Proceedings of the ASME-JSME-KSME 2011 Joint Fluids Engineering Conference

AJK-Fluids2011
July 24-29, 2011, Hamamatsu, Shizuoka, JAPAN

AJK2011-0

DESIGN OF A TYPICAL GAS TURBINE BASED ON THERMODYNAMIC RELATIONS

AND CFD ANALYSIS OF ITS ROTOR BLADE

Maryam Mohammadi Seyed Sina Khamesi

Zanjan University Science and Research University
Zanjan , Iran Khorasan Razavi , Iran
Esmaeil Poursaeidi
Zanjan University
Zanjan , Iran

ABSTRACT force from expanding and accelerating of the gas within the
The process of reverse designing of gas turbine based on passes among blades. For that reason the most important
thermodynamic relations has been studied in this paper. ingredients of the turbine are its blades. In addition to many
Reverse designing is the process of perceiving and recognizing other factors, as better as possible operation of the turbine
technical principles of a system through its structure and depends on a uniform gas flow within the blades. From this
performance. This designing has been carried out by viewpoint, the importance of the blade profile will be very
mathematics and thermodynamic relations. The height and the evident. Thus, the carried out reviews, show that the proportion
exit angle of the fluid obtained from the rotor blade and gas of the thickness to the length of the chord has much influence
turbine nozzle, has been optimized in comparison with existing on the received tensions on the blade and for this reason finding
sample and the result from this optimizing, is increasing the gas an optimum ratio will lead to decrease of the failures arising
turbine power and output. The entire processes of designing, is from received tensions on the blade and increase of its firmness
carried out by a software code written in Matlab, and the results which will cause to decrease the costs arising from repairs and
of thermodynamic analysis are obtained in the form of pressure exchange of these sensitive and costly components and will
distribution, velocity and temperature. The optimized profiles also decrease the damages to other various parts of the turbine.
of different stages of turbines are illustrated in the software In this paper the reverse engineering designing process of the
output. The results from designed process, has an acceptable turbine was considered so that, by comparing solutions
conformity with existing gas turbine in power station industries. resulting from theory and what exists in a real typical gas
These results can be used for upgrading the turbine efficiency turbine, an optimized blade rotor and nozzle regarding
and consequently for increasing the power station efficiency. dimensions and fluid exit angle would be obtained.
Key words: gas turbine, blade height, output power optimizing, In the next section a CFD analysis based on finite volume
pressure and velocity distribution, CFD analysis. method (FVM) is presented by using the real operational
conditions of the turbine. Complicated geometry, high
INTRODUCTION temperature gas flow and high rotating velocity in gas turbines
Upgrading the production efficiency is one of the major are such major factors which cause the complicacy of the fluid
sections in electricity industries. Nowadays making use of gas flow analysis in the turbines. Since in gas turbines the moving
turbines in different industries such as generating electricity due blades due to rotation with high rotational velocity have been
to adaptability in consuming fuel, feasible mixed cycle and exposed to different tensions such as centrifuge tensions, are to
energy recovery from output waste products has found a carry out CFD analysis on these blades. Thus, the behavior of
specific importance. One of the functions of the turbine section the fluid flow which has obtained from a real condition of an
in the cycle is generating power for spinning the compressor. industrial gas turbine sample was studied on the moving blades
The turbine acquires the required power by extracting energy of the second stage of the simulated turbine. Then pressure and
from exhaust gases of combustion chamber which expand velocity distribution for an optimized blade regarding the
within turbine blades. Turbine blades at first tolerate an impulse height was computed and the differences between maximum
force from the early hit of hot gases and then tolerate a reaction pressure and velocities were reviewed.

