DISCUSSION ON GAS TURBINE DESIGN CONSIDERATION

Completed by : Mohammad Ibnul Hossain Executive Engineer (Operation) Tongi 80(105) MW GT Power Station Bangladesh Power Development Board E-mail : ibnulhossain@yahoo.com

Efficiency

Shape Size Flexibility Cost Control Stiffness Surface Finish Environment

Reliability
Thermal consideration

Corrosion

Wear

Friction
Utility Cost

Safety
Weight
Noise
Strength

Maintenance
Volume

The Brayton Cycle The Brayton cycle consists of two adiabatic work transfers and two constant pressure heat transfer heat processes .

T= 1268C

T= 1110C T= 365C

T= 15C

From State 1 to State 2 the gas undergoes an isentropic, adiabatic compression. This process increases the temperature, pressure, and density of the gas.

Static pressure(Ps ) The force per unit area exerted on the walls of a container by a stationary fluid. tire pressure Impact pressure (Pi) is the force per unit area exerted by fluids in motionthe pressure exerted on one's hand held outside a moving cars window Pt = Ps + Pi Part (a) illustrates the measurement of static pressure. Static pressure will not take into account the velocity of the air.

Part (b) illustrates the measurement of total pressure, which accounts for both static pressure and the pressure due to the moving fluid (impact pressure).

Here {

E + or }

v (velocity) Eg P & T pressure and temperature.

Here , v
Here , {

( small inlet to a larger outlet )

E + or } , , Pt Ps

(Pi)
So , Pt So , Ps

As , Pt = Ps + Pi

So , Pt

, so T

( Charls and Boyls Law)

DIVERGENT DUCT :

DIVERGENT DUCT :

Velocity Pressure Temperature

Axial flow compressor, P current stage > P previous stage [ incrementally] What a single stage of compressor consists of ? A set of rotor blades attached to a rotating disk . Flow area between rotor blade is slightly divergent .
BLADE VANE

Pt Ps

followed by stator vanes attached to a stationary ring. Flow area between compressor vanes is also divergent than blade . What is done by the blade ? convert mechanical energy into gaseous energy. ( Here , energy is added) . What happens? Pi So Pt and slight Ps for divergence

What is done in Stator Vane ? slow the air divergent duct shape, Here { E + or } v (velocity) Eg P & T pressure and

temperature.
BLADE VANE

Here , v (Pi)

( small inlet to a larger outlet )

Pt Ps

Here , { So , Pt
v

E + or } ,

As , Pt = Ps + Pi
So , Pt

Ps

Variable Inlet Guide Vane

IGV

Condition Startup - 2850 2850- Loading 34 57

IGV opening

Loading increases >> exhaust IGV opening increase temperature increase

At Base Load to keep the exhaust temp. from 570 C 84

At Peak Load to keep the 84 exhaust temp. not beyond to 575 C (+5 C)

Compressor

Compressor
inlet guide vanes, The axial-flow compressor section consists of the compressor rotor and the inclosing casing. the 17 stages of rotor and stator blading, the exit guide vanes.

Variable Inlet Guide Vanes (IGVs)

IGVs are used to control the airflow through the compressor, in turn controlling the airflow through the entire machine. The IGVs modulate during the start-up and acceleration of the gas turbine to rated speed, loading & unloading of the generator and deceleration of the gas turbine during shutdown.

Compressor Structure
Inlet Guide Vane

Compressor Structure
Compressor cylinder
Compressor cylinder has 3 parts:

Forward casing ; After casing compressor outlet casing.

Compressor Structure

Forward casing

After casing

Compressor Structure
Discharge casing

Compressor Structure
Compressor outlet casing

compressor structure
Compressor vane: IGV, stationary blade and EGV (Exhaust Guide vane)
Stationary Blade

IGV

EGV

Compressor Structure
Stationary Blade (lower half of the Cylinder )

Problems Occur during Operation of the Compressor and Its solution by design consideration Problem : Stalling and Surging during lower speed . Remedy : The inlet guide vanes are incorporated . It limits the amount of air flowing through the compressor and prevents stalling . Provisions for bleeding air from the compressor are provided at one or more stages. This prevent both stalling and Surging .

Compressor Structure
Compressor moving blade

Compressor Structure
compressor rotor Compressor rotor is a drum structure with 17 impellers (including a half shaft).17 impeller panels are tightly pulled by 16 long bolt pull rods to be integrated.

