"A flow control method for minimizing losses in a highly loaded compressor blade was analyzed. Passive and active flow control experiments with vortex generator jets were conducted on a seven blade linear compressor cascade to demonstrate the potential application of passive flow control on a highly loaded blade. Passive flow control vortex generator jets use the pressure distribution generated by air flow over the blade profile to drive jets from the pressure side to the suction side. Active flow control was analyzed by pressuring the blade plenum with an auxiliary compressor unit. Active flow control decreased profile losses by approximately 37 % while passive flow control had negligible impact on the profile loss of a highly loaded blade. Passive flow control was able to achieve a jet velocity ratio, jet velocity to upstream velocity, of 0.525. The success of active flow control with a velocity ratio of 0.9 suggests there is potential for passive flow control to be effective. The research presented in this thesis is motivated by the potential savings in the applications of passive flow control in gas turbine axial compressors by increasing the aerodynamic load of each stage. Increased stage loading that is properly controlled can reduce the number of stages required to achieve the desired pressure compression ratio."

Further improvements of the thermal efficiency of gas turbine cycle are closely coupled to the increase of turbine inlet temperature. This requires intensive and efficient cooling of the blades. In this perspective, experimental investigations of the gas temperature and heat transfer distribution around the airfoil are of primary importance. The present work aims at the development of two measurement techniques based on applications of the thin film sensors: the two-layer gauge for the wall heat transfer determination and the dual thin film probe for flow temperature measurements. Both techniques are used in short duration tunnels of the von Karman Institute (VKI) under engine representative conditions and are able to resolve both time-averaged component and time-resolved component i.e. periodic blade passing events at ~5-7 kHz with harmonics up to 50 kHz. In order to derive the wall heat flux with the two-layer gauge, the unsteady conduction equation is solved in the two-layer substrate using the measured value of the wall temperature as a boundary condition. The gauges are extensively calibrated and the data reduction method is validated on a blade of the second stator of the VKI turbine. A very good repeatability is achieved. Measurements are also performed on the complex geometry of a blade tip in a cascade configuration revealing the high three dimensionality of the flow. The dual thin film probe combines the operation of two thin films and determines the flow temperature from two independent heat flux measurements. The probe is calibrated and then validated with measurements downstream a cascade. The robustness and the reliability of the probe are also demonstrated by measurements downstream of the rotor and the second stator of the VKI turbine.

