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Copyright © 1992 by ASME

Condition Monitoring and Diagnostic Aspects of Gas

Turbine Transient Response
CYRUS B. MEHER-HOMJI and RAKESH BHARGAVA
Boyce Engineering International Inc.
Houston, TX 77099

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
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changes in the mass flow rates into and out of components.
 3. Heat balances are not satisfied during transients with heat being
either absorbed or rejected by engine components i.e.,
compression and expansion are non adiabatic.
4. During transients, dimensions of various components can change
due to temperature and centrifugal effects. Tip clearances can be
affected.
In large critical turbomachines however, problems often develop
under transient conditions due to factors such as increased loading,
thermal stresses, changes in tip clearances and changes in thrust
position. Several gas turbine operators have used transient analysis
when they measure coastdown times or plot startup curves using strip
charts or trending packages.
For critical gas turbines, regular transient analysis should be done
for a comprehensive condition asscessment. With large advanced gas
turbines being used in peaking service, transient analysis of startups
and shutdowns will be of diagnostic value to make an asscessment of
durability. A durability surveillance program including on line
monitoring for the GE Frame 7F advanced gas turbine is described by
Ondryas et al. (1992). The application of transient analysis for the
fleet testing of gas turbines (in a test cell environment) also bears great
promise. Currently, the approach is to evaluate the turbine using a set
of "acceptance maps" that indicate if parameters fall within acceptable
tolerances. In this paper, we have provided concepts and approaches
for the implementation of transient analysis for stationary gas turbines.
GAS TURBINE PERFORMANCE DEGRADATION
The causes of gas turbine deterioration fall into two categories. The
first cause is aerodynamic or performance related. The deterioration
can be either recoverable (such as fouling) or non recoverable (such as
seal wear, erosion or casing distortion). The second cause for turbine
deterioration is of a mechanical nature associated with increased
vibration, bearing problems or increased mechanical losses.
Performance Degradation.
Causes of performance degradation include:
1.Dirt Deposits and Fouling. These form mainly on the compressor
blading causing loss of flow capacity and efficiency. The turbine
section can also foul. The effects of fouling are a change in the
turbine-compressor match point, a drop in output and a worsening of
specific fuel consumption. There are also several peripheral problems
that may be created such as cooling hole blockage, imbalance, blade
root lockup and hot corrosion. Fouling deterioration is described by
Meher-Homji (1990).
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
the air filtration system present.
3. Increases in clearances for vanes, blades and seals (i.e.. wear)
Wear is a significant problem specially during the early stages of
engine operation. Even small physical dimension changes can cause
significant performance changes. For example, 10 thousandths of an
inch on a tip radius of 18" can cause a 0.33 % change in fuel
consumption. It can be caused by thermal growth problems, and
centrifugal growth. Tip clearance increase also causes deterioration in
the stage efficiency. Tip stalls can be caused by blade tip erosion.
4. Foreign and Domestic Object Damage (FOD/DOD') FOD can be
caused due to excessive icing, carbon deposits breaking off fuel
nozzles or by components of the filtration system that break off and
are ingested. Domestic Object Damage is caused by internal
components that come loose.
5. Hot Section Problems. Problems can include detached liners,
cracks or unbalanced fuel nozzles. Problems of this nature are often
detected by evaluation of exhaust gas temperature (or inter turbine
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temperature) spreads'. An excellent set of papers on gas turbine
degradation and detection methods have been presented by
Saravanamuttoo and MacIsaac(1983), Muir et al.(1988) and
Saravanamuttoo (1974). Grosby (1986) provides a review of the
factors causing performance deterioration in a turbofan engine.
Diakunchak (1991) provides a detailed treatment of performance
deterioration in industrial gas turbines.
