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Gas Turbine Introduction
Gas Turbine Introduction
Gas Turbine Introduction
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CONTENTS
INTRODUCTION
OPERATION PRINCIPAL & THERMODYNAMIC CYCLE
INTRODUCTION TO GE GAS TURBINES AT FFC
LAYOUT OF TURBINE & GENERATOR
MAIN COMPONENTS & THEIR WORKING
STARTING EQUIPMENT
AIR INLET EQUIPMENT
AIR COMPRESSOR
VARIABLE INLET GUIDE VANES
COMBUSTION SECTION
TURBINE
EXHAUST SECTION
GENERATOR
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TURBINE AUXILARY SYSTEMS & THEIR
WORKING
GAS FUEL SYSTEM
LUBE OIL/ HYDRAULIC OIL SYSTEM
COOLING & SEALING AIR SYSTEM
ATOMIZING AIR SYSTEM
COOLING WTER SYSTEM
FACTORS AFFECTING PERFORMANCE OF GAS
TURBINE
OPERATION PRACTACES & TURBINE
MONITORING
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PRIME MOVERS
Gas Turbine
Steam Turbine
I.C. Engine
Electric Motor
Expansion Turbine
Comparison
Thermal efficiency of G.T. ~25- 32% whereas in I.C. Engine ~35-45%.
For the same power output, larger size Engine required as compared to
G.T.
Maintenance cost at I.C. Engine is much higher than G.T.
Thermal efficiency of Steam Turbine ~70-80 %.
Steam turbine requires installation of Boiler, condenser, pumps etc. so
initial capital investment becomes higher.
Motors becomes un-economical at higher power output because of
in-efficient conversion of energy into electric power.
Expansion Turbines used to recover waste energy from process. These
supplement the main prime mover.
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GAS TURBINE APPLICATIONS
Gas Turbine developments in early nineties.
G. T. available in wide power range ( 7 KW-300 MW )
Applications.
Stationary applications
As a Prime mover for;
Compressors
Large Pumps
Electric Generators
Mobile Applications
Aircraft field
Marine propulsion
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GAS TURBINE OPERATING PRINCIPLE
Conversion of Chemical Energy of fuel to Mechanical
Energy.
Air Compressor/Turbine mounted on single shaft are brought to
speed by diesel engine.
Air Compressor draws atmospheric air & increases its pressure.
High pressure air flows to combustion chamber where fuel
admitted under pressure.
Spark ignites fuel/air mixture initially.
Hot gases at high pressure expand thru Turbine wheels.
Rotor spins and produces shaft output.
Part of the shaft output is used internally by air compressor, the
remaining output available for driven unit.
Gas Turbine Flow Diagram
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THERMODYNAMIC CYCLE
Thermodynamic Terminologies
Reversible Process
Fluid & Surrounding can always be restored to their original state.
Criteria for Reversibility
Process must be Frictionless.
Pressure difference between Fluid & its Surrounding must be infinitely
small.
Temperature difference between Fluid & its Surrounding must be
infinitely small.
Ir-reversible Process
No process in practice is truly Reversible.
Process in reciprocating piston close to reversibility.
Process in rotary machinery highly ir-reversible due to high degree of
turbulence.
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Isothermal or Constant Temperature Process
In isothermal Expansion heat to be continuously added to keep
temperature at initial value.
In isothermal Compression heat to be continuously removed to
keep temperature at initial value.
Isothermal Flow Equation
PV = CONSTANT (For Perfect Gas)
Adiabatic Process
In Adiabatic Process NO heat transfer To or From the fluid.
Adiabatic Process may be Reversible or Ir-reversible.
Adiabatic Process flow Equation
PV γ = CONSTANT (γ= CP / CV)
For Reversible Adiabatic Process, Temperature/Pressure
relationship
(T2 / T1) = (P2 / P1) (γ- 1)/γ (For Perfect Gas)
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Entropy
Entropy defined as:
dS = dQ/T
Change of Entropy of system is Heat added or removed from the system at
constant Temperature.
For any reversible process ∆S = 0
For any ir-reversible process ∆S > 0
Isentropic Process
The process in which entropy of system remains constant. i.e. ∆S = 0 or ∆Q
=0
Adiabatic reversible process is called Isentropic process.
Polytropic Process
Process in rotary machinery (compressors/turbines) naturally ir-reversible.
i.e. ∆S > 0
In polytropic process entropy of system does not remains constant.
