Table Of ContentTURBO-MACHINERY
DYNAMICS
Design and Operation
A. S. Rangwala
Gas Turbine Consulting Engineer
McGRAW-HILL
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DOI: 10.1036/0071467041
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ABOUT THE AUTHOR
A. S. Rangwala received a Master of Science degree in Mechanical Engineering from
Drexel University, Philadelphia, and a Master of Science degree in Industrial Engineering
from the University of Cincinnati. He has worked for three decades in the field of struc-
tural dynamics on compressors and gas turbines applicable to aircraft engines, and steam
turbines and generators for power plant applications. Mr. Rangwala has written papers
and reports on all facets of machinery system and component dynamics. He has worked
in General Electric Company’s Aircraft Engines Group, both in Cincinnati and in Lynn,
Massachusetts, and in GE’s Large Steam Turbines Department in Schenectady, New
York. Mr. Rangwala has also worked at Siemens-Westinghouse Power Corporation in
Orlando, Florida. He now works as an international consultant and teaches short courses
for practicing engineers on structural vibrations of rotating and reciprocating machinery.
He has also served as an adjunct professor at Cincinnati State Technical College.
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CONTENTS
Foreword xi
Preface xiii
List of Symbols xv
Part 1 Applications
Chapter 1. Advanced Turbine Technology 3
1.1. Introduction / 3
1.2. Historical Firsts / 4
1.3. Aircraft Propulsion / 6
1.4. Power Generation Overview / 8
1.5. Marine and Industrial Turbines / 10
1.6. Supercharging for Diesel Engines / 10
References / 12
Bibliography / 12
Chapter2. Aircraft Power Plant 15
2.1. Introduction / 15
2.2. Major Considerations / 17
2.3. High-Bypass Turbofan Engine / 18
2.4. Cycle Analysis Trend / 19
2.5. Performance Evaluation / 27
2.6. Component and Spool Match / 33
2.7. Compressor and Fan Sections / 35
2.8. Turbine Module / 39
2.9. Nacelle Design Concepts / 42
2.10. Experiments in Variable Geometry Intake / 45
2.11. Attachment with Aircraft / 48
2.12. Enhanced Power for Fighter Aircraft / 50
2.13. Life Prediction / 52
2.14. Propeller Blade Separation Incident / 55
References / 58
Bibliography / 58
Chapter 3. Industrial Gas and Steam Turbines 61
3.1. Introduction / 61
3.2. Simple-Cycle Gas Turbine / 63
3.3. Industrial Combustion Turbine / 67
v
vi CONTENTS
3.4. Classification and Characteristics of Steam Turbines / 71
3.5. Advances in Steam Path Technology / 77
3.6. Combined Cycle Mode / 80
3.7. Combined Cycle for Periodic Demand / 83
3.8. Cogeneration / 86
3.9. Heat Recovery Steam Generator / 87
3.10. Compressor Rotor and Stator / 89
3.11. Turbine Construction Features / 94
3.12. Performance Upgrade / 97
References / 101
Bibliography / 101
Chapter 4. Derivative Engines for Marine and Industrial Use 103
4.1. Introduction / 103
4.2. Ship Propulsion Plant / 105
4.3. Gas Compression Systems for Pipeline Pumping / 109
4.4. Operational Experience of LM2500 Engine / 111
4.5. Power for Heavy Military Vehicles / 113
References / 115
Bibliography / 115
Chapter 5. Diesel and Automotive Engine Turbochargers 117
5.1. Introduction / 117
5.2. Supercharging Methods / 119
5.3. Fluid Flow and Thermodynamic Considerations / 123
5.4. Turbocharger Mechanism / 128
5.5. Performance under Pulsating Conditions / 133
References / 137
Bibliography / 137
Part 2 Component Design
Chapter 6. Fan and Compressor Airfoils 141
6.1. Introduction / 141
6.2. Stall and Surge / 143
6.3. Airfoil Design Considerations / 146
6.4. Unsteady Viscous Flow / 150
6.5. Flow Characteristics at Stall Inception / 152
6.6. Rotating Instability from Vortex at Blade Tip / 156
6.7. Prospects for Active Stall Control / 159
