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ABSTRACT Subscripts
1 Inlet to compressor
Most engine health monitoring systems used for land based 2 Compressor Discharge Station
systems are based on steady state operation. Diagnostic analysis has 3 Gas Generator inlet Station
traditionally been conducted under steady state conditions with on-line 4 Gas Generator Discharge Station
systems tending to concentrate on map based performance diagnostics c Compressor
using pattern analysis, fault matrices or expert systems. Transient t Turbine
analysis is a relatively a new technique and is being applied to some b Combustor
aeroengines. There is significant diagnostic content in turbine startup mech Mechanical
and shutdown data and in data obtained during power or speed
changes. This data can be captured if an automatic on-line system is
employed. This paper provides an overview of the use of both INTRODUCTION
performance and mechanical transient analysis as a means to detect gas
turbine problems. The paper covers the need for transient analysis In the past decade there has been increasing interest in the
and covers transient analysis techniques. Examples and a discussion application of condition monitoring systems to gas turbines. There are
of how transient analysis can be integrated within an existing on-line now condition monitoring systems available that provide integrated
monitoring system is made. performance and mechanical information. Several new developments
in the area of sensors have resulted in the availability of detailed
NOMENCLATURE information on the gas path, tip clearances, blade metal temperatures,
oil condition and exhaust gas debris. Typically, these sensors are not
DET = Deterioration found on commercial gas turbines. Clearanceometers have been
Ts = Starter Torque developed for the monitoring of blade tip clearances. Pyrometers have
Tggt = Gas Generator Torque been used for years for the measurement of blading temperatures and
Td = Drag Torque have been applied in aeroengines and also on power generation
PR = Pressure Ratio machines. Oil debris sensors (both intrusive and non-intrusive) are
CDP = Compressor Discharge Pressure currently available. Some advanced condition monitoring techniques
rila = air mass flow rate are described by Cross and Barkhoudarian (1991).
mf = fuel mass flow rate Steady state operation is defined as a condition wherein parameters
B = Efficiency are at a relatively steady state with only random scatter occurring. In
steady state, the mass balances in the turbine are totally satisfied and
7 = Cp/Cv there is no accumulation of mass. This means that the mass flow from
LHV = Lower Heating Value one component equals the mass flow to the adjoining component.
N1 = Gas Generator Speed Historically, most condition monitoring systems rely on "steady state
GG Gas Generator data" i.e., data in which time based variation is at a minimum.
EGT Exhaust Gas temperature A transient condition is said to occur when condition parameters
ITT Inter Turbine Temperature such as speed, firing temperature and load vary with time. Obviously,
Q Rotor Amplification Factor startup and shutdown are transient events as is a change in load or an
HP High Pressure acceleration event. White (1988) has summarized the four main
LP Low Pressure differences between steady state and transient conditions:
Of, Acceleration 1. During transients, shaft inertia will either demand or produce
t Cycle Time power (depending on whether it is being accelerated of
decelerated)
Pressure and temperature gradients occur
2. http://www.asme.org/about-asme/terms-of-use
Downloaded From: https://proceedings.asmedigitalcollection.asme.org on 03/10/2019 Terms of Use: during transients causing
changes in the mass flow rates into and out of components.
3. Heat balances are not satisfied during transients with heat being temperature) spreads'. An excellent set of papers on gas turbine
either absorbed or rejected by engine components i.e., degradation and detection methods have been presented by
compression and expansion are non adiabatic. Saravanamuttoo and MacIsaac(1983), Muir et al.(1988) and
4. During transients, dimensions of various components can change Saravanamuttoo (1974). Grosby (1986) provides a review of the
due to temperature and centrifugal effects. Tip clearances can be factors causing performance deterioration in a turbofan engine.
affected. Diakunchak (1991) provides a detailed treatment of performance
In large critical turbomachines however, problems often develop deterioration in industrial gas turbines.
under transient conditions due to factors such as increased loading,
thermal stresses, changes in tip clearances and changes in thrust Other sources of deterioration include:
position. Several gas turbine operators have used transient analysis
when they measure coastdown times or plot startup curves using strip • Excessive drop in inlet filter differential pressure
charts or trending packages. • Excessive back pressure - this can be of importance when HRSG's
For critical gas turbines, regular transient analysis should be done are present
for a comprehensive condition asscessment. With large advanced gas • Increased mechanical losses (gearboxes, bearings, couplings etc.)
