Fatigue Strength and Metal Condition in the Context of Gas Turbine Buckets Life Extension

2012 ◽  
Author(s):  
Sergey A. Ivanov ◽  
Alexander I. Rybnikov
Keyword(s):  
Fatigue Strength ◽  
Service Life ◽  
Gas Turbine ◽  
Fatigue Resistance ◽  
Gas Turbines ◽  
Life Extension ◽  
Term Operation ◽  
Life Estimation ◽  
Metal Properties

Criteria for remaining life estimation and methods for enhancing fatigue resistance of heavy-duty gas turbine bucket metal are based on the analysis of changes in the structure and properties of metal after long-term operation. High-cycle fatigue (HCF) resistance is shown to be a decisive characteristic in the residual life estimation of turbine buckets after operation over 100,000 hours. The tests of the buckets from cast and wrought nickel-based alloys after long-term operation demonstrated decreasing of fatigue strength by up to 25%. The metal structure in operation undergoes notable deterioration mainly in phase redistribution. The size and configuration of metal phases are changing also. It caused the changes in metal properties. The decrease of the bucket fatigue strength correlates with the decrease of metal ductility. The reconditioning heat treatment resulted in restoring mechanical properties of metal. The fatigue resistance also increased nearly to the initial level. The influence of operational factors on bucket fatigue strength deterioration has been established. The mechanical damages on bucket airfoil may decrease the fatigue resistance. We found the correlation of endurance limit and damages depth. The procedures for metal properties recovering and buckets service life substantial extension have been developed. It has resulted in the extension of the buckets service life by up to 50% over the assigned life in gas turbines operated by Gazprom.

Research and Development of Practical Industrial Cogeneration Technology in Japan

2000 ◽  
Author(s):  
Toshiaki Abe ◽  
Takashi Sugiura ◽  
Shuji Okunaga ◽  
Katsuhiro Nojima ◽  
Yasukata Tsutsui ◽  
...  
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
High Temperatures ◽  
Gas Turbines ◽  
High Efficiency ◽  
Development Project ◽  
Term Operation ◽  
Resistance To Heat

This paper presents an overview of a development project involving industrial cogeneration technology using 8,000-kW class hybrid gas turbines in which both metal and ceramics are used in parts subject to high temperatures in order to achieve high efficiency and low pollution. The development of hybrid gas turbines focuses mainly on the earlier commercialization of the turbine system. Stationary parts such as combustor liners, transition ducts, and first-stage turbine nozzles (stationary blades) are expected to be fabricated from ceramics. The project aims at developing material for these ceramic parts that will have a superior resistance to heat and oxidation. The project also aims at designing and prototyping a hybrid gas turbine system to analyze the operation in order to improve the performance. Furthermore, the prototyped hybrid gas turbine system will be tested for long-term operation (4,000 hours) to verify that the system can withstand commercialization. Studies will be conducted to ensure that the system’s soundness and reliability are sufficient for industrial cogeneration applications.

Development of the Hybrid Gas Turbine: 1st Year Summary — Research and Development on Practical Industrial Cogeneration Technology in Japan

2001 ◽  
Author(s):  
Ryozo Tanaka ◽  
Testuo Tastumi ◽  
Yoshihiro Ichikawa ◽  
Koji Sanbonsugi
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Industrial Applications ◽  
Medium Size ◽  
Test Plant ◽  
Inlet Temperature ◽  
Term Operation ◽  
Generation Technology

Based on the successful results of the Japanese national project for 300 kW ceramic gas turbine(CGT302) development (this project was finished in March 1999), the Ministry of International Trade and Industry (MITI) started “Research and Development on Practical Industrial Co-generation Technology” project in August 1999. The objective of this project is to encourage prompt industrial applications of co-generation technology that employs hybrid gas turbines (HGT; using both metal and ceramic parts in its high-temperature section) by confirming its soundness and reliability. The development activities are performed through material evaluation tests and long-term operation tests for the HGT of the medium size (8,000-kW class). It is expected that the development can realize low pollution and reducing the emission of CO2 with highly efficient use of energy. The HGT will be developed by applying ceramic components to an existing commercial 7,000-kW class gas turbine. The development targets are thermal efficiency of 34% or higher, output of 8,000-kW class, inlet temperature of 1250deg-C, and 4,000hrs of operation period for confirmation of reliability. The HGT for long-term evaluation tests and the test plant are under development. This paper gives the summary of last year’s developments in the HGT project.

