13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics

THERMODYNAMIC MODELING AND PERFORMANCE OPTIMIZATION FOR

SIMPLE-CYCLE GAS TURBINE WITH AIR COOLING

Wenhua Wang, Lingen Chen* and Zemin Ding

*Author for correspondence
Institute of Thermal Science and Power Engineering,
Naval University of Engineering,
Wuhan, 430033,
P. R. China
E-mail: lgchenna@yahoo.com and lingenchen@hotmail.com

NOMENCLATURE is established. The thermodynamic performance of the cycle is

A = Surface area (m2) investigated. The calculation flow chart of the power output
c = Specific heat (kJ/kg.K); Blade chord length (m) and the efficiency is exhibited, and the verification computation
I = Enthalpy (J) is performed based on the design performance data for 80-
L = Blade height (m) type industrial gas turbine plant developed by Ukraine. The
m = Mass flow rate (kg/s) results indicate the model is reasonable and can predict the
P = Power (kJ/kg) design performance of gas turbine cycle effectively. The
p = Pressure (kPa) maximum power output, the maximum efficiency and their
s = Blade pitch (m) corresponding cooling air percentages are obtained by
T = Temperature (K) optimizing the pressure ratio of the low-pressure compressor
V = Velocity (m/s) and the total pressure ratio, respectively. The results also
Greek symbol indicate that the outlet temperature of combustor chamber or
= Efficiency the inlet temperature of turbine affects the thermodynamic
= flow outlet angle performance of the cycle evidently.
= Pressure ratio
= Mass density (kg/m3)
INTRODUCTION
= Pressure loss coefficient
One of the most effective technological innovations to
enhance specific power output and efficiency of gas turbine
= Cooling air percentage
cycle is to enhance outlet temperature of the combustion
superscript
chamber or the inlet temperature of the turbine. To prevent the
0 = Relative
turbine blades from hot corrosion, part of compressed air in the
- = Mean
compressor must be bled to cooling the front blade stages of the
subscripts
turbine [1, 2]. In general, the cooling air should be so sufficient
a =air; fitting coefficient
that it will cool the blades effectively, but bleeding too much
b = fitting coefficient
compressed air will decrease the mass flow rate of main
c = Cooling air; working fluid in the later flow path and then decrease the power
CC =Combustion chamber output and efficiency of the gas turbine cycle [3]. How to
f = Fuel determine the optimal cooling air percentages with respect to
g = Gas different cooling measures is very difficult. To solve this
HC = High-pressure compressor problem, many scholars have performed lots of research work.
i = Inlet Ref.[2] presented a predicting model of cooling air percentage
HT = High-pressure turbine without involving the thermodynamic modelling of gas turbine
LC = Low-pressure compressor cycle. Based on Ref.[2], Horlock et al [4, 5] and Jordal [6]
LT = Low-pressure turbine pursued further studies with considering ideal air as working
max = Maximum fluid [4, 5], and estimating the cooling air percentage with
o = Outlet convection cooling and air film cooling [6]. Yong and Wilcock
PT = Power turbine [7, 8] studied the thermodynamic performance of single-shaft
1,2,21, 3 = State points ideal gas turbine cycle by considering the air cooling and the
specific heat ratio of the air changes with temperature only, and
ABSTRACT the established thermodynamic model couldn't reflect the real
A predicting model of cooling air percentage for turbine operation process as the mass flow rate ratio of the fuel and the
blades with respect to simple-cycle triple-shaft gas turbine plant air was taken as perfect. Refs.[9-11] built the thermodynamic
considering the thermophysical properties of the air and the gas model of gas turbine cycle with the help of ASPEN soft, and

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 13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics

reckooned the coolling air percenntage for a siingle-shaft, siimple- I = a0 + a1T + a2T 2 + a3T 3 + a4T 4 + a5T 5 (1)
cyclee gas turbin ne. Refs.[12--18] estimatedd or analyzeed the
charaacteristic perrformance baased on the simple-cyclee gas lg = b0 + b1T + b2T + b3T + b4T + b5T
0 2 3 4
(2) 5

