Blade Damage in PowerGen Turbine Losses and Blade Health Monitoring

2016 ◽  
Author(s):  
Bin Zhou
Keyword(s):  
Condition Monitoring ◽  
Gas Turbines ◽  
Vibration Monitoring ◽  
Steam Turbines ◽  
Data Loss ◽  
Blade Vibration ◽  
Path Component ◽  
Monitoring Technologies ◽  
Abnormal Behaviors

Losses of gas turbines and steam turbines in the power generation industry are often due to mechanical breakdowns associated with flow-path component damage, especially on rotating blades. Advanced condition monitoring technologies, such as Noncontact Blade Vibration Monitoring (NBVM), have been shown to effectively detect abnormal behaviors of blades during turbine operation, and thus help to mitigate the turbine loss. Following a brief review of the technology, this paper focuses on results of analyses performed using FM Global’s turbine loss data. Loss events were categorized according to different blade damage mechanisms, turbine types and damage locations; and analyzed in order to identify the realizable benefits through noncontact blade monitoring. Based on the results of the analysis, field applications of the technology for improvement of long-term turbine condition monitoring are discussed.

PowerGen Gas Turbine Losses and Condition Monitoring: A Loss Data-Based Study

2016 ◽  
Vol 2 (2) ◽  
Author(s):  
Bin Zhou
Keyword(s):  
Gas Turbine ◽  
Condition Monitoring ◽  
Gas Turbines ◽  
Evaluation Process ◽  
Failure Detection ◽  
Operating Conditions ◽  
Steam Turbines ◽  
Loss Event ◽  
A Chain

In situ condition monitoring (CM) is a crucial element in protection and predictive maintenance of large rotating PowerGen equipment, such as gas turbines or steam turbines. In this work, selected gas turbine loss events occurring during a recent 10-year period at our clients’ power generation plants were evaluated. For each loss event, a loss scenario or a chain of failures was outlined after investigating the available loss record. These loss events were then categorized based on the nature of the associated loss scenario. The study subsequently focused on the variables that could be monitored in real-time to detect the abnormal turbine operating conditions, such as vibration characteristics, temperature, pressure, quality of working fluids, and material degradations. These groups of CM variables were then matched with detectable failures in each loss event and prioritized based on their effectiveness for failure detection and prevention. The detectable loss events and the associated loss values were used in this evaluation process. The study finally concluded with a summary of findings and path-forward actions.

scholarly journals Vibration Monitoring and Diagnostic Instrumentation for Industrial and Marine Gas Turbines

1973 ◽  
Author(s):  
Vern Maddox
Keyword(s):  
Gas Turbines ◽  
Operating Conditions ◽  
Vibration Monitoring ◽  
Full Time ◽  
Steam Turbines ◽  
Performance History ◽  
Machine Performance ◽  
Environmental Extremes ◽  
Malfunction Diagnosis ◽  
Current Operating

The application of vibration monitoring and diagnostic instrumentation to industrial and marine gas turbines requires some important special considerations. An initially important consideration is the proper selection and location of vibration transducers. Next, a full-time monitoring system must be selected to afford the machine complete protection against failures caused by excessive vibration. And finally, diagnostic instruments must be selected on the basis of required data for malfunction diagnosis, past machine performance history, and current operating conditions of the machine. There are a number of vibration instrument considerations peculiar to gas turbines in general, as opposed to other types of rotating machinery such as steam turbines, compressors, gears, etc. These considerations can be classified as: (a) temperature extremes, (b) environmental extremes, (c) machine casing flexibility, or stiffness, as compared to the rotor. Both the heavy-duty industrial type and the lightweight, or aircraft derivative, type of gas turbine are widely used. A distinction will not be made between these types since most special considerations apply equally well to all gas turbines.

Integration of Condition Monitoring Technologies for the Health Monitoring of Gas Turbines

1992 ◽  
Author(s):  
Cyrus B. Meher-Homji ◽  
Jim P. Cullen
Keyword(s):  
Gas Turbine ◽  
Condition Monitoring ◽  
Gas Turbines ◽  
Monitoring Techniques ◽  
Condition Monitoring Systems ◽  
Monitoring Technologies ◽  
Operational Envelope ◽  
Turbine Design ◽  
New Generation ◽  
High Output

Rapid advancements in gas turbine technology have created a need for advanced condition monitoring systems for critical applications of gas turbines. With a new generation of high temperature and high output engines (150–200 MW) the objectives of attaining a high availability and limiting degradation are of paramount importance. There are several condition monitoring techniques available to gas turbine users. Most publications tend to focus on a specific technique and do not address the need for integration of techniques. Several vibration problems that occur in gas turbines are manifestations of aerodynamic problems. To detect underlying problems of this nature, one is required to integrate performance, vibration and other condition monitoring data. This paper provides a comprehensive review of condition monitoring techniques and presents the thesis that for meaningful condition monitoring one requires the utilization of a variety of condition monitoring techniques coupled with an understanding of gas turbine design and its operational envelope. Case studies are provided to indicate the need for an integrated condition monitoring approach.

