GAS TURBINES

P.MAHADEVAN
Objective
Comprehend the thermodynamic
processes occurring in a gas turbine
Comprehend the basic components of gas
turbines and their basic operation
Comprehend the support systems
associated with gas turbines
What is Gas Turbine?
Energy converter
Chemical Energy to Mechanical Energy
FUNCTION
Prime Mover - Provide Power for movement /
transportation
Mechanical drive (Compressors, Pumps,
Blowers)
Electricity Generation (Generator)
What is Gas
Turbine?
Its an high technology engine
It an high speed rotating machine (3.000-30.000 rpm)
In industrial application may drive generators(GD =
Generator Drive) or pumps and compressors (MD =
Mechanical Drive)
Its used for mobile application as aircraft ships etc.
Power range of gas turbine is between 100 kW and 350 MW
Its efficiency is between 25% and 40%
High specific power (light and powerful machine)
May use a large typology of fuels (gas and liquid types)
It may operate continuously without stop also for one year
WHY GAS TURBINE ?
High efficiency
Low emissions
Low installed cost
Low cost power generation
Short lead time, modular
Multi-fuel capabilities
HISTORICAL PERSPECTIVE
Man tried to develop some turbo machine right from BC
days
Claude Burdin (1790-1873) was the first to use the word
turbine derived from the Latin word turbo (spins)
Stolze developed the first gas turbine in 1872
First successful stationary gas turbine operation in 1940
HISTORICAL PERSPECTIVE (Contd)
150 BC - Hero - earliest example of jet propulsion
1500 AD - Leonardo da Vinci sketch
1629 - Giovanni Branca - first practical application of a
steam turbine
1765 - Reciprocating Steam Engine invented by J ames Watt
1791 - J ohn Barber - first patent for a turbine engine
1827 -1840 - Hydraulic Turbine
1872 - Stolze - first true gas turbine
1883 - Steam Turbine by De laval
1939 - Heinkel Aircraft Co. - credited for the first flight of a
gas turbine powered jet propelled aircraft
1959 - Gas turbines first used as emergency power
generation
Gas Turbines in Oil and Gas
Applications
Principal GT Application Areas:
Upstream
a) Oil Field and Offshore Power Generation
b) Gas Lift (Enhanced Oil Recovery -EOR)
c) Water Injection
f) Export Compression
g) Gas Gathering
h) Gas Plant and Gas Boost
i) Gas Storage/ Withdrawal
Gas Turbines in Oil and Gas
Applications (Contd)
Midstream
a) Pipeline Compression
b) Oil Pipeline Pumping
c) LNG Plant (refrigeration,
compression, power)
Gas Turbines in Oil and Gas
Applications (Contd)
Downstream
a) Refinery power (Steam and Power
Cogeneration)
b) Refinery Integrated Gasification
Combined Cycle
c) Methanol / Fischer-Tropsch /
Ethanol Fueled Plants
Brayton Cycle
Open cycle, unheated engine
1-2: Adiabatic compression of air in compressor
2-3: Constant pressure burning (Combustion) in a combustor
3-4: Adiabatic Expansion through Turbine and Exhaust Nozzle
(4-1: Atmospheric Pressure)
Basic Components
Basic Components
Basic Components
Compressor
Draws in air & compresses it
Combustion Chamber
Fuel pumped in and ignited to burn with
compressed air
Turbine
Hot gases converted to work
Can drive compressor & external load
Basic Components
Compressor
Draws in air & compresses it
Combustion Chamber
Fuel pumped in and ignited to burn with
compressed air
Turbine
Hot gases converted to work
Can drive compressor & external load
Basic Components
Compressor
Draws in air & compresses it
Combustion Chamber
Fuel pumped in and ignited to burn with
compressed air
Turbine
Hot gases converted to work
Can drive compressor & external load
