Gas Turbine

Turbomachinery
Turbomachinery

Pump Turbine

The purpose of Pump is to add energy to the The purpose of Turbine is to extract energy from
fluid, resulting an increase in fluid pressure, not fluid, resulting a decrease in fluid pressure, not
necessarily an increase of fluid speed across the necessarily a decrease of fluid speed across the
pump. turbine.
Turbine
Classification according to Working Fluid

Gas Turbine

Steam Turbine

Hydro Turbine

Wind Turbine
Gas Turbine History
• Gas turbine is an internal combustion engine, it is designed to accelerate a stream of gas, which is used to
produce a reactive thrust to propel an object or to produce mechanical power to turn a load
• The principal of operation of the gas turbine can be explained by the following examples,

• 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 turned the roasting spit so provide power to the attached
mechanism.

1500AD-Old Style Gas Turbine for BARB-Q not for Power generation!
(The sketch is drawn by Leonardo de Vinci)
Gas Turbine stages of development
• 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 first successful
turbojet airplane in Britain.
• The reason why the gas turbine appeared so much later than other types of internal 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 burning
gas without melting or weakening.
Classification of Gas Turbine
1
• Gas turbine that produce
mechanical power to drive a load
(land base).

2
• Gas turbine that produces thrust
(propulsion) which is used to move
an air planes.

3
• Open cycle or closed cycle or
combined cycle.
Gas Turbine Technical data
Compressor Turbine Bearing Starting power Turbine Control
Axial flow 3 stages 2 Journal Diesel engine MARK V
17 stages Fixed nozzle area 1 thrust
Variable Inlet Guide Vane
12 : 1 Compression ratio
Major Components and section

Rotor Compressor Combustion Chamber Turbine Stator

Basic Operation
• The working medium of GT is ambient air, which is sucked by air compressor of GT at pressure and
temperature of present site.
• Compressor increases the pressure , also as a function of this compressor work temperature increases
• To perform this work the axial compressor will be driven by turbine.
• The compressor and 3 turbine stages together built the rotor
• At rated speed 5100 rpm and base load condition the compressor sucks in an air flow of 403504 m3/h (
taking air density 1.21 kg/m3 ) , it is 491468 kg/h means 136 kg/s.
Basic Operation
• Using standard value of ambient condition – Temperature : 15° C and Pressure : 1.013 bar

• Compressor working on Compressor ratio of almost 12 : 1. so discharge Pressure from compressor is about
11.957 bar and discharge Temperature is 348° C.

• Compressed air is directed to the combustion chamber where it mix with fuel ( fuel flow = 2.41 kg/s)

• At discharge of combustion chamber temperature is 1164° C.

• This working gas enter to 3 stages Turbine, Where thermal energy converted to mechanical energy as a
result pressure and temperature drops. At exhaust of turbine Temp. = 548° C and Pressure drops to
atmospheric Pressure.

• 60 % of total energy is used to drive compressor and remaining 40 % is available as drive power for
Generator.
Need of Compressor
Compressor details
• 17 stages compressor, 1 stage = Rotary (bucket) + Stationary (nozzle) blades

• Stationary blade give specific direction to air & Rotary blades increase pressure of air.
• First 8 stages are having protective paint to avoid corrosion due to temperature difference.
• Stage View
Compressor details
• Compressor rotor blades mounted on 1 forward stub shaft + 15 individual wheel + 1 aft stub shaft

• Forward Stub shaft

Thrust Collar : carries upstream and downstream Forward weight balance: To attach weight for
forces to prevent axial moment of vibration control
rotor
Compressor details
• Forward Stub shaft
Journal Surface : for Bearing No 1 Forward flange: To connect forward stun
Surface for seals : air seal and oil seal shaft to auxiliary gear box.

