Gas Turbine Engineering Handbook, Second Edition

1014 Pages·2002·18.81 MB·English

Gas Turbine
Engineering
Handbook
Third Edition
Meherwan P. Boyce
Managing Partner,The Boyce Consultancy
Fellow, American Society of Mechanical Engineers
Fellow, Institute of Diesel and GasTurbine Engineers, U.K.
Boston Oxford Auckland Johannesburg Melbourne NewDelhi
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LibraryofCongressCataloging-in-PublicationData
Boyce,MeherwanP.
Gasturbineengineeringhandbook/MeherwanP.Boyce.–3rded.
p.cm.
Includesbibliographicalreferencesandindex.
ISBN0-88415-732-6(alk.paper)
1.Gas-turbines–Handbooks,manuals,etc.I.Title.
TJ778.B672001
(cid:1)
621.433–dc21
2001040520
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ISBN13:978-0-7506-7846-9
ISBN10:0-7506-7846-1
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PrintedintheUnitedStatesofAmerica
To the memory of my father, Phiroz H.J. Boyce
Preface
GasTurbineEngineeringHandbookdiscussesthedesign,fabrication,installa-
tion,operation,andmaintenanceofgasturbines.Thethirdeditionisnotonlyan
updating of the technology in gas turbines, which has seen a great leap forward
in the 2000s, but also a rewriting of various sections to better answer today’s
problems in the design, fabrication, installation, operation, and maintenance of
gas turbines. The third edition has added a new chapter that examines the case
historiesofgasturbinesfromdeteriorationoftheperformanceofgasturbinesto
failures encountered in all the major components of the gas turbine. The chap-
teronMaintenanceTechniqueshasbeencompletelyrewrittenandupdated.The
revisedchapterdealswithLongTermServiceAgreements(LTSAs),andspecial
maintenance tables have been added so that you can troubleshoot problems on
gasturbinesthatyoumayencounter.
◦ ◦
Thenewadvancedgasturbineshavefiringtemperaturesof2600 F(1427 C),
and pressure ratios exceeding 40:1 in aircraft gas turbines, and over 30:1 in
industrialturbines.ThishasledtotherewritingofChapter7,tofullyunderstand
the operating mechanics of these high pressure ratio axial-flow compressors.
Thechaptercoversindetailtheadventofsurge,anddescribesingreatdetailthe
different mechanisms of surge, rotating stall, and choke flow conditions in the
compressor of the gas turbine.Advances in materials and coatings have spurred
thistechnology,andtheneweditionhastreatedthisnewareaingreatdetail.The
emphasisonlowNO emissionsfromgasturbineshasledtothedevelopmentof
x
a new breed of Dry Low NO combustors, and their problems are dealt with in
x
depth in this new edition. The third edition deals with an upgrade in the design
andmaintenanceofadvancedgasturbinesanddealswithmostoftheapplicable
codesbothintheareaofperformanceandmechanicalstandards.
Theneweditionhasbeenwrittenwiththeexperiencedengineerinmindwho
isworkinginpowerplants,andinpetrochemicalandoffshoreinstallations.This
editionshouldhelphimorherunderstandmoreclearlyproblemsencounteredin
thefield,andhowtopreventthem.
Thebookalsoprovidesthebasicfluidmechanicsandthermodynamicsforthe
young engineering graduate or undergraduate student who is being exposed to
theturbomachineryfieldforthefirsttime.Thebookisveryusefulasatextbook
for undergraduate or graduate turbomachinery courses as well as for in-house
x
Preface xi
company training programs related to the petrochemical, power generation, and
offshoreindustries.
The use of gas turbines in the petrochemical, power generation, and offshore
industrieshasmushroomedinthepastfewyears.Thepowerindustryinthepast
ten years 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.
However,duetothespiralingcostsofnaturalgas,manyoftheseplantsdesigned
for base load service have been cycled on a daily basis from part loads of 50%
tofullload,andinmanycaseshavehadtobeshutdownonweekends.Thenew
maintenance chapters, with their case histories, should be of great assistance to
the engineers in the field who have to operate their plant at other than design
conditions of base loaded operation. Investigation of operating these plants on
otherfuelsisalsohandledinthisedition.
The book will give the manufacturer a glimpse of some of the problems
associated with gas turbines in the field and help users to achieve maximum
performanceefficiencyandhighavailabilityoftheirgasturbines.
