Gas Turbine, Finned Heat Exchanger

Republic of Iraq
Ministry of Higher Education and Scientific Research

Al- Mustansiriya University
College of Engineering
Mechanical Engineering Department
The Enhancement of Two- Shaft Gas Turbine

Performance Using Improved Air Temperature
A THESIS SUBMMITTED TO THE COLLEGE OF ENGINEERING OF

AL- MUSTANSIRIYA UNIVERSITY AS PARTIAL FULLFILMENT OF
THE REQUIREMENTS FOR THE DEGREE OF MASTER IN
MECHANICAL ENGINEERING SCIENECE
BY
Ali Ahmed Abdulrasool
Supervised
by
Dr.Ali Hussain Tarrad Asst.Prof Dr. Fouad Alwan Saleh
2009
‫ﻦ اﻟ َّﺮﺣِﻴ ِﻢ‬
‫ِﺑﺴْ ِﻢ اﻟَّﻠ ِﻪ اﻟ َّﺮﺣْ َﻤ ِ‬
‫ن‬
‫ب وَاﻟْﻤِﻴﺰَا َ‬
‫ت وَأَﻧْﺰَﻟْﻨَﺎ َﻣ َﻌ ُﻬ ُﻢ اﻟْ ِﻜﺘَﺎ َ‬
‫ﺳ َﻠﻨَﺎ ﺑِﺎﻟْ َﺒ ِّﻴﻨَﺎ ِ‬
‫َﻟ َﻘﺪْ أَرْﺳَﻠْﻨَﺎ ُر ُ‬
‫ﺤﺪِﻳ َﺪ ﻓِﻴ ِﻪ ﺑَﺄْسٌ ﺷَﺪِﻳﺪٌ َو َﻣﻨَﺎ ِﻓ ُﻊ‬

‫ﻂ وَأَﻧْﺰَﻟْﻨَﺎ اﻟْ َ‬
‫س ﺑِﺎﻟْ ِﻘﺴْ ِ‬
‫ِﻟ َﻴﻘُﻮ َم اﻟ َﻨّﺎ ُ‬
‫ن اﻟَّﻠ َﻪ َﻗ ِﻮيٌّ‬
‫ﺐ ِإ َّ‬
‫ﺳ َﻠ ُﻪ ﺑِﺎﻟْ َﻐﻴْ ِ‬
‫ﺼ ُﺮ ُﻩ َو ُر ُ‬
‫س َو ِﻟ َﻴﻌْ َﻠ َﻢ اﻟَّﻠ ُﻪ َﻣﻦْ َﻳﻨْ ُ‬
‫ﻟِﻠ َﻨّﺎ ِ‬
‫ﻋَﺰِﻳﺰٌ‬
‫ﺻﺪق اﷲ اﻟﻌﻈﻴﻢ‬
‫ﺳﻮرة اﻟﺤﺪﻳﺪ اﻵﻳﺔ )‪(25‬‬

Supervisor Certificate
We certify that the preparation of this thesis entitled (THE
ENHANCEMENT OF TWO SHAFT GAS TURBINE PERFORMANCE
USING IMPROVED AIR TEMPERATURE) was made under our
supervision at the Mechanical Engineering Department , College of
Engineering , Al-Mustansiriya University in partial fulfillment of the
requirements for the degree of MASTER OF SCIENCE IN MECHANICAL
ENGINEERING.
(SUPERVISORS)
Signature: Signature:
Name: Name:
Date: Date:
In view of the available recommendation I forward this thesis for

debate by the examining committee
Signature:
Name:
Date:
(CHAIRMAN OF MECHANICAL ENGINEEING DEPARTMENT)
EXAMINATION COMMITTEE CERTIFICATE
We certify that we have read the thesis entitled (THE ENHANCEMENT OF

TWO SHAFT GAS TURBINE PERFORMANCE USING IMPROVED
AIR TEMPERTURE) and as an examining committee, examined the student
(Ali Ahmed Abdulrasool) in its context and that in our opinion it is adequate
as a thesis for the degree of MASTER OF SCIENCE IN MECHANICAL
ENGINEERING.
Signature:
Name:
Date:
(Chairman)
Name: Name:
Date: Date:
(Member) (Member)
Name: Name:
Date: Date:
(Supervisor) (Supervisor)
Approved by the Dean of College of Engineering
Signature:
Name:
Date:
DEDICATION
TO MY DEAR FAMILY
WITH
LOVE AND RESPECT
ALI
Acknowledgement
All praise is due to Allah, the lord of the worlds
I would like to express my deep sense of appreciation and thank to my
supervisors (Dr.Ali Hussain Tarrad and Dr. Fouad Alwan Saleh)
for their continuous encouragement and support during the study.
Finally, I would like to thank for all of people who helped me and introduce
their opinion and companion to end this thesis including: Mr. Ahmed Muneer
Dein, Mr. zyaad Talal ,Mr. Wa'al Najam and Mr. Nehaad Hashim.
Ali
ABSTRACT
In the present research, a study of the performance improvement of a two-

shaft gas turbine engine is conducted. This has been accomplished by utilizing
sensible load cooling system. It is related to the effect of reducing compressor
inlet temperature on gas turbine performance. An experimental study has been
done on an existing a two-shaft gas turbine with a (5 kW) power, taking into
consideration the effect of reducing compressor inlet temperature. An
instrumented experimental rig was built for this object by adding an air-
cooled heat exchanger in series with water supplying system. The
experimental results for gas turbine performance showed that the percent of
design increases by (15%) for the power output increasing overall efficiency
by (25%).Moreover, heat consumption has been reduced by (10%) when
reducing compressor inlet temperature from (30°C to 15 °C).The percent of
design is defined by the ratio between the parameter difference at both
temperatures to the design point.
A simplified new numerical model based on the step by step technique has
been developed for the design and predicting the air cooled heat exchanger
performance. The numerical model was designed in a new form so that
variation of all design parameters can be calculated. The model has been
checked and validated using the experimental laboratory data. The maximum
discrepancy between the experimental data and model predicted values of the
overall heat transfer coefficient and heat load were about (5%). This
percentage value was obtained for the given range of the simulated conditions.
Furthermore, a computational model program to investigate theoretically the
effect of compressor inlet temperature on the performance of the gas turbine
has been developed. The model utilizes a non-dimensional approach. The
discrepancy percentage between the experimental and theoretical predictions
was about (18 %).
TABLE OF CONTENTS
Title Pages
List of Figures VIII
List of Tables XII
Nomenclature XIII
CHAPTER ONE: Introduction 1

1.1 General 2
1.2 Two Shaft Engine 2
1.3 Influence of External Factors on the Gas Turbine Performance 3
1.4 Gas Turbine Inlet Air Cooling 5
1.4.1 Evaporative Cooling 5
1.4.2 Cooling with Absorption Chiller 5
1.5 Compact Heat Exchanger 6

1.6 Aims of the Present Work 7
CHAPTER TWO : Literature Survey 8
2.1 General 9
2.2 The Previous Work 9
2.2.1 Modeling and Simulation of Air Cooled Heat Exchanger 9
2.2.2 Performance Improvement of the Gas Turbine Engine 11
2.3 The Present Work 16
CHAPTER THREE: Experimental Work 18
3.1 Test Rig for Heat Exchanger 19
3.1.1 Heat Exchanger 19
3.1.2 Water Supplying System 19
3.1.3 Measuring Instrumentation 21
3.1.4 The Electrical Board 21
3.1.5 Air Circulation System 22
3.2 Experimental Setup 26
3.3 Gas Turbine 26
3.3.1 Design Information 28
3.3.2 Performance design 28
3.4 Operating Principles 28
3.5 Main Component Parts of Gas Turbine 29
3.5.1 Gas Generator: 29
3.5.1.1 Centrifugal Compressor 29
3.5.1.2 Combustion Chamber 30
3.5.1.3 Gas Generator Turbine 31
3.5.2 Power Turbine 31
3.5.3 Fuel System 32
3.5.4 Oil Lubricating System 32
3.5.5 Starting System 33
3.6 Dimensionless and Parameter Groups 33
3.6.1 Corrected Compressor Data 34

3.6.2 Corrected Basic Data 35
3.6. 3 Corrected Derived Data 36

3.7 Experimental Work Procedure 40
3.8 Test Procedure 40
CHAPTER FOURE : Mathematical Model 43

4.1 General 44
4.2 Heat Exchanger Thermal Design 44
4.2.1 A Comprehensive Design Procedure 44
4.2.2 Numerical Modeling of Cross Flow Compact Heat Exchanger 46
4.2.2.1 Grid System 46
4.2.2.2 Physical Characteristics of Heat Exchanger 49

4.2.2.3 Mass Conservation 49
4.2.2.4 Log-Mean Temperature Difference 50
4.2.2.5 Heat Load 51
4.2.2.6 Overall Heat – Transfer Coefficient (Uo) 51
4.2.2.7 Forced Convection Heat Transfer coefficient Inside Tube 52
4.2.2.8 Forced Convection Heat Transfer coefficient for Air Side 52

4.2.2.9 Power of Fan 54
4-2-2-10 The Computer Program 55
4.3 Gas Turbine 57
4.4 Basic Gas Turbine Cycles 58

4.5 A non-Dimensional Analyses of Gas Turbine 58
Performance
4.5.1 Component Performance 59
4.5.2 Graphical Plot 61
4.6 Computer Calculations for Two-Shaft Gas Turbine 61
4.7 Results and Discussion of Theoretical Calculations 62

4.7.1 The effect of compressor inlet temperature on maximum to 62
minimum ratio (Ø)
4.7.2 The effect of compressor inlet temperature on the expansion 64
ratio
CHAPTER FIVE : Results & Discussion 70
5.1 General 71
5.2 Computational Model Results for Heat Exchanger 71
5.2.1 Heat Load for heat exchanger 72
5.2.2 Heat Transfer Coefficient for air side 72

5.2.3 Overall Heat Transfer Coefficient 73
5.2.4 Air Temperature Distribution 74
5.2.5 The Effect of Core Aspect Ratio (H/L) and Size (LXDXH) 74
5.3 Experimental Results for Gas Turbine 75
5.3.1 Effect of Compressor Inlet Temperature on Power Output 76

5.3.2 Effect of Compressor Inlet Temperature on Fuel Mass Flow 76
Rate
5.3.3 Effect of Compressor Inlet Temperature on Specific Fuel 77
Consumption
5.3.4 Effect of Compressor Inlet Temperature on Heat 77
Consumption
5.3.5 Effect of Compressor Inlet Temperature on Heat Rate 78
5.3.6 Effect of Compressor Inlet Temperature on Overall 78

Efficiency
5.3.7 Effect of Compressor Inlet Temperature on Air Mass Flow 78
Rate
5.3.8 Effect of Compressor Inlet Temperature on Pressure Ratio 78
5.3.9 Effect of Compressor Inlet Temperature on Power Input to 79
Compressor
5.3.10 Effect of Compressor Inlet Temperature on Turbine Inlet 79
Temperature
5.4 Percent of Design 80
5-5 Comparison between the Experimental and Theoretical 81
Predictions of the gas turbine engine
5.6 Conclusion 81
CHAPTER SIX : Conclusions & Recommendations 114
6.1 Conclusions 115
- 6.2 Recommendations 116
References 117
Appendix (A)Experimental Work ,Data Tables 122
Appendix (B) Flow Charts and Computer Program 134
Appendix (C)Gas Turbine parameter Groups 146

List of Figures
Title Pages
Figure (1.1) Two Shaft Gas Turbine Diagram 3

Figure (1.2) Influences of External Factors on the Gas Turbine Performance 4
Figure (1.3) Evaporative Cooler 5
Figure (1.4 )Air "Chilling Cooling" System, Based on Absorption 6
Figure (2.1)Effect of Compressor Inlet Temperature on Gas Turbine Performance 13
Figure (2.2) Temperature-Power-Speed Interrelationships 15
Figure 2.3 Net Output Power Versus Inlet Temperature for Gas Cycle 16
Figure (3.1a) Schematic Diagram of the Built Rig (Heat Exchanger) 23
Figure (3.1b) Configuration of the Built Rig (Heat Exchanger) 24
Figure (3.1c) Configuration of the Test Rig (Inlet Cooling System) Preparing 24
to Gas Turbine
Figure (3.3.a) Top View of Heat Exchanger Geometry 25
Figure (3.3.b) Front View of Heat Exchanger Geometry 25
Figure (3.3) Schematic Diagram of the Test Rig (Overall) 27
Figure.(3.4) Schematic Arrangement for Gas Turbine (GT-85) 32
Figure (4.1) Methodology of Heat Exchanger Design 45
Figure (4.2) Step by Step method with two Directions 47
Figure (4.3a) Slice for inlet single Tube 48
Figure (4.3b) Exit of one row inlet to next row 48
Figure (4.3c) Nodal Points Distributions with two directions 49
Figure (4.4) The Mean Temperature Difference Along a Single Pass 50
Figure (4.5) Basic Gas Turbine Engine 59
Figure (4.6 )(T-s) Diagram for Irreversible Two-Shaft Circuit Simple Plant 56
Figure (4.7)Specific Heats and Their Ratios for ‘Real’ Gases-Air and Products of 62
Combustion
Figure (4.8) Theoretical Overall Efficiency as a Function of (T3/T1 Ratio) 65

with Isentropic Efficiency (ηt,ηc =0.9) ,T3=699 0C
with Isentropic Efficiency (ηt,ηc =0.9) ,T3=628.5 0C
with Isentropic Efficiency (ηt,ηc =0.9) ,T3=588 0C
with Isentropic Efficiency (ηt,ηc =0.9) ,T3=547.5 0C
Figure (4.12)The Effect of Turbine Inlet Temperature (High Pressure Turbine)on 67

the Theoretical Overall Efficiency ,Expansion Ratio=1.12
Figure(4.13) The Effect of Turbine Inlet Temperature (High Pressure Turbine)on 67
the Theoretical Overall Efficiency ,Expansion Ratio=1.08
Figure (4.14) Theoretical Overall Efficiency as a Function of Expansion Ratio 68
with Isentropic Efficiency (ηt,ηc =0.9) andT1=150C
Figure (4.15) Theoretical Overall Efficiency as a Function of Expansion Ratio 68
with Isentropic Efficiency (ηηt,ηc =0.9) andT1=300C
Figure (4.16) The Effect of Compressor Inlet Temperature (with Variable 69
Expansion Ratio)on the Theoretical Overall Efficiency, T3= 669 0C
Figure(4.17)The Effect of Compressor Inlet Temperature (with Variable 69

Expansion Ratio) on the Theoretical Overall Efficiency, T3= 628.5 0C
Figure (5.1) Comparison between the Experimental and Present Model for the 93
Effect of Air Velocity on Heat Load at Water Flow Rate 2000 (L/h)
Figure (5. 2) Comparison between the Experimental and Present Model for the 94
Effect of Air Velocity on Heat Transfer Coefficient.ha (w/m2.c) at
Water Flow Rate 2000 (L/h)
Figure (5. 3) Variation Heat Transfer Coefficient ha.(w/m2.c) a long Heat 95
Exchanger Height at Water Flow Rate 2000 (L/h), Air Flow
Rate 2000 cfm
Figure(5. 4) Variation Heat Transfer Coefficient ha.(w/m2.c) a long Heat 96

Exchanger Height at Water Flow Rate 2000 (L/h),Air Flow
Rate2000 cfm
Figure (5. 5) Variation Heat Transfer Coefficient. ha ( w/m2. c) a long 97

Heat Exchanger Depth at Water Flow Rate 2000 (L/h), Water
Entering Temp. 10 0C, Air Flow Rate 2000 cfm
Effect of Air Velocity on Overall Heat Transfer Coefficient (w/m2. c)
at Water Flow Rate 2000 (L/h)
Figure(5. 7) Variation Overall Heat Transfer Coefficient (w/m2.c) a long 99

Heat Exchanger Height with Water Flow Rate 2000
(L/h), Air Flow Rate 2000 cfm
Figure(5. 8) Variation Overall Heat Transfer Coefficient (w/m2.c) a long 100
Heat Exchanger Height at Water Flow Rate 2000 (L/h),
Air Flow Rate 500 cfm
Figure(5. 9) Variation Overall Heat Transfer Coefficient ( w/m2. c) a long 101

Heat Exchanger Depth at Water Flow Rate 2000 (L/h),
Water Entering Temp. 10 0C, Air Flow Rate 2000 cfm
Effect of Air Velocity on Air Exit Temperature (0C)
At Water Flow Rate 2000 (L/h)
Figure (5. 11) Variation Exit Air Temperature (0C) a long Heat 103
Exchanger Height with Water Flow Rate 2000 (L/h), Air Flow Rate
2000 cfm
Figure(5. 12)Variation Exit Air Temperature (0C) a long Heat Exchanger 104
Height atWater Flow Rate 2000 (L/h), Air Flow Rate 500 cfm
Figure(5. 13) Variation Air Exit Temperature ( 0C) a long Heat 105
Exchanger Depth at Water Flow Rate 2000 (L/h), Water Entering
Temp. 10 0C,2000 cfm
Figure (5. 14) The Effect of Aspect Ratio (H/L) with Different Core Size 105
(L × D × H) on the Pressure Drop in Air Side Water Flow Rate 2000
(L/h) ,Air Flow Rate 500 cfm
Figure (5.15) The Effect of Turbine Inlet Temperature on the Power Output 106
with Variable Compressor Inlet Temperature at Rang Gas Generator
Speed (50000-65000 RPM)
Gas Generator Speed ) on the Fuel Mass Flow Rate
Figure (5.17) The Effect of Compressor Inlet Temperature (with Variable Gas 107
Generator Speed ) on the Specific Fuel Consumption
Generator Speed) on the Heat Consumption
Figure (5.19) The Effect of Turbine Inlet Temperature (with Variable 108
Compressor Inlet Temperature) on the Heat Rate,
at Rang Gas Generator Speed (50000-65000 RPM)
Figure (5.20) The Effect of Turbine Inlet Temperature (with Variable 108
Compressor Inlet Temperature) on the Overall Efficiency (%),at Rang
Gas Generator Speed (50000-65000 RPM)
Generator Speed) on the on Air Mass Flow Rate
Gas Generator Speed) on the on Air Flow Rate
Generator Speed) on the on Compression Ratio
Generator Speed) on the on Compressor Work
Figure (5.25) The Effect of Turbine Inlet Temperature (°C )on the HP.Turbine 111
Work (kW) with variable Compressor Inlet Temperature (°C)
At Rang Gas Generator Speed (50000-65000 RPM)
Figure (5.26) The Influence Compressor Inlet Temperature (°C )on Gas Turbine 112
Performance at (Gas Generator Speed 45000 RPM)
Figure (5.27) The Influence Compressor Inlet Temperature (°C )on Gas Turbine 112
Performance at(Gas Generator Speed 55000 RPM)
Figure (5.28) Comparison between the Experimental and Theoretical Predictions 113
of the gas turbine engine (GT-85)
List of Tables
Title Pages
Table (2-1) GE-Design Parameters 12

Table (2-2) Turbine Inlet Cooling Options 14
Table (3.1) Heat Exchanger Geometry 20
Table (5.1) Air Temperature Distribution Along H.EX.Depth,Vw=2000 83
0
(l/h),Va=2000 (cfm) , Tw (in)=10 C
0
(l/h),Va=2000 (cfm), Tw (in)=50 C
0
(l/h),Va=500 (cfm), Tw (in)=10 C
0
(l/h),Va=500 (cfm), Tw (in)=50 C
Table (5-5) Air Temperature Distribution a long First Row Height 87
(No. of Slice in i-Direction), Core Size=55 × 3.6 × 37
Table (5-6) Air Temperature Distribution a long Second Row Height 88