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 NOMENCLATURE 3. Fluid radial velocity along the turbine is zero.
A Area
c Chord length Turbine entry parameters are presented in table 1.
Ca Axial velocity
Ci Absolute velocity Table 1. ENTRY PARAMETERS OF A 250MW POWER
Cp Constant pressure specific heat SATATION
h Blade height
Parameters Amount
m Flow rate
Inlet Static Pressure 1013250
M mach number
(Pascal)
ns Number of the turbine stages
Inlet Temperature (°C) 1000
N Number of blades
Rotating velocity Flow Rate (kg/s) 116.23
N
P Total pressure Rotating Velocity (rpm) 5100
P01 Static pressure
R Gas universal constant 4. The entry fluid into the turbine has been taken
rm Mean radius account as ideal gas.
rt Blade tip radius
S Pitch Velocity Triangle Analysis
t Thickness The velocity diagram for a stage of the turbine is according
T01 Static temperature to Fig. 1.
𝛥Tos Static temperature difference
U Linear velocity
Vi Relative velocity
ηp Isotropic output
ρi Gas density
Λ Reaction degree
α Nozzle blade angle
β Rotor blade angle
γ Specific heat ratio
ψ Blade force coefficient
 Flow coefficient

TURBINE THERMODYNAMIC ANALYSIS

To achieve the results such as number of turbine stages,
number of blades in a stage, entry and exit velocity of the fluid,
the ratio of the entry and exit angles of the fluid to the blades,
profiles of temperature and pressure in the entry and exit of the
blades, thermodynamic analysis is required to be performed at
first. The basis is to get energy from the gas based on
decreasing the high pressure energy gradually through
converting it into kinetic energy, this task is performed by
alternative passing of the gas on the moving and fixed blades.
The kinetic energy of the gas decreases on the moving blades
and recovers on the fixed blades. It is necessary to decrease the
gas density while passing through the turbine gradually and
thus, if axial velocity along the turbine is kept constant the
blades height will increase toward the low pressure losses of
FIGURE 1. VELOCITY TIANGLE IN FISRT STAGE OF THE
the turbine. For explaining the situation of the fluid in the
TURBINE
stages of the turbine the following hypothesis were considered:
According to Fig. 1. The velocities will be as follow:
1. Flow conditions in mean radius are taken into
U: blade linear velocity
consideration except the implied cases. C2, C3: fluid absolute velocities
2. The ratio of the blade height to the mean radius is low V2, V3: fluid relative velocities
and therefore we can use the theory of two dimensions α2, α3: entry angle into the nozzle and out of the nozzle
flow. β2, β3: entry angle to the moving blade and out of it.

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 Before performing the velocity analysis, it is necessary to 1
introduce the three dimensionless parameters which have been tan 3  tan  3  (6)
used for designing the turbine:  )14(

1. Blade force coefficient or the temperature difference 1

tan  3  ( 0.5  2 ) (7)
coefficient which indicates the work capacity of each
2
stage.
1
2C p Tos 2Ca tan  2  ( 0.5  2 ) (8)
  2
 (tan  2  tan  3 ) (1) 2
U U
1
tan 2  tan  2  (9)
Where the terms of Eq. (1) are as follows: 
ΔTos: temperature difference in each stage
Cp: specific heat of fluid on constant pressure
With having α2 from Eq. (9), absolute velocity in exit of the
Ca: velocity
nozzle will be obtained from Eq. (10).
Required Cp should be calculated from combustion
Ca 2
equation which is shown below:[2] C2  (10)
C H  75.5( O  3.76 N ) 
12.9 23.9 2 2
(2) cosα 2
12.9CO2  11.95 H 2O  56.625O2  283.88 N 2
2. Reaction degree: For obtaining other exit absolute velocities the computations
were followed up as below:
Where Ca is the flow axial velocity and is obtained from Eq.
Ca
 (tan  3  tan  2 ) (3) (11).
2U
Ca  U (11)
3. Flow coefficient

Ca Which it has been taken into account from reference [3]

 (4) 0 .8    1
U
Ca
C3  (12)
Computation of Entry and Exit Angles and the Fluid cos  3
Velocity
The following amounts were taken into account.
1  0 Ca
V2  (13)
 3  15  cos  2
pressure ratio  2.7
 p  0.85 Ca
V3  (14)
ΔTos is computed from Eq. (5) cos  3
 1
 
   
 
1
Tos   PT01 1   Temperature Distribution
  P01 P03   (5)
Since no work is done in the nozzle according to first law
  of thermodynamic, Eq. (15) will be established.