Analysis of Long-Term Gas Turbine Operation With a Model-Based Data Reconciliation Technique

2015 ◽  
Author(s):  
Christian Rudolf ◽  
Manfred Wirsum ◽  
Martin Gassner ◽  
Stefano Bernero
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Engine Performance ◽  
Combined Cycle ◽  
Data Reconciliation ◽  
Data Set ◽  
Operating Data ◽  
Term Operation

The continuous monitoring of gas turbines in commercial power plant operation provides long-term engine data of field units. Evaluation of the engine performance is challenging as, apart from variations of operating points and environmental conditions, the state of the engine is subject to changes due to the ageing of engine components. The measurement devices applied to the unit influence the analysis by means of their accuracy, which may itself alter with time. Furthermore, the available measurements do usually not cover all necessary information for the evaluation of the engine performance. To overcome these issues, this paper describes a method to systematically evaluate long term operation data without the incorporation of engine design models since the latter do not cover performance changes when components are ageing. Key focus of the methodology thereby is to assess long-term emission performance in the most reliable manner. The analysis applies a data reconciliation method to long-term operating data in order to model the engine performance including non-measured variables and to account for measurement inaccuracies. This procedure relies on redundancies in the data set due to available measurements and the identification of suitable additional constituting equations that are independent of component ageing. The resulting over-determined set of equations allows for performing a data set optimization with respect to a minimal cumulated deviation to the measurement values, which represents the most probable, real state of the engine. The paper illustrates the development and application of the method to analyse the gas path of a commercial gas turbine in a combined cycle power plant with long-term operating data.

Modelling of Gas Turbine NOx Emissions Based on Long-Term Operation Data

2016 ◽  
Author(s):  
Christian Rudolf ◽  
Manfred Wirsum ◽  
Martin Gassner ◽  
Benjamin Timo Zoller ◽  
Stefano Bernero
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Engine Performance ◽  
Combined Cycle ◽  
Data Set ◽  
Operating Data ◽  
Emission Performance ◽  
Term Operation

The continuous monitoring of gas turbines in commercial power plant operation provides long-term engine data of field units. Evaluation of the engine performance from such data is challenging since, apart from variations of operating points and ambient conditions, the state of the engine is subject to change due to ageing of engine components. The installed measurement devices influence the analysis due to their accuracy, which may itself alter with time. Furthermore, the available measurements usually do not cover all necessary information for assessment of the engine performance. To overcome these issues, this paper describes a method to systematically evaluate long term operation data without the incorporation of engine design models that depict the design state of the engine, but do not cover performance changes when components are ageing. Key focus of the methodology is thereby to assess long-term emission performance in the most reliable manner. The analysis applies a data reconciliation method to long-term operating data in order to model the engine performance including non-measured variables and to account for measurement inaccuracies. This procedure relies on redundancies in the data set due to available measurements and the identification of suitable additional constituting equations that are independent of component ageing. The resulting over-determined set of equations allows for performing a data set optimization with respect to a minimal cumulated deviation to the measurement values, which represents the most probable, real state of the engine. The paper illustrates the development and application of the method for analysing emission performance with long-term operating data of a commercial gas turbine combined cycle power plant.

Some Aspects of Operated Blades HCF Analysis: Rejuvenation and Life Estimation

2018 ◽  
Author(s):  
Sergey A. Ivanov ◽  
Maxim G. Guralnik ◽  
Alexander I. Rybnikov
Keyword(s):  
Shot Peening ◽  
Gas Turbines ◽  
Turbine Blades ◽  
Life Extension ◽  
Ultrasonic Shot Peening ◽  
Industrial Gas Turbines ◽  
Hcf Strength ◽  
Blade Failure ◽  
Metal Properties ◽  
The Cost

The lifecycle of modern industrial gas turbines can reach hundred thousand hours and usually the turbine blades need to be replaced. The use of super alloys and application of advanced coatings makes the cost of turbine lifecycle rather high. The methods for blade rejuvenation and life extension are based on the analysis of the main defects which can considerably reduce blade strength. The effect of long operation and typical defects in turbine blades has been studied in correlation with HCF. The decrease of blades HCF under the effect of operation has been considered as the result of influence of mechanical and thermal factors. The influence of FOD on the blade HCF strength is studied. Some random defects in turbine blades which resulted in HCF decreasing and blade failure are considered. The rejuvenation heat treatment for the blades of ZhS6K and EI893 and its positive effect on metal properties is demonstrated. The ultrasonic shot peening for operated blades have been considered. It is demonstrated that HCF strength of blades after shot peening is about 25–30% higher. Relaxation of compressing stresses in operation is shown as not essential. The remaining life of operated blades can be estimated using the correlation of endurance limit and run time.

