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Proceedings
ASME Turbo Expo 2006: of Land,
Power for ASME Sea
Turbo
andExpo
Air 2006
Power of Land, Sea,
May 8-11, 2006, Barcelona, Spainand Air
May 8-11, 2006, Barcelona, Spain
GT2006-90932
GT2006-90932
(
t ct = (t c ). k g k ct ) (24)
p,t
Tb (continuous)
0.875
1010 K
0.92
1123 K
kct, coating thermal conductivity is assumed to vary linearly (continuous) 0.42 0.20
TBC Film
between 0.72 W/m.K at 289 K and 2.73 W/m.K at 1770 K based Stage
rows rows
3 0 0 3 2 3
on reference [26]. kg, gas thermal conductivity can be U (linear increase:0.1) 450 m/s 500 m/s
approximated as proportional to T2/3 [5]. 0.5 0.6
3 (linear decrease:0.5) 20 20
MODEL CALIBRATIONS AND VALIDATIONS st rt 0.4 0.45 0.3 0.35
In this section, appropriateness of the program is verified by Tb,max,st1 Tb,max,rt1 1050 K 1020 K 1110 K 1090 K
simulating performance of real gas turbines. To use the Tb,max,st2 Tb,max,rt2 1020 K 980 K 1100 K 1080 K
Tb,max,st2 Tb,max,rt2 980 K 950 K 1050 K 1000 K
program routine, specified data are needed. Two current gas Kcomb1 Kcomb2 Kcomb3 0.02 0.01 0 0.08 0.02 0.01
turbines from large capacity high-performance engines to small
scale engines which have sufficient data are selected as in Table 4: Reference gas turbine input data
Table 1. pc 0.91 Pc 1% Fuel CH4
Table 2 shows the results of two different models for two
aforementioned gas turbines. Some of the main parameters and pt 0.90 Pcc 4% Tfuel 288 K
their values of each gas turbine are listed in Table 3 which are
m 0.99 Pet 3% Blade speed 400 m/s
used for model calibration, while errors of efficiency, power
and TET are minimized. The inputs for DP are: DPinlet=0.01, cc 0.99 Disk cooling 10% 2
DPc.c. =0.04, DPexh=0.02 for all turbines. The agreement
between prediction results and engine data is satisfactory. Yst 0.15 max 2.5 0.6
Tb,max Absolute exit
Yro 0.20 1123 K 20
MODELS CAMPARISON (1st stator) angle
Due to characteristics of continuous model that has no need Kcomb Tb,max Hub to tip
0.08 1098 K 0.8
(1st stator)4 (1st rotor) ratio
to define the number of stages, we compare the effect of the Kcomb Tb,max
number of turbine stages in new stage by stage model with 0.01 1093 K Bi 0.2
(1st rotor)5 (rear stators)
simple continuous model. First, we assume a reference gas Kcomb
0.02
Tb,max
1068 K TTBC / c 0.008
turbine for comparison of different models, and then in the next (1st stator)4 (rear rotors)
section we use this reference to study the effect of
First, we describe the results of stage by stage model with
modifications on gas turbine cooling technologies and coolant
constant number of stages. Figures 3 and 4 show the differences
properties. The input data for calculating the reference gas
between reference gas turbine (continuous model) with new
turbine are listed in Table 4.