By knowing ΔTos we can compute the blade force coefficient h  0  T  0  T01  T02  1273 K (15)
from Eq. (1). Now with specific ψ amount, Λ value and entry
and exit angles of the fluid are computed from the following Thus, T'2 is obtained from Eq. (16)
relations [3,4]:
C 22
T02  T2   N (16)
2c p

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 For the reason that, there is friction, according to Eq. (17) 
P01   1  1 P
temperature distribution will be obtained. Exit isotropic ( )  1.853  01 (23)
temperature from the nozzle, T'2 , with assumption λN=0.05 is Pc 2 P2
computed.[3] If Eq. (23) does not satisfy, Mach number condition smaller
C2 than 0.75 is examined and if this term does not satisfy in
T02  T2   N 2 (17) designing process too, the entry parameters must be changed.
2c p
Computation of the Pitch and the Blade Number
Pressure Distribution By using the optimum ratio 2< h/c <4 for the blade, we can
Pressure distribution in each section is obtained from Eq. compute the chord value. Then by using the entry and exit
(18). [5] angles of the blade, the pitch proportion to the chord is obtained
 1 from the following diagram. By computing the pitch, the blade
P0 i T ( 
)
 ( 0i ) (18) numbers is obtained from Eq. (24).
Pi1 Ti1
2 rm
Blades Area Computing n (24)
For achieving to blades area, after computing temperature
s
and pressure distribution, the flow density, is obtained from Eq.
(19).
P2
2  (19)
RT2
Then the intended areas which are shown in Fig. 2 will be
obtained. (According to Eq. (20))
m
A2 
 2Ca 2 (20)

FIGURE 3. OPTIMUM RATIO

Computation of the Exit Power of the Turbine

The industrial type of this turbine produces 75MW power
FIGURE 2. EXHIBITION OF SECTIONS UNDER REVIEW which 25MW of it will remain in the outlet and the other will
be used in the compressor.
Blades Height Computation
Blade mean radius has been computed from Eq. (21) and W  m c p Tos ns (25)
then by using Eq. (22), blade height, h, was computed.
Where ns in Eq. (25) is the number of the turbine stages.
U m  2Nrm (21) REVIEW OF THE FLOW COEFFICEINT, THE FLUID
EXIT ANGLE AND THE INFLUENCE OF THEM ON
AN EFFICIENCY INCREASE
h (22) Figure 4 indicates the role of the flow coefficient φ and
Um fluid exit angle from the rotor of gas turbine stages on changing
the efficiency. Empirical findings indicate that, the decrease of
In order not to occur chocking phenomenon in the nozzle, the exit angle (α3) from the rotor blade has an important role on
the critical pressure ratio for nozzle is taken into account, for the efficiency increase, because increase of this angle causes to
this purpose Eq. (23) must be established. increase the loss and flow turbulence in the subsequent nozzle
and turbine exit. The highest efficiency is obtained in α3<20
and 0.6< φ<0.8. The obtained results from the performed

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 computations in this paper indicate that by increasing φ, the coefficient, the blade height decreases and the isotropic
blade height decreases. Furthermore increase of the exit angle efficiency increases. These results have been shown in Tab. 4.
from the fluid causes to decrease the blade height. These results
have been shown in Tabs. 2 and 3. TABLE 4. THE HEGIHT CHANGES WITH THE CHANGE OF
THE FLOW COEFFICIENT AND THE FLUID EXIT ANGLE

First stage
Flow coefficient 0.61 0.63 0.65 0.67 0.69
Flow exit angle 27.24 25 23 21 19
Rotor blade 0.095 0.0929 0.0909 0.0891 0.0874
height [m]
Second stage
Flow coefficient 0.74 0.76 0.78 0.8 0.82
Flow exit angle 21.02 19 17 15 13
Rotor blade 0.22 0.2174 0.2153 0.2136 0.2122
height [m]

