LESSON

2
LECTURE
GAS TURBINES
CONSTRUCTION
SUB - OBJECTIVE
At the end of this lesson, the trainee ill !e a!le to "-
#$ List the %ain &o%'onents of the (as t)r!ine$
2$ Understand the f)n&tions of the *ario)s &o%'onents$
+$ ,no all of the a)-iliar. s.ste%s and e/)i'%ent ith (as t)r!ine$
0$ 1ra the line dia(ra% of a)-iliar. s.ste%s$
2$ ,no a!o)t the instr)%entation and &ontrol s.ste% of the (as t)r!ine$
#$3 CO45RESSORS
The use of the gas turbine as a practical prime mover has been dependent upon
the development of high efficiency compressors. The reason being that the
proportion of the gas turbine output used up in driving the compressor is so large
that the compressor must operate efficiently in order to achieve a useful net output
of power from the plant. About two-thirds of the total turbine output is absorbed in
driving the compressor.
Compressors can be divided in two general types.
#$# 16NA4IC T65E
This type of compressor imparts a high velocity head to the air by means of rotating
blades and then converts this to a pressure head before discharging. The
centrifugal and axial - flow compressors are of dynamic type.
#$#$# A7IAL - 8LO9 CO45RESSORS
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 eual, the compressor is said to be
symmetrically staged and is similar to a reaction turbine !in reverse".
#ig. $-%-& is a plan view of a '((( ).* single shaft gas turbine built by Clark +rother
Co. of ,.-. and shows a typical multi-stage axial flow compressor.
.nlike the centrifugal compressor, the pressure increase in each stage of the axial
compressor is uite small. The pressure ratio per stage is about &.%/& but the
efficiency of the axial compressor is about 012 which is higher than the centrifugal.
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The axial compressor has the disadvantage that its discharge pressure becomes
unstable at low output and this can cause severe surging with possible damage to
compressor and turbine.
#$#$2 CENTRI8UGAL CO45RESSORS
This type !sometimes called radial-flow compressors" operates on a principle similar
to that used by the centrifugal pump. The suction is taken into the center of the
impeller and discharges from the periphery.
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Lands&a'e 5a(e
8i($ :-2-#, Clar; Bros$ <333 =5 Sin(le Shaft Gas T)r!ine$
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8i($ :-2-2, Elliott Co To-Sta(e Co%'ressors$
#ig. $-%-%, shows a two-stage compressor manufactured by 7lliott Company.
Their principal advantages are simple and rugged construction, short length, high
pressure ratio per stage about </& and the fact that their discharge pressure
remains stable over a wider range of loading than the axial flow compressor.
Their disadvantages are that when built in multi-stage form they are very bulky, and
suffer pressure losses in the inter stage passages. Their efficiency is about $12
and these disadvantages make the axial type preferable for gas turbine power plant
work. )owever centrifugal compressors are used for smaller turbines.
#$2 5OSITIVE 1IS5LACE4ENT CO45RESSORS
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The compressor of this type is used with gas turbine when large variations of load or
speed have to be provided. The reciprocating compressor does not find application
with the gas turbine but the lobe type of rotary compressor does. It has a very
desirable characteristic in that although its discharge pressure may vary with the
uantity of the air drawn in and with the compressor speed, it will always remain
stable. It will not surge under any condition of loading.
#ig. $-%-;, shows the principle of the 9oots and 6ysholm compressors.
#ig. $-%-;-a. has rotors rotating in opposite directions within a casing, air is carried
round from inlet to discharge in the spaces between rotors and casing in the
manner of gear pump. The air flow is transverse, across the axis of the rotors.
#ig. $-%-;-b, has two rotors with lobes arranged helically on each. The rotors mesh
very closely without actual contact. The rotors draw air from the inlet end of the
casing and compress it in the decreasing spaces between the lobes as it passes
axially towards the discharge end.
These compressors can be built in large si>es and have high efficiencies !0(-012"
together with stable operation over a wide range of loading.
