GAS TURBINES

Performance, Maintenance and Troubleshooting

FOR JUNIOR ENGINEERS

Presented By
Hesham M. Khalil, PhD, CEng

Rotating Equipment Section Head

Egyptian Natural Gas Company, Gasco
 Gas Turbine
Overview

Explain gas turbine advantages and

disadvantages, background and industrial
applications.
Identify the types of gas turbines, their major
components and describe the operating
principles of a simple gas turbine.
General Description Gas Turbine
Overview
Simple Gas Turbine Operating Principles

• A gas turbine engine is a prime mover/motor used to drive other rotating equipment such as

pumps, compressors and generators.

• It achieves its function through two stage process; first, creating high energy; high enthalpy flow,

then, extracting mechanical energy; shaft rotating torque from it.

• Most common applications of industrial gas turbines are to drive:

1. Compressors for transporting gas through pipelines

2. Generators that produce electrical power

General Description Gas Turbine
Overview
Simple Gas Turbine Operating Principles
General Description Gas Turbine
Overview
Simple Gas Turbine Operating Principles

• Ambient air enters the air compressor and is

compressed to a pressure of 1100 – 3000 kPa and

then passes to the combustion chamber.

• The combustion chamber adds fuel (natural gas or

oil) to some of the air from the compressor to

achieve continuous combustion.

General Description Gas Turbine
Overview
Simple Gas Turbine Operating Principles

• This combustion causes a sudden increase in

temperature to about 2000°C, which is the flame

temperature.

• By mixing the combusted products with the

remaining compressed air, the temperature is

reduced to 918°C at the exit of the combustion

section to achieve a temperature low enough for the

turbine materials.
General Description Gas Turbine
Overview
Simple Gas Turbine Operating Principles

• The hot gases from the combustion chamber then

enter the turbine. The turbine expands the air from

the combustion section and produces mechanical

power to drive the air compressor and a generator,

which produces electricity.

• These gases exit the turbine at nearly atmospheric

pressure, but still at a temperature of up to 500 –

640°C.
Gas Turbine Major Components Gas Turbine
Overview

• While gas turbines exist in many different designs, every gas turbine has three major

components:
The Cycle On The T-S Diagram Gas Turbine
Overview
Brayton Cycle
Process from 1 to 2 is compression (power extracting)
Process from 2-3 is heat adding (combustion)
Process from 3-4 is expansion (power generation)
Gas Turbine Major Components Gas Turbine
Overview

Axial Compressor
Gas Turbine Major Components Gas Turbine
Overview

Combustion Chamber
Gas Turbine Major Components Gas Turbine
Overview

Turbine Section
Gas Turbine Applications Gas Turbine
Overview
Aircraft
The fan rotates & sucks in air. About 80% of the air passes through the by-pass duct, cools the engine, &
makes most of the thrust. The other 20% of the air is compressed, mixed with fuel, & ignited. The
explosion passes through the turbine, making the turbine rotate. A shaft connects the turbine to the fans
& compressors, so when the turbine rotates, the fans & compressors also rotate. The gases then pass
through smaller & smaller areas, decreasing the pressure. Finally, the gases pass out of the exhaust nozzle
at very high speed, giving the engine thrust.
- Newton III (Action/Reaction)
Gas Turbine Applications Gas Turbine
Overview
Air Crafts
Gas Turbine Applications Gas Turbine
Overview
Power Plants
Types Of Industrial Gas Turbines Gas Turbine
Overview

• There are two basic types of industrial gas turbines: aero-derivative - derived from the jet engines

used in aircraft; and heavy-duty gas turbines – only designed for land-based applications.

• Each type has advantages and disadvantages, which make them more suitable for certain

applications.

• However, there is considerable overlap in their usage and there are no hard and fast application

rules.
Types Of Industrial Gas Turbines Gas Turbine
Overview
Aero Derivative Gas Turbines

Aero-derivative gas turbines, such as the 55 MW General Electric LM 5000, are aircraft (jet) engines

adapted for industrial use by expanding the engine gases through an added power turbine to drive a

generator or mechanical load, rather than expanding the exhaust through a jet nozzle as occurs in aircraft
Types Of Industrial Gas Turbines Gas Turbine
Overview
Aero Derivative Gas Turbines
Types Of Industrial Gas Turbines Gas Turbine
Overview
Aero Derivative Gas Turbines

In general, aero-derivative gas turbines are:

• Low weight which makes them suitable for locations such as offshore platforms, ships, trains and vehicles

where weight is important

• Easily maintained, removed and replaced which maximizes availability

• Fast starting which is crucial for backup power generation and pipeline applications

• Usually less durable with a shorter life than heavy-duty gas turbines
Types Of Industrial Gas Turbines Gas Turbine
Overview
Heavy Duty Gas Turbines

Heavy-duty gas turbines share many design aspects

with steam turbines, compressors and plant

machinery.

