EVITA Study: Evaluation of Unscheduled Aircraft and Industrial Gas Turbine Part Failure Cases

2008 ◽  
Author(s):  
Gerrit Kool ◽  
Jacques van den Elshout ◽  
Eric Vogelaar ◽  
Ron van Gestel ◽  
Andre´ Mom
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Contributing Factors ◽  
Root Cause ◽  
Component Design ◽  
Design Changes ◽  
Study Evaluation ◽  
Turbine Component ◽  
Industrial Gas Turbine ◽  
Original Component

Maintenance costs of gas turbines are mainly driven by replacement costs of expensive parts. Reconditioning of these parts is considered to decrease the costs significantly, but it is the impression that re-used parts tend to be more involved in part failures. This is sometimes related to microstructural changes in the substrate materials owing to part repair. One hundred and nine (109) unscheduled gas turbine component failure cases have been collected and analyzed to identify causes of failure and contributing factors, and also to provide guidance on corrective measures such as design changes, new repair methods, missing information links and future R&D efforts. It was found that the most frequently reported failure mechanisms are mechanical and thermal fatigue and changes in the microstructure. Fifty percent (50%) of the reported failure cases have a root cause in the original component design and repair design, and consequently permanent solutions can be achieved by design modifications only. The paper concludes with the identification of knowledge gaps.

Some Effects of Size on the Performances of Small Gas Turbines

2003 ◽  
Author(s):  
C. Rodgers
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Engine Performance ◽  
Lessons Learned ◽  
Rapid Expansion ◽  
Cycle Performance ◽  
Frictional Drag ◽  
Component Design ◽  
Turbine Component ◽  
Performance Development

By the new millennia gas turbine technology standards the size of the first gas turbines of Von Ohain and Whittle would be considered small. Since those first pioneer achievements the sizes of gas turbines have diverged to unbelievable extremes. Large aircraft turbofans delivering the equivalent of 150 megawatts, and research micro engines designed for 20 watts. Microturbine generator sets rated from 2 to 200kW are penetrating the market to satisfy a rapid expansion use of electronic equipment. Tiny turbojets the size of a coca cola can are being flown in model aircraft applications. Shirt button sized gas turbines are now being researched intended to develop output powers below 0.5kW at rotational speeds in excess of 200 Krpm, where it is discussed that parasitic frictional drag and component heat transfer effects can significantly impact cycle performance. The demarcation zone between small and large gas turbines arbitrarily chosen in this treatise is rotational speeds of the order 100 Krpm, and above. This resurgence of impetus in the small gas turbine, beyond that witnessed some forty years ago for potential automobile applications, fostered this timely review of the small gas turbine, and a re-address of the question, what are the effects of size and clearances gaps on the performances of small gas turbines?. The possible resolution of this question lies in autopsy of the many small gas turbine component design constraints, aided by lessons learned in small engine performance development, which are the major topics of this paper.

scholarly journals Ceramic Composites for Industrial Gas Turbine Engine Applications: DOE CFCC Phase 1 Evaluations

1995 ◽  
Author(s):  
Gregory S. Corman ◽  
Jeffrey T. Heinen ◽  
Raymond H. Goetze
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Phase 1 ◽  
Engine Performance ◽  
Ceramic Composites ◽  
Gas Turbine Engine ◽  
Turbine Engine ◽  
Performance Improvements ◽  
Component Design ◽  
Industrial Gas Turbine

Conceptual design evaluations of the use of continuous fiber ceramic composite (CFCC) turbine shrouds and combustor liners in an industrial gas turbine engine were performed under Phase 1 of the DOE CFCC program. Significant engine performance improvements were predicted with the use of CFCC components. Five composite systems were evaluated for use as shrouds and combustor liners, the results of which are discussed with particular reference to Toughened Silcomp. Several current CFCC materials were judged to be relatively close to meeting the short term performance requirements of such a system. However, additional CFCC property data are required for significant component design optimization and life prediction, two key design steps that must be completed before ceramic composites can be utilized in large gas turbines.

Advancements in Gas Turbine Vane Repair

2006 ◽  
Author(s):  
Julie McGraw ◽  
George Van Deventer ◽  
Reiner Anton ◽  
Andrew Burns
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Life Cycle Cost ◽  
High Strength ◽  
Turbine Vane ◽  
Turbine Component ◽  
Industrial Gas Turbines ◽  
The Many ◽  
Industrial Gas Turbine ◽  
Repair Techniques

