Which Air Compressor You Can Use In Gas Turbine Power Plant?

Gas Turbine is used in Power Plant for driving the Generator,by which we can produce Electricity with other arrangements.Compressed Air plays the vital role in every Gas Turbine Plant.This Compressed Air is obtained from Air Compressor.

Usually Rotary Air Compressor are used with a Gas Turbine.Mostly Centrifugal Compressors or Axial Compressors are used.

Now we will see the details of each Air Compressor.

01)Centrifugal Air Compressor:-

The Impeller which consist of large number of Blades,is mounted on the Compressor Shaft,inside the Stationary Casing.As the Impeller rotates,the Pressure in suction region falls and hence the Air enters through the Eye and flows Radially outwards through Impeller Blades.As a result Velocity and Pressure of Air increases.

Later this Air enters and flows through the Convergent Passages formed by the Diffuser Blades.At this stage the Velocity of Air is decreases but the Pressure increases still further.We may say that,during this stage the Velocity Energy is converted into Pressure Energy.

Finally this High Pressure Air escapes from the Compressor Delivery Portion.This is Single Stage Compression and is suitable for small pressure ratios.You can obtain High Pressure Ratios by arranging the number of Air Compressor in series.

02)Axial Air Compressor:-

This type of Compressors are more commonly used now a days.In Axial Compressor,the Air flows in an Axial Direction right from Intake to the Delivery.

The Working Principle is as illustrated below.

The Stator,which have Stator Blades encloses the Rotor,which are provided with Rotor Blades.As the Air enters from Suction Region,it flows through the alternately arranged Stator and Rotor Blade Rings.

In flowing through each pair of Blade Rings formed up of one Rotor Blade Ring and one Stator Blade Ring,the Air gets Compressed successively.The Air is finally Delivered from Delivery Region,which is smaller in size compare to Suction side.

I have tried to disclose as much as knowledge I have, but engineering is such a vast field that can not be covered in single post.You can still search from Internet for more details.

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5 Main Advantages Of Gas Turbine Over Steam Turbine.

Turbines are used to generate Power,this Power can be generated by Gas turbine or Steam turbine.The basic working principle of Gas Turbine is nearly same as the working principle of Internal Combustion Reciprocating Engine.The Fuel used for Combustion in Gas Turbine Plant may be Oil,Coal,Procedure Gas etc.


In Steam Turbine,the Heat Energy contained in the Steam is first employed to set the Steam itself in motion and this in turn is made to do work on Blades mounted on a Shaft or Drum,which is free to rotate.

However,Gas Turbine has certain Advantages over Steam Turbine,which are as below.


01)The Gas Turbine Plant is simple in Design and Construction.It has few Reciprocating Parts and is lighter in weight.

02)In Steam Turbine Plant,water is used for cooling purpose,hence there are chances of Freezing in winter nights.There are no likelihood of Freezing in Gas Turbine Plant.

03)The Gas Turbine is quite useful in the regions where due to scarcity it is not possible to supply water in abundance for raising steam.


04)The Gas Turbine has been built to operate at the Inlet Temperature of 800 Degree Centigrade and even more,while the Steam Turbine and Boiler have been built for Temperatures up to about 580 Degree Centigrade.The Efficiency of Gas Turbine is much higher than that of Steam Turbine due to High Inlet Temperature,when other things being equal in both Turbines.

05)The Gas Turbine does not require any Boiler as like in Steam Turbine,hence the weight and space of Gas Turbines are less than those of Steam turbine.For the same output,the Gas Turbine is more compact than a Steam Turbine.The Capital Cost of Gas Turbine is much lower than Steam Turbine.

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Why Gas Turbine is better than Internal Combustion Engine?

Gas Turbine and Internal Combustion Engines,both are used to produce Power for operations of other Machines.Below are some points,which shows that the Gas Turbine is better in performance and use,than Internal Combustion Engine.