PV n = Constant n = 1- ∞ (any number)
If n = 1 (Isothermal Process)
n = γ (Adiabatic Process)
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GAS TURBINE CYCLE
AIR
INLET TURBINE EXHAUST
PLENUM COMPARTMENT
ACCESSORY COMPARTMENT PLENUM
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LAYOUT OF G.E GAS TURBINE AT FFC
Generator
Control Accessories Turbine Exhaust Load Gear Electric Generator
Air Inlet Plenum Auxiliary
Compartment Compartment Compartment Plenum Compartment Generator Bearing
Compartment
Mark-II / V Starting Diesel Variable inlet Axial air Turning Reduction Stator & Generator Static
Speedtronic Engine guide vanes. compressor vanes gear Rotor Bearing exciter
System
Torque Combustion Diffuser Coupling 2 Lubeoil low Main
CO2 fire converter chambers pressure breaker
protection Bearing 2 switch.
system Jaw clutch 2 stage Generator
turbine protection
Battery & Ratchet devices
Charger
Accessory gear Current /
potential
Coupling 1 transformer
Bearing 1
MainLube oil
system
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MAIN COMPONENTS & THEIR WORKING
STARTING EQUIPMENT
Diesel Engine make : CUMINS USA
Engine Power : 465 HP
Engine rpm : 2100
Cranking or rotation of Gas turbine Shaft By Diesel Engine.
Diesel Engine transmits rotating speed through torque converter &
Jaw clutch to accessory gear.
Main functions of Starting Device
Supply high torque at zero speed to breakaway the turbine.
Drive the unfired Gas Turbine to Firing Speed (18% or 1000 rpm)
Assist the Fired Gas turbine to self sustaining speed after which
starting device is declutched from Gas Turbine.
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STARTING SYSTEM COMPONENTS
Diesel Engine
Hydraulic torque converter Assembly
Hydraulic Ratchet system
Starting Jaw clutch
ENGINE OPERATION
Schematic Diagram
With start signal , Ratchet Pump starts , Starting Clutch
engaged, & Diesel Engine starting DC motor energized.
Engine at idle speed (600 rpm) for two minutes warm up period.
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At the end of warm-up period, Engine governor set at maximum
speed (2100 rpm) until Turbine shaft starts rotation.
Engine speed set between idle & maximum ( 1800 rpm , governor
speed).
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RATCHETING
Ratcheting is slow turning of gas turbine shaft.
Ratcheting Required:
During the cool down period of gas turbine to avoid Shaft BOW.
During the start-up to help diesel Engine for Gas turbine’s shaft
break away from zero speed.
In ratcheting Turbine shaft rotates 47 degrees in 10 seconds after
every 03 minutes.
A small DC-motor (125V) rotates the shaft through Hydraulic self
sequencing valve assembly.
Ratchet mechanism de-energized when the G.T shaft break-away
achieved.
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AIR INLET EQUIPMENT (Filter House)
Gas turbine kind of air breathing machine.
Design consumption of Air at our Gas turbine is 436 Tons/hr
at 15 0C & 1.013 bar corresponding Air/fuel ratio of 40.
Performance of Gas turbine very sensitive to the quality of
Air & affected through:
Fouling of compressor Blades
Erosion of compressor/Turbine Blades
Fouling reduces the efficiency of the axial compressor by ingestion of
substances which adhere to surface e.g., oil vapors & smoke.
Erosion results due to hard particles in air such as sand & mineral dust
etc. These particles when hit on the blades, cut away as small portion of
metal thus causing serious damage to machine.
Filtration of Air upto 10 micron size before entering axial
compressor.
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Filter House consists of three stage filter assembly:
Inlet screens & Inertial separators
Pre-Filters (Primary Filters)
High Efficiency filters (secondary filters)
Inlet screens
Screens at upstream of inertial separators to avoid entry of birds,
leaves, twigs papers etc.
Inertial Separators
Larger particles separated from air due to Inertia & ejected in common
chute.
A bleed fan maintains a constant flow (~10%) through the collection
chute.
Pre-Filters (Primary Filters)
150 Nos. Pre-filters located down stream of inertial separators &
immediately upstream of high efficiency filters.
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Pre-filters extend the useful life of high efficiency filters. These are layer type
& directly attached to high efficiency filters. Generally replaced when P
across the filter house reaches 12 cm wc.
High Efficiency Filters (Secondary Filters)
Made with special paper fabric & have efficiency of 99.7% particles removal.
Large particles remove by sieve-like action where as smaller ones adhere to
fabric. Normal life is about 6 months.