The turbine technology improvements from 1980 onwards have considerably increased mechanical and thermal stresses on turbine oils which, cause oil oxidation and thereby turbine oil degradation (Livingstone et al., 2007; Sasaki & Uchiyama, 2002). If the oil degradation problem is ignored, this might result in serious turbine system erratic trips and start-up operational problems (Overgaag et al., 2009). Oil oxidation by-products, in other words, sludge and varnish contaminants, lead stated turbine operation-tribological problems. Hence, sludge and varnish presence in turbine oil become a major reason for declining turbine reliability and availability. In the power generation industry, heavy-duty gas turbines as well as steam turbines have been lubricated with mineral based turbine oils for many decades (Okazaki & Badal, 2005). First, generally Group I oils (mineral base oils produced by solvent extraction, dewaxing) were used. Nevertheless, this group of oils has lower oxidation resistance. Therefore, modern gas turbines demand oils which have better oil oxidation resistance, and lower sludge and varnish contaminants tendency (Hannon, 2009). Today, there are many turbine lubricants available on the market. Besides Group I oils, more and more Group II oils (mineral base oils produced by hydro cracking and hydro treating) are selected in service, and having increased oil oxidation resistance. However field inspections demonstrate that Group II oils also experience sludge and varnish problems as well as Group I oils. Primary reason for these phenomena is the antioxidant additive packages that are used in Group II oils (Overgaag et al., 2009). In any case with recent oil formulations, oil degradation products still exist in current turbine oils, and will continue to do so in natural process. These sludge and varnish contaminants are less than 1 micron in size. Thus, they can pass turbine oil system standard mechanical filters without obstruction. With regard to keep the turbine systems in best operational conditions, external turbine oil cleaning practices became crucial to remove these less than 1 micron size oil degradation products from turbine oils. Current effective method for removing the sludge and varnish is to use electrostatic oil cleaners (Moehle & Gatto et al., 2007). Since the majority of turbine user and operator population have been shifted to use Group II based oils to counter the increased sludge and varnish problems, traditional oil cleaners became insufficient to remove sludge and varnish from Group II. (Due to Group II oils have different oil characteristics such as oil oxidation stability and solvency capability). With this awareness, thesis project is looking for ways to introduce and develop an Advanced Electrostatic Oil Cleaner to increase the availability and reliability figures of heavy-duty gas turbines against the rising amount of oil degradation products in modern formulated turbine oils. ECC (Electrostatic Cooled Cleaner) is an electrostatic oil cleaner device to clean and cool mineral based turbine oils for heavy-duty gas turbine applications by removing the sludge and varnish - oil contaminants from turbine oils. The basic principle of the ECC is based on the electrostatic force produced by parallel positioned electrodes which are charged with a high D.C. voltage. Oil contaminants- sludge and varnish have polar nature. Therefore, they are attracted by electrostatic forces whose intensity is proportional to the voltage applied. With the oil flowing in parallel to these electrodes, the polar particles in the oil (which is only neutral /no polar) are caught by filter media positioned between these electrodes. Small investments on advanced oil cleaner result in big savings on turbine system performance. Increased turbine availability and reliability predominantly reduce maintenance costs and risks besides, and thus maximizing revenue by extending heavy-duty gas turbine operational life. An introduced prototype of the ECC-D4 model was tested using two Group II and one Group I oils. The amounts of 200 liter (each) test oils were circulated approximately 300 times through the ECC-D4. In each 3 oil cleaning test sessions, it is proved that the oil insolubles content decreased approximately 40% in tested turbine oils within about 240 ECC-D4 operating hours. With taken base of heavy-duty gas turbine characteristics such as 400 MW power production capacity, annually 8000 operating hours, and 15000 liter oil reservoir volume; it is estimated that the ECC-D4 can extend the oil service-life from 24000 to 48000 operating hours (which is approximately the oil service end-life). In addition to that, assuming the ECC-D4 investment cost as 30k€, about 15k€ savings per year through the new turbine oil and component replacement costs, besides turbine operation profit losses. Moreover, the ECC-D4 returns on investment with a rate of 39 % for defined heavy-duty gas turbine. In general perspective of ECC-D4, it makes heavy-duty gas turbine infrastructure innovative, fully integrated and committed to fulfilling the need for clean, efficient, reliable power production practices in an environmental manner.

This thesis describes an investigation on the blowout phenomenon in gas turbine combustors. The combustor primarily used for this study was a swirl- and dump-stabilized, atmospheric pressure device, which did not exhibit dynamic combustion instabilities. The first part of the thesis work concentrated on finding a sensing methodology to be able to predict the onset of approach of combustor blowout using optical methods. Temporary extinction-reignition events that occurred prior to blowout were found to be precursor events to blowout. A threshold based method was developed to identify these events in the time-resolved sensor output. The number and the average length of each event were found to increase as the LBO limit (fuel-air ratio) is approached. This behavior is used to predict the proximity to lean blowout. In the second part of this study, the blowout sensor was incorporated into a control system that monitored the approach of blowout and then actuated an alternate mechanism to stabilize the combustor near blowout. Enhanced stabilization was achieved by redirecting a part of the main fuel to a central preinjection pilot injection. The sensing methodology, without modification, was effective for the combustor with pilot stabilization. An event based control algorithm for controlling the combustor from blowing out was also developed in this study. The control system was proven to stabilize the combustor even when the combustor loading was rapidly changed. The final part of this study focused on understanding the physical mechanisms behind the precursor events. High speed movies of flame chemiluminescence and laser sheet scattering from oil droplets seeded into the reactants were analyzed to explain the physical processes that cause the extinction and the reignition of the combustor during a precursor event. A physical model for coupling of the fluid dynamics of vortex breakdown and combustion during precursor and blowout events is proposed. This model of blowout phenomenon, along with the sensing and control strategies developed in this study could enable the gas turbine combustor designers to design combustors with wider operability regimes. This could have significant payoffs in terms of reduction in NOx emissions from the combustor.

This thesis describes the development of a sensing technique for temperature nonuniformity along the line of sight through combustion exhaust, geared for gas turbine applications. Tunable diode laser absorption spectroscopy is used to measure three absorption lines and compute a variable to characterize the level of temperature nonuniformity along the laser path. Nonuniformity information is obtained from one line of sight sensor because the absorption has a nonlinear dependence on temperature. This dependence is analyzed to determine the behaviour, shape, and response of absorption lines measured through mediums with nonuniform temperature profiles. Based on this analysis a new line selection process for nonuniformity sensing is developed. A sensor for temperature nonuniformity is proposed and demonstrated through computer simulations and experiments in the exhaust of a laboratory-scale combustor. The nonuniformity variable, U, is shown to monotonically track the level of temperature nonuniformity along the laser path. The capabilities of this sensing technique are determined based on a comprehensive analysis of errors and their effect on sensor performance. Methods to mitigate these errors are described, and the overall sensor capability is determined based on the characteristics of state of the art diode laser and absorption sensor technology. Such a sensor is capable of measuring minimum temperature deviations of 17% or more, which is well within the needed capabilities for industrial applications. Furthermore, the results and knowledge presented in this thesis apply to other absorption based sensing techniques.