01)In winter nights,specially in cold regions,some provision has to be made to prevent Freezing in Internal Combustion Engines using Water Cooling when the Temperature of the Atmosphere falls to sub zero values.Anti-Freezer is generally used for this purpose.

There is no danger of Freezing,as Gas Turbine does not use any Water.On the other hand Gas Turbine works better if the Temperature of the Atmosphere falls below.

02)The Output from a Gas Turbine increases if the Inlet Temperature of the working Fluid decreases.At the High Altitudes where the Temperature of the Air is quite low,the Output of the Aviation Gas Turbine can be well maintained.

While the Output of Internal Combustion Engine at High Altitude would decreases.

03)For the same Output,the weight per Horse Power of a Gas Turbine is about one third that of Reciprocating Piston Type Internal Combustion Engine.That is why,the Turbojet Engines are being more commonly used in AirCrafts.

04)A Low Grade Fuel can be used in Gas Turbine.In some cases even Coal and Peat have been burnt.Low Grade Fuel can not be used in InternalCombustion Engines.

05)The Fuel and Lubrication cost in Gas Turbine is lower comparing to Internal Combustion Engine.

You can add few points,if you know something about the topic.

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Can we use Coal as Fuel in Gas Turbine?

In Gas Tubine engineering, different types of Fuels can be used to perform its operations.The Coal may also be used as a Fuel in Gas Turbine plant.But it may contain asmuch as 20% of its Weight of dirt in the form of Ash.

In case the Ash Particles are allowed to pass through the Turbine the later's Bldes are likely to be blocked and even damaged.

Experiments with some success have already been conducted in England and United States so as to devise means by which Ash in the Coal has been removed or rendered innocous by making it small enough to pass through the Gas Turbine.

For the removal of Ash,two methods have been used.First method employes,suitable cleaning devices.In second method,the Coal is burnt at such a Higher Temperature that the Ash melts and flows down to the bottom of the Combustion Chamber from where it can be removed.

But in second case the removal of Ash is only 95% has been ensured,the rest 5% remains unremoved.Suitable Cleaner can be installed to remove this part or at least large sized particles in it,which would otherwise cause more damage to the Gas Turbine Blades than small particles.

The presense of even minute traces of the large sized particles in the Combustion Gases is harmful for the Turbine Baldes.

I hope,from above details,you come to know that Coal can be used as Fuel in Gas Turbine with due care to be taken.

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What is the difference between An Impulse and a Reaction Turbine.

The Turbine is a Prime Mover in which a Rotary Motion is obtained by Centrifugal Force brought into action by changing the Direction of Jet of a Fluid escaping from a Nozzle at High Velocity.

This Turbines are classified by several ways.The most important and common division being with respect to the action of the Steam and they are as,
01)Impulse Turbine
02)Reaction Turbine
03)Combination of Impuse and Reaction Turbine.

Difference between Impuse and Reaction Turbine:-

In an Impulse Design of Steam Turbine,there is an attempt to attain no Expansion of Steam within the Moving Blades and as such its Pressure remains constant while passing over the Blades.

The Expansion of Steam,however,takes place in a set of Stationary Nozzels which lower its Pressure but impart a High Velocity to it.The Velocity attained in a properly designed Nozzel depends upon the Pressure drop through it.

Impuse Turbine Design may be classified as Single Stage,Multi Pressure Stage,Multi Velocity Stage and Combination of Multi Pressure and Velocity Stage.

The term Pressure Stage refers to unit of Nozzels combined with Moving Blades in which the Energy of the Steam resulting from each Pressure drop,isutilised.

The Velocity Stage refers to the number of Moving Blades in which the energy of the Steam in each Pressure drop is absorbed.

In case of Reaction Turbine the Steam expands as it flows over the Blades which,therefore act as Nozzles.In fact it is this drop in Pressure that gives a Reaction and hence Motion to the Rotor.

A pure Reaction Turbine,comprises of two or more Radial Tubes rotating and communicating with another pipe or turnnion through which Steam is supplied to Nozzle which are screwed into the ends of the Radial Pipes and arranged with their Axis in the Tangential Direction.

