2NH- GT SHOW

COMPRESSOR & GAS TURBINE WORKSHOP GAS TURBINES - Slide 1
GAS TURBINES
& Centrifugal Compressor
Prepared & Presented by
Nauman Hannani
November 2012

Nauman Hannani
I completed my MS in Mechanical
Engineering with Specialization in Energy
from Chalmers Tekniska Högskola
Gothenburg Sweden in 1990. I am working
with Gas Turbine from last 25 years & got
experience both in PG and O&G in Europe &
Asia Pacific. I worked as GT Power Plant
operation engineer, after sales manager, GT
& combined cycle performance engineer,
GT application engineer, fuel & emission
engineer, marketing head and sales head.
My current position is GM in Rolls-Royce
India. Prior to that I was Regional Sales
Manager (Oil & Gas), based in Rolls-Royce
Singapore since 2001. I was in a similar
positions with ABB and ALSTOM in
Malaysia since 1997. Prior to 1997, I worked
in ABB STAL AB (Finspǻng) Sweden (Now
Siemens) 8 years.
Sir Frank Whittle first gas
turbine,1930/7 Owned by
Rolls-Royce

Agenda
➨  Gas Turbine
➨  Principles
➨  Construction
➨  Types & Applications
➨  Centrifugal Compressor
➨  Compressors Overview
➨  Performance Curves
➨  Applications
•

main menu
Early Gas Turbine
Click on image to play
Leonardo da Vinci ingeniously used the hot gases from the fire for driving
the spit, thereby cooking the meat evenly. Fire provide the energy & conical
shape of the chimney made the gases accelerate through the turbine.

Simplified Gas Turbine Comparison with
Piston EnginePISTONENGINEGASTURBINE

Theory : Brayton Cycle Using Ideal Gases
2
4
3
1

Simplified Equations : Power
Power Output = Turbine power output - Compressor power absorbed
⎥
⎥
⎥
⎦
⎤
⎢
⎢
⎢
⎣
⎡
−⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
⎥
⎥
⎥
⎦
⎤
⎢
⎢
⎢
⎣
⎡
−⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
=
−−
1
P
P
mRT
1k
k
1
P
P
mRT
1k
k
Power
k
1k
1
2
1
k
1k
4
3
4
( )14
1
2
TT1
T
T
mR
1k
k
Power −⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
=
4
3
k
1k
4
3
k
1k
1
2
1
2
T
T
P
P
P
P
T
T
Since =⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
=⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
=
−−
⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
= 1
2
13
1
2
1
11
T
T
TT
1
T
T
T
VP
1k
k
Power 111 mRTVPSince =
⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
= 1
T
T
1
T
T
VP
1k
k
Power
2
3
1
2
11
1
31
T
TP
Power ∝
2
4
3
1

Simplified Equations : Efficiency
InputHeat
OutputPower
Efficiency =
⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
= 1
2
13
1
2
T
T
TT
1
T
T
mR
1k
k
Power
1
2
1
2
P
P
T
T
Efficiency ∝∝
( )23p TTmCInputHeat −=
( )
( )23p
23
2
1
1
2
TTmC
TT
T
T
1
T
T
mR
1k
k
Efficiency
−
−⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
=
⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−
−
=
2
1
p T
T
1
C
R
1k
k
Efficiency
⎟⎟
⎠
⎞
⎜⎜
⎝
⎛
−∝
2
1
1
T
T
Efficiency
2
4
3
1

Pressure & temperature Variation across a
Gas Turbine
Highest Pressure : Compressor Discharge Pressure govern the Efficiency of the Gas Turbine
Highest Temperature : Turbine Inlet Temperature (TIT) govern the Output of the Gas Turbine
1
31
T
TP
Power ∝
1
2
1
2
P
P
T
T
Efficiency ∝∝

Actual Working Cycle of Gas Turbine & Impact of Installation
1
8
6
4
2
9

Gas Turbine Performance
Ambient Condition Impact
1
2
1
2
P
P
T
T
Efficiency ∝∝
1
31
T
TP
Power ∝
•  Power decreases
•  Efficiency decreases
Ambient
Temperature
Increases
Altitude
Increases
•  Efficiency slightly
decreases
Relative
Humidity
Increases
•  Power slightly
increases
decreases

Gas Turbine Performance
Installation Impact
1
2
1
2
P
P
T
T
Efficiency ∝∝
1
31
T
TP
Power ∝
•  Efficiency decreases
Exh. losses
Increases
Inlet Losses
Increases
decreases

