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Gas Turbine Performance and Health Status Estimation Using Adaptive Gas Path Analysis
Gas Turbine Performance and Health Status Estimation Using Adaptive Gas Path Analysis
Keywords: gas turbine engine, performance adaptation, gas path diagnostics, Adaptive
GPA
1 Introduction Some techniques have been developed in the past in the field of
gas turbine engine performance matching or adaptation. Roth et
With the development of thermodynamic modeling techniques
al. 关1兴 introduced an optimization concept for an engine cycle
and softwares, performance simulation of gas turbine engines be- model matching and a minimum variance estimator algorithm 关2兴
comes a quick and reliable tool for gas turbine engineers to ana- for performance matching of a turbofan engine. Li et al. 关3兴 intro-
lyze engine performance. During gas turbine operation, however, duced an adaptation matrix manipulation method and genetic al-
the deviation of gas turbine performance is indicated by the de- gorithm adaptation method 关4兴 for gas turbine design point per-
viation of gas path measurements, such as gas path pressures, formance adaptation and successfully applied the methods to the
temperatures, shaft rotational speeds, fuel flow rate, etc. Such per- test data of an industrial gas turbine engine. Many gas path diag-
formance deviation may be due to varying ambient and operating nostic methods have been developed in the past and the typical
conditions or engine performance degradations associated with ones are Gas Path Analysis 共GPA兲 and its derivatives 关5–12兴, neu-
prolonged operation time and hostile operating environment. Nor- ral networks 关13–15兴, Bayesian belief networks 关16兴, genetic al-
mally, gas turbine engine performance is represented by engine gorithm 关17–19兴, fuzzy logic 关20–22兴, diagnostics using transient
performance parameters such as airflow rate, compressor pressure measurements 关23,24兴, etc. More comprehensive reviews on gas
ratios, compressor isentropic efficiencies, turbine entry tempera- turbine gas path diagnostic techniques were given by Li 关25兴,
ture, combustor combustion efficiency, turbine isentropic efficien- Singh 关26兴, and Jaw 关27兴.
cies, etc., while engine performance health is represented by en- In this paper, a novel gas turbine engine performance and health
gine health parameters such as compressor and turbine isentropic status estimation approach, called Adaptive Gas Path Analysis
efficiency indices and flow capacity indices. Gas turbine engine 共Adaptive GPA兲, has been developed. It uses the gas path mea-
performance and engine health status may not be directly mea- surements as input information to estimate changing engine per-
sured and therefore are not easily visible to engine operators. In- formance and degraded health of major engine gas path compo-
terpretation of the deviation of engine performance and health nents. The developed approach is applied to a model gas turbine
status relative to its initial condition by using gas path perfor- engine similar to Rolls-Royce aero engine Avon-300 implanted
mance analysis techniques is very important to both engine opera- with different component degradations to test the effectiveness of
tors and designers alike. the approach. Analysis and conclusions are made accordingly.
2 Adaptive GPA
Contributed by the International Gas Turbine Institute of ASME for publication in Engine performance status is represented by engine component
the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received
March 23, 2009; final manuscript received March 26, 2009; published online January
performance parameters, such as engine airflow rate, bypass ratio,
25, 2010. Review conducted by Dilip R. Ballal. Paper presented at the ASME Gas compressor pressure ratios, compressor isentropic efficiencies,
Turbine Technical Congress and Exposition, Orlando, FL, June 8–12, 2009. combustor combustion efficiency, turbine entry temperature, tur-
Journal of Engineering for Gas Turbines and Power APRIL 2010, Vol. 132 / 041701-1
Copyright © 2010 by ASME
ating conditions, the measurement data should be corrected to the squares sense.