Numerical Assessment of Fan-Ducting Coupling for Gas Turbine Ventilation Systems

2015 ◽  
Author(s):  
Alessandro Corsini ◽  
Giovanni Delibra ◽  
Stefano Minotti ◽  
Stefano Rossin
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Static Pressure ◽  
Numerical Study ◽  
Characteristic Curve ◽  
Ventilation System ◽  
Maximum Pressure ◽  
Term Operation ◽  
Axial Fans ◽  
Pressure Discontinuity

Gas turbines enclosures entail a high number of auxiliary systems which must be preserved from heat, ensuring therefore the long term operation of the internal instrumentation and of the data acquisition system. A dedicated ventilation system is designed to keep the enclosure environment sufficiently cool and dilute any gas coming from potential internal leakage to limiting explosion risks. These systems are equipped with axial fans, usually fed with air coming from the filter house which provides air to the gas turbine combustion system, through dedicated filters. The axial fans are embedded in a ducting system which discharges fresh air inside the enclosure where the gas turbine is housed. As the operations of the gas turbine need to be guaranteed in the event of fan failure, a backup redundant system is located in a duct parallel to the main one. One of the main requirements of a ventilation fan is the reliability over the years as the gas turbine can be installed in remote areas or unmanned offshore platforms with limited accessibility for unplanned maintenance. For such reasons, the robustness of the ventilation system and a proper understanding of coupling phenomena with the axial fan is a key aspect to be addressed when designing a gas-turbine system. Here a numerical study of a ventilation system carried out with RANS and LES based methodologies will be presented where the presence of the fan is synthetized by means of static pressure discontinuity. Different operations of the fans are investigated by means of RANS in order to compare the different operating points, corresponding to 1) clean and 2) dirty filters operations, 3) minimum and 4) maximum pressure at the discharge section. Large Eddy Simulations of the same duct were carried out in the maximum loading condition for the fan to investigate the unsteady response of the system and validate its correct arrangement. All the simulations were carried out using OpenFOAM, a finite volume open source code for CFD analysis, treating the filters as a porous medium and the fan as a static pressure discontinuity according to the manufacturer’s characteristic curve. RANS modelling was based on the cubic k-ε model of Lien et al. while sub-grid scale modelling in LES was based on the 1 equation model of Davidson. Computations highlighted that the ventilation system was able to work in similarity for flow rates between 15 m3/s and 23.2 m3/s and that the flow conditions onto the fan suggest that the aerodynamic stress on the device could be reduced introducing in the duct flow straighteners or inlet guided vanes.

Long-Term Degradation of Ceramics for Gas Turbine Applications

2007 ◽  
Author(s):  
Mark van Roode ◽  
Mattison K. Ferber
Keyword(s):  
Water Vapor ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Protective Coatings ◽  
Ceramic Matrix Composites ◽  
Oxide Ceramic ◽  
Component Design ◽  
Temperature Capability ◽  
Silicon Based

A study has been conducted to establish the effect of long-term (30,000+ hours) properties of monolithic ceramics (Si3N49 SiC), SiC/SiC and oxide/oxide ceramic matrix composites (CMCs), and protective coatings on component life in gas turbine engines with pressure ratios (PRs) ranging from 5:1 to 30:1. A model has been presented that shows the interaction between two major long-term degradation modes of ceramics, creep and degradation from water vapor attack in the ceramic hot section. Water vapor attack is the most severe mode overshadowing creep for long-term (∼30,000 hours) gas turbine operation, and its impact on component durability becomes more severe as PR increases. Components in the turbine hot section, downstream from the combustor (blades, integral turbine rotors, nozzles), fabricated from Si3N4 without protective coatings, have a temperature limitation of ∼800°C for gas turbines with PR ranging from 5:1 to 30:1. These ceramic components afford little, if any, advantage over metallic components for improving gas turbine performance. The application of a BSAS-type Environmental Barrier Coating (EBC) would improve temperature capability of turbine nozzles and rotating parts to ∼1100–1200°C. For small low-PR (5:1) engines, thick (∼10 mm) uncoated monolithic silicon-based combustor liners can be used up to ∼1360°C and thinner (∼3 mm) SiC/SiC CMCs up to ∼1100°C. These temperatures are reduced for higher-PR engines. The incorporation of a BSAS-type EBC improves temperature capability of silicon-based ceramic combustor liners. Oxide/oxide CMCs with protective coatings have a predicted temperature capability of ∼1220-∼1380°C over the range of PR range studied. They can be used as structural materials for combustor liners and other stationary turbine hot section components. As PR increases the durability of coated oxide/oxide CMCs improves relative to that of silicon-based monolithics and CMCs. As expected, ceramic component durability increases for shorter component design lives, making these materials more acceptable for shorter-term applications, such as automotive transportation (∼3,000 hours/150,000 km).