I have been involved in the research, design, operation, and maintenance of
gasturbinessincetheearly1960s.Ihavealsotaughtcoursesatthegraduateand
undergraduate level at the University of Oklahoma andTexasA&M University,
andnow,ingeneral,totheindustry.Therehavebeenover4000studentsthrough
mycoursesdesignedfortheengineerinthefield,representingover450compa-
nies from around the world. They have used the book, and their comments and
my field troubleshooting experience have been very influential in the updating
of material in this edition.The enthusiasm of the students associated with these
courses gave me the inspiration to undertake this endeavor. The many courses
I have taught over the past 35 years have been an educational experience for
me as well as for the students. The discussions and consultations that resulted
from my association as a consultant to the power, petrochemical, and aviation
industrieswithhighlyprofessionalindividualshavebeenamajorcontributionto
bothmypersonalandprofessionallifeaswellastothisneweditionofthebook.
In this edition I have tried to assimilate the subject matter of various papers
(and sometimes diverse views) into a comprehensive, unified treatment of gas
turbines. Many illustrations, curves, and tables are employed to broaden the
understanding of the descriptive text. I have provided extensive new charts that
canbeusedtodiagnoseproblems.Inaddition,thereferencesdirectyoutosources
of information that will help you investigate and solve your specific problems.
I hope that this book will serve as a reference text after it has accomplished its
primaryobjectiveofintroducingyoutothebroadsubjectofgasturbines.
I wish to thank the many engineers whose published work and discussions
havebeenacornerstonetothiswork.TheTurbomachinerySymposium,ofwhich
I had the distinct honor and pleasure of founding and chairing for eight years,
xii Preface
andtheproceedingsoftheSymposium,havecontributedmanyinterestingtech-
nology issues from both a design and maintenance point of view. A special
thanks also goes to my colleagues on the Advisory Committee of the Texas
A&M UniversityTurbomachinery Symposium, of which I have been a member
for 34 years, and to Dr. Dara Childs, who is now the chairman of theAdvisory
Committee.
I wish to acknowledge and give a very special thanks to my wife, Zarine, for
her readiness to help and her constant encouragement throughout this project.
AspecialthanksalsotomysecretaryandexecutiveassistantDonnaMastersfor
thehoursshehasspentworkingwithmeonthisnewedition.
Isincerelyhopethatthisneweditionwillbeeducationalandwillenableyou
to get a new updated look at gas turbine technology and enhanced maintenance
practices, while retaining the basic theory that governs the development of gas
turbines.
MeherwanP.Boyce
Houston,Texas
September2005
Preface to the Second
Edition
GasTurbineEngineeringHandbookdiscussesthedesign,fabrication,installa-
tion, operation, andmaintenanceofgasturbines.Thesecondeditionisnotonly
anupdatingofthetechnologyingasturbines,whichhasseenagreatleapforward
in the 1990s, but also a rewriting of various sections to better answer today’s
problems in the design, fabrication, installation, operation, and maintenance of
◦
gasturbines.Thenewadvancedgasturbineshavefiringtemperaturesof2600 F
◦
(1427 C), and pressure ratio’s exceeding 40:1 in aircraft gas turbines, and over
30:1inindustrialturbines.Advancesinmaterialsandcoatingshavespurredthis
technology, and the new edition has treated this new area in great detail. The
emphasis on low NO emissions from gas turbines has led to the development
x
ofanewbreedofdrylowNO combustors,whicharedealtwithindepthinthis
x
newedition.Thesecondeditiondealswithanupgradeofmostoftheapplicable
codesbothintheareaofperformanceandmechanicalstandards.
Thebookhasbeenwrittentoprovideanoverallviewfortheexperiencedengi-
neerworkinginaspecializedaspectofthesubjectandfortheyoungengineering
graduate or undergraduate student who is being exposed to the turbomachinery
fieldforthefirsttime.Thebookwillbeveryusefulasatextbookforundergrad-
uateturbomachinerycoursesaswellasforin-housecompanytrainingprograms
relatedtothepetrochemical,powergeneration,andoffshoreindustries.
The use of gas turbines in the petrochemical, power generation, and offshore
industrieshasmushroomedinthepastfewyears.Inthepast10years,thepower
industryhasembracedtheCombinedCyclePowerPlantsandthenewhigheffi-
ciency gas turbines are at the center of this growth segment of the industry.
This has also led to the rewriting of Chapters 1 and 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 associated with his equipment
in the field and help the user to achieve maximum performance efficiency and
highavailabilityofhisgasturbines.