THE PRODUCED CODE BY MATLAB SOFTWARE FOR

PERFORMING THERMODYNAMIC ANALYSIS
The steps of performing thermodynamic analysis and
tension analysis in the written code by Matlab software has
been presented in Figs. 5-7. Using the presented code, a two
stages turbine analysis has been performed and the results have
come in Tab. 5.
FIGURE 4. DIAGRAM OF THE OUTPUT CHANGES WITH
Step I
THE FLOW COEFFICIENT CHANGE ANF THE FLUID EXIT
ANGLE

TABLE 2. FLOW COEFFICIENT INCREASE AND THE

γ-1
HEIGHT DECREASE γ
1
ΔTos =ηp T01 1- P01
P03
Flow 0.65 0.7 0.75 0.8
Stage

coefficient
First

2Cp ΔTos
Rotor blade 0.904 0.846 0.797 0.755 ψ=
U2
height [m] Ca
Flow 0.75 0.8 0.85 0.9 ϕ=
U
Second
Stage

coefficient
Rotor blade 0.2133 0.2027 0.1938 0.1861
height [m]

TABLE 3.
1
FLOW EXIT ANGLE INCREASE AND THE HEIGHT tanβ3 =
2ϕ
(0.5ψ+2Λ)
DECREASE tanβ2 =
1
(0.5ψ-2Λ)
2ϕ α1 , α3
1
Flow exit angle 5 10 15 20 tanα3 =tanβ3 -
ϕ
𝛽2 , 𝛽3
Stage
First

1
Rotor blade 0.0985 0.0967 0.095 0.0935 tanα2 =tanβ2 +
ϕ
height [m]
Flow exit angle 10 15 20 25
Second
Stage

Rotor blade 0.2302 0.2247 0.220 0.216

height [m] FIGURE 5. FISRT STEP

Therefore, the performed computations for obtaining the

highest output, optimum value of the height and the blade angle
proves that by increasing the exit angle and decreasing the flow

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 Step
Step
II
III

ϕ U
Pi
ρi =
RTi
m
Ai =
ρi Cα
Cα =ϕ×U
C
Ci = α
cos αi
Ci
Vi = ρi
cos βi
Ai

Ci Um
Vi rm =
2πN
Um A
h=
N
rt rm +0.5h
=
rr rm +0.5h
C2i
T0i -Ti =
2cp
cp

2<h/c< 4
s/c
T0i
Ti
2πrm
n=
S
γ
P0i T
=( 0i )γ-1
Pi+1 Ti+1
4
(σcl ) = πN2 ρA
max 3

m Cα2 +Cα3 h 1
σgb = × ×
max n 2 zc3

P0i P0i
< =1.853 NO
Pi+1 Pc t
c

M=
Vi
γRTi
FIGURE 7. THIRD STEP

YES
TABLE 5. THE ANALYSIS RESULTS FOR THE TYPE OF
TWO SATEGS TURBINE BY USING THE CODE
YES M≤0.75
Station Total Static Temperature Density
pressure pressure [°C] [kg/m3]
[Pascal] [Pascal]
NO 1 88152.75 1013250 1000 2.49
First 2 409353 768.1 1.35
stage 3 324240 273577.5 745 1.1
Step Step
III I Second 1 324240 273577.5 745 1.1
stage 2 126656.25 543.5 0.53
3 91192.5 101325 510 0.39

FIGURE 6. SECOND STEP

RESULTS AND COMPARISIN
Using mathematics and thermodynamic relations, reverse
designing has been performed and the designed turbine results
were compared with the data of a real typical turbine. In the
present gas turbine sample, the rotor blades height and the fluid
exit angle from the rotor are according to the Tab. 6.

