Concordia University

Faculty of Engineering and Computer Science

Department of Mechanical Engineering

Gas Turbine Design

Project Report
Winter 2009

1
2
 Summary
1. Part A: Engine Design

1.1 LPC exit (2)

1.2 HPC exit (3)

1.3 Combustor exit (4)

1.4 HPT exit (5)

1.5 Inter-turbine duct (6)

1.6 LPT exit (7)

1.7 Inter-turbine duct (8)

1.8 Power turbine (8)

1.9 Engine horsepower and SFC

2. Part B: Turbine Design

2.1 Mean Line design of HPT

2.1.1 Rotational speed and gas path

2.1.2 Velocity triangles and nozzle & rotor loss coefficients

2.2 Hub and tip velocity triangles

2.3 Vane and Blade parameters

2.4 Nozzles and rotor loss coefficients

2.5 Off-design performance

2.5.1 Reduction of the speed by 20%

2.5.2 Reduction of the pressure ratio by 20%

3
 Introduction
Blah blah blah

4
1. Part A: Engine Design
In this part we have to determine the cycle points, temperatures, pressures,
compressors and turbine work and the engine horsepower

General assumptions at intake:

Altitude= 4000 ft =1219.2m To1 = 100oF= 310.78 oK P01 =

88100,15 Pa

1.1 LPC exit (2)

γ −1
T γ Assumptions
T02 = T01+ 01 ( P.R − 1)
η m = 12 lb/sec
P.R=4.25 η=.86
P02 = P.R * P01
Results
W2= Cp (T02 – T01)
p0 374425,6
2 3 Pa
T0
2 497,02 K
W 186339,6
2 3 J.kg-1

1.2 HPC exit (3)

m3= (1-10%) m2

γ −1
T γ
T03 = T02+ 02 ( P.R − 1) Assumptions
η cooling air = 10%
P03 = P.R * P02
P.R=2.65 η=.84

W3= Cp (T02 – T01) Results

m
3 5,44 Kg/s
p0 992227,9
3 3 Pa
T0
3 686,99 K

5
 W 190870,4
3 3 J.kg-1

m4= m3 (1+Fuel air ration)

P04 = P03(1-ΔP/P)
1.3 Combustor exit (4)
(m 3 C p T03 +η * f .a.r * m 3 * HV )
T04 =
C p ( m 3 + m fuel )
Assumptions
Fuel ration=0.02 HV=16760
BTU/lb η=.99 ΔP/P=0.02

Results

m4 4,90 Kg/s
972383,3
p04 7 Pa
T04 1331,07 K
m5= m4+ (1+0.5*cooling air)

γ
 T  γ −1
P05 = P04 1 + 1  05 −1

 η  T04


1.4 HPT exit (5)
(m Ci p (T03 −T02 )
T05 = T04 -
m5 C p
Assumptions
W5= Cp (T05 – T04) η=.88

Results

m5 5,17 Kg/s
505486,6
p05 0 Pa
T05 1154,45 K
W5 -202945,7
0 J.kg-1

m 6= m 5

 ∆p 
P06 = P05 
1 + 
 p 

1.5 Inter-turbine duct (6)
T06 = T05

Assumptions
ΔP/P=0.02

6
 Results

p06 495376,
m7= m6+ (1+0.5*cooling air)
87 Pa
γ T06 1154,45 K
 T  γ −1
P07 = P06 1 + 1  07 −1
 
η  T06 
 

(m Ci p (T02 − T01 ) 1.6 LPT exit (7)

T07 = T06 -
m7 C p

W7= Cp (T07 – T06) Assumptions

η=.90

Results

m7 5,44 Kg/s
p07 244768,5
1 Pa
m 8= m 7 T07 986,67 K
W7 -192798,4
 ∆p  1 J.kg-1
P08 = P07 
1 + 
 p 


T08 = T07

1.7 Inter-turbine duct (8)

Assumptions ΔP/P=0.02

Results

p08 239873,1
m 9= m 2
4 Pa
T08 986,67 K
 
 P 
09  atm 
P =  ∆ P 
1− 
 P 

γ −1
1.8 Power turbine (8)
 
  p 09 γ 
T09 = T08 - η * T08 1 − 
p 
 
  08   Assumptions
 
η=.93
W9= Cp (T09 – T08)
ΔP/P=0.02

7
 Results

m9 5,44 Kg/s
p09 89898,11 Pa
T09 787,16 K
HP= m9*W9 W9 -229265,8
5 J.kg-1
f .a.r
SFC = m3*
HP

