GAS TURBINE

Training Package PTP 9.2

COMPONENTS AND FUNCTIONS

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 Table of Contents

Page Numbers

1. Introduction 03

2. Compressor 03

3. Turbines 07

4. Combustion Chamber 10

5. Gas Fuel System 10

6. Auxiliaries of the combustion Gas Turbine 11

7. The Oil Circulation System 15

GAS TURBINE COMPONENTS

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1. INTRODUCTION
The industrial gas turbine has, since its introduction as a prime mover, found many
uses throughout the world, particularly in the oil and gas industry. The reliability of
the industrial gas turbine in both its purpose-designed mode and as an aero derived
mode, its ability to run on many types of fuel, and its general compactness has been a
major factor in its success. Industrial gas, turbines are now the principle units on off
shore platforms and remote fields for power generation, gas compression, pumping
and on pipe lines throughout the world.

As per the old definition Gas Turbine is a form of internal combustion engine in
which hot gas from one or more combustion chambers drive a turbine.
PTP 9.1 explains the basic principles of Gas turbines.
The following components are included in this section.
a) Compressor
b) Turbine
c) Combustion Chamber
d) Auxiliaries

2. COMPRESSOR

There are two kinds of compressors used on gas turbine engines, they are:
(i) Centrifugal flow (ii) Axial flow
Each compressor is made up of two separate parts:
(a) The rotating component the rotor or impeller
(b) The stationary component the stator or diffuser.

Centrifugal Compressor
Air is continuously drawn into the center or eye of the rapidly rotating impeller and
thrown radially outwards due to centrifugal force with a high velocity and an increase
in pressure into the diffuser. There the air decelerates and converts the velocity into
a further pressure increase. (Fig - 1)

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Axial flow Compressor

Fig 2 shows an axial flow compressor, which consists of a rotating drum with rows of
aerofoil section blades mounted around the edge of it. The rotor rotates within the
stator casing. Located in the stator casing are its stator blades, which are also of
aerofoil section. A compressor stage consists of a row of rotating blades followed by a
row of stator blades.

Fig- 2

The compressor is a multistage unit as the pressure increase by each stage is small. At
the inlet to the compressor is an additional row of stationary blades known as the inlet
guide vanes (IGVs). On some turbines the IGVs are variable, that is the angle of
incidence of the blade can be varied during start up and running. On other turbines
the IGVs are fixed, that is the angle of incidence does not change, they are used to
guide the air smoothly onto the first row of the rotor blades. There is a gradual
reduction in the air annulus area from the low to the high pressure end i.e. from the
inlet to the exit end of the compressor. At the exit end of the compressor are usually
fitted exit guide vanes. These are used to straighten the airflow, leaving the end of
the compressor to remove swirl from the air before entering into the combustion
chamber at a reasonably uniform axial velocity. E.g.: fig. 4

Compressor Function

The compressor rotor is rotated at fairly high speed by the turbine. Air is continuously
drawn into the inlet of the compressor, and accelerated rearward by the rotor blades.
The high velocity air then flows onto the stator blades, where the velocity of the air is
reduced and converted into a small pressure rise. This process continues across each
stage of the compressor gradually increasing the pressure from inlet to outlet.

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PRINCIPLE - 1

Air flow through divergent and convergent ducts

Typical Axial flow Compressor outlet casing

Fig 4

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 PRINCIPLE 2

VELOCITY - INCREASING
PRESSURE - DECREASING
TEMPERATURE - DECREASING

Fig: 8

Due to the design features of a compressor, it can only operate efficiently at the higher
and over a relatively small R.P.M. range. If the compressor is operating at [Link]
below this range, that is during start up and low load conditions,
EXAMPLE it canTURBINE
- FLOW THROUGH become
unstable with the possibility of going into a condition known asNOZZLE
stall orGUIDE VANES
surge.
Fig 5

Blow off valves or Bleed air valves are provided as a protection against surge.

Blow off valves and Bleed air valves are provided as a protection against surge.

E.g. 1. Blow off valves on RUSTON TB 5000

Two blow off valves are provided from the intermediate stages of the air compressor.
These two valves will open and vent air to avoid a surge on the machine as a
protection to the compressor. Two more valves are provided at the final discharge of
the air compressor. Following picture shall explain the working principles of the blow
off valves.

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E.g. 2. Bleed Air Valve on Solar Turbine

3. TURBINES

There are two basic types of turbines.

