Cairo University

Gas Turbines Faculty Of Engineering

OVERVIEW OF GAS TURBINES

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Gas Turbines Gas Turbine Power Plant Cairo University

Faculty Of Engineering

(1) Gas Turbine

(2) Generator
(3a) Air Intake
(11) Filterhouse
(12) (3b) Air Intake Duct
(4a) Exhaust Diffuser
(3a)
(3b) (4b) Exhaust Stack
(5a) Power Control
Center
(10) (4b)
(9) (6) Auxiliaries with
(2) Enclosure
(7)
(1) (7) GT Enclosure

(5a) (6) (8) Fin Fan Lube Oil

Cooler
(9) Generator Bus
(4a) Ducts
(10) Unit Transformer
(11) HV Switchgear
(8) (grid
connection)

2 (12) Fuel Oil Tank

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 Cairo University
Gas Turbines Faculty Of Engineering

GAS TURBINES
INTRODUCTION
In spite of the successful development of steam
turbines, they have an inherent disadvantage which is
that the production of high pressure -high temperature
steam involves the installation of bulky and expensive
steam generating equipment. This is due to the fact
that the hot gases are used indirectly to produce an
intermediate fluid, namely steam. Clearly a much more
compact power plant results when the hot gases
themselves are used to drive the turbine and hence this
type of turbine is known as gas turbine. These turbines
are suitable for small powers and they are very
compact.
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Cairo University
Gas Turbines Faculty Of Engineering

The ever-growing use of combined cycles in the last

years and the world wide acceptance of these units, as
a result of their outstanding thermal efficiency and
other many advantages, has pushed manufacturers to
raise unit capacity. New machines range from 300-kW
small industrial cogeneration units up to 480 MW single-
shaft power generation units with a steam-cooled
combustion section.

Simple cycle thermal efficiencies range from under 25%

to over 41% with turbine rotor inlet temperature as
high as 1450°C base load.

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Gas Turbines Faculty Of Engineering

In the gas turbine plants, in order to produce an

expansion through the turbine, a compressor is essential
to compress the working fluid followed by a combustion
chamber where heat is added to the cycle. Thus, the
simplest gas turbine cycle consists of a compressor, a
combustion chamber and a turbine.
These components are separate in the sense that they
can be designed, tested and developed individually, and
these components can be linked together to form a gas
turbine unit in a variety of ways. The possible number of
components is not limited to the three already
mentioned.

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Cairo University
Gas Turbines Faculty Of Engineering

Other compressors and turbines can be added, with

intercoolers between the compressors and reheat
combustion chambers between the turbines, in order to
increase unit capacity and to improve thermal performance.
The two main factors affecting the performance of gas
turbine plants are the components efficiencies and turbine
working temperature. The higher they can be made, the
better will be the performance.
The working temperature of the highly stressed turbine
blades must not be allowed to exceed a certain critical
value. This value depends upon the creep strength of the
materials used in the construction of the turbine and the
working life required. Also, it depends on whether the
nozzle and rotor blades are cooled or not.

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Gas Turbines Faculty Of Engineering

GAS TURBINES are classified as :

1- Industrial heavy-duty gas turbines
2- Aircraft-derivative gas turbines
3- medium-range gas turbines
4- Small gas turbines

ESSENTIAL DESIGN CONSIDERATIONS

High efficiency - High reliability &
availability - Ease of service - Ease
of installation - Fuel flexibility -
Conformance with environmental standards

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Cairo University
Gas Turbines Faculty Of Engineering

HEAVY-DUTY GAS TURBINES

The early HDGT design was largely an extension of

steam turbine design. Restrictions of weight and space
were not important factors. Pressure ratio of these
units varied from 5:1 for the earlier units to 35:1 for the
units in present-day service. Now, maximum turbine
inlet temperature is around 1450 C and power up to
500 MW.
Axial flow compressors are most widely used for these
units. Many of HDGT have dual fuel flexibility.