Compressor
Supplies high pressure air for
combustion process
Compressor types
Radial/centrifugal flow compressor
Axial flow compressor
Compressor Types
Radial/centrifugal flow
Adv: simple design,
good for low
compression ratios (5:1)
Disadv: Difficult to
stage, less efficient
Axial flow
Good for high
compression ratios
(20:1)
Most commonly used
Axial Compressor Operation
COMPRESSOR
is the part of the
engine where air is
compressed
Compressor Discharge:
(1) 30% for primary air (combustion air)
(2) 5% operation of gas turbine accessories:
-bleed air and seal air
-gas turbine start and motor air
-gas turbine anti-icing
(3) remaining air is used as secondary air to:
- cool combustion gases
- Provide film cooling of the gas generator turbine
Use of Compressed Air
Primary Air (30%)
Passes directly to combustor for combustion
process
Secondary Air (65%)
Passes through holes in perforated inner shell &
mixes with combustion gases
Film Cooling Air (5%)
Insulates/cools turbine blades
COMPRESSED AIR
Combustion Chambers
Where air & fuel are mixed, ignited, and burned
Spark plugs used to ignite fuel
Types
Tubular (Single Can)
Preferred by European manufacturers
Simple design, long life
Annular: for larger, axial compressors
Popular in aircraft designs
Can-annular: for really large turbines
Preferred by American manufacturers
Most common type, ease of maintenance
TUBULAR TYPES
SINGLE CAN COMBUSTOR
CAN ANNULAR COMBUSTOR
Combustor Types
Another Classification
Standard Combustor
Dry Low Nox (DLN)
Combustor
Combustion Chamber(s) Operation
is the part of the engine
where air is mixed with
fuel and burned
COMBUSTOR(s)
Typical Gas Turbine Combustor
Conventional GT Fuel Nozzle
Gas Fuel
Liquid Fuel
Atomizing Air
Primary Air
Primary Air
Dual Fuel Nozzle Assembly
Turbine Operation
TURBINE
The turbine extract kinetic energy fromthe expanding gases as the gases come
fromthe burner, converting this energy into shaft power to drive the compressor
andthe engine accessory.
Nearly three fourths of all energy available from the product of combustion is
neededto drive the compressors.
The turbine is composed froma ring of stator vanes called NOZZLE and a ring of
rotor blades calledBUCKETS
Turbines
Consists of one or more stages designed
to develop rotational energy
Uses sets of nozzles & blades
Single Shaft Gas Turbines
Single Shaft Gas Turbine
( with Shaft Coupling) :
Power Turbine and Gas
Generator Turbine on
Same Shaft
Fixed Speed
Applications (Range:
90%-100% Full Speed)
Mostly used for Electric
Power Generation; i.e.,
Generator Drive via
Gearbox (1500 rpm
50 Hz, 1800 rpm 60
Hz)
SINGLE SHAFT GAS TURBINE
COMBUSTIBILE
AIR
LOAD
COMBUSTORS
EXHAUST GAS
4
3
2
1
TURBINE
AXIAL
COMPRESSOR
AUXILIARY GEARBOX
STARTING MOTOR
60 MW 120 MW 60 MW
(50%) (100%) (50%)

1-2 AIR COMPRESSION

2-3 COMBUSTION
3-4 EXPANSION
LOAD =ELECTRIC GENERATOR (OFTEN) COMPRESSOR, PUMP
(NOT COMMON)
AUXILARY GEAR BOX=DRIVES OIL PUMPS AND TRANSMITS
TORQUE FROMSTARTING MOTOR
Single Shaft Gas Turbines
Two-Shaft Gas Turbines
Two-Shaft Gas Turbine ( no
Shaft Coupling) :
Power Turbine
Independently
Supported on its Own
Shaft and Bearings
Variable Speed
Applications (Range
25%-100% Full Speed)
Used for Compressor,
Pump and Blower
Applications
Gas Generator
Power Turbine
Types of Couplings
Gear Couplings
Grid-type
Pin-type
Coupling Guards Non sparking
GEARS
Power Transmission System
Reduction gears used to transfer torque
With split shaft, turbines can run @
different speeds
Load Gear
Between driver GT and driven