same ambient and operating conditions before the data can be Due to that the engine performance may deviate nonlinearly
used. from its initial baseline condition because of nonlinear thermody-
When an engine is clean 共i.e., undegraded兲 and operates at a namic behavior of engine performance, the linear performance
specified operating condition, the performance status of the engine adaptation may not be able to provide accurate estimation of en-
is denoted by subscript “0”. If the engine operates at a slightly gine performance deviation. Therefore an iterative process, a
deviated condition due to engine degradation, the engine perfor- Newton–Raphson method, is introduced to improve the accuracy
mance represented with Eq. 共1兲 can be expanded in a Taylor series of the estimation where linear adaptation is applied iteratively
expansion around condition 0, assuming that the engine perfor- until a converged solution is obtained 关11兴 共Fig. 1兲. The above
mance deviation is small, method is called the nonlinear performance adaptation. Theoreti-
冏 冏
cally, the nonlinear performance adaptation has the potential to
h共x៝ 兲 provide better adaptation results than its linear partner.
z៝ = z៝0 + 共x៝ − x៝ 0兲 + HOT 共2兲 The convergence of the nonlinear performance adaptation pro-
x៝ 0 cess shown in Fig. 1 is declared when the predicted measurement
where HOT is the higher order terms of the expansion and can be parameters are very close to the actual measurement parameters.
neglected when the performance deviation is small. Therefore, a This criterion is shown in Eq. 共8兲 where the root mean square
linearized gas turbine performance model can be expressed with 共rms兲 of the difference between the predicted and actual measure-
Eq. 共3兲. ment parameters is smaller than when convergence is declared:
冑
in Sec. 2.1, and therefore the operating point of the compressor
M can be located on the compressor map as B and B⬘ that corre-
兺 关共z
i=1
i,predicted − zi,actual兲/zi,actual兴
2 sponds to an operating point A and A⬘ at the same rotational speed
when the engine is clean. It can be seen in Fig. 2 that points B and
rms = ⬍ 共8兲 B⬘ may be at different locations on the same speed line if pressure
M ratio and flow capacity degrade differently. In addition, multiple
where is a very small number 共 = 0.001 in this study兲. solutions may be obtained if the determination of SFc,PR and
Such performance status estimation method is fast in computa- SFc,FC is made only based on the location of A, A⬘, B, and B⬘. To
tion speed, and the accuracy of the estimation is mainly deter- avoid multiple solutions of the degradation analysis, it is assumed
mined by the accuracy of the gas path measurements. that the flow capacity index is always the same as the pressure
Although different gas turbine design point performance adap- ratio index, Eq. 共12兲, based on the fact that the degradation of
tation methods 关1–4兴 have been developed, this is the first time pressure ratio on engine performance has similar effect to that of
one of these methods is introduced to estimate performance status flow capacity degradation.
of a degraded engine. Such estimation method has the advantage
that it does not need any component characteristic maps. As the SFc,FC = SFc,PR 共12兲
result of the performance status estimation, the deviated engine Based on such assumption, only two degradation indices are used
performance due to engine degradation can be predicted. to describe compressor degradation 共while the pressure ratio index
2.2 Engine Health Status Estimation. Once the degraded becomes implicit兲, and they are the flow capacity index SFc,FC
performance of an engine is obtained, it can be compared with the and the isentropic efficiency index SFc,eff. Point A can then be
initial engine performance when the engine was new. Such com- located by the intersection between a line passing through B as
parison can be done at a component level by comparing the oper- well as also satisfying Eq. 共12兲 and the clean speed line at the
ating point of each component on its characteristic map when the same rotational speed. Once point A is located, corresponding
component is degraded with the operating point on the same map point A⬘ can be located easily on the c − FCc map, where point
when the component is not degraded. This leads to the estimation A⬘ has the same rotational speed and the same mass flow rate as
of degradation of every major engine component of compressors, that of point A. Therefore the pressure ratio, mass flow rate, and
combustors, and turbines. To assist the analysis of gas turbine isentropic efficiency at points A and A⬘ can be determined. Due to
degradation, it is assumed that the degraded characteristic maps of that the same degradation indices are applied to the whole com-
compressors, combustors, and turbines will keep more or less the pressor map, any corresponding points on the map between clean
same shape as their original maps, based on the fact that their and degraded conditions can be used to calculate the degradation
geometries do not change significantly after they are degraded. indices. Therefore, the degradation indices representing the com-
The degradation of the components is represented by the shift of pressor degradation can be estimated with Eqs. 共9兲–共11兲 by using
the characteristic curves on the maps, and such shift is represented the values obtained at A, A⬘, B, and B⬘.