Because weight is less of an issue in many

applications, their layout is more flexible and their

design is more rugged than aero-derivatives.

Types Of Industrial Gas Turbines Gas Turbine
Overview
Heavy Duty Gas Turbines
Types Of Industrial Gas Turbines Gas Turbine
Overview
Heavy Duty Gas Turbines

In General, Heavy-Duty Gas Turbines Are:

• Larger and heavier than their aero-derivative equivalents

• Very durable with long intervals between overhauls which makes them especially suitable for base load

applications

• More efficient than aero-derivative engines of the same capacity

• Able to use all fuels including distillates, residuals and crude oil

• Able to accommodate a flexible layout between compressor, combustors and turbine to allow for inter-cooling,

regeneration, steam injection, combined cycle, closed cycle and reheat

Advantages and Disadvantages of Gas Turbines Gas Turbine
Overview
Advantages of Gas Turbines

Modern gas turbines have a number of significant advantages over other types of power plants,
including:

 Capability to produce large amounts of power, currently up to 250 MW

 High power to weight ratio, making them especially suitable for applications (such as offshore)
where weight must be minimized

 Ability to use a wide range of liquid and gaseous fuels

 High HP per Dollar installed cost

Advantages and Disadvantages of Gas Turbines Gas Turbine
Overview
Advantages of Gas Turbines

Modern gas turbines have a number of significant advantages over other types of power plants,
including:

 Ability to start rapidly, which is important for backup power generation

 Relatively simple and compact design with few and simple auxiliary systems

 High availability and reliability and ability to minimize outage time by quick replacement of the gas
turbine in case of major failure

 Remote operation capability with minimal operational manpower requirements

Advantages and Disadvantages of Gas Turbines Gas Turbine
Overview
Disadvantages of Gas Turbines

 The turbine engine is low thermal efficiency engine, which have prevented its widespread use in
many applications such as auto motives.

 Turbine engines have high manufacturing costs - Because of the complicated design, manufacturing
is expensive

 Skilled technicians are required to operate the gas turbine

 A gas turbine is less suitable for low-power applications - At partial throttle conditions, the efficiency
of the gas turbine decreases

 A turbine requires intercoolers, regenerators and/or reheaters to reach efficiencies comparable to

current gasoline engines; this adds significant cost and complexity to a turbine engine

 High noise levels

 Gas Turbine
Cycles

Describe open cycle and closed cycle

operation. & describe the cycle
improvements.
Gas turbine operating cycles (open – closed) Gas Turbine
Cycles
Open Cycle Operation
Gas turbine operating cycles (open – closed) Gas Turbine
Cycles
Open Cycle Operation

• An open cycle gas turbine system is shown in Figure.

• Air is drawn into the compressor inlet from the atmosphere, compressed and supplied to the turbine

after heating with oil in the combustion chamber.

• It then expands through the gas turbine and exhausts to atmosphere.

• The system is termed “open cycle” because the working fluid (air) is drawn from the atmosphere at

the beginning of the cycle and returned to atmosphere at the end of the cycle.

• The term “simple” is used because the plant has no additional features such as heat exchangers,

reheaters, intercoolers, and so on.

Gas turbine operating cycles (open – closed) Gas Turbine
Cycles
Closed Cycle Operation

• Higher pressures can be used throughout the cycle and therefore

higher densities of the working fluid are obtained. This increases the

output of the machine for the same physical dimensions.

• The working fluid is clean, and does not cause corrosion or erosion of

the turbine.

• The working fluid need not support combustion and may be chosen for

its superior thermodynamic properties.

• A cheap fuel may be used.

Gas turbine operating cycles (open – closed) Gas Turbine
Cycles
Heat Exchanger ?
Gas turbine operating cycles (open – closed) Gas Turbine
Cycles
Closed Cycle Operation

Closed Cycle System Disadvantages

• A supply of cooling water is required.

