Engineering and metallographic aspects of gas turbine engine failure investigation. Ep1978223a3 determining bleed valve failures in gas. Failure mode and effect analysis fmea of aeronautical gas. Ge aeroderivative gas turbines design and operating features ge power systems ger3695e 2 ge industrial aeroderivative gas turbine performance characteristics mechanical drive gas turbine ratings output heat rate exhaust flow exhaust temp. Life of gas turbine components national aerospace laboratory. Failure analysis of gas turbine blades in a thermal power. Chapter 9 powerplant troubleshooting efficient maintenance of any aircraft depends upon the operating and maintenance personnels familiarity with the aircraft and its associated parts.
The common failures found in gas turbine blades due to metallurgical defects are. Request pdf common failures in gas turbine blades modern aviation gas turbine engines are considered to be highly reliable in that failures in service are. Dotfaact901 statistics on aircraft gas turbine engine. A crack can be initiated by a number of causes, such as. Given the serious consequences of such breakdowns, determina tion of the causes of bearing failure and methods of effective. Knowing what can go wrong and how to anticipate turbine failures can help you avoid a difficult unplanned outage. The fracture surface in the root section of this particular blade is shown in the lower photograph. Aeroderivative and heavyduty gas turbines ge power. Therefore, it is necessary to conduct a failure investigation to analyze the root cause of failure and eventually to mitigate similar failures in any oil and gas production and. The system ends with delivery of fuel to the combustion chambers through fuel nozzles in the form of highly atomized spray.
Almost all commercial electrical power on earth is generated with a turbine, driven either by wind, water, steam or burning gas. High pressure temperature hpt turbine blade is the most important component of the gas turbine and failures in this turbine blade can have dramatic effect on. The low pressure compressor is from the 6fa industrial gas turbine. Assumptions and state descriptions the following assumptions are used in this work. Pdf failure analysis of gas turbine blades semantic scholar. Fuel system the fuel system of the gas turbine engine begins at the enginedriven fuel pump. The engine extracts chemical energy from fuel and converts it to mechanical energy using the gaseous energy of the working fluid air to drive the engine and propeller, which, in turn, propel the airplane. The gas turbine outlet temperature is maintained at the level of t4a 630 c.
Such blade failures were observed in aircraft, marine and stationary gas turbine plants. Adequate investigation is therefore essential following a failure to ensure there is no reoccurrence. Common service troubles are wrong types of fuel, water or other foreign matter in the fuel. Nlr offers a multidisciplinary approach to evaluate the condition and assess the life by integration of the following disciplines. Failures of blades in a gas turbine are often catastrophic in the sense that this causes severe damages in the turbine, associated with a significant economic loss. First, there is an air compressor, and after the combustion has taken place, there is a turbine section. Our heavyduty and aeroderivative gas turbines are proven performers in a range of applications, capable of achieving. Ep1978223a2 determining bleed valve failures in gas turbine.
Practical techniques for modeling gas turbine engine performance je ryes w. It can be used in several different modes in critical industries such as power generation, oil and gas, process plants. The mechanisms for different types of hot corrosion are discussed. Torsten fransson examiner supervisors hina noor dr. He has 21 years of industry experience including gas turbine and compressor design, troubleshooting, and engine development. Failure mode and effect analysis, fuzzy rule based rpn, fuzzy risk priority. When a gas turbine goes down, recovery can be an expensive, timeconsuming process. There have been several studies in the literature investigating failures of gas turbine blades after an incident or accident by applying metallurgical 2,6,14,15, mechanical 14,16 or chemical analysis 17 or other analytical methods 3,4.