Agenda
➨  Gas Turbine
➨  Principles
➨  Construction
➨  Applications
•

Gas Turbine Pressure & Temperature air Profile

Gas Turbine on Skid with Auxiliaries & Control
GG LO Module
Fuel Module
1x100%
Hyd Start Module
Dual Certified
Electrical Module
Turbine Module
Gas Turbine Control
GG LO Module
Fuel Module
1x100%
Hyd Start Module
Dual Certified
Electrical Module
Turbine Module
Gas Turbine Control
33 FT

Gas Turbine Package
Air Intake Exhaust Stack Ventilation
Driven Equipment
(Compressor)
Driven Equipment
(Auxiliaries)
Gear Box
Auxiliaries
Gas Generator &
Power Turbine Control

•  Compressor & Compressor turbine
coupled together and free power
turbine drives the DE hence suitable
for both MD and PG applications
•  Gas Generator Shaft speed varies
(= compressor mass flow varies)
•  Part Load control by optimization of
TIT and GG speed (= Good Part Load
Efficiency)
•  Light shafts & requires no barring & no
interlock
•  Easy to maintain
Gas Turbine Shaft Arrangement
FUEL
CTC B DEPT
Two Shafts
FUEL
C B CT+PT
Single Shaft
DE
•  Compressor, turbine & Driven equip.
(DE) coupled to the same shaft
•  Mainly used for power generation
•  Shaft speed constant for Power
Generation ( = compressor mass flow
constant)
•  Part Load control by TIT (= Poor Part
Load Efficiency )
•  Shaft is heavy & requires barring
•  Difficult to maintain

Combustor – Types of burner

Influence of temperature on CO and NOx emissions
Combustion temperature K
NOx ppm
High temperature
promote Unnatural
production of NOx.
CO ppm
Insufficient air
to fuel & local
cooling of the
flame promotes
CO emission.
1400 1500 1600 1700 1800 1900 2000
120
100
80
60
40
20
0
30
25
20
15
10
5
0
NOx
CO
Emission Is A Major Concern In Gas Turbine Industry
Effect of Water / Steam Injection
DLE Burner
Low flame temp. &
good air/fuel mixing
due to stage
combustion

Dry Low Emissions
First Generation DLE System
Combustion Module
Parallel
Staged
Pre-Mix
Part LoadFull Load
Part LoadFull Load
Series
Staged
Pre-Mix
25% split Cone50% Split - Full Load
EV &
AEV
burners
A
B
C
AFT LOOKING
FORWARD
A
C
B
Primary 2nd
Air/Fuel Mix

Agenda
➨  Gas Turbine
➨  Principles
➨  Construction
➨  Applications
•

Types of Gas Turbine Cycle
GT with INTERCOOLING
COMBUSTOR
HIGH PRESSURE
COMPRESSOR POWER TURBINE
INTERCOOLER
LOW PRESSURE
COMPRESSOR
INLET AIR
FUEL
HOT
GAS
COOLANT
EXHAUST
GAS
GT with REGENERATION
COMBUSTOR
POWER TURBINE
COMPRESSOR
FUEL
INLET AIR
COMPRESSED
AIR
REHEATED
AIR
HOT
GAS
EXHAUST
GAS
GT with REHEATER
COMPRESSOR
TURBINE ONE TURBINE TWO
COMBUSTOR REHEATER
FUEL MORE FUEL
INLET AIR
COMPRESSED
AIR
HOT
GAS
EXHAUST
GAS
Simple Gas Turbine
COMBUSTOR
COMPRESSOR
POWER TURBINE
FUELINLET AIR
Standard Solar
Mercury
50
R-R
WR-21
Alstom
GT24/26

Types of Industrial Gas Turbines
•  Heavy Weight
•  Light Weight
•  Aero-derivatives

New
bleed
duct
Modified casings
Low emission
combustion
system
Modified power
turbine
Industrial Trent
Aero Trent
New
compressor
Common IP and HP systems
Fan
Derivation from Aero to Industrial
Aircraft Engine Lineage The Industrial TrentGas Turbine Component