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2$3 CO4BUSTION C=A4BERS
The combustion chamber, or combustor, in the open cycle gas turbine is used to
heat the working air after its discharge from the compressor and before entry to the
gas turbine. It must do this with a minimum loss of pressure and with the minimum
of combustion impurities since these will be carried with the air into the turbine
blading.
About %(2 of the air entering the combustor is mixed with the fuel in the flame tube
as combustion air, the remainder 0(2 flows on the outside of the tubes serves as
cooling air.
The temperature of the burning gases in the tube will be &;1( ?C to &<1( ?C but the
final mixture of air and hot gas leaving the combustor is limited to the temperature
that the turbine blading can withstand over its working life.
8i($ :-2-+$ Roots Co%'ressor, L.sho% Co%'ressor$
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The temperature of the gas in the gas turbine may be as high as &(0( ?C. This
increased temperature causes large thermal stresses in the gas turbine.
4ne direct result of the high temperature is creep, the gradual growing of turbine
parts as the material is heated and cooled a number of times.
8everal methods are used to combat high temperature such as use of superalloys,
coating on internal turbine parts and @ or cooling of internal turbine parts.
8ome 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.
:enerally 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.
#ig. $-%-= shows a section of a combustion chamber of the single type as used by
+rown +overi. The air inlet is located low down and the air flows upwards between
the inner and outer Aackets. Approximately halfway up some of the air is mixed with
the combustion gases through adAustable mixing no>>les, the remaining air serves
to cool the telescopically arrangement cylindrical sections forming the inner tube,
finally flowing through the annular spaces between sections. About %(2 of the total
inlet air reaches the top of the combustor and enters the swirler to act as
combustion air for the fuel. An electrically heated ignition rod is positioned close to
the swirler.
8i($ :-2-0, Co%!)stion Cha%!er of a Gas T)r!ine Installation$
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8i($ :-2-2, Co%!)stion Cha%!er Arran(e%ent$
8i($ :-2->, Se&tion Thro)(h a Gas T)r!ine Set$
#ig. $-%-1, illustrates a section through a combustor used by associated electrical
industries ltd. 8ix of these combustors are used on a machine of <.1 3B output
burning natural gas or distillate oil.
+$3 BLA1ING
:as turbines use impulse and reaction blading, working on the same principles as
the blading in steam turbines. The main difference between gas and steam turbine
blading arises from the difference between the working medium. :as turbines have
a much less number of stages because the total pressure drop available is relatively
small. The spacing of the blades is much greater because of the high volume flow.
The stresses in the turbine rotors and blading are high because of high gas
temperatures. In order to withstand this, the rotors are made from heat resisting
steel, and owing to the difficulty of making large forgings of this material the rotors
are generally made of discs bolted or welded together.
#ig. $-%-<, shows a section through a +rown +overi gas turbine set in which both
the gas turbine and the axial flow compressor rotors are made up of welded discs.
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#ig. $-%-$ !a" C !b" show a Besting house gas turbine rotor of bolted construction.
:as turbine blading is made of heat resisting steel, forged and machined to shape.
8teps are taken in some designs to cool the blading, using hollow blading with some
coolant such as compressed air flowing through.
#ig. $-%-0 !a" and !b" show a turbine moving blade and a turbine fixed blading half
diaphragm respectively, manufactured by A.7.I. Co.
8i($ :-2-:, Gas T)r!ine Rotor of Bolted Constr)&tion$
8i($ :-2-?, T)r!ine 4o*in( Blade, T)r!ine 8i-ed Blade$
0$3 AU7ILIAR6 S6STE4S @ EAUI54ENT
0$# CO45RESSE1 AIR S6STE4
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The purpose of the compressed air system is to produce and deliver compressed air
for the pneumatically controlled components and for the cleaning and starting
systems.
Atmospheric air is drawn through an augmented self-cleaning filter.
Bhen the pressure drops on the system the compressor automatically cuts in to
recharge the air receiver.
An outlet from the compressed air system goes to the fuel system for actuating the
fire valve and also to be used for clean blowing the fuel no>>les to prevent
carboni>ation !coke". The operating air is blown backwards through the system to
displace the oil back to the fuel oil tank.