Other sources of deterioration include:
• Excessive drop in inlet filter differential pressure
• Excessive back pressure - this can be of importance when HRSG's
are present
• Increased mechanical losses (gearboxes, bearings, couplings etc.)
• Internal losses
• Stator nozzle plugging (or turbine fouling)
As per Williams (1981), the common faults in pipeline operations are
(in order of importance):
• Compressor efficiency degradation
• Drop in compressor mass flow rate (for given corrected Nt
speed)
• Overboard Leakage
• High Pressure Turbine Efficiency
• Low Pressure Turbine Efficiency
• Change in High Pressure Turbine Flow Function, F= (m 'IT)/P
• Change in Low Pressure Turbine Flow Function
Mechanical Degradation.
Causes of mechanical degradation include wear in bearings and
seals, coupling problems, excessive vibration and noise, or problems
in the lube oil system. Vibration is a common indicator of mechanical
degradation. Several problems that manifest themselves as vibration
may, in fact, have underlying causes that are aerodynamic (or
performance) related in nature.
Bearing problems are often caused by low oil pressure (malfunction
in pump or leaks), line blockage, or excessive loads due to factors
such as misalignment. The lube oil pressure and scavenge
temperatures can be measured and correlated to a parameter such as
rotor speed. The expected pattern during speed changes can be noted
and subsequent checks made during transients.
Combustor fuel nozzles can also plug up. There can be several
causes such as coking, erosion and missassembly. Severe
temperature distortions can create a host of problems in the hot
section 2 . The pattern of the EGT spreads can be monitored during
transient conditions to indicate nozzle problems.
TRADITIONAL METHODS FOR ENGINE HEALTH
MONITORING AND DIAGNOSTICS
There are a host of condition monitoring techniques available.
Meher-Homji and Cullen (1992) provide the means and rationalization
for integrating appropriate techniques taking into account failure
modes, operational and maintenance objectives. The application of
transient analysis is made in context of an on-line condition
monitoring system that is currently offered. These systems have been
described by Boyce et al.(1989), Meher-Homji et al. (1989), Cullen
(1988) and Meher-Homji and Mani (1988) and have been applied to
gas turbines, steam turbines, large water pumps and compressors. In
essence, these systems utilize a real time mini-computer to collect and
analyze both mechanical and performance related data. Due to the
rapid scan rates these systems are particularly valuable in analyzing
transient data. Transient data can be stored and viewed in any of the
1 Nozzle coking problems could also result in changes in combustor outlet
profile factor which can in turn result in problems with downstream
components.
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.
 formats that are available for steady state display- trends, bar charts.
x-y plots. The data can be acted on by a rule based system.
Some of the complexities experienced with traditional systems 3 are:
1. Not all problems are detectable by examining parameters under
steady state operation. This holds true both for performance related
problems and vibration problems.
2. Skill and experience of the user is particularly important when
gas path analysis techniques are used. The user needs to have a
detailed understanding of the aerothermodynamics of the gas turbine
and matching considerations to deal with complexities caused by
multiple faults, sensors errors and biases.
3. For meaningful trending and to get an accurate representation of
degradation, the following basic facts have to be recognized. First,
several aerothermal and mechanical parameters (both analog input and
computed) will vary with operating regimes of the machine (i.e., with
Power level, flow etc.) Several monitoring and trending systems on
the market have a steady state assumption implicit within them. For
example, trending an overall gearbox vibration or an exhaust gas
temperature (EGT) has little meaning without referencing the trend to
other operational parameters. Gearbox vibration level (especially at the
gear mesh frequency) is a strong function of load. Similarly, EGT is
a function of machine loading. The same holds true for bearing
temperatures. Second, with off design operation, there is a change in
several aerothermal parameters that occur not because of deterioration
but due to the machine operating off design. Changes in the
