Cleverson Bringhenti

Methodology for gas turbine performance improvement using variable-geometry compressors and turbines

Abstract Poor part-load performance is a well-known undesirable characteristic of gas turbines. Running off-design, both compressor and turbine lose performance. Flow misalignment at the various rows causes losses to increase sharply, thereby decreasing net output faster than decreasing fuel consumption. To bring the flow to alignment with the blade passages, it is required to restagger the blades both at the compressor and at the turbine. To avoid mechanical complexities, it is generally accepted to restagger only the stators. This work deals with a numerical approach to the simulation of a gas turbine equipped with variable stators at the compressor and at the turbine, enabling the search for better-performance operation. A computer program has been developed to simulate virtually any gas turbine having variable stators at the compressor stages and turbine nozzle guide vanes. Variable-inlet guide vanes (VIGVs), variable-stator vanes (VSVs), variable-nozzle guide vanes (VNGVs), variable-geometry compressors (VGCs) and variable-geometry turbines (VGTs) are the focus in this work, which analyses a one-shaft free power turbine for power generation in the search for performance improvement at part load.

EFFECTS OF TURBINE TIP CLEARANCE ON GAS TURBINE PERFORMANCE

There are many different sources of loss in gas turbines. The turbine tip clearance loss is the focus of this work. In gas turbine components such as compressor and turbine the presence of rotating blades necessitates a small annular tip clearance between the rotor blade tip and the outer casing. This clearance, although mechanically necessary, may represent a source of large loss in a turbine. The gap height can be a fraction of a millimeter but can have a disproportionately high influence on the stage efficiency. A large space between the blades and the outer casing results in detrimental leakages, while contact between them can damage the blades. Therefore, the evaluation of the sources of the performance degradation independently presents useful information that can aid in the maintenance action. As part of the overall blade loss the turbine tip clearance loss arises because at the blade tip the gas does not follow the intended path and therefore does not contribute to the turbine power output and interacts with the outer wall boundary layer. Increasing turbine tip clearance causes performance deterioration of the gas turbine and therefore increases fuel consumption. The increase in turbine tip clearance may as a result of rubs during engine transients and the interaction between the blades and the outer casing. This work deals with the study of the influence of the turbine tip clearance on a gas turbine engine, using a turbine tip clearance model incorporated to an engine deck. Actual data of an existing engine were used to check the validity of the procedure. This paper refers to a single shaft turbojet engine under development, operating under steady state condition. Different compressor maps were used to study the influence of the curve shapes on the engine performance. Two cases were considered for the performance simulation: constant corrected speed and constant maximum cycle temperature.© 2008 ASME

Gas Turbine Transients With Controlled Variable Geometry

A small 5-kN thrust gas turbine, designed and manufactured having in mind a thorough source of validation data, serves as basis for the study. The engine is an uncooled turbine, 5:1 pressure ratio axial flow compressor, delivering 8.1 kg/s air mass flow, whose control is made by a FADEC. Cold runs of the jet engine version have already been completed. The engine characteristics are being developed using the technology indicated in the paper. Accelerations and decelerations from idle to full power in a prescribed time interval and positive surge margin are the limitations imposed to the control system. In order to accomplish such requirements, a proportional, integral and derivative (PID) has been implemented to control the variable geometry transients, which proved to drive the engine to the required operating points. Compressor surge is avoided during accelerations or decelerations, imposing operation limits to the surge margin. In order to simulate a jet engine under transient operation, use was made of high-fidelity in-house developed software. The results presented in the paper are related to the compressor inlet guide vane (VIGV) transients. The engine transient calculations were predicted with the IGV settings varying with time, and the results are being used for the initial calibration of the transfer functions for the real time control.© 2012 ASME

MULTIPLE FAULTS DETECTION OF GAS TURBINE BY MLP NEURAL NETWORK

This paper describes a procedure to measure the performance of detection and isolation of multiple faults in gas turbines using artificial neural network and optimization techniques. It is on a particular form of artificial neural networks, the traditional multi-layer perceptron (MLP). Error back-propagation and different activation functions are used. The main goal is to recognize single, double and triple faults in a turboshaft engine, whose performance data were output from a gas turbine simulator program, tuned to represent the engine running at an existing power station. MLP network is a nonlinear interpolation function usually made of input layer, hidden-layer and output-layer, with different neuronal units, but in this work, only one hidden-layer was used. Weights were altered by error back-propagation from the initial values established from a seed fixed between 0 and 1. The activation function in the MLP algorithm is the sigmoid function. The best moment to stop the training process and avoid the over fitting problem was chosen by cross-validation. Optimization of convergence error was achieved using the momentum criteria and reducing the oscillation problem in all nets trained. Several configurations of the neural network have been compared and evaluated, using several noise graduations incorporated to the data, aiming at finding the network most suitable to detect and isolate multiple faults in gas turbines. Based on the results obtained it is inferred that the procedure reported herein may be applied to actual systems in order to assist in maintenance programs, at least.Copyright