equipment
Accessory Gear
For pumps and / or starter
GAS TURBINE TYPES
Industrial Heavy-Duty
Aero Derivative
Medium Range
Small
Industrial Heavy Duty Gas Turbines
Designed shortly after World War II and introduced to
the market in early 1950s
Design Characteristics; Heavy wall horizontally split
casing, sleeve bearings, large dia combustors, thick
airfoil sections for blades and stators
Advantages: Long life, high availability, slightly higher
overall efficiencies, Comparatively low noise level
Primarily used in Power plants. Ideal for base load
operation
Aero Derivative Gas Turbines
An aircraft-derivative gas generator and a free-
power turbine
The gas generator is an aircraft engine modified
to burn industrial fuel
Mostly used by gas transmission companies and
on gas reinjection platforms
Advantages: favourable installation cost,
Adaptation to remote control
Medium Range Gas Turbines
Ratings between 5000-15000 hp
Design similar to Heavy Duty GTs
Mainly used on offshore platforms and
petrochemical plants
SIMPLE CYCLE
Gas Turbine exhaust
gas heat is wasted to
the atmosphere
COMBINED CYCLE
Use Gas Turbine Exhaust Heat to
Generate Steam in HRSG
Use Steam from HRSG to drive steam
turbine generator
COMBINED CYCLE
COMBINED CYCLE
COMBINED CYCLE
Gas Turbine Generator
Stack Bypass Stack
Boiler
Economizer
Supplementary Duct
Firing
CLOSED CYCLE APPLICATION
FACTORS AFFECTING GT PERFORMANCE
PRIMARY FACTORS
- ambient temperature
- ambient pressure (site elevation)
SECONDARY FACTORS
- humidity
- inlet system pressure drop
- exhaust system pressure drop
- power losses in the driven equipment (gear, pipeline
compressor or electric generator)
EFFECT OF AIR INLET TEMPERATURE
EFFECT OF AIR INLET TEMPERATURE
EFFECT OF ELEVATION
EFFECT OF INLET LOSS
EFFECT OF EXHAUST LOSS
EFFECT OF INLET LOSS
-100 -75 -50 -25 0 25 50 75 100
Change in Inlet Ducting Loss mmH2O
0.98
0.99
1.00
1.01
1.02
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Exhaust Temperature
Datum conditions of:
Engine inlet temperature 15 C
Ambient pressure 101.3 kPa
Relative humidity 60 %
Inlet duct loss 100 mmH
2
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Exhaust duct loss 200 mmH
2
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Based on 'dry' operation in full base load region
EFFECT OF EXHAUST LOSS
-200 -150 -100 -50 0 50 100 150 200
Change in Exhaust Ducting Loss mmH2O
0.98
0.99
1.00
1.01
1.02
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Heat Input
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Datum conditions of:
Engine inlet temperature 15 C
Ambient pressure 101.3 kPa
Relative humidity 60 %
Inlet duct loss 100 mmH
2
0
Exhaust duct loss 200 mmH
2
O
Based on 'dry' operation in full base load region
5/11/97 21/08/02
EFFECT OF INLET & EXHAUST LOSS
EFFECT OF ELEVATION
Effect of Relative humidity
-40 -30 -20 -10 0 10 20 30 40
Change in Relative Humidity %
0.997
0.998
0.999
1.000
1.001
1.002
1.003
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Exhaust Temperature
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Datum conditions of:
Engine inlet temperature 15 C
Ambient pressure 101.3 kPa
Relative humidity 60 %
Inlet Ducting Loss 100 mmH
2
O
Exhaust Ducting Loss 200 mmH
2
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GAS TURBINE RATING
ISO RATING
Power rating
at design speed and
at sea level i.e. Ambient pressure is 14.7
psia (1.0 bar) with
an ambient temperature of 59F (15C) and
ambient relative humidity of 60%
The ISO rating considers inlet and outlet losses to
be zero.
