Version | 1.1 |
Unit Name | INDUSTRIAL GAS TURBINES |
Unit Code | MME508A |
Unit Duration | 1 Term (online) or 1 Semester (on-campus) |
Award |
Graduate Diploma of Engineering (Mechanical) Master of Engineering (Mechanical) |
Year Level | One |
Unit Coordinator MME Course Coordinator |
Dr Farshid Fathinia Dr Milind Siddhpura |
Stream/ Common/ Elective: | Elective |
Pre/Co-requisites | None |
Credit Points |
3 Grad Dip total course credit points = 24 Masters total course credit points = 48 |
Mode of Delivery | Online or on-campus. |
Unit Workload |
10 hours per week: Lecture - 1 hour Tutorial Lecture - 1 hours Practical / Lab - 1 hour (where applicable) Personal Study recommended - 7 hours (guided and unguided) |
Unit Description and General Aims
Gas turbines play a significant role in many industries. It is essential for engineers to have a basic understanding of them; either superficially, or in depth, depending on the engineer's responsibilities. The former will be used for basic operation and minor maintenance, whereas the latter will be used for unit installation and heavy maintenance.
The first aspect of this topic is to determine where gas turbines are necessary rather than other prime movers. This depends on the processes being supported, location, expected reliability level, financial considerations, and environmental effects. The students will be provided with templates to assist them in making calculations that will lead to correct decisions.
The purpose of this unit is to provide an understanding of the operation and maintenance of gas turbines. Components covered will include gas compressor types (centrifugal, axial, and mixed flow), combustor designs, turbines, and exhaust systems. The selection of materials for improved power, efficiency and engine life will be covered. Aero-thermal operations will be studied. The student will also learn about heat recovery systems, COGEN, and Combined Cycle. As well as the many systems that makes up any gas turbine installation. Gas turbine operation will be covered, with maintenance, inspection, and repair practices, especially where in-house actions can bring about significant savings vis-a-vis contracting these activities to OEMs.
Learning Outcomes
On successful completion of this Unit, students are expected to be able to:
- Judge the economics, and other factors, for installing gas turbines in preference to other prime movers.
- Bloom’s Level 5
- Determine in detail the construction of a gas turbine engine, its major components, and their aero-thermal interactions.
- Bloom’s Level 5
- Critique all gas turbine operating phases and be able to discover where both minor and major maintenance is necessary.
- Bloom’s Level 5
- Synthesise existing, and recommend new applications, for gas turbines. To be able to evaluate, from given data, efficiencies and economic feasibilities of Combined Cycle as well as COGEN facilities.
- Bloom’s Level 6
- Make judgements based on information to optimise both gas turbine operation and maintenance practices; and reflect on the veracity of information and the commercial and regulatory implications on their use for power generation and other applications such as COGEN.
- Bloom’s Level 5
- Construct a rudimentary gas turbine using one of several available design packages, this will enhance understanding of the Brayton Cycle and practical limitations on achieving the ideal cycle.
- Bloom’s Level 6
Student assessment
Assessment Type |
When assessed |
Weighting (% of total unit marks) |
Learning Outcomes Assessed |
Assessment 1 Type: Weekly Quizzes Description: Students will need to complete multiple-choice quiz questions to demonstrate a good understanding of the fundamental concepts. Topics covered: 2-11 |
Weekly |
10% |
All |
Assessment 2 Type: Test (Invigilated) Description: Students will need to answer some short and/or long answer questions and/or solve some numerical problems.
Example Topics for reference: Gas turbine operation, inspection, maintenance, repair, and troubleshooting. With engine specifications and other data from manufacturers or other sources understand and be able to measure by calculation engine performance. Troubleshoot performance losses arising from these measurements and propose remedial actions.