As described in [11], [27] and [28], continuous model is model for a three and four stages turbine, respectively. In three
stages case, with increasing CPR, efficiency difference between
suitable for study of how variation of CPR and TIT affects gas
two models decreases while, power, cooling air mass flow and
turbine cycle performance, While the stage by stage model is
TET differences increase. For four stages turbine, the trend is
not suitable for these studies because of its high inputs and
quite inversed and efficiency difference increases with increase
complexity. A reason for this problem is need to determination
in CPR, but power, cooling air mass flow and TET differences
of the number of stages and this quantity will hold constant
decrease. It can be concluded that varying CPR in stage by
through CPR variations. A solution for this problem is to use
stage model with constant number of stages, causes large
equation (9) to estimate the number of turbine stages with
difference between actual and calculated data, while with
variation in CPR. In reference [28], it has been shown that with
change in number of stages with increase in CPR, the average
Variations (K)
5
-30
Coolant Flow Ratio Variations (%)
11 20
Variations (K)
2 -50
5 5
1
3 0 -60
0
1 -5
-1 -70
-1 -10 6 10 14 18 22 26 30 34
Efficiency Variations
1900 K 1750 K 1600 K 1450 K 5
4 40 -5
3.5 4
30 3 -15
3
Power Variations (kJ/kg)
Efficiency Variations
2
2.5
20 -25
2 1
1.5 10 0
-35
1 -1
0 -2 -45
0.5
6 10 14 18 22 26 30 34
0 Compressor Pressure Ratio
-10
-0.5 (b) Power and efficiency Variations for four stages from continuous
-1 -20 Figure 4 - The comparison of continuous and stage by stage model for
6 10 14 18 22 26 30 34 different TITs and CPRs
Compressor Pressure Ratio
(b) Power and efficiency Variations for three stages from continuous 1950 1800
Figure 3 - The comparison of continuous and stage by stage model for
different TITs and CPRs 1700
1800
1600
Form equation (9), increase in CPR causes to increase in 1650
Temperature (K)
Temperature (K)
1500
number of stages. Usually for CPR higher than 15-16, number 1500 1400
of stages will increase from 3 to 4. The net effect is that in these
1350 1300
cases, variations of all the above differences are kept as low as
1200
possible with variation in CPR. This enables us to use new 1200
stage by stage model in thermodynamic evaluation with CPR 1100
1050
variation. Using this model, can help to estimate how different 1000
Variations (K)
-1 20
Coolant Flow Ratio Variations (%)
10 -3 10
1
Variations (K)
-4 5
5
-5 0
0
0 -6 -5
-1 -7 -10
-5 6 10 14 18 22 26 30 34
-2
Compressor Pressure Ratio
-10
Efficiency Variations
1 25
1.4
30
0.9
20 1.2
0.8 20
Power Variations (kJ/kg)
15 1
Efficiency Variations
0.7 10
0.8
10
0.6
0
0.6
0.5 5
0.4 -10
0.4
0
0.3 0.2 -20
-5 6 10 14 18 22 26 30 34
0.2 Compressor Pressure Ratio
-10
0.1 (b) Power and efficiency Variations
0 -15 Figure 7 - The effect of addition 2 coated rows respect to 2 film rows for
6 10 14 18 22 26 30 34
different TITs and CPRs
Compressor Pressure Ratio
(b) Power and efficiency Variations In this case, the cooling flow for the rear stages increases,
Figure 6 - The effect of increase the number of film cooled rows from 2 to 3
for different TITs and CPRs therefore the compressor work decreases, but this augmentation
is not too high to increase the total cooling flows because the
Change in the number of film cooled rows does not change reduction in required cooling flow in high pressure order (at
the total number of cooled rows, while CMF changes. In end of compressor) is dominant.
CPR=14, for lower and upper bound, number of cooled rows It can be seen that although two rows TBC with three film
decrease from 5 to 4 and 6 to 5, respectively. rows reduces CMF more, but with increase in TIT, this effect
Figure 6b shows that increasing film cooled rows improve will be lower and it can be concluded that in higher TIT than
power, significantly for high TIT and this improvement 1900 K, there will be no considerable reduction in CMF with
decreases with decrease in TIT. Similar to CMF trend, for two TBC row cooled. TET again increases with blade cooling
TIT=1600 K, power decreases due to increase in cooling air improvement.
mass flow and in TIT=1900 K, it increases significantly from Figure 7b again shows different trend with figure 6b. For all
10 to 14 and then remains approximately constant. Similar to TITs, power has increased very much relative to reference, but
other cases, improvement in efficiency is higher for high TIT. now for TIT=1900 K, the highest steep occurs in CPR in the
In TIT=1600 K, power decreases with CPR growth, also CMF range of 14 to 18. Using TBC, CMF decreases too much, so the
increases (combustion chamber flow decreases) and efficiency rear stage inlet temperature increases and for CPR=10-14, the
remains constant over a wide range of CPR. For TIT=1900 K, number of cooled rows reduces from 6 to 5 (stage 3 has
power increases (or remains constant in higher CPR), also CMF adiabatic or uncooled expansion). It is why the steepest
decreases (or remains constant), so efficiency improves with reduction in CMF also occurs between 14 and 18. Of course
increase in CPR (or remains constant). again in CPR=14-18 efficiency has the highest increase.
