Gas Turbines

Brayton combines rigorous thermodynamic modeling with advancements in heat transfer, aerodynamics, and combustion sciences. The foundation of optimal gas turbine design starts with comprehensive cycle and system analysis. Brayton has developed internal codes to perform the integrated cycle analysis for the computational modules listed below.

Technical Expertise

Design point simulations
Simple gas turbine cycles
Intercooled recuperated and reheat cycles
Part-load performance simulation
Incorporating physical compressor and turbine maps
Parametric representation of the recuperator and intercooler
Combustion stability and CO emission over the operating envelope
NOx emissions over the gas turbine operating envelope
Turbine and compressor sizing and parametric performance analysis
Static and rotating ceramic hot sections
Axial, radial & screw machinery
Combined heat/ power (CHP) systems
Hi-temp ceramics & blade cooling

Approach

Rigorous Design of Aerodynamic components:

Tools + Experience + Facilities

Empirical Experienced-based Design Tools

Computational Fluid Dynamics

Solid Model Generation or FEA & Life Analysis

Rapid Prototyping

Specialized Instrumentation Techniques

Advanced Techniques in Component Testing

Validation: Data vs Analysis

GAS TURBINE Test Facilities

Turbine and Compressor Test Rigs

Brayton’s test facilities include five combustion gas stands dedicated to the characterization of turbomachinery and gas turbine combustors. The test cells are equipped with precision instrumentation, including highly specialized pressure traversing instruments and cobra probes, thermocouples, mass flow meters, and calibration equipment. Brayton maintains a host of data acquisition equipment, as well as borascope, thermal imaging system, and emission test equipment.

Aerodynamic Testing:

Traversing 2-axis remote control cobra probe (large and micro-scale) for components <50 mm
TC raking and traversing
Calibration: NBS traceable flow, pressure and temp
Custom instrumentation for controls and data acquisition
Model validation
Endurance testing

In-house Ceramic DevelopmentAdvanced ceramics for gas turbines

Brayton Energy has been pushing firing temperatures in hot turbine sections incorporating both static and rotating ceramic hardware developed from a variety of manufacturing methods such as isostatic pressing, slip casts and ultra precision CNC grinding to achieve tolerances.

Brayton’s expertise focuses on extremely low thermal expanding and conductive ceramics with superior strengths and machinability.

CM furnace for ceramic firing used on microturbine hot sections. Capable of temperatures up to 1600°C at specific sintering…

Hi-temp (1100°C operating) ceramic hardware used in our 350kW 3-stage microturbine

In-house firing of ultra low CTE ceramics

Custom slip-mold patterns to yield ceramic components in pre-fired “bisk” form.

Bisk ceramic expander pulled from mold ready of firing.

Ceramic-to-metal joint qualifications. Brayton has several development engines requiring a shrink fit or brazed joint between the ceramic turbine and a metallic shaft. In these applications metallic shafts on rotating hardware are required for bearing seats.

Centrifugal ceramic turbine withstands localized 600°C operating temperatures at metal joint.

In-house torque testing of joint samples.

In house fatigue and thermal stress testing of ceramics

Screw Compressor and Expander Development

Design, prototype manufacturing and testing
Advanced high temperature ceramic screw expander. (up to 1200°C)
Non contacting, non-wear parts for exceptionally long life.
Compressible coatings to close shroud clearances, increasing efficiency.
Partnerships with profile grinding industry experts providing custom coated tooling and fixtures.
In-house diagnostics and performance characterization of design.

Rapid prototyping on Brayton’s new HASS CNC milling station.

Brayton’s simultaneous 4-axis machining of the 4 x 6 lobe compressors from steel.

Ceramic screw expander set with metallic shafts designed to operate with 67 micron shroud-to-shroud clearances

“Main” 4-lobe ceramic expander requires precision grinding from custom tooling holding a 15 micron profile tolerance.

Metallic compressor: The gray finish to the compressor screw profile is a Teflon coating designed to compress and close shroud clearances.

Ceramic expander thermal gradient studies. Qualifying operating temperatures up to 1200°C.

Gas Turbines Related Projects

1.2 MW Gas Turbine

Direct biomass combustion (solid fuel internal combustion) eliminates much of the costly fuel processing associated with making either bio-oils, ethanol, or standard gasifiers. To effectively achieve direct biomass combustion in a gas turbine Read More