Concordia University

Faculty of Engineering and Computer Science

Department of Mechanical Engineering

Gas Turbine Design

Project Report
Winter 2009

1
2
 Summary
1. Part A: Engine Design

1.1 LPC exit (2)

1.2 HPC exit (3)

1.3 Combustor exit (4)

1.4 HPT exit (5)

1.5 Inter-turbine duct (6)

1.6 LPT exit (7)

1.7 Inter-turbine duct (8)

1.8 Power turbine (8)

1.9 Engine horsepower and SFC

2. Part B: Turbine Design

2.1 Mean Line design of HPT

2.1.1 Rotational speed and gas path

2.1.2 Velocity triangles and nozzle & rotor loss coefficients

2.2 Hub and tip velocity triangles

2.3 Vane and Blade parameters

2.4 Nozzles and rotor loss coefficients

2.5 Off-design performance

2.5.1 Reduction of the speed by 20%

2.5.2 Reduction of the pressure ratio by 20%

3
 Introduction

Blah blah blah

4
1. Part A: Engine Design
In this part we have to determine the cycle points, temperatures, pressures, compressors and turbine
work and the engine horsepower

General assumptions at intake:

Altitude= 4000 ft =1219.2m T o1 = 100oF= 310.78 oK P01 = 88100,15 Pa

1.1 LPC exit (2)

 1 Assumptions
T01 
T02 = T01+ ( P.R  1) m = 12 lb/sec P.R=4.25 η=.86

Results
P02 = P.R * P01

p02 374425,63 Pa
W2= Cp (T02 – T01)
T02 497,02 K
W2 186339,63 J.kg-1

1.2 HPC exit (3)

Assumptions
m3= (1-10%) m2
cooling air = 10% P.R=2.65 η=.84
 1
T02  Results
T03 = T02+ ( P.R  1)

m3 5,44 Kg/s
P03 = P.R * P02 p03 992227,93 Pa
T03 686,99 K
W3= Cp (T02 – T01)
W3 190870,43 J.kg-1

5
1.3 Combustor exit (4)

Assumptions
Fuel ration=0.02 HV=16760
BTU/lb η=.99 ΔP/P=0.02
m4= m3 (1+Fuel air ration)
Results
P04 = P03(1-ΔP/P)

T04 = m4 4,90 Kg/s

m C3 p T03 
p04
  * f .a.r * m3 * HV
T04
972383,37 Pa
1331,07 K
C p ( m3  m fuel )

1.4 HPT exit (5)

Assumptions
m5= m4+ (1+0.5*cooling air)
η=.88

 T    1
P05 = P04 1  1  05  1 

   T04 

Results
m C
i p (T03  T02  m5 5,17 Kg/s
T05 = T04 -
m5 C p p05 505486,60 Pa
T05 1154,45 K
W5= Cp (T05 – T04) W5 -202945,70 J.kg-1

1.5 Inter-turbine duct (6)

Assumptions
ΔP/P=0.02
m6 = m 5

 p 
P06 = P05 
1  
 p  Results

T06 = T05 p06 495376,87 Pa

T06 1154,45 K

6
1.6 LPT exit (7)

Assumptions
m7= m6+ (1+0.5*cooling air) η=.90

 T    1
P07 = P06 1  1  07  1 

   T06 
 Results

m Ci p (T02  T01  m7 5,44 Kg/s

T07 = T06 -
m7 C p p07 244768,51 Pa
T07 986,67 K
W7= Cp (T07 – T06) W7 -192798,41 J.kg-1

1.7 Inter-turbine duct (8)

Assumptions
ΔP/P=0.02
m8 = m 7

 p 
P08 = P07 
1  
 p 
Results
T08 = T07
p08 239873,14 Pa
T08 986,67 K

1.8 Power turbine (8)

Assumptions
m9 = m 2 η=.93
ΔP/P=0.02
 
 P 
09  atm 
P =  P 
1 
 P 

 1
 
  p 09    Results
T09 = T08 - * T08 1  
 p  
  08  
 
m9 5,44 Kg/s
W9= Cp (T09 – T08) p09 89898,11 Pa
T09 787,16 K
W9 -229265,85 J.kg-1

