CIPS PRACTICAL

REPORT

JACOB CHETHIPUZHA VARGHESE

S321237
S321237 JACOB CHETHIPUZHA VARGHESE

Contents
A brief on channel island power station ................................................................................................. 1
Different number of compressor and turbine stages. ............................................................................ 2
General working of a gas turbine........................................................................................................ 2
Velocity and pressure variations in a compressor section ..................................................................... 4
Type of combustors ................................................................................................................................ 5
Annular type combustor ..................................................................................................................... 5
Other combustor types ....................................................................................................................... 6
Can type combustor ............................................................................................................................ 6
Can annular type ................................................................................................................................. 6
Flame stabilization in gas turbine engines .............................................................................................. 7
Thermal efficiency variation and turbine blade degradation ................................................................. 8
Selection of blade material ................................................................................................................. 8
Efficiency improvements made at CIPS .................................................................................................. 9
Lubrication system ................................................................................................................................ 10
Cooling air flow system ......................................................................................................................... 10
Bearing supports ................................................................................................................................... 10
References ............................................................................................................................................ 11
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S321237 JACOB CHETHIPUZHA VARGHESE

A brief on channel island power station

Being the largest power station in the Northern territory, channel island power station (CIPS) is the
main source of electricity in the Darwin -Katherine region. Power station mainly runs on natural gas
with diesel as a backup. CIPS is equipped with 9 power deriving gas turbine units. 5of the gas
turbines are GE frame 6B gas turbines (MS6001B), also there is an aeroderivative GE LM6000 engine.
CIPS also uses waste heat recovery methodology by directing the waste heat energy from 4th and 5th
units of frame 6B gas turbines to a steam turbine. Apart from these7 power delivering units in the
CIPS, two additional Rolls- Royce Trent 60 gas turbines were added in the in the year 2011, which
increased the capacity of CIPS BY 25%. In addition, there is a diesel reciprocating engine at CIPS.

Fig 1: channel island power station (Territorygeneration.com.au. (2019).

Different number of compressor and turbine stages.

Usually in gas turbines a greater number of compressor stages are present than the turbine stage. At
channel island power station MS6001B and LM6000 gas turbines are present. In an MS60001B gas
turbine there are 17 stages in a compressor and 3 stages in a turbine. Compressor of LM6000 has 19
compressor stages with 8 turbine stages.

General working of a gas turbine

This variation trend in compressor and turbine stages discussed above are followed in every gas
turbine. Compressor forms the first unit in a gas turbine. Even though a centrifugal compressor could
increase the pressure ratio to a greater extent than that of an axial compressor, the latter is chosen.
This is because multistage can be easily be produced in an axial compressor without any extra
components or aircraft drag.

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Axial compressor is composed of rotating disks known as rotors followed by stationary disks known
as stators. Compressor rotates from the work output produced by the turbine blades. As the air is
drawn in, it initially flows through rotating blades, where its total energy is increased by adding
swirls to the flow. Total energy is a combination of pressure, velocity and temperature energies.
Hence there is an increase in each of these parameters. In the second phase air flows through
stationary blades wherein its kinetic energy is converted into internal energy which is associated
with an increase static pressure.

This increase in pressure is made possible through diverging flow area between the stationary
blades. Pressure increase in the second phase is more compared to the initial phase. This cycle
continues accordingly to the no of stages in a compressor, where each stage involves one set of
rotors and stators.

Compressor stage is followed by combustion and later the turbine stage. Turbines are also
composed of stator blades and rotor blades. In turbines high temperature, high velocity exhaust gas
flows initially through stators followed by rotors. Aerodynamic shape of stators is such that flow area
between the blades are decreased at the end, hence increasing the velocity and decreasing the
pressure. There after this gas flows through the rotors, rotor blades are shaped in such a way to
produce lift. Kinetic energy of the fluid is converted into rotational mechanical energy of the turbine
blades. In the rotor stage pressure and velocity is decreased considerably.

Fig 2: cross section of MS6001B showing different compressor and turbine stages (Ge.com. (2019)

In short, gases move through high pressure zones in a compressor and low-pressure zones in a
turbine. If we decrease the no of stages in a compressor like that of turbine there will be too much
pressure increase per stage accompanied by velocity increase. This may result in boundary layer
separation of gases from the blades and result in stalling. This problem could be solved by providing
more stages to the compressor and thereby allowing a gradual increase in the pressure. On the
other hand, exhaust gas flow through turbine blades are associated with lower pressure zones.
There is no flow separation or loss of energy associated with sudden pressure reduction, and hence
turbine could work efficiently with lower number of stages.