turbines being used in peaking service, transient analysis of startups • Internal losses
and shutdowns will be of diagnostic value to make an asscessment of • Stator nozzle plugging (or turbine fouling)
durability. A durability surveillance program including on line
monitoring for the GE Frame 7F advanced gas turbine is described by As per Williams (1981), the common faults in pipeline operations are
Ondryas et al. (1992). The application of transient analysis for the (in order of importance):
fleet testing of gas turbines (in a test cell environment) also bears great • Compressor efficiency degradation
promise. Currently, the approach is to evaluate the turbine using a set • Drop in compressor mass flow rate (for given corrected Nt
of "acceptance maps" that indicate if parameters fall within acceptable speed)
tolerances. In this paper, we have provided concepts and approaches • Overboard Leakage
for the implementation of transient analysis for stationary gas turbines. • High Pressure Turbine Efficiency
• Low Pressure Turbine Efficiency
• Change in High Pressure Turbine Flow Function, F= (m 'IT)/P
GAS TURBINE PERFORMANCE DEGRADATION • Change in Low Pressure Turbine Flow Function
The causes of gas turbine deterioration fall into two categories. The Mechanical Degradation.
first cause is aerodynamic or performance related. The deterioration Causes of mechanical degradation include wear in bearings and
can be either recoverable (such as fouling) or non recoverable (such as seals, coupling problems, excessive vibration and noise, or problems
seal wear, erosion or casing distortion). The second cause for turbine in the lube oil system. Vibration is a common indicator of mechanical
deterioration is of a mechanical nature associated with increased degradation. Several problems that manifest themselves as vibration
vibration, bearing problems or increased mechanical losses. may, in fact, have underlying causes that are aerodynamic (or
performance) related in nature.
Performance Degradation. Bearing problems are often caused by low oil pressure (malfunction
Causes of performance degradation include: in pump or leaks), line blockage, or excessive loads due to factors
such as misalignment. The lube oil pressure and scavenge
1.Dirt Deposits and Fouling. These form mainly on the compressor temperatures can be measured and correlated to a parameter such as
blading causing loss of flow capacity and efficiency. The turbine rotor speed. The expected pattern during speed changes can be noted
section can also foul. The effects of fouling are a change in the and subsequent checks made during transients.
turbine-compressor match point, a drop in output and a worsening of Combustor fuel nozzles can also plug up. There can be several
specific fuel consumption. There are also several peripheral problems causes such as coking, erosion and missassembly. Severe
that may be created such as cooling hole blockage, imbalance, blade temperature distortions can create a host of problems in the hot
root lockup and hot corrosion. Fouling deterioration is described by section 2 . The pattern of the EGT spreads can be monitored during
Meher-Homji (1990). transient conditions to indicate nozzle problems.
2. Erosion. Erosion changes airfoil shape contour and surface finish.
It typically contributes 45% of the deterioration in modem turbofans.
On stationary gas turbines this does not pose a major problem due to TRADITIONAL METHODS FOR ENGINE HEALTH
the air filtration system present. MONITORING AND DIAGNOSTICS
3. Increases in clearances for vanes, blades and seals (i.e.. wear) There are a host of condition monitoring techniques available.
Wear is a significant problem specially during the early stages of Meher-Homji and Cullen (1992) provide the means and rationalization
engine operation. Even small physical dimension changes can cause for integrating appropriate techniques taking into account failure
significant performance changes. For example, 10 thousandths of an modes, operational and maintenance objectives. The application of
inch on a tip radius of 18" can cause a 0.33 % change in fuel transient analysis is made in context of an on-line condition
consumption. It can be caused by thermal growth problems, and monitoring system that is currently offered. These systems have been
centrifugal growth. Tip clearance increase also causes deterioration in described by Boyce et al.(1989), Meher-Homji et al. (1989), Cullen
the stage efficiency. Tip stalls can be caused by blade tip erosion. (1988) and Meher-Homji and Mani (1988) and have been applied to
gas turbines, steam turbines, large water pumps and compressors. In
4. Foreign and Domestic Object Damage (FOD/DOD') FOD can be essence, these systems utilize a real time mini-computer to collect and
caused due to excessive icing, carbon deposits breaking off fuel analyze both mechanical and performance related data. Due to the
nozzles or by components of the filtration system that break off and rapid scan rates these systems are particularly valuable in analyzing
are ingested. Domestic Object Damage is caused by internal transient data. Transient data can be stored and viewed in any of the
components that come loose.