I have been involved in the research, design, operation, and maintenance of
gasturbinessincetheearly1960s.Ihavealsotaughtcoursesatthegraduateand
undergraduate level at the University of Oklahoma andTexasA&M University,
andnow,ingeneral,totheindustry.Therehavebeenover3,000studentsthrough
mycoursesdesignedfortheengineerinthefieldrepresentingover400companies
xiii
xiv PrefacetotheSecondEdition
from around the world. Companies have used the book, and their comments
havebeenveryinfluentialintheupdatingofmaterialinthesecondedition.The
enthusiasmofthestudentsassociatedwiththesecoursesgavemetheinspiration
toundertakethisendeavor.ThemanycoursesIhavetaughtoverthepast25years
have been an educational experience for me as well as for the students. The
TexasA&M University Turbomachinery Symposium, which I had the privilege
toorganizeandchairforovereightyearsandbepartoftheAdvisoryCommittee
for30years,isagreatcontributortotheoperationalandmaintenancesectionsof
this book. The discussions and consultations that resulted from my association
with highly professional individuals have been a major contribution to both my
personalandprofessionallifeaswellastothisbook.
In this book, I have tried to assimilate the subject matter of various papers
(and sometimes diverse views) into a comprehensive, unified treatment of gas
turbines. Many illustrations, curves, and tables are employed to broaden the
understanding of the descriptive text. Mathematical treatments are deliberately
held to a minimum so that the reader can identify and resolve any problems
beforeheisreadytoexecuteaspecificdesign.Inaddition,thereferencesdirect
the reader to sources of information that will help him to investigate and solve
his specific problems. It is hoped that this book will serve as a reference text
after it has accomplished its primary objective of introducing the reader to the
broadsubjectofgasturbines.
I wish to thank the many engineers whose published work and discussions
have been a cornerstone to this work. I especially thank all my graduate stu-
dents and former colleagues on the faculty of Texas A&M University without
whose encouragement and help this book would not be possible. Special thanks
go to the Advisory Committee of the Texas A&M University Turbomachinery
Symposium and Dr. M. Simmang, Chairman of the Texas A&M University
Department of Mechanical Engineering, who were instrumental in the initiation
ofthemanuscript.
I wish to acknowledge and give special thanks to my wife, Zarine, for her
readinesstohelpandherconstantencouragementthroughoutthisproject.
I sincerely hope that this new edition will be as interesting to read as it was
for me to write and that it will be a useful reference to the fast-growing field of
turbomachinery.
Finally, I would like to add that the loss of my friend and mentor Dr. C.M.
Simmangwhohaswrittentheforewordtothefirsteditionofthisbookisadeep
loss not only to me but also to the engineering educational community and to
manyofhisstudentsfromTexasA&MUniversity.
MeherwanP.Boyce
Houston,Texas
Preface to the First Edition
Gas Turbine Engineering Handbook discusses the design, fabrication, instal-
lation, operation, and maintenance of gas turbines. The book has been written
toprovideanoverallviewfortheexperiencedengineerworkinginaspecialized
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
bookwillbeveryusefulasatextbookforundergraduateturbomachinerycourses
aswellasforin-housecompanytrainingprogramsrelatedtothepetrochemical,
powergeneration,andoffshoreindustries.
The use of gas turbines in the petrochemical, power generation, and offshore
industries has mushroomed in the past few years. It is to these users and man-
ufacturers of gas turbines that this book is directed. The book will give the
manufacturer a glimpse of some of the problems associated with his equipment
in the field and help the user to achieve maximum performance efficiency and
highavailabilityofhisgasturbines.
I have been involved in the research, design, operation, and maintenance of
gasturbinessincetheearly1960s.Ihavealsotaughtcoursesatthegraduateand
undergraduate level at the University of Oklahoma andTexasA&M University,
and now, in general, to the industry. The enthusiasm of the students associated
withthesecoursesgavemetheinspirationtoundertakethisendeavor.Themany
coursesIhavetaughtoverthepast15yearshavebeenaneducationalexperience
for me as well as for the students.TheTexasA&M UniversityTurbomachinery
Symposium, which I had the privilege to organize and chair for seven years,
is a great contributor to the operational and maintenance sections of this book.
Thediscussionsandconsultationsthatresultedfrommyassociationwithhighly
professionalindividualshavebeenamajorcontributiontobothmypersonaland
professionallifeaswellastothisbook.
In this book, I have tried to assimilate the subject matter of various papers
(and sometimes diverse views) into a comprehensive, unified treatment of gas
turbines. Many illustrations, curves, and tables are employed to broaden the
understanding of the descriptive text. Mathematical treatments are deliberately
held to a minimum so that the reader can identify and resolve any problems
beforeheisreadytoexecuteaspecificdesign.Inaddition,thereferencesdirect
the reader to sources of information that will help him to investigate and solve
his specific problems. It is hoped that this book will serve as a reference text
xv