aerodynamics and match points in the engine result in a drop in
component efficiency 4 . Mathematically,
DETtotal = DET off design + DETanp al
Third, vibration parameters vary with operating conditions (this is
particularly true of amplitudes at gear mesh and blade pass
frequencies). However the presence of resonances, interaction effects
and several other factors make trending even more complicated.
There are several approaches to meaningful trending. One approach
is by means of segmenting data in parameter ranges using parameters
such as power, flow etc. Thus, trends can be called up for a given
power range and deterioration can be observed qualitatively. Another
approach is to provide multiple trends and allow the observer to
determine deterioration by examining different power settings. An
alternative method is the baseline transpose trend approach. For
vibration data, the use of adaptive modelling can be applied wherein
vibration can be characterized on a statistical basis as a function of a
large number of operational parameters. Even with these trending
approaches, there are a class of problems that may not show up in a
long term trend. In cases such as these, transient behavior will often
be the best descriptor of the problem.
Methods of Fault Detection.
There are several approaches to fault detection and fault isolation. A
common thread is that there is some measurable set of parameters or
pattern that can be used to detect problems. Approaches include:
Aerothermal analysis- this uses thermodynamic relations commonly
used in gas turbine performance work. Computations of key health
parameters such as the air flow rate and turbine entry temperature are
computed by iterative procedures based on work and flow
balances(Meher-Homji and Boyce, 1982).
Gas Path Analysis- These methods deal with thermodynamic
models and are based on the premise that changes in the gas path will
result in a changes in aerothermodynamic parameters (Urban,
1972,1974). The approach encounters some practical difficulties 5
resulting in an approach suggested by Stamatis and Papailiou (1988),
3 By "traditional systems" we mean systems that emphasize steady state conditions
for diagnostic analysis purposes.
4 The effect is less severe with split shaft machines and variable geometry
engines.
5 To increase the reliability of performance estimation and for fault isolation,
several sensor points are required.
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Stamatis et al. (1989,1990), known as Discrete Operating Condition
Gas Path Analysis (DOCGPA)
Fault Matrix Technique- This method as presented by Dupuis and
Saravanumuttoo (1985) utilizes a simulation model wherein faults can
be introduced by modifying component efficiencies and losses.
Use of Acceptance Maps- these are valuable diagnostic indicators
but in borderline cases one has to ensure that performance shifts due
to engine degradation are greater than normal, random scatter.
Spool Sneed Relationship-As the Nl/N2 relationship is affected by
matching considerations (torque and mass flow) gas path problems
indicate themselves by a change in the spool speed relationship.
Figure 1 indicates a N1, N2 relationship plot on a two spool gas
generator. This applies to fixed geometry machines.
TRANSIENT ANALYSIS OF PERFORMANCE
PARAMETERS
There are two approaches to utilize performance related transient
data. The first involves plotting measurable data during a transient for
comparative qualitative & quantitative analysis over a succession of
starts of the gas turbine. The second (and more complex) approach
involves applying some form of simulation to determine what the
transient response should be. This can then be compared to the actual
response.
In order to utilize transient data, several approaches attempt to
model the turbine behavior by means of gas path analysis. In order to
link gas path analysis with dynamic modelling, the information
required are the basic aerothermal relations, component maps, fuel and
control information, rotor inertias, and component heat capacities.
Based on the compressor and turbine maps, a set of equilibrium
(match) points may be defined. The compressor- turbine match point
is determined by plotting turbine performance data on the compressor
characteristic. Thereafter, an iterative process can be implemented
based on speed and mass flow compatibility and component power
balances. Detailed matching computations may be found in Cohen,
Rogers and Saravanumuttoo (1986).