GAS TURBINE PACKAGE
Gas Turbine Package Components
Gas Turbine Package Components
INSIDE THE PACKAGE
Fuel System
- Natural Gas
- Liquid (pumped)
Lube Oil System - Supply bearings and gears with oil
- Tank
- Filter
-Pumps (main, pre/post, backup)
Starter (pneumatic, hydraulic, AC motor, diesel engine)
Controls (on-skid, off-skid)
Seal Gas System (compressors)
Gas Turbine Package Components
OUTSIDE THE PACKAGE
Enclosure
Fire Protection
Ventilation air inlet
Ventilation exhaust
Ventilation Fans
Air Inlet System combustion air
Air-filter (self-cleaning, barrier,
inertial)
Silencer
Exhaust System
Silencer
Stack
Lube Oil Cooler (water, air)
Motor Control Center
Switchgear, Neutral Ground
Resistor
Inlet Fogger/Cooler
Fire Protection cabinet
FUEL SYSTEM
The purpose of the fuel system is to
deliver fuel to the individual combustors of
the turbine under the following conditions:
At the required pressure and temperature
In the right quantity to meet the load
demand
Free of contaminants, which may be
harmful to the turbine
FUEL SYSTEM (Contd)
The fuel system may be
Gaseous fuel
Liquid fuel
Dual fuel
FUEL SYSTEM (Contd)
The fuel system can be divided into:
The combustion control system
located on base at the turbine
The fuel receiving, storage and
forwarding system
TYPICAL FUEL GAS SYSTEM
TYPICAL LIQUID FUEL STORAGE &
FORWARDING SYSTEM
TYPICAL TURBINE LIQUID FUEL SYSTEM
DUAL FUEL SYSTEM
DUAL FUEL NOZZLE
TYPICAL ATOMIZING & PURGE AIIR
SYSTEM
Wobbe Index
It is customary to give a Wobbe number without unitseven
though it has the dimensions Btu per scfbecause to do so
would lead to confusion with the volumetric heating value of
the gas.
The usefulness of the Wobbe number is that for any given
orifice, all gas mixtures that have the same Wobbe number will
deliver the same amount of heat.
The Wobbe Index (WI) is the main indicator of the
interchangeability of fuel gases
It is used to compare the combustion energy output of different
composition fuel gases
Less than 5% deviation is desired
LUBRICATING & HYDRAULIC OIL SYSTEMS
The purpose of the lube oil system is to supply
the lubricant to the bearings and gear box
At the right pressure
At the right temperature
Clean and free from dirt, dust or material particles
The lube oil system works on a closed cycle
TYPICAL LUBE OIL SYSTEM
LUBE OIL SUMP
TURBINE
GENERATOR
TYPICAL GTG LUBE OIL SYSTEM
TYPICAL CONTROL (TRIP) OIL SYSTEM
TYPICAL HYDRAULIC OIL SYSTEM
Starting System
Purpose
To get compressor initially rotated
Once at certain RPM, fuel injected and spark
ignited
Types
Electric motor
Diesel engine
Gas Expander/ pneumatic starter
STARTER ARRANGEMENT
Air Intake & Exhaust
Must minimize space and weight
Must keep air inlet losses to a
minimum to ensure maximum
performance
Intake has screens/filters to ensure
clean, filtered air at all times
INLET AIR FILTER TYPES
Self Cleaning Filter
Air Intake Filter
Exhaust
Exhaust generates thermal and
acoustic problems
Possible damage to personnel &
equipment
Silencers and eductor nozzles used to
silence and cool exhaust
Exhaust orientation axial or
transverse
TYPICAL COOLING WATER SYSTEM
GT ENCLOSURE
TYPICAL GT ENCLOSURE
GT ENCLOSURE (Contd)
Requirements:
Acoustic
Weatherproof
Fire protection
Ventilation
Lighting
Doors
TYPICAL GT COMPARTMENT VENTILATION
FIRE PROTECTION
Fire Detection
Types of Detectors
Ultraviolet (UV)
Infrared (IR)
Rate Compensated Thermal
Fire Suppression
Types of agents
Halon
CO
2
High Pressure or Low Pressure
Inergen
Water Mist
Gas detection
Infrared (IR)
Electro catalytic
Typical CO
2
Fire Protection System
TYPICAL CONTROL PANEL
HOT END DRIVE
GENERATOR GEARBOX
Air Inlet
Compressor
Combustor
Turbine
Exhaust
BASE FRAME
MATERIALS OF CONSTRUCTION
Alloy steels for compressor & turbine
Nickel or Cobalt based alloys for combustor
Stainless Steel for Combustion Air Intake and
Lube Oil Systems.