As shown, increasing the number of film rows does not Figure 8 shows the effect of three rows TBC on cycle
change power and efficiency significantly, therefore use of performance relative to two film rows. CMF reduces again, but
TBC is necessary for the first stage. First we consider two rows not significantly. The trend for increase in CPR and TIT is
with TBC (figure 7). In figure 7a, it is interesting to note that similar for CMF, TET, power and efficiency. In this case,
change in the number of cooled rows with CPR again occurs in
Variations (K)
-2 26, then it increases. But the efficiency variation does not
-3 15
change for different TIT significantly. It is because with
-4
5
increase in TIT, CMF does not decrease with the rate of power
-5
increment.
-6
-7
-5
With FP using waste heat of CAP, as shown in figure 12,
-8 -15
power increases similar to CAP alone. But due to increase fuel
6 10 14 18 22 26 30 34
temperature, efficiency increases in all CPR.
Compressor Pressure Ratio
(a) TET and CMF variations 1600 K 1750 K 1900 K 1600 K 1750 K 1900 K
4 10
1600 K 1750 K 1900 K 1600 K 1750 K 1900 K
Variations (K)
45
Efficiency Variations
1
2
2
35 0 0
1.5 25 -2
-1
-4
15 -2
1
-6
5 -3
-8
0.5
-5 -4 -10
6 10 14 18 22 26 30 34
0 -15
Compressor Pressure Ratio
6 10 14 18 22 26 30 34
Compressor Pressure Ratio
Figure 9 - Variations of CMF and TET due to 200 K CAP for different
(b) Power and efficiency Variations TITs and CPRs
Figure 8 - The effect of increase the number of coated rows from 2 to 3 for
different TITs and CPRs
1600 K 1750 K 1900 K 1600 K 1750 K 1900 K
0.04
Although with three TBC rows, for higher than 1900 K 0.02 12
-0.02 7
-0.06
2
- IMPROVEMENT IN COOLANT PROPERTIES -0.08
mc Tg ,max Tb
-0.14
C
= .. Pg (25) -0.16 -8
m g Tb Tci C Pc 6 10 14 18 22
Compressor Pressure Ratio
26 30 34
where and are functions of Stg, area ratio, cooling efficiency Figure 10 - Variations of efficiency and power due to 100 K CAP for
different TITs and CPRs
and cooling technology. For each gas turbine they are constant
values.
1600 K 1750 K 1900 K 1600 K 1750 K 1900 K
For constant cooling technology, flame temperature and 0.1 25
0 15
Efficiency Variations
CAP and the ratio of specific heats increases, but the effect of -0.25 -10
decreasing coolant enthalpy is dominant. The net effect is
-0.3 -15
decrease in CMF. 6 10 14 18 22 26 30 34
Compressor Pressure Ratio
Figure 9 shows the effect of precooling on CMF and TET
Figure 11 - Variations of efficiency and power due to 200 K CAP for
for three rows TBC air-cooled turbine. With increase in CPR, different TITs and CPRs
for all TITs, CAP has more effect on CMF due to increase in
Tci with increase in CPR. But as can be seen, for high
TIT=1900 K, CAP with 200 K precooling does not reduce
0.9
Turbine Cycles: Part 2-A Model for Expansion in Cooled
0.8
20
Turbines, ASME J. Eng. Gas Turbines Power, 108, pp.
0.7
0.6
10 [5] El-Masri, M. A., 1988, GASCAN-An Interactive Code for
0.5 5 Thermal Analysis of Gas Turbine Systems, ASME J. Eng.
0.4
0
Gas Turbines Power, 110, pp. 201209.
