Life Management and Extension Studies

8/2/2019 Life Management and Extension Studies

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Life Management and Extension StudiesSeveral life management and extension (LM&E) studies for hot section components of various turbinesare performed at Southwest Research Institute (SwRI). The methodology for LM&E includes:

Condition Assessment

Material and coating degradation

Material properties evaluation Nondestructive evaluation

Stress Analysis

Mechanical analysis

Aero and thermal stress analysis

Vibration analysis and frequency testing Life Evaluation

Failure modes

Life evaluation methodology

Turbine Condition Assessments

SwRI performs condition assessments of hot section components to evaluate the extent of basematerial and coating degradation and to help clients make run, repair, and replacement decisions.

We have developed algorithms and computerized programs for life prediction, life management, and lifeextension of gas turbine engines to increase component usage, maximize engine availability, andreduce maintenance costs.

We have has also developed methodologies and software to predict the life of gas turbine hot sectionblades for GE frame gas turbines. Extensive materials testing of new and service-exposed componentswas conducted to develop pertinent material properties, which were used in the life assessmentalgorithm and software, GTD LIFE. Using these data in their turbine fleet life management program,clients can realize economic gains by prudently scheduling the inspection and maintenance intervalswhile maintaining good availability and reliability of their engines.

SwRI can offer you a full range of capabilities and experience in gas turbine technology includingbecoming an extension of your engineering department.For more information about our gas turbine life

management and extension studies and capabilities, or how you can contract with SwRI, pleasecontactKlaus Brun, Ph.D., [email protected] (210) 522-5449.

gasturbine.swri.org
http://www.swri.org/4org/d18/mechflu/planteng/gasturb/conditas.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/conditas.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/stresthr.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/stresthr.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/lifevalu.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/lifevalu.htmhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nmailto:[email protected];[email protected]?subject=Life%20Management%20and%20Extension%20Studiesmailto:[email protected];[email protected]?subject=Life%20Management%20and%20Extension%20Studiesmailto:[email protected];[email protected]?subject=Life%20Management%20and%20Extension%20Studieshttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmmailto:[email protected];[email protected]?subject=Life%20Management%20and%20Extension%20Studieshttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/lifevalu.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/stresthr.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/conditas.htm


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he most current technology, including finite element and boundary element methods, is applied to thestress analysis of gas turbine components at Southwest Research Institute (SwRI). SwRI is a pioneer inprobabilistic structural mechanics, which integrates computational mechanics and probabilistic methodsto manage distribution of material properties, dimensions, and loads. Computational facilities include acentral VAX computer, distributed workstations, and access to CRAY supercomputers. Availablenumerical codes include ABAQUS, ANSYS, and NASTRAN.

Two of the vibrational modes of a space

shuttle APU turbine blade are shown. SwRI

combined its vibrational analysis with

Institute-developed probabilistic structural

analysis methods to determine allowable

inspection intervals. NASA is using the results

for engine maintenance.

Air-cooled gas turbine blades have complex

temperature and stress profiles. Temperatures are

shown in the upper figure and longitudinal stresses

are below. This analysis uses a generalized plane

strain finite element methodology.

SwRI can offer you a full range of capabilities and experience in gas turbine technology includingbecoming an extension of your engineering department.For more information about our gas turbinestress and thermal analysis capabilities, or how you can contract with SwRI, please contactKlaus Brun,

Ph.D., [email protected] (210) 522-5449.

gasturbine.swri.org
http://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nmailto:[email protected];[email protected]?subject=Stress%20and%20Thermal%20Analysismailto:[email protected];[email protected]?subject=Stress%20and%20Thermal%20Analysismailto:[email protected];[email protected]?subject=Stress%20and%20Thermal%20Analysishttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmmailto:[email protected];[email protected]?subject=Stress%20and%20Thermal%20Analysishttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205n


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Failure Modes

To evaluate the life of components, it is essential to identify the probable failure modes for a givencomponent. The possible failure modes for hot section components include thermal mechanical fatigue(TMF), hot corrosion, creep, and coating oxidation and degradation.

Engineers at Southwest Research Institute (SwRI) examine the parts using state-of-the-art laboratory

facilities. They examine hot section parts failed in service and identify the most probable cause offailure.

Life Evaluation Methodology

In gas turbines, the life and integrity of the coatings, applied to protect the components fromenvironmental attack and degradation, govern the life and maintenance intervals of hot sectioncomponents. SwRI has developed state-of-the-art coating and TMF life prediction methods for severalsubstrate/coating systems. The TMF model has been calibrated with service experience and can beused to predict the life of a specific coating on turbine blades in service.

Through an industry consortium program, GTD LIFE software was developed to calculate the remaininglife of GE MS5002 engine first-stage buckets. This software is available to turbine users.

Coating Oxidation Coating Degradation

Photomicrographs showing bond coating oxidation and degradation

Photograph of a corrosion-attacked area on a Frame 5 blade

after 40,000 hours of service

Flow diagram shows the tasks required to develop a life

management system for determining the life of gas turbine

components. SwRI is one of the few organizations capable of

performing each step in the development of these systems.
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Metallography Results COATLIFE Calculation

Click photo for larger image Click photo for larger image

In-service degraded coating of a 7FA blade (left) and a 9FA b lade (right) after

21,000 hours of service

COATLIFE validation for Frame 7/9FA

blades (GT29+ coating). Model

prediction is in good agreement with

metallographic results.

Metallography Results COATLIFE Calculation

Click photo for larger image Click photo for larger

image

Click graph for larger image

7FA blade after 21,000 hours of

service

9FA blade after 17,000

hours of service

TMF model validation for Frame 7FA and 9FA blades. Model

prediction is in good agreement with metallographic results.

Typical interface cracking and crack growth as a function of

time

Cracking at the bond coat/ thermal barrier coating (TBC)

interface leads to TBC spallation. The results generated at SwRI

show that these cracks form at the early stages of component

life.

SwRI can offer you a full range of capabilities and experience in gas turbine technology includingbecoming an extension of your engineering department.For more information about our gas turbine life
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evaluation capabilities, or how you can contract with SwRI, please contactKlaus Brun, Ph.D.,[email protected] (210) 522-5449.

gasturbine.swri.org
http://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205nmailto:[email protected];[email protected]?subject=Life%20Evaluationmailto:[email protected];[email protected]?subject=Life%20Evaluationmailto:[email protected];[email protected]?subject=Life%20Evaluationhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmhttp://www.swri.org/4org/d18/mechflu/planteng/gasturb/default.htmmailto:[email protected];[email protected]?subject=Life%20Evaluationhttp://www.swri.org/iProfiles/ViewiProfile.asp?k=367zf00k4a8205n

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Life Management and Extension Studies