by degradation indices to be discussed later. 2.2.2 Combustor Degradation Estimation. Combustor degra-
The detailed procedure of such idea forms the second step of dation can be represented with the degradation of combustor com-
the Adaptive GPA, and its detailed approach is the major contri- bustion efficiency. Combustor combustion efficiency varies with
bution of this paper described in detail as follows. combustor load. A typical combustor characteristic map is shown
2.2.1 Compressor Degradation Estimation. Most open litera- in Fig. 3 where the solid line represents the combustion efficiency
ture has only mentioned compressor degradation represented by when combustor is clean 共i.e., undegraded兲 while the dotted line
two degradation parameters relevant to compressor isentropic ef- represents the combustion efficiency when combustor is degraded.
ficiency and flow capacity. However, the degradation of a com- The combustor load is a function of the combustor inlet total
pressor may be described more realistically by the deviation of pressure 共Pb兲 and temperature rise across combustor 共⌬Tb兲, Eq.
three degradation indices relevant to its isentropic efficiency, flow 共13兲,
capacity, and pressure ratio. A typical compressor characteristic
map is shown in Fig. 2 where the relationship among four com- combustor load = f共Pb,⌬Tb兲 共13兲
pressor characteristic parameters, i.e., pressure ratio PRc, isentro- A combustion efficiency index 共combustion efficiency degradation
pic efficiency c, flow capacity FCc, and relative rotational speed scaling factor兲 is introduced to represent the degradation of a com-
CNc, at different operating conditions is represented. In the figure, bustor and is shown in Eq. 共14兲.
Journal of Engineering for Gas Turbines and Power APRIL 2010, Vol. 132 / 041701-3
Implanted degradation
共%兲
Component and health parameter Test case 1 Test case 2 Test case 3
Journal of Engineering for Gas Turbines and Power APRIL 2010, Vol. 132 / 041701-5
ment noise is random in quantity and follows the Gaussian distri- the Adaptive GPA based on gas path measurements is called “pre-
bution. The maximum measurement noise for different gas path dicted performance.”
measurable parameters is based on the information provided by In these test cases, the two sets of measurement deviations of
Dyson and Doel 关30兴. test cases 1 and 2 shown in Fig. 8 are input to the Adaptive GPA
To reduce the negative impact of measurement noise on perfor- separately, and both the linear and nonlinear Adaptive GPAs are
mance and diagnostic analyses, multiple gas path measurement used to estimate the deviated engine performance and predict the
samples are obtained in the simulation, and a ten-point rolling corresponding engine degradation. The estimated deviated engine
averaging is applied to get an averaged measurement sample be- performance represented by the deviated value of component per-
fore the measurements are fed into the Adaptive GPA. The math- formance parameters and its comparison with the actual degraded
ematical expression for the rolling averaging is shown in Eq. 共19兲. performance for the two test cases are shown in Tables 3 and 4.