Another outlet from the compressed air system provides on air supply, when
reuired, for the mobile cleaning unit.
#rom the air receiver the high pressure starting air passes through a filter and then
through a starting air valve where the pressure is reduced to about &1 +ar !g". The
large volume of air created by the pressure drop passes through Aet pumps which,
by the eAector effect, pulls in more air from the surrounding space and goes into the
air inlet of the gas turbine. This air flowing through the turbine causes the rotors to
rotate and increase acceleration to such a stage whereby fuel inAection and
combustion are made possible very uickly.
Bhen the self-sustaining speed is reached the compressors start to pull more air
than can be provided by the starting air system and the pressure in the air intake
decreases. At this point the hood opens and the starting air device is closed.

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LAN1SCA5E 5AGE
8i($ :-2-<, Sin(le Line 1rain( Co%'ressed Air S.ste%$
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LAN1SCA5E 5AGE
8i($ :-2-#3, Sin(le Line 1rain( Co%'ressed Air S.ste%$
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8i($ :-2-##, Si%'lified 8lo, Co%'ressed Air S.ste% - Startin($
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8i($ :-2-#2, Si%'lified 8lo, Co%'ressed Air S.ste% - O'eratin($
0$2 STARTING 1EVICE
The starting device has the function to put the gas turbine under rotation and to
bring it to a self sustaining speed. The starting device can be a A@C motor, diesel
engine or a device driven by compressed air.
0$+ TURNING GEAR
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The purpose of the turning gear is to keep the hot rotor under slow rotation after the
unit has been stopped. This will help cool the rotor uniformly to prevent any
deformation caused by temperature gradients.
Bhen the turbine is stopped, the heat tends to go upwards. This may give rise to
shaft distortion.
The turning gear must run till the shaft is sufficiently cool. Bhile restarting the
turbine, the turning gear gives a slow rotation to prevent any sudden torue. The
turning gear consists of an electrical motor, a double torue converter, worn screw
and helical gear.
0$0 AIR INTA,E 8ILTER
The augmented self-cleaning !A8C" air - intake filter, used for cleaning atmospheric
air, is a single stage, self cleaning system. 5ust laden air enters the A8C system by
passing through the filter panel pack within the housing. The clean filtered air
progress through the ventures into the air intake room and to the turbine.
0$2 LUBRICATING OIL S6STE4S
The gas turbine unit is euipped with a common closed lubricating oil system that
provides oil for the bearings of the compressor, gas turbine and the generator.
5uring normal operations the lube oil is pumped from the oil tank by an A@C driven
centrifugal pump to the system. A spare pump is provided for the lube oil system
and also a hydraulic driven emergency pump for use during A@C power failures and
the cooling down period. 4il temperature in the tank can be controlled by circulating
the oil using a small centrifugal pump and passing it through an electric heater back
to the tank.
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LAN1SCA5E 5AGE
8i($ :-2-#+, Sin(le Line 1rain( of L)!ri&atin( Oil S.ste%$
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LAN1SCA5E 5AGE
8i($ :-2-#0, Sin(le Line 1rain( of L)!ri&atin( BOil Cooler 8loC$
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The lubricating oil is pumped by the main oil pump through an air cooler which is
euipped with a hydraulically driven variable speed transmission cooling fan. After
the coolers the oil passes through a duplex filter before going to the bearings of the
gas turbine, air compressor and driven euipment. 4il leaving the bearings returns
to the lube oil tank by gravity. 4il leakage along the shafts is prevented by an oil
mist vapour extractor fan which maintains a slight vacuum in the oil tank, return
piping and bearing casings.
#ig. $-%-&; shows the line diagram of lubricating oil system. #ig. $-%-&= shows
lubricating oil cooler flow.
0$> LIAUI1 8UEL S6STE4
9efer to #ig. $-%-&1.
#uel oil is pumped from the diesel oil system through a duplex filter into the internal
fuel oil tank. The tank level is controlled by a float valve.