1 Nozzle coking problems could also result in changes in combustor outlet
5. Hot Section Problems. Problems can include detached liners, profile factor which can in turn result in problems with downstream
cracks or unbalanced fuel nozzles. Problems of this nature are often components.
detected by evaluation of exhaust gas temperature (or inter turbine 2 Severe temperature distortions can create serious dynamic loads on blading
possibly inducing fatigue problems. Strain gauge tests reportedly have indicated a 2
to 5 times increase in blading alternating stress with severe blockage.
=
w
c0 be significantly improved during reslams. Slam accelerations do not
CE
60 occur with most stationary gas turbines. For propulsion turbines
O however such as the Ml tank AGT- 1500, 3 spool gas turbine or the 2
t_n
o 49 spool LM2500 used for naval propulsion, slam effects are important if
0
0
transient response is being monitored. The test cell procedure for the
— Right engine
AGT-1500 does call for a slam acceleration test though no analysis of
20
— Left engine the transient profile is made (only a response time check is made)
6. Instrumentation and Repeatability- If trending of transient data is
to be considered then it is important to ensure that the sensor data
8 t0
TIME {SEC) acquisition system behaves in a repeatable way. Statistical techniques
can be used here.
Merrington's significant work (Merrington et al., 1990,
".120
UI AFTER HP COMPRESSOR DAMAGE Merrington, 1988a, 1988b)in transient analysis was mainly driven by
CE
the fact that military engines rarely operate at steady state conditions.
W ton . His work centers around the correlation of engine dynamic
a
characteristics with particular engine faults.
UI ea A paper by Bruce and Cartwright (1991), covers a transient data
gathering system used at the Royal Aerospace Establishment at
60. Famborough, UK. In this engine test facility, selected parameter are
scanned at at rates exceeding 1 KHz. Figure 4 (Bruce and Cartwright,
CE 40
1991) shows an interesting depiction of corrosion in a combustor
0 where a flame blowout had occurred. In this reported case, ignition
w 20 .Right engine
occurred approximately 5 seconds later (through the inter combustor
Left engine duct). The unburnt fuel caused the power turbine inlet temperature to
rise within 1°F of the trip level. Bruce and Cartwright noted that this
defect could not have been observed by examining steady state engine
TIME (SEC) performance.
Figure 3. Compressor transient discharge pressure as a diagnostic
tool, Cue and Muir (1990).
(1974). Kerr et al., (1991) describe a second generation Kalman filter -G^ ii^Ar r5 —► / \
algorithm for the real time estimation of gas turbine damage. Further
references can be found in Luppold et al. (1989) and Lucas and Paas
(1987).
HIGH SSV
Pp'7
VSV Stator Vane Schedule - Figure 8 shows a Variable Stator Vane
(VSV) schedule of a 30,000 SHP two shaft gas turbine with variable oQ
geometry. By the use of a VSV measurement system, it is possible to
plot the actual response on the map. QQ^
•e. .n t.. C .O^
CDP and Wheel Space Temperature Analysis Detection of bleed racouc.cr ,w .carz
valve problems- several gas turbines utilize bleed valves for surge Frequency in Hz
protection during startup and shutdown. In some machines, these Figure 6. Transient vibration cascade indicating rotor bearing
may be butterfly valves which may stick in a partially open position stability. Plot shows startup, compressor loading and trip
during a start event. The effect of this is to reduce the compressor due to sub synchronous vibration.
discharge pressure (hence pressure ratio). With a machine on
//
exhaust gas temperature. Examining a startup transient of the CDP as
well as wheel space temperatures is therefore of value.
Problems detectable by Mechanical Transient Analysis include:
0
■
develop a rotor bow due to excessive ramp in inlet temperature
(> 1O 0 F/minute). Similar problems can occur in gas turbines. Figure 9
2 3 4 5 5 7 9
shows the startup data on a 20 MWe aeroderavative gas turbine. The
Scavange Pressure
effect of temperature changes (EGT) on the vibration behavior can be
clearly seen. The high vibrations die out when some heat soak has Figure 7. Lube oil system transient behavior.
occurred.
