07.1 P Gas Turbine Refresher

Gas Turbine Applications
Siemens Oil & Gas
Gas Turbine Refresher

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.
 The gas turbine is an internal combustion engine.

 The working cycle of the gas turbine is similar to that of a four-
stroke piston engine.
 In the piston engine combustion occurs at constant volume
whereas in the gas turbine it occurs at constant pressure (both
engine cycles are shown on the following slide). In each instance
there is induction, compression, combustion and exhaust.
 In the piston engine these processes are intermittent but occur
continuously in the gas turbine. Only one stroke is utilised for the
production of power in the piston engine, the others utilised for
induction of fuel/air mixture, compressing the mixture and
exhausting the products of combustion.
 By contrast the gas turbine eliminates the three idle strokes thus
allowing more fuel to be burnt in a shorter time giving the gas
turbine far greater power for its size.

Page 2 Aug 2010 Energy Sector - Lincoln Power Generation Oil & Gas and Industrial Applications
Comparison of Gas Turbine and Reciprocating Engine Cycle
AIR INTAKE FUEL COMBUSTION EXHAUST
COMPRESSION
Continuous
Intermittent
AIR/FUEL INTAKE COMPRESSION COMBUSTION EXHAUST

 There are two basic rotor layouts Single shaft and Twin shaft.
 Single shaft
 The air compressor and turbine are on a common shaft
rotating at the same speed. Only minor changes in speed can
be accommodated without severe performance impact.
 Used for power generation at fixed speed
 Twin shaft
 The air compressor and its turbine are on a common shaft
rotating at the same speed. The power turbine is on a
separate shaft which operates at a lower speed and can
accommodate larger variation with minor performance impact.
 Used for mechanical drive
 Allows variable speed operation (Typically 60 – 105% speed)
 Can be used for power generation
 Transient response inferior to single shaft unit
Combustion
Single Shaft Chamber Exhaust
Turbine
Drive End Compressor
Centre journal
Gas turbine thrust bearing
bearing Exhaust
Inlet journal Exhaust

bearing Power
Turbine
Interduct
Combustion
Inner & outer
Twin Shaft Chamber
journal bearings
Compressor Drive End
Centre journal
Gas generator bearing
thrust bearing
Compressor Power turbine
Turbine thrust bearing

Rotor Layout
Single Shaft
Overhung Beam
Twin Shaft

You may also hear the terms “twin spool” or “multi spool” engine, these refer
to aero engines where the gas generator has more than one coaxial shaft
and provides the hot gas to drive a free power turbine or the low pressure
compressor stage is removed and the low speed shaft powers the driven
equipment directly. This latter arrangement has severe power restrictions at
lower speeds if used to drive a compressor
LP Compressor HP Compressor LP Turbine
HP Turbine
HP Spool
LP Spool
Aero Engine Industrial Free Power Turbine

Twin Spool High By-pass Aero Engine

Optimum bypass ratio is approximately 5 - 1
New LP Stage
Bypass Fan
Inlet Exhaust
Plenum Plenum
High By-pass Aero Engine with fan blade removed & new LP stage added
providing power output via the low speed spool (shaft) to the driven unit

Single shaft gas turbine Turbine & Exhaust Casing

Compressor Casing & Stators
Rotor
Combustion

Twin Shaft Gas Turbine
Compressor Turbine & Casing

Power Turbine & Exhaust Casing
Compressor Casing & Stators
Twin shaft gas turbine
Compressor & Power Turbine Rotor
Combustion
Gas Turbine cycle
Factors effecting power

 Mass flow
 Cycle temperature
Factors effecting efficiency

 Pressure ratio
 Cycle temperature

Gas Turbine Performance
Factors affecting performance :
Ambient air temperature

Fuel type
Barometric pressure/altitude
Relative Humidity
Inlet and exhaust ducting losses
Combustion system type (negligible)
Wet injection for emission control