Working Principle : air is confined to the space between the rotor and stator blading >>>>compressed in stages by a series of alternate rotating (rotor) and stationary (stator) airfoil shaped blades.
The rotor blades supply the force needed to compress the air in each stage and the stator blades guide the air so that it enters in the following rotor stage at the proper angle.

The compressed air exits through the compressor discharge casing to the combustion chambers. Air is extracted from the compressor for turbine cooling, for bearing sealing, and during start-up for pulsation control.

Problems Occur during Operation of the Compressor and Its solution by design consideration :
Problem : Air has the natural tendency to flow toward low-pressure zones. If air were allowed to flow "backward" into the lower pressure zones, the efficiency of the compressor would decrease tremendously as the energy used to increase the pressure of the air was wasted. Remedy : seals are incorporated at the base of Each row of vanes to prevent air leakage. The tip clearances of the rotating blades are also kept at a minimum by the use of coating on the inner surface of the compressor case.

GROWTH OF PRESSURE RATIO OF GAS TURBINE

The MS5001N and P, the MS7001A and B, and the MS9001B are essentially the same

What is achieved ? Reliability

What is achieved ? Performance Reliability

Some Initiative to improve performance of Compressor and Implementation by design consideration ( Improving Design) Goal : Increase the Pressure Ratio. Increase the Air Flow . How It is Implemented ? Increase the Diameter of the inlet-stage. No. of stages are added. What Result We get ? Model - MS5000 - pressure ratio 6.78 MS5001N -compressor operated at a pressure ratio of 9.8. and Now we get more the 10 in the frame-9 Machine.

What is achieved ?
More Efficiency

To improve performance of Compressor and Implemented by design consideration ( Improving Design) : Goal : To provide higher firing temperature at reduced load for regenerative-cycle and combined-cycle applications. Implemented by : The fixed inlet guide vane was replaced with a variable guide vane

What is achieved ? Flexibility of Operation

GROWTH OF AIR FLOW OF GAS TURBINE

Lists some of the parameters of these axial compressors. By starting with an efficient, reliable design and improving this design in a gradual manner, improved overall compressor performance has been achieved without sacrificing reliability or mechanical integrity.

Objective of Design consideration optimizing compressor wheel material characteristics, cost, and service conditions

How it is done ? & How it is incorporated ? This type of construction reduces weighs reduction , minimizes acceleration during start-up. The disks are assembled with a number of axial tie-bolts, with the bolt-circle diameter selected to produce a dynamically stiff rotor and good torque transmission. Weight loss+ Stiffness Ensures V critical > V running . Axial clearance is provided between wheel rims to allow thermal expansion during startup.

Figure

Goal Achieved Weight reduction , stiffness thermal consideration Cost Service condition

Objective of How it is done ? & How it is Design incorporated ? consideratio n

Using Right Quality Material in last compressor stage to compensate the temperature rise , minimize thermal stress during start-up , shut-down, Higher-strength material (CrMoV) (Chromium Molybdenum steels- 0.5 to 5% Cr and 0.5 to 1.5% Mo with small additions of vanadium) used in the last compressor stage. high-temperature strength after testing stringent process controls and ultrasonic inspection procedure. wheel life of 30 years at base load. designed for may thousands of starts and shut-down. Remainder of the compressor wheels are made of three basic grades of steel, CrMo, NiCrMo, and NiCrMoV the principal alloying elements. Processing of these alloys produces a balance of desired material properties including tensile strength and fracture

Figure

Goal Achieved

strength thermal stress Life span

Objective of Design consideration Using Right Quality Material in last compressor stage to produces a balance of desired material properties including tensile strength and fracture toughness.

How it is done ? & How it is incorporated ? CrMo, NiCrMo, and NiCrMoV Materials are used . optimization of these material has resulted in a 35% improvement in fracture toughness

Figure

Goal Achieved strength fracture toughness.

The Brayton Cycle

The Brayton cycle consists of two adiabatic work transfers and two constant pressure heat transfer heat processes (Figure 3).

From State 2 to State 3, heat is added at constant pressure. For a gasturbine, heat is added through a combustion process.