General electrics turbine troubles raise more red flags. Thus, cases of rotor blade failures were discovered in a generating gas turbine plant after operation for to 6000 h. At the heart of a combinedcycle power plant is the gas turbine, the machine that has the power to make a good solution great. Meherhomjis areas of interest are power augmentation, aerothermal analysis, gas turbine deterioration, blade failures, and vibration analysis. Modern aviation gas turbine engines are considered to be highly reliable in that failures in service are rare. Therefore, it is necessary to conduct a failure investigation to analyze the root cause of failure and eventually to mitigate similar failures in any oil and gasproduction and. Causes and solutions steam turbine rotors bend during operation, but the bearing and supports are designed to keep the static and dynamic forces under control. Gas turbine failures are costly and disruptive to power generation whether they be due to minor maintenance issues or due to catastrophic damage to the machine. Gas turbine failures are a major source of losses for the above insurance. Engineering and metallographic aspects of gas turbine. Ep1978223a2 determining bleed valve failures in gas. Onload fuel changeover gas to liquid fuel and liquid fuel to gas robust dle. Littz nasa glenn research center, cleveland oh, 445, usa. Pdf failure analysis of gas turbine blades semantic.
These cases will be presented on the course and there will be a lot of exercises to let the delegates have a deep understanding in solving major gas turbine failure. Troubleshooting bearing and lube oil system problems thomas h. Two failed blades were broken from the root and from the airfoil. Failure of first stage gas turbine blades sciencedirect. Failure analysis of a gas turbine compressor in a thermal power plant article pdf available in journal of failure analysis and prevention 3 june 20 with 2,937 reads how we measure reads. The objectives of the work are to identify the root causes and to make sound engineering recommendations to avoid repeat failures.
To minimise the likelihood of a repeat failure, it is necessary to carry out an appropriate investigation. Analysis of hot section failures on gas turbines in process plant service 11 figure 1. A quick excursion to aerodynamics any gas turbine consists of several turbomachines. Pdf failure analysis of gas turbine blades in a gas. The fractographic study revealed a static cracking mechanism initiated at blade edges. Corrosionfatigue failure of gasturbine blades in an oil and. Longterm gas turbine operation leads to the structural degradation of superalloy blades there is a change in a number, shape and size of. Fundamentals of gas turbine engines introduction the gas turbine is an internal combustion engine that uses air as the working fluid. Corrosionfatigue failure of gasturbine blades in an oil. Sgt600 industrial gas turbine dependable engine with excellent fuel flexibility. Low cycle fatigue thermal fatigue material defect corrosion pitting once a crack has initiated, high cycle fatigue is a common mechanism for crack propagation. In fact, the problem is intensifying in aeronautical gas turbine blades and vanes as greater emphasis is placed on internal cooling of hollow airfoils to permit higher gas temperatures. The failure of turbine blades may have severe impact on safety and reliability of the gas turbine engine.
Lm2500, tm2500, lm5000 lm6000, and lms100 gas turbine engines. High pressure temperature hpt turbine blade is the most important component of the gas turbine and failures in this turbine blade can have dramatic effect on the safety and performance of the gas turbine engine. The main corrosion issues are hightemperature environmental attack in the form of hightemperature oxidation and hot corrosion. From the study, it is observed that maximum outages in the gas turbine power plants are due to corrosion fatigue failure of turbine blades.
Study of failure analysis of gas turbine blade patil a. Pdf failure analysis of a gas turbine compressor in a. Failures can occur even in the best run power plant. The failure of a second stage blade in a gas turbine was investigated by metallurgical and mechanical examinations of the failed blade. When they happen, there is an inevitable tension between efforts to return a turbine to service as quickly as possible and carrying out a failure investigation. Common failures in gas turbine blades request pdf researchgate. Our heavyduty and aeroderivative gas turbines are proven performers in a range of applications, capable of achieving worldclass efficiency with nextgeneration capabilities.
The investigation of gas turbine blade failures requires an interdisciplinary approach calling for expertise in gas turbine design, operation and metallurgy. Gas turbine engines derive their power from burning fuel in a combustion chamber and using the fast flowing combustion gases to drive a turbine in much the same way as the high pressure steam. The object of this paper is to show, in the context of blading problems, the interrelationship between design, operation, maintenance, and the operational envelope. Senanayake commissioner contact person abstract the overall performance of an open gas turbine can be judged with the knowledge of the main. The invention derives a modified exhaust gas temperature derivative k 6 as the predictive criteria in conjunction with a control logic to determine bleed valve position discordances that may indicate a mechanical failure in a valve, or in the control means for a valve. In fact this is a misconception, and freedom from service failures is largely the result of stringent standards imposed during frequent inspections.