The evolution of industrial gas turbines has been a driving factor in the advancement of repair techniques for industrial gas turbine components. Turbine vane segments (also known as stationary blades, non-rotational airfoils, or nozzles) are among the many components that have been a focus for repair development. Due to increasing engine efficiencies, the design of gas turbine vane segments continues to become progressively more complex. Neoteric vanes are cast of highly developed superalloys, have complex cooling designs, and are coated with the latest generation coating systems which utilize advanced oxidation resistant bondcoatings combined with thermal barrier coatings. While advanced technologies enable these vanes to operate at the extreme hot gas path running temperatures of today’s engines, they also significantly increase the level of technology required to successfully repair them. The ability to repair these components is essential to minimize the operators’ life cycle cost of the gas turbine. Recoating, reestablishing of critical cooling, dimensional restoration, along with surface and structural restoration using high strength weld and braze techniques are essential for these vanes. Conventional and advanced repair techniques are key elements in the continuing evolution of industrial gas turbine component repair development. This paper will focus on a variety of Siemens’ technical competencies applied during the restoration of service run vane segments for the turbine section of a gas turbine. These repair competencies and technology/service options include: • Dimensional restoration techniques utilizing hot and cold straightening; • Utilization of refurbished blade rings for completed roll-in/roll-out exchanges; • Coupon repair techniques; • Braze restoration of cracks; • Laser etching; • Strain tolerant coatings; • Future technologies under development.

scholarly journals Feasibility of a Helium Closed-Cycle Gas Turbine for UAV Propulsion

2020 ◽  
Vol 11 (1) ◽  
pp. 28
Author(s):  
Emmanuel O. Osigwe ◽  
Arnold Gad-Briggs ◽  
Theoklis Nikolaidis
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Pressure Ratio ◽  
Low Noise ◽  
Closed Cycle ◽  
Propulsion Systems ◽  
Component Design ◽  
Readiness Level ◽  
Aerial Vehicle ◽  
Turbine Design

When selecting a design for an unmanned aerial vehicle, the choice of the propulsion system is vital in terms of mission requirements, sustainability, usability, noise, controllability, reliability and technology readiness level (TRL). This study analyses the various propulsion systems used in unmanned aerial vehicles (UAVs), paying particular focus on the closed-cycle propulsion systems. The study also investigates the feasibility of using helium closed-cycle gas turbines for UAV propulsion, highlighting the merits and demerits of helium closed-cycle gas turbines. Some of the advantages mentioned include high payload, low noise and high altitude mission ability; while the major drawbacks include a heat sink, nuclear hazard radiation and the shield weight. A preliminary assessment of the cycle showed that a pressure ratio of 4, turbine entry temperature (TET) of 800 °C and mass flow of 50 kg/s could be used to achieve a lightweight helium closed-cycle gas turbine design for UAV mission considering component design constraints.

scholarly journals Breaking the Barriers

2012 ◽  
Vol 134 (05) ◽  
pp. 32-37
Author(s):  
Lee S. Langston
Keyword(s):  
Fluid Mechanics ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Solid Mechanics ◽  
Commercial Aircraft ◽  
Commercial Aviation ◽  
New Developments ◽  
Exhaust Heat ◽  
Turbine Component ◽  
Made In

This article explores the new developments in the field of gas turbines and the recent progress that has been made in the industry. The gas turbine industry has had its ups and downs over the past 20 years, but the production of engines for commercial aircraft has become the source for most of its growth of late. Pratt & Whitney’s recent introduction of its new geared turbofan engine is an example of the primacy of engine technology in aviation. Many advances in commercial aviation gas turbine technology are first developed under military contracts, since jet fighters push their engines to the limit. Distributed generation and cogeneration, where the exhaust heat is used directly, are other frontiers for gas turbines. Work in fluid mechanics, heat transfer, and solid mechanics has led to continued advances in compressor and turbine component performance and life. In addition, gas turbine combustion is constantly being improved through chemical and fluid mechanics research.

Fits and Starts: A Current Look at Marine and Industrial Gas Turbine Electric Start Systems

2017 ◽  
Author(s):  
Glenn McAndrews
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Life Cycle Cost ◽  
Large Scale ◽  
Past History ◽  
New Technology ◽  
Cost Benefit ◽  
New Production ◽  
Intense Activity ◽  
Industrial Gas Turbine

Electric starter development programs have been the subject of ASME technical papers for over two decades. Offering significant advantages over hydraulic or pneumatic starters, electric starters are now poised to be the preferred choice amongst gas turbine customers. That they are not now the dominant starter in the field after decades of investment and experimentation is attributable to many factors. As with any new technology, progress is often unsteady, depending on budgets, market conditions, customer buy-in, etc. Additionally, technological advances in the parent technologies, in this case electric motors, can abruptly and rapidly change, further disturbing the best laid introduction plans. It is therefore not too surprising that only recently, is the industry beginning to see the deployment of electric starters on production gas turbines. The earliest adoption occurred on smaller gas turbine units, generally less than 10 MW in power. More recently, gas turbines greater than 10 MWs are being sold with electric starters. The authors expect that regardless of their size or fuel supply, most all future gas turbine users will opt for electric starters. This may even include the “larger” frame machines with power greater than 100 MW. Starting with some past history, this paper will not only summarize past development efforts, it will attempt to examine the current deployment of electric starters throughout the marine and industrial gas turbine landscapes. The large-scale acceptance of electric start systems for both new production and retrofit will depend on the favorable cost/benefit assessment when weighing both first cost and life cycle cost. The current and intense activity in electric vehicle applications is giving rise to even more power dense motors. The paper will look at some of these exciting applications, the installed products, and the technologies behind the products. To what extent these new products may serve the needs of the gas turbine community will be the central question this paper attempts to answer.