• Heat-exchanger efficiencies are considerably lower

than those of direct internal combustion.

• The complexity, size, and cost of the system have been

considerably increased.
Efficiency and Rating of Gas Turbines Gas Turbine
Cycles

• Gas turbines are normally rated in terms of the power produced at the output shaft where it connects to

the generator or compressor.

• The power rating specified by the manufacturer will be in Kilowatts/Megawatts, at a standard of 15°C and

at sea level, using natural gas as a fuel, air with 60% humidity and with no intake or exhaust losses.

• Thermal efficiency is the ratio in % of the rated power and the fuel energy rate.

• The fuel energy rate is calculated by multiplying the fuel flow rate by the lower heating value of the fuel.

• Modern gas turbines are able to reach efficiencies of 35% to 40% in simple cycle mode without the cycle

improvements or combined cycle described after.

Gas Turbine Cycle and Its Improvement Gas Turbine
Cycles
Cycle Improvements
Regeneration

• The most common cycle improvement is regeneration where exhaust heat is used to increase the temperature

of compressed air before combustion.

• This is accomplished by installing a heat exchanger in the exhaust to preheat the air between the compressor

and the combustors.

• This approach, which is becoming less common, allows the efficiency of the gas turbine to be improved by 15-

20%.

• Disadvantage is the increased capital cost.

• Instead, many installations now use the exhaust heat for combined cycle or cogeneration.
Gas Turbine
Cycles
Gas Turbine Cycle and Its Improvement Gas Turbine
Cycles
Cycle Improvements
Intercooling

• In some gas turbine arrangements, the compression of the inlet air is done in two stages with the air being

cooled between the stages in a heat exchanger (intercooler).

• Since isothermal compression (compression without an increase in temperature) takes less work than adiabatic

compression (compression where no heat is removed so that the air temperature increases), more of the

turbine power will be available for the output load.

• Another advantage of intercooling is that the specific volume of the air is reduced, permitting a smaller physical

size for the machine.

Gas Turbine Cycle and Its Improvement Gas Turbine
Cycles
Cycle Improvements
Intercooling

• A high-pressure ratio means that losses through the intercooler become more significant.

• Using an intercooler is more beneficial if it is combined with regeneration as more of the exhaust heat will be

recovered and this will improve the overall cycle efficiency.

• The intercooler is a shell and tube heat exchanger similar in construction to the regenerator.

• Cooling water passes through the tubes while the air passes over the outside of the tubes.
Gas Turbine
Cycles
Gas Turbine Cycle and Its Improvement Gas Turbine
Cycles
Cycle Improvements
Reheat

• The gas turbine plant may also be arranged to expand the hot gases in two stages, with the gases being

reheated between the stages.

• The gases are expanded first in a high-pressure turbine and then reheated before entering a low-pressure

turbine.

• The effect of this reheating is to increase the energy content of the gases and thus improve the thermal

efficiency of the cycle.

• The reheating is done by burning fuel in a second combustion chamber using the excess oxygen content of the

gases from the high-pressure turbine for combustion.

Gas Turbine
Cycles
Gas Turbine Cycle and Its Improvement Gas Turbine
Cycles
Combined Cycle

• Gas turbines can be integrated into a wide variety of combined cycle or cogeneration systems.

• Many of these are in use today, and their utilization is increasing.

• These systems usually extract the exhaust heat from the gas turbine by means of a heat exchanger, usually a

type of boiler.

• Steam is produced, which can be used to drive a steam turbine, or to provide steam for process plant purposes

or other heating applications.

• The steam turbine can be connected to the same generator as the gas turbine, another generator, a

compressor or some other mechanical drive.

Gas Turbine Cycle and Its Improvement Gas Turbine
Cycles
Combined Cycle
Gas Turbine Main
Components

Describe the types of gas turbine shafts and

gas turbine main components and its types.
Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications
Shaft Types – Single Shaft

• In the single shaft arrangements, the compressor, turbine and load are all connected and rotate at

the same speed.

• The more common situation is for the load to be connected to the turbine.

• Another arrangement, is for the load to be connected to the compressor.

Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications
Shaft Types – Single Shaft
Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications
Shaft Types – Dual/Twin Shaft

• In the dual shaft arrangement shown, the compressor is driven by a high pressure turbine while the

load is driven by a low pressure turbine with no mechanical linkage between the low pressure and

the high pressure turbines.

Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications
Shaft Types – Dual/Twin Shaft
Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications
Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications
Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications

• A single-shaft arrangement is used for power generation where a constant speed is required but is

rarely used for other applications.

• It is mechanically simpler than a two-shaft arrangement, but requires a large starting motor.

• This is because, in single shaft systems, the starting motor must turn the turbine and load mass, as

well as the compressor, whereas in two-shaft arrangements, the starting motor does not have to

turn the load mass along with the compressor.

Gas Turbine Categories (Single–Dual/Twin shaft) Gas Turbine Main
Components
and Their Applications

• The advantage of this arrangement is greater flexibility. The load may be operated at varying speeds

while the compressor speed remains constant.

• Conversely, the load speed may be constant as in the case of a generator while the compressor

speed may be varied.

• Another advantage of the dual shaft machine is that a smaller starting motor may be used, as

during start-up it is only necessary to turn the compressor and the high-pressure turbine.
Compressor Types Gas Turbine Main
Components

• In small gas turbines, centrifugal compressors are often used, in combination with several axial

stages. The majority of large gas turbines use a multi-stage axial compressor.

• Since the compressor absorbs up to ⅔ of the energy provided by the fuel, it must be structurally

sound, as well as efficient.

Compressor Types Gas Turbine Main
Components
Compressor Types Gas Turbine Main
Components
Centrifugal (Radial) Compressors

• These compressors take air in at the center or “eye” of

the rotor.
• Due to the high rotational speeds of the rotor, the air is
accelerated by the blades and forced radially to the edge
of the rotor at high velocity by centrifugal force.
• There, the air is received by the diffuser, which in turn,
converts the high velocity to pressure energy.
• Advantages of the radial or centrifugal compressor are
simplicity, strength and short length.
Compressor Types Gas Turbine Main
Components
Centrifugal (Radial) Compressors
Compressor Types Gas Turbine Main
Components
Centrifugal (Radial) Compressors
Compressor Types Gas Turbine Main
Components
Axial Compressor
Compressor Types Gas Turbine Main
Components
Axial Compressor

• This type of compressor operates on a principle similar to a turbine, but acting in reverse.

• The moving blades act upon the air so as to increase its velocity and discharge it axially into the next

row of fixed blades, rather as though each moving blade was a small section of a propeller.

• The fixed blades tend to slow the air down in its passage through them and so raise its pressure.

• If the moving blades are properly shaped, they will cause the air to be compressed in its passage

through them so that compression takes place in both fixed and moving blading.

• If the pressure rise in each is equal, the compressor is symmetrically staged and is similar to a reaction

turbine (in reverse).

Compressor Types Gas Turbine Main
Components
Theory of
Compression
Axial Compressor
Compressor Types Gas Turbine Main
Components
Theory of
Compression
Axial Compressor
Compressor Types Gas Turbine Main
Components
Theory of
Compression
Axial Compressor
Compressor Types Gas Turbine Main
Components
Axial Compressor
Compressor Types Gas Turbine Main
Components
Axial Compressor

Compressor Stator

Compressor Rotor/ Drum /

Wheel / Inner Casing

Compressor Outer Casing

Compressor Bleed Valves

Compressor Types Gas Turbine Main
Components
Axial Compressor
Compressor Types Gas Turbine Main
Axial Compressor
Components
Compressor Types Gas Turbine Main
Components
Surge
Compressor Types Gas Turbine Main
Components
Surge
Compressor Types Gas Turbine Main
Components
Surge
Compressor Types Gas Turbine Main
Components
Surge
Compressor Types Gas Turbine Main
Components
Surge
Axial Compressor is protected against surge by:

Inlet Guide Vanes

Compressor Types Gas Turbine Main
Components
Surge
Axial Compressor is protected against surge by:

Bleed Valves
Compressor Types Gas Turbine Main
Axial Compressor
Components
Compressor Types Gas Turbine Main
Inlet Guide Vanes
Components
Compressor Types Gas Turbine Main
Inlet Guide Vanes
Components
Gas Turbine Combustors Gas Turbine Main
Components
Gas Turbine Combustors Gas Turbine Main
Components
Gas Turbine Combustors Gas Turbine Main
Components
Purpose

• The combustion chamber, or combustor, in the open cycle gas turbine is used to heat the working air

after its discharge from the compressor and before entry to the gas turbine.