• Aft Stub Shaft

Aft flange Aft balancing groove Labyrinth teeth Machined Fan

Compressor details
• IGV (Inlet Guided Vane) ( 64 blades)
• According to load adjust the flow of Air.
• Movement of inlet guide vanes are actuated by a hydraulic cylinder
connected to the inlet guide vane control ring that turns the individual
pinion gears mounted at the end of each vane.
• IGV Control – ON
• This mode causes an operation of IGV as a function of the exhaust
temperature to keep exhaust temperature at part load condition.
• During start up IGV will be kept in “close” (34° angle) position until certain
speed level has been obtained.
• IGV now move to “Min. Open” (54°) until certain temperature has been
obtained (Normal 371° C)
• During operation IGV will be operated between “Min. Open” (54°) to “max.
Open” (84°) position as a function of exhaust temperature.
• IGV Control – OFF
• This mode causes, when turbine is in operation, that the IGV will be always
in “Max. Open” position independent of exhaust temperature.
Compressor details
• EGV (Exit Guided Vane) – 2 Nos
• Give direction to air after 17th stage

• Air Extraction Groove

• Extraction ports in casing permits removal of 5th and 11th stage compressor air. This air is used for
cooling and sealing function and also used for starting and shutdown pulsation control.
Combustion chamber
• 10 combustion chamber
• 10 liner
• 10 flow sleeve
• 10 transition piece
Combustion chamber
• 10 cross fire tube • 2 spark plug

• 10 fuel nozzle • 4 flame detector

Turbine details
• As Hot gases expand, thermal energy convert into kinetic energy. This Kinetic energy of gases converted into
mechanical shaft power by means of TURBINE.
• 3 Stages of turbine. Each stage = 1 stage of stationary nozzle + 1 stage of rotary bucket

• Nozzle material – Nickel base super alloy – IN738

• Bucket material – Cobalt base alloy – FSX414
• Method used for manufacturing – lost wax investment casting with ceramic coring
Turbine details
• Turbine shell
• Function is to control radial and axial position of shroud and nozzle and also maintain relative clearance
between nozzle and bucket
Turbine details
• Turbine Shroud
• Turbine blade don’t run directly against the stator casing but run against the curved surface called
shrouds
• Primary function is to provide a cylindrical surface for minimizing
• Secondary purpose is to provide a high thermal resistance between the hot gases and turbine shell by
accomplishing this function, the shell cooling load is drastically reduced.

• First stage shroud

• Thermal Barrier Coating
• Second and Third stage Shroud
• Labyrinth seal
• Honeycomb seal
Turbine details
• First stage nozzle
• 18 segments – Each segments contain two aerofoil partition

• Bucket cooling
• Compressor air enters the partition at the outside diameter of the nozzle.
• The air flows around a core piece in the vane section and is distributed around the inner surface.
• The air is then discharge through holes near the trailing edge providing a film which cools portion of
vanes
Turbine details
• Turbine Wheel space
• Turbine rotor must be cooled to
maintain reasonable operating
temperature and so cooling is
accomplished by means of a positive
flow of cool air radially outward
through a space between wheel and
bucket and discharge to main gas
flow

• Wheel space temperature is

monitored by thermocouple.

• Alarm at 427°C
Bearings
• Turbine rotor is supported in 2 journal bearings. Bearing 1 and Bearing 2.
• To compensate axial forces Bearing 1 is additionally equipped with a Thrust bearing
• Bearing 1 – combined bearing located in the compressor inlet
• Bearing 2 – journal bearing located in exhaust casing
Bearing 1
• Main 3 bearing parts
• Active thrust bearing
• Inactive thrust bearing
• Journal bearing
• In addition
• 2 labyrinths
• 1 bearing housing

Bearing 2
• 1 elliptical bearing lobe
• Labyrinth seal
• Bearing housing
Starting mean req. to start GT
• The Starting mean system is used to start the GT rolling, crank it to firing speed and assist the fired turbine to
self-sustaining speed.
• This is accomplished by a motor, Generator or other staring device operating through torque convertor
coupled to the accessory gear.
• This arrangement provides the cranking torque for turbine start-up and during shutdown this continue to
rotate the turbine rotor at slow speed for cool down purpose
Important Operation
• Cranking
• It is a process during which turbine is made to run at a required speed during start up and shutdown
operation in order to prevent turbine rotor undergoing hogging and sagging.

• Purging
• Purging means flush out
• It is required to push out any combustible gases in the fuel nozzle, also prevent backflow of hot gases
into the fuel nozzle
• Depending on the type of fuel used in combustion chamber the purge timer is set.

• Warming up
• Sudden heating and cooling of hot gas components affect mechanical and metallurgical properties of
components
• In order to have low cycle fatigue on hot gas components, they are internally heated and exposed to
constant temperature.
Start up Steps