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The Gas

Turbine Handbook:
Principles and Practices
2nd Edition

by
Tony Giampaolo, MSME, PE

©2003 by The Fairmont Press. All rights reserved.


Library of Congress Cataloging-in-Publication Data

Giampaolo, Tony, 1939-


The gas turbine handbook: principles and practices/by Tony
Giampaolo.--2nd ed.
p. cm.
Includes bibliographical references and index.
ISBN 0-88173-414-4 (electronic)
1. Gas-turbines--Handbooks, manuals, etc. I. Title.

TJ778.G48 2002
621.43'3--dc21 2002027117

The gas turbine handbook: principles and practices by Tony Giampaolo--Second


Edition
©2003 by The Fairmont Press. All rights reserved. No part of this
publication may be reproduced or transmitted in any form or by any
means, electronic or mechanical, including photocopy, recording, or
any information storage and retrieval system, without permission in
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and editors cannot be held responsible for any errors or omissions.

©2003 by The Fairmont Press. All rights reserved.


Dedication
This second edition is dedicated to the memory of
my daughter, Lisa Marie, who died in an auto-
mobile accident on August 25, 2001 at the age of
34. I did not realize until her death how she in-
fluenced the lives of so many people. I loved her
and will always love her, and am proud of what
she accomplished in her short life.

©2003 by The Fairmont Press. All rights reserved.


Contents
PREFACE
ACKNOWLEDGMENTS

Chapter 1—THE GAS TURBINE EVOLUTION


1. History
2. Technical Improvements

Chapter 2—APPLICATIONS
1. Jets
2. Mechanical Drive

Chapter 3—HARDWARE
1. Heavy Industrial
2. Aero-Derivative

Chapter 4—GAS TURBINE SYSTEMS THEORY


1. Gas Turbine Operating Cycle
2. Component Efficiencies
3. Compressor
4. Burner Section
5. Turbine

Chapter 5—GAS TURBINE CONTROL


1. Gas Turbine Controls

Chapter 6—ACCESSORIES (Lube Oil, Coolers, Power)


1. Starting Systems
2. Ignition Systems
3. Lubrication Systems
4. Characteristics of Lube Oils

Chapter 7—PARAMETER CHARACTERISTICS


1. Vibration
2. Vibration Measurement
3. Exhaust Gas Temperature (EGT)
4. Rotor Speed
5. Oil Pressure & Temperature

©2003 by The Fairmont Press. All rights reserved.


Chapter 8—GAS TURBINE INLET TREATMENT
1. Inlet Air Filters
2. Inlet Air Cooling

Chapter 9—GAS TURBINE EXHAUST TREATMENT .


1. Water Injection
2. Steam Injection .
3. Selective Catalytic Reduction

Chapter 10— GAS TURBINE ACOUSTICS


AND NOISE CONTROL
1. Turbine Acoustics and Noise Control
2. Acoustical Units of Measurement
3. Noise Criterion .
4. Noise Control

Chapter 11—DETECTABLE PROBLEMS


1. Gas Path Analysis
2. Turbine Blade Distress
3. Compressor Fouling
4. Combustor Distress & Plugged Fuel Nozzles
5. Foreign/Domestic Object Damage
6. Worn Air/Oil Seals
7. Fuel Control Problems

Chapter 12—BOROSCOPE INSPECTION


1. Objectives & Expectations
2. A Back-up to Confirming Suspected Problems
3. Assessing Damage to the Compressor,
Combustor, and Turbine

Chapter 13—CASE HISTORY 1

Chapter 14—CASE HISTORY 2

Chapter 15—CASE HISTORY 3

Chapter 16—THE GAS TURBINE’S FUTURE

©2003 by The Fairmont Press. All rights reserved.


Appendix A
1. Gas Turbine Manufacturers
(Names, Addresses, Phone Numbers)

Appendix B
1. Accessory Manufacturers
(Names, Addresses, Phone Numbers)

Appendix C
1. Stanford Research Institute Chart
2. PWA Material Chart
3. Formulas (Interrelationship of Engine Parameters)
4. Hazardous Area Classification
5. Air Filter Selection Guideline Checklist
6. Air/Oil Cooler Selection Guideline Checklist
7. Gaseous Fuel Properties
8. Liquid Fuel Properties
9. List of Symbols
10. Conversion Factors
11. Inlet Water Cooling (Fogging)
12. Overall A-weighted Sound Level Calculation
13. Occupational Noise Exposure
14. Elden F. Ray, Jr., P.E. Resume

Appendix D
1. Technical Societies
2. Technical Articles

©2003 by The Fairmont Press. All rights reserved.


Preface to the First Edition

Over the past 30 years, I have had the opportunity of participat-


ing in the development of the gas turbine as the power plant for flight
applications and as the land based prime mover in electric genera-
tion, compression, and pump drive applications. In my present role as
a consultant, I continue to use the information I gathered through
experience over these many years. Several years ago I was invited to
present this information, and my experiences, in a one day seminar
on the operation and maintenance of the gas turbine.
Initially it was thought that the seminar, hosted by the Central
California Association of Power Producers in Bakersfield, California,
would attract an audience of 20 to 30 people. Therefore, it was quite a
surprise that, only days after the seminar was announced, registra-
tion had exceeded 50 people. It was a bigger surprise that registration
had to be closed at 100 participants due to lack of space. That semi-
nar helped me to realize that their was a need for much of the infor-
mation that I possessed and took for granted. This book, which is
modeled from the seminar, is an effort to provide this information.
Originally this effort was directed to plant engineers, operators
and maintenance technicians. However, I soon realized that there
was information that would be useful to others; companies planning
to purchase a new unit or modify an existing one; experienced engi-
neers and technicians considering a career change; young engineers
looking for a career path. Hopefully this final version of the book
satisfies these objectives.
When I started putting my thoughts down on paper I intended
to show how the gas turbine evolved from the steam turbine. As I
started doing research along these lines I began to understand that
the gas turbine did not evolve from the steam turbine, but that the
gas and steam turbines evolved simultaneously. Up through most of
the 19th Century turbines were merely ideas or concepts with no real
working hardware. As hardware was developed the two technologies
leapfrogged each other. Steam was used to cool the gas down to tem-
peratures suitable from the materials of the day; and water was used
internally to cool the metal. Today we see the same techniques being