Nomenclature
Symbol Description Units
A Total Heat Transfer Surface Area m²
Af Fin Area m²
Acw Crosse Sectional Area of Water Side m2
Aca Crosse Sectional Area of Air Side m2
Aexp Exposed Area of the Bare Tube
Cpa Specific Heat Capacity of Dry Air J/kg..k
Cpw Specific Heat Capacity of Water J/kg..k
Cpg Specific Heat Capacity of Gas J/kg..k
dh Hydraulic Diameter mm
Dt Tube Depth mm
Df Fin Depth mm
D Heat Exchanger Depth cm
ha Convection Heat Transfer Coefficient of Air Side W/m².k
hw Convection Heat Transfer Coefficient of Water Side W/m².k
Ht Tube Height cm
H Heat Exchanger Height cm
H.V Heating Value kJ/kg
Lf Fin Length mm
L Heat Exchanger Length cm
m& a Air Mass Flow Rate Kg/s
m& f Fuel Mass Flow Rate Kg/s

hd
Nu Nusselt Number = -
k
Nt Number of Tubes -
Nr Number of Rows -
N Number of Slices -
P Pressure bar
Q& Rate of Heat Transfer Loss or Gain W

ρud h
Re Reynolds Number = -
μ
R Gas Cosatant J/kg.K
rC Compression Ratio -
rT Expansion Ratio -
sg Specific Gravity of Fuel -
T Temperature °C
−
Gauge Measurement Temperature °C
T
tf Fin Thickness mm
tt Tube Thickness mm
Uo Overall Heat Transfer Ccoefficient W/m².˚K
.
V Volumetric Flow m3/s
v Velocity m/s
.
W Power Watt
XT Transverse Space mm
XL Longitudinal Space mm
T2 s
xc Isentropic Temperature Ratio for Compressor = -
T1
T3
xt Isentropic Temperature Ratio for Turbine = -
T4 s
Greek Letters
ηo = 1−
Af
(1 − η ) Overall Surface
f Efficiency
A
ηf Fin Efficiency
ρ Density (kg/m³)
μ Viscosity (kg/m.s)
Ø Maximum to Minimum Temperature Ratio through the gas turbine

engine
α t* Ø η c* η
ηo Overall Efficiency of Gas Turbine
ƒ Fuel / Air Ratio
λt Perimeter of Tube Side (m3)
λf Perimeter of Fin (m3)
γ Specific Heat Ratio
Ŧ Torque (N.m)
Subscripts
a Air
C Corrected Value
c Compressor
f Fin
g Gas
i Input
o Output
s Isentropic Process
t Tube
T turbine
w Water
1 Compressor Inlet
2 Compressor Discharge
3 1stTurbine Inlet
4 1st Turbine Outlet
5 2nd Turbine Outlet
Abbreviations
NDCW Non-dimensional Compressor Work
NDTW Non-dimensional Turbine Work

c.c Combustion Chamber
ISO International Standard Organization
HVAC Heating, Ventilating and Air Conditioning
CBT Compressor Burner Turbine simple cycle
LMTD Logarithmic Mean Temperature Difference
HP High Pressure
LP Low Pressure
CHAPTER ONE
Introduction
Chapter One…………………………………………………………………….Introduction
1.1 General
Gas turbines are used in a wide range of services; they power aircraft of all
types and drive mechanical equipment such as pumps, compressors, and
generators in electric utilities. They also generate power for peak loads and
base-load duties. Recently, the interest in gas turbines has grown significantly
in combined-cycle plants. These plants use combinations of gas and steam
turbines in various configurations of turbines, heat recovery steam generators,
and regenerators.
Gas turbines have many advantages over steam plants. These are as followed:
1. They are smaller in size, mass, and initial cost per unit output.
2. Their delivery time is relatively short and they can be installed quickly.
3. Their starting is quicker (as low as 10 s) Philip (2002) [1], often by
remote control.
4. Their running are smooth and have a capacity factor (percent of time
the unit is operating at full power) of 96 to 98 percent.
5. They can be used in a wide variety of liquid and gaseous fuels
including gasified coal and synthetic fuels.
6. They can be subjected to fewer environmental restrictions other than
prime movers.
1.2 Two Shaft Engine
A two shaft gas turbine Figure (1.1) consists of an air compressor, a
combustor, a gas generator turbine, and a power turbine. The air compressor
generates air at a high pressure, which is fed into to the combustor where the
fuel is burned. The combustion products and excess air leave the combustor at
high pressure and high temperature. This gas is expanded in the gas generator
turbine, which has the sole task of providing power to turn the air compressor.
After leaving the gas generator turbine, the gas still has a high pressure and a
high temperature. It is now further expanded in the power turbine. The power
turbine is connected to the driven equipment. It must be noted at this point

that the power turbine (together with the driven equipment) can run at a speed
which is independent of the speed of the gas generator portion of the gas
turbine. The gas generator is controlled by the amount of fuel which was
supplied to the combustor. Its two operating constraints: the firing
temperature and the maximum gas generator speed. If the fuel flow is
increased, both firing temperature and gas generator speed will also increased
until one of the two operating limits is reached.
Exhaust
Combustion
Chamber
Power Turbine
Driven
Compressor
Turbine
Equipment
Gas Generator
Inlet Air
Figure 1.1 Two Shaft Gas Turbine Engine
1.3 Influence of External Factors on Gas Turbine Performance

A gas turbine uses ambient air; therefore, its performance is greatly
affected by all factors that influence the flow rate of air delivered to the
compressor, in terms of weight and its physical conditions. These factors are:
1. Ambient Temperature
2. Ambient Pressure
3. Relative humidity
In this regard, the reference conditions for the three above-mentioned factors
[2]
are (15 °C, 1013 mbar, and 60 %) respectively, ISO (1973) .When the
compressor inlet temperature increases, the specific work needed to compress
air will also be increased. However, the weight of the air delivered will be
decreased (because of a decrease in specific weight). Consequently, the
turbine efficiency and useful work (and, therefore, power) diminish as well. If
compressor inlet temperature decreases, the reverse process occurs. This
temperature depends on the air aspirated by the compressor. The power and
efficiency varies from turbine to turbine, according to cycle parameters,
compression and expansion output and air delivery rate…etc. And as a result,
the variation ratio of gas turbine performance parameters is taken proportional
to design point (manufactured levels). Figure (1.2) shows an example of how
power, heat consumption, heat rate and the delivery rate of exhaust gases
depend on ambient temperature. Design point performance is a central to the
engine concept design process. The engine configuration, cycle parameters,
component performance levels and sizes are selected to meet the given
specification.
Figure 1.2 Influences of External Factors on the Gas Turbine

Performance, Frank (2002) [3]
1.4 Gas Turbine Inlet Air Cooling

The turbine inlet air cooling methods can be divided into two categories:
1.4.1 Evaporative Cooling
In this process water is distributed over pads of fibers through which the
passing air should be humidified. Spray intercoolers or fogging systems were
also used to cool the inlet air. When the power and efficiency can be
increased by decreasing compressor inlet temperature ,the latter can be
reduced artificially by using an evaporative cooler located upstream of the
suction filter. Water, fractioned into drops or in the form of a liquid film,
cools the air by evaporating in the cooler as it flows in contrary direction.
Figure 1.3 Evaporative Cooler
1.4.2 Cooling with Absorption Chiller

The absorption chiller works on the principle of vapor absorption
refrigeration cycle. The main advantage of this chiller lies in the fact that the
inlet air can be cooled down to a specific temperature for a wide range of
ambient air temperatures. Thus, the power output of a gas turbine remains
more or less constant, independent of ambient air conditions.
The low grade exhaust energy can be used to drive the chiller. The chilled
water produced by the absorption system, is passed through the inlet air
cooler, which is an indirect type air to water heat exchanger.
Figure 1.4 Air "Chilling Cooling" System, Based on

Absorption, GE [4]
1.5 Compact Heat Exchanger

Compact heat exchangers have been widely used in various applications in
thermal fluid systems including automotive thermal management systems.
Radiators for engine cooling systems, evaporators and condensers for HVAC
systems, oil coolers, and intercoolers are typical examples of the compact heat
exchangers which can be found in ground vehicles. Among the different types
of heat exchangers for engine cooling applications, cross flow compact heat
exchangers with plain fins are of a special interest. This is because of their
higher heat performance capability with the lower flow resistance.
1.6 Aims of the present Work

The drop in overall performance of gas turbine engines is believed to be due
to the increasing of compressor inlet temperature above ISO condition
(15°C).The present work is an attempt to improve the gas turbine
performance and bringing it near to ISO condition. This is accomplished by
applying sensible cooling technique consisting of air cooled heat exchanger
and water supplying system. In the present work a theoretical and
experimental study has been developed for both, air cooled heat exchanger
and gas turbine engine. A predictive numerical model for the air cooled heat
exchanger has been developed which is based on step by step technique
method so that a design tool for the heat exchanger can be developed.
Such work requires developing a versatile experimental facility to examine
the air cooling effect on gas turbine performance. This aim can not be
achieved without some important requirements which can be summarized as
follows:
1- Studying the performance of an existing gas turbine system available in the
laboratory. This was achieved by controlling the inlet air temperature to the
compressor.
2- An experimental rig was built up to conditioned air at different
temperatures controlled by the water supply temperature and then studying
this effect on the gas turbine performance.
3- Making theoretical assessments for the heat exchanger performance and the
effect of compressor inlet temperature on the gas turbine performance.
4-Developing a computational program for simulate the heat exchanger
design and estimating its performance with variable inlet conditions. This is
done by feeding with the experimental data to validate this simulation. A
computational program to predict the effect of air inlet temperature on the gas
turbine performance was built for this object depending on the engine design
information only.
CHAPTER TWO
Literature Survey
Chapter Two……………………………………………………………….Literature Survey
2.1 General
The gas turbines are generally used for large scale power applications. The
basic gas turbine cycle has low thermal efficiency. So it is important to look
for improved gas turbine based cycles. The inlet air cooling helps to increase
the performance of gas turbines. The demand of energy in the developing
regions of the world, particularly in Asia, has witnessed pronounced increase
in the recent past. According to a report of International Energy Outlook
(2004)[5], the world net power consumption is expected to be doubles nearly
over the next two decades. Much of the growth in new electricity demand is
expected to come from countries of the developing world. Therefore, it is
important to find improved technologies for power generations that have a
high efficiency and specific power output, low emissions of pollutants, low
investment, and low operating and maintenance cost for a sustainable use of
available fuels.
2.2 Pervious Work
The previous work can be classified into two categories: The first one is
concerned with modeling and simulation of air cooled heat exchanger. The
other related with the performance improvement of the gas turbine engine.
The improvement of two-shaft gas turbine performance by making
modifications or addition of some parts to the main components. This will
lead to decrease in the compressor inlet temperature and enhance the power
output and thermal efficiency of gas turbine.
2.2.1 Modeling and Simulation of Air Cooled Heat Exchanger
Ganapathy (1979) [6] concluded that for air- cooled condensers, the ambient
air is the most important variable in the design. Since ambient temperature in
a location varies throughout the year. Using higher value, would result in over
sizing the unit. Where as A lower value would give poor performance.
Current practice is to use a design temperature that exceeds (2 to 5%) of the
annual period.
Hedderich and Kellehere (1982)[7] developed a computer code for the

analysis of air cooled heat exchangers and was coupled with a numerical
optimization program to produce an automated air cooled heat exchanger
design leading to optimization procedure.
A general iteration free approximation method was used for the analysis
which calculates the mean overall heat transfer coefficient and the overall
pressure drop for many arrangements.
The analysis takes into account the variation of heat transfer coefficients
and the pressure drop with temperature and length of flow path .The
capability is demonstrated by the design of an air cooled finned tube heat
exchanger and is shown to be useful tool for the heat exchanger design.
Zhang (1994) [8] proposed three dimension numerical model predicting the
performance for large power plant condensers. He compared his predicted
results with the experimental data. The prediction was achieved by solving the
governing mass, momentum and air concentration using semi implicit
consistent control-volume for simulation model with different conditions in
work of condenser.
Matthew and Joseph (2002) [9] developed a conceptual designs for wet and
dry cooling systems applied to a new ,gas –fired, combined cycle 500-MW
plant at four sites chosen to represent conditions in California. The
requirements for cooling dry systems are four to six times those for wet
systems. Dry systems, which are limited by the ambient dry bulb temperature,
cannot be achieved as low a turbine back pressure as wet systems, which are
limited by the ambient wet bulb temperature.
Dohoy and Dennis (2006)[10] divided the heat exchanger core into small
control volumes along the tube. Finite Difference Method (FDM) with
staggered grid system was utilized in study. FDM can take into account the
significant air temperature increase as well as the local variations of the
properties and the heat transfer coefficient. The maximum difference between
the experimental data and calculated results was noticed to be 5% for the
given range of the simulated conditions.
[11]
Tarrad, et al. (2008) investigated the performance prediction of the
cross flow air-cooled heat exchanger. They developed a new simplified
correlation for the air side heat transfer coefficient which depends on the
dimensional analysis with Buckingham-pi theorem. The discrepancy between
the predicted and their own experimental values of the overall heat transfer
coefficient and heat duty were within 2% and 4% respectively for both of the
tested tube banks.
2.2.2 Performance Improvement of the Gas Turbine Engine
There are two basic methods available for inlet air-cooling evaporative
cooling and chilling cooling. The most widely accepted system is evaporative
air-cooling. Evaporative coolers make use of the evaporation of water, and are
the most cost-effective way to improve machine capacity during warm
weather. Mostly percent of design concept is used to examine gas turbine
performance. Of the two cooling methods of inlet air, namely, evaporative
cooling and the absorption cooling, the absorption cooling technique
demonstrated a higher gain in power output and efficiency than evaporative
cooling for a simple cycle gas turbine.
[12]
De Lucia, et al.(1995) reported that evaporative inlet-cooling is
economical and simple, but only suitable for dry hot climates.
they concluded that evaporative inlet cooling could enhance power out put by
(2–4)% depending on the weather.
Saleh (1996)[13] presented that water can be injected in a simple two shaft
gas turbine (GT-85) to improve the performance. The studied cases were
water injection prior to the combustion chamber and water injection in intake
of the compressor. Maximum increasing in performance data was obtained
when water injection prior to the combustion chamber where, the increase of
the power output up to (40.4٪) and thermal efficiency up to (34.8٪) .In

addition, specific fuel consumption was reduced by (32.12٪ ).
[14]
Ait-Ali (2001) presented the concept of inlet air refrigeration to boost
the power output from the gas turbine. Chillers can increase the gas turbine
power output by 15-20%.The absorption chiller works on the principle of
vapor absorption refrigeration cycle. The main advantage of this chiller lies in
the fact that the inlet air can be cooled down to a specific temperature for a
wide range of ambient air temperatures. Therefore, the power output of a gas
turbine remains more or less constant, independent of ambient air conditions.
A typical absorption chiller with a capacity of 3000 refrigeration tons and a
COP of 0.70. This absorption system uses the waste heat to produce required
steam by the chiller.
Nuovo Pignone (2002)[15] publishing curves of the compressor inlet
temperature effect on gas turbine performance as shown in fig.(2.1).It is
obvious that power output and heat rate are improved as compressor inlet
temperature was decreased. Lowering the compressor inlet temperature can be
accomplished by installing an evaporative cooler or inlet chiller in the inlet
ducting downstream of the inlet filters. General electric estimates theses
performance curves with respect to the design point and maximum speed as
shown below in table (2-1).
Table (2-1) GE-Design Parameters

Figure 2.1 Effect of Compressor Inlet Temperature on Gas Turbine Performance [15]
Donald and Icksoo (2003)[16] presented the various types of turbine inlet
cooling applicable to small to mid-size turbines .These have been described
along with their comparative benefits. The greatest benefit was shown to be
obtainable from an exhaust heat-powered ammonia absorption cycle. An
ammonia absorption cycle was especially designed for this application. A
300-refrigeration ton aqua ammonia refrigeration unit is required to cool the
inlet of a (5 MW) gas turbine from (35°C to 5°C). This cooling will increase
the power output by 1 MW. The added power was at a marginal efficiency of
39%, compared to 29% for the base turbine power. The cooling option is
listed in table (2-2).
Table (2-2) Turbine Inlet Cooling Options
4.7 MWe Simple Brayton Cycle - 30% efficiency at ISO
Hameed (2004)[17] concluded that water injection in the air intake is

strongly effecting the performance parameters of the two-shaft gas turbine
cycle (GT-85) . the power output has been increased up to (23.15%) for
simple cycle and the thermal efficiency is higher than that of normal cycle by
(29%).
[18]
Benjalool (2006) concluded that, in September, the range of ambient
temperature in the Nafoora oil field varies typically between (29-36 °C). The
temperature variation leads to change the maximum engine power output
from (5.1 MW) to (4.85 MW).
[19]
Tony Giampaolo (2006) concluded that at a constant gas generator
speed, and ambient temperature decreases, turbine inlet temperature will be
decreased slightly, and power output will be increased significantly, fig.
(2.2).This increase in gas horsepower results from the increase in compressor
pressure ratio and aerodynamic loading. Therefore, the control must protect
the gas turbine on cold days from overloading the compressor airfoils and
over-pressurizing the compressor cases. Sensing ambient inlet temperature
helps insure that engine internal pressures are not exceeded, and sensing
turbine inlet temperature insures that the maximum allowable turbine
temperatures are not exceeded. Sensing gas generator speed enables the
control to accelerate through any critical speed points (gas turbines are
typically flexible shaft machines and, therefore, have a low critical speed).
Figure 2.2 Temperature-Power-Speed Interrelationships
Kuamit (2006) [20] concluded that the effect of compressor inlet temperature
has an important role on the power output as shown in fig.(2.3). It may be
seen that the power out put is influenced by compressor inlet temperature due
to the change of air density and compressor work .Since a lower compressor
inlet temperature leads to a higher air density and a lower compressor work
that in turn gives a higher gas turbine output.
160
150
Output Power, (MW) 140
130
120
110
100
270 290 310 330
260 280 300 320 340
Inlet Temp, (K)
Figure 2.3 Net Output Power Versus Inlet Temperature for Gas Cycle
2.3 Summary and Motivation

From the review of previous works it is obvious that industrial gas turbines
performance is different from turbine to turbine. It depends on the type and
what full performance at ISO conditions .Also, what equipment that used to
improve the performance. Clearly, the performance is not only affected by
compressor inlet temperature, but also by other parameter such as relative
humidity, inlet pressure, maximum temperature in the cycle, and speed of the
shaft. However, operating at constant speed has constant volumetric flow rate.
Since the specific volume of air is directly proportional to temperature, cooler
air has a higher mass flow rate. It generates more power in the turbine. Cooler
air also requires less energy to be compressed to the same pressure as warmer
air. Thus, gas turbines generate higher power output when incoming air is
cooler. A gas turbine inlet air cooling system is a good option for applications
where electricity prices increase during the warm months. The power output
increases by decreasing the compressor inlet temperature of the incoming air.
The aim of this work is to study the approach used in the enhancement of
gas turbine performance by making the compressor inlet temperature supplied
to the gas turbine closed to ISO conditions. This was achieved by building a
cooling system for entering air to the compressor consisting of air cooled heat
exchanger and water supply system. In this regard, a theoretical and
experimental study for both air cooled heat exchanger and gas turbine engine
will be conducted.
A supporting computer program to simulate a new technique of heat
exchanger design has been developed. In this model, heat exchanger was
described in two directions, the height and depth to form horizontal slices
which will described later. A computer program prepared for this purpose has
the ability to analyze heat exchanger performance for any slice to be located
in two heat exchanger dimension. The heat exchanger type used was a type of
air cooled heat exchanger (finned-tube surfaces, flat tubes, continuous fins). It
is part of cooling system accommodating different components like valves,
pipe fittings, supply pump, and two reservoirs (hot reservoir and cold
reservoir).
CHAPTER THREE
EXPERIMENTAL
WORK
Chapter Three…………………………………………………………Experimental Work
3.1 Test Rig for Heat Exchanger