COMPARISON ON TYPES OF GAS TURBINE
TYPICAL DATA HEAVY WEIGHT LIGHT WEIGHT AERO
PRESSURE RATIO
EFFICIENCY
TURBINE INLET TEMP. (TIT)
POWER / WEIGHT RATIO
POWER / SIZE RATIO
TIME BETWEEN OVERHAULS
ENGINE REMOVAL
Low (~10)
Low (~29%)
Low (~950oC)
0.25 MW/ton
0.6 MW/m2
~48000 hrs
No
Medium (~14)
Medium (~33%)
Medium (~1100oC)
0.45 MW/ton
0.7 MW/m2
~25000- 40000 hrs
Yes
High (~20)
High (~37%)
High (~1200oC)
0.6 MW/ton
0.8 MW/m2
~25000 hrs
Yes
BEARING / LUBRICATION Journal /
Mineral
Tilting Pad /
Mineral
Ball Bearing /
Synthetic
DOWN TIME LONG Short Short

POWER, MW
EFFICIENCY, %
COMPRESSOR STAGES
PRESSURE RATIO
TURBINE INLET TEMP.,TIT
FRAME 5C
28.3
29.4
16
8.9
963
FRAME 5D/ E
980
32.6/ 32
30.3/ 36
17/ 11
10.8/ 17
SGT600
1182
24.7
34.2
10
13.6
SGT700
1260
29
36
11
18
UPRATING OF GE FRAME5 UPRATING OF GT10
Demand of more Power & Efficiency from given size driving
industry to go for Aero Technology, Examples…..
Types

Applications
PowerGenerationOil&Gas
main menu
MarineAerospace

Driving Pipeline Compressors Driving Pumps
Driving Barrel Compressors Driving Electrical Generators
Gas Turbine Applications in Oil & Gas

Simple cycle, Co-generation, Combined Cycle
An Aero Engine Power Generating Gas Turbine
Performance at Malaysian conditions
14% Losses
Waste Heat
Recovery Unit
53% Heat
33%
Electric
Power100% FUEL
GT
33%
100% FUEL
15%
Waste Heat
Recovery Unit
16%
Steam Turbine
7oC
36%
67%
33%
100% FUEL
Mostly used in O&G application
Maximum Electrical Efficiency
Lowest Electrical & Thermal Efficiency
Mostly used in Utilities & IPP
Maximum Thermal Efficiency
Mostly used in industrial
application where both power
and steam is required
Simple
Cycle Co-generation
Combined
Cycle

Aircraft Engine Lineage The Industrial TrentGas Turbine Combined Cycle application

Utility PG
ü  Location are often urban
ü  Site is often safe area
ü  Site Overhaul / maintenance is usual
ü  Limited outage is acceptable
ü  Full load operation
ü  Cogen & Combined cycle applications
ü  Fuel cost is critical
ü  Emissions levels are stringent
ü  Redundant units are rare
Oil & Gas
ü  Location are often remote or offshore
ü  Hazardous environment
ü  Site O&M is not usual
ü  High demand on reliability & avail.
ü  Part load Operation
ü  Cogen & CC application are rare
ü  Fuel cost is often not critical
ü  Emissions becoming a concern
ü  Redundant units are common

Agenda
➨  Gas Turbine
➨  Principles
➨  Construction
➨  Applications
•

Compressor
• A Compressor is a device that
transfers energy to a gaseous fluid
to
Ø  overcome the effects of
system resistance so the
required flow can be
supplied to meet process
requirements
Ø  raise the pressure of the
fluid by at least 5.0 psig
(34.5 kPag)
• Devices that develop less than 5
psig are classified as fans or
blowers.

Types of Compressors & Selection Criteria
Ø  Positive Displacement
Compressors
Ø  Piston compressor
(Reciprocating)
Ø  Screw compressor
Ø  Vane compressor
Ø  Lobe compressor
Ø  Dynamic Compressors
Ø  Centrifugal compressor
Ø  Axial compressor
Dischargepressure,psia
Inlet flow acfm
10
1
10
5
10
4
10
3
10
2
10 10
5
10
4
10
3
10
2
10
6
Reciprocating
Centrifugal
Axial

Characteristic Curves for Reciprocating, Axial
and Centrifugal Compressors

Comparison of Reciprocating, Centrifugal and
Axial Compressors
Type Advantages Disadvantages
Centrifugal
- Wide operating range
- Low maintenance
- High reliability
- Unstable at low flow
- Moderate efficiency
Axial
- High efficiency
- High speed capability
- Higher flow for a
given size
- Low pressure ratio per stage
- Narrow flow range
- Fragile and expensive blading
Positive
displacement
- Pressure ratio
capability not affected
by gas properties
- Good efficiencies at
low specific speed
- Limited capacity
- High weight to capacity ratio
- Higher maintenance
requirements
- Introduces vibrations into the
system
- Bigger foundation
requirements