Figure 2 shows a compressor map with lines of constant
temperature (To3/Tol). During gas turbine acceleration, the fuel
injection rate and turbine work increases. The increased torque
accelerates the shaft. With excessive overfueling, the temperature line
moves upwards before the speed increases thus moving the operating
point towards the surge line 6 .
A Review Work Done in Transient Analysis.
A detailed description of transient analysis as it is applied to the GE
F-404 engine is described by Cue and Muir (1990) and Muir et al.
(1988). The GE 404 is a 2-spool afterburning turbofan used on the F-
18 Hornet with a maximum thrust rating of 16,000 lbs. The engine
has an on-board data recorder. In brief, the approach involved:
1.Recording of data during the ground roll of the aircraft at each
takeoff.
2.Health Indices used include:
• Time v. Compressor Discharge Pressure(CDP) Rise: This is used
as an indicator of HP compressor damage. Figure 3 (Cue and
Muir, 1990)shows the effect of HP compressor damage.
• Fan Rotor Acceleration Time: A measurement is made for the time
to accelerate.
• Nl/N2 Speed Ratio.
• The scheduling of the main fuel control is also monitored. This
data has been of use in detecting fuel control problems.
6 This is of particular concern with steam injected gas turbine units or
cogeneration machines using variable IGV control. These factors, along with
severe compressor fouling can significantly (and dangerously) reduce the surge
margin.
 5000 • Maximum thrust, vibration and oil pressure are also monitored as
is engine airflow (based on nozzle area, exhaust gas pressure and
exhaust gas temperature).
Henry (1988) provides some interesting insight into transient
8000
testing of the F-404 engine. As the engine diagnostics of the F-404
2
are based on transient acceleration, Henry has studied the variables
0. influencing acceleration and the repeatability effects of transient data.
These are presented below along with what we consider are
N
z implications for transient analysis for stationary gas turbines.
7000
1. Ambient Conditions - these were not found to have a major
effect. For stationary gas turbines, an experimental verification of the
effect of ambient temperature should be made. Also in land based gas
turbines, the inlet air filtration system may be sensitive to conditions
6000 such as excessive humidity, fogs etc. and this could cause rapid
3000 4000 5000 6000 7000
turbine fouling.
Ni. RPM 2. Starting Speed of Acceleration- Gold and Rosenzweig (1952)
Figure 1. Ni v.N2 spool speed relationship for a gas generator as a showed that the time constant for the spool speed response was a
diagnostic indicator. function of the initial and final acceleration speeds. In single shaft gas
turbines this is not a factor of concern during the start to idle phase.
The control system closely defines idle and other setpoint speeds.
3. Variable Geometry- As the F-404 has variable geometry,
(variable fan, 11P compressor and exhaust nozzle) the geometry had
to be checked. Test data showed that the variable exhaust nozzle
immediately moved to and remained in the fully closed position for
approximately 4 seconds. Thus, the data collected in this time frame
SING was essentially with fixed geometry. Several stationary gas turbines
utilize variable geometry and tests would have to be considered on a
machine specific basis to check the effects.
4. Rate of Throttle Movement- The rate of throttle movement was
found to influence the amount of fuel added by the main fuel control.
However, at a certain rate, a maximum fuel schedule was attained
making engine transient performance independent of throttle
movement. For stationary gas turbines, loading is rarely done
manually. With land based gas turbines, the control system will
provide a clear digital time reference signal as to when certain transient
Figure 2. Axial compressor surge map showing operating lines. events begin (or end). These are invaluable for transient analysis as it
permits accurate trending of data.
5. Reslatn Effects- This occurs when two slam accelerations occur
in quick succession. During the first acceleration, a rapid heating of
6^ 120
BEFORE HP COMPRESSOR DAMAGE the gas turbine internals occur. As the second acceleration occurs
W
CE before "cooling down", it occurs with less heat transfer to the engine
tau body. The heating of the engine body causes changes in the tip
x 80
clearances and component efficiencies. Saravanamuttoo and Fawke
(1971) have used a dynamic model to show that speed response will

