Gas turbine engineering handbook

816 Pages·2002·10.34 MB·English

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GasTurbine
Engineering
Handbook
Second Edition
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GasTurbine
Engineering
Handbook
Second Edition
Meherwan P. Boyce
Managing Partner, The Boyce Consultancy
Fellow, American Society of Mechanical Engineers
Fellow, Institute of Diesel and Gas Turbine Engineers, U.K.
Boston Oxford Auckland Johannesburg Melbourne New Delhi
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Gulf Professional Publishing is an imprint of Butterworth±Heinemann.
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Library of Congress Cataloging-in-Publication Data
Boyce, Meherwan P.
Gas turbine engineering handbook / Meherwan P. Boyce. ± 2nd ed.
p. cm.
Includes bibliographical references and index.
ISBN 0-88415-732-6 (alk. paper)
1. Gas-turbines±Handbooks, manuals, etc. I. Title.
TJ778 .B67 2001
0
621.43 3±dc21
2001040520
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library.
Illustration Credit: Unless otherwise cited, the illustrations appearing in this book are
supplied courtesy and used with the permission of the Turbomachinery Laboratories,
Department of Mechanical Engineering, Texas A&M University, College Station, Texas
77843. These illustrations were published and are copyright # by the Turbomachinery
Laboratories in the annual proceedings of their Turbomachinery Symposia.
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1 0 9 8 7 6 5 4 3 2 1
Printed in the United States of America
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To the memory of my father, Phiroz H.J. Boyce
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Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . x
Preface to the First Edition . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
Foreword to the First Edition . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
Part I Design: Theory and Practice
1 An Overview of Gas Turbines . . . . . . . . . . . . . . . . . . . . . . . . 3
Gas Turbine Cycle in the Combined Cycle or Cogeneration Mode. Gas Turbine Performance.
Gas Turbine Design Considerations. Categories of Gas Turbines. Major Gas Turbine Compon-
ents. Fuel Type. Environmental Effects. Turbine Expander Section. Materials. Coatings. Gas
Turbine Heat Recovery. Supplementary Firing of Heat Recovery Systems. Bibliography.
2 Theoretical and Actual Cycle Analysis. . . . . . . . . . . . . . . . . . . 58
The Brayton Cycle. Actual Cycle Analysis. Summation of Cycle Analysis. A General Overview
of Combined Cycle Plants. Compressed Air Energy Storage Cycle. Power Augmentation.
Summation of the Power Augmentation Systems. Bibliography.
3 Compressor and Turbine Performance Characteristics . . . . . . . . . .112
Turbomachine Aerothermodynamics. The Aerothermal Equations. Efficiencies. Dimensional
Analysis. Compressor Performance Characteristics. Turbine Performance Characteristics. Gas
Turbine Performance Computation. Bibliography.
4 Performance and Mechanical Standards. . . . . . . . . . . . . . . . . .141
Major Variables for a Gas Turbine Application. Performance Standards. Mechanical Parameters.
Application of the Mechanical Standards to the Gas Turbine. Specifications. Bibliography.
5 Rotor Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Mathematical Analysis. Application to Rotating Machines. Critical Speed Calculations for Rotor
Bearing Systems. Electromechanical Systems and Analogies. Campbell Diagram. Bibliography.
Part II Major Components
6 Centrifugal Compressors. . . . . . . . . . . . . . . . . . . . . . . . . .221
Centrifugal Compressor Components. Centrifugal Compressor Performance. Compressor
Surge. Process Centrifugal Compressors. Bibliography.
7Axial-Flow Compressors . . . . . . . . . . . . . . . . . . . . . . . . . .257
Blade and Cascade Nomenclature. Elementary Airfoil Theory. Laminar-Flow Airfoils. Cascade
Test. Velocity Triangles. Degree of Reaction. Radial Equilibrium. Diffusion Factor. The
Incidence Rule. The Deviation Rule. Compressor Stall. Performance Characteristics of an
Axial-Flow Compressor. Stall Analysis of an Axial-Flow Compressor. Bibliography.
8 Radial-Inflow Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . .319
Description. Theory. Turbine Design Considerations. Losses in a Radial-Inflow Turbine.
Performance of a Radial-Inflow Turbine. Bibliography.
vii
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viii Contents
9 Axial-Flow Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
Turbine Geometry. Impulse Turbine. The Reaction Turbine. Turbine Blade Cooling Concepts.
Turbine Blade Cooling Design. Cooled-Turbine Aerodynamics. Turbine Losses. Bibliography.
10 Combustors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
Combustion Terms. Combustion. Combustion Chamber Design. Fuel Atomization and
Ignition. Typical Combustor Arrangements. Air Pollution Problems. Catalytic Combustion.
Bibliography.
Part III Materials, Fuel Technology, and Fuel Systems
11 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
General Metallurgical Behaviors in Gas Turbines. Gas Turbine Materials. Compressor Blades.
Forgings and Nondestructive Testing. Coatings. Bibliography.
12 Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436
Fuel Specifications. Fuel Properties. Fuel Treatment. Heavy Fuels. Cleaning of Turbine
Components. Fuel Economics. Operating Experience. Heat Tracing of Piping Systems. Types
of Heat-Tracing Systems. Storage of Liquids. Bibliography.