Agenda
➨  Gas Turbine
➨  Principles
➨  Construction
➨  Applications
•

Compressor Map
More Speed Yields
More Head and
Flow
Less Flow
Gives More
Head
Distinct Areas
of High
Efficiency
Surge & Choke

Compressor Performance Envelope
Head
Flow
Choke
Region
Normal
Operation
Minimum Speed
Surge
Region
The area of desired
compressor operation is
bounded on the left by the
surge line, on the right by the
choke line, on the top by the
maximum speed line, and on
the bottom by the minimum
speed line.
Operation of the machine in
this region will allow the
machine to meet the process
requirements with safe and
reliable performance.

Typical Performance Curve
109%
100%
85%
60%
70%
80%
100%
110%
120%
60% 70% 80% 90% 100% 110% 120% 130% 140%
FLOW (% of design point value)
HEAD(%ofdesignpointvalue)
90%
☛  Head Rise to Surge
☛  Head fall to Stonewall
☛  Surge Flow
☛  Stonewall Flow
☛  Speed Range
9%
15%
70%
130%
70 - 105%
Constant Speed Curve

Fan Laws
Flow α Speed
2
1
2
1
N
N
Q
Q
=
2
2
1
2
1
N
N
H
H
⎥
⎦
⎤
⎢
⎣
⎡
=
3
2
1
2
1
N
N
PWR
PWR
⎥
⎦
⎤
⎢
⎣
⎡
=
Head α Speed2
Power α Speed3
% Head
% Flow
25
100755025
100
75
50
100%
125
110
125105
105%
70%
70
49

Typical Compressor Map

Agenda
➨  Gas Turbine
➨  Principles
➨  Construction
➨  Applications
•

Multi-Stage Horizontally Split
Horizontally Split Compressors:
Multi-Stage / Multi-Section Compression
•  Low Pressure / High Flow Applications
•  Up to 6300 kPag (900 psig) Maximum Working Pressure
•  Cast Steel and Forged Steel Casings
•  Wet or Dry Gas Seal System
•  Down Nozzle Arrangement is Maintenance Friendly
due to Top Half Casing Removal

Vertically Split Barrel Type Compressors:
Multi-Stage / Multi-Section Compression
•  Variable Flow Range Capability
•  High Pressure Ratio / Head Applications
•  Up to 72,500 kPag (10,500 psig) Maximum Working Pressure
•  Wet or Dry Gas Seal Systems
•  Less Maintenance Friendly for Inspection of Internals
Multi-Stage Vertically Split - Barrel Type

Multi-Stage Centrifugal Impeller Arrangements
• High Head/Pressure Ratio
• Thrust via Aerodynamic Compensation - Center
Seal Need to be carefully design
• Reduced Recirculation
• Reduces Bearing Span for Better Rotor Dynamic
Stability
• Inter-cooling Between Sections
•  Conventional
•  Medium Head/Pressure Ratio
•  Thrust Limitations - Balance Piston
•  Higher Recirculation Losses
Straight Through / Front-to-Back Back to Back

Gas Transmission Booster Compressors:
Single-Stage and Multi-Stage Compression
•  Primarily used for natural gas transmission service
•  Very high aerodynamic efficiencies
•  Moderate-to-high volume flows & low-to-moderate heads
•  Dry Gas Seal Systems
Gas Transmission Booster Compressors

Axial Inlet Single-Stage
Compressor
Conventional Single-Stage
and Multi-Stage Compressor
Gas Transmission Booster Compressors Configuration

Centrifugal Gas Transmission Boosters
Conventional: • Horizontally opposed nozzles/side inlet
• Between bearings (and overhung) rotor designs
• Wide pressure ratio/head flexibility - up to five stages
• High aerodynamic efficiencies - 88% polytropic
• Fixed casing design per frame size
• Fixed pressure ratings up to 17,240 kPag (2500 psig)
Axial Inlet: • Highest aerodynamic efficiencies - Near 90% isentropic
• Limited to single-stage designs (1.45:1 Pressure Ratio)
• Overhung rotor design (single dry gas seal design)
• Pressures up to 12,410 kPag (1800 psig)
• Fixed casing design per frame size

• Upstream Sector
–  Gas Injection
–  Gas Lift
–  Gas Boosting / Export
•  Gas Transmission
–  Gas Pipeline Compression
–  Gas Storage / Withdrawal
Compression
Typical Natural Gas Compression Application

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