Topics covered: 1-5 |
During Topic/Week 6 |
25% |
2, 3, 4 |
Assessment 3 Type: Practical (Report) and Demonstration Description: Simulations using software in Remote labs. Designing a rudimentary gas turbine using one of several available design packages. Topics covered: 1-9 |
After Topic 9 |
25% |
6 |
Assessment 4 Type: Research (Report) and Presentation Word length: 3000 excluding diagrams and references. Example Topic for reference: By first nominating criteria relating to geographic location, local populace, climate, and economic situation, select and justify by calculations (both engineering and economic) if possible, what gas turbine installation you would install. Critically analyse different engines in the same category, with natural gas and hydrogen as fuels. Show calculations. Topics covered: All |
Final Week |
35% |
1,2,3,4,5 |
Attendance / Tutorial Participation Example: Presentation, discussion, group work, exercises, self-assessment/reflection, case study analysis, application. |
Continuous |
5% |
1 - 6 |
Prescribed and Recommended readings
Required Textbook (One Required reading, which covers at least 60% of weekly topics)
- M.P. Boyce, Gas Turbine Engineering Handbook, 4th edition, Gulf Publications, Houston,2012
Reference Materials
Other texts, peer-reviewed journals, and websites (Others may be advised during lectures).
- Gas Turbines: Fundamentals, Maintenance, Inspection and Troubleshooting, 7th revision, IDC Perth Australia publication
- C. Soares, Gas Turbines, A Handbook, 2nd edition, Butterworth-Heinemann, Burlington MA, 2015
- The Jet Engine, Rolls-Royce plc, 6th edition, Derby England, 2005
- T. Giampaolo, Gas Turbines Principles and Practice, 6th edition, Fairmont Press, Lilburn GA, 2012 (Available from Kindle)
- Rolf Kehlhofer, Combined-cycle gas and steam turbine power, Fairmont Press, Lilburn GA, 1991
- GSP 11 Gas Turbine Simulation Program, File version 11.4.0.0 (Shareware), National Aerospace Laboratory of the Netherlands, Amsterdam
Unit Content
One topic is delivered per contact week
Topic 1
Introduction to Gas Turbines – Part 1
A brief history of gas turbine development; including gas turbine types, their construction and operation
- Gas turbine evolution, History
- Technical improvements
- Economic Comparison of Various Generation Technologies
- Categories of Gas Turbines - Types
- Frame Type Heavy-Duty Gas Turbines.
- Aircraft-Derivative Gas Turbines
- Industrial Type-Gas Turbines
- Small Gas Turbines.
- Micro-Turbines.
- Simple cycle gas turbine
- Regenerative gas turbine
- Gas Turbine Performance
- Major Gas Turbine Components
Physics as applicable to gas turbines
- Basics of:
- Fluid flow theory
- Velocity vectors
- Reynolds number
- Bernoulli’s theorem
Required knowledge of thermodynamics and aerodynamics
- Fundamentals:
- Enthalpy, Entropy, Work done calculations
- T-S and H-S diagrams, Efficiency etc.
- Theoretical and Actual Cycle Analysis
- Reversible cycles with ideal gases
- The Brayton Cycle
- Constant pressure or Brayton cycle layout
- Basic work and efficiency calculation
- Ideal inter-cooled and reheat cycles
- Blade profile nomenclature
- Elementary Airfoil Theory
- Laminar-Flow Airfoils
Topic 2
Introduction to Gas Turbines – Part 2
Various gas turbine cycle layouts
- Actual gas turbine cycles
- The Brayton-Rankine Cycle
- The Regenerative Cycle
- The Intercooled Simple Cycle
- The Reheat Cycle
- The Intercooled - Regenerative Reheat Cycle
- The Steam Injection Cycle
- The Evaporative Regenerative Cycle
- Combined Cycle Plants
- Comparison of power output and efficiency of the above cycles.