scholarly journals Industrial Gas Turbine Uprates: Tips, Tricks and Traps

1997 ◽  
Author(s):  
T. L. Ragland
Keyword(s):  
Gas Turbine ◽  
Output Power ◽  
Gas Turbines ◽  
Customer Value ◽  
Low Cost ◽  
Pressure Ratio ◽  
Original Design ◽  
Advantages And Disadvantages ◽  
Industrial Gas Turbine ◽  
Cycle Efficiency

After industrial gas turbines have been in production for some amount of time, there is often an opportunity to improve or “uprate” the engine’s output power or cycle efficiency or both. In most cases, the manufacturer would like to provide these uprates without compromising the proven reliability and durability of the product. Further, the manufacturer would like the development of this “Uprate” to be low cost, low risk and result in an improvement in “customer value” over that of the original design. This paper describes several options available for enhancing the performance of an existing industrial gas turbine engine and discusses the implications for each option. Advantages and disadvantages of each option are given along with considerations that should be taken into account in selecting one option over another. Specific options discussed include dimensional scaling, improving component efficiencies, increasing massflow, compressor zero staging, increasing firing temperature (thermal uprate), adding a recuperator, increasing cycle pressure ratio, and converting to a single shaft design. The implications on output power, cycle efficiency, off-design performance engine life or time between overhaul (TBO), engine cost, development time and cost, auxiliary requirements and product support issues are discussed. Several examples are provided where these options have been successfully implemented in industrial gas turbine engines.

scholarly journals A Test Rig for the Realization of Water Recovery in a Steam-Injected Gas Turbine

1996 ◽  
Author(s):  
Xueyou Wen ◽  
Jiguo Zou ◽  
Zheng Fu ◽  
Shikang Yu ◽  
Lingbo Li
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Steam Injection ◽  
Water Recovery ◽  
Test Rig ◽  
Design Point ◽  
Test Conditions ◽  
Demineralized Water ◽  
Spiral Plate ◽  
Industrial Gas Turbine

Steam-injected gas turbines have a multitude of advantages, but they suffer from the inability to recover precious demineralized water. The present paper describes the test conditions and results of steam injection along with an attempt to achieve water recovery, which were obtained through a series of tests conducted on a S1A-02 small-sized industrial gas turbine. A water recovery device incorporating a compact finned spiral plate cooling condenser equipped with filter screens has been designed for the said gas turbine and a 100% water recovery (based on the design point) was attained.

Gas Turbine Efficiency (GTE) Benefits of GTE Water Wash Systems

2008 ◽  
Author(s):  
Thomas Wagner ◽  
Robert J. Burke
Keyword(s):  
Power Generation ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Process Efficiency ◽  
Compression Process ◽  
Lower Efficiency ◽  
Fuel Gas ◽  
Air Filter ◽  
Turbine Efficiency ◽  
Industrial Gas Turbine

The desire to maintain power plant profitability, combined with current market fuel gas pricing is forcing power generation companies to constantly look for ways to keep their industrial gas turbine units operating at the highest possible efficiency. Gas Turbines Operation requires the compression of very large quantities of air that is mixed with fuel, ignited and directed into a turbine to produce torque for purposes ranging from power generation to mechanical drive of pumping systems to thrust for air craft propulsion. The compression of the air for this process typically uses 60% of the required base energy. Therefore management of the compression process efficiency is very important to maintain overall cycle efficiency. Since fouling of turbine compressors is almost unavoidable, even with modern air filter treatment, and over time results in lower efficiency and output, compressor cleaning is required to maintain gas turbine efficiency.

Failure Investigation of 1st Stage Buckets From Frame 3002, 10 MW Gas Turbine Unit

2011 ◽  
Author(s):  
Girish M. Shejale ◽  
David Ross
Keyword(s):  
Gas Turbine ◽  
Test Results ◽  
High Carbon ◽  
High Carbon Content ◽  
Metallurgical Investigation ◽  
Root Cause ◽  
Failure Investigation ◽  
Surface Failure ◽  
Grain Boundary Embrittlement ◽  
Industrial Gas Turbine

The 1st stage buckets in Frame 3002, 10 MW industrial gas turbine experienced premature failures. The buckets failed unexpectedly much earlier than the designed bucket life. Bucket material is Inconel 738, with platinum-aluminized coating on the surface. Failure investigation of the buckets was performed to know the root cause of the failure. The failure investigation primarily comprised of metallurgical investigation. The results of the metallurgical investigation were co-related with the unit operational history. This paper provides an overview of 1st stage buckets investigation. The metallurgical investigation performed concluded prime failure mechanism due to high carbon content of bucket material and improper heat treatment. The bucket coating was initially damaged during the first loading and fracture occurred due to grain boundary embrittlement in short span of service. The metallurgical tests performed included Visual inspection, Scanning Electron Microscopy (SEM), Energy Dispersive Analysis of X-ray (EDS), Chemical analysis, Tensile test and Hardness survey. The test results, discussions and conclusions are presented in this paper.

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