1.9 Engine horsepower and SFC

Engine 1247912,3
Horspower 8 W 1673,48 HP

kg/Kw/ 516290, lb/hp/

SFC 0,314046 h 09 h

8
9
2. Part B: Turbine Design
2.1 Mean Line design of HPT

2.1.1 Rotational speed and gas path

Assumptions
2
AN
N= AN2 4E+1
π( rt 2 −rh 2 ) 0 rpm.in²
Uh 1100 ft/sec
rt π* AN 2 M1 0,1
= 2
+1
rh 30 2 * U h
M3 0,4
α1 10 deg
60
rh =U h α3 10 deg
2πN

Results

rh/r
Hub to tip ratio t 0.71
0.10 m
Hub radius rh
3.79 in
0.14 m
Tip radius rt
5.34 in
Rotational 30019.0 rp
speed N 51 m

The radius rh is calculated from the blade hub speed. The radius rt is calculated
m1RT1
from the area A1 which is calculated from the formula A1 = calculated later
P1V1
in the report.

10
2.1.2 Velocity triangles and nozzle & rotor loss
coefficients

T01 T03 2 2
T1 = T3 = Vr 3 − Vr 2
γ −1 2 γ −1 T2 = T3 +
1+ M1 1+ M3
2
2Cp
2 2

P01 P03 P01

P1 = γ
P3 = γ
P2 = γ
 γ −1 2  γ −1  γ −1 2 
γ −1  T01  γ −1
1 + M 1  1 + M 3   
 
 2   2   T '2 

V1 = M 1 . γ .R.T1 V3 = M 3 . γ .R.T3 T’2=T2-λN(T02-T2)

Va1= V1 cos α1 Va3= V3 cos α3 Va2

=Vu2/tanα2

Vu1= V1 sin α1 Vu3= V3 sin α3 Vu2=-

WHPT/Um –Vu3

m1RT1  U + Vu 3 
A1 = α r 3 = tan −1  m  Vr2=Vu2-Um
P1V1  Va 3 

Vr3=Va3/cos αr3
2 2
V r 2 = V ru + V a 2

m3 RT3
A3 = 2
V 2 = Vu + V a 2
2
P3V3

P2
ρ2 =
R.T2
Results

at at at
1 2 3
71.3 m/ 511. m/ 262.
V1 1 s Vu2 36 s V3 39
Vu 12.3 m/ 186. m/ Vu 45.5
1 8 s Va2 12 s 3 6
Va 70.2 m/ 544. m/ Va 258.
1 3 s V2 18 s 3 40
V 146. m/ 484.
ru2 95 s Vr3 61
237. m/
Vr2 14 s

11
12
 P01 - P02 P0r2 - P0r3
YN = YR =
P02 - P2 P0r3 - P3

γ γ
T  γ −1  T  γ −1
P0 r 2 = P2  0 r 2  P0 r 3 = P3  0 r 3 
 T2   T3 

V 2  V 2 
T0 r 2 = T2 +  r 2  T0 r 3 = T3 +  r 3 
 2C p   2C p 
   

The nozzle and rotor loss coefficients are:

YN 0,111
YR 0,166

Efficie
ncy

ξN 0,0768
ξR 0,1204
ηtt 0,87

These losses were verified by the efficiency calculated from the losses, which is
87% knowing that the efficiency should be 88%.

13
2.2 Hub and tip velocity triangles

Free vortex : Vu1= cste1/r Vu2= cste2/r Vu3= cste3/r U=N.r

2 2 2 2 2 2
V1 = Vu1 + V a1 V 2 = Vu 2 + V a 2 V3 = Vu 3 + Va 3

Vru 2 = Vu 2 − U

2
Vr 2 = Vru 2 + Va 2
2
Vr 3 = Va 3 / cos α r 3

V  V  V 
α 1 = tan −1  u1  α 2 = cos −1  a 2  α 3 = tan −1  u 3 
 Va1   V2   Va 3 
V   U + Vu 3 
α r 2 = tan −1  ru 2  α r 3 = tan −1  
 Va 2   Va 3 

V2  V 2   (V 2 − Vr 2 2 
T1 = T01 −  1  T2 = T02 −  2  T3 = T2 −  r 3 
 2C   2C   2C p 
 p   p   

V 2  V 2 
T0 r 2 = T2 +  r 2  T0 r 3 = T3 +  r 3 
 2C   2C 
 p   p 

P2 = ρ 2 .R.T2 P3 = ρ 3 .R.T3

γ γ
T  γ −1 T  γ −1
P02 = P2  02  P03 = P3  03 
 T2   T3 

T2 − T3
R=
T1 − T3

M = V / γ .R.T

The Results are:

r 0.10 0.11 0.12 0.13 0.14

T2 1151.00 1180.15 1202.21 1219.31 1232.82
T3 1124.09 1124.32 1124.50 1124.63 1124.74
p2 597057.7 612182.9 623626.3 632492.5 639501.3