©2003 by The Fairmont Press. All rights reserved.


applied to extend turbine material life, increase power, and reduce
emissions.
I have tried to present a basic understanding of gas turbine
theory without dwelling on that subject. There are sufficient books on
theory that the reader can pursue. My objective was to provide suffi-
cient information so that the reader could use the engineering rela-
tionships presented in this book with a degree of confidence. Engi-
neering derivations are held to a minimum, and many charts, tables,
and curves are provided to enhance understanding and facilitate ap-
plication of the engineering concepts.
From the onset this book was envisioned as a reference text to
set the groundwork for understanding gas turbines. To guide the
reader in expanding his or her knowledge of the gas turbine, I have
included a large list of technical articles in Appendix D2. I also en-
courage participation in one or more of the many engineering societ-
ies, listed in Appendix D1, that deal with gas turbines.
I sincerely hope that this book will be of interest to the reader
and will be of continued use for years to come.

Tony Giampaolo
Mission Viejo, CA
January 1997

©2003 by The Fairmont Press. All rights reserved.


Preface to the Second Edition

As I was completing the first edition of this book in 1997, I


realized that I had not addressed acoustics. I considered delaying
publication in order to include acoustics, but decided against that
when it was pointed out that a book on gas turbines had not been
published in almost 20 years. The decision to include acoustics led me
to an old friend and acoustics engineer, George Hessler. George has
been solving acoustic problems as Hessler Associates for over 25
years. George turned this effort over to one of his able associates, Mr.
Elden Ray, Jr., P.E. Elden is a Professional Engineer having over 20
years experience in acoustical design, noise control and analyses,
product design and development, testing and analyses of equipment
including industrial sites and power plants. He is Board Certified by
INCE, a national and international professional organization that is
made up of noise control and acoustical professionals across industry.
Mr. Ray’s resume can be found in Appendix C-14.
Plant engineers, project engineers on new units, operators,
maintenance technicians, and engineers and technicians considering
gas turbines as a career will benefit for the treatment of acoustics in
Chapter 10. Not only does it provide the basics of acoustics but it also
addresses how noise emanates from the gas turbine and how some
acoustic treatments are unsuccessful.
Another area that has received considerable attention in the
past few years is inlet cooling for power augmentation or NOx control.
While this concept was discussed in Chapter 8 of the First Edition, it
was obvious from the questions I have been getting that more detail
was necessary. Of particular interest is inlet cooling using small mi-
cron size water droplets (fog) evaporated in the gas turbine inlet and
injecting small water droplets directly into the gas turbine compres-
sor inlet. Evaporating water in the inlet duct capitalizes on cooling
(as the water is evaporated) at constant enthalpy to reduce inlet
temperature, while water droplets injected into the gas turbine-com-
pressor utilizes heat of vaporization (compressor intercooling) to
lower compressor discharge temperature. The combination of reduced
inlet and discharge temperatures and additional mass flow result in

©2003 by The Fairmont Press. All rights reserved.


power augmentation. This approach has also been used to lower NOx
emissions at constant (or near constant turbine temperature).
In addition the following information in Appendix B (Accessory
Manufacturers) has been updated; and Appendix C-11 (Guide for Es-
timating Inlet Air Cooling Affects of Water Fogging), Appendix C-12
(Overall A-weighted Sound Level Calculation), and Appendix C-13
(Occupational Noise Exposure) have been added.
I hope this edition will be of continued use for the reader.

Tony Giampaolo
Mission Viejo, CA
March 28, 2002

©2003 by The Fairmont Press. All rights reserved.


Acknowledgments

I wish to thank the following people for their assistance in proof-


reading this book and for their suggestions and ideas: Robin Kellogg,
Editor of Western Energy Magazine; Carl Gipson, Jr., MSME, my
sister Loretta Giampaolo, BAN, RN; and my son Vince Giampaolo,
MSM&PO, MANS&SS, Lt. Comdr., USN. I must also thank Paul
Crossman for his support in arranging the first Gas Turbine Seminar,
upon which this book is based.
I am also grateful for the support I have received from my fam-
ily: my wife, my children and their spouses.
I would like to acknowledge the contribution of Mr. Eldon F.
Ray, Jr., P.E., for his effort in providing the chapter on acoustics
(Chapter 10).
Finally I would like to thank the following companies for their
confidence and support by providing many of the photographs and
charts that are in this book:

ABB STAL AB
American Air Filter International
ASEA Brown Boveri AG
Baltimore Aircoil Company
Capstone Turbine Corp.
Catalytica Combustion Systems
Cooper Cameron Corporation
DEMAG DELAVAL Turbomachinery Corp.
Diesel & Gas Turbine Worldwide Catalog
Farr Filter Company
General Electric Company
Harbor Cogeneration Company
Olympus America Inc.
Rolls Royce Industrial & Marine Gas Turbines Limited
Solar Turbines Incorporated
SRI International
United Technologies Corporation Hamilton Standard Division
United Technologies Corporation Pratt & Whitney Aircraft
United Technologies Corporation Pratt & Whitney Canada

©2003 by The Fairmont Press. All rights reserved.

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