Ambient air temperature

As temperature increases, density decreases, mass flow
decreases
Result: Power reduction
Fuel type
Liquid fuel tends to burn hotter and less efficiently than gas fuel
Turbine de-rated on liquid fuel in order to compensate for higher

temperatures
Engine efficiency on liquid fuel approx 1.3% lower than on gas
As power reduces, so turbine efficiency reduces

GasTurbine Performance
Barometric Pressure/altitude
Barometric pressure decreases as altitude increases
As barometric pressure decreases, air density decreases

Power output decreases
Inlet depression/exhaust back pressure

As pressure drops increase, power output decreases
Inlet pressure drop has greater effect than exhaust back

pressure
Maximum allowable pressure drop depends on system/engine
design
Each engine manufacturer will specify his limits
Effects of Increasing Humidity

 Water vapour is lighter than air, the engine mass flow will be
reduced at constant speed.
 For the same reason, the pressure ratio for a given head
will decrease.
 The specific heat of the combustion chamber exit gas will
increase with increased amounts of water vapour. Therefore
the turbine can produce more power under otherwise the
same conditions.

Combustion System Type

 Effect on power output negligible
 Significantly less than engine to engine variation
 DLE can have marginal adverse effect on engine efficiency
 Less than 0.5%
 Again less than engine to engine variation
 Performance curves issued by engine manufacturers tend not
to differentiate
 Differences less than the thickness of a line

What else can affect performance?
Air Compressor
Compressor discharge pressure lower than design?
IGV Actuator working incorrectly
Foreign Object Damage (FOD)
Bleed Valve leaking, stuck open.
Air Filters plugged.
Air Compressor fouled.
Combustion
Fouled burners (particularly on liquid fuel)
Low fuel pressure
Turbine fouling
Contaminated fuel
Most often during liquid fuel operation
Increased clearances
Normal wear and tear
Power typically degrades circa 2% on industrial machines
Can be significantly more for aero-derivative machines
Gas Turbine Systems
There are two basic types of compressor used in gas turbines one
centrifugal the other axial which are driven by the compressor turbine.
 Centrifugal compressors are used in small gas turbines or as a high
pressure section in an aero engine and some industrial gas turbines.
 Both types accelerate the air and diffuse it to produce the required
pressure rise, the centrifugal uses a separate diffuser section whereas the
axial uses the stator vanes following each rotor stage.
 There are advantages and disadvantages with both types, the centrifugal
compressor is more robust and is easier to develop and manufacture
whereas the axial compressor can swallow far more air for the same
diameter.
 As air mass flow is an important factor in determining the power output

most manufacturers use the axial compressor to achieve maximum power
for minimum size/weight.
Gas Turbine Systems
Compressors
Centrifugal
 Used in small gas turbines
Axial
 Used in larger gas turbines
Axi-centrifugal
 Used in small aero engines
 Used in some industrial turbines (rarely)

Combustion Systems
CONVENTIONAL COMBUSTION (Diffusion Flame)

 Can burn wide range of fuels
 LPG & Naphtha
 Natural gases with high inerts
 Bio Fuels
DLE COMBUSTION (Pre-mixed Lean Burn)

 Narrower range of fuels
 Fuel Range expanding following continuing R & D
 Any pipeline quality gas acceptable (Wobbe Index
37 to 49 MJ/m3)
 Natural gases with some inerts (Wobbe Index 25
MJ/m3) on a case by case basis
Combustion Systems
ANNULAR
Tends to be used on aero engines
Tends to be used on medium and large
gas turbines
Tends not to be site servicable
CAN-ANNULAR
Versatile
Can be changed out at site
Silo
Used in some medium and large gas turbines
Conventional Can
Can be single or dual combustors DLE Can

Environmental Effects
POLLUTANT EFFECT METHOD OF CONTROL
Carbon Dioxide Greenhouse Gas Cycle Efficiency
Carbon Monoxide Poisonous DLE System
Sulphur Oxides Acid Rain Fuel Treatment
Nitrogen Oxides Ozone Depletion DLE System