=
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).

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 This brings out a very important point. On line systems that E•4€ TO .eo C^ /, -,\

conduct transient analysis (indeed even steady state analysis) must

have the software capability to report excursions of this nature even
when the parameter does not cross an "alarm" threshold. What is
important here is that a qualitative change in pattern or level occurred
and this should be flagged as it may have significant diagnostic
content. p ;/
u
CO OS5TOO 1
- CO..euSroa7.
- Co ,eIS , OA S
'' — ---
W
rC00 5E -
101 fl TA ----COMBUStOC%
fm
Use of the Kalman Filter Technique for Transient
Analysis.
In essence, transient analysis problem reduces to detecting
(discriminating) between random scatter effects and shifts due to a
problem as shown in Figure 5. With repeated transient analyses, more
confidence can be gained regarding data scatter effects and the 4e
confidence interval can be improved. The Kalman Filter is a recursive Time. See
Sao linear algorithm which estimates these effects as is described by Gelb ^_^

(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).

MECHANICAL TRANSIENT ANALYSIS / ' - , +COMBUSTER 3 RELIT

336 //
Compared to aerothermal transient analysis, mechanical transient COMBUSTER 3 FLAME BLOWOUT

analysis has been extensively used in condition monitoring systems.

Included under mechanical analysis are vibration analysis, bearing
temperature analysis, lube oil system performance analysis and debris
:G
monitoring techniques. -=--
0 IL 2y 76 At
uF SEC
Vibration Transient Analysis.- The use of high density spectral Time, Sec
cascades permit a visual representation of the frequency content of
vibration signal during startup or shutdown as shown in Figure 6. Figure 4. Transient plot of exhaust temperature showing combustor
This cascade shows the vibration behavior caused by subsynchronous damage. Bruce and Cartwright (1991).
instability of a centrifugal pipeline compressor driven by a gas turbine.
The instability occurred when the compressor was loaded (pressure
ratio increased by closing of the bypass valves). The first lateral
critical vibration grew to 8 mils and caused a trip. Examination of the
cascade clearly indicated that the vibration was at the 1st rotor critical 8i 11^Un ON
speed. This was caused due to an incorrect bearing clearance.
Techniques are available to check rotor related and fixed frequency
amplitudes during transient conditions. Vibration cascades can be
formed either on a delta time or delta RPM basis as described by MEASURED CURVE
Muster and Muster (1990) Also described in this reference is a
technique to accelerate the rate of data acquisition during transients.
The Bode and Nyquist plots are classic rotor dynamic transient gU,f^ DUE WAL
displays of great value with flexible shaft machinery. Work by
Gasper et. al,(1988) discusses the use of rundown frequency
response data. The use of acceptance regions utilizing a polar plot Nt/^
format of amplitude and phase angle data is an important and useful Figure 5. Difference between random scatter and problem related
tool. Another useful representation for transient analysis is based on a data shift.
vectorial summation technique of proximity probe gap voltages. This
can be used in a display to depict the movement of the shaft within the
bearing during startup /shutdown. The examination of transient thrust COt1PR I/S-VERT, GCCN & ST ST
movements during startup is also very valuable.
IXRPM RESPONSE THROUGH CRITICAL SPEED

Lube Oil Parameters - For startup analysis of lube oil parameters

(lube/scavenge oil temperatures, and pressure) it is possible to prepare
maps showing these parameters as a function of rotor RPM.
Examples for a three spool 1500 SHP engine are shown in Figure 7. °^,M1Fa.r

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

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 1170 --
temperature control, this means that the unit will run at a higher

//
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:

i. Bearing Wear and damage (this can be detected by evaluating the

transient data for changes in amplification factor (Q factor) . Bearing
metal temperature is a popular means of detecting hearing related
problems or rotor dynamic excursions and is a better analog of load
20 w so 6a 70 90 90
than lube oil drain temperature. Scan rates of the data acquisition r.IANIFoLD OIL PRESSURE. psi
system must be high as unusual transient events can cause a rapid
excursion (e.g., a surge cycle) in shaft movement, a consequent rub
and a momentary peaking in bearing metal temperature.
Subsequently, bearing metal temperatures may actually drop due to the
increase in oil flow area. The rate of change of bearing temperature is 0
also important. In these rapid transient excursions, it is important to 9
C
use corroborative evidence and examine associated vibration behavior, XI
changes in shaft position (radial and axial) and other analog and
performance data. a
2. Thermal Bows occurring in the rotor: Some steam turbines will C.'