1) Radial flow turbine or centripetal turbine.
2) Axial flow turbine.

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The radial flow turbine is not commonly used therefore only the axial flow type will
be considered. As with the axial flow compressor the turbine also consists of two
parts:
i) The rotating assembly (the rotor)
ii) The stationary assembly (the stator or nozzles).

The turbine can be a single stage assembly or multi-stage assembly with each stage
consisting of one row stator or nozzle-followed by one row rotor.

The turbine provides the power to drive the compressor plus shaft power to drive the
driven unit producing the load. In the two shaft gas turbine these functions are
divided between the compressor turbine and the power turbine. The turbines
extract the energy from the high pressure hot gases coming from the combustion
system and expand them to a lower pressure and temperature.

Air leaving the combustion chamber flows through a transition piece to the turbine.
The transition piece is a duct or passage, long enough to make sure that the hot air is
thoroughly mixed so that there are no " hot pockets ".

Fig 8

The turbine rotor like the compressor rotor contains a series of discs. Each disc
supports a set of blades. In this turbine, the rotor discs are fastened to a single shaft
and rotate with it. Between each set of rotor blades the air passes through a set of
stator blades. Air enters the turbine section at high pressure. In order to turn the rotor,
the air must be moving. Air pressure must therefor be changed into air velocity or
movement Air exerts pressure in all directions. Air moving at high velocity exerts
most of its force in one direction. When pressure is converted to velocity, most of its
force is exerted in one direction, and the force of air in other direction is decreased.
As air velocity increases, air pressure decreases. A nozzle is used to increase the
velocity of air.

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Fig 9

The nozzle allows air to escape in one direction. Air escape through the nozzle at high
velocity. Pressure energy is used up to increase the velocity of the air. There are two
ways to use air velocity to move the rotor blades.

1. IMPULSE 2. REACTION
In the impulse effect the nozzle is stationary. The air shoots out and strikes an object
in its path. The object moves in a direction the same as the direction of the air jet is
moving. The reaction effect works like a rocket. The nozzle moves in the opposite
direction from the air movement The blades of most turbines are designed to take
advantage of these two different effects of a moving air stream. Both the impulse
effect and the reaction effect are used to move the blades. Turbine can also be named

by what they drive. The turbine that drives the turbine compressor is called "the
compressor turbine ". A load turbine drives the load. Most combustion gas turbines
have two drive shafts. One shaft drives the load, the other shaft drives the compressor
which forces high-pressure air into the combustion chamber. The compressor uses
twice as much power as the load. The compressor turbine has a greater number of
rotor discs than the load turbine. The hot air from the combustion chamber gives up
energy to the compressor turbine before it reaches the load turbine. The pressure of
the air entering the load turbine is lower than the pressure of the air entering the
compressor turbine. As the air pressure increases in the compressor, the volume of the
air decreases. As the air pressure decreases in the turbine, the volume of the air
increases. To handle the large volume of air, the size of the rotor blades in the load
turbine is greater than the size of the rotor blades in the compressor turbine.

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 Fig: 10

It is easier to break off the longer blades of the load turbine. The longer blades on the
load turbine must be stronger and attached to the disc more firmly than the shorter
blades on the compressor turbine. To reduce the strain on the blades of the load
turbine, the load shaft often rotates slower than the compressor shaft. As air is
compressed in the compressor section, it warms up. As air expands through the
turbine section, its temperature decreases. The temperature of the air entering the
compressor turbine is higher than the temperature of the air entering the load turbine.
The compressor turbine must be designed to withstand higher temperatures.

4. COMBUSTION CHAMBER
The purpose of the combustion chamber, which is a difficult task, is to burn large
quantities of hydrocarbon fuels, supplied by the burner, mixed with even larger
quantities of compressed air, fed from the compressor, and releasing the heat in such a
manner that the air is expanded and accelerated rearwards so as to give a smooth flow
of uniformly heated gas to the turbine assembly under all operating conditions. This
task must be accomplished with the minimum loss in pressure, and also the maximum
amount of heat release within the limited space available. In this way the chemical
energy in the fuel is converted into heat energy in the gas stream. Within the
combustion chamber, we consider that it is split up into three separate zones. These
are known as (1) Primary (2) Secondary (3) Cooling or tertiary zones.

