Table Of Content

GAS TURBINE PROPULSION SYSTEMS Aerospace Series List Advanced ControlofAircraft,Rocketsand Tewari July2011 Spacecraft BasicHelicopterAerodynamics:Third Seddonetal. July2011 Edition CooperativePath PlanningofUnmanned Tsourdosetal. November 2010 AerialVehicles PrinciplesofFlightforPilots Swatton October2010 AirTravel andHealth:A Systems Seabridgeetal. September 2010 Perspective Designand AnalysisofComposite Kassapoglou September 2010 Structures:Withapplicationstoaerospace Structures Unmanned AircraftSystems: UAVSDesign, Austin April2010 Developmentand Deployment IntroductiontoAntennaPlacement & Macnamara April2010 Installations PrinciplesofFlightSimulation Allerton October2009 AircraftFuelSystems Langtonetal. May 2009 TheGlobalAirlineIndustry Belobaba April2009 ComputationalModellingandSimulationof Diston April2009 AircraftandtheEnvironment:Volume1- PlatformKinematicsand Synthetic Environment Handbookof SpaceTechnology Ley, WittmannHallmann April2009 AircraftPerformanceTheory andPracticefor Swatton August2008 Pilots SurrogateModellinginEngineeringDesign: Forrester,Sobester,Keane August2008 A PracticalGuide AircraftSystems,3rd Edition Moir&Seabridge March 2008 IntroductiontoAircraftAeroelasticityAnd Wright& Cooper December 2007 Loads Stabilityand ControlofAircraftSystems Langton September 2006 MilitaryAvionicsSystems Moir&Seabridge February2006 Designand DevelopmentofAircraftSystems Moir&Seabridge June2004 AircraftLoadingandStructuralLayout Howe May 2004 AircraftDisplaySystems Jukes December 2003 CivilAvionicsSystems Moir&Seabridge December 2002 GAS TURBINE PROPULSION SYSTEMS Bernie MacIsaac RetiredFounderandCEO,GasTOPSLtd,Canada Roy Langton RetiredGroupVPEngineering,ParkerAerospace,USA A John Wiley & Sons, Ltd., Publication Thiseditionfirstpublished2011 ©2011,JohnWiley&Sons,Ltd Registeredoffice JohnWiley&SonsLtd,TheAtrium,SouthernGate,Chichester,WestSussex,PO198SQ,UnitedKingdom Fordetailsofourglobaleditorialoffices,forcustomerservicesandforinformationabouthowtoapplyforpermissionto reusethecopyrightmaterialinthisbookpleaseseeourwebsiteatwww.wiley.com. TherightoftheauthortobeidentifiedastheauthorofthisworkhasbeenassertedinaccordancewiththeCopyright, DesignsandPatentsAct1988. Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmitted,inany formorbyanymeans,electronic,mechanical,photocopying,recordingorotherwise,exceptaspermittedbytheUK Copyright,DesignsandPatentsAct1988,withoutthepriorpermissionofthepublisher. Wileyalsopublishesitsbooksinavarietyofelectronicformats.Somecontentthatappearsinprintmaynotbeavailable inelectronicbooks. Designationsusedbycompaniestodistinguishtheirproductsareoftenclaimedastrademarks.Allbrandnamesand productnamesusedinthisbookaretradenames,servicemarks,trademarksorregisteredtrademarksoftheirrespective owners.Thepublisherisnotassociatedwithanyproductorvendormentionedinthisbook.Thispublicationisdesigned toprovideaccurateandauthoritativeinformationinregardtothesubjectmattercovered.Itissoldontheunderstanding thatthepublisherisnotengagedinrenderingprofessionalservices.Ifprofessionaladviceorotherexpertassistanceis required,theservicesofacompetentprofessionalshouldbesought. LibraryofCongressCataloguing-in-PublicationData MacIsaac,Bernie. Gasturbinepropulsionsystems/BernieMacIsaac,RoyLangton. p.cm. Includesbibliographicalreferencesandindex. ISBN978-0-470-06563-1(hardback) 1.Airplanes–Turbojetengines.2.Jetboatengines.3.Vehicles,Military.I.Langton,Roy.II.Title. TL709.3.T83M252011 629.134(cid:2)353–dc23 2011016566 AcataloguerecordforthisbookisavailablefromtheBritishLibrary. PrintISBN:978-0-470-06563-1 ePDFISBN:978-1-119-97549-6 oBookISBN:978-1-119-97548-9 ePubISBN:978-1-119-97614-1 MobiISBN:978-1-119-97615-8 Typesetin10/12ptTimesRomanbyLaserwordsPrivateLimited,Chennai,India Contents About the Authors x Preface xii Series Preface xiv Acknowledgements xvi List of Acronyms xviii 1 Introduction 1 1.1 Gas Turbine Concepts 1 1.2 Gas Turbine Systems Overview 6 References 9 2 Basic Gas Turbine Operation 11 2.1 Turbojet Engine Performance 11 2.1.1 Engine Performance