• It must do this with a minimum loss of pressure and with the minimum of combustion impurities since

these will be carried with the air into the turbine blading.

• About 20 per cent of the air entering the combustor is mixed with the fuel in the flame tube as

combustion air; the remainder - 80% - flows on the outside of the tube and services as cooling air.
Gas Turbine Combustors Gas Turbine Main
Components
Purpose

• The temperature of the burning gases in the tube will be 1370°C to 1650°C but the final mixture of the air

and hot gas leaving the combustor is limited to the temperature that the turbine blading can withstand over

its working life.

• This is about 650 to 900°C in present day practice so that the cooling air and hot gas must be thoroughly

mixed before leaving the combustor.

• Some of the gas turbine designs use a single, large volume combustor and others a series of smaller

combustors disposed radially around the engine between the compressor and the turbine. Generally the

large combustion chamber will be used when a regenerator is included in the plant or where heavy oil is to

be the fuel used.

Gas Turbine Combustors Gas Turbine Main
Components
Combustion Chambers Types

• Figure illustrates a section through a combustor used by Associated Electrical Industries (Canada) Ltd. Six of

these combustors are used on a machine of 6.5 MW output burning natural gas or distillate oil.

• Each combustor is made up of an inner chamber, which is carried on radial pins to allow relative expansion,

and an outer casing. Interconnecting pipes are provided between the six combustors to give uniform

combustion conditions and to carry the flame from one to the other during the starting sequence, only two

of the combustors carry igniter elements.

Gas Turbine Combustors Gas Turbine Main
Components
Straight Through Combustion Chambers
Gas Turbine Combustors Gas Turbine Main
Components
Reversed Flow Combustion Chambers
Gas Turbine Combustors Gas Turbine Main
Components
Types Of Combustors
There are three basic designs for combustors:
 Can-annular
 Annular
 Single-can

Single-can Annular Can-annular

Gas Turbine Combustors Gas Turbine Main
Components

Can-Annular

In the can-annular design, combustion takes place in multiple

combustors, also called combustion cans, which are placed
around the centerline of the gas turbine. Some are straight
through, as shown in Figure. Usually these are older aero-
derivative designs where minimum frontal area is important.

The advantage of a “Can” setup is that problems associated

with aerodynamics and combustion, such as non-uniform
outlet temperatures, are minimized. The disadvantages are
that multiple igniters and fuel lines are required and also that
the 'Can' setup is not the most efficient use of space in an
annular volume.
Gas Turbine Combustors Gas Turbine Main
Components

Can-Annular
Gas Turbine Combustors Gas Turbine Main
Components

Annular

This type of combustion chamber, shown in Fig., consists

of a single concentric flame tube surrounding the spools.

This is the most efficient use of the space available to the

airflow. The main advantage of the annular combustion

chamber is that for the same power output, there is up to

25 % reduction in the weight. As a single large combustion

chamber, the combustion process is more evenly

distributed in the tube.

Gas Turbine Combustors

Annular
Gas Turbine Combustors Gas Turbine Main
Components
Single Can

Chambers are arranged around the engine and the air is delivered into ducts in each chamber. Each chamber has an inner
flame tube. All the tubes are interconnected which allows each tube to operate at the same pressure. The early axial flow
compressor engines used this type of chamber. The burners are arranged in a circular fashion around the engine. Each
chamber has a separate flame tube although they are all interconnected. Each tube operates at the same pressure, which
provides identical operating conditions.
Gas Turbine Combustors Gas Turbine Main
Components
Combustion Chambers Main Components

Most of the commonly used combustors or combustion chambers are designed with several main parts and areas so
that combustion is continuous and complete The Parts of the Combustor are:

• The Combustion Chamber housing (Combustor) is

the outside housing

• The Combustion Chamber Liner (Flame Tubes) is

the inside of the housing

• The Fuel Nozzle (Fuel Injector, Atomizer, or

Vaporizer) injects the fuel

• The Igniter Ignites the Fuel/Air Mixture

• The air swirler for good mixing between the air and
fuel
Gas Turbine Combustors Gas Turbine Main
Components
The zones in the combustion chamber

There are three zones in the combustion chamber as following:

• The primary zone: is the first part of the combustion chamber liner where fuel is injected and ignition begins
• The secondary zone: is where combustion continues and begins to mix with the secondary air
• Dilution zone: is where combustion should be complete but secondary air is mixed with the burnt gases
Gas Turbine Combustors Gas Turbine Main
Components
Gas Turbine Combustors Gas Turbine Main
Components
Turbine Section Gas Turbine Main
Components
Turbine Blade

• The turbine extracts power from the hot gases supplied from the combustion section by decreasing pressure

and temperature.