The test rig layout was built as shown in Figure (3.1). It consists of inlet air
cooling system having air cooled heat exchanger, tank, and water circulation
system, pump and control panel. The water circulation system is a
modification of an existing laboratory system, which had already built by
Tarrad and Mohammed (2006) [21].
3.1.1 Heat Exchanger
The test section is made of a compact heat exchanger which is of 19
80Chevette radiator type using, Cross-flow exchanger with one flow mixed.
Edges of flat vertical tubes, having dimensions of (55 cm) length,(3.5 cm)
depth and (37 cm) height, heat exchanger geometry is illustrated in table
(3.1). The Compact heat exchanger configuration is shown in Fig. (3.2). The
water flows in the tubes in cross direction to the air flowing normal to the
tubes. Thermometers are connected to the heat exchanger. The gauges are
fixed in the specially prepared pockets mounted on the required locations.
3.1.2 Water Supplying System

The cold water is supplied by a constant tank head of (200 liters) capacity.
The water is pumped by a single stage centrifugal pump from the tank
through the test section, and then it returns back to the tank. The water in the
hot tank is heated by four electrical heaters, which have a total heating
electrical power of (12 kW). The four heaters are fixed in the same level at
150 mm from the bottom of the hot tank separated at (90◦) apart. The hot tank
is opened in cold tank by gating valve which be found in the pipe that linked
the two tanks, as shown in Fig. (3.1). This arrangement of cold and hot tanks
enable as to control manually the temperature in the tank .It is will help in
providing a good control of the water temperature during tests. The mixing of
water has been accomplished in the cold tank to obtain the required
temperature. A piece of ice was immersed into cold tank so that the mixture
becomes homogenous.
Table (3.1) Heat Exchanger Geometry

Parameter Dimension
Core Length (L) 550 mm
Depth (D) 35 mm
Height (H) 370 mm
No.of Tubes 110
No.of tube/row 55
No.of fins/ tube 256
Normal Distance (XT) 9.92 mm

Longitudinal Distance (XL) 20.46 mm
Fin Pitch (Pf) 1.46 mm
Length (Lf) 7.52 mm
Depth (Df) 15.88 mm
Thick (Tf) 0.24 mm
Tube Height (Ht) 2.4 mm
Depth (Dt) 15.88 mm
Thick (Tt) 0.28 mm
A special transparent glass tube level is fixed on the outer shell of the tanks
in order to monitor the water level. Temperature gauge (thermometer) is
connected to the shell of tank to monitor the water temperature in the tank
during tests. Both hot and cold water flow is controlled by gate valves and the
flow is measured by using a vertical variable area rotameters. Piping system
was made of carbon steel metal, insulated by glass wool to minimize the heat
loss.
3.1.3 Measuring Instrumentation

The parameters which are to be measured during the test as follow:
(1) The inlet and outlet temperatures of the heat exchanger.
(2) The air flow rate across the heat exchanger.
(3) The water flow rate of the tube side.
Thermometers:
Thermocouples having a range of (0 ◦C – 120 ◦C), are used to measure the
temperatures at inlet and outlet of heat exchanger. The accuracy rang is about
(0.02).
Pressure Gauges:
Two pointer pressure gauges installed on both sides of heat exchanger to
measure the pressure of the water and have a range of (0 – 2.5 bar), which are
connected to the heat exchanger the accuracy rang about (0.03).
Rotameters :
Two vertical variable area rotameters are used to measure the flow rates of
the water. A rotameter of (200 – 3000) L/h range is used the accuracy rang
about (0.02).
Pitot Tube:
Pitot tube is located at end of air flow duct is used to measure air flow rates
by calculating pressure difference for two points.
3.1.4 The Electrical Board

The electrical board contains the main circuit breaker and other secondary
switches, supplying power to the whole system components of the test rig.
The board consists of an electrical contactor of (4×16 Amp), which is
connected to a thermostat and four heaters. This contactor is controlled and
receives the electrical signal from the thermostat switching on and off the
electricity to the four heaters. There are four separate switches each of which
controls one heater. In addition for safety, there is a switch controling the
operation of the contactor (i.e., controls the operation of the four heaters and
the thermometer), Tarrad and Mohmmed [21].
3.1.5 Air Circulation System
The air was supplied to the test heat exchanger through a fan. A forced
draught arrangement was selected for the test object by variable fan speed.
Three volumetric flow rate was prepared of capacity of (2000) cfm ,(1000
cfm) and (500 cfm) .The fan was close enough to the test section avoiding
leakage of air to the surrounding. The air volumetric flow rate is measured by
using (Pitot-Tube) .The pressure drop was calculated for two points through
air flow duct.
Heat Exchanger
Duct T
Fan P
P T
Rotameter
Rotameter
By Pass
Valve
Hot Tank Cold Tank

Valve
Heaters Ice
Pump
Valve
Figure (3.1a) Schematic Diagram of the Built Rig (Heat Exchanger)

Fan
Cold Tank
Figure (3.1b) Configuration of the Built Rig (Heat Exchanger)
Pitot-Tube
Rotameter
Heat
Exchanger Gas
Turbine
Hot
Tank
Figure (3.1c) Configuration of the Test Rig (Inlet Cooling System)

Preparing to Gas Turbine
XL
Dt
XT
Ht
Figuer (3.2.a) Top View of Heat Exchanger Geometry
Pf
Lf
H
Figure (3.2.b) Front View of Heat Exchanger Geometry

3.2 Experimental Setup

A schematic diagram of the experimental setup is shown in Figure (3.3).
The test loop was designed to allow easy control parameters such as upstream
air flow rate to heat exchanger, and compressor inlet temperature to gas
turbine. As mentioned in the previous section, the loop consists of the heat
exchanger set prior to gas turbine apposite inlet box. To achieve this it is
required building up the main experimental rig with measuring
instrumentations obtaining the suitable circumstances regarding air dry bulb
temperatures, and flow rate. The air leaving the heat exchanger is fed directly
to the compressor intake of the gas turbine engine.
3.3 Gas Turbine

The chosen test engine for this present work is a two-shaft gas turbine type
(GT-85) of 5 kW two shaft machine for industrial drive (Pumps,
Compressors).The design strategy of a gas turbine unit is divided into two
fields. These are; design information and performance information. Design
information such as the compressor whether it is a centrifugal or axial flow,
pressure ratio, the number of fuel nozzle in combustion chamber, a single
shaft or two shaft. The performance information such as output power, heat
rate, exhaust flow, exhaust temperatures. GT-85 performance parameter
measurements have been obtained over variable gas generator speed. The
speed variation is accomplished by manual fuel flow control valve. The
measuring parameters obtained for a particular gas generator speed (N1) are,
Vf,P2,T1,T2,T3,P3,T4,P4,T5,N2.
Combustor
Rotameters
Duct
Ambient
Air
Heat Exchanger
LP.Turbine
HP.Turbine
Compressor
Dynomometer
Cold Hot
Tank Tank
Hot Tank
Cold Tank
Valve Valve
Pump
Figure (3.3) Schematic Diagram of the Test Rig (Overall)

3.3.1 Design Information

Compressor:
• Centrifugal flow
• Pressure ratio , 2:1
Combustion:
• Annular combustion, single chamber
• Liquid fuel capability
Turbine:
• High Pressure turbine 1 stage , 1.69:1 expansion ratio
• Low Pressure turbine 1 stage 1.18:1 expansion ratio
Package:
• Gas Generator, Power Turbine and auxiliary system mounted on a
single base plate
• Control system (instrumentation, sensors ,electronic panel,
mechanical regulation) to monitor temperature and pressure
3.3. 2 Performance design
• Power turbine output: 5 KW
• Maximum cycle temperature: 750 (°C)
• Maximum Gas generator speed : 90000 RPM
• Maximum Power turbine speed: 35000 RPM
The performance power, fuel consumption, temperatures, shaft speeds... etc.
of a gas turbine engine is crucially dependent upon its inlet and exit
conditions. The environmental envelop is impartment item for any gas turbine
plant performance.
3.4 Operating Principles
A gas turbine works in the following way:
• It aspirates air from the surrounding environment
• It compresses it to a higher pressure
• It increases the energy level of compressed air by the addition of fuel gas
which undergoes combustion in a combustion chamber

• It directs high pressure and high temperature air to a turbine section, which
converts thermal energy into mechanical energy allowing shaft to revolve.
This serves on one hand, to supply useful energy to the driven machine,
coupled to the machine by means of a coupling and, on the other hand, to
supply energy necessary for air compression, which takes place in a
compressor connected directly with the turbine section itself.
• The remaining energy is supplying through power turbine, finally
• Gas turbine sensors are designed to withstand the vibration and high
temperatures found in these engines ,Watlow (2001) [22].
3.5 Main Component Parts of Gas Turbine
3.5.1 Gas Generator:
The gas generator consists of a centrifugal compressor; a combustion
chamber and a radial flow turbine as shown in Fig. (3.3).Air enters the
centrifugal compressor through an intake silencer and a bell mouth air flow-
meter. The outlet of the compressor is directed towards a vertically oriented
combustion chamber which in turn is connected to the compressor turbine.
The compressor and turbine run at a maximum speed of 90000 RPM. Such a
compressor speed can achieve a compression ratio of 2:1 for this particular
compressor design. The speed of the compressor and turbine is measured by
means of an opto-electronic technique.
3.5.1.1 Centrifugal Compressor :
The centrifugal compressor draws in air at the center or the eye of the
impeller and accelerates it around and outward. It consists of an impeller, a
diffuser and compressor manifold. The diffuser is bolted to the manifold, and
often the entire assembly is referred to as the diffuser. The impeller may be
either single entry or dual entry. The principal differences between a single
entry and the dual are the size of the impeller and the ducting arrangement.
The single entry impeller permits ducting directly to the inducer vanes, as
opposed to the more complicated ducting needed to reach the rear side of the
dual-entry type .Although it is slightly more efficient in receiving air, the
single-entry impellers must be of a greater diameter to provide sufficient air.
The compressor draws in air at the hub of the impeller and accelerates it
radially outward by centrifugal force through the impeller. It leaves the
impeller at high speed and low pressure flowing through the diffuser.
The diffuser converts the high speed, low–pressure air to low-speed, high-
pressure air. The compressor manifold diverts the low-speed, high-pressure
air from the diffuser into the combustion chamber. In this design, the
manifold has one outlet port for each combustion chamber. The outlet ports
are bolted to an outlet elbow on the manifold. The outlet ports ensure that the
same amount of air is delivered to each combustion chamber. The outlet
elbows change the airflow from radial to axial flow. The diffusion process is
completed after the turn .Each elbow contains from two to four turning vanes
that perform the turning process and reduce air pressure losses by providing a
smooth turning surface.
3.5.1.2 Combustion Chamber:
In a gas turbine, the hydrocarbon fuel is burnt in the combustion chamber
as a continuous process at essentially constant pressure. The combustion
system of the (GT- 85) consists mainly of two components: the swirl unit
incorporating a spray nozzle and the combustion chamber. The swirl unit
produces a swirling air flow which mixes with the finely atomized fuel
sprayed from the nozzle. The air/fuel mixture issuing from the swirl generator
is fed into the combustion chamber as an expanding swirling flow. Schematic
drawing Fig.(3.4), shows the flow issuing from swirl generator into the
combustion chamber and the subsequent flow patterns. As it will be seen from
the figure, the flow initially on entering the combustion chamber should form
a toroidar vortex. This vortex being formed as a result of the expanding swirl
flow and the air entry through the primary holes. Combustion takes place here
under an approximately stoichiometric air/fuel ratio, i.e., A/F =15:1. The

second row of holes, defined as the secondary zone admits more air to cool
the combustion products and gives an overall A/F at this point of about 35:1
The dilution zone contains larger holes than any of the preceding sections and
admits a larger quantity of air producing an exit gas flow with an overall a/f
ratio of approximately 70:1 .For all sections in the combustion chamber,
series of small holes is provided around the circumference of the combustion
chamber. These holes provide a cooling flow for the walls and maintain the
wall temperature within the safe operating temperature.
3.5.1.3 Gas Generator Turbine:
A radial flow turbine consists essentially of a stationary casing containing
a rotating impeller which is rotated as a result of the high velocity flow
leaving the stationary nozzles. The function of the casing is to accelerate the
flow smoothly producing uniform high velocity to the impeller tip. The
turbine impeller is of radial vane type. Both the compressor and generator
turbine run at the maximum speed of 90000 RPM.
3.5.2 Power Turbine:
The hot gas issuing from the exhaust of the gas generator turbine is passed
through a flexible circular duct to the inlet of the power turbine. The power
turbine is larger than the gas generator turbine and is of inward radial flow
design. The turbine operates at a maximum speed of 35000 RPM .The
maximum power output is (5 kW) with an inlet temperature of 700C and a
speed of 35000 RPM .The power turbine is directly coupled to the eddy-
current brake by means of a special high speed coupling .The speed of the
power turbine is measured by electromagnetic sensor and a digital frequency
meter.
Fig.(3.4) Schematic Arrangement for Gas Turbine (GT-85)
3.5.3 Fuel System:

The gas turbine utilizes kerosene as the operating fuel system. During the
starting sequence, methylated alcohol (starting fuel) is ignited by the ignition
system to provide a large flame in front of for the initiation of the kerosene
combustion process. The fuel is pumped by an electrically driven gear pump
at a pressure of 6 bars. The fuel flow is regulated by a manuall valve located
on the control panel. Fuel flow rate is measured by a ‘Rotometer’. For safety
operating process, a solenoid valve is incorporated in the fuel feed piping
system to the combustion chamber. This will automatically stop the supply of
fuel in the event of malfunction.
3.5.4 Oil Lubricating System:
As mentioned before, the gas generator turbine and the power turbine run
at very high speed. Therefore, a lubricating system, Fig.(3.4) is incorporated
to ensure a safe running to turbines . Oil pressure of minimum 3 bars should
be provided to lubricate the journal bearings by the gear type oil pump. Oil
temperature and pressure are automatically monitored and the gas turbine will
be shutdown in case of a non-safe running.
3.5.5 Starting System:
In order to start the gas turbine, it is required to drive the compressor to a
certain speed to achieve the required air flow rate to the combustion chamber,
so that the starting fuel (methylated alcohol) can be ignited. This is done by
blowing air through the compressor inlet duct using three electrical fans.
The flow rate of air supplied by these fans is regulated by a gate valve. High
energy spark ignition system is used to ignite the starting fuel. The sustained
flame generated by starting fuel burning will raise the flow gases temperature
to the required temperature to ignite the kerosene fuel. Consequently, self
sustained gas generator running is obtained and the air blowing fans will be
switched off Gilbert and Gordon LTD (1978) [23].
3.6 Dimensionless and Parameter Groups
The importance of dimensionless, referred and scaling parameter groups to
all aspects of gas turbine performance cannot be over emphasized.
Understanding and remembering the form of the parameter group
relationships allows judgments concerning the performance effects of
changing ambient conditions, scaling an engine, a change of working fluid,
see Appendix C (Engine Parameter Groups)
The parameter group for mass flow is then a function of , Philip (2004) [24]:
1. Ambient temperature
2. Ambient pressure
3. Engine rotational speed
4. Engine diameter (scale factor)
5. Gas constant of working fluid
7. Gamma for working fluid
8. Viscosity of working fluid
in order to rationalize the performance data obtained from the gas turbine
engine operating with a wide range of inlet conditions, it is necessary to
reduce the data to known standard intake conditions. The correction formula
used to achieve this rationalization can be derived by a non-dimensional
analysis of the components in the gas turbine cycle. Non-dimensional analysis
leads to various dimensionless parameters which are based on the dimension's
mass (M) , length (L) , and time (T) . Based on these elements, one can obtain
various independent parameters. These parameters will lead to form various
dimensionless groups.
By using non-dimensional groups as applied to the following basic equation
for compressor non-dimensional analysis, Cohen,et al. (1996) [25]:
f ( Nc, ma , P1 , P2 , R × T1, R × T2 ) =constant ……………….…….…..(3-1)
3.6.1 Corrected Compressor Data

From the equations are illustrated in Appendix (C), and that referring to
equation (3-1) for compressor non-dimensional analysis, and since :-
Ncc Nc
= ……………………………………………………………...…(3-2)
Ts T1
. .
M a Ta M ac Ts
= ……………………………………………………..…(3-3)
Pa Ps
T2 T2c
= …………………………………………………………………(3-4)
Ta Ts
where:
Ts= 15 (°C) =288.16 (k)
Ps= 1.0133 bar
For other values of Ta different from the standard value a correction should be
made as follows:
288.16
N cc = N c ………………………………………………….….….(3-5)
Ta
.
. 1.0133 M a Ta
M ac = × ……………………………………………..…..(3-6)
288.16 Pa
⎛ 288.16 ⎞
T2c = ⎜⎜ ⎟⎟T2 ………………………………………………………….(3-7)
⎝ Ta ⎠
3.6.2 Corrected Basic Data

Corrected basic data for the effects of variation in both, ambient pressure
and temperature should be done. In the case of the actual test data, the
pressure measurements taken are all static values, whilst the temperature
measurements will be essentially total values. For the formula below, no
differentiation between total and static is made because of the small
differences will be small between the total and the static value of pressure or
temperature. The following formulas are the corrected basic data, which are
suggested by the manufacturer.
−
1. Ta = Ta ( o C ) + 273.16 K
Barometer Re ading (mbar )
2. Pa = bar
1000
− 288.16
3. T1C = (T1 + 273.16)( ) K
Ta
4. P1 = Pa − 97.9 Χ10 −6 (ΔP) bar

−
5. P2c = P2 + Pa bar
− 288.16
6. T2 c = (T2 + 273.16)( ) K
Ta
−
7. P3C = P3 + Pa bar
− 288.16
8. T3c = [T3 + 273.16]( ) K
Ta
−
9. P4 c = P4 + Pa bar
− 288.16
10 T4 c = (T4 + 273.16)( ) K
Ta
− 288.16
11. T5c = (T5 + 273.16)( ) K
Ta
12. P5c = P4 c − 0.001333(ΔP4 5 ) bar
3.6.3 Corrected Derived Data

The measured variables during the tests on the (GT-85) are presented in
tables shown in Appendix (A).When the temperature and pressure at each
point around the cycle, the following formulas may be used for the
performance calculation in the experiments.
The following represents the data reduction method applied in the present
work.
1. Compression Ratio ( rc )
P2c
rc = …………………………………………………………………..(3-8)
P1c
2. Compressor Isentropic Efficiency (η c )
T1c ( γ −1) γ
ηc = (rc − 1) × 100 0 0 ……………………………….………….(3-9)
T2 c − T1c
3. Air Mass Flow Rate (kg/s)
T1 ΔP
m& a = 0.3005
P1 P1
Ta
m& a c = m& a( )
288.16 ............................................................................(3-10)
where : ΔP in mm wg
T1 in K
4. Fuel Flow Rate (kg/s)
v f × 10 −3 288.16
m& fc = ρ f …………………………………..……….…(3-11)
3600 Ta
where:
ρ f = ρ w ∗ sg
The specific gravity of the fuel (sg) is 0.774
5. Air/Fuel Ratio (A/F)
A/F = m& ac m& fc ……………………………………………………………(3-12)
6. Combustion Chamber Temperature Rise (K)

−
43740 − 10 T2 c
ΔTcct = +2 ………………………………………..…….(3-13)
1.0078 A F + 6.6
−
Where: T2C = T2 c − 273.16
7. Combustion Chamber Pressure Loss (٪)
P2 c − P3c
ΔPcc = ( ) × 100 ……………………………………………….…..(3-14)
P2 c
8. Gas Generator Turbine Expansion Ratio
P3c
rt1 = …………………………………………………………………(3-15)
P4c
9. Theoretical Power Input to Compressor ( w& )
W& C = m& aCpa(T2 c − T1c ) ……………………………………………………(3-16)