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8i($ :-2-#2, Sin(le Line 1rain( of E-ternal 8)el Oil S.ste%$
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8i($ :-2-#>, Sin(le Line 1rain( of Internal Oil S.ste%$
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8i($ :-2-#:, Si%'lified 8lo, Li/)id 8)el S.ste% - 8illin($
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8i($ :-2-#?, Si%'lified 8lo, Li/)id 8)el S.ste% - O'eration$
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8i($ :-2-#<, Si%'lified 8lo, Li/)id 8)el S.ste% - Clean Bloin($
#rom the fuel oil tank the ).* fuel pump !gear pump" discharges the oil through a
shut off valve to the fuel no>>les. A spill back flow line from the no>>les is
connected via the shut off valve and the fuel control valve back to the tank. The
fuel inAection is controlled by throttling the spill back and this method allows simplex
fuel no>>les to be used.
+y using the spill back, the system can be automatically filled before start and blown
clear after service.
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,ote that any fuel treatment e.g. filtration, water separation and additive dosing etc.
must be accomplished before the fuel reaches the internal system.
0$: CO45RESSOR CLEANING S6STE4
Bhen salt particles are present in the air, any fouling on the compressor blades
contains a lot of sodium. 8ince sodium together with sulphur !from the air or the
fuel" causes high temperature corrosion it is of utmost importance that such fouling
is removed before it cracks, peals off and contaminates the hot section of the
engine.
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8i($ :-2-23, Sin(le Line 1rain( of Co%'ressor Cleanin( S.ste%$
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A mobile cleaning unit includes a car with containers for solid and fluid agents,
piping and valves. The car is connected to the front end of the gas turbine skid by
means of hoses. 4perating air for the unit is taken from the starting air system.
0$? ALTERNATOR COOLER COOLING 9ATER S6STE4
9efer to #ig. $-%-%&. The system comprises of two A@C motor driven pumps, one in
operation and one stand-by, a cooling water tank and three air cooled water coolers.
Cooling water is pumped from the tank to the alternator cooler, mounted on top of
the alternator. The water leaves the alternator cooler and passes through water
coolers which are cooled by A@C motor driven fans.
6ow pressure on the system starts the stand by pump.
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8i($ :-2-2#, Alternator Cooler Coolin( 9ater 8lo$
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0$< 8IRE 8IG=TING AN1 VENTILATION S6STE4S
The gas generator room and the auxiliary room are euipped with a common
automatic halon sprinkler system. The halon container is located in a separate
room. Bhen halon is released it is distributed to the two rooms through no>>les and
pipes from the container. The halon container !cylinder" has a pressure switch
which gives an alarm at low pressure.
:as fuel and dual fuel versions are euipped with gas detectors in the gas
generator room and the auxiliary room. )igh gas concentration gives alarm and
high-high gas concentration gives unit trip, the ventilation fans and releases the
halon system.
Bhen the fire alarm in box is released or the .D detector is activated the fire
fighting system comes into effects as follows /-
&. The halon system is released.
%. The ventilation fans are tripped.
;. The fire shutters close.
=. The gas turbine is tripped.
1. An alarm sounds in the control room.
<. #ire siren alarm sounds in the protected rooms.
$. A flashing alarm light is activated outside the entrance doors.
The ventilation system operates automatically. )ydraulically driven fans supply the
gas generator room and the auxiliary room with ventilating air during operation and
cooling down periods.
AC power is used for the hydraulic system in normal service. 5C power from a
battery is used after an AC failure trip to keep the engine skin temperature low.
The fans for the generator and auxiliary rooms are euipped with weather louvers
and fire shutters on the air inlet and exhaust ducts. The air inlet is also provided
with a filter.
If the fire shutters go to the closed position the turbine is tripped and the start up is
interlocked.
The control module is ventilated by an air conditioning unit and the battery room is
ventilated by a fan. These two devices are always in operation.
2$3 INSTRU4ENTATION @ CONTROL S6STE4
The operation of a gas turbine plant will involve the following general functions.