Smog
Unburned Poisonous Greenhouse DLE System
Hydrocarbons Gases
Smoke Visible Pollution DLE System
Main Pollutants
Combustion Systems
Diffusion Flame
Combustion
Local Max Temp 2717 K with high
temperature
in the
25% primary zone
Primary Film Cooling Air
Dilution Air
Air Flow
Lean Premix
Combustion
with lower
temperature Local Max Temp 1870 K
in the
primary zone
50 -70% Cooling and Dilution air demand reduced by

Primary Air Flow using same air for both duties
Combustion Systems
]
s
/m
100000 NOx/CO TRADE-OFF

p p m
10000
Typical Diffusion Flame

[
1000
Peak Temperatures
Rate [ppmm]
F o r m a tio n R a te
100
Emissions level
10
1
Optimum
Temperature
NOxX Formation
Peak Temperatures
Typical Lean Burn
0.1
0.01
0.001
N O
0.0001
0.00001 Reactor temp

0.000001
1300 1500 1700 1900 2100 2300 2500 2700 2900 Excessive Excessive
Flame Temperature [ K ] CO NOx
Flame Temperature [K]

Emission Control with Conventional Combustion
Water Injection Steam Injection

NOx reduced as a result of flame NOx reduced as a result of flame
temperature reduction by injecting temperature reduction by injecting
water into the combustion chamber steam into the combustion chamber
NOx reduces as water injection rate NOx reduces as steam injection rate
increases increases
CO increases as water injection rate CO increases as steam injection rate
increases increases
Increase in turbine Power Output Increase in turbine Power Output
Reduction in engine efficiency Increase in engine efficiency
Potential issues with combustion No potential issues with combustion
chamber life chamber life
High quality de-mineralised water High quality demineralised
required superheated steam required

DLE Combustion- Part Load Performance
VGV schedule for turndown on single shaft gas turbines
Bleed for turndown on two shaft gas turbines
60
20 NOX with no bleed
P2 NOX with bleed
Bleed CO with no bleed 50
CO with bleed
Combustor 18
40
16
NOX @ 15% O2 (ppmvd) 30
12 CO
Compressor Turbine 20
8
10
4
Gas Operation
0
0 20 40 60 80 100
Load (%)
Excellent Turndown

Turbine
The turbine converts the energy in the hot gases to mechanical energy
Mechanical energy used to:
Drive the engine compressor
Provide rotational energy to the driven equipment
Each Turbine Stage consists of two sections

The Nozzle
Guides the hot gases in the correct direction onto the rotating turbine wheel
Converts pressure into velocity
The Turbine Wheel

Rotates at high speed to provide mechanical power

How Does It Work ?
Turbine
 For the single shaft gas turbine the turbine section provides
the power to drive the air compressor and the output shaft for the
generator.
 In the twin shaft gas turbine the turbine section is divided into
two parts, the compressor turbine and the free power turbine. The
compressor turbine provides the power to drive the air compressor
with the free power turbine providing the output shaft power to drive
a compressor or pump.
 The turbines do this by extracting energy from the hot gases

produced in the combustion system and expanding them to lower
pressure and temperature.
 To produce the driving torque, the turbine may consist of

single or multiple stages each using one row of stationary nozzle
guide vanes and one row of moving blades. The number of stages
is determined by the relationship between the power required from
the gas flow and the rotational speed at a given turbine diameter.

Turbine
 The design of the nozzle guide vanes and turbine blades is based on a combination of
aerodynamic and efficiency considerations compatible with the compressor and combustion
design. Basically the pressure and temperature entering the turbine stage.
 There are two fundamental types of turbine, impulse and reaction although most gas
turbines use a combination of impulse and reaction types generally in a 50/50 ratio.
 In the impulse design the total pressure drop across a stage occurs in the nozzles which
increase the gas velocity, as a result of their convergent shape, while reducing pressure. The
high velocity gas impacts on the blades creating rotation.
 In the reaction design the nozzles change the direction of the gas without a reduction in
pressure. The gas enters the convergent blade passages where it expands and accelerates
generating a reaction force creating rotation.
NOZZLE TURBINE NOZZLE TURBINE
Comparison Between Impulse and
Impulse/Reaction Turbines
Turbine driven by
the impulse of the
Turbine driven by gas flow and its
the impulse of the subsequent reaction
gas flow only as it accelerates
through the blade
passage
Impulse Turbine Impulse/Reaction Turbine