scholarly journals Detection of Rotor Forced Response Vibrations Using Stationary Pressure Transducers in a Multistage Axial Compressor

2015 ◽  
Vol 2015 ◽  
pp. 1-10 ◽  
Author(s):  
William L. Murray ◽  
Nicole L. Key
Keyword(s):  
Gas Turbines ◽  
Axial Compressor ◽  
Fast Response ◽  
Forced Response ◽  
Vibration Monitoring ◽  
Blade Vibration ◽  
Response Condition ◽  
Pressure Transducers ◽  
Forcing Function ◽  
Cross Covariance

Blade row interactions in turbomachinery can lead to blade vibrations and even high cycle fatigue. Forced response conditions occur when a forcing function (such as impingement of stator wakes) occurs at a frequency that matches the natural frequency of a blade. The objective of this research is to develop the data processing techniques needed to detect rotor blade vibration in a forced response condition from stationary fast-response pressure transducers to allow for detection of rotor vibration from transient data and lead to techniques for vibration monitoring in gas turbines. This paper marks the first time in the open literature that engine-order resonant response of an embedded bladed disk in a 3-stage intermediate-speed axial compressor was detected using stationary pressure transducers. Experiments were performed in a stage axial research compressor focusing on the embedded rotor of blisk construction. Fourier waterfall graphs from a laser tip timing system were used to detect the vibrations after applying signal processing methods to uncover these pressure waves associated with blade vibration. Individual blade response was investigated using cross covariance to compare blade passage pressure signatures through resonance. Both methods agree with NSMS data that provide a measure of the exact compressor speeds at which individual blades enter resonance.

PowerGen Gas Turbine Losses and Condition Monitoring: A Loss Data Based Study

2014 ◽  
Author(s):  
Bin Zhou
Keyword(s):  
Gas Turbine ◽  
Condition Monitoring ◽  
Gas Turbines ◽  
Evaluation Process ◽  
Failure Detection ◽  
Operating Conditions ◽  
Steam Turbines ◽  
Loss Event ◽  
A Chain

In-situ condition monitoring (CM) is a crucial element in protection and predictive maintenance of large rotating Power-Gen equipment such as gas turbines or steam turbines. In this work, selected gas turbine loss events occurring during a recent ten-year period at FM Global clients’ power generation plants were evaluated. For each loss event, a loss scenario or a chain of failures was outlined after investigating the available loss record. These loss events were then categorized based on the nature of the associated loss scenario. The study subsequently focused on the variables that could be monitored in real time to detect the abnormal turbine operating conditions, such as vibration characteristics, temperature, pressure, quality of working fluids and material degradations. These groups of condition monitoring variables were then matched with detectable failures in each loss event and prioritized based on their effectiveness for failure detection and prevention. The detectable loss events and the associated loss value were used in this evaluation process. The study finally concluded with a summary of findings and path-forward actions.

scholarly journals Application of Blade-Tip Sensors to Blade-Vibration Monitoring in Gas Turbines

10.5772/29550 ◽  
2012 ◽  
Author(s):  
Ryszard Szczepanik ◽  
Radosaw Przysowa ◽  
Jarosaw Spychaa ◽  
Edward Rokicki ◽  
Krzysztof Kazmierczak ◽  
...  
Keyword(s):  
Gas Turbines ◽  
Vibration Monitoring ◽  
Blade Vibration ◽  
Blade Tip

Integrated Condition Monitoring System Strategy at CEMIG

1998 ◽  
Author(s):  
Michael M. Hastings ◽  
Wander Luiz de Oliveira ◽  
Raimundo Jorge Ivo Metzker
Keyword(s):  
Monitoring System ◽  
Condition Monitoring ◽  
Gas Turbines ◽  
Vibration Monitoring ◽  
Maintenance Cost ◽  
Monitoring Systems ◽  
Process Data ◽  
Power Station ◽  
Integrated Monitoring ◽  
Condition Monitoring System

The condition monitoring section at the Brazilian power utility CEMIG is implementing an effective condition-based maintenance strategy that ensures the over 40 power plants spread out over a large area operate with minimal downtime and at a minimal maintenance cost. The condition monitoring system needed to fulfil CEMIG’s needs for the larger plants did not exist, so it was decided to integrate several monitoring systems for this purpose. A computerized, permanently installed vibration monitoring system is planned to be integrated to other systems dedicated to specific periodic machine condition monitoring applications (e.g. air gap monitoring, oil analysis, magnetic flux monitoring, partial discharge analysis). This integrated monitoring approach results in a distributed system with a single system technique for alarm handling, and a user interface and database for analysis, diagnosis and fault correlation. The vibration monitoring system will also be extended for importing process data from the existing distributed supervisory and control system for monitoring calculated performance parameters such as efficiency and head. Testing is also under way for investigating the possibility of more effectively monitoring cavitation without purchasing a separate stand-alone system. Several of the larger plants at CEMIG will eventually be remotely monitored this way, but this paper focuses primarily on the monitoring system, strategy and current operating experience at the Nova Ponte hydroelectric power station. Even before integrating the other monitoring systems, the installed condition monitoring section played a large role in ensuring the plant operates safely, cost effectively and with maximum availability. Although the monitoring system is installed at a hydro-electric power station, some examples are briefly given on how the same integrated monitoring system approach could equally be advantageous in detecting and/or diagnosing certain faults within gas turbines and compressors.