P
Compared with the clean engine performance, TET is unchanged
due to that it is the engine handle and kept constant by engine
兺
1
z̄i = zi 共19兲 control system. In test case 1, engine airflow rate 共ma兲, compres-
P i=1
sor pressure ratio 共PRc兲, and compressor turbine isentropic effi-
where zi is the gas path measurement samples, and P is the num- ciency 共c兲 are deviated from their clean value in the quantity
ber of samples 共P = 10 for ten-point rolling average兲. between ⫺1.5% and ⫺1.95% while the combustor combustion
Measurement samples may be continuously obtained. The av- efficiency 共b兲 and power turbine isentropic efficiency 共t兲 show
eraged sample using ten-point rolling average at a particular time very little change. In test case 2, changes of ⫺1.1%, 1.9%,
is the average of the last ten samples up to that moment. An ⫺1.1%, and ⫺0.8% happen to engine air mass flow rate 共ma兲,
example of simulated measurement samples after data averaging compressor pressure ratio 共PRc兲, compressor isentropic efficiency
and their comparisons with the true values is shown in Fig. 7. 共c兲, and turbine isentropic efficiency 共t兲, respectively, and al-
By implanting the different degradations shown in Table 1 into
most no change to combustor combustion efficiency 共b兲.
the PYTHIA engine performance model, the gas path measurement
deviations 共fault signatures兲 in the three test cases are shown in The comparison of prediction errors relative to the actual de-
Fig. 8. It shows that these engine degradations result in different graded performance in percentage is shown in Figs. 9 and 10
engine performance deviations indicated by different gas path where the maximum error for the linear and nonlinear Adaptive
measurement deviations. To test the Adaptive GPA system, the gas GPAs is about 0.2% in test case 1 and about 0.3% in test case 2.
path measurement deviations are input to the system, assuming It is also interesting to see that the estimated engine performance
that the degradation of the compressor, combustor, and turbine is status provided by both the linear and nonlinear Adaptive GPAs is
unknown to the system. very close to each other, indicating that the linear approach is able
to provide almost the same results as its nonlinear partner al-
3.1 Test Cases 1 and 2. In this study, the simulated engine though it is normally believed that the nonlinear approach pro-
performance with implanted engine degradation is called “actual vides better results than its linear partner. This may be due to that
performance” while the predicted engine performance by using this model engine performance deviates almost linearly when deg-
Table 3 Prediction of actual engine performance using linear and nonlinear Adaptive GPAs in
test case 1
radation happens and also due to that the measurement noise neously, and the implanted degradation is shown in Table 1. The
makes the difference between the linear and nonlinear approaches deviation of engine performance and the corresponding measure-
invisible. ment deviation due to such degradation are shown in Fig. 8. Both
The engine component degradations in the two test cases pre- the linear and nonlinear Adaptive GPAs are applied to the test case
dicted by the linear and nonlinear Adaptive GPAs are shown in to predict both the deviated engine performance and engine
Figs. 11 and 12 where the predicted deviations of all health pa- degradation.
rameters 共i.e., the degradation indices兲 are compared with the im- Resulted from the first step of the Adaptive GPA, a comparison
planted degradations. It can be seen that the predictions of the among the actual clean and degraded engine performance, the
degradations from both the linear and nonlinear approaches are predicted degraded engine performance, and its deviations from
satisfactory, indicating that both the linear and nonlinear Adaptive the clean performance is shown in Table 5. It can be seen that
GPAs are able to isolate and quantify engine component degrada- deviation of around ⫺2.7% in engine airflow rate 共ma兲, 0.2% in
tions satisfactorily. The maximum prediction error of degradation compressor pressure ratio 共PRc兲, ⫺2% in compressor isentropic
is around 0.24%. It also shows that the smearing effect 共predicted efficiency 共c兲, ⫺1.9% in combustor combustion efficiency 共b兲,
degradation is distributed among all health parameters, although and ⫺0.7% in turbine isentropic efficiency 共t兲 are predicted
some of them are not really degraded兲, normally seen in some when TET is kept unchanged. Figure 13 shows that the maximum
diagnostic approaches, is comparable to the level of measurement prediction error for performance estimation from the linear ap-
noise 共⬍0.4%兲 and is satisfactory even with the existence of mea- proach is about 0.23% while the maximum error for the nonlinear
surement noise. approach is about 0.2%. By looking at the prediction errors for all
the performance parameters, it can be seen that the prediction
3.2 Test Case 3. In test case 3, all major engine components
共compressor, combustor, and turbine兲 are degraded simulta-
Fig. 9 Comparison of linear and nonlinear Adaptive GPA er- Fig. 11 Predicted degradation with linear and nonlinear Adap-
rors in test case 1 tive GPAs in test case 1
Fig. 10 Comparison of linear and nonlinear Adaptive GPA er- Fig. 12 Predicted degradation with linear and nonlinear Adap-
rors in test case 2 tive GPAs in test case 2
Journal of Engineering for Gas Turbines and Power APRIL 2010, Vol. 132 / 041701-7
errors from the nonlinear Adaptive GPA are generally similar to test cases 1 and 2 共Figs. 11 and 12兲 where the maximum smearing
that from the linear one, Fig. 13, with the existence of measure- effect is around ⫺0.37%. This is also due to the negative impact
ment noise. of measurement noise and numerical errors of the Adaptive GPA.