3. Rotor Rubs- these can be monitored by noise detection using a
microphone during coastdown.
4. Alignment changesllocked coupling- This is best detected by
vibration and correlation with axial movements. On-line hot alignment
•4 ' 0 2E Pp, 1941 49$25 PP
-B aBBB 5200 5629 4000 01302 6600 72ee 2600 Br10r 8.00 00410 9200 0600
A COMPUTATIONAL METHOD FOR EXAMINING [OPPECTEA HGC 10001
1 i :.
purposes. It is based on basic gas turbine component matching s +soo
considerations. Factors that can effect the startup profile include:
1. Startup system health- this includes the capability of the starter
electric motor, state of the battery (charge deterioration), condition ^ 140.
of diesel engine or hydraulic start system.
2. Turbine related problems- This includes clogged fuel filters, fouled 2 •^IYY H i FI In ly
compressor, damaged turbine blades, damaged variable geometry 0 1.1 Va a
11.
system including the IGV, damaged bleed valves, nozzle coking 7
and excessive air filter differential pressure. 6 E
7 This can cause improper spray paters and delayed Iightoffs Figure 9. Startup transient on a 20 MW gas turbine showing effect
$Problem sensors are inlet temperature sensor of the ITT or EGT sensors, of temperature on vibration. Power turbine vibration
shown.
model the LP and HP sections even though the starting is done via the TcGT
HP spool. The approach assumes that a condition monitoring system
COMPRESSOR
exists and that actual behavior can be tracked and compared to the OCT PT LOAD
behavior that is theoretically derived.
IGV
STEP 1
Initilize Ni =0; Acceleration = 0; 71t, Tl c. Tl b = manufacturers
predicted efficiencies. CALCULATE STARTER I
DEVICE TORQUE
1CONDITION M06
SYSTEM
STEP 2
In this step, the acceleration is determined based on the starter torque PERT. MATCHING ORTAIN ACTUAL
and the power generated by the gas generator turbine. Prior to light CALCULATIONS START PROFILE
off, the only torque supplied would be from the starter as the gas
generator torque would be zero. DEVELOP CALCULATED
START PROFILE
a={T S +TAT}/I (1)
Ni new = Ni old + 7- acceleration (2)
Using a mf v, N t map find rnf COMPARE & TREND
FOR TIME R PROFILE
VARIATIONS
STEP 3
Assume Pressure Ratio for the compressor. This does not have to be
accurate as an iteration process is to be used. GAS PATH ANALYSIS
PROGRAM IF SIGNIFICANT
STEP 4
(a) Using a compressor map and pressure ratio assumed in STEP 3, Figure 10. Procedural flow chart for startup transient analysis.
find m a and lie
(b) Calculate compressor temperature rise.
AT = IT, (PR) Y-/Y- t }/ 11c (3)
The shaft acceleration can be calculated:
(c) Use a energy balance to determine turbine entry temperature. dN/dt = KI (T s r K2 - Tag )/ Polar Moment of Inertia (9)
where Kt is a factor to account for loss in the coupling and/or gear
(m a + tit f) T3 Cp = m a Cp T2 + mf (LHV) 'n b (4) box between the start system and the gas turbine shaft and K2 a factor
to account for the gear ratio.
which yields,
rrta CpT2+t11(LHV) Tlb
T3= (5) TRANSIENT ANALYSIS CASE STUDIES
Cp (ina +thf)
Some examples of transient behavior are presented here from both
(d) The gas generator non dimensional mass flow is given by: our experiences and published information.
m3•IT3/ P3 =(ma'l(T 1 /PI)I x IP)/P21 xIP2/P31 xl`^T3/ 1'tl ( 6 )
Lieht Off Behavior of an Aeroderivative Ermine.
(e) Using this value of non dimensional flow, find the gas generator Diagnostics are under implementation on the startup behavior of a
expansion ratio. LM 2500 gas turbine engine used for propulsion purposes.
Essentially, an examination is made of the inter turbine temperature
STEP 5 (i.e., the GG EGT) after light off. The typical profile is shown in
Check if gas generator expansion ratio equals compressor pressure Figure 11 . The quantity AT is measured and can be trended over
ratio. If not, return to STEP 3. If a match occurs, then a match point several startups. Similar plots can be made for CDP and RPM
has been attained. profiles which can be compared over several startups.