Manufacturers of commercial, power-generating, gas turbine engines continue to develop combustors that produce lower emissions of nitrogen oxides (NOx) in order to meet the environmental standards of governments around the world. Lean, premixed combustion technology is one technique used to reduce NOx emissions in many current power and energy generating systems. However, lean, premixed combustors are susceptible to thermo-acoustic oscillations, which are pressure and heat-release fluctuations that occur because of a coupling between the combustion process and the natural acoustic modes of the system. These pressure oscillations lead to premature failure of system components, resulting in very costly maintenance and downtime. Therefore, a great deal of work has gone into developing methods to prevent or eliminate these combustion instabilities. This dissertation presents the results of a theoretical and experimental investigation of a novel Fuel System Tuner (FST) used to damp detrimental combustion oscillations in a gas turbine combustor by changing the fuel supply system impedance, which controls the amplitude and phase of the fuel flowrate. When the FST is properly tuned, the heat release oscillations resulting from the fuel-air ratio oscillations damp, rather than drive, the combustor acoustic pressure oscillations. A feasibility study was conducted to prove the validity of the basic idea and to develop some basic guidelines for designing the FST. Acoustic models for the subcomponents of the FST were developed, and these models were experimentally verified using a two-microphone impedance tube. Models useful for designing, analyzing, and predicting the performance of the FST were developed and used to demonstrate the effectiveness of the FST. Experimental tests showed that the FST reduced the acoustic pressure amplitude of an unstable, model, gas-turbine combustor over a wide range of operating conditions and combustor configurations. Finally, combustor acoustic pressure amplitude measurements made in using the model combustor were used in conjunction with model predicted fuel system impedances to verify the developed design rules. The FST concept and design methodology presented in this dissertation can be used to design fuel system tuners for new and existing gas turbine combustors to reduce, or eliminate altogether, thermo-acoustic oscillations.

Brayton cycles are open gas turbine cycles extensively used in aviation and industrial applications because of their advantageous volume and weight characteristics. With the bulk of waste exhaust heat and engine emissions associated, there is need to be mindful of environmentally-friendliness of these engine cycles, not compromising good technical performance, and economic viability. This research considers assessment of power plants in helicopters, and aeroderivative industrial gas turbines combined-heat-and-power (ADIGT-CHP) in the petrochemical industry. Thus, it consists of two parts: part A focuses on performance analysis of helicopter gas turbines, while part B entails technoeconomic and environmental risk assessment of ADIGT-CHP in the petrochemical industry. The investigation encompasses comparative assessment of simple cycle (SC) and advanced gas turbine cycle options including the component behaviours and the environmental and economic analysis of the systems. The advanced cycles considered include: recuperated (RC), intercooled (IC), intercooled-recuperated (ICR), and low pressure compressor zero-staged (LPC-ZS), cycles. The helicopter engines are analysed and subsequently converted to small-scale ADIGT engines. Also, modelling combined-heat-and-power (CHP) performances of small-scale (SS), and large-scale (LS) ADIGT engines is implemented. More importantly, a large part of the research is devoted to developing a techno-economic model for assessing, predicting, and comparing viability of simple and advanced cycle ADIGT-CHP in the petrochemical industry in terms of net present value (NPV), internal rate of return (IRR), and simple payback period (SPBP). The techno-economic performances of the ADIGT-CHP cycles are measured against the conventional case of grid power plus on-site boiler. Besides, risk and sensitivity of NPV with respect to uncertain changes in grid electricity cost, gas fuel cost, emission cost, and electricity export tariff, are investigated. Two case studies underlie the development of the techno-economic model. One case study demonstrates the application of the model for large-scale (LS) ADIGT-CHP, and the other for small-scale (SS) ADIGT-CHP, all in the petrochemical industry. By so doing, techno-economic and environmental risk analysis framework (a multi-disciplinary preliminary design assessment tool comprising performance, emissions, economic, and risk modules) is adapted to ADIGT-CHP in the petrochemical industry, which is the aim of this research. The investigation and results led to the conclusions that advanced cycle helicopter and ADIGT engines exhibit higher thermal efficiencies than simple cycle, and that savings exist in operational costs of ADIGT-CHP above the conventional case. Thus, for both SS ADIGT-CHP, and LS ADIGT-CHP cases, all ADIGT-CHP cycles are profitable than the conventional case. For LS ADIGT- CHP category, the IC ADIGT-CHP is the most profitable, whereas for SS ADIGT-CHP category, the RC ADIGT-CHP is the most profitable. The contribution to knowledge of this research is the development of a technoeconomic model for assessing, predicting, and comparing viability of simple and advanced cycle ADIGT-CHP in the petrochemical industry in terms of NPV, SPBP, and IRR over the conventional case of grid power plus on-site boiler. A second contribution is the derivation of simple and advanced cycle small-scale ADIGT and ADIGT-CHP from helicopter engines. Cont/D.