turbiine plant connsidering air ccooling but didn't

d optimizze the w
where ai and bi (i=0, 1, 225) are the t fitting cooefficients
cyclee key charactteristic parameters such as the pressure ratio, r
respectively, a the relatiive pressure 0 is the rattio of the
and
etc. with respect to the cycles. Shi et al [19] proposes a new loocal pressuree p and thee standard prressure p0 under u the
cooliing method which
w integrattes steam and air for gas tuurbine
r
reference conddition.
vanee cooling withh the aim to solve the probblem of a veryy high
Considerinng an adiabattic and irreveersible thermo odynamic
thermmal load at thhe trailing edgge region of a steam-cooleed gas
turbiine vane. Moskalenko
M ett al [20] stuudied the coooling p
process, the air isentropicc relative prressure ratio 2s 0
and
efficciency of thhe first stagee turbine bllade for diffferent e
enthalpy I 2 att LC outlet cann be written as
a
param meters of coooling mediuums of air and water vapor, v 20s = 10 LC , I 2 = I1 + ( I 2 s I1 ) / LC (3)
respeectively. Sanjjay [21] studiied the therm moeconomics of o gas
turbiine cycle withh air film bladee cooling. where , I1 , LC , LC aand I 2s denotte the air inleet relative
w 0
1
Inn this paper, a predicting m model of coolling air percenntages p
pressure ratioo, inlet enthaalpy, efficienccy, pressure ratio
r and
for different
d turbiine blades witth respect to simple-cycle
s t
triple- isentropic outllet enthalpy off the LC.
shaftt gas turbinne plant coonsidering thhe thermophhysical a isentropic relative presssure 3s0 and enthalpy
Also, the air
propperties of thee air and thee gas will bee established. The
thermmodynamic performance oof the cycle will w be investiggated. I 3 at HC outleet can be writtten as
The calculation flow chart oof the poweer output andd the 3s0 = 210 HC , I 3 = I 21 + ( I 3s I 21 ) / HC (4)
efficciency will bee exhibited, aand the verificcation compuutation
will be performed d based on thhe design perrformance daata for w
where , I 21 , HC , HC and I 3s denotte the air inleet relative
0
1

800-type indusstrial gas turbine plant deveeloped by Uk kraine. p

pressure ratioo, inlet enthaalpy, efficienccy, pressure ratio
r and
The maximum power output, thhe maximum efficiency e andd their isentropic outllet enthalpy off the HC.
correesponding coooling air perrcentages will be obtaineed by According to mass and eenergy conservation, one haas
optimmizing the prressure ratio oof the low-prressure comprressor mg = ma mc + m f , m f HuCC = mg I 4 (ma mc ) I311 (5)
and the
t total presssure ratio, resppectively.
mHT = mg + mcHT , mHT HT ( I 4 I 5 s ) = ma ( I 3 I 21 ) (6)
CYC CLE MODEL LLING mLT = mHT T LT ( I 5 I 6 s ) = ma ( I 2 I1 )
H + mcLT , mLT (7)
Fig.1
F shows a simple-cyclle triple-shaftt gas turbine (GT) where I 31 , I 4 and CC denoote the workin
w ng fluid inlet enthalpy,
plantt considering air cooling. Inn the figure, ma denotes innlet air
masss flow rate of the low pressuure compresso or (LC), mc deenotes ooutlet enthalpyy and efficiency of the CC;; mHT , mcHT , HT and
the cooling
c air maass flow rate tthat is bled froom the outlet of the I 5s denote thee main gas maass flow rate, cooling air mass m flow
high-pressure com mpressor (HC C). In the coombustion chaamber r
rate, efficienccy and isentrropic outlet enthalpy e of the
t high-
(CC)), the fuel (mmf denotes fuel mass flow rate) r is igniteed and p
pressure turbiine (HT); and m LT , mcLTT , I 5 , HT and I 6 s
burnned with the aiir and the prodduct (gas, via. the mixture of the
d
denote the maain gas mass fl flow rate, coolling air mass flow rate,
resid
dual air and pure
p gas) masss flow rate at a the outlet ofo the
innlet enthalpy,, efficiency annd isentropic outlet enthalpy of the
combbustion cham mber is mg. LC C and HC are driven by thee low-
loow-pressure turbine
t (LT).
presssure turbine (LT) and thhe high-presssure turbine (HT),
The powerr output and thhe efficiency of o the cycle arre
respeectively. The power turbinne (PT) drivees the load solely. s
Conssidering the thermophysica
t al properties of the fluid (air
( in P = mPT PT ( I 6 I 7 s ) / ma , = Pma / (m f HuCC ) (8)
comppressors and gas in GT hoot section) is changeable
c w its
with w
where mPT , PT and I 7 s denote the gas mass flow f rate,
tempperature and components ass it passes alonng the flow paath. e
efficiency andd isentropic ouutlet enthalpy
y of the poweer turbine
(
(PT). Obvioussly, mPT = mLTT .