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S321237 JACOB CHETHIPUZHA VARGHESE

Velocity and pressure variations in a compressor section

Gas turbine uses axial compressors for its purpose. Even though centrifugal compressor is a best
option when compared to axial compressor in terms of compression ratio, latter is opted for its
higher efficiency and flowrates. Centrifugal compressors will also require additional components to
redirect the radial flow back to axial, which may result in pressure losses.

In an axial compressor more no of stages are required when compared to a centrifugal compressor
due to its low pressure rise per stage. Axial compressors include multiple stages, with a set of rotor
blade and stator blade. rotor blades are rotating blades that are attached to the shaft driven by the
turbine while stator blades are stationary and are attached to the casing.

In turbines for e g LM6000 there are high pressure as well as low pressure compressors. High
pressure compressors are driven by the corresponding high-pressure turbines while low pressure
compressors are driven by low pressure turbine blades. High pressure compressors work at higher
pressure conditions and vice versa for low pressure compressors

In a compressor, rotors are followed by stators. When the inlet air drawn by the rotation of
compressor blades enter the rotor, the total energy associate with the fluid increases. These rotating
blades adds swirls to the air drawn in and increases its kinetic energy. Along with the pressure
increase there is a slight pressure increase due to the divergence of the blade flow paths. So
generally, in a rotor stage there is an increase in velocity as well as pressure. Then after the fluid
reaches the stationary blades, its kinetic energy is converted into internal energy by a static pressure
rise. Therefore, there is a velocity reduction associated with the pressure rise in the stator stage.
Increase in flow areas of the stator blades is the reason behind this pressure rise.

Fig 3 pressure and velocity variations in an axial compressor Web.mit.edu. (2019).

In short, even though there is a pressure increase in both rotor and stator stages of a compressor,
velocity increases only in rotor stage. In a stator velocity is decreased as the stationary blades
decreases the swirls from the flow.

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Type of combustors
Annular type combustor
LM6000 gas turbine uses an annular type combustion chamber. These type of combustion chambers
are commonly used in engines with axial compressors and low air flow rate requirements. This
combustor is simple in design with lower pressure losses. It involves a single chamber with
concentric cylinders mounted coaxially about the engine axis. The outside diameter of the
compressor is similar to the combustor inlet, hence providing a streamlined design. These
combustors are composed of continuous shrouds through which the fuel enters, and the secondary
air enters through the holes provided. Secondary air functions to provide the required turbine inlet
temperature and to maintain the flame stability.

Fig3 annular type combustor (Sciencedirect.com. (2019).

Advantages

• Lower pressure losses.

• Smaller size
• It can be used in high temperature applications.
• High efficiency

Disadvantages

• Entire combustion chamber has to be removed in case of any of any inspection or repair.
• Warping tendencies.
• Structurally weak.

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Other combustor types

Can type combustor
In this combustor, small units called cans are mounted around the axis of an engine such that the
outlet air from the compressor is split and directed into each can. Each chamber has its own casing
and fuel injectors. These combustors are easy to maintain, as individual cans could be separately
inspected and removed. The type of compressors used in these combustors are centrifugal
compressors as the outlet air could be easily split and directed. There are secondary air ducts for
every flame tube and these flame tubes are interconnected.

Fig4: Can type combustor (Sciencedirect.com. (2019)

Advantages

• High structural strength

• Higher durability
• Easy maintenance

Disadvantages

• Unusual large sizes

• Possibility for formation of hot spots due to inefficient mixing of primary and secondary air

Can annular type

This type of combustor is an extension of both can type and annular type combustion chamber. It
includes individual cans fitted inside a cylindrical shaped chamber. Cans are connected each other
through flame tubes. This is done for easy flame propagation

Fig6 can annular type combustor (Sciencedirect.com. (2019)

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Advantages

• Make good use of space

• Lower pressure loss
• Temperature distribution is uniform, hence reducing the possibility of formation of
Hot spots

Disadvantages

• Not efficient for high temperature applications

• Interconnection of tubes effects the behavior of ignition

Flame stabilization in gas turbine engines

Velocity of air leaving the compressor is too high, it is in the range of 200 m/s, this could extinguish
the flame and prevents the combustion. Therefore the air velocity has to be controlled and this is
achieved by passing the air through a diffuser, which may reduce the velocity to one fifth of the
initial vallue.as the air passes through a diffuser, there is a pressure increase associated with the
velocity loss and the pressure at the exit of diffuser is the highest recorded pressure in that
corresponding gas engine. Apart from combustion problems higher air velocity may also causes
higher pressure loss in the combustion chamber, which may result in lower turbine performance.