Fmeca for meefog gas turbine inlet fogging systems 3 mee industries inc gas turbine division proprietary information 1. Gas turbine blades have numerous applications in the aerospace industry. Gas turbine blade failures causes, avoidance, and troubleshooting. Gas turbine blades must exhibit a high level of resistance to the oxidizing and corrosive environment generated by the combustion gases and be resistant to any. Fretting fatigue, super alloy, failure analysis, elevated temperature. These investigations focus on specific engine blade stages.
High fuel flexibility with different options of combustion systems. Failure analysis of gas turbine blades in a gas turbine engine used. Turbine blades are subjected to very strenuous environments inside a gas turbine. The invention detects gas turbine bleed valve position discordances. Data on the distribution by size of generatordrive gas turbines insured by allendale. In addition to failures in turbine generators, bearing failures in other rotating equipment, including pumps, fans, and auxiliary gas turbines and motors, can also lead to plant outages. Pdf failure mechanisms in turbine blades of a gas turbine engine. In a number of cases, the structural degradation results in a significant change in the. The heavyduty gas turbine is actually one of the success stories of ge power in recent years, and theres a case for arguing that if it hadnt been so successful, then ge. Gas turbine power plant performance evaluation under key failures 1875 journal of engineering science and technology july 2017, vol. Fatigue is a common cause of failure of gas turbine bladesvanes. Simplified physical understanding of gas turbine matching in a gas turbine engine, the operating point is defined by the match between the compressor and the turbine. Model fuel shp kws btuhphrkjkwhr lbs kgs deg f deg c.
Damage to hollowcored first stage turbine buckets in. Gas turbine thermodynamic and performance analysis methods using available catalog data k. Gas turbine manufacturers and packagers are invited to provide current data for all their machine configurations, in a form common to all. The fuel system of the gas turbine engine begins at the enginedriven fuel pump. Lms100 comprises a low pressure compressor, an intercooler, a supercore and a power turbine. Depending on the design of the gas turbine, the turbine section may consist either of a gas generator turbine. Increase in firing temperature it also should be remembered that the gas turbine axial flow compressor consumes between 55%65% of the power produced by the turbine section of the gas turbine. Life of gas turbine components dedicated to innovation.
Rotor fragments were generated in 170 of the failures experienced and, of these, 12 7. Supercore comprising hp compress or, compressor rear frame, high pressure turbine and intermediate pressure turbine is a development of the lm6000. Practical techniques for modeling gas turbine engine. Introduction fmeca failure modes effects and criticality analysis is a bottomup analysis of componentlevel failures and their effects on. Ge won nearly half of the large gas turbine orders globally over the past two decades. Jim oswald has resolved many major gas turbine failures that can not be solved by many consultants before him. Chief engineer gas turbines, rollsroyce more than 20 years experience gas turbine failure investigations established and runs own consultancy specializing in gt failures since 2003 published international papers on gas turbine variable area nozzle, gas turbine recuperators and wind turbine grid deployment major gas turbine failures. Sep 20, 2018 ge won nearly half of the large gas turbine orders globally over the past two decades. Request pdf failure analysis of gas turbine blades in a thermal power plant a case study of failure analysis of a 40 mw gas turbine blade made of udimet 500 is presented. However, its market share has shrunk to just 11% so far this year, according to ubs. The degree of blade material deterioration for individual blade differs and it depends on several factors such as total service time, operational conditions, manufacturing process and history of turbine. Damage to all four rows of blades in large, generator drive gas turbine. Common failures in gas turbine blades sciencedirect.
This is then combined with a systematic investigation framework, such as fishbone or cause and effect. Lm2500, tm2500, lm5000 lm6000, and lms100 gas turbine. At elevated temperatures hot corrosion often takes place in gas turbines and other combustion turbomachinery. Two case histories of gas turbine hot components are presented. Ep1978223a3 determining bleed valve failures in gas turbine.
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