- 8tarting and stopping.
- 8peed or load control.
- Temperature and rate of temperature change control.
- 7mergency shut-down control.
The control system employed may be manual, semi-automatic, fully automatic or
even a fully automatic arrangement with a remote control. The starting seuence
will include energi>ing of the auxiliaries, engaging the clutch between the starting
motor and the set, control of the acceleration of the starting motor and control of
fuel increases reuired to bring the machine up to operating speed.
2$# 8UEL CONTROL S6STE4 BIN GENERALC
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:as turbine output depends upon the supply of fuel to the combustors. This supply
is regulated by the governor control system. #ig. $-%-%% is a schematic of a
governor control system. The governor control system responds to changes in
speed, load and turbine exhaust temperature by comparing actual values with set
points.
8i($ :-2-22, Go*ernor Control S.ste%$
#ig. $-%-%= illustrates the control diagram for a single shaft gas turbine, showing the
layout from the central control panel, through the speed governor and fuel control
system to the turbine. Included is a fuel limit relay sensitive to maximum
temperature and to the rate of increase of the temperature. The governor control
system responds to changes in speed, load and turbine exhaust temperature by
comparing actual valves with set points.
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8i($ :-2-2+, 8)el S.ste% for A$E$I$ Gas T)r!ine$
8i($ :-2-20, T.'i&al 8)n&tional Control 1ia(ra% for Sin(le Shaft Gas T)r!ine$
If a change is reuired to correct speed, load or exhaust temperature, a control
signal is fed to the fuel control system. This will regulate the uantity of fuel being
supplied to the combustors. The actual fuel control system depends upon the type
of fuel being used.
#ig. $-%-%< shows a simple arrangement in which natural gas is the fuel. In this
schematic, the stop valve is normally open, and the control valve opening is
adAusted according to the control signal coming from the govenror control system.
The control valve throttles the uantity of gas being supplied to the combustor
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no>>les. The stop valve shuts off fuel to the combustors in the vent of an extreme
condition that could damage the unit. This will be discussed later.
#ig. $-%-%1 shows a fuel control system using light oil. The variable displacement
pump may be either a vane-type eccentric pump or a variable-stroke reciprocating
pump. This pump is driven directly by the turbine, and its fuel output varies
according to the control signal input. #rom the fuel pump discharge, fuel is fed
through the free wheeling flow divider.
The flow divider consists of a number of small gear pumps, one for each combustor.
The gear pumps are interconnected, so they must all rotate at the same speed.
9otation is caused by the passage of fuel through the pumps. In this way, the flow
divider assures eual fuel distribution to each of the combustors. #uel is also used
as servo control oil for the variable displacement pump.
The free-wheeling flow divider Aust described is satisfactory for use with light fuel oil.
Bhere heavy fuel oil is burned, a different type of flow divider and control system is
reuired. Bith this system, the flow divider gear pumps are all driven by a common
hydraulic motor. +y controlling the speed of the hydraulic motor, we can control the
uantity of fuel being passed through the divider and into the combustors. The
hydraulic motor speed is controlled in turn by the hydraulic mechanism, which
responds to the electric control signal from the governor.
#ilters and strainers are installed in all of the fuel systems. It is vital that fuel be kept
absolutely clean and free of foreign matter. 5irt or scale can clog the fuel pump and
the flow dividers, and dirt in the fuel can cause a flame out if it blocks the fuel
no>>le.
The fuel control system is an essential part of the gas turbine, since it controls the
output of the turbine. In an emergency condition, protective devices will operate
and cause the stop valve to close. This shuts off all fuel supply to the turbines.
Bith no energy input to the turbine, the turbine will run down to a stop.
The control systems we have been dealing with here are typical. The are other
systems in use, depending on the type of gas turbine and the fuel provided.
#ig. $-%-%; illustrates fuel system for A.7.I. gas turbine.
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8i($ :-2-22, 8)el Control for Li/)id 8)el$
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8i($ :-2-2>, 8)el Control for Gas 8)el$

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