Characteristics 18 2.1.2 CompressorSurge Control 22 2.1.3 Variable Nozzles 28 2.2 Concluding Commentary 35 References 35 3 Gas Generator Fuel Control Systems 37 3.1 Basic Concepts of the Gas Generator Fuel Control System 37 3.2 Gas Generator Control Modes 40 3.2.1 FuelSchedule Definition 42 3.2.2 OverallGas GeneratorControl Logic 45 3.2.3 SpeedGoverningwith AccelerationandDecelerationLimiting 46 3.2.4 CompressorGeometryControl 62 3.2.5 Turbine GasTemperature Limiting 63 3.2.6 OverspeedLimiting 65 3.3 Fuel System Design and Implementation 65 3.3.1 A Historical Reviewof FuelControl Technologies 67 3.3.2 FuelPumping and MeteringSystems 72 vi Contents 3.4 The Concept of Error Budgets in Control Design 77 3.4.1 MeasurementUncertainty 79 3.4.2 SourcesofError 80 3.5 Installation, Qualification, and Certification Considerations 84 3.5.1 FuelHandling Equipment 84 3.5.2 Full-authority Digital Engine Controls (FADEC) 86 3.6 Concluding Commentary 88 References 88 4 Thrust Engine Control and Augmentation Systems 89 4.1 Thrust Engine Concepts 89 4.2 Thrust Management and Control 92 4.3 Thrust Augmentation 95 4.3.1 WaterInjection 96 4.3.2 Afterburning 97 Reference 103 5 Shaft Power Propulsion Control Systems 105 5.1 Turboprop Applications 110 5.1.1 TheSingle-shaft Engine 110 5.1.2 TheFree Turbine Turboprop 112 5.2 Turboshaft Engine Applications 119 Reference 130 6 Engine Inlet, Exhaust, and Nacelle Systems 131 6.1 Subsonic Engine Air Inlets 131 6.1.1 Basic Principles 132 6.1.2 TurbopropInletConfigurations 133 6.1.3 InletFiltration Systems 135 6.2 Supersonic Engine Air Inlets 136 6.2.1 Oblique Shockwaves 137 6.2.2 CombinedOblique/Normal Shock Pressure RecoverySystems 139 6.2.3 Supersonic Inlet Control 141 6.2.4 OverallSystem Developmentand Operation 143 6.2.5 ConcordeAir InletControl System (AICS)Example 144 6.3 Inlet Anti-icing 150 6.3.1 Bleed-airAnti-icing Systems 151 6.3.2 ElectricalAnti-icing Systems 151 6.4 Exhaust Systems 151 6.4.1 Thrust ReversingSystems 152 6.4.2 Thrust VectoringConcepts 155 References 160 7 Lubrication Systems 161 7.1 Basic Principles 161 7.2 Lubrication System Operation 169 Contents vii 7.2.1 System DesignConcept 170 7.2.2 System DesignConsiderations 174 7.2.3 System Monitoring 174 7.2.4 CeramicBearings 179 References 179 8 Power Extraction and Starting Systems 181 8.1 Mechanical Power Extraction 181 8.1.1 FuelControl SystemsEquipment 181 8.1.2 Hydraulic PowerExtraction 183 8.1.3 Lubrication and ScavengePumps 184 8.1.4 ElectricalPowerGeneration 184 8.2 Engine Starting 187 8.3 Bleed-air-powered Systems and Equipment 189 8.3.1 Bleed-air-drivenPumps 191 8.3.2 BleedAir for EnvironmentalControl, Pressurization and Anti-icing Systems 192 8.3.3 FuelTank Inerting 193 References 194 9 Marine Propulsion Systems 195 9.1 Propulsion System Designation 197 9.2 The Aero-derivative Gas Turbine Engine 198 9.3 The Marine Environment 199 9.3.1 Marine Propulsion Inlets 200 9.3.2 Marine Exhaust Systems 203 9.3.3 Marine Propellers 204 9.4 The Engine Enclosure 206 9.4.1 TheEngine Support System 207 9.4.2 Enclosure Air Handling 208 9.4.3 Enclosure Protection 208 9.5 Engine Ancillary Equipment 209 9.5.1 Engine Starting System 209 9.5.2 Engine Lubrication System 211 9.5.3 FuelSupply System 212 9.6 Marine Propulsion Control 214 9.6.1 Ship Operations 214 9.6.2 OverallPropulsion Control 217 9.6.3 Propulsion System Monitoring 219 9.6.4 Propulsion System Controller 222 9.6.5 Propulsion System Sequencer 224 9.7 Concluding Commentary 224 References 225 10 Prognostics and Health Monitoring Systems 227 10.1 Basic Concepts in Engine Operational Support Systems 229 viii Contents 10.1.1 Material Life Limits 229 10.1.2 Performance-relatedIssues 232 10.1.3 UnscheduledEvents 234 10.2 The Role of Design in Engine Maintenance 234 10.2.1 Reliability 235 10.2.2 Maintainability 237 10.2.3 Availability 239 10.2.4 Failure Mode, Effects, and Criticality Analysis 241 10.3 Prognostics and Health Monitoring (PHM) 243 10.3.1 TheConceptof aDiagnostic Algorithm 244 10.3.2 Qualification of a Fault Indicator 245 10.3.3 