Where: cpa = 1000 J kgK
10. Theoretical Power Output Of Gas Generator Turbine ( w& )
W& t 1 = (m& ac + m& fc )Cp g (T3c − T4c ) ……………………………………………(3-17)
where: cp g = 1150 J kgK
11. Compressor Mechanical Efficiency (η mc )
2 w& c
η mc = ( ) × 100 ………………………………………………………(3-18)
w& c + wt′1
12. Gas Generator Turbine Mechanical Efficiency (η mt1 )
W& C + W& t1
η mt1 = ( ) × 100 …………………………………………….….……(3-19)
2W&t1
13. Compressor Overall Efficiency (η oc )
η mc
η oc = η c × ……………………………………………………..………(3-20)
100
14. Power Turbine Expansion Ratio

P4 c
r12 = …………………………………………………………………(3-21)
P5c
15. Power Turbine Isentropic Efficiency (η12 )
T4C − T5C
η12 = × 100 ………………………………………………(3-22)
1 (γ −1) γ
T4C [1 − ( ) ]
r12
where: γ = 1.33
16. Power Turbine Power Output ( w& )
2πN 2τ Ta
W& t 2c = ……………………………………………………(3-23)
60 288.16
Where: N 2 power turbine speed (RPM) and τ is the torque in (N.m)
17. Power Turbine Theoretical Power Output ( w& )
W& t 2 = (m& ac + m& fc )Cp g (T4c − T5c ) ………………………………….………….(3-24)
18. Power Turbine Mechanical Efficiency (η mt 2 )
W& t 2 c
η mt 2 = ( ) × 100 …………………………………………………………..(3-25)
W& t 2
19. Power Turbine Overall Efficiency (η ot 2 )
η mt 2
η ot 2 = η t 2 × …………………………………………………………….(3-26)
100
20. Overall Thermal Efficiency (η th )
W& t 2 c
η th = ( ) × 100 …………………………………………………..…(3-27)
H .V × m& fc
Where: H.V= L.C.V × 4.1868 kJ kg for kerosene used in the tests (GT-85), and
L.C.V= 10300 Kcal kg the lower calorific value of the fuel used, Gilbert and
Gordon LTD [23].
21. Specific Fuel Consumption ( kg Kw.s )
m& fc
sfc = ( ) × 1000 ……………………………………………………..…..(3-28)
W&t 2c
22. Heat Consumption (kW)

Heat Consumption = fuel mass flow * heating value
= mf (kg) × H.V (kW/kg)……………………………...(3-29)
23. Heat Rate
Heat Rate = specific fuel consumption × heating value
= sfc (kg/kW) × H.V (kW/kg)………………………………….(3-30)
3.7 Experimental Work Procedure:

Since the main object of present work is the enhancement of gas turbine
performance by improved intake air temperature therefore, the test procedure
has been separated to classify for heat exchanger once and gas turbine again
another time. This was because of the following reasons :
1. Parameters effected on the design and performance calculations for heat
exchanger are needed high air flow rate values, which are negatively effect on
gas turbine performance.
2. The high inlet velocity into compressor may be increasing pressure drop for
what of which negatively effect on gas turbine performance.
3. Difficulty to make sure of compressor inlet temperature at desired value for
present work requirements.
3.8 Test Procedure:
Two types of experiments were performed:
1. Measurements for the heat exchanger:
On commencing the tests, all valves around the constructed rig are closed
without water circulation through the heat exchanger. For the chilled water
circulation tests, a piece of ice was added to the water tank continuously to
keep a constant feeding temperature to the test heat exchanger section. The
hot water tests were conducted by switching on the immersion heaters of the
hot tank and controlling the temperature by setting the thermostat at the
required water temperature. A check should be made to the air supplying fan
prior to the experiments.
After completing checking above steps, the test process begins by
switching on the circuit breaker that supplies power to the system. The water
pump will start and open the gate valve for the cold tank that controls the flow
rate of water which circulates on the tube side of the heat exchanger. At
particular time, when the temperature inside the cold tank is reaching (10°C),
the operation conditions for heat exchanger were recorded when the air flow
rate was fixed at (2000 cfm).Since the air flow passes through the duct that
connected the heat exchanger to gas turbine, the air flow rate (cfm) can be
measured by using (pitot-tube) fixed at compressor inlet box.
After a few minutes, the gate valve of the hot tank is opened, so that the hot
water is mixed with cold water to increase the temperature gradually until
reaching particular values such as (20°C) , (30°C) , (40°C) and (50°C) .The
process was repeated for other air flow rate such as (1000 cfm) and (500 cfm)
for different circulated water flow rates.The following operating conditions
were measured during the tests for each air flow rate:
• The inlet and exit temperature of water side across the heat exchanger.
• The circulated water flow rate.
• The air temperature on both sides of the heat exchanger.
The experimental data collected for the heat exchanger are listed in
Appendix (A).
2. Measurements for the gas turbine:
The Kerosene fuel is supplying in fuel tank about (20 Lit.), for lubricating
shafts oil (SAE-10) is supplying in oil tank. The gas turbine engine is
connected to a water supplying source to cooling purpose. Starting operation
begins by firing of about (0.3) liter of (methylated alcohol) to ensuring the
appropriate flame for kerosene combustion.
The gas turbine was allowed to operate until it reaches the required
conditions at a particular speed; at this time the engine takes the appropriate
air flow rate .The compressor inlet temperature is fixed at indicated value
such as (15°C) ,(20°C), (25°C) and (30°C) by utilizing from:
• Variation of ambient temperature along the day and season.
• Variation of air exit temperature from heat exchanger.
The time was too long to take the measurement variations of the ambient
temperature (during the season) due to the fact that the temperature gradient
across heat exchanger (Single-Pass Elliptical Tube, two Row Radiator) is
small. It was decided to run the rig for (5 to 10) times at each specified
ambient temperature with different times along the year. When the
compressor inlet temperature is fixed at (15°C),the tests were conducted at
different gas generator speed starting from (45000 RPM) . This speed was
increased to (55000 RPM) by burning more fuel. The data were collected for
each specified speed and compressor inlet temperature. The same procedure
was repeated for other air intake temperature such as (20°C),( 25°C)and
(30°C). At all tests, the ambient temperature was changing from (18°C) to
(30°C).To show the relationship between the gas generator speed ,compressor
inlet temperature and turbine inlet temperature, the turbine inlet temperature
was fixed at a particular value such as (586 °C) and compressor inlet
temperature was taken at different time such as (15 °C) and (22°C).The data
collected during the tests are shown in Appendix (A).
CHAPTER FOURE
Chapter four…………………………………………………………………………Theory
4.1 General
This chapter deals with the mathematical modeling of the core design of
heat exchanger (Length, Depth, Height) corresponding to the intake air box of
gas turbine and mathematical modeling of gas turbine.
The step by step technique will be used to simulate core design of the air
cooled heat exchanger. In this method, the heat exchanger is divided into two
dimensions (Depth, Height) ,as it will be described later.
On other hand, Modeling of the computational program to predicate the
effect of compressor inlet temperature on gas turbine performance by using
the non-dimension method was also considered.
4.2 Heat Exchanger Thermal Design:
4.2.1 A Comprehensive Design Procedure
The methodology of arriving at an optimum heat exchanger design is a
complex one. Not only because of the arithmetic involved, but it is more
particularly because of the many qualitative judgments that must be
introduced. The design procedure in a schematic presentation is shown in Fig
(4.1) Kays and London (1984) [26].
The design theory procedure can be set-up on a computer program. The
inputs to the design theory procedure include:
1. Surface Characteristics: flattened tubes, surfaces with flow normal to banks
of smooth tubes, Finned-tube surfaces, normal distance (XT), longitudinal
distance (XL) …etc.
2. Problem Specifications: The problem statement may specify a
consideration of different exchangers. For instance, periodic-flow and direct-
transfer types. Like cross flow, inline tubes, both fluids unmixed flow …etc.
3. Physical Properties: Some options may be allowed in the physical
properties the matrix material to be used in a periodic flow type exchanger.
Surface
Characteristics
Design
Problem Theory Physical
Specifications Procedure Properties
Optional
Solutions
Evaluation Evaluation Optimum

Criteria Procedure Solution
Figure 4.1 Methodology of Heat Exchanger Design
4. Optional Solutions: optional solutions may represent an estimate of what a

competitor may offer, others may represent customer's suggestions. For
example, what are exit parameters from heat exchanger, heat transfer
coefficient, heat load …etc.
5. Evaluation Procedure: The theoretical design must be furnished with

evolutions criteria to obtain optimum solutions for design theory.
4.2.2 Numerical Modeling of Cross Flow Compact Heat Exchanger

In order to develop a numerical model with the predictive capability for
various design parameters of the heat exchanger, step by step method with
two dimensions was employed in this study. Each tube row was divided into a
number of horizontal slices occupying the total length of the heat exchanger
and for air side the exit of one row considering inlet to next row as shown in
Fig. (4.2).Step by step method enables us to take into account the significant
air temperature increase as well as the local variations of the properties and
the heat transfer coefficient. Forms of the mass and the energy conservation
equations were derived for two dimensional grid systems.
4.2.2.1 Grid System
In the present study the following assumptions were assumed :
1. Homogenous temperature distribution of air all over the frontal face area of
the heat exchanger and hence for each slice.
2. Uniform mass flow distribution for both stream sides of heat exchanger.
3. The exit air condition for each row represents a mean value for all of the
slices of the considered row. This will be the inlet condition for the next row.
4. The inlet air velocity for each row was assumed to be uniform represented
by a mean representative value.
5. The water temperature variations between the rows were also assumed to
be negligible.
6. The air velocity stream and maximum air velocity difference assumed to
be negligible.
In the present study the design requirements for the theoretical model are:
1. The velocity in tube side (vw)
2. The velocity of air side (va.)
Figure 4.2 Step by Step method with two Directions

3. The air temperature difference (∆Ta) per row

4. The air mass flow for each slice.
Therefore only a single fin tube of one horizontal slice assembly was
explained as shown in Fig. (4.3a) and the heat exchanger performance for any
locate can be calculated the performance for each slice and calculating
performance for each row Fig.(4.3b). The nodal points for the calculation of
the variables of the air and the coolant were defined as illustrated in Fig.
(4.3c). Nodal points for air temperature were assigned on the east and the
west sides of the control volume and the nodal points for the coolant were
assigned on the north and the south sides of the control volume. The nodes
were evenly distributed in two directions Ni × Nj. The heat transfer
coefficient and heat load were calculated at each control volume.
Twi Water Flow

Tao
Lf
Slice 1
Dt
Tar2
Tar1
Slice 2
Tai
Two
Air Flow
Figure (4.3a) Slice for Figure (4.3b) Exit of one row

inlet single Tube inlet to next row
J=1 2 ………………Nr
I=1
N-1.………………….……2
Figure (4.3c) Nodal Points Distributions

with two directions
4.2.2.2 Physical Characteristics of Heat Exchanger
From the selected velocity of the tube side of the water stream and the
known tube cross section dimension, the total number of tubes of the heat
exchanger can be calculated from:
.
Vw
(Nt) = [ ] ………………………………………………….(4-1)
N r × v w × Acw
This value will be used for the estimation of the length and depth of the heat
exchanger as:
L = X T × ( N t + 1) ………………………………………………….(4-2)
D = [ X L × ( Nr − 1)] + Dt ………………………………………………….(4-3)
4.2.2.3 Mass Conservation

Mass conservation of the water flow through the tube is simply
. .
Σ m in −Σ m out = 0 ………………………………………………….(4-4)
and the mass conservation equation for the water at each slice can be written
as:
. .
m w(i+1,j)= m w(i,j) ………………………..…..………………………….(4-5)
In case of the heat exchangers with plain continuous fins, the mass flow rate
in the air flow direction can be calculated by the following equation.
.
. .
m a(j)= ρ a ( j ) × V a ( j ) ……………………………………………………...(4-6)
4.2.2.4 Log-Mean Temperature Difference

To estimate the true mean temperature difference ( ΔTm ) between the two
fluids Fig. (4.4) shows the possible flow direction of both streams in compact
heat exchanger.The following relations may be used for the estimation of the
logarithmic mean temperature difference according to counter flow directions,
Smith(1997) [26]:
(Ta (i, j ) − Tw (i, j + 1)) − (Ta (i + 1, j ) − Tw (i, j ))

LMTD = ………………………….(4-7)
(Ta (i, j ) − Tw (i, j + 1))
ln
(Ta (i + 1, j ) − Tw (i, j ))
Ta,(i,j)
∆Tm
Tw,(i,j+1) Ta,(i+1,j)
∆Tm
Tw,(i,j)
0 Atotal
area
Figure 4.4 The Mean Temperature Difference Along a Single Pass
The actual temperature difference of a cross flow compact heat exchanger is

obtained by applying a correction factor (F) to the (LMTD) value as, Hewitt
(1998) [27]:
ΔTm = F × LMTD …………………………………………………….(4-8)
where:
( R 2 + 1) ln (1 − S ) (1 − RS )
F= ……………………………………….(4-8a)
2 − S[ R + 1 − ( R 2 + 1) ]
( R − 1) ln[
2 − S [ R + 1 + ( R 2 + 1) ]
(Th (i, j ) − Th (i + 1, j ))
R= ……………………………………….(4-8b)
(Tc (i. j + 1) − Tc (i, j ))
(Tc (i, j + 1) − Tc (i, j ))

S= ……………………………………….(4-8c)
(Th (i, j ) − Tc (i, j ))
4.2.2.5 Heat Load

The heat load passes through a control volume on the water side is:
.
Q (i,j)= m (i,j) × Cp (i,j) × ΔT (i,j) …………………………………..…….(4-9)
It can be expressed with the overall heat transfer coefficient, U(i,j), as follows:
Q(i,j)= Uo (i,j) × A × (i,j) × ΔTm (i,j) ……………………………...…….(4-10)

The above equation is applying for each slices per one row.
4.2.2.6 Overall Heat – Transfer Coefficient (Uo):

The local overall heat transfer coefficient for each slice based on the outside tube
area can be written as follows , Holman(1989) [28]:
1
U o (i, j ) = ....(4 − 11)
1 tt 1 1
[( )+( )+( )+( )]
ha (i, j ) × η o K t ( Ain Aout ) hw (i, j ) × ( Ai n Ao ut ) h f × ( Ai n Ao ut )
4.2.2.7 Forced Convection Heat Transfer Coefficient Inside Tube:

Numerous relations have been proposed for predicting fully developed
turbulent flow in tubes. The popular Dittus-Boelter equation, Dittus-Boelter
(1930) [30] is usually given in the form:
k
h w = 0 . 023 Re 0.8 Pr n ( ) ………………………………………... (4-12)
d hw
and cross flow area for water side (rectangular tube with semi circular ends ):
[ ]
Ac w = [( H t − Tt ) × ( Dt − H t )] + ( H t − Tt ) 2 × π ……………………………..(4-13)
also
ρud h w
Re = ……………………………………..…………………….(4-14)
μ
4 Acw
dh = ……………………………………..………………….….(4-15)
λt
μCp
Pr = ……………………………………..…………………....….(4-16)
k
where the ranges of Re and Pr are:

6000 ≤ Re ≤ 10 7
0.5 ≤ Pr ≤ 120
[31]
where the coefficient (0.023) is recommended by McAdams (1954) in
place of (0.0243) originally given by Dittus-Boelter.
Also,
n= 0.4 for heating
n= 0.3 for cooling
4.2.2.8 Forced Convection Heat Transfer Coefficient for Air Side:
The entrance region for the development of the longitudinal velocity profile
and the temperature profile is about 10 times the hydraulic diameter. This
criterion is particularly valid for calculating the time-averaged coefficient for
fluids (air and water) Adrian [32] . There are several empirical relationships for
heat transfer between the duct surface and the fully developed flow, the
analytical form of these relationships is based on exploiting the analogy

between momentum and heat transfer. The popular Dittus-Boelter equation is
also used for fully developed turbulent flow (air side):
k
h a = 0 . 023 Re 0 .8 Pr n ( ) ………………………………………….. (4-17)
d ha
For laminar flow, the Sieder and Tate (1930) [33] correlation can be used.
0.3
⎛ d ha ⎞ k
ha = 1.86(Re Pr )
0 .3
⎜ ⎟
D f ⎠ d ………………………………….……..….….(4-18)
( )
⎝ ha
where cross flow area for air side:

Pf
Ac a = ( )( X T − H t ) ………………………………………………..….(4-19)
2
The hydraulic diameter for the air side:
4 Aca
dha = ……………………………..………………….….(4-20)
λf
λ f =2 Lf + pf
The number of slices (N) depends on the water temperature difference along
the tube bare; by assuming the air mass flow rate across frontal area is divided
equally on the slices (N), therefore the Reynolds number for air side is
represented by:
.
. ma ( j )
ma(i, j ) = …………………………………………………………..(4-21)
N
.
m (i, j )
Ga = a ……………………………………..………………..……. (4-22)
( Aca )
(d h a Ga )
Ra (i, j ) = ………………………………..………………….… (4-23)
μ a (i, j )
By assuming that there is no temperature gradient between the tubes that

share the fins then the fin can be considered to be insulated at the center.
Therefore fin efficiency (ηf) can be calculated as that for the case with an
adiabatic tip, Briggs and Young (1963) [34]:
Lf
[tanh(m × ( ))]
ηf = 2 ………………………………..………………… (4-24)
Lf
(m × ( ))
2
where:
(ha (i, j ) × ( Pf )
m= [ ………………………………..………………..… (4-25)
( K t × Aca )
The overall surface fin efficiency is:
Af
η o = 1 − [( ) × (1 − η f )] ………………………………..………………… (4-26)
A
where:
Af 1
= (4 × L f × D f )( ) ………………………………..……………….. (4-27)
H Pf
Aexp 1
= [((π × H t ) + (2 × ( Dt − H t )) − (2 × T f )]( ) ………..………………… (4-28)
H Pf
A Af Aexp
=( )+( ) ………..…………………………………. ………….. (4-29)
H H H
The log- mean temperature difference and overall heat transfer coefficient is
calculated to obtain the height for one slice as follow:
Q(i, j )
H (i, j ) = …………………………………….(4-30)
(U o (i, j ) × A × F × LMTD (i, j ))
4.2.2.9 Power of Fan:

The pressure drop across heat exchanger can be calculated from the general
pressure drop relationship, London(1983)[35] is most often written in terms of
hydraulic diameter,
2
va Df
ΔP = ( ρ )× f × …………………………………………………..(4-31)
2 d ha
To calculate ΔP, the friction factor ƒ must be known and it can be derived
from the flow solution.The friction factors derived from the Colburn [35] flows
described by eqs. (3.32) for fully developed laminar flow:
64
ƒ= …………………………………………………………………...(4-32)
Ra
For isosceles triangular ducts, Bhatti and Shah(1987)[36] recommend, for
fully-developed turbulent flow:
0.078
ƒ= ……………………………………………………………….(4-33)
( Ra) 0.25
For the power of the fan the equation is:

.
V air Δp
Pfan = ……………………..………………………………….….(4-34)
η fan
And,
. m& air
V air = ……………………..………………………………..…….(3-35)
ρ air
Thus,
Pfan
Pmotor , fan = ……………………..…………………………….….(3-36)
η motor , fan
4.2.2.10 The Computer Program

The computer program was built in this study to establish the thermal
design of the compact heat exchanger incorporating the quick-basic computer
language. The flow chart of the program (CPHE) is shown in appendix
(B).The following procedure describing the calculation technique of the
present model :
1. Input surface characteristics and inlet operation conditions for both fluids.
2. Calculating the cross sectional area of tube side.
3. Choosing the velocity in tubes and input water flow rate V&w
4. Calculating (No. of Tubes / Row) ,Eq.(4-1)
5. Calculating the length and depth of heat exchanger Eq.(4-2) and Eq.(4-3).
6. Calculating the No. of slices from water temperature conditions.
7. Loop (j=1…….j=no. of row)
8. Assume the air exit temperature for first row.
9. Calculating the air mass flow rate for first row, Eq (4-6).
10. Assume the air velocity over tubes.
11. Calculating the height of the heat exchanger.
12. Loop (I=.1……i=no. of slices).
13. Choosing the water temperature difference for each slice.
14. Calculating the heat load for first slice and first row, Eq.(4-9).
15. Assume the air mass flow rate for each slice, Eq.(4-21).
16. Calculating the air exit temperature for first slice.
17. Correct the fluids properties.
18. Calculating the correct heat load for first slice.
19. Calculating the correct air exit temperature for first slice.
20. Calculating the cross sectional area, hydraulic diameter, Reynolds k No.,
Nusselt No, Eq.(4-13) to Eq.(4-20).
21. Calculating the overall heat transfer coefficient, Eq.(4-11).
22. Calculating the height of heat exchanger, Eq.(4-30).
23. Repeat the calculation with the iterated value of air exit temperature until
the error percent calculated from:
(Varible cal. − Varible assu.)
ξ% = is converged to a value within 1 × 10 −3 .hence,
Variable cal.
the variable here is air exit temperature or air velocity over tubes.
24. Repeat process for all slices (Ni).
25. Calculating the mean air exit temperature and check it with assumed value.
26. Repeat the process for all rows (Nj).
27. Calculating heat exchanger performance (heat transfer coefficient for air
side (ha), overall heat transfer coefficient (Uo), heat load)
28. Calculating height of heat exchanger (H).