Apart from the diffuser, for the flame to stabilize there is a formation of toroidal recirculation zone
in the combustion region. A strong vortex flow is generated in combustion chamber. Due to the low-
pressure region formed at the combustion axis, there occurs a recirculation of flame towards the
nozzle. Radial holes in the flame tubes supply air to the center of vortex resulting in the growth of
flame. Jet angles and penetration results in an upstream flow which results in the recirculation zone.
This results in better flame stabilization and heat release rate. The formation of toroidal vortex also
prevents the flame being taken out of the combustion chamber.

A strong vortex flow is generated in combustion chamber which could be achieved through various
ways; one method is injecting the fuel in the same direction of air stream. Primary air is introduced
through twisted radial vanes, called swirl vanes and the combustion is initiated with primary air.
Later, rest of the air that passes through swirl vanes, and secondary air supplemented through radial
holes combines to form the vortex, resulting in efficient combustion, and flame stabilization.

Fig 7 flame stabilization (Gas turbine engineering handbook)

Some other methods for achieving this are, positioning of holes downstream hemispherical baffle of
flame tube or usage of a vaporization system.

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S321237 JACOB CHETHIPUZHA VARGHESE

Thermal efficiency variation and turbine blade degradation

Gas turbine engines works according to constant pressure or Brayton cycle. Cycle consists of four
main process that are;

Fig 7 T-S Diagram of Brayton Cycle (Nuclear Power. (2019)

• Isentropic compression from 1 to 2, ambient air is compressed in the compressor and the
work required for this process is given by Cp (T2 - T1)
• Isobaric heat addition from 2 to 3, air flows through the combustion chamber and
combustion takes place.
• Isentropic expansion from 3 to 4, expansion of pressurized air and work is done by the
turbine. Work done by turbine is Cp (T3 – T4)
• Isobaric heat removal from 4 to 1
𝑛𝑒𝑡 𝑤𝑜𝑟𝑘 𝑜𝑢𝑡𝑝𝑢𝑡
Overall thermal efficiency of the open gas turbine cycle is given by , η t = ℎ𝑒𝑎𝑡 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑

Net work output = work output – work input

=Cp (T3 – T4) - Cp (T2 – T1)

Heat supplied = Cp (T3 -T2)

Cp (T3 – T4) − Cp (T2 – T1)
Therefore, η t = Cp (T3 −T2)

From the graph of Brayton cycle, it is clear that T3 is the turbine inlet temperature. Turbine inlet
temperature is directly related to the turbine work output. On increasing the turbine inlet
temperature, work output increases which in turn give rise to network output. Therefore, for higher
efficiency of the gas turbine it is desirable to high greater turbine inlet temperature.

Selection of blade material

Selection of turbine blade material is so important as turbine blades are constantly being subjected
to high stresses and temperature ranges. Iron, nickel and cobalt are the basic materials used in the
manufacturing of turbine blades. Alloy metal like chromium is also added to improve resistance to
oxidation.

Selected blade material must have the following properties;

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• Ability to withstand high temperatures

• Resistance to centrifugal stresses produced due to high rotational velocities of turbine
blades
• Ability to withstand higher bending stresses
• Turbine blades must be resistant to corrosion effects of combustion gases.

In the early days stay blade steel was used as the blade material. Later on, it was replaced by
austenitic steel called Rex78.Thenafter, nickel and chromium containing alloys called NIMONIC alloys
were used, these alloys contain 80% nickel and 20% chromium. Wide varieties of NIMONIC alloys
have been discovered so far like NIMONIC 90 (where an extra 20% of cobalt has been added),
NIMONIC 105 and 115 alloys with considerable amount of titanium and Aluminum. Later
developments in this area are Rene 77 (with high rupture strength), B1900 and Mar M200 with
additions of elements like molybdenum and tungsten.

Many alloy materials have been developed and tested as the blade materials. Research is going in
this field to develop blade materials with high temperature and stress resistance. Newer versions of
the material have been developed from stainless steel alloys and nickel chromium alloys.