COOLING BLADE MODELLING

C
There are two major bblade cooling processes: coonvection
c
cooling processs and film cooling process..
For convection coolingg process perrformed in thhe turbine
b
blades (Fig.2)), the cooling air flows intto and out th he hollow
b
blades throughh inner passagges, takes awayy quantity of heat
h from
thhe turbine blades,
b decreases workingg temperature of the
Figgure 1 The sim
mple gas turbinne plant consiidering air coooling s
surface of turbbine blade, andd then blends into the mainn gas flow.
I Fig.2, Vg and Vc are gas and cooling
In c air velocities,
v
Based
B on Ref.[22], the enthhalpy and the relative
r pressuure of r
respectively. Tgi and Tgo arre gas inlet annd outlet tempperatures,
the air/pure
a gas can be obtaiined by the fitting
f formullas as Tci and Tco are cooling air inlet annd outlet
r
respectively.
belloow

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 13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics

tempperatures, resppectively. Asgg and Tbl are blade surfacee area w

where fg deenotes the heaat exchange co
oefficient betw
ween the
and temperature, respectively. Ag is the efffective area of
o the a film and blade surface.
air
bladee inner passagge. Defining f = (Tgi Taw ) / (Tgi Tco ) and
a combininng it with
Eq.(12) gives
E
c ] / [cool (1 0 )] (13)
= mc / mg = C[ 0 (1 coool ) f 0 f cool
w
where C = St
S g c pg / c pc .
The total pressure losss resulted froom the mixtuure of the
ccooling air and
a the gas stream (Fig..4) will decrrease the
e
efficiency of thhe simple-cyccle gas turbinee plant.
Figgure 2 Convecction cooling thermal
t modeel for turbine blade
b

Inn order to annalyse problem

m convenientlly, the air bleeeding
m the compressor outlet to cool
from c CC is ign
nored. Accordding to
the law of conservvation of energ
gy, one has
Tco Tggi
Qneet = mc c pc (T )dT = mg c pg (T )dT = g Asg (Tgi Tbll ) (9)
Tci Tgoo

wherre g denotess the heat exxchange coeffficient betweeen the

bladee surface and the gas [4, 5]. F
Figure 4 The mixture modeel for cooling air and the gaas stream
Defining
D cooling efficienncy cool = (Tco
c Tci ) / (Tbl Tci ) ,
The total pressure
p loss coefficient is determined
d as [5]
combbining it with mg = g AgVg and Eq.(9) gives
g pt / pt = 0.5 kkM g2 / (1 + Tc / Tg 2 cos ) (14)
= mc / mg = St g (c pg / c pc )((Tgi Tbl ) / [ coool (Tbl Tci )] (10) w
where = Vc / Vg , M g Mg iis the gas macch number andd is
wherre = Asg / Ag = 2Lc / ( Ls cos ) = 2c / (s cos ) ; L, c, s thhe angle betw
ween the veloccity directions of the coolingg air and
and denote the bladesb height, chord, pitchh, flow outlet angle,
a thhe gas.
respeectively. Generally, s/c=0.8 8 and =75 are designated in
turbiine blades co ooling air perrcentages num merical calcuulation MODEL VER
M RIFICATION
[5]; St g = g / (c pgg gVg ) ; and g denotes th he gas mass deensity. Using thhe simple-ccycle triple-shaft gas turbine
thhermodynamiic model andd turbine blaade air coolinng model
Defining
D 0 = (Tgi Tbl ) / (Tgi Tci ) and combining itt with m
mentioned aboove, one makees approximatte calculation about the
Eq.(10) gives thhermodynamiic performancce and coolin ng air informaation and
= K 0 / (1 0 ) (11) c
compare the result with ddesign perforrmance public-data of