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 TABLE 6. THE HEGHIT, EXIT ANGLE AND THE characterized by using the industrial plans and gas turbine
COEFFICIENT OF THE FLOW COEFFICIENT OF THE REAL moving blade.
GAS TURBINE SAMPLE Using NACA standards and the reference [6], tip, middle
Rotor blade Flow exit angle Flow coefficient and root profile of the blade was obtained. By becoming
height [m] [degree]
characterized, the dimensions and profile of the blade tip,
First stage 0.095 27.24 0.61
middle and root, this geometry was made in Solid Works 2008
Second stage 0.220 21.02 0.74
software. For simulation and perform the finite volume
computations a proper mesh is required, that Gambit 2.3
software was used for this purpose. The intended mesh
The performed computations for optimizing the height and the
according to the following picture was produced. In this
fluid exit angle indicate the following new values:
software the mesh quality was formulated very carefully, as
shown in Fig. 8, that in view of accuracy and the time of
TABLE 7. THE HEGHIT, EXIT ANGLE AND THE COEFFICIENT performing computations it is optimum perfectly. The produced
OF THE FLOW COEFFICIENT OF THE OPTIMUM GAS mesh for finite volume analysis is recalled in Fluent 6.3
TURBINE SAMPLE software.

Rotor blade Flow exit angle Flow coefficient

height [m]
First stage 0.0874 19 0.69
Second stage 0.2122 13 0.82

The new produced power computation indicates an increase of

%1 for the exit power and the gas turbine output, which this
output increase, has been along with the blade height decrease
and also causes to decrease the construction and repair costs
arising the blade height.
FIGURE 8. THE CREATED MESH IN GAMBIT 2.3 SOFTWARE.

TABLE 8. CHARACTERISITC OF THE OPTIMIZED AND

REAL TURBINE BEHAVIOR OF THE FLOW ON THE WALL
In the boundary regions beside the wall, due to existence of
Real turbine Optimized turbine the pressure and velocity gradients in the fluid, turbulence
Produced power of 34.243 34.623 modeling needs a specific accuracy. The regions on the wall
1st stage [Mw] divide into three following parts [7]:
Produced power of 35.169 35.505  Viscous under layer which has a perfectly laminar
2nd stage [Mw]
flow.
Total produced 69.412 70.128
power [Mw]  Middle layer which the viscosity and turbulence
Total output % 92.549 93.504 influences on it is very important.
Rotor blade 0.095 0.0874  The outer layer which has the perfectly turbulence
height1st stage [m]
Rotor blade 0.220 0.212
flow.
height 2nd stage [m]
Due to simulation the two middle and outer layers, enhance
wall function model is used, for reviewing turbulence on
TABLE 9. CHANGES AND INCREASED OUTPUT the wall.

Rotor blade height decrease of 1st stage % 8 CONVERNEGCE

Rotor blade height decrease of 2nd stage % 4 During solving geometries with rotary reference frame and
Total output increase % 1 rotary flows with high velocities due to coupling momentum
equations which produce great rotary terms, result converging
is delayed. The high rotary velocities cause to produce great
radius pressure gradient which make the flow move along axial
GEOMETRY AND MESH and radial directions. Coupling these momentum equations
For exact and real simulation of the gas turbine moving causes solve instability which needs a specific techniques to
blade at the first step, the general geometry of the design was converge. In this paper for characterizing velocities in terms of

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 moving region the relative velocities were used. This causes to The force uniformly distribution from down to top of the
decrease the solving time which is resulting of the use of the blade is very important. Unequal load distribution causes the
equations with relative velocities that omits the need for gases go out of the blade with different pressure and velocities.
absolute velocities. The under relaxation factors are about 0.6 The rotary velocity difference in the root and the tip makes the
for momentum and about 0.7 for turbulence viscosity. gas relative velocity be less and consequently in comparison
with the root less force reaches to the blade tip. The modern gas
turbines use the blades which have impulse state in root and in
the tip they have reaction state. In this type of the blades, the
blade exit pressure remains relatively constant. The pressure
loss required for the blade reaction appears in the blade tip and
gradually changes to the conditions without loss for the impulse
in the blade root. More pressure in the tip makes the gases
move toward the blade root which acts unlike the centrifugal
forces which flow the gases toward the blade tip. Consequently
the equal force distribution is created.
The gas turbine rotor blade function conditions are
according to the Tab. 10.