Part-Load Versus Downrated Industrial Gas Turbine Performance

For distributed power generation, sometimes the available gas turbines cannot match the power demands. It has been usual to uprate an existing gas turbine in the lower power range by increasing the firing temperature and speeding it up. The development costs are high and the time to make it operational is large. In the other hand, de-rating an existing gas turbine in the upper power range may be more convenient since it is expected to cut significantly the time for development and costs. In addition, the experience achieved with this engine may be easily extrapolated to the new engine. This paper deals with the performance analysis of an existing gas turbine, in the range of 25 MW, de-rated to the range of 18 MW, concerning the compressor modifications that could be more easily implemented. Analysis is performed for the base engine, running at part-load of MW. A variable geometry compressor is derived from the existing one. Search for optimized performance is carried out for new firing temperatures. A variable geometry turbine analysis is performed for new NGV settings, aiming at better cycle performance.© 2004 ASME

Performance Study of a 1 MW Gas Turbine Using Variable Geometry Compressor and Turbine Blade Cooling

This work presents the performance study of a 1 MW gas turbine including the effects of blade cooling and compressor variable geometry. The axial flow compressor, with Variable Inlet Guide Vane (VIGV), was designed for this application and its performance maps synthesized using own high technological contents computer programs. The performance study was performed using a specially developed computer program, which is able to numerically simulate gas turbine engines performance with high confidence, in all possible operating conditions. The effects of turbine blades cooling were calculated for different turbine inlet temperatures (TIT) and the influence of the amount of compressor-bled cooling air was studied, aiming at efficiency maximization, for a specified blade life and cooling technology. Details of compressor maps generation, cycle analysis and blade cooling are discussed.Copyright

Gas Turbine Fault Detection and Isolation Using MLP Artificial Neural Network

This work deals with a nonlinear model, based on a particular form of artificial neural networks, ANN, for application to gas turbines fault diagnosis. The traditional multi-layer perceptron (MLP) is used, with error back-propagation and different activation functions. The application of the model is illustrated using test data from a gas turbine simulation computer program. A specially developed computer program is used to simulate the engine in operation, generating all needed engine data for both baseline and deteriorated engine. A test case using a turboshaft engine is used to demonstrate the capacity of this ANN to identify faults that may occur during engine operation.Copyright

Gas Turbine Performance Simulation Using an Optimized Axial Flow Compressor

Gas turbines need to operate efficiently due to the high specific fuel consumption. In order to reach the best possible efficiency the main gas turbine components, such as compressor and turbine, need to be optimized. This work reports the use of two specially developed computer programs: AFCC [1, 2] and GTAnalysis [3, 4] for such purpose. An axial flow compressor has been designed, using the AFCC computer program based on the stage-stacking technique. Major compressor design parameters are optimized at design point, searching for best efficiency and surge margin. Operation points are calculated and its characteristics maps are generated. The calculated compressor maps are incorporated to the GTAnalysis computer program for the engine performance calculation. Restrictions, like engine complexity, manufacture difficulties and control problems, are not taken into account.Copyright

Evaluation of Different Squealer Cavity Configurations in a HPT Blade Tip Region and its Influence on the Heat Transfer

In high performance turbomachines the tip region is a key point to improve aiming at high pressure ratios without high penalties. In the case of HPT, several techniques are still in development by academic research laboratories and industry. Some geometrical configurations were created at the rotor tip region, as winglets and squealers geometries. In the case of squealers, the depth of their cavity is an important parameter to evaluate, because its values can cause different flow behavior on this region. Changing the heat transfer. In this work, the rotor blade of a HPT developed in the E3 program was changed, the aim is to study the influence of the squealer cavity depth variation on its performance. The flow within the turbine was calculated using a commercial CFD package. The details of the rotor geometrical changes, the differences between a simple flat rotor tip surface and squealer configurations are discussed and presented.Copyright

Influence of Variable Geometry Transients on the Gas Turbine Performance

During the design of a gas turbine it is required the analysis of all possible operating points in the gas turbine operational envelope, for the sake of verification of whether or not the established performance might be achieved. In order to achieve the design requirements and to improve the engine off-design operation, a number of specific analyses must be carried out. This paper deals with the characterization of a small gas turbine under development with assistance from ITA (Technological Institute of Aeronautics), concerning the compressor variable geometry and its transient operation during accelerations and decelerations. The gas turbine is being prepared for the transient tests with the gas generator, whose results will be used for the final specification of the turboshaft power section. The gas turbine design has been carried out using indigenous software, developed specially to fulfill the requirements of the design of engines, as well as the support for validation of research work. The engine under construction is a small gas turbine in the range of 5 kN thrust / 1.2 MW shaft power, aiming at distributed power generation using combined cycle. The work reported in this paper deals with the variable inlet guide vane (VIGV) transients and the engine transients. A five stage 5:1 pressure ratio axial-flow compressor, delivering 8.1 kg/s air mass flow at design-point, is the basis for the study. The compressor was designed using computer programs developed at ITA for the preliminary design (meanline), for the axisymmetric analysis to calculate the full blade geometry (streamline curvature) and for the final compressor geometry definition (3-D RANS and turbulence models). The programs have been used interatively. After the final channel and blade geometry definition, the compressor map was generated and fed to the gas turbine performance simulation program. The transient study was carried out for a number of blade settings, using different VIGV geometry scheduling, giving indication that simulations needed to study the control strategy can be easily achieved. The results could not be validated yet, but are in agreement with the expected engine response when such configuration is used.Copyright