6.8. Cascade Flutter Analysis / 167
6.9. Fault Identification in Variable Stator Vanes / 170
6.10. End-Wall Blockage / 173
6.11. Acoustic Resonance in Multistage Compressors / 177
6.12. Finite Element Method in Blade Vibrations / 181
6.13. Swept Fan Blade / 186
6.14. Design of Axial Compressor / 190
6.15. Increased Power by Zero Staging / 193
6.16. Prediction of Forced Response / 197
CONTENTS vii
6.17. Random Blade Mistuning / 202
6.18. Stresses in Dovetail / 206
6.19. Example Problems / 210
References / 219
Bibliography / 221
Chapter 7. Impeller and Bladed Disk 223
7.1. Introduction / 223
7.2. Impeller Design Features / 224
7.3. Diffuser for Industrial Gas Turbine / 228
7.4. Interaction Between Impeller and Volute / 230
7.5. Flow Characteristics in Vaned Diffuser / 235
7.6. Radial Inflow Turbine / 238
7.7. Stresses in Rotating Disk / 244
7.8. Twin Web Disk / 247
7.9. Disk Burst Capability / 250
7.10. Fluid-Flow Forces in Whirling Impeller / 253
7.11. Uncontained Failure from Fracture of Fan Hub / 256
7.12. Compressor Disk Failure Investigation / 259
7.13. Example Problems / 263
References / 267
Bibliography / 268
Chapter 8. Turbine Blade and Vane 269
8.1. Introduction / 269
8.2. Design Aspects / 273
8.3. Individual Blade Vibration / 274
8.4. Cumulative Damage Theory in Life Prediction / 277
8.5. Integrity Evaluation of Turbine Blades / 280
8.6. Secondary Flow Loss Control / 284
8.7. Wake–Wake Interaction / 289
8.8. Clocking Effects in Turbine / 294
8.9. Steam and Air Cooling / 297
8.10. Impingement Cooling Aspects / 302
8.11. Nozzle Vane Design / 304
8.12. Example Problems / 308
References / 313
Bibliography / 314
Chapter 9. Combustion System 317
9.1. Introduction / 317
9.2. Fuels for Various Applications / 319
9.3. Combustion Principles / 324
9.4. Combustor Designs and Selection / 327
9.5. Control of Pollutants / 336
9.6. NO Formation / 340
x
9.7. Effects of Swirl / 342
9.8. Dry Low NO Combustion System / 345
x
9.9. Catalytic Combustor for Utility Turbine / 349
9.10. Acoustic Resonance / 351
9.11. Active Combustion Instability Control / 355
viii CONTENTS
9.12. Thermal Protection of Combustor Liner / 359
9.13. Structural Design for Dynamic Pressure / 361
9.14. Example Problems / 364
References / 368
Bibliography / 370
Chapter10. Bearings and Seals 371
10.1. Introduction / 371
10.2. Fluid Film Bearing / 373
10.3. Journal Bearing Types / 377
10.4. Dynamic Characteristics / 380
10.5. Thrust Bearing / 385
10.6. Rolling Element Bearing / 387
10.7. Vapor Phase Lubrication / 392
10.8. Deformation in Ball Bearing / 396
10.9. Tip Clearance Actuation with Magnetic Bearings / 399
10.10. Impact of Flexible Support / 405
10.11. Seals and Dampers / 409
10.12. Labyrinth and Honeycomb Seal Evaluation / 412
10.13. Damping Seal Dynamic Characteristics / 415
10.14. Squeeze Film Damper / 417
10.15. Example Problems / 422
References / 427
Bibliography / 429
Part 3 Materials and Manufacture
Chapter11. Superalloys for Turbines 433
11.1. Introduction / 433
11.2. Strengthening Methods / 435
11.3. Nickel Base Alloys / 437
11.4. Cobalt Base Alloys / 440
11.5. Nickel–Iron Alloys / 442
11.6. Processing of Wrought Alloys / 443
11.7. Directionally Solidified Airfoil Technology / 446
17.8. Oxidation and Corrosion Resistance at Elevated Temperatures / 452
11.9. Protective and Thermal Barrier Coats / 453
11.10. Fracture Mechanism of Coats / 458
11.11. Fiber-Reinforced Ceramics for Combustor Liner / 465
11.12. Ceramic Components in MS9001 Engine / 469
References / 472
Bibliography / 473
Chapter 12. Manufacturing Methods 475
12.1. Introduction / 475
12.2. Centrifugally Spun Alloy Steel Casting / 476
12.3. Investment Castings / 480
12.4. Powder Metallurgy Process / 483
12.5. Welding Methods / 486