80 -type inndustrial gas turbine developed by Ukraaine [23].
wherre K = C / coool and C = St
S g cpg / c pc .
T results aree listed in Tabb.1.
The
For
F film cooliing process pperformed in the turbine blades b
(Fig..3), as the coo
oling air flow
ws out the holllow blades thhrough Tab.1 the callculation valuees and design value of 880 plant
innerr passages it forms a film in the high-p pressure gas stream
s Design Caalculation Relative
R
Name, unit
and covers the blades
b surfacee like fire wall.
w In Fig.3, Taw value value error
LLow-pressure turbine
otes the air film
deno f temperatuure which is resulted from m the 1070 1083.5 1.26%
ooutlet temperaature T6, K
mixiing condition of hot gas annd cooling air and differentt from
PPower turbine outlet
Tbl . 773 754.8 2.35%
ttemperature T7, K
LLow-pressure
ccompressor innlet air 85 83.4 1.88%
mmass flow ratee ma, kg/s
PPlants efficieency 34.25% 36.81% 7.47%
CCooling air peercentage
15.12% 13.40% 11.38%
oof high-pressuure ture HT
CCooling air peercentage
Figure 3 Film
m cooling therrmal model foor turbine bladde 3.61% 2.95% 18.28%
oof low-pressurre ture LT
According
A to the
t law of connservation of energy,
e one haas It shows thhe relative erroors of the tem
mperatures andd the inlet
Tcoo
Qnet = Asg fg (Taw Tbl ) = mc c pc (T )dT = mc c pc (Tco Tci ) (12) aair mass flow rate are less than 3%, but the calculatio on results
Tci
o the coolingg air flow rates and the plan
of nts efficiencyy seem to
b relatively laarge as compaaring those to the design vaalues. The
be

894
 13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics

reasoons maybe: (1) The maathematical models m are not

n so
accuurate that moree realities are should be takken into accou
unt; (2)
Actuually, the designers and the manufacctures intentioonally
increease the cooliing air mass flow
f rate to well
w ensure thhe gas
turbiines safety as it operates in the most atrocious
a conddition.
The mathematicaal model buuilt above can give helpful h
guidelines in cooliing system deesign of turbinne blade.

CYC CLE PERFOR RMANCE OP PTIMIZATION N FLOW CHA ART

The
T thermodyynamic performance calcuulation of the gas
turbiine plant conssidering blade air cooling inncludes three steps:
(1) estimate the quantity off the coolingg air that needed n
neceessarily in eachh blade row; (2) estimate thhe total energgy and
total pressure losss resulted from m the heat traansfer betweeen gas
streaam and coolin ng air and mixxture, et al; (3)
( the plant power
p
output and efficien ncy calculatioon based on steeps (1) and (22).
Considering
C the simple-ccycle triple-sshaft gas tuurbine
displlayed in Fig.11, one can divvide the turbinne into three parts:
the high-pressuree turbine (ssingle-stage), the low-preessure
turbiine (single-staage) and the ppower turbinee (multi-stage)). The
bladees of the front
fr three roow (the higgh-pressure tuurbine
Figure 5 The
h thermodynam
mic performancee calculation flo
ow chart
statio
onary blade roow A and rotoor blade row B, B the low-preessure
turbiine stationary blade row C)) need air coolling while thee latter
OPTIMIZATIO
O ON RESULT TS AND ANA ALYSES
bladee rows needdnt as wherre the gas stream s tempeerature
Fig.6 illusttrates the chaaracteristics off P , and versus
decreeases markedlly. It is assum
med that the coooling air is alll bled
from
m the high-presssure compresssor outlet. LC . It showss that P and decrease while
w increeases with
Inn the calculattion, some innitial values arre set: the ammbient inncrease in LC as the outlet temperature of coombustion
tempperature is T0=300.15K, the standdard pressurre is
cchamber T4 iss given and thhe turbine blades are appo
ointed air
p0=1.013bar, eachh GT componnents isentroppic efficienciees are
c
cooling measuure.
LC =0.88, HC =0.88,
= and HT = LT = PT =0.96, thee low
calorrific value of fuel is Hu=422700kJ/kg, thee total pressurre loss
fficient of combustion chaamber is B =0.02, and outlet
coeff
tempperature of com
mbustion cham mber is T4=17700K.
First,
F assuminng the surfacee temperaturee of the statiionary
badee row A Tbl =11073K, cool =0.7
= and f =0.4 [4, 5], onne can
obtaiin 0 and A . Then, takinng it for grannted that the rotor
bladee row B inlett gas stream teemperature TgB
g =( T4 + T5 )/2
2, one
can obtain
o B . Heere, as the airr cooling proccesses of statiionary
and rotor blades of the HT arre consideredd separately, Eq.(6) E
shouuld rewritten as
a
HTg
H (mg + mcHTg )( I 4 I 5 gs ) + HT
Tb mHT ( I 5 g I 5 s ) = ma ( I 3 I 21 )
(15)
he characterisstics of P , and versus
Figure 6 Th LC
wherre HTg andd HTb are isentropic effficiencies of the
statio
onary blade row A and rrotor blade row r B of thee HP, Fig.7 illusttrates the chaaracteristics off P , and versus
respeectively, mcHTTg is working fluid mass fllow rate in roow A, thhe total presssure ration witha selecteed LC = . It shows
I5gs and I5g are row
r A outlett gas stream isentropic andd real thhat P and increase first and theen decrease while
enthaalpy, respectiively, and mcHT is the air a mass flow w rate inncreases withh increase in . There exiists an optimuum P max
cooliing the HT. Like
L A and B , C can bee obtained. Fiinally,
w
which leads to nding Pmax and
t Pmax with the correspon a Pmax .
accoording to Eq.((13) one can obtain the tottal pressure lo oss in
the mixture
m process and efficciency loss of o each turbinne, in T
There also exxists an optim
mum max
leads to max with the
furth
her, power ouutput and efficciency, even exergy
e loss in
n each
compponent, of thee simple-cyclee triple-shaft gas
g turbine plaant are c
corresponding dent that Pmaax < max .
g Pmax and max . It is evid
derivved. The corrresponding computer calcculation flow chart Consideration both plant poower and its efficiency,
C e thee suitable
based on Matlab is displayed inn Fig.5. tootal pressure ratio
r should raange from Pmax
m
to max .