This dissertation investigates the problem of developing verifiable stable control architectures for gas turbine engines. First, a nonlinear physics-based dynamic model of a twin spool turboshaft engine which drives a variable pitch propeller is developed. In this model, the dynamics of the engine are defined to be the two spool speeds, and the two control inputs to the system are fuel flow rate and prop pitch angle. Experimental results are used to verify the dynamic model of JetCat SPT5 turboshaft engine. Based on the experimental data, performance maps of the engine components including propeller, high pressure compressor, high pressure, and low pressure turbines are constructed. The engine numerical model is implemented using Matlab. Second, a stable gain scheduled controller is described and developed for a gas turbine engine that drives a variable pitch propeller. A stability proof is developed for a gain scheduled closed-loop system using global linearization and linear matrix inequality (LMI) techniques. Using convex optimization tools, a single quadratic Lyapunov function is computed for multiple linearizations near equilibrium and non-equilibrium points of the nonlinear closed-loop system. This approach guarantees stability of the closed-loop gas turbine engine system. To verify the stability of the closed-loop system on-line, an optimization problem is proposed which is solvable using convex optimization tools. Through simulations, we show the developed gain scheduled controller is capable to regulate a turboshaft engine for large thrust commands in a stable fashion with proper tracking performance. Third, a gain scheduled model reference adaptive control (GS-MRAC) concept for multi-input multi-output (MIMO) nonlinear plants with constraints on the control inputs is developed and described. Specifically, adaptive state feedback for the output tracking control problem of MIMO nonlinear systems is studied. Gain scheduled reference model system is used for generating desired state trajectories, and the stability of this reference model is also analyzed using convex optimization tools. This approach guarantees stability of the closed-loop gain scheduled gas turbine engine system, which is used as a gain scheduled reference model. An adaptive state feedback control scheme is developed and its stability is proven, in addition to transient and steady-state performance guarantees. The resulting closed-loop system is shown to have ultimately bounded solutions with a priori adjustable bounded tracking error. The results are then extended to GS-MRAC with constraints on the magnitudes of multiple control inputs. Sufficient conditions for uniform boundedness of the closed-loop system is derived. A semi-global stability result is proven with respect to the level of saturation for open-loop unstable plants, while the stability result is shown to be global for open-loop stable plants. Simulations are performed for three different models of the turboshaft engine, including the nominal engine model and two models where the engine is degraded. Through simulations, we show the developed GS-MRAC architecture can be used for the tracking problem of degraded turboshaft engine for large thrust commands with guaranteed stability. Finally, a decentralized linear parameter dependent representation of the engine model is developed, suitable for decentralized control of the engine with core and fan/prop subsystems. Control theoretic concepts for decentralized gain scheduled model reference adaptive control (D-GS-MRAC) systems is developed. For each subsystem, a linear parameter dependent model is available and a common Lyapunov matrix can be computed using convex optimization tools. With this control architecture, the two subsystems of the engine (i.e., engine core and engine prop/fan) can be controlled with independent controllers for large throttle commands in a decentralized manner. Based on this D-GS-MRAC architecture, a "plug and play" (PnP) technology concept for gas turbine engine control systems is investigated, which allows us to match different engine cores with different engine fans/propellers. With this plug and play engine control architecture, engine cores and fans/props could be used with their on-board subordinate controllers ready for integration into a functional propulsion system. Simulation results for three different models of the engine, including the nominal engine model, the model with a new prop, and the model with a new engine core, illustrate the possibility of PnP technology development for gas turbine engine control systems.