Implosion Doors
Two implosion doors provided downstream of secondary filters.
Designed to open at P if 15 cm wc. These doors avoid abnormal blockage in
air inlet system.
Inlet ducting & silencing
An air inlet duct connects the Filter House to air inlet plenum at compressor
suction.
Silencing provided in the duct by the use of acoustically perforated sheets.
Silencing baffles eliminate typical compressor tone.
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AIR COMPRESSOR
17 stage axial compressor with inlet variable guide vanes.
Compressed air exits through compressor discharge casing to the
combustion chambers.
Air also extracted from the compressor for turbine cooling & bearing
oil sealing.
Compressor divided into four portions:
Inlet section
Forward section
Aft section
Discharge section
FIG. (Comp/Turbine Rotor assembly)
FIG. (Compressor Casing Lower half)
Inlet section
The inlet section directs air flow from Filter House into compressor
blading.
This section contains variable inlet guide vanes assembly, the No. 1
bearing assembly & Low pressure air seals.
Variable inlet guide vanes (IGV) permit fast, smooth acceleration of Gas
turbine without compressor surge.
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IGV operated through hydraulic system & rotate through a large ring gear
& multiple small pinion gears.
At start up of Gas turbine IGV’s are set at 43 0 position & when Turbine
accelerates to 95% speed they turn to 85 0 position.
When turbine stops vanes rotated to 430 at once.
FIG. (Guide Vanes Pinion gear ring)
Aft Section
This is at down stream of inlet section & contains the stator Blading for
stages 4 through 9.
Bleed air from the 4th rotor stage (between 3rd & 4th stator stage) used
for cooling of turbine shell & supports.
Discharge Section
This section down stream of the aft section, contains the stator blading
for the stages 10 through 16 & exit guide vanes stages 1& 2.
This section provides the mounting surface for combustion chambers.
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COMBUSTION SECTION
Components of Combustion section
Combustion chambers
Fuel Nozzles
Spark plugs
Flame detectors
Transition pieces
Combustion Chambers (Diagrams)
Ten combustion chambers arranged concentrically around the axial
flow compressor & bolted to compressor discharge section bulkhead.
Combustion Air supplied directly from the discharge of axial flow
compressor to combustion chambers.
Fuel fed into the chamber through the fuel nozzles that extend into
each chamber’s liner cap.
Combustion chamber outer casing bolted to compressor discharge.
Combustion takes place in inner liner.
Chambers called as reverse flow type.
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Holes along the length of combustion chamber’s liner
Dilution holes
Located at end of combustion liner flow path & Larger in size (4 holes in
each).
They help to reduce the gas temperature at the inlet on turbine first stage
nozzles.
Cooling louvers
Louvers all along the length of combustion liner & protect the flame tube
(liner) with air film.
Secondary Holes
Propagates flame with secondary combustion air.
Primary Holes
Primary holes used for combustion of fuel.
Temperature near the flame zone is about 1700 °C & to be brought
down to about 800-1000°C before the hot gases enter the turbine
stage.
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Fuel Nozzle
Dual Fuel Nozzles.
Three external connecting Flanges on Fuel Nozzle body.
Liquid Fuel (Diesel)
Atomizing air
Gas Fuel
FIG. (External View of Fuel Nozzle)
FIG. (Internal View of Fuel Nozzle)
Gas Fuel routed through the nozzle’s internal passage to the Orifice
located in the gas tip.
Primary combustion air enters through slots in the swirl plate to combine
with the gas fuel at the Orifice.
Swirl plate creates a high energy vortex of combustion air surrounding
the atomized fuel.
Continuous ignition of fresh fuel due to recirculation of combustion
products in the low pressure core of the vortex.
Lean fuel/air mixture prevents soot formation which would appear as
smoke in gas turbine exhaust.
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Spark Plugs
Combustion of fuel & air mixture initialed by spark plugs.
Spark plugs installed in two of combustion chambers & receive
power from the ignition transformers.
The chambers without spark plugs (08 chambers) fired with flame
from the fired chambers through interconnected cross-fired tubes.
Flame Detectors
Two ultra-violet type flame detectors provided on the combustion
chambers opposite to those having spark-plugs.
They detect the presence of ultra-violet radiation which is emitted
by a hydrocarbon flame. The detectors provide a signal when the
radiation is sensed for approx. 0.2 sec.
On failure of both flame detectors Gas Turbine trips.
Flame sight ports on individual chambers.