The step by step method is formulated in this program to establish the
following characteristics and operating conditions of the heat exchanger:
1. Air exit temperature
2. Air mass flow
3. Heat transfer coefficient for both sides
4. Overall heat transfer coefficient
5. Heat load
6. The height of heat exchanger (H)
7. The length of heat exchanger (L)
8. The depth of heat exchanger (D)
9. Number of fins per tube
10. Number of tubes per row
11.In addition, heat exchanger performance can be predicted for any required
point in heat exchanger in two direction (Ni X Nj).
4.3 Gas Turbine
.
A conventional power plant receiving fuel energy (Qadd), producing work ( w )
and rejecting heat to a sink at low temperature (Qrej) is shown in Fig.( 4.5) as
a block diagram.
Figure. 4.5 Basic Gas Turbine Engine

The objective is to achieve the least fuel input for a given work output as this
will be economically beneficial in the operation of the power plant.
Usually, a gas turbine plant operates on ‘open circuit’, with internal
[37]
combustion Horlock(1987) . Air and fuel pass into the compressor and
combustion chamber, respectively, and the combustion products leave the gas
turbine after expansion through the turbine.
4.4 Basic Gas Turbine Cycles

In power plant thermodynamics for high thermal efficiency led us to
emphasis on raising the maximum temperature T3 and lowering the minimum
Temperature T1. Thus, the efficiency will be increased with the ratio (T3/T1).
In a gas turbine plant, this search for high maximum temperatures is limited
by material considerations and cooling of the turbine is required. This is
usually achieved in ‘open’ cooling systems, using some compressor air to
cool the turbine blades and then mixing it with the mainstream flow. In
practical open circuit gas turbine plants with combustion, real gas effects are
present (in particular the changes in specific heats, and their ratio, with
temperature), together with combustion and duct pressure losses.
4.5 A non- Dimensional Analyses of Gas Turbine Performance:

In practical open circuit gas turbine plants with combustion, real gas effects
are present (in particular the changes in specific heats, and their ratio, with
temperature), together with combustion and duct pressure losses. Now some
modifications of the air standard analyses and their graphical presentations for
such open gas turbine plants must be developed, as an introduction to more
complex computational approaches.
[38]
The Hawthorne and Davis(1956) analysis is first generalized for the
[CBT] open circuit plant, with fuel addition for combustion, (ƒ) per unit air
flow, changing the working fluid from air in the compressor to gas products
in the turbine, as indicated in Fig.(4.6).
T 3
Combustion Fuel
4
2
2s 4s (1+ƒ)
5 Gases Products
5s
S
Figure 4.6 (T-s) Diagram for Irreversible Two-Shaft Circuit Simple Plant
Real gas effects are present in this open gas turbine plant; specific heats and
their ratio are functions of ƒ and T, and allowance is also made for pressure
losses.
4.5.1 Component Performance
Before moving on to the air standard analyses of irreversible gas turbine
cycle, need to be define various criteria for the performance of some
components. In addition, to the irreversibilities associated with these
components, pressure losses (Δp) may occur in various parts of the plant (in
the entry and exit ducting, the combustion chamber, and the heat exchanger).
These are usually expressed in terms of non-dimensional pressure loss

coefficients,
Ѕ= Δp/ (p)in ……………………………………………………………(4-37)
where:
(p)in=is the pressure at entry to the duct.
P2 − P3
ΔP23= ………………………………………………………..(4-37a)
P2
P5 − Pa
ΔP5a = (Pa is ambient pressure)………………………….…(4-37b)
Pa
As alternatives to the isentropic efficiencies for the turbomachinery

components, ηT, ηC, which relate the overall enthalpy changes, small-stage or
polytropic efficiencies (ηpT and ηpC) are often used.
The pressure-temperature relationship along an expansion line Fig.(3.6) is
then
P/ Tz = constant ………………………………………………………(4.38)
where:
Zg=γg / [(γg-1) × ηpT ] …………………………………………………..…(4.39)
and the entry and exit temperatures are related by
T4 / T5s =( rT)1/Zg = xt …………………………………………………..(4.40)
Along a compression line,
P/ Tz = constant …………………………………………………….….(4.41)
where:
Za=[γa × ηpC]/ (γa-1) ……………………………………………………...(4.42)
and exit and entry temperatures are related by
T2s / T1 =( rC)1/Za = xc ………………………………………………….(4.43)
4.5.2 Graphical Plot

In graphical interpretation, using isentropic rather than polytropic
efficiencies,Hawthorne and Davis [38] plotted the following non-dimensional
quantities, all against the parameter x = r (γ-1)/γ as follows:-
(i) Non-dimensional compressor work,
Wc= cpa × T1 × (xc-1)/ηc …………………………………………………(4.44)
(ii) NDCW = Wc/cp(T3 – T1) = =(Xc-1)/(ηc × (Ø-1)) ………………….....(4.45)
Non-dimensional turbine work,

WT=(1+ƒ) × cpg × T3 × ηt(1-1/xt) …………………………………………(4.46)
(iii) NDTW = WT/cp (T3 – T1) ==((1+f) × ηt × (1-1/Xt))/((1-1/Ø) × n) .…(4.47)
Non-dimensional overall efficiency,

ηo=NDTW /(H. V × (1+ƒ)) …………………………………...…………(4.48)
where:
Ø=T3/T1 ratio ……………………..……………………………………(4.49)
n= cpa/ cpg ……………………………………………………………(4.50)
4.6 Computer Calculations for Two-Shaft Gas Turbine

The analytical approach outlined above for the two-shaft gas turbine plants
is that used in modem computer codes. However, gas properties, taken from
tables such as those of Keenan and Kaye(1945) [39] as shown in fig. (4.7).The
flow chart of the program (CPTGTP) is illustrated in Appendix [B].
Figure 4.7 Specific Heats and Their Ratios for ‘Real’ Gases-Air and
Products of Combustion
The purpose of the computer calculations is to examine the possibility of
increasing the overall performance of two-shaft gas turbine depending on inlet
conditions only.
4.7 Results and Discussion of Theoretical Calculations
The dimensionless parameter such as overall efficiency, expansion ratio,
and maximum to minimum ratio (Ø) can be used for predicting the effect of
compressor inlet temperature on gas turbine performance. The prediction is
focused on the following concepts:
4.7.1 The effect of compressor inlet temperature on maximum to
minimum ratio (Ø):
One of two operating limits for gas turbine it is the turbine inlet
temperature. It is not often when the engine runs at topping temperature will
produce higher overall efficiency, but it depends on the minimum
temperature. Therefore, wherever the minimum temperature is reduced, the
engine will be at higher efficiency. This is due to the fact that the equilibrium
condition between the compressor power requirement (which increases at
high minimum temperatures) and the power produced by gas generator
turbine (which is not directly influenced by the minimum temperature) will be

satisfied at a lower value. Figures (4.8) to (4.11) show the effect of the Ø on
the overall efficiency for inlet high pressure turbine temperature of
(699°C),(628.5°C),(588°C) and (547.5°C) respectively at expansion ratios of
1.08 and 1.12.It is clear from these figures that for a given expansion ratio the
overall efficiency shows a gradual increase with Ø .Further, the trend shows
a raise in the overall efficiency as the inlet turbine temperature increases for a
given expansion ratio. It is obvious that the increasing percentage varies with
expansion ratio or turbine inlet temperature. When turbine inlet temperature
was (699°C) the increasing percentage of overall efficiency was about (18%)
at expansion ratio (1.08), while the increasing percentage of overall efficiency
fell to (15%) at expansion ratio (1.12).Also, for the turbine inlet temperature
(547.5°C) the increasing percentage of overall efficiency was about (20%) at
expansion ratio (1.08),while the increasing percentage of overall efficiency
was reduced to about (17%) at expansion ratio (1.12). However, there is
relationship between (T3), (T1), and engine speed, at full load. Two shaft
engines will run either at temperature topping or at speed topping. At speed
topping, the engine will not reach its full firing temperature, while at
temperature topping; the engine will not reach its maximum speed.
The effect of the compressor inlet temperature on the overall efficiency is
shown in figures (4.12) and (4.13) for expansion ratios of 1.12 and 1.08
respectively. When reducing the compressor inlet temperature from (30°C) to
(15°C), the overall efficiency shows an increase by (17%) at expansion ratio
(1.12).Also, the overall efficiency shows an increase by (19%) at expansion
ratio (1.08).Noting that the higher the expansion ratio, the higher the overall
efficiency is obtained as shown above.
4.7.2 The effect of compressor inlet temperature on the expansion ratio:

Changes in the minimum temperature have less impact the component
efficiencies than the overall cycle output.Therefor, the impact of minimum
temperature is usually less pronounced for the expansion ratio than for the
overall efficiency. It is known from gas turbine cycle when expansion ratio
increases, the overall efficiency will be increased as fig.(4.14),and fig.(4.15).
But as both turbine inlet temperature (T3 ) and Ø (maximum to minimum
ratio) increased it was found that the overall efficiency will be increased too.
From the mentioned conditions, it can be concluded that any gas turbine
cycle shows an improvement in thermal efficiency as long as increasing the
turbine inlet temperature (T3) or lowering compressor inlet temperature. As,
the expansion ratio increases, the work consumed by the compressor is
reduced. Figure (4.16) and figure (4.17) showed the effect of reduced
compressor inlet temperature on the overall efficiency. It is obvious that this
effect can be clearly seen when the engine runs at high speed. So, when
reducing compressor inlet temperature from (30°C) to (15°C), the increasing
percentage in overall efficiency is fluctuated among (15 %), (17%) and (20%)
at expansion ratio (1.12), (1.1) and (1.08), respectively.
7
Theoretical Overall Efficiency (%)
4
Expansion
Expansion Ratio
Ratio (rT)rT=1.
=1.12
12
3
Expansion
Expansion Ratio
Ratio (rT)rT=1.
=1.0808
2
3.08 3.1 3.12 3.14 3.16 3.18 3.2 3.22 3.24 3.26 3.28
T3/T1 ( Ø )
Fig (4.8) Theoretical Overall Efficiency as a Function of (T3/T1 Ratio)

with Isentropic Efficiency (ηt,ηc =0.9) ,T3=699 °C
6.5
5.5
4.5
3.5
Expansion Ratio(rT)
Expansion Ratio rrT=1.
=1.12
T=1. 12
12
3
2.5 Expansion Ratio(rT)

T=1. 08
08
=1.08
2
3.08 3.1 3.12 3.14 3.16 3.18 3.2 3.22 3.24 3.26 3.28
T3/T1 ( Ø)

with Isentropic Efficiency (ηt,ηc =0.9) ,T3=628.5 °C
6.5
6
5.5
4.5
3.5
3 Expansion Ratio r(rT) =1.12

T=1. 12
2.5
Expansion Ratio r(rT)
T=1. 08
=1.08
2
3.08 3.1 3.12 3.14 3.16 3.18 3.2 3.22 3.24 3.26 3.28
T3/T1 ( Ø)
with Isentropic Efficiency (ηt,ηc =0.9) ,T3=588 °C
6.5
6
5.5
4.5
3.5
3
rT=1.=1.12
Expansion Ratio (rT) 12
2.5
rT=1.
Expansion Ratio (rT) =1.0
08 8
2
3.08 3.1 3.12 3.14 3.16 3.18 3.2 3.22 3.24 3.26 3.28
T3/T1 ( Ø)

with Isentropic Efficiency (ηt,ηc =0.9) ,T3=547.5 °C
7.5
7
6.5
5.5
4.5
T1= 15 C
4
3.5 T1= 30 C
3
500 520 540 560 580 600 620 640 660 680
Turbine Inlet Temperature (T3)
Fig (4.12) The Effect of Turbine Inlet Temperature (High Pressure Turbine)on the
Theoretical Overall Efficiency ,Expansion Ratio=1.12
5.5
5
4.5
3.5
3
T1= 15 C
2.5
T1=30 C
2
500 520 540 560 580 600 620 640 660 680
Turbine Inlet Temperature (T3)
Fig (4.13) The Effect of Turbine Inlet Temperature (High Pressure Turbine)on the
Theoretical Overall Efficiency ,Expansion Ratio=1.08
7.5
7
6.5
5.5
4.5
T3=669 C , Ø=3.2
4
T3=628.5 C,Ø =3.1
3.5
T3=588 C, Ø =2.9
3
1.075 1.08 1.085 1.09 1.095 1.1 1.105 1.11 1.115 1.12 1.125
Expansion Ratio (rT)
Fig (4.14) Theoretical Overall Efficiency as a Function of Expansion Ratio

with Isentropic Efficiency (ηt,ηc =0.9) and T1=15°C
5.5
4.5
4
T3= 699 C, Ø =3.10
3.5 T3=628.5 C, Ø=2.97
T3=588 C, Ø=2.84
3
1.075 1.08 1.085 1.09 1.095 1.1 1.105 1.11 1.115 1.12 1.125
Fig (4.15) Theoretical Overall Efficiency as a Function of Expansion Ratio

with Isentropic Efficiency (ηηt,ηc =0.9) and T1=30°C
7
4
Expansion Ratio (rT) =1.12
Expansion Ratio rT=1.
rT=1.1212
3 Expansion Ratio
Expansion Ratio rT=1.
(rT) =1.11
Expansion Ratio
(rT) = 1.08
T=1. 08
08
2
10 15 20 25 30 35
Compressor Inlet Temperature (C)
Fig (4.16) The Effect of Compressor Inlet Temperature (with Variable Expansion Ratio)
on the Theoretical Overall Efficiency, T3= 669 °C
6.5
5.5
4.5
3.5 rT= =1.12

3 Expansion Ratio (rT)

r =1.1
T=
2.5 rT= =1.08
2
10 15 20 25 30 35
Fig (4.17) The Effect of Compressor Inlet Temperature (with Variable Expansion
Ratio) on the Theoretical Overall Efficiency, T3= 628.5 °C
CHAPTER FIVE
Results & Discussion

Chapter Five .......................................................................................Results &Discussion
5.1 General
Since gas turbine is an air-breathing engine, its performance is changed by
anything that affects the density and/or mass flow of the air intake to the
compressor. The volumetric flow is constant with any shaft speed, it is
possible to increase mass flow rate by increasing air density. Air-cooled heat
exchanger has been sitting prior to intake of compressor .In order to find out
the effect of compressor inlet temperature on the gas turbine performance.
These important variables are: power output, fuel mass flow rate, heat
consumption, heat rate, overall efficiency, air mass flow. The design and
thermal performance of air-cooled heat exchanger are also studied. A new
design technique is suggested which divided the heat exchanger in two
directions to get more accurate thermal performance: heat load, heat transfer
coefficient (air side), overall heat transfer coefficient, air mass flow, air exit
temperature from heat exchanger. The present study concentrates on getting
variable air exit temperature, air mass flow rate, size (aspect ratio), with
known inlet operation conditions for both fluids only.
5.2 Computational Model Results for Heat Exchanger
The computational model results of the developed program shall be
discussed, including heat load, heat transfer coefficient for air side (ha), and
overall heat transfer coefficient for each row of the heat exchanger. Air exit
temperature and air mass flow rate discharged from heat exchanger are to be
entered to gas turbine which must be controlled according to the requirements
of present study. The computational model has been fed with the same
operating conditions as those of the experimental test rig. For the object of
validity of the theoretical prediction it was decided to use two set of
experimental tests for the present heat exchanger in this work. These were
conducted at entering water temperature of (10 °C) and (50 °C) for water flow
rate of (2000 l/h) at two different air flow rates of (500 cfm) and (2000 cfm),
as shown in tables (5-1) to (5-4).For the performance simulation, these tests
were achieved at the same entering air temperature to the heat exchanger of
(32 °C) .In these tables, three different heat exchanger core sizes were
obtained for the same operating conditions on both sides, air and tube, sides
of the test section.
5.2.1 Heat Load for heat exchanger
Figures (5.1a) and (5.1b) show the variation of heat exchanger load with
the air flow velocity through the tube bank for water entering temperature of
(10°C) and (50°C) respectively. The air velocity was ranged between (1.2
m/s) and (4.6 m/s) corresponding to (500 cfm) and (2000 cfm) air flow rates
respectively. It is obvious that the heat load experience an increase as the air
flow rate increase .This is due to the improvement of the overall heat transfer
coefficient of the heat exchanger by increasing the air side heat transfer
coefficient. The heat load was increased by 3-4 times when the velocity was
raised from (1.2 m/s) to (4.6 m/s) respectively, at entering water temperature
of 10°C (Cooling Mode) and 50°C (Heating Mode). The heat exchanger load
was ranged between (1 kW) and (4.5 kW) for the whole range of air flow rate.
The step by step simulation model shows a good agreement with the
experimental data as shown in figure (5.1) for the whole range of air velocity.
The predicted heat exchanger performance (Heat Load, Overall Heat Transfer
Coefficient ...etc) fell within 5 % for most of the simulation range. The trend
of the lines of heat load is the same for upper point for both cases, but the
magnitude of heat load is having different values at low air velocities. For
example, in figure (5.1a) at air velocity (1.5 m/s), the heat load is (1 kW) at
entering water temperature of (10 °C) and figure (5. 1b) for entering water
(50 °C), the heat load is (1.5 kW).Which explains the heat load behavior is
affected by the fluid properties at high temperature.
5.2.2 Heat Transfer Coefficient for air side
Since the heat transfer performance of the heat exchanger for (gas-liquid)
type is dependent on heat transfer coefficient of air side .Figures (5.2a), and
(5.2b), show a comparison for the heat transfer coefficient for air side
between the theoretical prediction and the experimental data. These figures
represent the behavior of the heat transfer coefficient variation with water
flow rates of (2000 l/hr). It is obvious from these data that, the heat transfer
coefficient values decrease at low air velocity. And as a matter of fact, it has
lower value when water entering at (10 °C).The prediction of the present
model shows that it is possible to obtain the higher temperature difference for
the air side at the same heat exchanger load when using a fat heat exchanger.
This is due to the higher overall heat transfer produced at the same air flow
rate as shown in tables (5-1) to (5-4). The predicted values from the
computational model for the heat transfer coefficient for air side along its
depth (D) and along heat exchanger height (H) are shown in figures(5-3) and
(5-4) for air flow rates of (2000) and (500) cfm at water entering temperature
(10 0C) and (50 °C) respectively. It is obvious that the heat transfer coefficient
of the air side nearly stayed unchanged ,and it is essentially a constant value.
However, it is more pronounced when the heat exchanger geometry was
deeper in the depth direction as shown in figure (5.5).This is for a heat
exchanger having an overall dimension of (18 × 11 × 18) cm3, table (5-1).It
shows that the air heat transfer coefficient is in the range between (94) to (96)
W/m2.°C.
5.2.3 Overall Heat Transfer Coefficient
Figures (5.6a), (5.6b) show the variation of the overall heat transfer
coefficient with air flow velocity through heat exchanger at water entering
temperature of (10 °C) and (50 °C) respectively. The predicted values from
computational model for the overall heat transfer coefficient along its depth
(D) and along heat exchanger height (H) are shown in figures(5-7) and (5-8)
for air flow rates of (2000) and (500) cfm at water entering temperature
(10 °C) and (50 °C) respectively. It is obvious that the overall heat transfer
coefficient of the air side did not change much and it is essentially a constant
value. However, it is more pronounced when the heat exchanger geometry