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

systems are now available. Locked couplings can be detected by .e.a

changes in phase angle that occur from startup to startup.
36.0
5. Blading Problems- this accounts for a major portion of all gas
turbine failures and is one of the most complex problems in gas 32.0

turbines due to the complicated blade dynamics and interaction of x9.0

factors such as quality, environment (salt, high temperature) erosion, f1
4.e
and wear. While vibration and performance monitoring cannot predict
blade failures, several times the n r causes (air flow distortion, o e a. a^
surge, nozzle bowing/blockage etc.) can he detected thus providing a -'16.13
chance to Ay9jd the failure. Details pertaining to this area can be found
alr.e
in Me her-Homji and Focke (1985). There has considerable work been 01
done in the use of dynamic pressure and accelerometers to detect >1313

blading problems. Blade migration (walking) is a problem that can ..B

occur with transient loading eg. tip rubs that may cause root fixation
13.0
problems and subsequent migration.
-a,0

-B aBBB 5200 5629 4000 01302 6600 72ee 2600 Br10r 8.00 00410 9200 0600
A COMPUTATIONAL METHOD FOR EXAMINING [OPPECTEA HGC 10001

STARTUP TRANSIENT BEHAVIOR

Figure 8. Variable Stator Vane Schedule for a 2 shaft turbine.
Transient analysis profiles can be used for the detection of several
types of problems. The specific approach would be turbine
dependant. We provide a simplified algorithm here for conceptual

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

3. Controls and instrument problems- This would include faulty

PT FLM1tj. v 1000
thermocouple readings 5 , speed sensor problems or problems with
EGT • F
the control unit itself.
The general approach that can be followed is presented in Figure 10.
^ — i ---- i -- +- i 800
The engine model presented is based on a single spool gas generator 0 50 100 150 zoo 250 300 350 400 450 sag
CUM TIME, min

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.

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 generator and a power turbine. The model for a two spool gas
generator would be considerably more complex because of the need to Q 3
Q Q4

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,
find m a and lie
(b) Calculate compressor temperature rise.
AT = IT, (PR) Y-/Y- t }/ 11c (3)
(c) Use a energy balance to determine turbine entry temperature.
(m a + tit f) T3 Cp = m a Cp T2 + mf (LHV) 'n b (4)
which yields,
rrta CpT2+t11(LHV) Tlb
T3= (5)
Cp (ina +thf)
(d) The gas generator non dimensional mass flow is given by:
m3•IT3/ P3 =(ma'l(T 1 /PI)I x IP)/P21 xIP2/P31 xl`^T3/ 1'tl ( 6 )
(e) Using this value of non dimensional flow, find the gas generator
expansion ratio.
STEP 5
Check if gas generator expansion ratio equals compressor pressure
ratio. If not, return to STEP 3. If a match occurs, then a match point
has been attained.
Figure 10. Procedural flow chart for startup transient analysis.
The shaft acceleration can be calculated:
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
box between the start system and the gas turbine shaft and K2 a factor
to account for the gear ratio.
TRANSIENT ANALYSIS CASE STUDIES
Some examples of transient behavior are presented here from both
our experiences and published information.
Lieht Off Behavior of an Aeroderivative Ermine.
Diagnostics are under implementation on the startup behavior of a
LM 2500 gas turbine engine used for propulsion purposes.
Essentially, an examination is made of the inter turbine temperature
(i.e., the GG EGT) after light off. The typical profile is shown in
Figure 11 . The quantity AT is measured and can be trended over
several startups. Similar plots can be made for CDP and RPM
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

attained. In order to calculate the acceleration, art estimation is

required of the starter torque. This can be obtained from the starter ,. 5 10 15 20 25 30 35 40 45 50

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.