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Gas Turbines Faculty Of Engineering

AIRCRAFT-DERIVATIVR GAS TURBINES

ADGT consists of two basic components:
an aircraft-derivative gas generator and a free-power
turbine. The power turbine is not aircraft derived.
Aircraft-type turbine is mostly used by gas transmission
companies and on gas reinjection platforms. The benefits
to the transmission users are:
- favorable installation cost
- size and weight allow the unit to be packaged and
tested as a complete unit within the manufacturer’s
plant. Power ranges from 2.5 to 50 MW.
- adaptation to remote control
- off-site maintenance concept
9 - downtime is very short, few hours. Khalafallah 01/16

Cairo University
Gas Turbines Faculty Of Engineering

MEDIUM-RANGE GAS TURBINES

These turbines have a power range from 3 to 15 MW, they are
similar in design to the large heavy-duty gas turbines.
These units usually are split shaft designs that are efficient in
part load operations as the gas generator operates at
maximum efficiency while the power turbine operates over a
great range of speeds. Compressors are of the axial type, 10 -
16 stages, and pressure ratios ranges from 5 to 12.
SMALL AND MICRO GAS TURBINES
These units produce below 3 MW. Centrifugal or
combinations of centrifugal and axial compressors as well as
radial turbines are used. Efficiency is low due to limitation of
turbine inlet temperature, as turbine blades are not cooled,
and low efficiency of radial-flow impellers. Micro gas turbines
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have power less than about 350 kW. Khalafallah 01/16
 Cairo University
Gas Turbines Faculty Of Engineering

So, two classes of gas turbines may be distinguished:

the first one may be termed "industrial gas turbines"
while the second is termed "aircraft gas turbines".
This broad distinction has to be made for three main
reasons:
1. The life required of an industrial plant is of the order of
100,000 hours without major overhaul, whereas this is
not expected of an aircraft gas turbine.
2. Limitation of the size and weight of an aircraft power
plant is much more important than in the case of an
industrial plant.
3. The aircraft power plant can make use of the kinetic
energy of exhaust gases, whereas it is wasted in an
industrial plant and hence must be kept as low as
possible.

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Cairo University
Gas Turbines Faculty Of Engineering

These three differences in requirements can have a

considerable effect on design in spite of the fact that the
fundamental theory applies to both categories.
Turbomachinery of gas turbines designed specifically for
industrial purposes tends to look more like that of
traditional steam turbines in mechanical appearance.

The widest applications of the industrial gas turbines are

in pumping sets for oil and gas transmission pipelines
and peak load electricity generation. The next two slides
show diagrammatic arrangements of two industrial gas
turbines. In the first slide the compressor and the turbine
are of the radial type while in the second slide they are of
the axial type (higher powers).

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Gas Turbines Faculty Of Engineering

A small industrial
gas turbine

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Cairo University
Gas Turbines Faculty Of Engineering

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 Cairo University
Gas Turbines Faculty Of Engineering

An axial flow
gas turbine

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Cairo University
Gas Turbines Faculty Of Engineering

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 Cairo University
Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

The AGT 1500

1500 SHP at 3000 rpm – pressure ratio 14.5 –TIT 1193 C
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 Cairo University
Gas Turbines Faculty Of Engineering

The gas turbine cycle for aircraft applications is similar

to that of industrial types except that the turbine is
designed to produce just sufficient power to drive the
compressor. The exhaust gas is then expanded to
atmospheric pressure in a propelling nozzle to produce
a high velocity jet as in turbojet and turbofan engines.
In turboprop engines a part of turbine work is provided
to drive the propeller of the plane and the propulsive
force is a combination of propeller and jet effects.

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Cairo University
Gas Turbines Faculty Of Engineering

Today's new generation industrial gas turbines all

borrow heavily from jet engines designed for military
and commercial aircraft. This is true for the heavy
frame industrial machines as well as industrialized
aeroderivative designs. Their designs incorporate
advanced flow path aerodynamics, high-temperature
materials and coatings as well as advanced engine
component techniques.