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How Hydraulic Reciprocating Pump Works?

The Pump which raises Water from Lower Level to Higher Level by the Reciprocating Action of Piston inside the Cylinder is known as Reciprocating Pump.

A Reciprocating Pump,in its simplest form,consists of the following parts,

01)A Cylinder in which Piston works.The movement of Piston is obtained by a Connecting Rod,which connects the Piston and the Rotating Crank.

02)A Suction Pipe,connecting the source of Water and the Cylinder.

03)A Delivery Pipe,into which the Water is Discharged from the Cylinder.

04)A Suction Valve,which admits the flow from the Suction Pipe into the Cylinder.

05)A Delivery Valve,which admits the flow from the Cylinder into the Delivery Pipe.

During the Suction Stroke,the Piston moves from Zero to 180 Degree (which means towards right direction).Thus creating Vaccume in the Cylinder.This Vaccume causes the Suction Valve to open and Water enters the Cylinder.

During Delivery Stroke,the Piston moves from 180 Degree to 360 Degree (which means towards left direction).Thus increase pressure in the Cylinder.Due toincrease in Pressure,causes the Suction Valve to close and Delivery Valve to open,and Water is Forced into the Delivery Pipe.

A Hydraulic Reciprocating Pump,is also called a Positive Displacement Pump,as it discharge a definite quantity of Liquid during the Displacement of its Piston.This is why a Hydraulic Reciprocating Pump is ideally suitable for Grouting Operations in Dam Foundation.

To obtain a uniform Discharge from Reciprocating Pump,the Air Vessels are fitted to the Suction and Deliver Pipe,close to the Cylinder of the Pump.

An Air Vessel is a Cast Iron closed chamber,having an opening at its base,through which the water flows into the Vessel or from the Vessel.The Vessel is filled with Compressed Air.

Above description will definitely clear your idea about working of Hydraulic Reciprocating Pump.

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Why Piping System in Centrifugal Pump is so Important?

The Pump,which raises Water or a Liquid,from Lower Level to Higher Level by the Action of Centrifugal Force,is known as Centrifugal Pump.
This is the Machine which converts Mechanical Energy into Pressure Energy.

The Action of Centrifugal Pump is that of a Reversed Reaction Turbine.In Centrifugal Pump,the Water enters the Impeller Radially and leaves the Vanes Axially.

The successful working of Centrifugal Pump depends upon the correct selection and layout of its Piping System.An extreme care should always be taken in selecting the size of the pipe and their arrangement.

In general,Centrifugal Pump has,
01)Suction Pipe.
02)Delivery Pipe.

Suction Pipe:-
The Suction Pipe of Centrifugal Pump,plays an important role in the successful and smooth working of the Pump.A poorly designed Suction Pipe causes insufficient Net Positive Suction Head (NPSH),Vibration,Noise,Water Hammer,Excessive Wear etc.

While laying the pipe,a great care should be taken to make it Air Tight.
To avoid the entry of Foreign Matter,a Strainer Foot Valve is connected at the bottom of the Suction Pipe.

Since the Pressure at the Inlet of the Pump is Suction,which is also known as Negative and its value is limited to avoid Cavitation,it is therefore essentialthat the losses in the Suction Pipe should be as small as possible.For this purpose,bends in the Suction pipe are avoided and its diameter is often kept larger.

Double Suction Pump are those in which,the Suction Pipe is branched into two parts and the liquid is allowed to enter the Impeller from both sides.The Axial Thrust in Double Suction Pump is considerbly low.

Delivery Pipe:-
In order to protect the Pump from Water Hammer and to regulate the discharge from the Pump,a Check Valve is provided in the Delivery Pipe,near the Pump.The size and length of the Delivery Pipe depends upon the requirment.

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Are you interested to know,How Hydraulic Crane works?

Many of us know that Crane is a Device which is used to lift the Heavy Loads for transferring or shifting purpose.