7
1.9 Engine horsepower and SFC

HP= m9*W9

f .a.r
SFC = m3*
HP

Engine Horspower 1247912,38 W 1673,48 HP

SFC 0,314046 kg/Kw/h 516290,09 lb/hp/h

8
2. Part B: Turbine Design
2.1 Mean Line design of HPT

2.1.1 Rotational speed and gas path

Assumptions
2
AN
N= AN2 4E+10
 (rt 2  rh 2 ) rpm.in²
Uh 1100 ft/sec
M1 0,1
rt  * AN 2 M3 0,4
 2
1
rh 30 2 *U h α1 10 deg
α3 10 deg
60
rh  U h
2N
Results

Hub to tip ratio rh/rt 0.71

0.10 m
Hub radius rh
3.79 in
0.14 m
Tip radius rt
5.34 in
Rotational speed N 30019.051 rpm

The radius rh is calculated from the blade hub speed. The radius r t is calculated from the area A1 which
m1RT1
is calculated from the formula A1  calculated later in the report.
P1V1

9
2.1.2 Velocity triangles and nozzle & rotor loss coefficients

T01 T03
T1  T3 
2
Vr 3  Vr 2
2

 1 2  1 T2  T3 
1 M1 1 M3
2
2Cp
2 2

P01 P03 P01

P1  
P3  
P2  
  1 2 
 1   1 2 
 1  T01   1
1 
 M 1  1 
 M 3   
 2   2   T '2 

V1  M 1 .  .R.T1 V3  M 3 .  .R.T3 T’2=T2-λN(T02-T2)

Va1= V1 cos 1 Va3= V3 cos 3 Va2 =Vu2/tanα2

Vu1= V1 sin 1 Vu3= V3 sin 3 Vu2=-WHPT/Um –Vu3

m1 RT1  U  Vu 3 
A1   r 3  tan 1  m  Vr2=Vu2-Um
P1V1  Va3 

2 2
Vr3=Va3/cos r3 Vr 2  V ru  Va 2

m3 RT3
A3  2
V 2  Vu  V a 2
2

P3V3

P2
2 
R.T2

A2=A3

Results

at 1 at 2 at 3
V1 71.31 m/s Vu2 511.36 m/s V3 262.39
Vu1 12.38 m/s Va2 186.12 m/s Vu3 45.56
Va1 70.23 m/s V2 544.18 m/s Va3 258.40
Vru2 146.95 m/s Vr3 484.61
Vr2 237.14 m/s

10
11
 P01 - P02 P0r2 - P0r3
YN  YR 
P02 - P2 P0r3 - P3

 
T   1  T0 r 3   1
P0 r 2  P2  0 r 2  P0 r 3  P3 
 T 

 T2   3 

V 2  V 2 
T0 r 2  T2   r 2  T0 r 3  T3   r 3 
 2C   2C 
 p  p
The nozzle and rotor loss coefficients are:

YN 0,111
YR 0,166

Efficiency

ξN 0,0768
ξR 0,1204
ηtt 0,87

These losses were verified by the efficiency calculated from the losses, which is 87% knowing that the
efficiency should be 88%.

12
2.2 Hub and tip velocity triangles

Free vortex : Vu1= cste1/r Vu2= cste2/r Vu3= cste3/r U=N.r

2 2 2 2 2 2
V1  Vu1  V a1 V2  Vu 2  Va 2 V3  Vu 3  Va 3

Vru 2  Vu 2  U

2
Vr 2  Vru 2  Va 2
2
Vr 3  Va 3 / cos  r 3

V  V  V 
 1  tan 1  u1   2  cos 1  a 2   3  tan 1  u 3 
 Va1   V2   Va 3 
V   U  Vu 3 
 r 2  tan 1  ru 2   r 3  tan 1  
 Va 2   Va 3 

 V1 2   V2 2 
T1  T01    T2  T02   
 2C   2C 
 p   p 
 (V r 3 2  V r 2 2 
T3  T2   
 2C p 
 

V 2  V 2 
T0 r 2  T2   r 2  T0 r 3  T3   r 3 
 2C   2C 
 p   p 

P2   2 .R.T2 P3   3 .R.T3

 
T   1  T03   1
P02  P2  02  P03  P3 
T 

 T2   3 

T2  T3
R
T1  T3
The Results are:

r 0.10 0.11 0.12 0.13 0.14

T2 1151.00 1180.15 1202.21 1219.31 1232.82
T3 1124.09 1124.32 1124.50 1124.63 1124.74

13
 p2 597057.76 612182.97 623626.30 632492.59 639501.31
p3 454826.29 454919.95 454990.82 455045.72 455089.13
p02 1068336.66 991016.37 937404.70 898495.00 869247.20
p03 506035.91 505723.10 505486.60 505303.46 505158.76
α2 deg 73.18 71.58 70.00 68.45 66.94
α3 deg 11.99 10.91 10.00 9.23 8.57
Stagger angle is calculated from Fig5

