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Off-Design Performance Prediction of Gas Turbines Without the Use of Compressor Or Turbine Characteristics

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Off-Design Performance Prediction of Gas Turbines Without the Use of Compressor Or Turbine Characteristics Off-Design Performance Prediction of Gas Turbines without the use of Compressor or Turbine Characteristics by Janitha Kanishka Suraweera A thesis submitted to the Faculty of Graduate and Postdoctoral Affairs in partial fulfillment of the requirements for the degree of Master of Applied Science in Aerospace Engineering Carleton University Ottawa, Ontario © 2011 Janitha Kanishka Suraweera Library and Archives Bibliotheque et Canada Archives Canada Published Heritage Direction du Branch Patrimoine de I'edition 395 Wellington Street 395, rue Wellington Ottawa ON K1A0N4 Ottawa ON K1A 0N4 Canada Canada Your file Votre reference ISBN: 978-0-494-87806-4 Our file Notre reference ISBN: 978-0-494-87806-4 NOTICE: AVIS: The author has granted a non­ L'auteur a accorde une licence non exclusive exclusive license allowing Library and permettant a la Bibliotheque et Archives Archives Canada to reproduce, Canada de reproduire, publier, archiver, publish, archive, preserve, conserve, sauvegarder, conserver, transmettre au public communicate to the public by par telecommunication ou par I'lnternet, preter, telecommunication or on the Internet, distribuer et vendre des theses partout dans le loan, distrbute and sell theses monde, a des fins commerciales ou autres, sur worldwide, for commercial or non­ support microforme, papier, electronique et/ou commercial purposes, in microform, autres formats. paper, electronic and/or any other formats. The author retains copyright L'auteur conserve la propriete du droit d'auteur ownership and moral rights in this et des droits moraux qui protege cette these. Ni thesis. Neither the thesis nor la these ni des extraits substantiels de celle-ci substantial extracts from it may be ne doivent etre imprimes ou autrement printed or otherwise reproduced reproduits sans son autorisation. without the author's permission. In compliance with the Canadian Conformement a la loi canadienne sur la Privacy Act some supporting forms protection de la vie privee, quelques may have been removed from this formulaires secondaires ont ete enleves de thesis. cette these. While these forms may be included Bien que ces formulaires aient inclus dans in the document page count, their la pagination, il n'y aura aucun contenu removal does not represent any loss manquant. of content from the thesis. Canada ABSTRACT new method of predicting gas turbine off-design performance is presented. This Anethod, referred to as the core control method, is based on the idea that performance across a gas turbine depends on a single parameter that controls the energy input to the said gas turbine. It is shown that only the design-point performance of a gas turbine is needed to predict its off-design performance, and that neither compressor nor turbine characteristics are required. A thermodynamic model is developed for predicting the off-design performance of a single-spool turbojet and a two-spool gas generator with a free power turbine. This model is further developed to simulate the effects of handling bleed schedules, performance limiters and performance deterioration. The core control method is then used to predict the off-design performance of a Rolls-Royce Viper Mark 521 as a proof-of-concept, after which, the new and deteriorated off-design performance of three Rolls-Royce RB211-24GT gas turbines is predicted. i In addition to the discussions on the involved theories and the performance predictions, the process by which the deteriorated RB211-24GT performance data was analyzed, and the sources and propagation of measurement uncertainties are also discussed. ii Eye of the tiger...! iii ACKNOWLEDGEMENTS S my first thesis supervisor, I would like to thank Dr. Donald Gauthier of PSM ASystems, former professor at Carleton University and my first thesis supervisor, for tolerating my persistence, and for trusting in me when only a few others would and giving me a chance to prove myself. His reviews of many drafts of my thesis are also appreciated. I would also like to thank Prof. Metin Yaras, who became my second thesis supervisor, for his guidance and for reviewing countless drafts of my thesis. I am also thankful for Prof. Herb Saravanamuttoo, my thesis co-supervisor, for providing me with invaluable guidance with the finer points of gas turbine performance, and for him reviewing several drafts of my thesis. 