Flame detectors ensure combustion in other 08 chambers thru
cross-fired tubes.
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Transition Pieces
Provide hot gas path link between the combustion
chambers & 1st stage nozzle assembly.
Clamped to forward side of nozzle assembly.
Nozzle assembly sealed at both its outer & inner
periphery to prevent leakage of hot gases.
Compressor discharge air flows into the combustion
chambers, passing around transition pieces.
Cooling of transition pieces achieved by heat exchange
with discharge air.
FIG. (Transition Piece & Nozzle Arrangement)
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TURBINE SECTION
High temperature gases from combustion section converted to shaft
horsepower.
Power required to drive load package & compressor provided by the two-
stage turbine rotor.
Turbine components
First stage nozzles
First stage Buckets & wheel
Second stage nozzles
Second stage Buckets & wheel
FIG. (1st & 2nd Stage Wheels & Nozzles)
Combustion gases at about 800 °C expand through two stages of
Turbine.
Expansion takes place in fixed nozzles of both stages.
Nozzles convert heat & pressure energy into high velocity or kinetic
energy and direct this energy to buckets/rotating blades.
Rotating blades convert kinetic energy into useful shaft horse power.
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Temperature limitation on turbine wheels due to metallurgy.
Cooling of turbine parts (stationery nozzles, rotary blades, turbine shaft
& supports) with air drawn through compressor from different stages.
Turbine’s 1st Stage buckets are hollow & have cooling holes in the
buckets.
Cooling of wheel space area with compressor air.
Use of seals between nozzles & rotating buckets to restrict the hot gases
from leaking into the wheel space.
Operation of turbine with excessive wheel space temperatures can cause
failure of rotor studs connecting the turbine wheels & stationary nozzles.
Exhaust Section
Turbine exhaust gases discharged thru diffuser into the exhaust plenum at
temperature of about 450 0 C.
FIG. (Turbine Wheels, Exhaust Hood & Deflector)
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Generator
Principle
Conversion of mechanical energy into electrical energy.
When magnetic field is cut by conductor, voltage is
produced in the conductor.
The higher the strength of magnetic field, the higher
would be the voltage produced in the conductor.
Generator having two parts: 1. Stator 2. Rotor
Stator has 3-phase armature winding (stamping insulated with
paper) In star connection.
Rotor contains field winding which develops electromagnet.
Field excitation (Rotor magnetization) initially obtained thru
battery & then thru Static Excitation System.
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When rotor rotates, magnetic field produced by rotor also rotates.
Stator conductors are cut by rotating magnetic flux & emf is
induced in them.
Due to induced emf , current in armature flows in one direction &
then in other direction due to alternation of N & S poles of rotor.
Frequency of emf produced in stator conductor depends upon N
& S poles moving past conductor per second.
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Gas Stop/Speed ratio valve (VSR)
This valve is operated thru hydraulic cylinder & has two functions;
Stop Function
Tight shut-off of fuel gas achieved by hydraulic oil drainage thru SOV
(20FG).
Speed ratio Function
Regulated inlet pressure to upstream of control valve.
Pressure at downstream of stop/speed ratio valve maintained at 14.0
kg/cm.2
Electro-hydraulic servo ( 90 SR ) gives position control.
Input to electro-hydraulic servo ( 90 SR ) is the speed signal &
downstream pressure signal ( 96 FG ).
Actual position of valve sensed thru LVDT (liner variable differential
transformer,96 SR ).
LVDT installed on stem provides feedback signal to speedtronic.
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Gas Control Valve (VGC)
Gas control valve provides the final precise metering of fuel gas flow to gas
turbine.
It regulates gas pressure of 8-10kg/cm2 to fuel nozzles.
Speedtronic control gives its output signal called VCE to the electro-hydraulic
servo (65 GC). This servo adjusts the hydraulic pressure to the piston of gas
control valve.
Two LVDT’s (96 GC-1/2) provided at the stem of gas control valve give position
feedback to the speed tronic control.
VCE signal by the control circuit is compared with the position feed back signal by
LVDT’s. If the two signals do not match an “error” signal is generated and acts to
reposition the valve until the VCE & feed back signals match.
Fuel Gas Vent valve (20 VG)
Solenoid operated valve (20 VG) vents the gas from the piping in-between gas
stop/speed ratio valve & Gas control valve.
This solenoid is energized & vent valve closes when start signal is given to turbine,
it will remain closed until turbine is shutdown.
It provides block-n-bleed arrangement while gas turbine is shutdown.