V2 643.30 (rt - 588.92

rh ) 544.18 506.80 475.18
Chord V3
c
264.16 263.15 262.39 261.79 261.32
h/c
Vu2 615.79 558.74 511.36 471.39 437.21
Axial chord
Vu3 ca=c*cos(γ)
54.87 49.78 45.56 42.00 38.96
Va2 186.12 186.12 186.12 186.12 186.12
Va3 258.40  258.40
Pitch of vanes s  c a 258.40 258.40 258.40
Vr2 364.31 2.(tan 
292.18 1  tan  )
237.14
2 cos 2
 2201.07 186.44
Vru2 313.18 225.23 146.95 76.08 11.00
Vr3 441.09 2 .r462.26 484.61 507.95 532.12
Number of vanes/blades N m

R 0.13 s 0.27 0.37 0.45 0.52

This table shows:

 A radial increase in temperature and pressure for the leading edge, this is due to the change
in the radius so a change in the speed. However for the trailing edge, the radial conditions are
almost the same, since we are at the exit of the HPT,

 A temperature and a pressure drop between leading and trailing edge, which is normal since
we transfer energy from the flow to the blades in a turbine,

 The turning is lower as the radius increases, in order to reduce the losses on the tip (tip
leakage, secondary…)

 The reaction increases with the radius since the temperature follows the same pattern.

2.3 Vane and Blade parameters

14
Results

To be validated

Vane Blade

h/c 0,7 - h/c 1,3 -

Ψ 0,75 - Ψ 0,9 -
TAT 0,04 in TAT 0,02 in
C 0,056 m C 0,028 m
Ca 0,036 m Ca 0,022 m
γ 50 deg γ 38 deg
s 0,040 m s 0,018 m
Nv 18 vane Nb 44 blade

So the final design will be 18 vanes and 44 blades.

15
2.4 Nozzles and rotor loss coefficients

 YN = YP * fRE + YS + YTET +YTC

2 
YP = 0.914
 3 YP , AMDC K P  Yshock 

1
   1   1  
YP, AMDC = YP(  10)     
 YP(  1 2 ) - YP( 1 0)   t max /c  2

   2   2  
  0.2



With Kp = 1 – K2 (1- K1), K1 = 1-1.25(M2-0.2), K2 = (M1/M2)2

YS = 1.2 YS, AMDCKS

 cos 2   C  2 cos 2 2
   L 
 cos1   s/c  cos  m
3
YS, AMDC = 0.0334 f(AR)

CL 1  1  0.25 2  h c
 2 (tan  1  tan  2 )
1

With s/c = 2(tan1 + tan2) cosm m = tan f(AR) =

h c

Using AMDC loss system, the loss coefficients for the stator are:

profile losses secondary losses Trailing edge losses

book page 330
tmax/c 0,2 assumption fAR 1,02 t/s 0,026 ≠ 0,02
s/c 0,705 αm -0,91 rad correction factor 1,05 from graph
Yp (β1=0) 0,04 from graph -52,12 deg
Yp (β1=α2) 0,14 from graph CL/(s/c) 3,59 YTET 0,006
Yp AMDC 0,0387 Ys AMDC 0,08
Yshock 0 M1 is too small K3 0,84
M1 0,10 Ks 0,99
M2 0,80
K1 0,25
K2 0,015 Ys 0,093
Kp 0,99
Re 1,38E+06 reynolds > 10^6
f(Re) 0,938