FIGURE 9. FLOW FIELD EQUATIONS CONVERGENCY TABLE 10. THE FLOW INLET CONDITIONS
DIAGRAM ACCORDING TO REPETITION FOR MOVING
BLADE OF THE REAL TURBINE Inlet static pressure Inlet gauge static Inlet flow rate
[Pascal] pressure [Pascal] [kg/s]
1000 30398 0.967

THE HEIGHT DECREASE REVIEW ON THE MAXIMUM

PRESSURE AND VELOCITY
The obtained pressure distribution for two blades with the
characteristics of the Tab. 11 is according to Figs. 12 and 13.
The maximum pressure received to the blade has come in
Tab. 12. The obtained velocity distribution or two mentioned
blade is according to Figs. 14 and 15. The maximum flow
velocity round the blade tip is according to the Tab. 13.

TABLE 11. ANALYZED BLADE HEIGHT

FIGURE 10. FLOW FIELD EQUATIONS CONVERGENCY
DIAGRAM ACCORDING TO REPETITION FOR MOVING Optimized moving blade height Real moving blade height
BLADE OF THE OPTIMIZED TURBINE [m] [m]
0.212 0.22
ANALYSIS OF VELOCITY AND PRESSURE

TABLE 12. MAXIMUM PRESSURE RECEIVED ON THE

ANALYZED BLADES
Maximum pressure of the Maximum pressure of the real
optimized blade [Pascal] blade [Pascal]
3.35×105 3.38×105

TABLE 13. MAXIMUM FLOW VELOCITY AROUND THE

ANALYZED BLADE

Maximum flow velocity around Maximum flow velocity around

the optimized blade [m/s] the real blade [m/s]
FIGURE 11. THE QUALITY OF THE PRESSURE AND
427 438
VELOCITY CHANGES IN ENTIRE OF THE BLADE PROFILE

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 FIGURE 12. TOTAL PRESSRE CONTOUR FOR BLADE FIGURE 13. TOTAL PRESSRE CONTOUR FOR BLADE
WITH 0.220 M HEIGHT WITH 0.212 M HEIGHT

FIGURE 14. VELOCITY CONTOUR FOR BLADE WITH FIGURE 15. VELOCITY CONTOUR FOR BLADE WITH
0.220 M HEIGHT 0.212 M HEIGHT

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 DISCUSSION AND COLCLUSION
The performed analysis shows that, the pressure on the blade
tip is more than on its root which causes the uniform force
distribution along the blade. The obtained pressure and velocity
distribution in the optimized blade shows that, the height
decrease makes the loss of the maximum pressure and velocity.
These values have been brought in Tab. 14.

TABLE 14. CHARACTERISTICS OF THE OPTIMIZED AND

THE REAL TURBINE

REAL TURBINE OPTIMIZED

TURBINE
Moving blade 0.220 0.212
height [m]
Maximum 3.38×105 3.35×105
pressure [Pascal]
Maximum flow 438 427
velocity [m/s]

Thus the blade height decrease makes the pressure and the
blade maximum velocity to be decreased and causes its life to
be increased.

REFERENCES

[1] Goodger, E.M., 1975. "Hydrocarbon Fuels".

London: The Macmillan Press LTD.
[2] Holman,J.P., 1974. "Thermodynamics". Mc
Graw-Hill.
[3] Cohen, H., & Rogers, GFC., Saravanamutto,
HIH., 1996. "Gas Turbine Theory". Britain:
Longman Group Limited
[4] Meherwan, P. B., 2001. "Gas Turbine
Engineering Handbook". USA: Elsevier.
[5] Anderson, J. D., 2004. "Modern Compressible
Flow". USA: McGraw-Hill Book Company.
[6] Ira H. Abbott, Albert E.Von Doenhoff, 1949.
"Theory of Wing Sections". Dover
Publications. Inc, New York.
[7] Bruce R. Munson, Donald F. Young, Theodore
H. Okiishi, Wade W. Huebsch, 2010.
"Fundamentals of Fluid Mechanics", 6th ed.
John Wiley & Sons, Inc, Asia.

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