These Cranes have different types of Working Priniciple and Driving Media.You can operate Crane by Electric Power or by Water also.

Electric Driven Cranes are used in Engineering Manufacturing Plants where as Hydraulic Cranes are widely used on Dock Siding,Warehouse or Big Workshops.

In this post I will cover the details about Hydraulic Crane.A Hydraulic Crane can lift a heavy load upto 250 Tonnes in weight.

A Hydraulic Crane in its simplest form consist of a Vertical Post,Tie and Jib having Guiding Pulleys.All these parts are basic requirment of a Hydraulic Crane.

A Jigger is provided near the foot of Vertical Crane Post.The Jigger consist s of a fixed Cylinder,having a Pulley Block and containing a Sliding Ram.One endof the Ram is in contact with Water and other carries a Pulley Block.

A Chain or Wire Rope,one end of which is fixed,is taken round all the Pulleys of the two Blocks,through the Vertical Post and finally over the Guide Pulleys.

A Hook is attached to the other end of the Rope for handling the Load.There is a pipe connection for supplying water under High Pressure to the fixed Cylinder of the Jigger.

The Load to be lifted,is suspended on the free end of the Wire Rope.The Water,under High Pressure,is admitted into the Cylinder of Jigger.This Water,Forces the Sliding Ram to move towards the left.

This outward movement of the Sliding Ram,makes the Pulley Block to move outwards.Due to the increased distance between the two Pulley Blocks,the Wire Rope is pulled and the load is lifted up.

If the load is required to be shifted,the Vertical Post,of the Hydraulic Crane,can be rotated through the desired Horizontal Angle.

I hope,now you understand the working of hydraulic Crane.

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The Important Mechanical Properties of Metal.

The Mechanical Properties of the Metals are those which are associated with the ability of the Material to Resist Mechanical Forces and Load.

Following are the Important Mechanical Properties of the Metal.

01)Strength:-
The Internal Resistance offered by a part to an externally applied Force is called as Stress.It is the ability of a Material to resist the externally applied Forces with Breakdown or Yielding.

02)Stiffness:-
It is the ability of a Material to Resist Deformation under Stress.

03)Elasticity:-
It is the Property of a Material to Regain its original shape after Deformation when the External Forces are removed.

04)Plasticity:-
It is the Property of Material which retains the Deformation produced under Load permanently.This Property of Material is important for Forging and in Ornamental Work.

05)Ductility:-
It is the Property of Material enabling it,to be drawn into wire with the application of Tensile Force.A Ductile Material must be both Strong and Plastic.
06)Malleability:-
It is the special case of Ductility which permits Material to be Rolled or Hammered into Thin Sheets.A Malleable Material should be Plastic but it is not essential to be so strong.

07)Toughness:-
It is the Property of a Material to resist Fracture due to high impact Loads like Hammer Blows.The Toughness of a Material decreases when it is heated.

08)Brittleness:-
It is the Property of the Material of breaking of a material with little permanent distortion.Brittle Materials when subjected to Tensile Loads,snap off without giving any sensible Elongation.

09)Hardness:-
It embraces many different properties such as Resistance to Wear,Scratching,Deformation and Machinability etc.It also means the ability of a Metal to cut another Metal.

10)Creep:-
When a part is subjected to a constant Stress at High Temperature for a long period of time,it will undergo a slow and permanent Deformation called Creep.

Above properties are most essential in machine design and in engineering, every design engineer must know and keep in mind.

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What are the General Considerations in Machine Design.

01)Type of Load and Stresses caused by the Load:-
The load on the Machine Component,may act in several ways due to which the Internal Stresses are set up.

02)Motion of Parts:-
The successful operation of any Machine depends largely upon the simplest arrangements of the Parts,which will give the required motion.The Motion of the Part may be
A)Rectilinear Motion,which includes Unidirectional and Reciprocating Motion.
B)Curvilinear Motion,which includes Rotary,Oscillatory Simple Hormonic.
C)Constant Velocity.
D)Constant or Variable Acceleration.

