ‘As air passes through filter elements for a long period, the filters become dirty & thus the pressure drop across them will inere: - to overcome rapid incre: se in pressure drop either filter elements is replaced with new elements or air filter must be purged. The filter purging system is compressed air that provided from separate air compressor, if the pressure drop across any one of the filters raw increase to more than normal limit, this compressor will start to provide compressed air for cleaning these filters. *-The compressed air will released via small holes on the air lines located behind each filter .there are solenoid valves that operate with respect to each raw of filters to release that compressed air. *-Compressed air releasing process will done by pulsing .so some time filters cleaning system may named as pulse air system complete purging process may take 84 pulses (30 minutes duration ) & the cleaning process will start from top of the air intake to the bottom so that we avoid dust to sucked again by upper filter raw. Activation of ir system (Example from. ENS V94.2 Gas Turbine Pulse air system aim is to clean the dirty filters & to do so there are two ways to activate this system which are: a- high pressure drop across filters raw signal b- High ambient air relative humidity signal (humidity > 80% signal) a- high pressure drop across filters raw signal During gas turbine on load, the control system will monitor air intake filter house pressure drop via two pressure sensors: 39 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804First sensor is to measure air pressure before & after filters raw (this sensor activates pulse air system). Second sensor is to measure air pressure drop across air intake filter house (this sensor not activates pulse air system & itis associated with gas turbine protection only), AIR INTAKE FILTER HOUSE Figure (33) Schematic diagram of pulse air system If the second sensor indicate very high pressure drop, a gas turbine trip will initiated by the following steps: 1-As air intake pressure drop increases, the air pressure after silencer decreases, this will create a local vacuum area, 2-Due to the vacuum inside air intake filter house, the implosion doors (4 to 6 doors) will be sucked in 3-There are limit switch on each door so for any door reach full open position, this mean that the limit switch will send open signal which will initiate gas turbine trip to protect gas turbine from operating with air intake filter house is blocked. Implosion doors are designed to make sure that the pressure inside air filter house is equalized to the atmospheric pressure to avoid air intake damage. ated only due to press * If the gas turbine on load, normally pulse air system will a 40 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Pulse Air Figure (34) Pressure sensors used in air intake filter house b- High ambient air relative humidity signal (humidity > 80% signal) *There humi intake filter house entrance to measure ambient humi humidity is raise YY sensor on Ys to 80%, a signal will go to activate pulse air system, and complete purging process may take 168 pulses (1 hour uration), thi is to insure dry filter & avoid condensation which may block the filters during gas turbine operation. "Normally pulse air s stem activated by humidity sensor only when the unit is off load, pressure drop sensor will not sense any pressure drop because air is not entering inside filter house at high speed (no pressure difference). 41 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804GAS TURBINE -~AIR COMPRESSOR dy all iy sill Le Le "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Yatisls 5 gale y LéLiall se -18 18-What is the main purpose of a compressor? The compressor is located at the front behind the air intake. It consists of a spinning fan with a number of fixed blades arranged in several rows. Air is drawn into the engine from its surroundings by using compressor fans. These fans are driven from the turbine by a shaft, This air is heated by being compressed and is led into one of several combustion chambers, The Compressor can reach typical pressures up to 40 times higher than atmospheric pressure. Aig oN MS ay GL SRY God (ol) JS lal cl yell Laie cl SL -19 19-Why do we need to compress air before it is enter to the combustion chamber? Gas turbine efficiency will increase whenever pressure ratio increases. Refer to Fig (29) 0.7 0.6 5 4 Typical pressure Ks ratios for gas- oS turbine engines op 5 10 15 20 25 Pressure ratio. r,, Kigure (35) Pressure ratio versus gas turbine efficiency JAN ly ysl Ba el gel Bel pe elgl a 4-20 20-What are the main types of compressors which are used in gas turbine engines? In general compressors are classified in two main groups: 1-Positive displacement compressors (in which air pressure is increased by reducing its volume) 4B "Gas Turbines design & Operation"-Eng, Abdullah Zaman Al merza_ 212-Dynamic compressors (in which air pressure is increased by increasing its speed) ‘The following table summarizes compressors classification. yee Pres eg ive Displacement Og Vie Ligdt Rng Se Lobe Sighs Doub hee Pst Lityrach Dighnan kame Atee Figure (36) Compressors Classification *Most common compressors used in gas turbine are: 1- Centrifugal Compressor. 2. Axial Compressor. Note that both of them are of dynamic type. Ay SMa lias 5 NN (8 yoo a Lab | pecall as YL -21 21-Why reciprocating compressors are not used in gas turbine engines? Reciprocating compressors are not used in gas turbine due to: a- They have higher vibration level due to pulsation (coming from changing rotary motion reciprocal motion to rotary motion, b- They produce very high pressure c- As gas turbine size increase, the size of reciprocating compressor must be increased & due to its heavy parts it require larger power. d- They provide small air flow compare to centrifugal or axial compressors. ¢- They have a lot of moving parts (pistons, connecting arms, crank shaft, and intake & discharge valves). £- Relatively inefficient (20% - 45%). "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804g- High power consumption, h- High maintenance requirement since more moving parts are involved compared to other types of compressors. 