Part IV Auxiliary Components and Accessories
13 Bearings and Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . .469
Bearings. Bearing Design Principles. Tilting-Pad Journal Bearings. Bearing Materials. Bearing
and Shaft Instabilities. Thrust Bearings. Factors Affecting Thrust-Bearing Design. Thrust-
Bearing Power Loss. Seals. Noncontacting Seals. Mechanical (Face) Seals. Mechanical Seal
Selection and Application. Seal Systems. Associated Oil System. Dry Gas Seals. Bibliography.
14 Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
Gear Types. Factors Affecting Gear Design. Manufacturing Processes. Installation and Initial
Operation. Bibliography.
Part V Installation, Operation, and Maintenance
15 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541
Basic Oil System. Lubricant Selection. Oil Sampling and Testing. Oil Contamination. Filter
Selection. Cleaning and Flushing. Coupling Lubrication. Lubrication Management Program.
Bibliography.
16 Spectrum Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . .558
Vibration Measurement. Taping Data. Interpretation of Vibration Spectra. Subsynchronous
Vibration Analysis Using RTA. Synchronous and Harmonic Spectra. Bibliography.
17Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584
Rotor Imbalance. Balancing Procedures. Application of Balancing Techniques. User's Guide
for Multiplane Balancing. Bibliography.
18 Couplings and Alignment . . . . . . . . . . . . . . . . . . . . . . . . .605
Gear Couplings. Metal Diaphragm Couplings. Metal Disc Couplings. Turbomachinery
Uprates. Shaft Alignment. Bibliography.
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Contents ix
19 Control Systems and Instrumentation . . . . . . . . . . . . . . . . . . .634
Control Systems. Condition Monitoring Systems. Monitoring Software. Implementation of a
Condition Monitoring System. Life Cycle Costs. Temperature Measurement. Pressure Meas-
urement. Vibration Measurement. Auxiliary System Monitoring. The Gas Turbine. Failure
Diagnostics. Mechanical Problem Diagnostics. Summary. Bibliography.
20 Gas Turbine Performance Test . . . . . . . . . . . . . . . . . . . . . .692
Introduction. Performance Codes. Flow Straighteners. Gas Turbine Test. Gas Turbine. Perform-
ance Curves. Performance Computations. Gas Turbine Performance Calculations. Plant Losses.
Bibliography.
21 Maintenance Techniques. . . . . . . . . . . . . . . . . . . . . . . . . .722
Philosophy of Maintenance. Training of Personnel. Tools and Shop Equipment. Turbo-
machinery Cleaning. Hot-Section Maintenance. Compressor Maintenance. Bearing Maintenance.
Coupling Maintenance. Rejuvenation of Used Turbine Blades. Repair and Rehabilitation
of Turbomachinery Foundations. Large Machinery Startup Procedure. Typical Problems
Encountered in Gas Turbines. Bibliography.
Appendix: Equivalent Units . . . . . . . . . . . . . . . . . . . . . . . . . . .778
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .782
About the Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .799
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Preface
Gas Turbine Engineering Handbook discusses the design, fabrication, installa-
tion, operation, and maintenance of gas turbines. The second edition is not only
an updating of the technology in gas turbines, which has seen a great leap
forward in the 1990s, but also a rewriting of various sections to better answer
today's problems in the design, fabrication, installation, operation, and main-
tenance of gas turbines. The new advanced gas turbines have firing tempera-
tures of 2600 F (1427 C), and pressure ratio's exceeding 40:1in aircraft gas
turbines, and over 30:1in industrial turbines. Advances in materials, and coat-
ings have spurred this technology, and the new edition has treated this new area
in great detail. The emphasis on lowNOx emissions from gas turbines has led to
the development of a new breed of dry low NOx combustors, which are dealt in
depth in this new edition. The second edition deals with an upgrade of most of
the applicable codes both in the area of performance and mechanical standards.
The book has been written to provide an overall view for the experienced
engineer working in a specialized aspect of the subject and for the young
engineering graduate or undergraduate student who is being exposed to the
turbomachinery field for the first time. The book will be very useful as a
textbook for undergraduate turbomachinery courses as well as for in-house
company training programs related to the petrochemical, power generation,
and offshore industries.
The use of gas turbines in the petrochemical, power generation, and off-
shore industries has mushroomed in the past few years. In the past 10 years,
the power industry has embraced the Combined Cycle Power Plants and the
new high efficiency gas turbines are at the center of this growth segment of
the industry. This has also led to the rewriting of chapters 1and 2. It is to
these users and manufacturers of gas turbines that this book is directed. The
book will give the manufacturer a glimpse of some of the problems asso-
ciated with his equipment in the field and help the user to achieve maximum
performance efficiency and high availability of his gas turbines.
I have been involved in the research, design, operation, and maintenance
of gas turbines since the early 1960s. I have also taught courses at the
graduate and undergraduate level at the University of Oklahoma and Texas
A&MUniversity, and now, in general, to the industry. There have been over
3,000 students through my courses designed for the engineer in the field
representing over 400 companies from around the world. Companies have
x