The combustor of a gas turbine is the device that accepts both highly compressed air from the compressor and fuel from a fuel supply so that continuous combustion can take place.
High compressed air

Fuel

This raises the temperature of the working gases to a very high level. This combustion must take place with a minimum of pressure drop and emission production. The very high temperature gases flow from the combustor to the first stage turbine nozzles.

Combustion Chamber Design : Most Simple :

Fuel Injector

Impractical-f the excessive pressure loss resulting from combust on at high velocities. Pressure loss from combustion the air velocity squared. Velocity too high to establish stable combustion . Even if ignited initially , the flame will be carried downstream and cant be sustain without continuous ignition.

Adding Baffle :

baffle

Flame stabilization zone (Eddy region)

To secure flame at low velocity region is achieved by installing baffle which will further generate eddy region behind baffle and allow sufficient time for fuel to completely combust. At that place, flame will stabilize and gives us continuous ignition.

Adding Swirl :
Primary Zone

Vortex Swirl Dilution zone

strong vortex is produced using swirl vanes around fuel nozzle x will create low pressure region. Due to this pressure difference, air starts moving towards it from radial holes around liner. With this movement, flame start propagating up to some extent and will form a recirculation zone which stabilizes flame.
combustor air enters in the chamber through rings. and produce recirculation zone which further stabilizes flame for complete combustion.

So we have , Combustion takes place in the primary zone of the Combustor . Primary air = of total airflow) is used to support the combustion process. The remaining air, referred to as secondary or dilution air, is admitted into the liners in a controlled manner.

The secondary air controls the flame pattern, cools the liner walls, dilutes the temperature of the core gasses,
This cooling air is critical, as the flame temperature is above 1930C which is higher than the metals in the engine can endure.

 Important fuel nozzles and combustion liners control the burning and mixing of fuel and air under all conditions to avoid excess temperatures reaching the turbine or combustion cases. Maximum combustion section outlet temperature (turbine inlet temperature) in this engine is about 1070C

About the stabilization of flame, air velocity plays a vital role. To understand this effect, we will take the help of following graph

the velocity of air

range of burnable mixture

For the stabilization of flame, the size of baffle is also important. Flow velocity in the Flow velocity in the combustion chamber is maintained below blowout limit so that combustion chamber can support wide range of fuel to air ratios.

Combustion Chamber
Secondary Flame detector
Primary Flame Detector

Crossfire tube

Some notable arrangements in combustion Chamber: a)Primary Flame Detector in the Chamber 1,2,3,14 b)Secondary Flame Detector in the chamber 1,2,3,14 c) Primary , Secondary and Tertiary Fuel Connection clock wise direction from manifold .

Introduction of combustion chamber structure

TRASTION PIECE

FLOW SLEEVE

Cap-liner

Primary Nozzle

Secondary and Tertiary Nozzle

Tertiary Nozzle

Tertiary Nozzle

The number of combustors

the machine airflow by the pressure ratio Example

the MS9001E uses 14 combustors compared to 10 on the MS7001E because the 9E airflow is 1.44 times as large

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : a) Improve High Temperature Strength . b) Reduction Thermal Gradient. In the Liner Section Implementation : Improvement in the liner Construction and using better material . Example : In Model MS7001FA liner is 30% thicker and 210 mm (8.4 in.) and Using Hastelloy-X material and addition of HS-188 in the aft 278 mm (11.1 in.) portion and the application of thermal barrier coating to the internal surface.

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : a) Improve High Temperature Strength . b) Reduction Thermal Gradient. In the Transition Piece Section Implementation : Improvement in the Transition Piece Construction and using better material . Example : Nimonic 263, was introduced into service for transition pieces. This material is a precipitation-strengthened, nickelbase alloy with higher strength capability than Hastelloy-X. Since the early 1980s, Thermal Barrier Coatings (TBCs) have been applied to the transition pieces.

What is achieved ? Reliability High Temperature Strength Reduction Thermal Gradient. IN LINER and Transition Piece

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : a) Reduction of Combustion noise . b) Reduction Wear . In the Liner Section Implementation Incorporating More No. Nozzle instead of One with water Injection system. Example : MS7001E design to accommodate six fuel nozzles instead of one with water injection for NOx control (Discuss Later)

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : Reduction Wear .

In the Transition Piece

Implementation To increase the wear resistance of some transition pieces in the aft end Cobalt-base hard coatings applied by thermal spray improve the wear life of sealing components by more than four times.