TheElement ofTime in Diagnostics 250 10.3.4 DataManagementIssues 251 References 255 11 New and Future Gas Turbine Propulsion System Technologies 257 11.1 Thermal Efficiency 257 11.2 Improvements in Propulsive Efficiency 260 11.2.1 ThePratt & Whitney PW1000G GearedTurbofanEngine 261 11.2.2 TheCFM International LeapEngine 264 11.2.3 ThePropfan Concept 265 11.3 Other Engine Technology Initiatives 268 11.3.1 TheBoeing 787 BleedlessEngine Concept 268 11.3.2 NewEngine Systems Technologies 271 11.3.3 EmergencyPowerGeneration 276 11.3.4 On-boardDiagnostics 277 References 277 Appendix A Compressor Stage Performance 279 A.1 The Origin of Compressor Stage Characteristics 279 A.2 Energy Transfer from Rotor to Air 281 References 284 Appendix B Estimation of Compressor Maps 285 B.1 Design Point Analysis 288 B.2 Stage Stacking Analysis 291 References 293 Appendix C Thermodynamic Modeling of Gas Turbines 295 C.1 Linear Small-perturbation Modeling 295 C.1.1 Rotor Dynamics 296 C.1.2 Rotor DynamicswithPressure Term 297 C.1.3 Pressure Dynamics 298 C.2 Full-range Model: Extended Linear Approach 298 C.3 Component-based Thermodynamic Models 299 C.3.1 Inlet 301 Contents ix C.3.2 Compressor 302 C.3.3 Combustor 302 C.3.4 Turbine 304 C.3.5 JetPipe 305 C.3.6 Nozzle 306 C.3.7 Rotor 306 References 306 Appendix D Introduction to Classical Feedback Control 307 D.1 Closing the Loop 307 D.2 Block Diagrams and Transfer Functions 308 D.3 The Concept of Stability 310 D.3.1 TheRule for Stability 310 D.4 Frequency Response 311 D.4.1 Calculating FrequencyResponse 311 D.5 Laplace Transforms 315 D.5.1 Root Locus 317 D.5.2 Root LocusConstruction Rules 318 Reference 321 Index 323 About the Authors BD (Bernie) MacIsaac Dr MacIsaac received an Honors B. Eng. (Mechanical) from the Technical University of Nova Scotia in 1970. He was awarded a Science ’67 graduate scholarship which took himtoOttawatostudyJetEngineDynamicsandControlsatCarletonUniversity.Hewas awarded an M.Eng. in 1972 and a Ph.D. in 1974. Following completion of his studies, Dr MacIsaac spent four years at the National Research Council of Canada where he helped to develop the first 8-bit microprocessor control for general aviation gas turbines. He was awarded a patent for a control design to prevent in-flight engine stalls on helicopter engines. Dr MacIsaac formed GasTOPS Ltd. (Gas Turbines and Other Propulsion Systems ) in 1979,anOttawa-basedcompanywhichspecializesintheapplicationofintelligentsystems to machinery protection and machinery maintenance systems. Much of this company’s workhasfocusedonaerospaceandindustrialpowerplants.About1991,GasTOPSbegan thedevelopmentofanon-lineoildebrisdetectorfordamagerecognitionoftheoil-wetted components of power plants. This device is now fitted to many modern fighter aircraft, many land-based CoGen and pipeline engines and is selling well in the new emerging wind turbine market. This development has led to the establishment of a manufacturing facility and to worldwide sales of this product. Dr MacIsaac served as GasTOPS Ltd. President until 2007, at which point he turned management of the company over to his longtime colleague Mr David Muir. Since then, Dr MacIsaac has devoted his efforts to the establishment of an R&D group at GasTOPS, whichis responsible for the definition andsubsequent demonstration of new technologies that will form the basis of the next product line for GasTOPS. Dr MacIsaac participates as a lecturer in professional practice courses at both Ottawa and Carleton Universities as well as Carleton University-sponsored short courses on gas turbines. He is a past president of the Canadian Aeronautics and Space Institute and is a past Chairman of PRECARN, a network of companies engaged in collaborative applied research. He currently serves as Chairman of the Senior Awards Committee of the Cana- dian Aeronautics and Space Institute. DrMacIsaacwasbornin1945.Heismarried(1969)andhastwindaughterswhowere bornonChristmasDayin1973andthreegranddaughtersandonegrandson.Hehaslived in Ottawa, Canada with his wife Ann since 1970.