• It is used first to drive the compressor and then provides mechanical power for the generator, compressor or

other load.

• As was discussed earlier, the turbine may be split into one, two or even three separate sections and shafts.

Similar to compressors, turbines can be of the axial-flow or radial-inflow type although axial-flow turbines

are much more common. Turbines operate at very high temperatures, high blade loading and large rotational

stresses.
Turbine Section Gas Turbine Main
Components

Turbine Blade

Axial-Flow Turbines

• Because energy can be extracted much more efficiently, fewer stages are needed in the turbine than in the

compressor.
• In the axial-flow turbine, a stage consists of a row of stationary blades, usually called nozzle guide vanes or
nozzles, and a row of rotating blades, sometimes called buckets.
• The nozzles increase the velocity with a partial pressure drop and the moving blades extract power with a
further drop in pressure and temperature.
• This design is usually of the impulse or reaction type.
Turbine Section Gas Turbine Main
Components

Turbine Blade

Axial-Flow Turbines

• In impulse turbines, the nozzles decrease in area to convert pressure into velocity and this kinetic energy is

used to drive the turbine, which is of constant area.

• With reaction turbines, the nozzles are of constant area and serve only to redirect the flow at the right angle

for the turbine blades, which have divergent passages to reduce pressure and increase velocity.

• All gas turbines utilize turbines of the impulse-reaction type, which is a combination of the two.
Turbine Section Gas Turbine Main
Components

Turbine Blade

Impulse Blades The gases pass through a nozzle before they strike the turbine blades the nozzles are
arranged to direct the hot expanding gases at the best angle possible to harness their
energy. Impulse blades harness the energy of high-velocity gases only by the change in
direction of the gases. Impulse blades are symmetrical and have the blades tips parallel with
the rotating shaft. The blades are arranged around the circumference of the wheel. The
space between the adjacent blades forms a channel with a uniform path from entry to exit.
The significance of this uniform path is what when gases pass through there will not be a
change in pressure or velocity but only a change in direction if the blades are stationary. If
the impulse blades are moving, there were only be a change in velocity because some of
the energy will be transferred to the moving blade. Thus, the energy transferred to the
rotating blade is only due to a change in direction, which give the wheel an impulse.
Sometimes impulse blades are stationary and are used as re-directional blades.
Turbine Section Gas Turbine Main
Components

Turbine Blade

Impulse Blades
Turbine Section Gas Turbine Main
Components

Turbine Blade

Reaction Blades The gases pass through nozzles before they strike the turbine blades. Reaction blades are not
symmetrical and their tips are not parallel to the shaft. There is also an unequal distance
between adjacent blades from entry to exit. The distance gets smaller as the gas passes
between the blades. This causes the gases to accelerate as they pass through the reaction –
type blading. This creates a pressure drop from entry to exit of the blades (Bernoulli’s
principle). Due to the acceleration of the gases and the pressure difference, a reaction force is
produced as the gases pass through the moving blades. Reaction blades will also receive an
impulse from the gases due to the change in direction or the gases as they pass through the
blades. (In truth, reaction blades harnesses power by impulse and reaction principles, but are
only called Reaction.)
Turbine Section Gas Turbine Main
Components

Turbine Blade

Reaction Blades
Turbine Section Gas Turbine Main
Components

Turbine Blade

Typical Blades

Figure represents the profile of a typical

turbine blade which uses both impulse and
reaction principles. At the base (root) of
the turbine blade, the blade will be shaped
like an impulse blade, but closer to the tip;
the blade will resemble reaction blading,
this will make the blade appear twisted
from the base to the tip section. Providing
both impulse and reaction shapes in the
blades.
Turbine Section Gas Turbine Main
Components

Turbine Blade

Typical Blades
Turbine Section Gas Turbine Main
Components

Blade And Disc Cooling

The blades and nozzles get very hot, because both the nozzles and turbine blades are subjected to extreme
temperatures. To combat the heat, larger turbines have internally air cooled blades and discs to reduce these thermal
stresses
Turbine Section Gas Turbine Main
Components

Blade And Disc Cooling

• Many gas turbines use air-cooled (and sometimes water-cooled) blades to reduce metal temperature and

increase life. Air is supplied from the compressor section, circulated through the blade and then

extracted through holes in the leading edge, trailing edge and surface of each blade. The incorporation

of complicated cooling passages in turbine nozzles and blades is also a major manufacturing challenge

that has resulted in many special techniques and methods.