The fuel and part of the air enter the combustion chamber via the primary zone, where
they are mixed together in the correct ratio: approx. 15 parts of air to 1 part of fuel
(that is an air/. fuel ratio approx. 15:1 usually calculated by weight). They are ignited
and rapid combustion takes place. The heat of the combustion gases reaches a
temperature in the region of about 2000 deg.C. Since this temperature is well in
excess of the safe operating level of the turbine, the remaining parts of the air enter

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the combustion chamber via the secondary and cooling zones, therefore gradually
reducing the gas temperature down to the acceptable level of the turbine blading.

In order to achieve the acceptable temperature the minimum air/fuel ratio can be
approx.60:1

.
Fig 11

5. GAS FUEL SYSTEM

A typical gas fuel system has the following basic equipment.
The function of the system is to provide a constant supply of clean dry gas to the fuel
valve which can then supply variable pressures and quantities to the combustion
chamber to enable-starting, running, and load changes.

Fuel Gas Regulator: A pressure setting valve that is used to ensure a constant supply
(volume) of gas at the turbine manufacturers designed pressure.
Gas Demister: A filter that is capable of removing any condensate from the supply
gas prior to its use for combustion.
Main Gas Solenoid: An electrically operated fuel open and shut valve used for
isolation.
Pilot Gas Solenoid: An electrically operated fuel on /off valve used to supply ignition
fuel if system fitted.
Emergency Slam Shut Off Valve: This valve is an open and closed valve and if all
electrical power were lost would shut off the gas to the turbine.
Gas Fuel Valve: The throttle valve. Its function is to supply fuel to the fuel gas
burners at variable pressures and quantities as required by changing operating
conditions.
The Basic System (Gas)
Gas is supplied to the regulator. Pressure and volume are set. The gas travels to the
de-mister where any liquid is removed. The dry gas is passed through the solenoid
valve and the slam shut valve to the fuel (throttle) valve. This governor controlled
valve then supplies the correct amount of gas to suit engine running need to the fuel
gas burners located in the combustion chambers.

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 Fig 12

6. AUXILIARIES OF THE COMBUSTION GAS TURBINE

The Starter
The turbine needs a supply of high-pressure air. The compressor supplies this high-
pressure air. While the unit is running, the power to run the compressor is supplied by
the shaft of the compressor turbine. Before the unit can be started, the compressor
must be started so that it can begin supplying high-pressure air to the turbine
A small steam turbine, diesel engine, or electric motor is used to start the compressor.

The starter is coupled to the shaft of the [Link] the unit is started, the
starter can be uncoupled. The compressor now gets its power from the compressor
turbine. No steam or electricity is needed for the combustion gas turbine itself.
Steam, electricity, water or high pressure gas /air is needed only for the starter.

Governors
The gas turbine is most efficient near its "design speed." For most efficient operation,
the speed must be held as near as possible to the design speed. The speed of the
turbine may be adjusted by changing the volume of air that passes through it per
minute. Increasing the temperature in the combustion chamber makes the air
expand further. The speed of the turbine, then, is regulated by adjusting the fuel
supply to give the correct temperature in the combustion chamber.
Changes in speed caused by changes in the load are corrected by changing the fuel
supply. The governor valve regulates the amount of fuel entering the combustion
chamber. The governor valve controls the speed of the turbine.

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 Fig 12

Casing Seals
The compressor shaft and the turbine shaft extend through the stator.
There must be a clearance between the shaft and the stator so that the rotating shaft does
not rub against the stator. If this clearance space between the shaft and stator is too large,
high-pressure air escapes, and its efficiency reduced considerably.
If the shaft rubs on the stator, friction generates a tremendous amount of heat and can
damage the shaft or stator to warp or bow.
A packing box is inserted between the shaft and stator.
The labyrinth seal is used in high-speed gas turbines. which consists of teeth, fit closely to
the shaft.. The labyrinth seal minimises air leakage along the shaft. A labyrinth seal
allows some air leakage, since clearance is needed to prevent the shaft from rubbing on
the seal. Another type of seal used is carbon seal, they are dry contact seals which
consists of carbon rings held in place by spacers and axial spring. (fig.).

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 Fig 13

LABYRINTH SEAL

LABYRINTH
SEAL

CASING

SHAFT

OUTSIDE INSIDE

Fig 14

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Bearings
The compressor and turbine rotors must be kept in position while they turn.
The shaft must be free to rotate, but it must not be free to move in other directions.
Three types of shaft movement are shown in the drawing below. Besides rotating, the
shaft can tend to move in two other ways.
As hot air strikes the turbine blades, it may force the turbine shaft to move away from the
stator blades. This end-to-end movement is axial movement.
The shaft may also tend to move off-center. This is radial movement.