Introduction to utilisation economics
- Fuel economics
- Plant Power Optimization
- On-line Optimization Process
- Life Cycle Costs
Detailed description of all gas turbine engine configurations, major components and selection of materials
- Compressors
- Centrifugal Compressors
- Axial-Flow Compressors
- Turbines
- Radial-Inflow Turbines
- Axial-Flow Turbines
- Combustors
- Gas Turbine Materials
- General metallurgical behaviour in gas turbines
- Coatings
- COGEN and Combined Cycle plants
- COGEN** – Co-generation
- Combined cycle plants
Topic 3
Engine systems, the environment – Part 1
Cooling systems, bleeds
- Inlet Cooling
- Evaporative Cooling of the Turbine
- Absorption Cooling Systems
- Turbine Blade Cooling Design
- General metallurgical behaviour in gas turbines
Bearings, Bearing Design Principles
- Tilting-Pad Journal Bearings
- Bearing Materials
- Bearing and Shaft Instabilities
- Thrust Bearings, Factors Affecting Thrust-Bearing Design
- Thrust-Bearing Power Loss
Seals, Noncontracting Seals, Mechanical (Face) Seals
- Mechanical Seal Selection and Application, Seal Systems
- Associated Oil System. Dry Gas Seals.
Topic 4
Engine systems, the environment – Part 2
The lubrication system
- Basic Oil System
- Lubricant Selection
- Oil Sampling and Testing. Oil Contamination.
- Filter Selection. Cleaning and Flushing.
- Coupling Lubrication.
- Lubrication Management Program
Fuel systems, liquid and gas, fuel properties, treatment and storage on site
- Fuel Specifications.
- Fuel Properties.
- Fuel Treatment.
- Heavy Fuels.
Topic 5
Engine systems, the environment – Part 3
Auxiliary systems: starting, ignition, instrumentation, fire protection, air filtration, misting
- Starting system
- Control Systems. Condition Monitoring Systems. Monitoring Software
- Implementation of a Condition Monitoring System
Inlet Air Filters, Inlet Air Cooling
- Water injection for power and air pollution control,
- Sound suppression methods.
- Environmental standards
Topic 6
Gas turbine operation, inspection, maintenance, repair and troubleshooting – Part 1
Engine operating requirements
- Lubrication, operation and maintenance of lubrication system
- Balancing, Orbital Balancing, Modal Balancing, Multiplane Balancing
- Couplings and Alignment, Gear Couplings, Metal Diaphragm Couplings
- Shaft Alignment, The Shaft Alignment Procedure
Operating safety considerations
- Acoustics and Noise Control,
- Noise criterion, Noise control methods
- Other safety precautions
Compressor characteristics of surge and stall. Compressor maps
- Compressor Stall, Rotating Stall, Individual Blade Stall, Stall Flutter,
- Stall Analysis of an Axial-Flow Compressor
- Fuel Control Units to maintain normal operation
Engine starting, running, short and long term shut-down procedures
- Start-up Sequence
- Starting preparations
- Shutdown method
- Generator protection
Topic 7
Gas turbine operation, inspection, maintenance, repair and troubleshooting – Part 2
Abnormal operation and its correction. Troubleshooting
- Diagnostic system-Spectrum Analysis-Vibration Measurement
- Detectable Problems:
- Gas Path Analysis
- Turbine Blade Distress
- Compressor Fouling
- Combustor Distress & Plugged Fuel Nozzles
- Foreign/Domestic Object Damage
- Worn Air/Oil Seals
- Fuel Control Problems
- Condition Monitoring Systems, Monitoring Software
- Requirements for an Effective Diagnostic System
- Implementation of a Condition Monitoring System
- Campbell diagram
Operation when connected to an electrical grid, droop
- Grid frequency, control systems, Droop curves
Maintenance concepts, on- as well as off-load inspection methods
- Philosophy of Maintenance. Training of Personnel. Tools and Shop Equipment.
- Turbo-machinery Cleaning. Hot-Section Maintenance. Compressor Maintenance.
- Bearing Maintenance. Coupling Maintenance. Rejuvenation of Used Turbine Blades.
