Addis Ababa University

Addis Ababa Institute of Technology

School of Mechanical and Industrial Engineering

Turbomachinery- Lecture 2

Introduction

Prepared By:- Desta Lemma

Thermal & Energy
Conversion Stream

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Power Machine - Gas Turbine
▪ Gas turbine find application in electric power generation, mechanical drive
systems (Aircraft), supply of process heat and compressed air, pump drives
for gas or liquid pipelines (prime movers)
▪ Very high power-to-weight ratio
▪ Fewer moving parts
▪ Low operating pressures
▪ High operation speeds
▪ Low lubricating oil cost and consumption
▪ Goes for 30-50K hours before first overhaul. Usually runs for 100K-300K
hours (10+ years) life cycle

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Turbomachinery –Gas Turbine Components
▪ Inlet system Collects and directs air into the gas turbine.
✓ An air cleaner and silencer are part of the inlet system.

✓ It is designated for a minimum pressure drop while maximizing clean airflow into the gas
turbine.

▪ Compressor Provides compression & increases the air density for the combustion
process.
✓ The higher the compression ratio, the higher the total gas turbine efficiency

✓ Low compressor efficiencies result lower gas turbine output power.

▪ Combustor Adds heat energy to the airflow.

✓ The output power of the gas turbine is directly proportional to the combustor firing temperature; i.e.,
the combustor is designed to increase the air temperature up to the material limits of the gas turbine
while maintaining a reasonable pressure drop.

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Power Machine - Gas Turbine

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Power Machine - Gas Turbine
▪ Performance of Gas Turbines is limited by
➢ Component efficiencies
➢ Turbine working temperature
✓ Current state of the art
✓ Pr = 35/1
✓ components = 85-90%
✓ TIT = 1650 K

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Power Machine - Gas Turbine
Turbo-Jet

Turbo-Prop

Turbo-Fan

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Power Machine - Gas Turbine

Heavy Frame: Power generation Aeroderivative

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Turbomachinery –Steam Turbine vs Gas Turbine
▪ Pressure ratio
◦ GT normally 20, ST may exceed 6000 (300 bar/0.05bar)

▪ Density ratio
◦ GT about 10:1, ST 2500:1 or higher

▪ Mass flow rate

◦ GT < few hundred kg/s, ST may exceed 1000 kg/s

▪ Condensation problems
◦ Properties of the steam
◦ Erosion damage

▪ Rotor speed
◦ GT about 10000 rpm, ST 1500-3600 rpm

▪ Medium temperature
◦ TIT GT >1350-1450°C, TIT ST < 540-630°C

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WORKING MACHINES CLASSIFICATION
▪ According to the kind of flow medium and pressure
generated, working machines are further classified into:
1. Pumps (Liquid Medium)

2. Compressors (Gas Medium)

i. Fans

ii. Blowers

iii. Turbo-Compressors

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Pump Classification –Working Machine

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Pump Classification –Working Machine
▪ Positive Displacement: Moving
boundary forces fluid along by volume
changes.
• Closed volume is used to squeeze
or suck fluid.
✓ Reciprocating, rotary, screw, ...
▪ Rotodynamic: Momentum change by
means of moving blades or vanes (No
closed volume).

✓ Axial, centrifugal, mixed

• Flow conditioning..........Stators, scrolls

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Pump Classification –Working Machine

◦ Centrifugal pumps: fluid enters

axially, and is discharged radially.

◦ Mixed--flow pumps: fluid enters

axially, and leaves at an angle between
radially and axially.

◦ Axial pumps: fluid enters and leaves

axially.

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Centrifugal Pump Parts

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Centrifugal Pump Parts

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Centrifugal Pump Parts
▪ Rotor accelerate flow by imparting kinetic energy
▪ Stator decelerate (diffuse)
✓ Together results in an increase in fluid pressure
Rotor
▪ Inducer

▪ Impeller

▪ Bearings

▪ Shaft

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Centrifugal Pump Parts
Inducer
▪ Axial flow

▪ Increase total pressure

▪ Permits non-cavitating operation in impeller

▪ Used as a boost pump, permits the main pump to operate at higher speeds

Stator
▪ Casing

▪ Diffuser vanes

▪ Volute

▪ Seals

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Centrifugal Pump Parts

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Working Machines - Compressors, Blowers & Fans
▪ Compressor, Blowers and Fans are machines that move & compress
gases.
▪ Fans discharge large volumes of gas (usually air) into spaces or large ducts
▪ Fans are low-speed machines that generate very low pressures, on the order
of 0.04 atm.
▪ Blowers are high-speed rotary devices (using either positive displacement or
centrifugal force) that develop a max. pressure of about 2 atm.
▪ Compressors are also positive-displacement or centrifugal machines,
discharge at pressure from 2 atm to several thousand atmospheres.

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Working Machines - Compressors, Blowers & Fans
Equipment Ratio of discharge pressure over
suction pressure

Fans Up to 1.11
Blowers 1.11-1.20
Compressors
More than 1.20

▪ Compressors, Blowers & Fans have many everyday uses, such

as in :
✓ Air conditioners (car, home)

✓ Home and industrial refrigeration

✓ Air compressors for industrial manufacturing

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Compressors Classification

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Compressors Classification-Positive-displacement compressors
▪ Positive-displacement compressors
✓ Rotary positive-displacement compressors can be used for discharge pressures up to
about 6 atm.

✓ These machines operate mechanically in the same way as reciprocating pumps, with
the differences that leak prevention is more difficult and temperature rise is
important.