In the second step of the Adaptive GPA, the engine component With the assumptions in diagnostic analysis that the flow capac-
degradation predicted by the linear and the nonlinear Adaptive ity index equals the pressure ratio index for a compressor and the
GPA is shown in Fig. 14 where the predicted deviations of all flow capacity index inversely equals the enthalpy drop index for a
health parameters are compared with the implanted one. It can be turbine, reasonable unique solutions can be obtained from the
seen that the predictions of the degradation from both the linear Adaptive GPA. Although such assumptions are not ideal solutions
and nonlinear approaches are very satisfactory even when all three in diagnostic analysis, it is better than not considering the pressure
major components are degraded simultaneously. The maximum ratio index for compressors and the enthalpy drop index for tur-
prediction error is below 0.3% for both the linear and nonlinear bines. However, such assumptions may be lifted with further in-
approaches. vestigation in this area in the future.
The computational speed of the Adaptive GPA is very fast. For
3.3 Further Discussions. It can be seen in all the three test
example, the computational time is only a fraction of a second to
cases that the maximum prediction errors for both the perfor-
get a solution with the linear Adaptive GPA and about 3 s to get a
mance status estimations 共Figs. 9, 10, and 13兲 and degradation
solution with the nonlinear Adaptive GPA involving 14 iterations
predictions 共Figs. 11, 12, and 14兲 are comparable. Theoretically,
by using a laptop computer with a 2.4 GHz dual processor. Such a
the nonlinear approach has the potential to provide better results
calculation speed provides the possibility that the Adaptive GPA
than its linear partner. However, with the impact of measurement
may be used in online applications. A convergence process for test
noise, the slight difference in prediction accuracies is undermined.
case 3 is shown in Fig. 15 where the rms defined in Eq. 共8兲 varies
Small smearing effect in the diagnostic results can be seen in
against the number of iterations.
4 Conclusions
In this study, a novel Adaptive GPA approach has been devel-
oped and presented. Such Adaptive GPA is a two step approach.
The first step is the novel application of a design point perfor-
mance adaptation to estimate actual performance status of a de-
graded engine and locate the operating point of each engine com-
ponent on its component characteristic map. The second step is a
novel approach introduced in this paper for gas turbine degrada-
tion analysis where the degradation analysis is done at a compo-
nent level by comparing the operating point of each component
when it is degraded with the operating point when it is not de-
graded on its characteristic map. Three degradation indices for a
compressor, one for a combustor, and three for a turbine are used
Fig. 13 Comparison of Adaptive GPA errors in test case 3
Fig. 14 Predicted degradation with Adaptive GPA in test case Fig. 15 Convergence process of nonlinear Adaptive GPA in
3 test case 3
Journal of Engineering for Gas Turbines and Power APRIL 2010, Vol. 132 / 041701-9