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LUBE OIL / HYDRAULIC OIL SYSTEM
Closed loop forced oil lubrication system.
Lube oil Tank
Integral part of the turbine base in the area under accessory section.
Capacity of the system (tank & other components) is 1700 gallons.
Lube oil feed piping is contained within the lube oil tank or drain headers
to avoid safety risk in case of leakage.
Three lube oil pumps
The main lube oil pump is positive displacement type mounted in & driven
by accessory gear.
The auxiliary lube oil pump is a submerged centrifugal pump driven by
380V AC motor.
The emergency lube oil pump is a submerged centrifugal pump driven by
110 V DC motor.
Lube Oil Securities
High lube Oil Temperature alarm at 75 °C
High lube Oil Temperature Trip of turbine at 80 °C
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3.8 Kg/cm2
88 Kg/cm2
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Cooling & Sealing Air System
Different Turbine parts to be cooled;
First & second stage turbine wheel forward & aft faces.
First & second stage nozzles
Turbine shell
Turbine supports
Combustor’s casing , liners, transition Pieces.
Cooling air obtained from the compressor at following
locations;
Fourth stage Extraction Air.
Tenth Stage Extraction Air.
Compressor High Pressure Seal Leakage.
Compressor Discharge Air.
FIG (Schematic cooling sealing air)
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Fourth stage extraction air
Portion of shell surrounding the first & second stage nozzles
Aft surface of second stage turbine wheel
Supports which are in the exhaust gas hot path
Tenth stage extraction air
Main part goes through bleed valves to exhaust plenum
Second part for cooling of 1st. & second stage nozzles
Third part routed to bearing’s seals through dirt separator
Compressor high pressure seal air leakage
Cooling for first stage wheel & discharged to exhaust hot gas
path
Compressor discharge air
Cooling of aft surface of first stage turbine wheel forward surface
of second stage turbine wheel 1st stage nozzle ring & partitions
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ATOMIZING AIR / PURGE AIR SYSTEM
Atomizing air required when Gas Turbine operates on liquid fuel (diesel).
Atomizing air recirculates in closed loop when Gas Turbine operates on Gas
fuel.
Schematic Diagram
Air drawn through the discharge of axial air compressor at 7.0 kg/cm2.
Atomizing air compressor driven through accessory gear develops ΔP of
about 1kg/cm2.
Air passes through cooler in each cycle before entering the atomizing air
compressor. Cooling of air through exchanger protects compressor against
over temperature in continuous operation.
A solenoid valve (20 AA) operates piston type bypass valve (VA-18).
A small flow of air through the atomizing air passages prevents entry of
combustion products that could foul this passage.
Purge Air admitted to Purge Air manifold thru diaphragm valve (VA-19), in
Gas Fuel operation.
Purge Air purges oil passage in fuel nozzles to prevent accumulation of oil
fuel in nozzle.
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Cooling Water System
Closed Cooling Water System
Heat removal from lube oil & diesel engine systems
Demineralized water as make-up & Nalcool-2000 as corrosion inhibitor
Cooling Water System Components
Accessory gear shaft driven pump ( 400 gpm)
Two cooling water tanks
Two cooling water fan skids
Temperature regulating valves
Schematic Diagram
Water from Tanks to gear driven pump & diesel engine water pump
Diesel engine water pump drives water to engine cooling jacket
Accessory gear driven water pump drives water to lube oil cooler &
atomizing air cooler
Cooling of water in Fan skids (2 units for each turbine)
Fan Skids, finned tube air to water heat exchangers with two fans under
each skid
Cooling water flow regulated thru Temperature regulating valves sensing
lube oil temperature.
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FACTORS AFFECTING PERFORMANCE OF GAS TURBINE
Turbine Monitoring
Logging of parameters on two hourly basis.
Routine Checklist (once in shift).
TMP data for performance evaluation (quarterly basis)
Start-Up checklist.
Performance Improvement
Performance of compressor decreases by fouling of
blades with solid & oily deposits.
Compressor Cleaning
Two types of cleaning
Carbo Blasting with nutshells/rice (For fouling from dry deposits)
Wet Washing with hot water & detergent (For fouling from oily
deposits)
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G. T. ENCLOSURE
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DUAL FUEL NOZZLE
1. Crossfire Tube
2. Atomizing Air Inlet Pipe
3. Oil Fuel Inlet Pipe
4. Dual Fuel Nozzle
5. Sighting Port
6. Gas Fuel Inlet Pipe
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