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Turbomachinery Project Dr.

Shengmin Guo ME 4853 Bryan Lutz

Objectives:
This project involves the design of the axial compressor used in General Electrics Frame 7F gas turbine engine. The objectives of the project were defined beforehand and are included below: Find the flow rate, pressure ratio, temperature distribution, and rotor speed? Examine the basic geometry of the compressor blades. Choose a compressor stage, obtain the crosssection profiles at the tip. Draw velocity triangles. Use free vortex for other blade heights (Use Matlab or Excel) Using Eulers equation for energy calculation. Discuss whether the results match the engine specifications. Discuss why we need 18 stages of compressor to achieve a pressure ratio of 18 Discuss the offdesign conditions and how to start the engine. Discuss the function of the inlet guide vanes. Discuss compressor map.

Introduction:
Axial compressors are rotating compressors based on an airfoil type design. The working fluid is moved through the compressor axially by the spinning airfoil type compressor blades. Axial compressors produce a continuous flow of the working fluid and often have high mass flow capacity and efficiency. Since these compressors require several stages of airfoil blades to reach high pressure ratios, they can become quite expensive due to their complex design. Axial compressors are used in Turbo-machinery to compress a fluid (typically air) which is routed to a combustion chamber. Fuel is combusted in the presence of the compressed air and used to drive a turbine which provides power for the compressor plus excess power to be utilized. Axial compressors are commonly used in gas turbines like power plant turbines and jet engines.

Compressor Design Theory, Calculations, and Figures

It is important to understand the design process behind how these compressors are produced. The process begins with a velocity diagram and blade profile design and continues to thermodynamic analysis followed by modeling. The study of the axial compressor used in General Electrics Frame 7F gas turbine was started by studying photos of the rotor and stator blades. From these photos, the blade tip flow geometry was estimated using a photo editing program and a digital protractor. The geometrical values found can be located in the following table: Stage 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Blade Length (m) 0.381 0.36576 0.3175 0.26924 0.23876 0.21336 0.19812 0.1778 0.16256 0.14478 0.14224 0.14224 0.1397 0.13716 0.13716 0.13462 0.13208 0.127 Hub Diameter (m) 1.48082 1.50876 1.53416 1.5621 1.5621 1.5875 1.61544 1.64084 1.69418 1.74752 1.75006 1.75006 1.75006 1.75006 1.75006 1.75006 1.75006 1.75006 Flow Area (m2) 2.228499493 2.153952689 1.846948761 1.549025032 1.350801066 1.207098825 1.128782117 1.015847154 0.948232108 0.860693324 0.845593441 0.845593441 0.829378802 0.813204699 0.813204699 0.797071133 0.780978103 0.748913654 1 (deg) 65 58 56.5 55 55 55 57.5 60 61 62 63.5 65 65 65 66 67 68 70 2 (deg) 55 50 46 42 41 40 42 44 41.5 39 42.5 46 48 50 51 52 53 54 2 (deg) 39 45 45 45 51 35 40 35 37 48 53.5 50 48 56 54 55 55 55 3 (deg) 6 24 24 23 18 15 15 16 16 25 29 27.5 35 40 41 40 40 40

Some parameters were given for General Electrics Frame 7F gas turbine. The mass flow rate and rotor speed were used in calculations throughout the project while the given pressure ratio was used to check the results. The mass flowrate, pressure ratio, and rotor speed are given in the following figure: Mass Flow (kg/s) Pressure ratio Speed (RPM)

403.7

18.0

3600

Where the following picture represents the above variables.

The compressor flow passage profile was graphed for reference and is shown in the figure below:

Compressor Flow Passage Profile


1.20 1.00 Displacement [m] 0.80 0.60 0.40 0.20 0.00 0 5 10 Stage 15 20 Hub Radius [m] Blade Length + Hub Radius [m]

Many axial Compressors are designed such that the gas is often atmospheric air and as it is compressed, it becomes denser and the area is reduced from stage to stage, often in such a way that the axial velocity remains constant. [1] In this project it was assumed that the axial velocity stays constant. The inlet velocities and rotor blade tip velocities were calculated using the following equations:

From Geometry the following velocity values were found at the rotor blade tips for each stage using Microsoft Excel:

Stage 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

U1 [m/s]

V_x [m/s]

V_u [m/s]

V [m/s]

W_x [m/s]

W_u [m/s]

W [m/s]

422.76 422.28 408.88 395.95 384.46 379.67 379.19 376.32 380.63 383.98 383.50 383.50 382.54 381.59 381.59 380.63 379.67 377.76

147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88

739.89 658.94 632.30 607.14 595.65 590.87 611.32 632.46 647.41 662.10 680.10 700.63 699.67 698.72 713.73 729.01 745.69 784.05

754.53 675.33 649.36 624.89 613.74 609.09 628.95 649.51 664.09 678.42 696.00 716.07 715.13 714.19 728.89 743.86 760.21 797.88

147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88 147.88

317.13 236.66 223.42 211.19 211.19 211.19 232.13 256.14 266.78 278.12 296.60 317.13 317.13 317.13 332.14 348.38 366.02 406.30

349.91 279.06 267.93 257.82 257.82 257.82 275.23 295.76 305.03 314.99 331.42 349.91 349.91 349.91 363.58 378.47 394.76 432.37

The density Distribution was found assuming that mass flow rate and axial velocity stayed constant. The following formula shows how density was calculated for each stage:

Specific work for each compressor stage can be calculated using the following equation: ( ( ) ( ))

The total specific work needed was found to be 883116 J/Kg. The total power needed for the axial compressor was about 357MW. The work in seems reasonable for a compressor of this size. The turbine makes a net power of 211MW with a 38.5% efficiency. This means that the compressor uses about 65% of the overall energy put into the turbine in the form of fuel. There is error associated with these results which is mention later in the report. The specific work needed for each stage is graphed below:

Specific Work
90000 80000 70000 60000 50000 40000 30000 20000 10000 0 0 5 10 Stage 15 20 Specific Work [J/Kg]

The temperature of the inlet and outlet of each rotor stage was calculated using the specific work values shown above and constant specific heats. The distribution of temperature across each rotor stage is graphed below:

Temperature Distibution
1600 1400 Temperatur [K] 1200 1000 800 600 400 200 0 0 5 10 Stage 15 20 Temperature In to Stage [K] Temperature Out of Stage [K]

After a Temperature distribution is found, the pressure ratio can easily be found for all 18 stages. The final pressure ratio can also be obtained by multiplying the pressure ratios of each stage together. The overall pressure ratio in this project was found to be 18.3686 which correlates to the given pressure ratio of about 18. The pressure ratio was found assuming a compressor efficiency of ratio of each stage can be found using the following equation: =90%. The pressure

))

The pressure ratio was then graphed for each of the compressor stages. This graph is shown below:

Pressure Ratio
1.28 1.26 Pressure Ratio 1.24 1.22 1.2 1.18 1.16 1.14 1.12 0 5 10 Stage 15 20

Sources of Error
The results in this project are subject to several sources of error. The main source of error is in the blade geometry recorded by measuring the compressor blade angles from the pictures provided. Although an image editing program was used, the pictures of the compressor rotor and stator blades were difficult to estimate accurate blade angles from due to the perspective on some stages. The work calculations were done assuming constant specific heats.

Works Cited [1] Korpela, S. A. Principles of Turbomachinery. Hoboken, NJ: Wiley, 2011. Print.

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