0.3 [6] S. Consonni, 1990, Performance Prediction of Gas/Steam
-5
0.2 Cycles for Power Production, PhD thesis, Princeton
-10
0.1 University, Thesis No. 1893-T.
0
6 10 14 18 22 26 30 34
-15
[7] Young, J. B. and Wilcock, R. C., 2002, Modeling the Air-
Compressor Pressure Ratio Cooled Gas Turbine: Part 2-Coolant Flows and Losses,
Figure 12 - The effect of 200 k CAP with FP on efficiency and power for ASME J. Turbomach., 124, pp. 214221.
different TITs and CPRs [8] Torbidoni, L. and Horlock, A. F., 2002, A New Method to
Calculate the Coolant Requirements of a High-
CONCLUSIONS Temperature Gas Turbine Blade, ASME J. Eng. Gas
In this paper, different models for cooling of gas turbine Turbines Power, 127, pp. 191-199.
blades are presented, including continuous and different stage [9] Bolland, O. and Stadaas, J. F., 1995, Comparative
by stage models. Two stage by stage models are analyzed and a Evaluation of Combined Cycles and Gas Turbines with
new model having advantages of both previous models is Water Injection, Steam Injection and Recuperation, ASME
developed. The new model validated with manufactures data. J. Eng. Gas Turbines Power, 117, pp. 138-145.
Main achievements of this research are: [10] Jordal, K., 2001, Modeling and Performance of Gas
In constant number of stages, varying CPR increase Turbine Cycles with Various Means of Blade Cooling,
differences between real and calculated data of gas Ph.D. thesis, Lund University.
turbine performance. With varying number of stages [11] Khaledi, H., 2004, Thermodynamic Modeling of
with CPR, the average difference remains constant or Advanced Gas Turbine Combined Cycles with
decreases. Application of Combined Pinch & Exergy Approach,
Increasing the number of film cooled rows and TBC M.S. Thesis, Sharif University of technology.
layer causes better performance for gas turbine but the [12] Wu, C.S. and Louis, J.F. , 1986, A Comparative Study of
effect of TBC on efficiency and especially power is the Different Means of Turbine Cooling on Performance
clearer. of Combined Cycles, J. ENG. G. T. & Pwr., 108, pp. 151-
Increasing CPR with constant number of stages has 159.
two different effects on CMF. First, increasing air [13] Stecco, S.S. and Facchini, B., 1989, A computer for
cooling temperature, increases CMF, second cooled expansion in gas turbine, The 3rd ASME
increasing SPR decreases it. Cogenturbo Symposium.
With three film cooled rows, in medium TIT (1600 K), [14] Holland, M. J. and Thake, T. F., 1980, Rotor Blade
the first effect overcomes the second one, so total Cooling in High Pressure Turbines, J. Aircr., 17, pp. 412
CMF increase relative to two film row with increase in 418.
CPR. This trend will be inversed for high TIT (1900 [15] Torbidoni, L. and Massardo, A. F., 2002, Analytical
K) and CPR in the range of 10-14. Blade Cooling Model for Innovative Gas Turbine Cycle
Use of three film rows and TBC cooled blades, may be Evaluations Supported by Semi-Empirical Air Cooled
change the number of cooled rows. Blade Data, ASME J. Eng. Gas Turbines Power, 126, pp.
For high TIT (more than 1900 K), current 498506.
modifications in blade cooling technology can not [16] Mukherjee, D. K., 1976, Design of Turbines, Using
improve efficiency, significantly. Distributed or Average Losses; Effect of Balding,
Precooling the coolant air alone, increases power, AGARD 195, 8-1.
significantly but reduce efficiency. Thus, FP with [17] Haselbacher, H, 1989, Gas turbines. In Thomas C. Elliott,
cooling air will increase efficiency, too. The effect of editor, Standard Handbook of Power Plant Engineering,
CAP on power in higher CPR is more. chapter 2.5. McGraw-Hill.
[18] Holland. M. J., 1992, Cranfield lecture notes-Rotor Blade
Cooling in HP Turbines. Technical report, Rolls Royce
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plc.
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[20] Goldstein, R.J. and Haji-Sheikh, A., 1967, Prediction of
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