How Does It Work ?
Turbine
Turbine nozzle guide vanes and blades
Stagger are “twisted” providing a stagger angle that
Angle
is greater at the tip than the root. The twist
is there to ensure that the gas flow does
BLADE TIP equal work along the length of the blade
and to generate uniform axial velocity of
the flow into the exhaust system.
DIRECTION
OF FLOW This changes the velocity, pressure and
temperature across the turbine. This
Stagger degree of reaction varies from root to tip
Angle with the highest at the tip and the lowest at
BLADE MID the root with the mid height having a value
HEIGHT
of 50%.
DIRECTION
OF ROTATION The torque applied to the turbine is
controlled by the gas flow rate and the
change of energy between the inlet and
outlet of the blades. The turbine blades
are designed so that the majority of the
BLADE ROOT
whirl is removed from the gas stream thus
straightening out the flow to give axial exit
to the exhaust system minimising losses.
Turbine
Subject to high temperatures

Gas temperatures 1050 – 1250OC depending on engine type
Need for high temperature nickel based alloys
Recent material developments have increased creep capability
Chrome content reduced
Reduction in oxidation/corrosion resistance
Coatings applied to compensate
Despite use of high temperature alloys, nozzle and blade cooling

is required
Without cooling, blade life could be less than 10 hours
Cooling would normally cool metal temperatures to below
900OC

Turbine Nozzle Cooling
Film cooling Cooling air feed
Impingement cooling
Film cooling
Cooling air feed

Trailing edge ejection

Turbine Nozzle Cooling
Film cooling holes
Trailing edge ejection
Slots for inter section sealing

How Does It Work ?
Rotor Blade Cooling
Cooling air feed
Bottom Feed


07.1 P Gas Turbine Refresher

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Gas Turbine Applications

Siemens Oil & Gas

Gas Turbine Refresher

 The gas turbine is an internal combustion engine.

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

AIR INTAKE FUEL COMBUSTION EXHAUST

AIR/FUEL INTAKE COMPRESSION COMBUSTION EXHAUST

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Inlet journal Exhaust

Compressor Drive End

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Aero Engine Industrial Free Power Turbine

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Twin Spool High By-pass Aero Engine

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Single shaft gas turbine Turbine & Exhaust Casing

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Twin Shaft Gas Turbine

Compressor Turbine & Casing

Factors effecting power

Factors effecting efficiency

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Factors affecting performance :

Ambient air temperature

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Ambient air temperature

Turbine de-rated on liquid fuel in order to compensate for higher

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

As barometric pressure decreases, air density decreases

Inlet depression/exhaust back pressure

Inlet pressure drop has greater effect than exhaust back

Effects of Increasing Humidity

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Combustion System Type

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

 As air mass flow is an important factor in determining the power output

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

CONVENTIONAL COMBUSTION (Diffusion Flame)

DLE COMBUSTION (Pre-mixed Lean Burn)

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

POLLUTANT EFFECT METHOD OF CONTROL

Carbon Dioxide Greenhouse Gas Cycle Efficiency

Carbon Monoxide Poisonous DLE System

Sulphur Oxides Acid Rain Fuel Treatment

Nitrogen Oxides Ozone Depletion DLE System

50 -70% Cooling and Dilution air demand reduced by

100000 NOx/CO TRADE-OFF

Typical Diffusion Flame

0.00001 Reactor temp

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Water Injection Steam Injection

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

VGV schedule for turndown on single shaft gas turbines

Bleed for turndown on two shaft gas turbines

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Each Turbine Stage consists of two sections

The Turbine Wheel

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

 The turbines do this by extracting energy from the hot gases

 To produce the driving torque, the turbine may consist of

Copyright © Siemens Industrial Turbomachinery Ltd 2006. All rights reserved.

Impulse Turbine Impulse/Reaction Turbine