Steady State Detection in Industrial Gas Turbines for Condition Monitoring and Diagnostics Applications

2014 ◽  
Author(s):  
Cesar Celis ◽  
Érica Xavier ◽  
Tairo Teixeira ◽  
Gustavo R. S. Pinto
Keyword(s):  
Steady State ◽  
Condition Monitoring ◽  
Gas Turbines ◽  
Signal Analysis ◽  
Operating Regime ◽  
State Detection ◽  
Industrial Gas Turbines ◽  
Monitoring And Diagnostics ◽  
Operating Regimes

This work describes the development and implementation of a signal analysis module which allows the reliable detection of operating regimes in industrial gas turbines. Its use is intended for steady state-based condition monitoring and diagnostics systems. This type of systems requires the determination of the operating regime of the equipment, in this particular case, of the industrial gas turbine. After a brief introduction the context in which the signal analysis module is developed is highlighted. Next the state of the art of the different methodologies used for steady state detection in equipment is summarized. A detailed description of the signal analysis module developed, including its different sub systems and the main hypotheses considered during its development, is shown to follow. Finally the main results obtained through the use of the module developed are presented and discussed. The results obtained emphasize the adequacy of this type of procedures for the determination of operating regimes in industrial gas turbines.

An Optimization Design Platform for Fir-Tree Root and Groove for Steam Turbine

2018 ◽  
Author(s):  
Deqi Yu ◽  
Xiaojun Zhang ◽  
Jiandao Yang ◽  
Kai Cheng ◽  
Weilin Shu ◽  
...  
Keyword(s):  
Stress Concentration ◽  
Steam Turbine ◽  
Gas Turbines ◽  
High Speed ◽  
Optimization Design ◽  
Turbine Blades ◽  
Local Stress ◽  
Optimization Method ◽  
Steam Turbines ◽  
Geometry Configuration

Fir-tree root and groove profiles are widely used in gas turbine and steam turbine. Normally, the fir-tree root and groove are characterized with straight line, arc or even elliptic fillet and splines, then the parameters of these features were defined as design variables to perform root profile optimization. In ultra-long blades of CCPP and nuclear steam turbines and high-speed blades of industrial steam turbine blades, both the root and groove strength are the key challenges during the design process. Especially, in industrial steam turbines, the geometry of blade is very small but the operation velocity is very high and the blade suffers stress concentration severely. In this paper, two methods for geometry configuration and relevant optimization programs are described. The first one is feature-based using straight lines and arcs to configure the fir-tree root and groove geometry and genetic algorithm for optimization. This method is quite fit for wholly new root and groove design. And the second local optimization method is based on B-splines to configure the geometry where the local stress concentration occurs and the relevant optimization algorithm is used for optimization. Also, several cases are studied as comparison by using the optimization design platform. It can be used not only in steam turbines but also in gas turbines.

Development of 1500-r/min 75-Inch Ultra-Long Last Stage Blades for Nuclear Steam Turbine

2017 ◽  
Author(s):  
Deqi Yu ◽  
Jiandao Yang ◽  
Wei Lu ◽  
Daiwei Zhou ◽  
Kai Cheng ◽  
...  
Keyword(s):  
Nuclear Power ◽  
Power Plants ◽  
Large Scale ◽  
Vibration Monitoring ◽  
Steam Turbines ◽  
Element Analysis ◽  
Rotating Blade ◽  
Lifetime Analysis ◽  
Computational Fluid Dynamics Cfd ◽  
Last Stage

The 1500-r/min 1905mm (75inch) ultra-long last three stage blades for half-speed large-scale nuclear steam turbines of 3rd generation nuclear power plants have been developed with the application of new design features and Computer-Aided-Engineering (CAE) technologies. The last stage rotating blade was designed with an integral shroud, snubber and fir-tree root. During operation, the adjacent blades are continuously coupled by the centrifugal force. It is designed that the adjacent shrouds and snubbers of each blade can provide additional structural damping to minimize the dynamic stress of the blade. In order to meet the blade development requirements, the quasi-3D aerodynamic method was used to obtain the preliminary flow path design for the last three stages in LP (Low-pressure) casing and the airfoil of last stage rotating blade was optimized as well to minimize its centrifugal stress. The latest CAE technologies and approaches of Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) and Fatigue Lifetime Analysis (FLA) were applied to analyze and optimize the aerodynamic performance and reliability behavior of the blade structure. The blade was well tuned to avoid any possible excitation and resonant vibration. The blades and test rotor have been manufactured and the rotating vibration test with the vibration monitoring had been carried out in the verification tests.

Sign in / Sign up

Export Citation Format

Share Document