was deeper in the depth direction as shown in figure (5.9).This is for a heat
exchanger having an overall dimension of (18 × 11 × 18) cm3, table (5-1).It
shows that the air overall heat transfer coefficient is in the range between
(84) to (85) W/m2.°C.The overall heat transfer coefficient of the heat
exchanger approaches (47) and (45) W/m2.°C at the maximum air velocity
falling to a minimum at (1.2 m/s) where Uo is (15 W/m2.°C) and (30 W/m2.°C)
for cooling and heating modes respectively. The simulation prediction and
experimental data showed a good agreement with maximum descripancy of
(5%) for the whole range of test conditions.
5.2.4 Air Temperature Distribution
Figure (5.10) shows the variation of the experimental and present model of
the exit air temperature out of the heat exchanger and the air velocity. For
both of the cooling and heating modes of the air passing through the heat
exchanger, the exit air temperature shows a trend of decreasing as the air
velocity increases. This is due to the fact that when the air velocity increases
causes an increase in the air side heat transfer coefficient (ha ) and the
(Uo )value which in turn produces higher heat exchanger load. However, the
exit air temperature per any row and slice is one of the dominant parameters
which were focused in the present work. Figures (5.11) and (5.12) show the
air temperature distribution along its depth (D) and along heat exchanger
height (H) for air flow rates of (2000 cfm) and (500 cfm) at water entering
temperature (10 °C) and (50 °C). Figure (5.13) shows the temperature
variation with row number with the leaving side for each row for a heat
exchanger of 6 rows having (18 × 11 × 18) cm3.
5.2.5 The Effect of Core Aspect Ratio (H/L) and Size (L × D × H)
The objective of this study is to develop a heat exchanger model which has
the capability to predict the heat exchanger performance depending on the
design parameters without relying on experimental data. The predictive
capability of the model was demonstrated by studying two different cases. For
the first case, the aspect ratio of the heat exchanger core was changed from
(0.67 - 1) when air velocity (1.2 m/s). The water flow rate was kept constant
at (2000 l/h). The aspect ratio is defined as the ratio of the height (H) to the
length (L) of the core for the heat exchanger. Since the model is based on the
down flow type with the water tanks on top and bottom of the core, larger
aspect ratio means relatively longer tubes. For a given range of the aspect
ratio, the results showed that a heat exchanger with smaller aspect ratio can
perform better than that of larger aspect ratio case as shown in Figure (5.14).
Pressure drop in air side (Δpa ) was increased by changing the aspect ratio
from (0.67 - 1) with the different core size (L × D × H). This is because at
higher aspect ratio, the frontal area decrease over air side experiencing more
abstraction in flow. For the second case, pressure drop variation with the
change of the core size was examined. The pressure drop was calculated for a
given water flow rate (2000 L/h) and air velocity (1.2 m/s) . The effect of core
downsizing on the pressure drop is presented in tables (5.1-5.4). As the core
size is reduced the pressure drop rate is increased. This is another evidence of
the importance of the predictive model which can properly reveal the effect of
the core size (L × D × H) variation on the pressure drop in air side.
5.3 Experimental Results for Gas Turbine
Changes in ambient temperature have an impact on full-load power and heat
rate, and, also on part-load performance and optimum power turbine speed.
Manufacturers typically provide performance maps that describe these
relationships for International Organization for Standardization (ISO)
conditions. The Design Point of the gas turbine engine is concerned with the
following concepts:
• Standard ambient conditions
• Improved fuel type
• Full gas turbine shaft speed
• Full power output

• Minimum heat rate
• Minimum heat consumption
The percent of design considers the change ratio of performance information
to gas turbine by changing location or operation conditions with respect to
original design point, as shown in figure (1.1).
Detailed discussion of the effect of compressor inlet temperature will be
carried out in the following sections:
5.3.1 Effect of Compressor Inlet Temperature on Power Output
The power output can be increased by increasing either air mass flow or
fuel mass flow. However, increasing fuel mass flow is used according to the
application but the power output can be increased by improving ambient
conditions which attempts to make it near standard conditions. Power output
versus turbine inlet temperature at various compressor inlet temperature is
shown in fig.(5-15).The increasing of power output is due to increasing
turbine inlet temperature and also because of reducing the compressor inlet
temperature ,which increases the mass flow rate across the power turbine. An
increase in power output about (22 %) was obtained due to reducing
compressor inlet temperature from (30 - 15 °C) at gas generator speed of
(65000 RPM).
5.3.2 Effect of Compressor Inlet Temperature on Fuel Mass Flow Rate
Burning hydrocarbons (Kerosene-RT 10) with air leads to combustion gases
that have practically the same gas constant as dry air. Thus the assumption
that R = 287 J/kg.K is valid for both compressor and turbine. But, the
isentropic exponents γC and γT are in reality not constant and they change
significantly with temperature. Fuel mass flow rate versus compressor inlet
temperature at various gas generator speed is shown in fig.(5-16).The
increasing of fuel mass flow rate is due to increasing both ,gas generator
speed and compressor inlet temperature. A decrease in fuel mass flow rate
about (10 %) was obtained due to reducing compressor inlet temperature from
(30 - 15 °C) at gas generator speed of (55000 RPM).
5.3.3 Effect of Compressor Inlet Temperature on Specific Fuel
Consumption
The fuel consumption is depended not only on the combustion chamber
design, but also on required power output. The high pressure turbine work is
accelerated by forced gas mass on it's blades. That means in decreasing
compressor inlet temperature will increase gas generator speed without
increasing in fuel mass flow. Also, specific fuel consumption is down to any
power required. Specific fuel consumption versus compressor inlet
temperature at various gas generator speed is shown in fig.(5-17).The increase
in specific fuel consumption was due to the increase of both gas generator
speed and compressor inlet temperature. A decrease in specific fuel
consumption about (44 %) was obtained due to reducing compressor inlet
temperature from (30 - 15 °C) at gas generator speed of (55000 RPM).
5.3.4 Effect of Compressor Inlet Temperature on Heat Consumption
Work from a gas turbine can be defined as the product of mass flow, heat
energy in the combusted gas (Cp), and temperature differential across the
turbine. The mass flow in this equation is the sum of compressor airflow and
fuel flow. The heat energy is a function of the elements in the fuel and the
products of combustion. The power output from gas turbine can be increases
by burning more fuel which means more heat consumption. Heat
consumption versus compressor inlet temperature at various gas generator
speed is shown in fig.(5-18).The increasing of heat consumption is due to
increasing gas generator speed and compressor inlet temperature. A decrease
in heat consumption of about (8 %) was obtained due to reducing compressor
inlet temperature from (30 - 15 °C) at gas generator speed of (55000 RPM).
5.3.5 Effect of Compressor Inlet Temperature on Heat Rate

Heat Rate is the inverse of efficiency, which is an indication of the ratio
between thermal energy, resulting from the combustion process, and
mechanical energy, obtained on the power shaft. Heat rate versus turbine inlet
temperature at various compressor inlet temperature is shown in fig.(5-
19).The increasing of heat rate is due to increasing of both turbine inlet
temperature and compressor inlet temperature. A decrease in heat rate of
(30 - 15 °C) at gas generator speed of (65000 RPM).
5.3.6 Effect of Compressor Inlet Temperature on Overall Efficiency
Overall efficiency versus turbine inlet temperature at various compressor
inlet temperature are shown in fig.(5-20).The increase in overall efficiency is
due to the increase in turbine inlet temperature and also because of reduction
of compressor inlet temperature. An increase in overall efficiency about
(40 %) was obtained due to reducing compressor inlet temperature from (30 -
15 °C) at gas generator speed of (65000 RPM).
5.3.7 Effect of Compressor Inlet Temperature on Air Mass Flow Rate
In general, for lowering compressor inlet temperature the air mass flow rate
will be increased because of increasing air specific weight at low temperature.
Air mass flow rate versus compressor inlet temperature at various gas
generator speed are shown in fig.(5-21) and fig.(5-22).The increasing of air
mass flow rate is due to the increase of gas generator speed and also because
of reduction of compressor inlet temperature. An increase in air mass flow
rate and air volumetric flow rate about (15 %) and (6 %) respectively were
obtained due to reducing compressor inlet temperature from (30 - 15 °C) at
gas generator speed of (55000 RPM).
5.3.8 Effect of Compressor Inlet Temperature on Pressure Ratio
The pressure ratio of the compressor at constant speed becomes smaller
with increasing compressor inlet temperature. There will be more work (or
head) required to achieve a certain pressure rise. The increased work has to be
provided by the gas generator turbine, and is thus a loss for the power turbine.
Pressure ratio versus compressor inlet temperature at various gas generator
speed are shown in fig.(5-23).The increasing of pressure ratio is due to the
increase gas generator speed and also because of reduction of compressor
inlet temperature. An increase in pressure ratio about (8 %) was obtained due
to reducing compressor inlet temperature from (30 - 15 °C) at gas generator
speed of (55000 RPM).
5.3.9 Effect of Compressor Inlet Temperature on Power Input to
Compressor
It is known the theoretical power input to compressor is equal to the
theoretical power to high pressure Turbine. The compressor overall efficiency
from isentropic efficiency and mechanical efficiency is increasing by
decreasing compressor inlet temperature together with compression ratio is
also increasing. Therefore, by reducing compressor inlet temperature the
energy consumed to compressor decreasing and theoretical power work (same
spool with high pressure gas turbine) increasing at the same gas generator
speed as showed in Fig (5.24). On other hand the high air weight is needed
little work to compress. Power input to compressor versus gas generator speed
at various compressor inlet temperature is shown in fig.(5-24).The increasing
of power input to compressor is due to the increase gas generator speed and
also because of reduction of compressor inlet temperature. An increase in
power input to compressor about (30 %) was obtained due to reducing
compressor inlet temperature from (30 - 15 °C) for at gas generator speed
(55000 RPM).
5.3.10 Effect of Compressor Inlet Temperature on Turbine Inlet
Temperature
The two parameters that play a main role in gas turbine design are pressure
ratio and turbine inlet temperature for both gas generator and power generator
engines. When decreasing compressor inlet temperature, both the

compression ratio will be increased and air mass flow increasing too. On
other hand turbine inlet temperature will be decreased. Therefore, the power
output is increased by burning more fuel with increasing gas turbine speed as
shown in the figure (5.25). Also an increase in high pressure turbine work of
(30 - 15 °C) for constant turbine inlet temperature at (650 °C) .
5.4 Percent of Design
Design point performance is vital to the engine concept design process. The
engine configuration, cycle parameters, component performance levels and
sizes are selected to meet a given specification. This section describes this
performance input, which cannot be divorced from component design. Design
point performance must be defined before analysing of any of the other
possible operating conditions. A number of key parameters that define overall
engine performance are utilised to assess the suitability of a given engine
design to the application. These engine performance parameters are described
below to the present study which was taken from design performance
calculations for gas turbine (GT-85) :
• The full power output is 5 (kW)
• The maximum overall efficiency is 3.5 (%)
• The minimum heat consumption
The maximum heat consumption can be add for gas turbine (GT-85) as
follow:
5
heat consumption = =142.8 (kW)
0.035
• The minimum heat rate

The minimum heat rate can be calculated for (GT-85) as follow:
1
heat rate= =28.56
0.035
Calculated Value at (T1 = 15 ) − Calculated Value at (T1 = 30 )

Percent of Design = × 100%
Design Value
One main concept from present study is to attempt to work or operate near
the above engine performance parameters of the design point as shown in
figures (5.26) and (5.27). The change in ratio relation to original design
(Percent of Design) is about about (15 %) increase in power output, (25 %)
increase in overall efficiency and (10 %) reduction in heat consumption, these
results were obtained with reducing compressor inlet temperature from (30 -
15 °C) at gas generator speed (55000 RPM).
5.5 Comparison between the Experimental and Theoretical Predictions of
the gas turbine engine
Figure (5-28) shows a comparison between experimental and theoretical
predictions for overall efficiency of gas turbine engine (GT-85) with variable
turbine inlet temperature. Both of the experimental data and the predicated
values have the same trend of variation showering an increase in overall
efficiency with raising turbine inlet temperature .The predicated values were
higher than that the experimental data for the whole temperature range in the
field between (550-675°C) about (18%) for the expansion ratio of (1.03).
When the expansion ratio is raised then, the discrepancy percentage will be
increased .However, the effect of irreversibility and operating with different
conditions makes this discrepancy between the experimental and theoretical
predictions for overall efficiency with the same turbine inlet temperature
increasing.
5.6 Conclusion
From literature survey and pervious discussion , it can be concluded that
there is a relationship among compressor inlet temperature, turbine inlet
temperature and gas generator speed. It is obvious that the effect of
compressor inlet temperature on gas turbine performance is reduced at high
gas generator speed. Therefore, it can be noticed that for a particular turbine
inlet temperature such as (650 °C) fig. (5.15), the power output is increased of
about (22%) due to reduction the compressor inlet temperature from (30-
15°C) at gas generator speed up to (65000 RPM). It can be also that an
increase of about (44%) when reduction compressor inlet temperature from
(30-15°C) at gas generator speed (55000 RPM).It is worth while mentioning
that the industrial gas turbine is carried out by two types: power output with
constant speed and power output with variable speed. The first type is popular
using in the power plant (Power Generation, Co-Generation), the speed is
important parameter which rely on it the current frequency, therefore the plant
worked at full speed for all time. The second type is used to feed power for
pumps and compressors (Oil, Gas). Therefore, the volumetric flow rate is
incorporated with the speed of device which is operating at higher speeds.
Table (5-1) Air Temperature Distribution Along H.EX.Depth ,Vw=2000 (L/h),Va=2000 (cfm)
Q (KW) Uo(w/m2. °C) ha w/m2. °C) Ta (in) °C Ta (out) °C Tw (in) °C Tw (out) °C ∆pa No. Core Size
of
×
×
(mbar) (L D H)
ROW
2.328 47.10219 50.60406 32 29.79 10 12 .242 1 Heat

Exchanger
×
2.328 47.28972 50.81485 29. 79 27.69 10 12 .241 2 (55 3.6

×
37) cm3
1.164 62.55761 68.36579 32 29.79 10 12 .242 1 Heat
Exchanger
1.164 62.80377 68.65057 29.79 27.69 10 12 .241 2
×
(28.5 7.7
×
27) cm3
1.164 63.05259 68.93851 27.69 25.69 10 12 .239 3
1.164 63.30411 69.22968 25.69 23.59 10 12 .238 4
.776 84.24339 94.18447 32 29.79 10 12 .242 1 Heat

Exchanger
.776 84.56969 94.57677 29.79 27.69 10 12 .241 2
×
(18 11
18) cm3
.776 84.89945 94.97345 27.69 25.69 10 12 .239 3
.776 85.56966 95.37463 25.69 23.59 10 12 .238 4
.776 85.23277 95.78031 23.59 21.49 10 12 .237 5

.776 85.91026 96.19064 21.49 19.39 10 12 .235 6

Table (5-2) Air Temperature Distribution Along H.EX.Depth ,Vw=2000 (L/h),Va=2000 (cfm)
Q (KW) Uo (w/m2. °C) ha (w/m2. °C) Ta (in) °C Ta (out) °C Tw (in) °C Tw (out) °C ∆pa No. Core Size
of
×
×
(mbar) (L D H)
ROW
2.284 45.04536 47.79097 32 34.09 50 48 .243 1 Heat

Exchanger
×
2.284 45.31548 48.59657 34.09 36.19 50 48 .245 2 (55 3.6

×
37) cm3
1.142 60.24699 65.00219 32 32.09 50 48 .243 1 Heat
Exchanger
1.142 60.69621 65.51846 32.09 34.19 50 48 .245 2
×
(28.5 7.7
×
27) cm3
1.142 60.46152 65.25092 34.19 36.29 50 48 .246 3
1.142 60.46152 65.76105 36.29 38.39 50 48 .247 4
.761 81.55405 89.90861 32 32.09 50 48 .243 1 Heat

Exchanger
.761 81.84826 90.2618 32.09 34.19 50 48 .245 2
×
(18 11
18) cm3
.761 81.53701 89.89323 34.19 36.29 50 48 .246 3
.761 81.82931 90.24413 36.29 38.39 50 48 .247 4
.761 82.11871 90.59176 38.39 40.49 50 48 .248 5

.761 81.81271 90.22915 40.49 42.59 50 48 .250 6

Table (5-3) Air Temperature Distribution Along H.X.Depth ,Vw=2000 (L/h),Va=500 (cfm)
Q (KW) Uo (w/m2. °C) ha (w/m2. °C) Ta (in) °C Ta (out) °C Tw (in) °C Tw (out) °C ∆pa No. of Core Size
×
×
(mbar) ROW (L D H)
E-02
.456 20.09592 20.64679 32 29.99 10 10.4 6.32 1 Heat
Exchanger
×
.456 20.13704 20.68979 29.99 27.89 10 10.4 6.29 2 (55 3.6

×
37) cm3
.2329 18.50125 18.97783 32 29.99 10 10.4 6.32 1 Heat
Exchanger
.2329 18.57706 19.05688 29.99 27.89 10 10.4 6.29 2
×
(28.5 7.7
×
27) cm3
.2329 18.65369 19.1368 27.89 25.78 10 10.4 6.25 3
.2329 18.73119 19.21763 25.78 23.67 10 10.4 6.22 4
.155 25.65959 26.50834 32 29.99 10 10.4 6.32 1 Heat

Exchanger
.155 25.76418 26.61876 29.99 27.89 10 10.4 6.29 2
×
(18 11
18) cm3
.155 25.86992 26.7304 27.89 25.78 10 10.4 6.25 3
.155 25.97685 26.8433 25.78 23.67 10 10.4 6.22 4
.155 26.08497 26.95747 23.67 21.57 10 10.4 6.18 5

.155 26.1943 27.07296 21.57 19.46 10 10.4 6.15 6

Table (5-4) Air Temperature Distribution Along H.X.Depth ,Vw=2000 (L/h),Va=500 (cfm)
Q (KW) Uo (w/m2. °C) ha (w/m2. °C) Ta (in) °C Ta (out) °C Tw (in) °C Tw (out) 0C ∆pa No. Core Size
of
×
×
(mbar) (L D H)
ROW
E-02
.684 23.18965 23.84225 32 34.12 50 49.5 6.41 1 Heat
Exchanger
×
.684 22.79861 23.4331 34.12 43.02 50 49.5 6.57 2 (55 3.6