What is achieved ? Reducing The Wear In Liner and Transition Piece & Noise In Liner Section

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : Reliability in Ignition Process IMPLEMENTATION : a)Using Two sparking Plug . b)Using Two Flame Detector . c) Using Cross Fire Tubes .

What is achieved ? Reliability In Ignition System

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : Completely burn of the residual fuel. Implementation: By allowing air jets in the combustion chamber for proper Stoichiometric air fuel mixture . Combustor length must be sufficient to provide for flame stabilization. combustion. and mixing with dilution air. The typical value of the length-to-diameter ratio for liners ranges from three to six.

What is Stoichiometric Ratio ? The Stoichiometric ratio is the perfect ideal fuel ratio where the chemical mixing proportion is correct. When burned all fuel and air is consumed without any excess left over

What is achieved ? Fuel Economy

To improve performance of Combustion Chamber and Implemented by design consideration ( Improving Design) :

Goal : To remove NOx from the combustion. What is NOx ? NO and NO2, collectively called NOx. Why Removal of NOx ? It is bad for the environment and bad for the health. Must below 100 ppm in the combustion product . Where it is produced ? 2 sources of NOx emissions .
1. NOx is generated by the fixation of atmospheric nitrogen in the flame. This is called thermal NOx. 2. Other NOx are also generated by the conversion of a fraction of any nitrogen chemically bound in the fuel (called fuel-bound nitrogen or FBN).

Thermal NOx Is an exponential function of the (T) temperature of the flame a linear function of time (t) To Minimize the NOx we have to design the combustion chamber Where The combustion temperature must below the NOx producing Temp. And The combustion process takes lesser time .

The combustion chamber Which is used for dln system

What is achieved ? Environment Friendly Machine

Some Design Factors must be done in designing combustion chamber : Wobbe Number : Wobbe Number is an indicator of the characteristics and stability of the combustion process.

Here , LHV Lower Heating Value of fuel , Sp. GR Specific Gravity Tamb Ambient Temperature the wobbe Number can cause the Flame to burn closer to the liner. Decreasing the wobbe Number can cause pulsations in the combustor.

Some Design Factors must be done in designing combustion chamber :

Pressure drop. 100 fps (30mps), 4% 80fps (24mps), 2.5%: 70fps (21 mps), 2%: 50fps (15mps), 1%.

Some Design Factors must be done in designing combustion chamber :

The Brayton Cycle

The heat-release the fuel-to-air ratio The heat-release the combustor pressure. The heat-release = ( Combustor capacity)

From State 3 to State 4 the gas passes through an adiabatic isentropic turbine which decreases the temperature and pressure of the gas

Static pressure(Ps ) The force per unit area exerted on the walls of a container by a stationary fluid. tire pressure Impact pressure (Pi) is the force per unit area exerted by fluids in motionthe pressure exerted on one's hand held outside a moving cars window Pt = Ps + Pi Part (a) illustrates the measurement of static pressure. Static pressure will not take into account the velocity of the air.

Part (b) illustrates the measurement of total pressure, which accounts for both static pressure and the pressure due to the moving fluid (impact pressure).

Convergent Duct

Velocity Pressure Temperature

Here { Here , v Here , {

E + or } (large inlet to a smaller outlet ) (Pi) E + or } Pt Pi So , Pt So , Ps

As , Pt = Ps + Pi

A static pressure decrease is seen as air flows through a convergent duct and goes through expansion. A temperature drop is associated with any expansion process.

Axial flow compressor, P current stage > P previous stage [ incrementally] What a single stage of compressor consists of ? A set of rotor blades attached to a rotating disk . Flow area between rotor blade is slightly divergent .
BLADE VANE

Pt Ps

followed by stator vanes attached to a stationary ring. Flow area between compressor vanes is also divergent than blade . What is done by the blade ? convert mechanical energy into gaseous energy. ( Here , energy is added) . What happens? Pi So Pt and slight Ps for divergence

Vane / Nozzle
Blade

nozzles convert the gaseous heat and pressure energy into higher velocity gas flow (Pi) In addition to accelerating the gas, the vanes "turn" the flow to direct it into the rotor blades at the optimum angle. As the mass of the high velocity gas flows across the turbine blades, the gaseous energy is converted to mechanical energy.