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 Coastdown Transient Behavior of Parameters on Heavy
Duty Gas Turbine.
Figure 12 shows a reported case (Cunningham) of how the RPM
coastdown profile can show a damaged bearing. The rundown of a
gas turbine is a time to listen for audible noises from gearboxes and
bearings. The potential for turbine rubs also exists because of the
thermal transients that occur. In generator drives, the generator inertia
is so large that a condition may occur where the generator (inertia)
drives the turbine. When reduction gearing is present, the gearing
may mesh on the backside of the teeth. It is during shutdowns that the
maximum thermal transients occur.
Close monitoring of the EGT during tightoff can provide valuable
information. If the EGT is in the normal range, but acceleration is
slow, the problems typically reside in the starter assist system. An
excessive EGT and higher than normal acceleration rate implies an
overfueling condition. Low speed compressor surge (stall/rotating
stall) can often create a situation of low acceleration but higher than
normal EGT. Rotating stall can be caused by a degraded (fouled )
compressor, inlet blockage or intake distortion, ignition delays
causing pulsations in the combustors or the improper operation of
bleed valves.
If an analysis of the transient parameters indicates that the set speed
is exceeded after acceleration, then this is indicative of control system
y00
or valving problems.
Detection of Damaged Bearings Based on Transient
Temperalure Monitoring upon Shutdown.
Bearing temperature readings can be used to indicate the presence
of severely scored bearing journals (i.e., one in which babbitt wipe
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
expected with an undamaged bearing. During transient operation, the
hydrodynamic film is thinner (film thickness is a function of speed)
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
0that damage has occurred.
a (0)
z
i0
z
a
urn!
Figure 12. Transient bearing temperature v. time plot as an
indicator of bearing distress.
4009
—a-- RPM-ssrsw
3000
—^— RPM. hmgdamag
2000
C
1000
10 Is 20 25 30
Coastdown Time. min.
Figure 13. Rotor coastdown profile as a indicator of bearing
condition.
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Transient Behavior of a Larioc Steam Turbine Compressor
Train.
Data taken from a large steam turbine in mechanical drive service is
shown in Figure 14. Figure 14a shows a baseline of vibration v.
time. The corresponding bearing temperature response is shown in
Figure 14b. The flow characteristic response with time is shown in
Figure l4c_ Figure 14d shows a transient scatter plot providing
variation in thrust bearing temperature with flow. Plots such as these
which can be generated by real time monitoring systems can be
valuable in checking the startup behavior in a qualitative sense. If a
sudden and unexpected deviation occurs from the profile then the
situation should be further investigated.
000T-201-SPEED :RPM
300
I)dC-201-2--IB-W Trio
VIBRATION TRANSIENT (A)
006T-201-THCIJST BEG TEMPERATURE :DEG F
BEARING TEMP TRANSIENTS (B)
Zan
400
L0 T-201-THRUST BRG TEMPERRTURE :0C F
^B]
290
FLOW TRANSIENT. KLbs'Hr
rc)
f to a.
100 200 305 400 5130 600 700 Soo 900
Seconds
THRUST BEARING TEMP TRANSIENT (F)
SCATTER S-Y PLOT
60000 9000012000015000018000021000040B00070000300000
0OC-201 1ST SUCTIQN FLUU-ISSS :Lbs-Hr
Figure 14. Set of startup plots for a large machanical drive steam
turbine.
Transient Startup Behavior of a 21 MW Gas Turbine.
Considerable insight can he attained into gas turbine performance
by the use of startup transient curves. Figures 15 a and 15 b show a
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
and shutdown transient plots of the gas generator EGT, power turbine
speed and gas generator speed. Point A represents the initiation of
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,
the time to attain break away conditions was an important diagnostic
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
characteristic. Figures 15 b and 15 c show another startup and run
plots.


Gc t6T REFERENCES
tea

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o
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tea - - -
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IMPLICATIONS FOR ON-LINE CONDITION
MONITORING SYSTEMS
Special transient analysis software modules are being currently
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CLOSURE
This paper has provided an overview of the need for transient
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9 We view this as particularly important in that the condition monitoring system

must have the ability to automatically trend, detect changes in transient behavior
and not rely on the user to create startup plots.

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