HOT END DRIVE
COLD END DRIVE LAYOUT
TYPICAL TURBINE START UP CURVE
TYPICAL GT LOADING CURVE
ABNORMAL CONDITIONS THAT REQUIRE
GAS TURBINE TRIP
Over speed.
Low lube oil pressure.
High turbine exhaust temperature.
Excess vibration.
Flame failure in combustor.
Inlet air filter having high differential pressure.
Any initiation of fire protection around the unit.
Gas leak detection
Service life of Gas Turbine
Components
Factors that may determine the service life of
gas turbine components:
starts and stops
load and temperature swings
running hours
whether components have protective coatings
material creep strength
endurance limit for fatigue strength evaluation
method of blade cooling
effect of steam injection
erosion wear noted during inspections
PERFORMANCE DEGRADATION
All turbomachinery experiences losses in
performance with time.
Recoverable
Usually associated with compressor fouling and can
be partially rectified by water washing or by
mechanically cleaning the compressor blades and
vanes after opening the unit
Non-recoverable loss
is due primarily to increased turbine and compressor
clearances and changes in surface finish and airfoil
contour
TYPICAL MAINTENANCE
INSPECTION
TYPE
INTERVAL
(EOH)
DOWNTIME
COMBUSTION
INSPECTION
16,000 7 DAYS
HOT GAS
PATH
INSPECTION
32,000 16 DAYS
MAJ OR
INSPECTION
64,000 25 DAYS
Turbine Performance
Degradation Curves*
Turbine Performance
Degradation Curves*
WATER WASH SYSTEM
On Line Wash
Off line Wash
With or Without detergent
Water quality
Fixed or mobile
EMISSIONS
EMISSIONS CONTROL ON ENGINE
Temperature Effects on CO/NOx
AIRFLOW
60%
40%
AIRFLOW
30%
70%
FUEL
FUEL
Conventional
Lean Pre-mixed
Same
Turbine
Inlet
Temp.
Diffusion vs. Pre-Mixed
Solar Turbines Incorporated
2900F
1870 K
4100F
2530 K
Catalytic Combustor
EMISSIONS CONTROL OFF ENGINE
Inlet Fogging & Wet Compression
Selective Catalytic Reduction (SCR)
Oxidation Catalysts for CO removal
SCONOx
Inlet Fogging & Wet Compression
SCONOx
SCR UNITS
GT APPLICATION CONSIDERATIONS
Oil & Gas Requirements:
Availability / Reliability
Ruggedness
High Power/Weight ratio
Efficiency not Critical
Industrial Power Generation
Requirements:
Cost of Electricity
Efficiency
Cost of O&M
INDUSTRY STANDARDS
STANDARD TITLE
API 616 Gas Turbines for the Petroleum, Chemical, and Gas
Industry Services
ASME PTC 22 Performance Test Code on Gas Turbines
API 613 Special Purpose Gear Units for Petroleum,
Chemical and Gas Industry Services
API 614 Lubrication, Shaft Sealing And Control Oil Systems
For Special Purpose Applications
API 670 Non-contacting Vibration And Axial Position
Monitoring System
API 671 Special-purpose Couplings For Refinery Services
FURTHER READING
BOOKS
Gas Turbine Theory - HIH Saravanamuttoo, G. Rogers and H.
Cohen
Sawyers Gas Turbine Engineering Handbook
Gas Turbine Engineering Handbook Meherwan P.Boye
The Gas Turbine Handbook: Principles and Practices - Tony
Giampaolo
J OURNALS
Gas Turbine World
Hydrocarbon Processing
Power Engineering
INTERNET
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