• This cooling can reduce blade temperature by as such as 300 C (572 F).

• By cooling both the turbine and nozzles blades, higher combustion temperatures are allowed which

make for a higher power, more efficient, and longer lasting turbine engine.
Turbine Section Gas Turbine Main
Components

Blade And Disc Cooling

Turbine Section Gas Turbine Main
Components

Turbine Assembly
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Methods of Mounting the Blades On A Rotor

• The rotor discs are welded or bolted to a low allow steel shaft. The turbine exerts a high torque load on the
shaft, which then exerts a high torque load on the compressor. The blades on the rotor discs are attached
and locked securely to the rotor with sufficient clearance to allow for thermal expansion.
• The turbine rotor assembly is dynamically balanced because of high rotational speeds. The speed range of
most industrial turbines is from 3,600 RPM to 9,000 RPM. Some small gas turbine may be up to 42,000 RPM.
These high rotational speeds impose severe centrifugal loads on the wheels. The temperature are also
severe, form 1050 F to 2300 F, which lower the strength of the materials. For this reason the engine speed
and temp. are controlled within safe limits by the governor and the fuel system.
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Methods of Mounting the Blades On A Rotor
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Methods of Mounting the Blades On A Rotor
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Methods of Mounting the Blades On A Rotor
Turbine Section Gas Turbine Main
Components

Turbine Assembly
Methods of Mounting the
Blades On A Rotor
Air Seals Gas Turbine Main
Components

• In gas turbine, labyrinth seals are used as

shaft seals on both the compressor and
turbine.
• These seals work the best, because of the
high rotational speed, high temperatures,
and high surface speeds encountered in the
gas turbine.
• Labyrinth seals are often assisted in sealing
by jets of air routed from the compressor
section
Air Seals Gas Turbine Main
Components
Air Seals Gas Turbine Main
Components
Fuel Nozzles Gas Turbine Main
Components
Fuel Nozzles (injectors, atomizer, vaporizer)
The fuel injectors is used to spray the fuel in a fine mist for combustion. Fuel injectors can also be called
atomizers or vaporizers. Some combustion chambers have spiral vanes before the injector to cause the
combustion air to swirl and mix with the fuel.
The fuels used in the gas turbine are either liquids or gas.
Liquid fuel: are injected into the combustor in two basic methods:
The first is to use an atomizer, which spray a fine mist into the chamber. The fuel is burned in this form. This
is the usual system.
The second way is to vaporize the fuel with the heat in the combustion chamber. Fuel is metered into a tube
surrounded by combustion gases that evaporate the fuel. The fuel mixture is discharged into the combustion
chamber where it is mixed with more air and ignited.
Gaseous fuel: will use larger injector nozzles than liquid fuels because the fuels are already in a vapor form.
Fuel Nozzles Gas Turbine Main
Components
Bearings Gas Turbine Main
Components
Bearings Gas Turbine Main
Components

Wedge Action
Bearings Gas Turbine Main
Components

Thrust Bearings
Bearings Gas Turbine Main
Components
Thrust Bearings
Bearings Gas Turbine Main
Components

Journal Bearings
Bearings Gas Turbine Main
Components

Journal Bearings
Bearings Gas Turbine Main
Components
Journal Bearings
 Gas Turbine
Systems

Describe the types of gas turbine shafts and

gas turbine main components and its types.
Intake and Exhaust Section Gas Turbine Main
Components

• A gas turbine always has an air intake that filters the air to remove contaminants and prevent damage
from foreign objects. The intake plenum ensures smooth flow into the gas turbine compressor section.
Since cooler air is denser than warm air, some air intakes incorporate special cooling systems to
decrease the air inlet temperature. This increase in air density means that more mass can flow through
the turbine and therefore produce more power.