1 -Good for service air application. ELLVERY OF | ro lschance [| conrnession Figure 37) Reciprocating Compressor ‘Centrifugal Compressor -g 8 4l) ahi! 43 be Wall ale 22 22-What are the operating principals of Centrifugal Compressor? Figure (38) Centrifugal Compressor "Gas Turbines design & Operation” Eng, Abdullah Zaman Al merza 20/102007 Mobile: ++9656492894 45Centrifugal Compressor is a dynamic compressor, it increases air pressure by accelerate it, the air enter centrifugal compressor at the center of compressor impellers & thrown out by centrifugal force to compressor discharge which is located at compressor casing arc (Direction of air flow discharge is perpendicular to the axis of rotation), Acceleration of the air is obtained through the action of one or more rotating impellers; the discharge air is free from pulsation, Figure (41) Multistage Centrifugal Compressor fAxial compressor geal be tall yal -23 23-What are the operating principals of axial compressor? All modern high output gas turbines use axial flow compressors, the principles of operation are shown in 46 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Figure (43). The air enters at the left and is speeded up by a set of revolving blades. The air leaves the first set of revolving blades and enters a set of stationary blades, where the air is slowed down and its kinetic energy converted to pressure energy. This process is repeated by a lot of stages depend on the desired output pressure. (The direction of flow is parallel to the direction of the rotation). Figure (42) Axial Compressor, the lower picture showing axial compressor of SEMENS -V94.2 gas turbine & the first six stages are coated with Aluminum Pigment —) ii 47 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804ROTOR GLADE STATOR BLADE Figure (43) Axial Compressor pressure & speed curves Refer to Fig (43): a- Moving blades accelerate air. b- Fixed blades slow down air & hence change kinetic energy of air into pressure energy. c- Discharge velocity should equal suction velocity. *-The design of compressor blades are different than turhine blades, compressor blades divergent profile which works as diffuser to increase air pressure, while turbine blades have convergent profile which is works as nozzle since turbine is reducing air pressure by changing its pressure energy into kinetic energy. Refer to Fig (44) Tubing ea ie Compressor blades Figure (44) Turbine & Compressor blades profile 48 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804*.Note that compressor blades are suffer from high stress but with lower temperature while combu: chamber suffer from high temperature but with relatively lower stress *1n axial compressor, design of moving blades are significance to provide aerodynamic shape with minimum losses, also blade tip clearance must be as minimum as possible to improve moving blade efficiency &avoid s, blade tip leakage. Normally compressor moving blades have blade clearance of 7 mm to minimize blade tip losses. *-During humid weather, high humidity may occur only on the first sex stages of compressor because air is heated so rapidly & condensate may occur. To overcome pitting damage to compressor blades, the first six stages are coated with Aluminum pigment. *-Air enter compressor may contain dust or dirt (even if its passes through air intake system) & such dust or contaminations will stick into compressor blades which will affect compressor performance because: a- It will reduce compressor stage efficiency since accumulation of dirt on the moving blade will cause change in discharge angle of blade by 7° which will result in changing output velocity direction to the next stage & hence reduce blade efficiency. b- Dirt or dust when stick on compressor blades will form a hot spots, recall that compressor blades will be heated during compressor operation due to friction coming from high rotation, Dirt or dust will generate high temperature spots on the blade because they have different thermal conductivity than steel,(compressor blades are made from steel),so these hot spots will produce thermal stresses on the blade which will result on blade failure if the dirt is not removed or washed c- Compressor blades fouling may produce turbulence to the flow; produce vibration & increase discharge temperature which will result in reduce blade efficieney. *-Most of gas turbine compressors have compressor washing unit in which compressor blades are washed with a mixture of demineralized water & special agent to remove any dirt or dust on compressor blades, washing process can be performed either when the gas turbine is running(on-line washing) or when gas turbine is stand by (off- line washing), 49 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Figure (45) Compressor blade fouling ehelall Jat She gals 24 24-What is compressor washing process? +The aim of compressor cleaning process is to remove deposits from blades that have caused a decline in output and efficiency of Gas Turbines. *-Pollution of the ambient air cannot he completely removed by the air intake filter system +-compressor washing are mainly two types online & off line washing. *-Compressor washing is carried out by using detergent solution and demineralized water for the final flushing Both fluids are sprayed onto the compressor blades through two types of nozzles: a- Jett nozzles which are consisting of two jet nozzles which inject water at high speed Jet nozzles are used for off load washing only since them inject high speed water jet which will be harmful to the blades of compressor which are rotating at synchronizing speed-3000 rpm. The effect of one droplet of water will become like a bullet b- Spray nozzles which are uniformly spaced around the circumference of compressor inlet, upstream of the variable compressor inlet guide vanes, each producing a gentle jet of water. *-Compressor cleaning skid is consisting from a tank & pumping unit, a centrifugal pump draws the cleaning solution and demineralized water from portable tank and feeds it through a hose to the jet or spray nozzles. The cleaning solution / demineralized water are delivered at a pressure of about 10 bars. Isolation valves are used to change over from the jet nozzles to the spray nozzles and vice versa. Refer to Fig(48). 50 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804Figure (47) Compressor Washing Skid fel Jul Leadiaall g 89) Gobi als 25 25-What are the alternative methods used for compressor cleaning? +Alternative methods for compressor cleaning include: a- Dissemble the compressor partially to clean the blades of the rotor, this method gives excellent result but it required long time outage. +b- Injection of crushed walnut shells, Injection of rice & Injection of concentrated carbon. The second method should not be used in modern gas turbines because: a- Fire hazard, 31 "Gas Turbines design & Operation" Eng, Abdullah Zaman Al merza 20/10/2007 Mobile: ++9656492804b- Oil system contamination & blockage. c+ Result in blade cooling system fouling. d- Barly hot component failure oon Tey car [ORs tig pt 00 90 rm) Cv cin waeing (GT opecsing on a) Gocerve proveriptons fT Manuals ess:sn eS oe ee aoa 1 Flatron Ja nozzae: hppiy onl for hard dopoet at comprossor blades Open tee mami Run'ontuming gear spo