14
 6 7 0 9 1
454826.2 454919.9 454990.8 455045.7 455089.1
p3 9 5 2 2 3
1068336. 991016.3 937404.7 898495.0 869247.2
p02 66 7 0 0 0
506035.9 505723.1 505486.6 505303.4 505158.7
p03 1 0 0 6 6
α2
deg 73.18 71.58 70.00 68.45 66.94
α3
deg 11.99 10.91 10.00 9.23 8.57

V2 643.30 588.92 544.18 506.80 475.18

V3 264.16 263.15 262.39 261.79 261.32
Vu2 615.79 558.74 511.36 471.39 437.21
Vu3 54.87 49.78 45.56 42.00 38.96
Va2 186.12 186.12 186.12 186.12 186.12
Va3 258.40 258.40 258.40 258.40 258.40
Vr2 364.31 292.18 237.14 201.07 186.44
Vru2 313.18 225.23 146.95 76.08 11.00
Vr3 441.09 462.26 484.61 507.95 532.12
R 0.13 0.27 0.37 0.45 0.52

This table shows:

 A radial increase in temperature and pressure for the leading edge, this is
due to the change in the radius so a change in the speed. However for the
trailing edge, the radial conditions are almost the same, since we are at
the exit of the HPT,

 A temperature and a pressure drop between leading and trailing edge,

which is normal since we transfer energy from the flow to the blades in a
turbine,

 The turning is lower as the radius increases, in order to reduce the losses
on the tip (tip leakage, secondary…)

 The reaction increases with the radius since the temperature follows the
same pattern.

15
2.3 Vane and Blade parameters

Stagger angle is calculated from Fig5

(rt - rh )
Chord c=
h/c

Axial chord ca=c*cos(γ)

ψ
Pitch of vanes s = ca
2.(tanα 1 + tan α 2 ) cos 2 α 2

2π .rm
Number of vanes/blades N=
s

Results

To be validated

Vane Blade

h/c 0,7 - h/c 1,3 -

Ψ 0,75 - Ψ 0,9 -
TAT 0,04 in TAT 0,02 in
C 0,056 m C 0,028 m
Ca 0,036 m Ca 0,022 m
γ 50 deg γ 38 deg
s 0,040 m s 0,018 m
Nv 18 vane Nb 44 blade

So the final design will be 18 vanes and 44 blades.

16
2.4 Nozzles and rotor loss coefficients

 YN = YP * fRE + YS + YTET +YTC

2 
YP = 0.914  YP , AMDC K P + Yshock 
 3 

β1
  β 1  β1    t /c
YP, AMDC = [
YP( β 1=0 ) +    YP( β 1=α 2 ) - YP( β1 =0 )   max ] 

α2

  α 2  α 2    0.2 

With Kp = 1 – K2 (1- K1), K1 = 1-1.25(M2-0.2), K2 = (M1/M2)2

YS = 1.2 YS, AMDCKS

 cosα 2   C L  2 cos 2α 2
   
 cosβ1   s/c  cos α m
3
YS, AMDC = 0.0334 f(AR)

CL 1  1 − 0.25 2 − h c
−1
 (tan α1 − tan α2 )
With s/c = 2(tanα + tanα2) cosαm αm = tan
2  f(AR) =
h c
1

Using AMDC loss system, the loss coefficients for the stator are:

secondary Trailing edge

profile losses losses losses
book page 330
0,02
tmax/c 0,2 fAR
assumption 1,02 t/s 6 ≠ 0,02
correction from
αm
s/c 0,705 -0,91 rad factor 1,05 graph
Yp (β1=0) 0,04 from graph -52,12 deg
0
Yp (β1=α2) CL/(s/c) ,00
0,14 from graph 3,59 YTET 6
Yp AMDC 0,0387 Ys AMDC 0,08
M1 is too
Yshock
0 small K3 0,84
M1 0,10 Ks 0,99
M2 0,80
K1 0,25
K2 0,015 Ys 0,093
Kp 0,99
Re 1,38E+06 reynolds > 10^6
f(Re) 0,938

Yp 0,022

17
 Total Pressure
Total AMDC loss loss
YN
0,12 compared to 0,11

Assuming an unshrouded blade with a radial tip clearance of 2% of blade height,

the loss coefficients for the rotor are:

secondary Tip clearance

profile losses losses losses

tmax/c 0,200 fAR 0,6083 book page 329

assumption of unshrouded
αm
s/c 0,525 -0,379 rad blades
from with radial tip clearance of
Yp (β2=0)
0,040 graph -21,73 deg 2% of blade height
from
Yp (β2=αr3) CL/(s/c)
0,100 graph 4.4146
(cosβ3/cosβ2)
Yp AMDC Ys AMDC 0,098 ^2
0,069 /(1+rm/rt) 0,263
Δp/q1 hub 0,027 K3 0,5397 λ 0,008
Δp/q1 shock 0,019 Ks 0,92 B(k/h) 0,010
Yshock 0,005 βm 0,354 rad
Mr2 0,350 Ys 0,108 Ys+Yk 0,121
Mr3 0,739
Trailing edge 0,01
K1
0,327 losses YTC 3
K2 0,224
Kp 0,849 book page 330
Re 5,16E+05 t/s 0,032 ≠ 0,02
correctio from
f(Re)
1 n factor 1,05 graph