895
 13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics

CONCLUSIO
C ON
This paperr establishes a predictive modelm of the aiir cooling
f different tuurbine blades with respect to simple-cyccle triple-
for
s
shaft gas tuurbine plant considering the therm mophysical
p
properties of thhe air and thee gas, and inveestigates the power
p and
e
efficiency peerformance oof the plant. Some charracteristic
p
parameters aree compared w with the design n performancee data for

80 -type inndustrial gas turbine develloped by Ukraine. The
r
results indicatte the model is reasonable and can prredict the
d
design perform mance of gass turbine cyccle effectively y. Further
o
optimization i performed by taking the
is t power ouutput and
e
efficiency of gas turbine plant as thee objectives based b on
n
numerical exam mple. The maaximum power output, the maximum m
F
Figure nd versus
7 The characteristiccs of P , an e
efficiency andd their correspponding cooliing air percenntages are
o
obtained by seearching the optimal total pressure ratioo and the
m , Pmax , Pmaax and
Fig.8
F illustratees the charactteristics of Pmax o
optimal pressuure ratio of thhe LC using the models esttablished,
a
and the effecct of the outllet temperatuure of the coombustion
Pmax
versus the outlet tempperature T4 of
o the combu
ustion c
chamber on the thermoddynamic perfformance of plant is
cham ws that Pmax , Pmax and Pmax increase while
mber. It show a
analysed.
The resultss and the analyyses indicate:
Pmax
decreases wiith increase inn T4. (1) givingg the outlett temperaturee of the coombustion
c
chamber and the
t total pressuure ratio and considering
c thhe turbine
b
blades are coooled by air, thhe power outtput and the efficiency
e
d
decrease whille the coolinng air perceentage increaases with
inncrease in thee pressure ratioo of the LC;
(2) giving the outlet teemperature off combustion chamber,
thhere exist diffferent total pressure ratioss lead to the maximum
m
p
power output and the maxximum efficiency, respectiv vely. The
c
cooling air percentage
p inccreases with increase in the total
p
pressure ratio;
(3) the maximum
m power and thee correspondding total
p
pressure ratio and coolingg air percentaage increase while w the
c
corresponding g efficiency deecreases as the outlet tempeerature of
thhe combustio on chamber inncreases. Thee maximum efficiencye
haracteristics of Pmax , Pmaxx , Pmax and Pmax
Fiigure 8 The ch a its corressponding totall pressure rattio decrease while
and w the
verssus T4 c
corresponding g power and coooling air percentage increaase as the
o
outlet temperaature of the combustion cham mber increasees.
Fig.9
F illustratees the charactteristics of max
m , Pmax , maax and

maxx
versus T4. It shows thaat max and max increase while
ACKNOWLE
A EDGEMENTS S
Pmax and max decreases as T4 increases.
i The authorrs wish to thaank the revieewers for theiir careful,
u
unbiased and constructive
c suuggestions, which
w led to thhis revised
m
manuscript.

R
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 13th International Conference on Heat Transfer, Fluid Mechanics and Thermodynamics

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