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The aerodynamic design of a highly loaded multistage fan drive turbine is discussed. Turbine flowpath and airfoil sections are presented along with respective pressure and velocity distributions. Vibrational modes are identified in the expected turbine operating range.
Ten energy conversion systems are defined and analyzed in terms of efficiency. These include: open-cycle gas turbine recuperative; open-cycle gas turbine; closed-cycle gas turbine; supercritical CO2 cycle; advanced steam cycle; liquid metal topping cycle; open-cycle MHD; closed-cycle inert gas MHD; closed-cycle liquid metal MHD; and fuel cells. Results are presented.
Open-cycle recuperated gas turbine plant with inlet temperatures of 1255 to 1644 K (1800 to 2500 F) and recuperators with effectiveness values of 0, 70, 80 and 90% are considered. A 1644 K (2500 F) gas turbine would have a 33.5% plant efficiency in a simple cycle, 37.6% in a recuperated cycle and 47.6% when combined with a sulfur dioxide bottomer. The distillate burning recuperated plant was calculated to produce electricity at a cost of 8.19 mills/MJ (29.5 mills/kWh). Due to their low capital cost $170 to 200 $/kW, the open cycle gas turbine plant should see duty for peaking and intermediate load duty.
Both recuperated and bottomed closed cycle gas turbine systems in electric power plants were studied. All systems used a pressurizing gas turbine coupled with a pressurized furnace to heat the helium for the closed cycle gas turbine. Steam and organic vapors are used as Rankine bottoming fluids. Although plant efficiencies of over 40% are calculated for some plants, the resultant cost of electricity was found to be 8.75 mills/MJ (31.5 mills/kWh). These plants do not appear practical for coal or oil fired plants.
Results of analytical studies to improve the low cycle fatigue lives and reliability of turbine disks in high-performance gas turbine engines are presented. Advanced disk concepts were evaluated for the first-stage high pressure turbines of the CF6-50 and JT8D-17 engines. The advanced disk designs are compared to the existing disks on the bases of cycles to crack initiation and overspeed capability for initially unflawed disks, crack propagation cycles to failure for initially flawed disks, and available kinetic energy of disk burst fragments.
Astroloy and V-57, two candidate turbine disk alloys for the auxiliary power unit (APU) of the space shuttle propulsion and power system were tested for their resistance to embrittlement in hydrogen environments. Samples of both these nickel-base alloys were subjected to notch and smooth tensile testing and to creep testing in hydrogen. The high resistance exhibited by Astroloy forgings to embrittlement by hydrogen is attributed to the microstructure produced by forging and also to the special heat treatment schedule. V-57 turbine disks successfully completed short-time performance testing in the experimental APU. The use of the Astroloy, however, would permit increasing turbine inlet temperature and the rotational speed beyond those possible with V-57.
The turbine developed design specific work output at design speed at a total pressure ratio of 6.745 with a corresponding efficiency of 0.855. The efficiency (0.855)was 3.1 points lower than the estimated efficiency quoted by the contractor in the design report and 0.7 of a point lower than that determined by a reference prediction method. The performance of the turbine, which was a forced vortex design, agreed with the performance determined by the prediction method to about the same extent as did the performance of three reference high stage loading factor turbines, which were free vortex designs.
Thermal barrier coating design option offers benefit in terms of reduced electricity costs when used in utility gas turbines. Options considered include: increased firing temperature, increased component life, reduced cooling air requirements, and increased corrosion resistance (resulting in increased tolerance for dirty fuels). Performance and cost data were obtained. Simple, recuperated and combined cycle applications were considered, and distillate and residual fuels were assumed. The results indicate that thermal barrier coatings could produce large electricity cost savings if these coatings permit turbine operation with residual fuels at distillate-rated firing temperatures. The results also show that increased turbine inlet temperature can result in substantial savings in fuel and capital costs.
An analytical investigation of present and advanced gas turbine power generation cycles incorporating thermal barrier turbine component coatings was performed. Approximately 50 parametric points considering simple, recuperated, and combined cycles (including gasification) with gas turbine inlet temperatures from current levels through 1644K (2500 F) were evaluated. The results indicated that thermal barriers would be an attractive means to improve performance and reduce cost of electricity for these cycles. A recommended thermal barrier development program has been defined.
The amount of nitrogen oxides introduced into the atmosphere by gas turbines is very significant in relation to the total amount of nitrogen oxide emissions produced by chemical installations and combustion engines. Turbine manufacturers are therefore working to develop combustion chambers with sufficiently low nitrogen oxide emission concentrations. Attention is given to aspects of nitrogen oxide formation in gas turbines, the parameters which determine this formation, and suitable approaches to reducing nitrogen oxide emissions.
Tests have been conducted on a 20-inch diameter single-stage air-cooled turbine designed to evaluate the effects of film cooling air on turbine aerodynamic performance. The present paper reports the results of five test configurations, including two different cooling designs and three combinations of cooled and solid airfoils. A comparison is made of the experimental results with a previously published analytical method of evaluating coolant injection effects on turbine performance.
Advanced materials, coatings, and cooling technology is assessed in terms of improved aircraft turbine engine performance. High cycle operating temperatures, lighter structural components, and adequate resistance to the various environmental factors associated with aircraft gas turbine engines are among the factors considered. Emphasis is placed on progress in development of high temperature materials for coating protection against oxidation, hot corrosion and erosion, and in turbine cooling technology. Specific topics discussed include metal matrix composites, superalloys, directionally solidified eutectics, and ceramics.
Tests were conducted in a 20 inch diameter single stage air cooled turbine designed to evaluate the effects of film cooling air on turbine aerodynamic performance. A comparison was made of the experimental results and an analytical method of evaluating film injection effects on turbine performance. The results are used to determine the effects of film cooling on overall engine performance for selected cycle conditions. The engine performance studies are used to show the cycle benefits of increased gas temperature at various coolant flow rates.
A review of research related to liquid cooling of gas turbines was conducted and an assessment of the state of the art was made. Various methods of liquid cooling turbines were reviewed. Examples and results with test and demonstrator turbines utilizing these methods along with the advantages and disadvantages of the various methods are discussed.
The experimental wind turbine was designed and fabricated to assess technology requirements and engineering problems of large wind turbines. The machine has demonstrated successful operation in all of its design modes and served as a prototype developmental test bed for the Mod-0A operational wind turbines which are currently used on utility networks. The mechanical and control system are described as they evolved in operational tests and some of the experience with various systems in the downwind rotor configurations are elaborated.
The development associated with large wind turbine systems is briefly described. The scope of this activity includes the development of several large wind turbines ranging in size from 100 kW to several megawatt levels. A description of the wind turbine systems, their programmatic status and a summary of their potential costs is included.
The state-of-the-art of automobile gas turbine technology, particularly with respect to fuel economy and emissions, was defined. An advanced gas turbine system is proposed which incorporates significant advances in technology, and has a fifty to sixty percent gain in fuel economy over the spark ignition engine, while meeting the same goals of the improved gas turbine engine.
The employment of the high operational temperatures makes it necessary to use, for the construction of the turbines, ceramic materials such as silicon nitride or silicon carbide. Investigations concerning the development of turbine components made of such materials are conducted by a German automobile manufacturer and the ceramics industry. The current status of these investigations is reviewed. Flame tubes and guide-vane rings have successfully passed tests lasting 20 hours. Prototype turbine wheels have withstood the effects of peripheral speeds of 450 m/s. They also showed resistance to thermal shocks which were as high as 6-0 K/s.