Efficiency improvements made at CIPS

Usage of combined gas cycle is an efficiency improvement done at CIPS. The Steam turbine is driven
by a waste heat recovery generator, connected to the number 4 and 5 frame 6B gas turbines.
Thermal efficiency of combined gas cycle using waste heat recovery is around 60 % while individual
steam turbines and gas turbines have efficiencies in the range of 30 – 40%. In a combined gas
cycle,60% of the work is done by gas turbine, while the rest is done by the steam turbine. Heat
exchangers with greater surface area are used in the cycle for steam generation.

Advantages of combined gas cycles are;

• High thermal efficiency, cooling is only required for steam turbines in a combined gas cycle
• High performance and operational stability

Apart from the 7 power delivering units in the CIPS, two additional Rolls- Royce Trent 60 gas turbines
were added in the in the year 2011, which increased the capacity of CIPS BY 25%.

Operations at CIPS are digitally controlled, this provides with better controlling as well as indicates
for any error in the functioning. Cooling techniques like usage of cooling towers are used for better
performance at CIPS

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Lubrication system
Lubrication system is used in a gas turbine engine for not only reducing the friction wear, but also
used for keeping the engine clean from dirt and other impurities. Lubrication oil carries this dirt up
to the oil filter, where it is strained out. Generally, gas turbines use self-maintained lubricating
system, where oil is transported to various sections and returned back to the tank by oil pumps.

Cooling air flow system

Maintaining a high turbine inlet temperature is required in a gas turbine to be efficient. Higher inlet
temperature could degrade the turbine blades, therefore in the dilution zone of a combustion
chamber exhaust gases are mixed with 20 % of air coming from the compressor, this reduces the
temperature of the composition to desirable conditions. This method of cooling by dilution occurs in
every gas turbine, it’s the final zone in the combustion process.

Various other cooling techniques are also used in the gas turbines to meet the temperature limits.
Air cooling is the most common method used while water cooling is also done in certain cases. In air
cooling method air is allowed to flow inside the turbine blades, where heat transfer takes place
through walls. Another method of cooling is impingent cooling where high velocity air jet is supplied
to the inner surface of the blade.

Bearing supports
The main function of bearing is to support the engine rotor. Number of bearings required, in a gas
turbine engine is directly dependent on the length and weight of the rotor, which is further affected
by the type of compressor. Frame 6B gas turbine uses three bearing rotor supports. Depending on
the manufacturer requirement for accommodating misalignment due to rotor or casing distortion,
this may be plan journal bearing or tilt pad bearings. A thrust bearing is also used to locate shaft
axially. Gas turbine engines also use anti friction bearings like ball and roller bearings to take the
radial and thrust loads. Newer engines also use hydraulic bearings.

Heavy duty gas turbines use large and rigid film plain bearings. These bearings use bearing housing,
which uses oil seals to prevent the oil leakage. Bearing housing also supplies oil to the bearing for its
lubrication by spray nozzles. Some gas turbine uses 3 bearing supports while others uses 2 bearing
support.

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References
• Grc.nasa.gov. (2019). Power Turbine. [online] Available at: https://www.grc.nasa.gov/WWW/K-
12/airplane/powturb.html
• Cset.mnsu.edu. (2019). Gas Turbine | Engaged in Thermodynamics. [online] Available at:
https://cset.mnsu.edu/engagethermo/components_gasturbine.html
• high-pressure turbine - an overview | ScienceDirect Topics Sciencedirect.com. (2019). high-
pressure turbine - an overview | ScienceDirect Topics. [online] Available at:
https://www.sciencedirect.com/topics/engineering/high-pressure-turbine
• Axial Compressors - an overview | ScienceDirect Topics
Sciencedirect.com. (2019). Axial Compressors - an overview | ScienceDirect Topics. [online] Available
at: https://www.sciencedirect.com/topics/engineering/axial-compressors [Accessed 7 Oct. 2019]
• Gas Turbine Combustion - an overview | ScienceDirect Topics
Sciencedirect.com. (2019). Gas Turbine Combustion - an overview | ScienceDirect Topics. [online]
Available at: https://www.sciencedirect.com/topics/chemical-engineering/gas-turbine-combustion
[Accessed 7 Oct. 2019].
• Citeseerx.ist.psu.edu. (2019). [online] Available at:
http://citeseerx.ist.psu.edu/viewdoc/download?doi=10.1.1.1013.8640&rep=rep1&type=pdf
[Accessed 7 Oct. 2019].

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