1 am also thankful for him letting me borrow rare literature without hesitation, but with threats for my personal safety should I misplace them! iv The guidance and supervision provided by Mr. Jerry Blackburn and Mr. Richard Hamby over 15 months during my time as a Graduate Research Student/Performance Specialist at Rolls-Royce Canada is something for which I am truly thankful. In addition to this, the support given to me by the departments of Functional Systems Integration, Combustion and Customer Service Business of Rolls-Royce Canada is also greatly appreciated. Furthermore, thanks are extended to Mr. Nick Corbett and Mr. Steve Brown of Rolls-Royce UK for providing me with engine data and help with the in-house analysis software, respectively. I am also thankful for Rolls-Royce Canada for providing me with research funding for the first half of my studies. Finally, I would like to thank my parents for their continuing guidance, encouragement, love and support, without which 1 would not be here today. I dedicate this work to my parents. v TABLE OF CONTENTS ABSTRACT i ACKNOWLEDGEMENTS iv TABLE OF CONTENTS vi LIST OF TABLES xii LIST OF FIGURES xiii NOMENCLATURE xviii 1 INTRODUCTION 1 1.1 Overview 3 2 LITERATURE REVIEW 4 2.1 Introduction 4 2.2 Off-Design Performance Simulation Methods 5 2.2.1 Component-Matching Methods 5 2.2.2 Stage Stacking Method 7 2.2.3 Methods based on Gas Path Analysis 9 vi 2.2.4 Methods based on Artificial Intelligence 12 2.2.5 Methods based on Kalman Filtering 16 2.2.6 Methods based on Fuzzy Logic 18 2.2.7 Methods based on Computational Fluid Dynamics 19 2.2.8 Wittenberg's Method 21 2.3 Performance Deterioration in Gas Turbines 27 2.3.1 Deterioration Mechanisms 28 2.3.2 Performance Recovery Methods 32 3 ENGINE DATA ACQUISITION AND ANALYSIS 35 3.1 Introduction 35 3.2 The Rolls-Royce Industrial RB211 36 3.2.1 Introduction 36 3.2.2 Mechanical Configuration 36 3.3 Overview of Engine Data 37 3.3.1 Data Sources 37 3.3.2 Engine Health Monitoring Measurements 37 3.3.3 Data Sampling Frequency 39 3.3.4 Measurement Instruments and Associated Errors 40 3.4 Field Data Analysis Process 45 3.4.1 Pre-Processing of Field Data 45 3.4.2 T07 Bias Error Correction 45 3.4.3 Instrument Calibration Error Correction 48 3.4.4 Field Dataset Analysis 50 vii 3.4.5 Processing of the Analysis Results 51 3.4.6 Error Propagation 52 4 GAS TURBINE OFF-DESIGN PERFORMANCE PREDICTION USING GASDYNAMICS RELATIONSHIPS 55 4.1 Introduction 55 4.2 An Introduction to the Core Control Method 56 4.3 Single-Spool Turbojet 58 4.3.1 Matching of the Turbine and the Exhaust Nozzle 60 4.3.2 Off-Design Performance Prediction 64 4.4 Simulating the Effect of Bleed Flows 65 4.4.1 Handling Bleeds vs. Cooling Bleeds 65 4.4.2 Effect of Bleed Extraction on Engine Performance 67 4.5 Two-Spool Gas Generator with a Free Power Turbine 71 4.5.1 Matching of the HP, LP and Free Power Turbines 74 4.5.2 Off-Design Performance Prediction 76 4.6 Deteriorated Engine Performance Prediction 79 4.7 Simulating Performance Limiters 81 4.7.1 Simulating the Temperature Limiter 81 4.7.2 Simulating the Speed Limiter 83 5 VALIDATION AND DISCUSSIONS 84 5.1 Introduction 84 5.2 Single-Spool Turbojet 85 5.3 Multi-Spool Gas Turbine - Clean Performance 94 viii 5.4 Multi-Spool Gas Turbine - Deteriorated Performance 102 6 CONCLUSIONS AND RECOMMENDATIONS 111 6.1 Conclusions 111 6.2 Recommendations 113 REFERENCES 114 APPENDIX A GAS CHROMATOGRAPH UNCERTAINTY 125 A.1 Overview 126 A.2 The Monte Carlo Method 126 A.3 Monte Carlo Simulation Result 127 APPENDIX B PROCESSING ANALYSIS RESULTS 129 APPENDIX C SENSITIVITY ANALYSIS 135 C.l Overview 136 C.2 Estimated Fuel Flow Rate 137 C.3 LP Compressor Isentropic Efficiency 138 C.4 HP Compressor Isentropic Efficiency 139 C.5 HP Turbine Isentropic Efficiency 140 C.6 LP Turbine Isentropic Efficiency 140 C.l Power Turbine Isentropic Efficiency 141 C.8 LP Compressor Capacity 141 C.9 HP Compressor Capacity 143 C.10 Core Bleed Flow 144 ix C. 11 Polytropic Compressor Efficiencies 144 C.12 Polytropic Turbine Efficiencies 146 C. 13 Uncertainties of the Recoverable Deterioration Factors 148 C. 14 Uncertainties of the Site Performance Data 157 C. 14.1 LP Compressor Pressure Ratio 157 C. 14.2 HP Compressor Pressure Ratio 157 C. 14.3 LP Compressor Corrected Mass Flow Rate 158 C. 14.4 HP Compressor Corrected Mass Flow Rate 158 C. 14.5 Gas Generator Exhaust Pressure 159 C. 14.6 Power Turbine Outlet Temperature 159 C. 14.7 Fuel Flow Rate 160 C. 14.8 Power Output 161 APPENDIX D SOLUTION PROCESSES OF THE CORE CONTROL METHOD 162 D.l Single-Spool Turbojet 163 D.l.l Introduction 163 D.1.2 Unchoked Turbine 165 D.l.3 Choked Turbine-Unchoked Nozzle 169 D.l.4 Choked Nozzle 170 D. 1.5 Post-Solution Process Calculations 172 D.2 Two-Spool Gas Generator with a Free Power Turbine 177 D.2.1 Introduction 177 D.2.2 Unchoked HP Turbine 180 x D.2.3 Choked HP Turbine-Unchoked LP Turbine 186 D.2.4 Choked LP Turbine-Unchoked Free Power Turbine 187 D.2.5 Choked Free Power Turbine 188 D.2.6 Post-Solution Process Calculations 189 D.3 Aerodynamic Coupling of the LP and HP Spools 194 D.4 Simulation of Bleed Flows in the Core Control Method 196 D.4.1 Introduction 196 D.4.2 Cooling Bleed Flows 198 D.4.3 Handling Bleed Flows 199 APPENDIX E DETERIORATED ENGINE PERFORMANCE 204 E.
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