Yp 0,022

Total AMDC loss Total Pressure loss

YN
0,12 compared to 0,11

16
Assuming an unshrouded blade with a radial tip clearance of 2% of blade height, the loss coefficients
for the rotor are:

profile losses secondary losses Tip clearance losses

tmax/c 0,200 fAR 0,6083 book page 329

s/c 0,525 αm -0,379 rad assumption of unshrouded blades
with radial tip clearance of 2% of
Yp (β2=0)
0,040 from graph -21,73 deg blade height
Yp (β2=αr3) 0,100 from graph CL/(s/c) 4.4146
(cosβ3/cosβ2)^2
Yp AMDC Ys AMDC 0,098
0,069 /(1+rm/rt) 0,263
Δp/q1 hub 0,027 K3 0,5397 λ 0,008
Δp/q1 shock 0,019 Ks 0,92 B(k/h) 0,010
Yshock 0,005 βm 0,354 rad
Mr2 0,350 Ys 0,108 Ys+Yk 0,121
Mr3 0,739
K1 0,327 Trailing edge losses YTC 0,013
K2 0,224
Kp 0,849 book page 330
Re 5,16E+05 t/s 0,032 ≠ 0,02
correction
f(Re)
1 factor 1,05 from graph

Yp 0,041 YTET 0,009

Total AMDC loss Total Pressure loss

YR 0,17 compared to 0,17

We notice that the loss coefficients calculated with the AMDC method are very close to those
calculated with the pressure losses.

We also notice that the most predominant losses are the secondary.

17
Blade metal area ration

τ 300 h
K1 15
K2 55,6
K3 -5,2
K4 0,6 lb/in3
ρ 0,315 -
Lm2 45,2 KSI maximum life
Lm1 45,2 KSI Actual life

σc 247,3 23,48 KSI

K5 175,7 16,68
AH/AT ≈1 2.3

Since the Lm1 equation is a second order equation, we have 2 solutions for σc and so for K5 , but only
one of them seems to be reasonable. We chose 2.3 as AH/AT.

18
2.5 Off-design performance

2.5.1 Reduction of the speed by 20%

i off  r 2 off = - β2 with β2 is metal angle (unchanged)

Incidence
 on the rotor
Umean off 291.52

β2 40.29 metal angle is cst
  1 2 1   1
1  rad M r 3  2  1 1
αr2 off Y’=0,88
 2  
 

50.39 1deg  1 2   1
 1  M r3 
 2 
i off 10,10 incidence on the rotor

2
 cos  2
 *  r 2 off   r 2 
d 
1.6
 2
Incident Loss x’=rotor
on   *  and  2  1   p
 s  cos  3 
incident profile losses incident secondary losses
 p
2
d/c 0,044 assumed =0.778*10-5 x’ + 0.56*10
'' -7 x’2 + 0.4*10
0,18-10 x’3 + 2.054*10-19 x’6

s/c 0.52 (Y/Ydes)S 2,08 0 < '' < ,3

 Y’’= Y s,des (exp(0.9 x ”) + 13 x ” 2 + 400 x ”)
d/s 0.08 YiS 0,225

β2 40.29 0,70
deg rad

β3 57.78 1,01
deg rad

αr2 38.29 deg Assume same TET and Tip clearance losses

Mr3 0.75

' 312.23

²P 0,00930 0 < ' < 800 Total loss

0,01173 YR 0,317
YiP

19
Efficiency drop YN
 N  2
1  0.5 *  * M 2
ξN 0,0690
ξR Y
  R 0,2298 R 2
ηtt 1  0.5 *  * M r 3 Knowing that we originally had to have 0,88
0,8256
dηtt 6,19 %
1
 tt off 
 .V   R (Vr3 ) 2
2
1 N
 2

2.(h 01  h03 )

With (h01-h03)=U2Vu2-U3Vu3=Um(Vu2-Vu3)

Reducing the speed by 20% will lead to:

 an increase of αr2 and then generate a positive incidence of 10 degrees

 an increase of losses on the rotor

 a reduction of the efficiency by 6.19%

20
2.5.2 Reduction of the pressure ratio by 20%

Design conditions 80% Pressure ratio

21
 Design 80% PR % decrease
V1 71.31 70.12 1.67
Vu1 12.38 12.18 1.67
Va1 70.23 69.05 1.67

Vu2 471.32 369.81 21.53

Va2 171.55 134.60 21.54
V2 501.56 393.54 21.54
Vru2 78.68 5.40 93.13
Vr2 188.73 134.71 28.62

V3 262.39 262.47 -0.03

Vu3 45.56 45.58 -0.03
Va3 258.40 258.48 -0.03
Vr3 508.71 484.66 4.73

The effect of reducing the pressure ratio by 20% on the velocity triangle is:

 a reduction of the incidence (so a reduction of losses),

 a reduction of speeds at the stator and the rotor,

 a reduction of the component Vu, which reduces the energy transfer.

22
Conclusion

23