✓ The cylinder walls & cylinder heads are cored for cooling jackets using water
refrigerant .

✓ Reciprocating compressors are usually motor-driven & nearly always double acting.

✓ These devices include sliding-vane, screw-type, and liquid piston compressors.

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Compressors Classification
QR-25

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Compressors Classification- dynamic compressor
▪ The dynamic compressor is continuous flow compressor is characterized by rotating impeller to
add velocity and thus pressure to fluid.
▪ It is widely used in chemical and petroleum refinery industry for specific services and as well as in
aircraft application
▪ There are two types of dynamic compressors
✓ Centrifugal Compressor

✓ Axial Flow Compressor

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Compressors Classification
Centrifugal Compressors
▪ Achieves compression by applying inertial forces to the gas by means of
rotating impellers.
▪ It is multiple stage ; each stage consists of an impeller as the rotating element
and the stationary element, i.e. diffuser
▪ Internal channels lead from the discharge of one impeller to the inlet of the
next.
▪ Fluid flow enters the impeller axially and discharged radially
▪ The gas next flows through a circular chamber (diffuser), where it loses
velocity and increases pressure.

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Compressors Classification

Centrifugal Compressor stage

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Compressors Classification
Centrifugal Compressors
▪ Compress enormous volumes of air or process gas-up to 340,000 m3/h at the inlet-to outlet
pressure of 20 atm.
▪ Smaller-capacity machines discharge at pressures up to several hundred atmospheres.
▪ Inter-stage cooling is needed on the high-pressure units.

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Compressors Classification
Axial Flow Compressors
▪ Working fluid principally flows parallel to the axis of rotation.

▪ Energy level of air or gas flowing through it is increased by the action of the
rotor blades which exert a torque on the fluid

▪ Have the benefits of high efficiency and large mass flow rate

▪ Require several rows of airfoils to achieve large pressure rises making them
complex and expensive

▪ Axial-flow machines handle even larger volumes of gas up to 1,000,000 m3/h),

but at lower discharge pressures of 2 to 12 atm.

▪ Inter-stage cooling is normally not required.

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Compressors Classification

Single stage Axial Compressor

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Compressors Classification -Why multi stage Compressors?
▪ High temp rise leads into limitation for the maximum achievable pressure rise.
▪ Discharge temperature shall not exceed 150ºC and should not exceed 1350C for hydrogen rich
services
▪ A multistage centrifugal compressor compresses air to the required pressure in multiple stages.
▪ Intercoolers are used in between each stage to removes heat and decrease the temperature of gas
so that gas could be compressed to higher pressure without much rise in temperature

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Rotodynamic Compressors
Advantages Disadvantages

Dynamic
Compressors

Centrifugal ▪ Wide operating range ▪ Instability at reduced flow

▪ High reliability ▪ Sensitive to gas
▪ Low Maintenance composition change

Axial ▪ High Capacity for given size ▪ Low Compression ratios

▪ High efficiency ▪ Limited turndown
▪ Heavy duty
▪ Low maintenance

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Positive Displacement Compressors
Advantages Disadvantages
Positive displacement
compressor
Reciprocating ▪ Wide pressure ratios ▪ Heavy foundation required
▪ High efficiency ▪ Flow pulsation
▪ High maintenance

Diaphragm ▪ Very high pressure ▪ Limited capacity range

▪ Low flow ▪ Periodic replacement of
▪ No moving seal diaphragm

Screw ▪ Wide application ▪ Expensive

▪ High efficiency ▪ Unsuitable for corrosive or dirty
▪ High pressure ratio gases

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Compressors Selection Consideration
▪ Safety
✓ Limiting gas properties (e.g., decomposition, flammability, toxicity).

✓ Compatibility of process gas with materials of construction

✓ Over-pressure protection

▪ Economics
✓ Life-cycle cost

✓ User and vendor capabilities and facilities for maintaining equipment

✓ Expected equipment reliability

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Working Machines – Fans
▪ Large fans usually centrifugal, operating exactly the same principle as the centrifugal pumps.
▪ Fan impeller blades may be curved forward, this would lead to instability in a pump, but not in
a fan.
▪ The impellers are mounted inside light sheet-metal casings.
▪ Clearances are large & discharge heads low, from 5 to 60 in. (130 to 1500 mm) H2O.
▪ Sometimes, as in ventilating fans, nearly all the added energy is converted to velocity energy and
almost none to pressure head.

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Working Machines – Fans

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Working Machines – Fans

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Working Machines – Fans

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Working Machines – Fans

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Working Machines – Fans
Cooling fans Cooling tower design

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Working Machines – Fans

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Classification of Turbomachines Based on Flow Path
▪ Based on the nature of flow path through the passages of the
rotor, blades or impeller turbomachine classified as:-
▪ Axial flow turbomachine if the flow is entirely or mostly
parallel to the axes of rotation
▪ Radial flow turbomachine: if the flow is entirely or mostly
perpendicular to the axes of rotation
▪ Mixed flow turbomachine: when radial and axial velocity
components are significant at the outlet of the device.

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Axial Flow Turbine Stage

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Radial Flow Turbine Stage

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Radial and Axial Flow Hydro-Turbine

(a) Typical radial-flow

Francis turbine. (b) typical
axial-flow Kaplan turbine.

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Mixed Flow Compressor

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Mixed Flow Impeller
Vaned diffuser for centrifugal compressor Mixed Flow Impeller

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Turbomachinery - Design Trade-offs
▪ Performance

▪ Weight

▪ Cost

▪ Life

▪ Reliability

▪ Structural Strength

▪ Maintainability

▪ Envelope

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