03)Selection of Material:-
Every Machine Design Engineer should have a thorough knowledge of the Properties of Material and their behaviour under working conditions.

04)Form and Size of the Parts:-
In order to design any Machine Part for form and size,it is necessary to know the Forces which the Part must sustain.Any suddenly applied or impact load must be taken into consideration,which may cause failure.The smallest Practicable Cross-Section may be used,but it may be checked that the Stresses induced in the Designed Cross-Section are reasonably safe.

05)Frictional Resistance and Lubrication:-
There is always a Loss of Power due to Frictional Resistance.Careful attention must be given to the matter of Lubrication of all surfaces which moves in contact with others.

06)Safety of Operator:-
A Machine Designer should always provide safety device for the safety of the operator.The Safety Appliances should in no way interfere with the operation of the Machine.

07)Use of Standard Parts:-
The use of Standard Parts are closely related to the Cost of Machine,because the Cost of Standard Parts is only a fraction of the cost of similar parts made to order.

08)Convenient and Economical Features:-
The operating feature of the Machine should be carefully studied.The Starting,Controlling and Stopping Levers should be located on the basis of convenient handling.

09)Workshop Facilities:-
A Design Engineer should be familiar with limitation of his Employer's Workshop,in order to avoid the necessity of having work-done in some other Workshop.

10)Assembling:-
Every Machine must be Assembled as a unit before it can function.The final Location of any Machine is important and the Design Engineer must anticipate the exact location and the local facilities for erection.

Above considerations are most important in machine design engineering.

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What is the General Procedure of Designing Machine Component?

In Designing a machine component,there is no rigid rule.The problem may be attempted in several ways.Every machine design engineer tried at his levelbest to overcome the possible problems,but machine designing is a continious process.

However,the general procedure to solve a design problem is as follows.

01)First of all make a complete statement of the problem,indicating the purpose for which the machine is to be designed.

02)Select the possible groups of mechanisms which will give the desired motion.
03)Find the forces acting on each member of the machine and the energy transmitted by each member.

04)Select the best material suited for each member of the machine.

05)Find the size of the each member by considering the forces acting and the permissible stresses for the material used.It should be kept in mind that each member does not deflect or deform than the permissible limit.

06)Modify the size of the member to agree with the past experience and judgement to facilitate manufacture.

07)Draw the detailed drawing of each component and the assembly of the machine with complete specification for the material and manufacturing process suggested.

Follow all the above points to design a best quality machine, and be the best design engineer.

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Trouble shooting and rectification In Automatic Starters.(Part-B)

Some faults are already covered in Part-A.In this post remaining faults about Automatic Starter will be disclosed.In Air Compressor,accessories are very important to keep the machine in running condition.

Automatic Starters (Contactor type) are mainly used to start Electric Motor so the Air Compressor coupled to that motor can be started.

Lets see remaining problems,its reason and rectification of Automatic Starters (Contactor type).

(E)FAULT:-NOISY CONTACTOR.

Reason:-(01) Dirty or rusty magnet and armature faces.
Rectification:-(01) Clean the magnet and armature face with soft cloth and apply petroleum Jelly.

Reason:-(02) Restricted movement or friction in magnetic movement.
Rectification:-(02) Check magnet by hand for free movement.

Reason:-(03) Intermittent contact on control circuit.
Rectification:-(03) Check all the contacts and control switches in control circuit for effective contacts.

Reason:-(04) Magnet and /or armature faces are not true.
Rectification:-(04) Change magnet and /or armature as the case may be.

Reason:-(05) Contactor chatter after changing the "No Volt" coil because the moving contact or carrier is fitted in reverse direction.
Rectification:-(05) Correct the direction.

(F)FAULT:-COIL BURNING.

Reason:-(01) Over voltage.
Rectification:-(01) Correct the incoming supply voltage.