0,04
Yp
1 YTET 0,009

Total Pressure
Total AMDC loss loss
YR 0,17 compared to 0,17

We notice that the loss coefficients calculated with the AMDC method are very
close to those calculated with the pressure losses.

We also notice that the most predominant losses are the secondary.

18
Blade metal area ration

τ 300 h
K1 15
K2 55,6
K3 -5,2
K4 0,6 lb/in3
ρ 0,315 -
maximum
Lm2 45,2 KSI
life
Lm1 45,2 KSI Actual life

σc 247,3 23,48 KSI

K5 175,7 16,68
AH/AT ≈1 2.3

Since the Lm1 equation is a second order equation, we have 2 solutions for σc
and so for K5 , but only one of them seems to be reasonable. We chose 2.3 as
AH/AT.

19
2.5 Off-design performance

2.5.1 Reduction of the speed by 20%

 ioff = α r 2 off - β2 with β2 is metal angle (unchanged)

Incidence on the rotor
Umean off 291.5
2 −γ

β2 
40.29 γ
metal
−1 angle 2iscst

1 γ−1
1− M r3  −1
 −1
φ
2
 2 
αr2 off  Y’=0,88 rad −γ
 γ −1 2 γ− 1
1 −1 + M r3 
50.39 deg 2 

i off 10,10 incidence on the rotor

* (α r 2 off − α r 2 )
−2
d 
−1.6
 cos β2 
φ 2 = 1 − ∆φ p
2
x’=   *  
 and
s   cos β3 

Incident Loss on rotor

∆φ p =0.778*10 x’ + 0.56*10
2
incident profile
-5
x’ + 0.4*10
incident x’ + 2.054*10
secondary
-7 2 -10 3 -19
x’6
losses losses
d/c 0,044 assumed 2 χ'' x ”) 0,18
Y’’= Ys,des(exp(0.9 x ”) + 13 x ” + 400
s/c 0.52 (Y/Ydes−)1S.5 2,08−0.3 0 < χ'' < ,3
αoff
r 2 − β2  cos β2 
*
d 
x” = 180 − (β2 + β3 )
*
 cos 
  
d/s 0.08  Yβ iS 3  0,225
 C

β2 40.29 0,70
deg rad

β3 57.78 1,01
deg rad
Assume same TET and Tip clearance
αr2 38.29 deg losses
Mr
3 0.75
χ' 312.23
0,0093
∆φ²P 0 0 < χ' < 800 Total loss
0,0117 0,31
YR
YiP 3 7

20
Efficiency YN
drop ξ N = 1 + 0.5 * γ * M 2
2

ξN 0,0690 YR
 ξR =
ξR 0,2298
1 + 0. 5 * γ * M r 3
2

ηtt 0,8256 Knowing that we originally had to

have 0,88
dηtt 6,19 % 1
η tt off =
 ξ .V + ξ R (Vr3 ) 2
2
1+ N 2
2.(h 01 − h03 )

With (h01-h03)=U2Vu2-U3Vu3=Um(Vu2-Vu3)

Reducing the speed by 20% will lead to:

 an increase of αr2 and then generate a positive incidence of 10 degrees

 an increase of losses on the rotor

 a reduction of the efficiency by 6.19%

21
2.5.2 Reduction of the pressure ratio by 20%

Design conditions 80% Pressure ratio

22
 %
Design 80% PR decrease
V1 71.31 70.12 1.67
Vu1 12.38 12.18 1.67
Va1 70.23 69.05 1.67

Vu2 471.32 369.81 21.53

Va2 171.55 134.60 21.54
V2 501.56 393.54 21.54
Vru2 78.68 5.40 93.13
Vr2 188.73 134.71 28.62

V3 262.39 262.47 -0.03

Vu3 45.56 45.58 -0.03
Va3 258.40 258.48 -0.03

23
 Vr3 508.71 484.66 4.73

The effect of reducing the pressure ratio by 20% on the velocity triangle is:

 a reduction of the incidence (so a reduction of losses),

 a reduction of speeds at the stator and the rotor,

 a reduction of the component Vu, which reduces the energy transfer.

24
Conclusion

25