Pt Ps

Velocity, temperature, and pressure of the gas are sacrificed in order to rotate the turbine to generate shaft power

Vane

Blade

Types of Gas Turbine : 1.Impulse

2.Reaction

P1 V1

P2

V2 Here , P1 > P2 v1> v2

Velocity-v, pressure-P

If Pressure decreases Velocity increases Kinetic Energy increases RMP increases

Change in pressure is done : 1) By Convergent Nozzle . 2) By Convergent Blade.

In Turbine ( Gas or Steam) : has Convergent Nozzle system and uniform blade system . Reaction Turbine has Convergent Blade system and uniform nozzle system

Impulse Turbine nozzle and blading arrangement

V1
Convergent Guide van Here : P1 >P2 V2> V1

P1

P2 V2
Constant Area Moving Blade

Fixed Blade

Moving Blade

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Impulse Turbine in Action

Reaction Turbine nozzle and blading arrangement

V1
Constant Area Guide vane

P1

P2 V2

Convergent Nozzle Here P1 > P2 V2> V1

Fixed Blade

Moving Blade

Reaction Turbine in Action

Reaction Turbine in Action

Reaction Turbine in Action

Reaction Turbine in Action

Reaction Turbine in Action

Reaction Turbine in Action

A reaction turbine is moved by two main forces:

1. There is expansion of steam is there , pressure is decreasing so there is increase in kinetic energy by increasing velocity . 2. the push or impulse of the gas impinging upon the blades

Impulse Turbine create large amounts of Tangential thrust

Reaction turbines create large amounts of axial thrust, and so require the use

So the combination of impulse reaction turbine is widely used .

Impulse Reaction Turbine reduces both the tangential and axial stress To the Rotor

Impulse Reaction Blade

The fixed blades are set in a reversed manner compared to the moving blades,

Schematic drawing of major components of gas turbine

Exhaust System

Air Inlet System

Compressor Section Combustion Section

Turbine Section

Air Inlet

Exhaust Section
Gas Turbine Auxiliaries Compressor Combustion Section Turbine Section

To improve performance of Turbine and Implemented by design consideration ( Improving Design) :

Goal : To improve the Higher firing temperature . How it is Implemented ?

Improved nozzle and bucket material . The air-cooling of this hardware. Simultaneous development in alloy corrosion and oxidation resistance and bucket surface protection systems have played a significant role in supporting firing temperature increases.

What is achieved ? More Efficiency

To improve performance of Turbine and Implemented by design consideration ( Improving Design) :

Goal : To make Vibration Free Bucket at all speed of the turbine and Making Thermal Isolation . How it is Implemented ?
The long-shank bucket and the bucket tip shroud is introduced.

How it works ?
Damping is introduced near the bucket mid span . The shank has a second important advantage in providing an effective thermal isolation between the gas path and the turbine wheel dovetail.

What is achieved ? Reliability in Operation By Vibration Control

Problems Occur during Operation of the Turbine and Its solution by design consideration :

Creep/Rupture

How it is overcome

A creep strain criterion is chosen to avoid creep cracking.

Problems Occur during Operation of the Turbine and Its solution by design consideration :

Thermal Fatigue
It is due to the temperature gradient for the cooling of the high temperature Component of gas turbine in both transient and steadyState operation , such as Vane in fig .

Cant be eliminated, but their impact can be mitigated by judicious design and careful operation.

What is achieved ? Thermal Consideration

Problems Occur during Operation of the Turbine and Its solution by design consideration :

Corrosion
The use of Ni-base super alloys as turbine blades in an actual enduse atmosphere produces deterioration of material properties. This deterioration can result from erosion or corrosion Erosion results from hard particles impinging on the turbine blade and removing material from the blade surface. Corrosion is described as hot corrosion and sulfidation processes. Hot corrosion is an accelerated oxidation of alloys caused by the deposition of Na2SO4. Oxidation results from the ingestion of salts in the engine and sulfur from the combustion of fuel. Sulfidation corrosion is considered a form of hot corrosion in which the residue that contains alkaline sulfates. Corrosion causes deterioration of blade materials and reduces component life.

Remedy :
Platinum-chromium-aluminide diffusion-type coatings developed Pt-Cr-Al coating developed

Combination of IN-738 and Pt- Cr-Al developed vacuum plasma spray coatings are overlay-type coatings developed

What is achieved ? Corrosion Control

Thank You