Reason:-(02) Coil rating wrong.
Rectification:-(02) Use proper rating coil.

Reason:-(03) Noisy contactor.
Rectification:-(03) Refer the rectification for noisy contactor as per fault (E).

Reason:-(04) Contactor fails to close.
Rectification:-(04) Refer the rectification for contactor fails to close from previous post.(Part-A)

(G)FAULT:-STARTER FAILS TO OPEN.
For this fault there are three conditions.

(A) The fault occurs,when the supply switch is "Off".Reason is,Residual magnetism in armature and magnet.Rectification is,Polish very little or put some punch on the centre line of armature.

(B) The fault occurs,when "Off" push button pressed.
Reason is,(1) Cover fixing screw are loose.
Rectification is,(1) Tighten the screw fully.
Reason:-(02) Push button length is short.
Rectification:-(02) Set the right push button.

(C) The fault occurs due to condition A & B
Reason is,(1) Contact tips welded.
Rectification is,(1) Change the defective contacts.

Reason:-(02) Moving contacts carrier sticky.
Rectification:-(02) Check the moving contacts carrier and rectify the cause of sticking.

So,the maximum possible faults,its reason and rectifications of Automatic Starters are covered in Part-A & Part-B.

You are suggested to add if you know something about this topic.My goal is to keep you informed about every field of Air Compressor and engineering.

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Trouble shooting and rectification In Automatic Starters.(Part-A)

In any Air Compressor unit,Electric Motor is the most important accessory to drive the air compressor.To start and run the electric motor starters are used you will find more details from electrical engineering books.

These starters are mainly of two types one is Automatic type and another is Manual operated starter.

Automatic Starters are Contactor type and mostly used in all Air

Compressor units now a days.The details about both Starters are already given in my earlier posts,which you may refer.

Here I will disclose some problems which may occur in Contactor type Starter (Automatic Starter) in two parts.I hope these post will help you to rectify problems of your Starter of Air Compressor.

Lets see some problems,its reason and rectification of Automatic Starters (Contactor type).

(A)FAULT:-CONTACTOR FAILS TO CLOSE.
Reason:-(01) Coil open circuited.
Rectification:-(01) Change the coil.
Reason:-(02) Loose control circuit connections.
Rectification:-(02) Tighten all the screws.
Reason:-(03) Voltage too low.
Rectification:-(03) Improve voltage conditions.
Reason:-(04) Coil rating wrong.
Rectification:-(04) Use correct rating coil.
Reason:-(05) Obstacles in moving contacts carriers movement.
Rectification:-(05) Remove the obstacles.

(B)FAULT:-FUSES BLOWS DURING STARTING.
Reason:-(01) Fuse rating is too low.
Rectification:-(01) Use correct rating of fuses.Fuse for DOL Starters should be 3 to 4 times of motor full load current and for Star-Delta 1.5 to 2.5 times.
Reason:-(02) Short circuit in the system.
Rectification:-(02) Check and rectify the faulty CCF.

(C)FAULT:-INADVERTENT TRIPPING OF STARTERS.
Reason:-(01) Overload Relay setting low or single phasing
Rectification:-(01) Check voltage and current drawn by the Electric Motor and adjust Overload Relay to motor full load current.
Reason:-(02) Motor takes very long time to accelerate due to very low incoming voltage.
Rectification:-(02) Improve the voltage condition and use proper size cables.
Reason:-(03) Motor overloaded.
Rectification:-(03) Unload the Air Compressor during the starting.

(D)FAULT:-SEVERE CONTACT BURNING OR WELDING.
Reason:-(01) Excessive voltage drop during starting preventing magnet from closing in one stroke.
Rectification:-(01) Check the cross section of the cables from supply source to motor.
Reason:-(02) Insufficient contact pressure.
Rectification:-(02) Check moving contact spring pressure,change if necessary.
Reason:-(03) Change over in Star-Delta is too early.
Rectification:-(03) Increase the timer setting.

Some more faults will be covered in next part-B.

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