Electrical generating sets powered by gas turbines are required for many applications, in particular for emergency situations due to their critical attributes; high reliability, lightweight, small size, multi-fuel capabilities, low maintenance, low noise and low gas emissions. This research contends that a permanent magnet axial flux (PMAF) high-speed generator with a small gas turbine engine offers advantages over the radial flux permanent magnet generators. Higher power densities can be achieved with the axial flux configuration when compared to their counter parts of the radial flux machines of similar output power. The attributes of the PMAF machines were certainly appealing; lightweight, small size, high efficiency and ease of construction. In this research, a design approach for the PMAF high-speed generator which accounts for the mechanical and electrical aspects was provided. The machine's key components such as retainment ring was carefully designed and the materials utilised in their structures were appropriately selected to insure high mechanical integrity, ease of construction and low manufacturing cost. The generator's principle dimensions were determined from a theoretical model which was derived from the machine's main design parameters. This theoretical model was then correlated by some empirical coefficients determined through the manipulation of the experimentally validated finite element (FE) results. The analytical results have shown that with the appropriate design considerations, PMAF high-speed generators can be designed with high power densities in the range of 6-8 kW/kg and high efficiencies ideally in the range of 94 - 96 %. The mechanical integrity and the steady state electrical performance of the machine were analysed using three-dimensional (3D) FE models. More in this research, a parametric study was carried out on the most influential parameters of the machine to improve its electrical performance through minimise rotor and stator eddy current losses. In addition, the total harmonic distortion in the output waveform was minimised through the appropriate and careful design of the magnet shape and topology with the aid of 3D electromagnetic FE analysis. Furthermore, using FE it was possible to design, optimise and analyse the rotor back-iron disc through the selection of best material, shape and size for use in the PMAF high-speed generator. A prototype of the PMAF high-speed generator was constructed and tested preliminary at low speed for the purpose of the evaluation of the electrical performance of the machine. Experimental results have shown that the machine was capable to meet the design requirements. For the mechanical integrity of the machine, the rotors were safely tested on a cold run test rig at the speed of 47,000 rpm. This thesis describes also the trends and the technical details in the manufacturing, construction and experimental setup for the PMAF high-speed generator.

Radial gas turbines engines have established prominence in the field of small turbomachinery because of their simplicity, relatively high performance and installation features. Thus they have been used in a variety of applications such as generator sets, small auxiliary power units (APu), air conditioning of aircraft cabins and hybrid electric vehicles turbines. The current research describes the design, manufacturing, construction and testing a radial type small gas turbine. The aim was to design and build the engine to drive directly a high-speed permanent magnet alternator running at 60000 rpmand developing a maximum of 60 W. This direct coupling arrangement produces a portable, light, compact, reliable and environment friendly power generator. These features make the generator set very attractive to use in many applications including emergency power generation for hospitals, in areas of natural disasters such as floods and earthquakes, in remote areas that cannot be served from the national grid, oil rigs, and in confined places of limited spaces. It is important to recognize that the design of the main components, that is, the inward flow radial UFR turbines, the centrifugal compressor and the combustion chamber involve consideration of aero-dynamics, thermodynamics, fluid mechanics, stress analysis, vibration analysis, selection of bearings, selection of suitable materials and the requirements for manufacturing. These considerations are all inter-linked and a procedure has been followed to reach an optimum design. This research was divided into three phases: phase I dealt with the complete design of the inward radial turbine, the centrifugal compressor, the power transmission shaft, the selection of combustion chamber and the bearing housing including the selection of bearings. Phase 2 dealt with mechanical consideration of the rotating components that is stress, thermal and vibration analyses of the turbine rotor, the impeller and the rotating shaft, respectively. Also it dealt with the selection of a suitable fuel and oil lubrication systems and a suitable starting system. Phase 3 dealt with the manufacturing of the gas turbine components, balancing the rotating components, assembling the engine and finally commissioning and then testing the engine. The current work in this thesis has put the light on a new design methodology on determining the optimum principal dimensions of the rotor and the impeller. This method, also, has defined the optimum number of blades and the axial length of the rotor and the impeller. Mathematical models linking the performance parameters and the design variables for the turbine and the compressor have been developed to assist in carrying out parametric studies to study the influence of the design parameters on the performance and on each other. Also, a new graphical matching procedure has been developed for the gas turbine components. This technique can serve as a valuable tool to determine the operating range and the engine running line. Furthermore, it would decide whether the gas turbine engine operates in a region of satisfactory compressor and turbine efficiencies.