×
37) cm3
.342 25.26978 25.73128 32 34.12 50 49.5 6.41 1 Heat
Exchanger
.342 26.01909 26.0863 34.12 43.02 50 49.5 6.57 2
×
(28.5 7.7
×
27) cm3
.342 25.5097 25.98009 43.02 54.46 50 49.5 6.78 3
.342 26.04461 26.53511 54.46 69.88 50 49.5 6.95 4
.228 35.53004 36.45073 32 34.12 50 49.5 6.41 1 Heat

Exchanger
.228 34.93548 35.82522 34.12 43.02 50 49.5 6.57 2
×
(18 11
18) cm3
.228 35.29956 36.2082 43.02 54.46 50 49.5 6.75 3
.228 35.51754 36.43759 54.46 69.88 50 49.5 6.98 4
.228 35.57734 36.50051 69.88 78.37 50 49.5 7.25 5

.228 36.40247 37.36954 78.37 88.12 50 49.5 7.58 6

Table (5-5) Air Temperature Distribution a long First Row Height

Tw. in = 10(°C) Tw.out =12(°C) Ta .in =32(°C) Vw = 2000 l/h Va=2000cfm

ha (w/m2.°C) Q (watt) Uo (w/m2.°C) Ta out (°C) A (m2)
50.60411 116.4624 47.09801 29.89904 .1187113
50.6041 116.4564 47.0985 29.89915 .1192767
50.6041 116.4504 47.09899 29.89925 .1198476
50.6041 116.4474 47.09924 29.89931 .1201254
50.6041 116.4474 47.09924 29.89931 .1201254
50.60409 116.4385 47.09997 29.89947 .1210062
50.60408 116.4326 47.10045 29.89958 .1215941
50.60408 116.4267 47.10094 29.89968 .1221879
50.60407 116.4208 47.10142 29.89979 .1227876
50.60406 116.4149 47.10191 29.89989 .1233933
50.60406 116.409 47.0239 29.9 .1240051
50.60405 116.4032 47.10287 29.9001 .1246231
50.60405 116.3974 47.10334 29.90021 .1252474
50.60405 116.3945 47.10359 29.90026 .1255509
50.60404 116.3858 47.10431 29.90042 .1265153
50.60403 116.3801 47.10478 29.90052 .1271591
50.60403 116.3743 47.10526 29.90063 .1278096
50.60403 116.3686 47.10573 29.90073 .1284669
50.60402 116.3629 47.1062 29.90083 .1291311
50.60402 116.3572 47.10667 29.90093 .1298023
Table (5-6) Air Temperature Distribution a long Second Row Height

Tw. in= 10(°C) Tw.out =12(°C) Ta .in =32(°C) Vw = 2000 l/h Va=2000cfm
ha (w/m2. °C) Q (watt) Uo (w/m2. °C) Ta out (°C) A (m2)
50.81489 116.4624 47.28552 27.799 . 129798
50.81488 116.4564 47.28601 27.7991 .131507
50.81488 116.4504 47.2865 27.79921 .132205
50.81488 116.4474 47.28675 27.79926 .1329107
50.81488 116.4474 47.28675 27.79926 .133253
50.81487 116.4385 47.28749 27.79943 .133253
50.81486 116.4326 47.28798 27.79953 .1343451
50.81486 116.4267 47.28846 27.79964 .1350742
50.81486 116.4208 47.28896 27.79975 .1358114
50.81485 116.4149 47.28944 27.79985 .1365567
50.81485 116.409 47.28992 27.79996 .1373105
50.81484 116.4032 47.29041 27.80006 .1380727
50.81483 116.3974 47.29089 27.80017 .1388436
50.81483 116.3945 47.29113 27.80022 .1396233
50.81482 116.3858 47.29185 27.80038 .140001
50.81482 116.3801 47.29234 27.80048 .1412096
50.81482 116.3743 47.29281 27.80058 .1420166
50.81481 116.3686 47.29329 27.80069 .142833
50.8148 116.3629 47.29376 27.80079 .1436589
50.8148 116.3572 47.29423 27.80089 .1444946

Tw. in= 50(°C) Tw.out =48(°C) Ta .in =32(°C) Vw = 2000 l/h Va=2000cfm
48.69674 114.1267 45.37363 34.09845 .1494603
48.69672 114.1362 45.37796 34.09862 .1503539
48.69672 114.1457 45.38214 34.0988 .1512587
48.69672 114.1504 45.38418 34.09888 .1516965
48.69672 114.1504 45.38418 34.09888 .1516965
48.6967 114.1645 45.39007 34.09914 .1531029
48.69669 114.1739 45.39383 34.09932 .1540425
48.69669 114.1833 45.39747 34.09949 .1549942
48.69668 114.1926 45.40099 34.09966 .1559581
48.69667 114.2018 45.40438 34.09983 .1569344
48.69666 114.2111 45.0767 34.1 .1579234
48.69665 114.2203 45.41086 34.10017 .1589252
48.69664 114.2295 45.41394 34.10034 .1599401
48.69664 114.234 45.41545 4.10042 .1604302
48.69663 114.2477 45.41983 34.10067 .1620101
48.69662 114.2567 45.42263 34.10084 .1630657
48.69662 114.2657 45.42537 34.10101 .1641354
48.69661 114.2747 45.428 34.10117 .1652195
48.6966 114.2837 45.43056 34.10133 .1663181
48.69659 114.2926 45.43305 34.1015 .1674317

Tw. in = 50(°C) Tw.out =48(°C) Ta .in =32(°C) Vw = 2000 l/h Va=2000cfm

48.49659 114.1226 45.19305 36.19837 .1674317
48.49654 114.1267 45.19515 36.19855 .1714795
48.49653 114.1362 45.19946 36.19872 .172653
48.49652 114.1457 45.20361 36.19881 .1738432
48.49652 114.1504 45.20564 36.19881 .1744162
48.49652 114.1504 45.20564 36.19907 .1744162
48.4965 14.1645 45.21149 36.19924 .1762752
48.4965 114.1739 45.21524 36.19941 .1775177
48.49649 114.1833 45.21885 36.19958 .1787783
48.49648 114.1926 45.22234 36.19976 .1800573
48.49648 114.2018 45.22573 36.19992 .1813552
48.49647 114.2111 45.229 36.2001 .1826723
48.49646 114.2203 45.23216 36.20026 .1840092
48.49645 114.2295 45.23523 36.20035 .1853661
48.49644 114.234 45.23672 36.2006 .1860176
48.49644 114.2477 45.24109 36.20076 .1881417
48.49643 114.2567 45.24387 36.20093 .1895614
48.49642 114.2657 45.24658 36.2011 .191003
48.49641 114.2747 45.2492 36.20126 .192467
48.49641 114.2837 45.25175 36.20142 .1939538
48.4964 114.2926 45.25422 36.20128 .195464

Tw. in = 10(°C) Tw.out=10.4(°C) Ta .in =32(°C) Vw =2000 l/h Va=500cfm

20.64677 116.4624 20.09579 29.89989 .2781911
20.64677 116.4564 20.09587 29.9 .2795178
20.64677 116.4504 20.09595 29.90011 .2808575
20.64676 116.4474 20.09598 29.90016 .2815096


20.73277 116.4624 20.17804 27.79996 .3081484
20.73277 116.4564 20.17811 27.80007 .3097861
20.73277 116.4504 20.17819 27.80018 .3114415
20.73276 116.4474 20.17823 27.80023 .3122447


19.86854 114.1267 19.32309 34.09974 .3509701
19.86854 114.1362 19.32381 34.09991 .353089
19.86854 114.1457 19.32451 34.10009 .3552339
19.86854 114.1504 19.32485 34.10017 .356272


19.52759 114.1267 18.99886 43.02019 .3620837
19.52758 114.1362 18.99919 43.02028 .3668006
19.52758 114.1457 18.99919 43.02028 .3668006
19.52758 114.1504 19.00015 43.02053 .3632253
6
Simulation
Experiment
5
Heat Load (kW) 4
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
• Entering water at 10 °C
Fig (5. 1a)
5
Simulation
Experiment
4
Heat Load (kW)
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
•
Entering water at 50 °C
Fig (5. 1b)
Fig (5.1) Comparison between the Experimental and Present Model for the
Effect of Air Velocity on Heat Load at Water Flow Rate 2000 (L/h)
60
Simulation
Experiment
Heat Transfer Coefficient .ha (W/m 2.C)

50
40
30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
Fig (5. 2a)
60
Simulation
Heat Transfer Coefficient. ha (W/m 2.C)
Experiment
50
40
30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
Entering water at 50 °C •
Fig (5. 2b)
Fig (5. 2) Comparison between the Experimental and Present Model for the Effect of Air
Velocity on Heat Transfer Coefficient ha, at Water Flow Rate 2000 (L/h)
Heat Transfer Coefficient ha.(w/m2.c)

50.45 50.5 50.55 50.6 50.65 50.7 50.75 50.8 50.85
1
Slice Number (Bar Tube)
2
ROW 1
ROW 2
Fig (5. 3a)

48.35 48.4 48.45 48.5 48.55 48.6 48.65 48.7 48.75
1
2
ROW 1
ROW 2
3
Fig (5. 3b)
Fig (5. 3) Variation Heat Transfer Coefficient (ha) a long Heat Exchanger
Height at Water Flow Rate 2000 (L/h), Air Flow Rate 2000 cfm

20.6 20.62 20.64 20.66 20.68 20.7 20.72 20.74
1
2
ROW 1
ROW 2
3
Fig (5. 4a)

19.4 19.4 19.5 19.5 19.6 19.6 19.7 19.7 19.8 19.8 19.9 19.9
1
Slice Number
2
ROW 1
ROW 2
Fig (5. 4b)
Fig(5. 4) Variation Heat Transfer Coefficient( ha )a long Heat Exchanger

96.5
96
Heat Transfer Coefficient (W/m2.c)
95.5
95
94.5
94
93.5
93
1 2 3 4 5 6
Row Number
Fig(5. 5) Variation Heat Transfer Coefficient (ha) a long Heat

Exchanger Depth at Water Flow Rate 2000 (L/h), Water Entering Temp.
10 °C, Air Flow Rate 2000 cfm
50
Overall Heat Transfer Coefficient (W/m 2.C)

Simulation
45
Experiment
40
35
30
25
20
15
10
0
0 1 2 3 4 5
Air Velocity (m/s)
Fig (5. 6a)
50
Overall Heat Transfer Coefficient(W/m 2.C)
Simulation
45
Experiment
40
35
30
25
20
15
10
5
0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
Fig (5. 6b)
Fig (5. 6) Comparison between the Experimental and Present Model for the Effect of Air
Velocity on Overall Heat Transfer Coefficient at Water Flow Rate 2000 (L/h)
Overall Heat Transfer Coefficient (w/m2.c)

47 47.05 47.1 47.15 47.2 47.25 47.3 47.35
1
2
ROW 1
ROW 2
Fig (5. 7a)

45.1 45.15 45.2 45.25 45.3 45.35 45.4
1
Slice Number
2
ROW 1
ROW 2
Fig (5. 7b)
Fig(5. 7) Variation Overall Heat Transfer Coefficient a long Heat

Exchanger Height at Water Flow Rate 2000 (L/h), Air Flow Rate
2000 cfm

20.04 20.06 20. 08 20.1 20.12 20.14 20.16 20.18 20.2
1
Slice Number
2
ROW 1
ROW 2
3
Fig (5. 8a)

18.8 18.9 19 19.1 19.2 19.3 19.4
1
Slice Number
2
ROW 1
ROW 2
3
Fig (5. 8b)
Fig(5. 8) Variation Overall Heat Transfer Coefficient a long Heat Exchanger

86.5
Overall Heat Transfer Coefficient(W/m2.c)

86
85.5
85
84.5
84
83.5
83
1 2 3 4 5 6
Row Number
Fig(5. 9) Variation Overall Heat Transfer Coefficient a long Heat

Exchanger Depth at Water Flow Rate 2000 (L/h),Water Entering Temp. 10 °C, Air
Flow Rate 2000 cfm
27.95
27.9
Air Exit Temperature (C ) 27.85
27.8
27.75
27.7
27.65
Simulation
27.6
Experiment
27.55
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
Fig (5. 10a)
44
43
42
Air Exit Temperature (C )
41
40
39
38
37
Simulation
36
Experiment
35
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Air Velocity (m/s)
Fig (5. 10b)
Fig (5. 10) Comparison between the Experimental and Present Model for the Effect
of Air Velocity on Air Exit Temperature at Water Flow Rate 2000 (L/h)
Exit Air Temperature (c)

26.5 27 27.5 28 28.5 29 29.5 30 30.5
1
2
ROW 1
ROW 2
Fig (5. 11a)

33 33.5 34 34.5 35 35.5 36 36.5
1
2
ROW 1
ROW 2
Entering water at 50 °C•

Fig (5. 11b)
Fig (5. 11) Variation Exit Air Temperature (°C) a long Heat Exchanger Height at
Water Flow Rate 2000 (L/h), Air Flow Rate
2000 cfm

26.5 27 27.5 28 28 .5 29 29.5 30 30.5
1
2
ROW 1
ROW 2
3
Fig (5. 12a)
Exit Air Tem perature (c)

30 32.5 35 37.5 40 42.5 45
1
2
Row 1
Row 2
Fig (5. 12b)
Fig(5. 12) Variation Exit Air Temperature) a long Heat Exchanger

Height at Water Flow Rate 2000 (L/h), Air Flow Rate
500 cfm
35
30
25
Air Exit Temperature (c)
20
15
10
0
1 2 3 4 5 6
Row
No.ofNumber
Row
Fig(5. 13) Variation Air Exit Temperature a long Heat Exchanger Depth
atWater Flow Rate 2000 (L/h), Water Entering Temp. 10 °C,2000 cfm
43
40 Water Inlet Temperature 10 C
Pressure Drop in Air Side (mbar)*10-2
37
34 Water Inlet Temperature 50 C
31
28
25
22
19
16
13
10
0.6 0.7 0.8 0.9 1 1.1
Aspect Ratio (H/L)
Fig (5. 14) The Effect of Aspect Ratio (H/L) with Different
Core Size (L × D × H) on the Pressure Drop in Air Side,
Water Flow Rate 2000 (L/h) Air Flow Rate 500 cfm
2.5
2
Power Output (kW)
1.5
0.5
T1=15 C
T1=30 C
0
610 620 630 640 650 660
Turbine Inlet Temperature (C )
Fig (5.15) The Effect of Turbine Inlet Temperature on the Power Output With Variable
Compressor Inlet Temperature, at Rang gas Generator Speed (50000-65000 RPM)
2.6
2.5
Fuel Mass Flow Rate (g/s)
2.4
2.3
2.2
2.1 45000 RPM
55000 RPM
2
10 15 20 25 30 35
Compressor Inlet Temperature (C )
Fig (5.16) The Effect of Compressor Inlet Temperature (with Variable Gas
Generator Speed) on the Fuel Mass Flow Rate
Specific Fuel Consumption (g/kW.s)

1.8
1.6
1.4
1.2
1
45000 RPM
0.8
55000 RPM
0.6
10 15 20 25 30 35
Generator Speed ) on the Specific Fuel Consumption
110
108
Heat Consumption (kW)
106
104
102
100
45000 RPM
98
55000 RPM
96
10 15 20 25 30 35
Generator Speed) on the Heat Consumption
100
90
80
70
Heat Rate (kj/kW.s)
60
50
40
30
20
T1=15 C
10
T1=30 C
0
610 620 630 640 650 660
Turbine Inlet Temperature (C)
Fig (5.19) The Effect of Turbine Inlet Temperature (with Variable Compressor Inlet
Temperature) on the Heat Rate, at Rang Gas Generator (50000-65000 RPM)
1.8
1.6
Overall Efficiency (%)
1.4
1.2
1
0.8
0.6
0.4
Ti=15 C
0.2
T1=30 C
0
610 620 630 640 650 660
Fig (5.20) The Effect of Turbine Inlet Temperature (with Variable Compressor Inlet
Temperature) on the Overall Efficiency (%),at Rang Gas Generator Speed
(50000-65000 RPM)
0.14
0.13
0.12
Air Mass Flow Rate (kg/s)
0.11
0.1
0.09
0.08
0.07
0.06 45000 RPM
0.05
55000 RPM
0.04
10 15 20 25 30 35
Generator Speed) on the Air Mass Flow Rate
450
400
350
cfm
300
250 45000 RPM
55000 RPM
200
10 15 20 25 30 35
Generator Speed) on the Air Flow Rate
1.44
1.39
Compression Ratio
1.34
1.29
1.24
45000 RPM
1.19
55000 RPM
1.14
10 15 20 25 30 35
Generator Speed) on the Compression Ratio
5
Compressor Work (kW)
45000 RPM
1
55000 RPM
0
10 15 20 25 30 35
Generator Speed) on the Compressor Work
7
HP.Turbine Work (kW)
2
T1=15 C
1
T1=30 C
0
610 620 630 640 650 660
Fig (5.25) The Effect of Turbine Inlet Temperature (°C) on the HP.Turbine
Work with variable Compressor Inlet Temperature (°C) ,
at Rang Gas Generator Speed (50000-65000 RPM)
80
70
60
Percent of Design
50
40
30
POWER OUTPUT
20
OVERALL EFFICIENCY
10
HEAT CONSUMPTION
0
10 15 20 25 30 35
Fig (5.26) The Influence Compressor Inlet Temperature (°C )on Gas Turbine
Performance at (Gas Generator Speed 45000 RPM)
80
70
60
Percent of Design
50
40
30
POWER OUTPUT
20
OVERALL EFFICIENCY
10
HEAT CONSUMPTION
0
10 15 20 25 30 35
Fig (5.27) The Influence Compressor Inlet Temperature (°C )on Gas Turbine
Performance at(Gas Generator Speed 55000 RPM)
2.8
2.6
2.4
Overall Efficiency (%)
2.2
1.8
Theoretical,Expansion
1.6 Ratio=1.03
1.4 Experimental,Expansion
Ratio=1.03
1.2
500 525 550 575 600 625 650 675 700
HP.Turbine Inlet Tem perature (C)
Fig (5.28) Comparison between the Experimental and Theoretical Predictions

of the gas turbine engine (GT-85)
CHAPTER SIX
Conclusions & Recommendations

Chapter Six ..................................................................... Conclusions &Recommendations
6.1 Conclusions:
The main goal of this work was to examine the possibility of increasing the
power output and overall efficiency of gas turbine engine. Also, it was aimed
to reduce heat rate. This was accomplished by reducing compressor inlet
temperature.
The following major conclusions are drawn from this work:
1. A computational model for design of air-cooled heat exchanger has been
developed. For validation of the model, the heat load performance of a typical
air-cooled heat exchanger was simulated over wide ranges of the air velocity
and water flow rate .These were compared with the experimental data
provided by experimental work. The specifications of the test heat exchanger
are given in [Table (3.1)] shows a good agreement with the predicted
operating conditions of the present model. The maximum discrepancy
between the experimental data and calculated results for overall heat transfer
coefficient and heat load was about (5%) for the given range of the simulated
conditions. The model evaluation is obtained by checking its validity against
experimental results obtained in the present work.
2. Increasing the ambient temperature lowers the density of the compressor
inlet air. Thus reducing the mass flow through the turbine, and therefore will
be reduced the power output. When the volume flow remains approximately
constant, the mass flow will increase with decreasing temperature and will be
decreased with increasing temperature. Therefore, when the compressor inlet
temperature reduced from (30 °C) to (15 °C), the percent of design increase
up to (15%) of the power output ,and ,the overall efficiency increased up to
(25%) ,while the heat consumption reduction was about (10%).
3. The prediction of the gas turbine performance by using non-dimensional
analysis is a good method which has been used in modern computer codes.
The results revealed that the discrepancy percentage between theoretical and
experimental prediction for gas turbine performance was about (18%).
Chapter Six ..................................................................... Conclusions &Recommendations
4. There is a relationship among the compressor inlet temperature, gas