Generally, gas turbines are of the axial reaction type

while for small powers they may be designed
centripetal (inward flow radial type). In what follows
some constructional and design details are presented.
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Gas Turbines Faculty Of Engineering

The basic idea of a gas turbine

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Cairo University
Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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 Cairo University
Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

Axial Compressor and Turbine Operation

Compressor Stages Turbine Stages

Rotating Rotating Rotating Rotating
Rotor Row Rotor Row Rotor Row Rotor Row

Gas flow
Airflow

Stationary Stationary Stationary Stationary

Vane Row Vane Row Nozzle Row Nozzle Row

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

Turbo-fan engine

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

Evaporative
cooling

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Cairo University
Gas Turbines Faculty Of Engineering

Chiller
cooling

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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 Cairo University
Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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 Cairo University
Gas Turbines Faculty Of Engineering

Heat Recovery Methods

• Direct Heating

• Fluid Heating / Hot Water

• Steam Production

• Absorption Chilling

• Preheated Combustion Air

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Cairo University
Gas Turbines Faculty Of Engineering

The Basic Concept – ‘simple cycle’

FUEL

AIR COMBUSTOR
INLET
EXHAUST
GAS

DRIVEN
EQUIPMENT

COMPRESSOR TURBINE

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Gas Turbines Faculty Of Engineering

Typical Cogeneration System

FUEL
EXHAUST
GAS

AIR COMBUSTOR
INLET

DRIVEN HEAT
EQUIPMENT EXCHANGER

COMPRESSOR TURBINE
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Cairo University
Gas Turbines Faculty Of Engineering

Combined Cycle (Brayton & Rankine Cycles)

EXHAUST GAS

LOW PRESSURE STEAM

(For Deaeration)
AIR FUEL
INLET INTERMEDIATE PRESSURE STEAM
(To Intermediate Pressure Steam Turbine)
COMBUSTOR
HIGH PRESSURE STEAM
GENERATOR (To High Pressure Steam Turbine)

HEAT RECOVERY
STEAM
GENERATOR GENERATOR

ELECTRIC COMPRESSOR TURBINE

POWER

ELECTRIC
POWER STEAM
HIGH INTERMEDIATE EXHAUST
PRESSURE PRESSURE
STEAM STEAM
GAS TURBINE STEAM TURBINE

CONDENSATE RETURN TO HRSG

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 Cairo University
Gas Turbines Faculty Of Engineering

Typical Industrial Cogeneration System

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Gas Turbines
V94.3A Arrangement for Simple-Cycle Cairo University
& Multi-Shaft Combined-Cycle Plants Faculty Of Engineering

Package for dual fuel operation

Air Intake
Filterhouse

Air Intake Duct Gas Turbine &

with Silencer Enclosure Steelwork
Ventilation
Duct
Exhaust Gas
Diffuser
Electrical
Generator

Power
Control
Center
for Electrical and
I&C equipment
Low-Voltage Lube Oil Fuel Gas NOx Water Fuel Oil Hydraulic
Transformers System with System System System System
for SEE&SFC Plate Cooler
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Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

Air--blown Entrained Flow Gasifier

Air
Air-Blown
Porous
- Lower auxiliary power Cyclone Filter
consumption than oxygen-blown Coal Gas + Char Syngas Calorie(kcal/Nm3-dry)
0 500 1000 1500
Two Stage
- Best balance of syngas calorie
Char
for GT combustion and high Reductor
temperature for melting ash (2nd Stage)

- Effective gas/slag quenching Coal

Gas Temperature
Syngas Calorie
at the 2nd stage with coal
gasification endothermic reaction Coal
Combustor
Dry-Coal-Fed (1st Stage) Air
Air
- Higher thermally efficient than 500 1000 1500 2000
Slurry-Coal-fed Molten Slag
Gas Temperature
(deg-C)

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Cairo University
Gas Turbines
Schematic Diagram of IGCC Faculty Of Engineering

Air-blown Gasifier Gas Cleanup (cold)

Gasifier Syngas
Dry Gypsum
Coal Porous Recovery
Feed Filter
Combustor

ASU
Char N2 G/T S/T
HRSG
Air O2
M Air Compressor

Combined Cycle System

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Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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Cairo University
Gas Turbines Faculty Of Engineering

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Gas Turbines Faculty Of Engineering

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