Hot-Gas-Path Life Extension Options for the V94.2 Gas Turbine

2000 ◽  
Author(s):  
Gerhard Bohrenkämper ◽  
Herbert Bals ◽  
Ursel Wrede ◽  
René Umlauft
Keyword(s):  
Power Plant ◽  
Service Life ◽  
Gas Turbine ◽  
Power Plants ◽  
Combined Cycle ◽  
Life Extension ◽  
Hot Gas ◽  
Maintenance Program ◽  
Path Component ◽  
Strategic Options

Gas turbine and combined cycle power plants are typically designed for a service life of over 30 years. If operated at base load in continuous duty, the gas turbine hot-gas-path components for example in a combined-cycle power plant need repair and replacement according to the maintenance program several times during plant life. Most of the hot components would reach the end of their service life, e.g. 100,000 equivalent operating hours (EOH), after 10 to 12 years. As this is well before the end of the overall plant service life defined in the power plant concept, such plant applications therefore necessitate life extension measures enabling to continuing operation beyond 100,000 EOH. This paper presents strategic options for hot-gas-path component life entension.

scholarly journals DEGRADATION DAMAGE OF REINFORCED CONCRETE FRAME IN LONG-TERM EXPLOITATION

2021 ◽  
Vol 9 (4) ◽  
pp. 11-15
Author(s):  
Mikhail Berlinov ◽  
Marina Belinova ◽  
Roman Korol ◽  
Aleksandr Tvorogov
Keyword(s):  
Reinforced Concrete ◽  
Service Life ◽  
Phenomenological Theory ◽  
Reinforced Concrete Frame ◽  
Term Operation ◽  
Concrete Frame ◽  
Aggressive Environment ◽  
Real Work ◽  
Combined Action

A method for calculating a reinforced concrete frame under rheological deformation conditions is proposed, taking into account degradation damage as a result of corrosion during long-term operation, reflecting their real work under the combined action of a load and an aggressive environment based on the modern phenomenological theory of deformation of an elastic-creeping body. The possibility of considering the processes of long-term deformation of reinforced concrete in conditions of long-term exploitation is shown. Analytical dependencies and a calculated example are given for the considered service life.

scholarly journals КОЭФФИЦИЕНТЫ ДЕГРАДАЦИИ ПРОЧНОСТИ СИЛОВЫХ ЭЛЕМЕНТОВ КУПОЛА ПАРАШЮТА ПОСЛЕ ДЛИТЕЛЬНОЙ ЭКСПЛУАТАЦИИ ИЛИ ХРАНЕНИЯ

2019 ◽  
pp. 62-71
Author(s):  
Петр Александрович Фомичев ◽  
Игорь Михайлович Сила
Keyword(s):  
Service Life ◽  
Breaking Load ◽  
Strength Characteristics ◽  
Test Results ◽  
Structural Elements ◽  
Term Operation ◽  
Lower Confidence ◽  
Strength Tests ◽  
Normal Law

The technique of processing the test results to the destruction of samples cut from slings and dome fabric after prolonged use or storage of the parachute is described. The normal law of load distribution before failure is adopted.It is proposed to find the minimum breaking load as the lower confidence limit depending on the number of tested samples and a confidence probability of 0.99.The results of strength tests of samples from the parachutes of the landing D-5 series 2 of 1983, the spare Z-5 of 1984, and the rescue S-5K series 2 of 1989 are presented.A total of 301 samples were tested, including 54 samples from slings D-5, 48 samples from slings Z-5 and S-5K, samples from fabrics of domes on the base and weft. Samples from slings were cut out at the edge of the dome, in the middle, at the arc buckles.Fabric samples were cut radially from the top to the edge of the dome. The dependence of the strength characteristics on the location of the samples along the length of the slings or the dome panel has not been established.There are no gross errors in the tests according to the Grubbs criterion.The strength degradation coefficients of the slings and fabrics of the domes are determined as the ratio of the breaking load after long-term operation or storage to the initial values adopted during the design.The proximity of the degradation coefficients of slings and dome fabrics was noted. Based on the set of test results in order to obtain the minimum values of the degradation coefficients, a linear dependence on the life of the parachute is established.This period should be counted from the year the parachute was made.The dependence of the minimum degradation coefficients (maximum degradation) on the service life makes it possible to assess the drop in the strength characteristics of the structural elements with increasing service life. This dependence allows you to predict the maximum allowable landing speed when deciding on the extension of the life of the parachute.

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