• The exhaust system provides a safe exit for the hot exhaust gases and may include a silencer to reduce
sound to acceptable limits. The exhaust may also flow to a waste heat recovery heat exchanger to supply
heat to some other process at the overall facility. This will be discussed later in this module. Both the
intake and exhaust need to operate with the lowest possible pressures losses to minimize resultant losses in
power and efficiency.
Air Intake System Gas Turbine
Systems
Air Intake System Gas Turbine
Systems
Air Intake System Gas Turbine
Systems
Air Intake System Gas Turbine
Systems
Intake and Exhaust Section Gas Turbine Main
Components
Air Intake System Gas Turbine
Systems
• Controls the air quality
• Directs a steady flow of air to the Compressor inlet
• The amount of air affects the engine performance and reliability
• The quality of air affects the life of valuable parts
Air Intake System Gas Turbine
Systems
Lube Oil System Gas Turbine
Systems
• Provides clean and cool oil to the bearings and other parts.
• Reduces friction between moving parts
• Oil film prevents metal to metal contact
Lube Oil System Gas Turbine
Systems
Lube Oil System
 Lube Oil System Gas Turbine
Systems

Oil systems are relatively maintenance free and automatic protection is usually provided against
common problems. Maintenance consists of:

 Checking for oil leaks (usually daily)

 Monitoring oil pressures and temperatures (usually daily)

 Checking chip detectors when they alarm

 Topping up the oil reservoir or secondary lube oil tank. Often a second supply tank with an automatic
slow fill valve and level control keeps the reservoir filled.

 Changing oil filters when the differential pressure alarms

 Cleaning the cooler externally

 Taking oil samples regularly for analysis and replacing oil when required

 Calibrating instrumentation and testing protective devices

Starting System Gas Turbine
Systems
 Starting System Gas Turbine
Systems
 Pneumatic starters using compressed air or gas
 Hydraulic motors
 Electric motors
 Turbo starters
 Starting System Gas Turbine
Systems

Turning Gear

On larger gas turbines, especially of the heavy-duty type, the rotors are quite heavy and they develop a
sag or bow when they cool down after shutdown. If a rotor becomes bowed, the rotor may lock and
prevent startup or it may result in high vibration until the bow slowly disappears.

To prevent this, a special turning motor is provided to slowly turn the shaft for a number of hours after
shutdown. This is sometimes a hydraulic ratchet or a slow turning electric motor. The motor and the
turbine shaft have corresponding gears. The turning motor gear can be engaged or disengaged (normal
turbine operation) with the shaft. A similar type of device is used on large steam turbines for their
warm-up and cool-down periods.
Starting System Gas Turbine
Systems
Fuel Gas System Gas Turbine
Systems
Fuel Gas System Gas Turbine
Systems
 Fire Detection System Gas Turbine
Systems
Detects a fire or serious
heat Conditions.
• Gas Detectors: Detects
fuel gas leakage
• Thermal Detectors:
Detects excessive heat
 Gas Turbine
Operation

Describe the Start-up Sequence of Gas

Turbines
 75% N 100% N
Supply Lube Oil to : Variable Guide
• Turbine 65% N vanes start to open
• Gear box Starter Drop out
• Generator bearings
• Bleed Valve
• Main L/O Pump start to close
• Accessory driver
supply all pressure
• Back-up Lube Oil
Pump stopped
N Percent

83 % Ngp
Turbine driven Bleed Valve
L/O Pump starts Fully closed
as Engine rotates
Purge
15% to 20% N
Ignition Command
General System
Fuel valve opened Operational
START Sequence
COMMAND Single shaft
Generator Set
Back-up Lube Oil Commence
Pump started
Rotation
Elapsed time
 Codes and
Standards

Describe codes and standards governing gas

turbines.
Gas Turbines for Petroleum, Chemical, and Gas Industry Services
API 616

Recommended Practice for Packaged Combustion Gas Turbines

API RP 11PGT
 Maintenance
System

Describe types of maintenance procedures.

Maintenance
Systems
Preventive Maintenance Maintenance
Systems
Corrective Maintenance Maintenance
Systems
Predictive Maintenance Maintenance
Systems
Thank you for
your attention!
Any Questions?
Contact Details

Hesham M. Khalil
Tel: 01002729088

[email protected]