Fig -15

Bearings support the shaft and allow it to rotate with minimum friction.
Bearings also control radial and axial movement of the shaft.
The lubricant to the bearing provides a fluid film between the rotating shaft and the
stationary parts supporting and centering the shaft.
This fluid film prevents the shaft and its stationary supports from rubbing against each
other. The radial or journal bearing on which the shaft rests controls radial movements.
The thrust bearing limits end-to-end movement of the shaft.
The thrust bearing limits the amount of axial or thrust movement.
Small gas turbines use ball bearings to control radial and thrust movement.

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 Fig 16

Both thrust and radial ball bearings support the shaft of this turbine.
Ball bearings are lubricated so that there is almost no wear or friction between the ball
and any of the other parts it touches. The ball bearings turn freely as the shaft rotates.
A ball bearing can be used as a radial bearing or a thrust bearing only where axial and
radial loads are not great. Ball bearings are used on small turbines.
Large turbines and compressors use heavy-duty sleeve bearings.
A sleeve bearing can support a very heavy or large shaft.

Thrust bearing consists of a stationary thrust shoe and a moving thrust collar.
The thrust shoes are attached to the stator and are stationary.
The thrust collar is attached to the shaft or rotor and rotates with it.
Oil is supplied under pressure to the thrust bearing.

When the shaft moves in either direction along its axis, the thrust shoe and the collar are
forced together. The oil between the surfaces prevents the surfaces from rubbing together
in direct contact. In another thrust bearing design often used in gas turbines, a stationary
collar is fitted with thrust shoes, which tilt when the moving thrust collar turns.
The tilting shoes form oil wedges between the collars. The oil wedges keep oil from being
squeezed out of the space between the thrust surfaces and the collar when the shaft
rotates. This is a typical bearing arrangement.
The sleeve bearings support the compressor rotor and also the compressor and load
turbine rotors. The sleeve bearings restrict the radial movements of the shaft.
The compressor, the compressor turbine, and the load turbine have one thrust bearing
each. Thrust bearings restrict the axial movements of the shaft.

7. The Oil-Circulation System

In the lubrication system, oil is supplied under sufficient pressure to the bearings
The turbine speed control and temperature control systems often use oil pressure to
operate hydraulic relays.
The governor system needs a supply of high-pressure oil to move the governor valve.
The lubrication system keeps a supply of clean oil flowing to the hydraulic relays and
also to the bearings.
The drawing represents a typical oil-circulation system.
Oil is forced to flow from the reservoir to the bearings and to the control system by means
of main oil pumps.
Oil may decompose if it becomes too hot and losses its quality as a lubricant. So
lubricating oil must have moderate temperature for proper lubrication.

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If the oil system fails to deliver oil to the bearings, severe damage from heat and friction
may result.
The bearings may melt or burn or fuse.
Thus, a flow of oil must always be maintained while the turbine is in operation.
Low flow of lube oil may cause shut down of the turbine.
An auxiliary filter, cooler, and pump may be used to maintain the flow of oil in an
emergency.

Oil
Return

The main oil pump is used during normal operations and the auxiliary pump in case of
emergencies. The turbine shaft drives the main oil pump. At startup, since the turbine
shaft is not rotating, the main oil pump does not operate.
A separate driver runs the auxiliary pump, so that it operates independently of the turbine.

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At startup, the auxiliary pump lubricates the bearings until the turbine is up to operating
speed.
At shutdown, the main pump is again put out of operation as the shaft slows down.
The auxiliary pump again keeps oil circulating through the bearings.
There are also two oil filters in the circulation system. When the lubricating oil pressure
becomes too low, some turbines may be stopped by a hydraulic trip. An automatic dump
valve releases oil from a trip cylinder to shut off the fuel supply when the oil pressure
becomes too low.
Some units are equipped with oil-pressure alarms.

A typical gas turbine lube oil system has the following equipment:
Main lube oil pump (mechanical drive)
Auxiliary lube oil pump AC
Emergency lube oil pump D.C.
Lube oil tank
Lube oil filters
Lube oil coolers
Pressure setting valve
Pressure indicators
Temperature indicators
Pressure switch
Temperature switch.
The function of the lube oil system is to lubricate and cool the turbine bearings.

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