STEP 6
Calculate gas generator temperature drop using Data from "LM2500 start transient'
fy-1/y
AT3-4 = T3r1t (l-(l/PR34) lf (7) 10000
-200
The turbine efficiency can be derived from the map. 5000
1000 6000
STEP 7 7000
At this point the torque produced by the engine that is available for • 800
6000
a
accelerating the gas generator (i.e., torque .n excess of compressor 600
5000
torque) can then be calculated as: 4000 =
'1'a = K{ [(maCpAT3-4)-(maCpAT1_2)J(1/Tlmech)}/N (S) 40D
3000
where K is a correction factor to derive consistent units. It is expected 200
—*-- EGT. IF 2000
that the torque will be negative till self sustaining conditions are —*— Ni RPM 1000
manufacturer and is dependant on the starting system used. Generally TIME (SEC)
a curve is available showing this. The effects of drag (Td) must be
incorporated. The fuel schedule for acceleration must also be known
but should be available from the control system specification. Figure 11. Gas generator EGT and RPM profile as a diagnostic
indicator.
has occurred). Due to the fact that the surface has broken down, the
journal will ride closer to the bearing and at certain low speed
conditions will cause the bearing temperature to be higher than those FLOW TRANSIENT. KLbs'Hr
expected with an undamaged bearing. During transient operation, the
hydrodynamic film is thinner (film thickness is a function of speed) rc)
and at a certain speed, a transition from hydrodynamic to boundary
layer lubrication occurs causing film breakthrough and consequent
metal temperature spikes. Figure 13 shows the nature of such an
excursion. It is important that speed decay transients be reviewed for
o both decay time and the decay profile to obtain corroborative evidence f to a.
0that damage has occurred. 100 200 305 400 5130 600 700 Soo 900
Seconds
a (0)
THRUST BEARING TEMP TRANSIENT (F)
z
i0
z
a
SCATTER S-Y PLOT
60000 9000012000015000018000021000040B00070000300000
0OC-201 1ST SUCTIQN FLUU-ISSS :Lbs-Hr
urn!
Figure 14. Set of startup plots for a large machanical drive steam
Figure 12. Transient bearing temperature v. time plot as an turbine.
indicator of bearing distress.
Transient Startup Behavior of a 21 MW Gas Turbine.
4009 Considerable insight can he attained into gas turbine performance
—a-- RPM-ssrsw by the use of startup transient curves. Figures 15 a and 15 b show a
3000
—^— RPM. hmgdamag transient startup of a 2 shaft aeroderavative gas turbine in cogeneration
service. The turbine comprises of a LM2500 gas generator and a two
stage power turbine. The graph shown in Figure I5a shows a start
2000
and shutdown transient plots of the gas generator EGT, power turbine
C
speed and gas generator speed. Point A represents the initiation of
1000 rapid acceleration of the gas generator rotor at light off. The RPM
(N I ) can be seen to rise. The EGT peaks and then dips. Point "B" is
the time when the Power turbine shaft "breaks away". In this case,
10 Is 20 25 30 the time to attain break away conditions was an important diagnostic
Coastdown Time. min. indicator as it was far greater than expected. This was due to the fact
that the gas generator was heavily fouled. This in turn, was detected
by examining the compressor discharge pressure rise v. rotor speed
Figure 13. Rotor coastdown profile as a indicator of bearing characteristic. Figures 15 b and 15 c show another startup and run
condition. plots.
Gc t6T REFERENCES
tea
GG SPEED Turbomachinery Maintenance Handbook, Turbomachinery International.
" Boyce, M.P., Meher-Homji, C.B. and Mani, G., 1989, "The Development and
o
j
—
FUEL FLOT
h
/' j ./
PT SPEE ➢ '=
1
`1
Implementation of Advanced On-line Monitoring and Diagnostic Systems for Gas
lurkinga". 1983 Tokyo International Gas Turbine Conference, Paper IGTC-94.
Bruce, C.1., & Cartwright, R.A.,1991. "Marine Gas Turbine Evaluation &
6a :i +8I ^ 36 3v as 13 35 , Z ,I+51 e9:4?:85 Research at the Admiralty Test House Rae Pyestock", ASME Paper 91-GT-134.
ELAPSED TIME {MINUTE)
Cohen, H., Rogers, G.F.C., Saravanamutto H.I.H., Longman,1986, "Gas . ,
10