generator speed and turbine inlet temperature. At the higher speeds the
increase in percentage of power output is lower than that of lower speeds
when reducing the compressor inlet temperature.
6.2 Recommendations:
1. At extreme high climate temperatures, the cooling of the ambient
temperature technique is preferable and worth doing where the benefits are
high. On the other hand, the benefits are low in regions with mild or low-
round temperatures, and that what has been detected through the experimental
data.
2. Using the computational model program to design and study the effect of
varying different design parameters: such as (number of rows, fin spacing, air
velocity, velocity in tube, number tubes. For air-cooled heat exchanger and
entering these parameters as data to intake of gas turbine is good idea,
therefore by using different of inlet cooling system like absorption
refrigeration cycle, evaporative cooling especially in low relative humidity
regions is benefits.
3. Modifying the computational model program to investigate the gas turbine
performance and study the effect of compressor inlet temperature on the
performance using non-dimensional analysis, this requires further future
investigation by other researchers.
References
1-Philip, K., "Power Generation Hand Book", 1st edition, McGraw-Hill
Professional, ISBN: 0071396047, pp.115-117, 2002.
http:// www.digitalengineeringlibrary.com
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for Standardisation, Geneva,(1973).
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Systems Schenectady, NY, GER-3567H, pp.6-8, 2002.
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Exchangers" ,Chemical Engineering,pp.418-425,McGraw-Hill Publication
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(1982).
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SAE.Paper , 2006-01-0726, The University of Michigan.
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the Prediction of the Thermal Performance for Cross Flow Air Cooled Heat
Exchangers with a New Air Side Thermal Correlation ", Journal of
Engineering and Development, vol. 12,No.3, 2008.
12-De Lucia ,M., Lanfranchi, C., and Boggio, V., “Benefits of compressor
inlet air cooling for gas-turbine cogeneration plants”, Proceedings of the
International Gas Turbine and Aero-engine Congress and Exposition,
Houston Texas, 5–8 June 1995.
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Performance", M.Sc.Thesis, AL-Mustansiria University College of
Engineering, 1996.
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compressor inlet air refrigeration.”, Journal of Engineering for Gas Turbines
and Power, Vol. 119, pp. 124–129, 2001.
15-GE Nuovo Pignone Internal DT-'N',"Gas Turbine Performance
Curves",Hyundi Engineering and Construction CO, Commessa-Job 1705520-
21,2002.
16- Donald C. Erickson and Icksoo Kyung, “Aqua Absorption Turbine Inlet
Cooler”, ASME International Mechanical Engineering Congress and
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17- Hameed,N.,"The Influence of Water Injection on Two-Shaft Gas Turbine
Performance with Regeneration", M.Sc.Thesis, AL-Mustansiria University
College of Engineering, 2004.
18-Benjalool,A.,"Evaluation of Performance Deterioration on Gas Turbines
due to Compressor Fouling",MSc Thesis,School of Engineering,Academic
Year, pp.46-48,2006,.
19-Tony Giampaolo, " Gas Turbine Handbook: Principles and Practices" 3rd
Edition, Published by the Fairmont Press, Inc.700 Indian Trail, 2006.
20-Kuamit, A.A.," Design of Combined Cycle Power Plant and Air Cooling
System", Ph.D,Thesis, AL-Mustansiria University College of Engineering,
2006.
21-Tarrad, A. H., and Mohammed, A. G., " A Mathematical Model for
Thermo-Hydraulic Design of Shell and Tube Heat Exchanger Using a Step by
Step Technique" Engineering and Development Journal, Vol. 10, No.4,
December 2006.
22-Watlow products and technical support delivered worldwide," Diesel and
Gas Turbine Temperatures sensors" Watllow electric Manufacturing
Company,2001.
23-Gilbert Gilkes and Gordon LTD, "Technical Handbook of Two-Shaft Gas
Turbine " , Gilkes, Kendal, England, 1978.
24-Philip P., Walsh," Gas Turbine Performance", Blackwell Publishing, 2nd
Edition, 143 pp, 2004.
25-H., Cohen, G., F., C., Rogers and H., I., H., Saravanamuttoo," Gas Turbine
Theory", 4th ed, 1996.
26-Kays, W.M., and London, A.L., "Compact Heat Exchangers", 3rdedition,
McGraw-Hill Book Company, 1984.
27-Smith, E.M.," Thermal Design of Heat Exchangers ,a Numerical
Approach", John Wiley and Sons, New York, 1997.
28-G.,F.,Hewitt, " Heat Exchanger Design Hand book",Begell House, New
York, 1998.
29- Holman, J.,P., "Heat Transfer" 7th edition McGraw-Hill, New
Yourk,1989.
30- Dittus, F.W., and Boelter, L.M.K., Univ. Calif. (Berkeley) Pub. Eng.,
Vol.2, pp.443, 1930.
31-McAdams, W.H., "Heat Transmission", 3rd, Ed., McGraw-Hill, New York,
1954.
32- Adrian, B.," Forced Convection: Internal Flows", Mechanical Engineering
and Materials Science, Chap. 5,420 pp.
33- Sieder, E.N., and Tate, C.E., "Heat Transfer and Pressure Drop of
Liquids in Tubes", Ind. Eng. Chem., Vol.28, pp.1429, 1930.
34- Briggs D.E. and Young, E.H., "Convection Heat Transfer and
Pressure Drop of Air Flowing Across Triangular Pitch Banks of Finned
Tubes", Chem. Eng. Prog. Symp. Ser. Vol.59, No.41, pp1-10, (1963).
35- London,A. L.,"Compact Heat Exchanger-Design Methodology",
ed.Kakac,S.,Shah,R.K.and Bergles,A.E.,Hemisphere,New
York,(1983).
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Convective Heat Transfer in Ducts",Single Phase Convective Heat
Transfer,Wiley,1987.
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Pergamon Press, Oxford, See also 2nd edn, Krieger, Melbourne, FL,
1987.
38-Hawthorne,W.R., and Davis, G.de V."Calculating gas turbine
performance", Engineering 181, 361 -367, 1956.
39- Keenan, J.H. and Kaye, J.," Gas Tables", Wiley, New York, 1945.
,
Appendix (A)
Experimental Work
Data Tables
The experimental Data for gas turbine:
Table (A-1)
Ambient Temperature: 19.5 (°C)
Ambient Pressure: 1.0133 bar
Compressor Inlet Temperature: 15 (°C)
Engine Parameters Gas Generator Speed Gas Generator Speed

(45000 RPM) (55000 RPM)
T1 (°C) 15 15
Δp (mmwg) 32 43
Vf (L/h) 5 6
P2 (bar) 0.23 0.32
T 2 (°C) 46 52
T3 (°C) 561 577
P3 (bar) 0.22 0.31
T4 (°C) 519 531
P4 (mmbar) 35 45
T5 (°C) 485 492
Δp 4/5 (mmHg) 25 30
Torque (N.m) 0.92 0.93
Power Turbine 14400 16300

Speed (RPM)
Table (A-2)
Ambient Temperature: 25 (°C)
Compressor Inlet Temperature: 20 (°C)
Engine Parameters Gas Generator Speed Gas Generator Speed

(45000 RPM) (55000 RPM)
T1 (°C) 20 20
Δp (mmwg) 30 40
Vf (L/h) 4.9 5.7
P2 (bar) 0.25 0.33
T 2 (°C) 57 63
T3 (°C) 588 604
P3 (bar) 0.23 0.31
T4 (°C) 546 558
P4 (mmbar) 37 50
T5 (°C) 506 517
Δp 4/5 (mmHg) 25 35
Torque (N.m) 1.3 1.36

Speed (RPM)
Table (A-3)
Ambient Temperature: 29 (°C)
Compressor Inlet Temperature:25 (°C)
Engine Parameters Gas Generator Speed Gas Turbine Speed

(45000 RPM) (55000 RPM)
T1 (°C) 25 25
Δp (mmwg) 40 50
Vf (L/h) 4.7 5
P2 (bar) 0.29 0.34
T 2 (°C) 56 63
T3 (°C) 618 635
P3 (bar) 0.25 0.31
T4 (°C) 551 565
P4 (mmbar) 40 52
T5 (°C) 508 523
Δp 4/5 (mmHg) 25 33
Torque (N.m) 0.66 0.85

Speed (RPM)
Table (A-4)
Ambient Temperature: 29(°C)
Compressor Inlet Tempertaur:30 (°C)
Engine Parameters Gas Turbine Speed Gas Turbine Speed

(45000 RPM) (55000 RPM)
T1 (°C) 30 30
Δp (mmwg) 39 59
Vf (L/h) 5 6
P2 (bar) 0.31 0.45
T 2 (°C) 64 73
T3 (°C) 631 650
P3 (bar) 0.28 0.35
T4 (°C) 552 578
P4 (mmbar) 38 59
T5 (°C) 511 531
Δp 4/5 (mmHg) 42 57
Torque (N.m) 0.71 1.9

Speed (RPM)
Table (A-5)
Ambient Pressure:1.0133 bar
Turbine Inlet Temperature: 586 (°C)
Running with Running with

Engine Parameters Compressor Inlet Compressor Inlet
Temperature 15 (°C) Temperature 22 (°C)
T3 (°C) 586 586
Gas Generator ( RPM) 55000 50000
Δp (mmwg) 43 47
Vf (L/h) 6.2 5.8
P2 (bar) 0.32 0.35
T1 (°C) 15 22
T2 (°C) 52 60
P3 (bar) 0.3 0.32
T4 (°C) 539 534
P4 (mbar) 50 46
T5 (°C) 499 496
Δp 4/5 (mmHg) 32 30
Torque (N.m) 1.09 0.74
Power Turbine(RPM) 18800 16500

Table (A-6)

T3 (°C) 590 590
Δp (mmwg) 39 33
Vf (L/h) 5.5 5
P2 (bar) 0.3 0.25
T1 (°C) 18 22
T2 (°C) 52 53
P3 (bar) 0.27 0.21
T4 (°C) 544 549
P4 (mbar) 45 40
T5 (°C) 504 509
Δp 4/5 (mmHg) 30 27
Torque (N.m) 1.16 1.33

Table (A-7)

T3 (°C) 620 620
Δp (mmwg) 44 40
Vf (L/h) 5.2 4.7
P2 (bar) 0.34 0.29
T1 (°C) 20 30
T2 (°C) 58 60
P3 (bar) 0.31 0.25
T4 (°C) 550 554
P4 (mbar) 50 40
T5 (°C) 500 510
Δp 4/5 (mmHg) 32 25
Torque (N.m) 0.69 0.66

Table (A-8)

Temperature 15 (°C) Temperature 30(°C)
T3 (°C) 625 625
Δp (mmwg) 53 38
Vf (L/h) 5.6 5.2
P2 (bar) 0.41 0.28
T1 (°C) 15 30
T2 (°C) 61 64
P3 (bar) 0.34 0.26
T4 (°C) 550 549
P4 (mbar) 55 35
T5 (°C) 508 500
Δp 4/5 (mmHg) 36 22
Torque (N.m) 0.59 0.36

Table (A-9)

T3 (°C) 635 635
Δp (mmwg) 41 39
Vf (L/h) 5.2 4.7
P2 (bar) 0.34 0.31
T1 (°C) 25 29
T2 (°C) 62 61
P3 (bar) 0.31 0.26
T4 (°C) 564 566
P4 (mbar) 52 45
T5 (°C) 522 523
Δp 4/5 (mmHg) 33 29
Torque (N.m) 0.85 0.79

The experimental Data for heat exchanger
Table (A-10)
Vw=2000 L/h , Va=2000 Cfm

Twi (°C) Two (°C) Tai (°C) Tao (°C)
50 48 32 36.7
40 38 32 35
20 22 32 27.7
15 17 32 27.5
10 12 32 28
Table (A-11)
Vw=2000 L/h , Va=1000 Cfm

50 49 32 36.2
40 38.9 32 35.9
20 21 32 28.2
15 15.9 32 28
10 10.9 32 27
Table (A-12)
Vw=2000 L/h , Va=500 Cfm

50 49.5 32 38.4
40 39.4 32 36.5
20 21.4 32 28
15 15.4 32 27.9
10 10.4 32 26.9
Table (A-13)
Vw=3000 L/h , Va=2000 Cfm

Twi (co) Two (co) Tai (co) Tao (co)
50 48.5 32 36.3
40 39.7 32 33
20 21.5 32 27.9
15 16.5 32 27.7
10 11.5 32 27
Table (A-14)
Vw=3000 L/h , Va=1000 Cfm

50 49.4 32 36
40 39.3 32 35
20 20.8 32 27
15 15.9 32 26.5
10 11.7 32 26.8
Table (A-15)
Vw=3000 L/h , Va=500 Cfm

50 49.8 32 35.8
40 39.7 32 35.1
20 20.4 32 27
15 15.4 32 26.9
10 10.4 32 26.4
Appendix (B)
Flow Charts and
Computer Programs
Flow Chart for Theoretical heat exchanger Performance Prediction(CPHE)
Start
Input Surface Characteristics

& Inlet Operation Conditions
for Both Fluids
Choose the Velocity in Tubes

Calculate the No. of Slices from Water
Temperature conditions
Calculate (No. of Tubes / Row) ,EQ.(3-1) &

Calculate Length of H.EX, EQ.(3-2) &
Calculate Depth of H.EX, EQ.(3-3)
YES
∆Twater = 0.1,
nw=0.3,na=0.4,F=1 IF (Twi >Two)
NO
∆Twater= 0.1,
nw=0.4 ,na=0.3,F=-1
Calculate the air mass flow rate for first row, Eq (4-6)
Calculate the Heat Load for First Slice
& First Row,EQ.(3-9)
Assume the Air Exit Temperature for First Row
B A
B A
Calculate the Air Mass Flow Rate for First Row
J=1,
Calculate the No. of Slices from Water Temp.
Conditions
I=.1,
Divided the Air Mass Flow Rate per No. of Slices
Calculate the Fluids Properties from Inlet Conditions
Calculate the Heat Load for First Slice
Calculate the Air Exit Temperature for First Slice
Correct the Fluids Properties
Calculate the Correct Air Exit Temperature for

First Slice
Assume the Air Velocity Over Tubes.
Calculate the Height of Heat Exchanger
D C E
C
D E
Calculate the Cross Sectional Area Temperature,

Hydraulic Diameter, Reynolds No., Nusslat No. .
Calculate the Overall Heat Transfer Coffi.,
Calculate the Height of Heat Exchanger

Calculate Error from Calculating Value &
Assuming Value.
Repeat Process for all Slices (Ni)
NO
IF Error
<=0.001
YES
Calculate the Mean Air Exit Temp.

Calculate the Error from Calculating Value &
Assuming Value
NO IF Error
<=0.001
YES
Repeat the process for all Rows (Nj)
Calculate Heat Exchanger Performance
Calculate Heat Exchanger Physical Characteristics
End
Flow Chart for Theoretical Gas Turbine Performance Prediction(CPTGTP)
STRAT
INPUT DESIGN INFORMATION

Tmax,T1,Rc,Rt,f,H.V,ηc,ηt
Ømax=Tmax/T1,M=0
For Ø=Ømax to 1 step -1

T3=Ø*T1
Za=γa/(γa-1), Xcm=(Rc)^(1/Za)
For Xc=Xcm to 1.1 step -.05

NDCW=(Xc-1)/(ηc*(Ø-1))
Zg=γg/(γg-1), Xtm=(Rt)^(1/Zg),n=cpa/cpg
NDTW=((1+f)*ηt*(1-1/Xt))/((1-1/Ø)*n)
ηo=NDTW/(H .v*(1+ƒ))
PRINT T3,Ø,Xc,Xt,ηo,NDCW
NDTW
NEXT Xc , NEXT Xt , NEXT Ø
END
Appendix (C)
Gas Turbine parameter
Groups
(C-1)
(C-2)

Gas Turbine, Finned Heat Exchanger

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Republic of Iraq

Ministry of Higher Education and Scientific Research

The Enhancement of Two- Shaft Gas Turbine

A THESIS SUBMMITTED TO THE COLLEGE OF ENGINEERING OF

Dr.Ali Hussain Tarrad Asst.Prof Dr. Fouad Alwan Saleh

‫ﺤﺪِﻳ َﺪ ﻓِﻴ ِﻪ ﺑَﺄْسٌ ﺷَﺪِﻳﺪٌ َو َﻣﻨَﺎ ِﻓ ُﻊ‬

‫ﺳﻮرة اﻟﺤﺪﻳﺪ اﻵﻳﺔ )‪(25‬‬

In view of the available recommendation I forward this thesis for

We certify that we have read the thesis entitled (THE ENHANCEMENT OF

LOVE AND RESPECT

All praise is due to Allah, the lord of the worlds

I would like to express my deep sense of appreciation and thank to my

supervisors (Dr.Ali Hussain Tarrad and Dr. Fouad Alwan Saleh)

for their continuous encouragement and support during the study.

In the present research, a study of the performance improvement of a two-

List of Figures VIII

List of Tables XII

CHAPTER ONE: Introduction 1

1.5 Compact Heat Exchanger 6

3.6 Dimensionless and Parameter Groups 33

3.6.1 Corrected Compressor Data 34

3.6. 3 Corrected Derived Data 36

3.8 Test Procedure 40

CHAPTER FOURE : Mathematical Model 43

4.2.2.2 Physical Characteristics of Heat Exchanger 49

4.2.2.4 Log-Mean Temperature Difference 50

4.2.2.5 Heat Load 51

4.2.2.6 Overall Heat – Transfer Coefficient (Uo) 51

4.2.2.7 Forced Convection Heat Transfer coefficient Inside Tube 52

4.2.2.8 Forced Convection Heat Transfer coefficient for Air Side 52

4.3 Gas Turbine 57

4.4 Basic Gas Turbine Cycles 58

4.7 Results and Discussion of Theoretical Calculations 62

5.2.2 Heat Transfer Coefficient for air side 72

5.3.1 Effect of Compressor Inlet Temperature on Power Output 76

5.3.6 Effect of Compressor Inlet Temperature on Overall 78

6.1 Conclusions 115

- 6.2 Recommendations 116

Appendix (A)Experimental Work ,Data Tables 122

Appendix (B) Flow Charts and Computer Program 134

Appendix (C)Gas Turbine parameter Groups 146

Figure (1.1) Two Shaft Gas Turbine Diagram 3

Figure (4.8) Theoretical Overall Efficiency as a Function of (T3/T1 Ratio) 65

Figure (4.12)The Effect of Turbine Inlet Temperature (High Pressure Turbine)on 67

Figure(4.17)The Effect of Compressor Inlet Temperature (with Variable 69

Figure(5. 4) Variation Heat Transfer Coefficient ha.(w/m2.c) a long Heat 96

Figure (5. 5) Variation Heat Transfer Coefficient. ha ( w/m2. c) a long 97

Figure(5. 7) Variation Overall Heat Transfer Coefficient (w/m2.c) a long 99

Figure(5. 9) Variation Overall Heat Transfer Coefficient ( w/m2. c) a long 101

Table (2-1) GE-Design Parameters 12

Table (5-7) Air Temperature Distribution a long First Row Height 89

m& f Fuel Mass Flow Rate Kg/s

Q& Rate of Heat Transfer Loss or Gain W

Ø Maximum to Minimum Temperature Ratio through the gas turbine

ηo Overall Efficiency of Gas Turbine

ƒ Fuel / Air Ratio

λt Perimeter of Tube Side (m3)

λf Perimeter of Fin (m3)

γ Specific Heat Ratio

NDCW Non-dimensional Compressor Work

NDTW Non-dimensional Turbine Work

turbine is connected to the driven equipment. It must be noted at this point