- Repair and Rehabilitation of Turbomachinery Foundations.
- Large Machinery Start-up Procedure
- Light and heavy maintenance planning, hot end inspections
- Following OEM requirements for inspection and repair, facilities and tooling
Topic 8
Measuring engine performance, troubleshooting performance losses
- Primary Measurements in GT (Pressure, Temperature, Flow)
- GT Testing
- Performance Curves / Maker’s Data
- What are Performance Curves
- How to read Performance Curves
- Performance and Data Correction
- Correction Curves
- Performance Equations
- Sample Calculations
Topic 9
Design a rudimentary gas turbine using a shareware software package
- Software for Gas turbine design
- GasTurb 14
- Smooth C and Smooth T
- Map Collection
- GasTurb DLL
- GasTurb Details
- GasTurb Names
- How to Calculate a Single Cycle
- Case Study
Topics 10 and 11
Further study and research on industrial gas turbines
- This report is far-reaching in its scope and will enable the student to show a good understanding of his/her knowledge of this topic. It will also give the student, to his/her credit, the ability to cover/emphasise aspects of gas turbines that may not have been fully dealt with in the above content.
- Use the gas turbine design developed and simulate steady state and transient conditions. Generate operating report.
- The student will also be asked to critically discuss selected aspects of current research and development underway.
- 5 or 6 latest academic publications from international journals can be provided to the students. Students may be asked to analyse any one of these papers and provide a report based on a predefined framework (Framework will be provided).
Topic 12
Unit Review
- Review/Refresher slides containing an overview of whatever is covered in the unit. May add pop quizzes to refresh memory.
- Analysis of different types of gas turbines being used in various industries with an elaboration on the reasons for their selection.
- Recent trends and future scopes
Engineers Australia
The Australian Engineering Stage 1 Competency Standards for the Professional Engineer, approved as of 2013. This table is referenced in the mapping of graduate attributes to learning outcomes and via the learning outcomes to student assessment.
Stage 1 Competencies and Elements Competency |
|
1. |
Knowledge and Skill Base |
1.1 |
Comprehensive, theory-based understanding of the underpinning natural and physical sciences and the engineering fundamentals applicable to the engineering discipline. |
1.2 |
Conceptual understanding of the mathematics, numerical analysis, statistics, and computer and information sciences which underpin the engineering discipline. |
1.3 |
In-depth understanding of specialist bodies of knowledge within the engineering discipline. |
1.4 |
Discernment of knowledge development and research directions within the engineering discipline. |
1.5 |
Knowledge of engineering design practice and contextual factors impacting the engineering discipline. |
1.6 |
Understanding of the scope, principles, norms, accountabilities and bounds of sustainable engineering practice in the specific discipline. |
2. |
Engineering Application Ability |
2.1 |
Application of established engineering methods to complex engineering problem solving. |
2.2 |
Fluent application of engineering techniques, tools, and resources. |
2.3 |
Application of systematic engineering synthesis and design processes. |
2.4 |
Application of systematic approaches to the conduct and management of engineering projects. |
3. |
Professional and Personal Attributes |
3.1 |
Ethical conduct and professional accountability. |
3.2 |
Effective oral and written communication in professional and lay domains. |
3.3 |
Creative, innovative, and pro-active demeanour. |
3.4 |
Professional use and management of information. |
3.5 |
Orderly management of self and professional conduct. |
3.6 |
Effective team membership and team leadership. |
Software/Hardware Used
Software
- Software: GasTurb
- Version: 14
- Instructions: https://gasturb.com/
- Additional resources or files: N/A
Hardware
- N/A
Unit Changes Based on Student Feedback
- The due dates of unit assessments were spaced out, which alleviated student stress and provided sufficient time to work on assessments of various units in each semester.
- Assessment 1 was converted from a traditional invigilated assessment to a more manageable ‘Weekly quizzes’ format.