V004t14a003 85 GT 102
V004t14a003 85 GT 102
V004t14a003 85 GT 102
ABSTRACT
This paper presents a study into the application of Recently, users of turbomachinery have become interested
Artificial Intelligence (AI) techniques (specifically Expert in the use of computer based systems for health mon-
Systems) to the problem of turbomachine diagnostics. The itoring. These Systems obtain both mechanical (vibration)
diagnostic process is described and a model for computer data as well as aerothermal (temperatures, pressures and
implementation provided. Some diagnostic examples are flows) in order to firm a prognosis and diagnosis of machine
provided to explain the methodology. Expert system health. [1][2][3]. While these systems provide a high level
development is underway at the author's corporation for of diagnostics for specific operating problems the system
incorporation in online monitoring and diagnostic systems. cannot be classified as an "expert" system. This paper
examines the concepts and feasibility as to how existing
INTRODUCTION AND NEED advanced monitoring and diagnostic systems can be inte-
grated within an expert system framework. The expert
The increasing sophistication of modern high speed turbo- system would then act as an aid to the troubleshooting
machinery with higher horsepowers and speeds has been engineers. While it is thought by some that expert systems
accompanied with a wide range of operating problems. are designed to "out think experts" the author envisions the
With critical machines in the petrochemical industry, down expert system to act as an aid to the troubleshooting
time costs (which can exceed $1 million/day) are pro- engineer. Moreover, expert systems for turbomachinery
hibitively high creating need for rapid means for diagnosis diagnostics would be a valuable training aid for young
and troubleshooting. Moreover, with increasing fuel costs engineers enabling them to "think through" complex op-
the need to operate units efficiently is paramount. erating problems via a keyboard.
Traditionally, troubleshooting and diagnostics of complex An "Expert System" is an intelligent computer code that
turbomachinery problems calls for an individual with both uses knowledge inference procedures to solve problems that
analytical skills and a wealth of experience so that he can are difficult enough to require significant human expertise
draw and integrate the complex data available to him, form for their solution. The knowledge base of an expert system
preliminary hypotheses, suggest tests and ultimately diag- consists of facts and heuristics. The facts constitute a
nose the operating problem. It is a practical reality that body of information that is widely shared and generally
there is always movement of these experts and often agreed upon by experts in a field. The heuristics are rules
vacuums are created when an experienced machinery of judgement and rules of good guessing that characterize
engineer leaves or is reassigned. In cases like this, young expert-level decision making in the field. An overview of
engineers have to build up experience, and develop heur- expert systems is provided by Hayes-Roth Et al [4] and
istics relating to diagnostics the hard way. Several large Davis [5]. Expert systems utilize IF-THEN rules (also
petrochemical organizations have developed some excellent known as "production" rules to codify knowledge.
maintenance manuals incorporating years of experience in
an attempt to avoid a "knowledge vacuum". Once again BASIC LOGIC FOR DIAGNOSTICS AND TROUBLESHOOTING
practical reality shows us that these manuals are either not OF TURBOMACHINES
consulted or specific information can not be located within
a short time frame. Current machinery health monitoring and diagnostic sys-
tems employ Boolean logic operations for diagnostic pur-
This paper examines the feasibility of a computer based poses. Considerable work has been also accomplished in
trouble-shooting/diagnostics procedure utilizing techniques the area of Vibration Diagnostics and in the integration of
and methodology developed in the Artificial Intelligence vibration and aerothermal diagnostics for gas turbines and
(AI) field. centrifugal compressors [1][2].
History &
Walk around Inspection
. Vibration Analysis
Low Level Discriptors
(Signs & Symptoms)
Two fundamental problems in setting up expert systems for
Tests . Log-Sheet Review troubleshooting diagnosis turbomachinery are:
. Lube Oil Tests . Efficiency Drop
. Maintenance Review . Vibration
. Data Analysis, etc. . Noise 1. The wide variety of machine types of varying aero-
. Operating Behavior
dynamic characteristics. Even machines of a similar
-Y type (say centrifugal machines) are so widely dif-
Sensors &
Probabilistic Description Observations "-/ ferent e.g., a gas compressor vs. a centrifugal pump).
of Initial State St
(Generate set of Machine
hypothesis as to Problem 2. Continuous changes in design concepts. Different
what problem is) designs of impellers, bearings and auxiliary systems
Heuristic Search to
apply best Ti
create several idiosyncracies that are more than
often not predictable by the use of analytical tech-
— Run Under Increase..
Surveillance
niques.
Repair
Change Lube Oil Temp. In addition to these two fundamental problems several
[Ti Realign minor problems exist:
Balance
(a) Complex interrelationships between mechanical
and aerothermal problems
_ Etc.
EXHAUST
• Coupling Problems
LOA
By Model Type
FUEL
COMBUSTOR
POWER TURBINE
OD\ PRESSOR
I/AR/gaze Apr
There are several important points that emerge from a Figure 4 shows how abductive logic can be applied in a
study of general troubleshooting methodology. Firstly, troubleshooting/diagnostic framework. The rough proce-
problem manifestations are statistically dependent and not dure would be as follows:
mutually exclusive; thus, diagnostic methods based on
Bayes rules are not always valid. For example, in the case 1. Obtain information (via keyboard). This would be an
of gears, misalignment may be accompanied by both tooth interactive query type session. In certain cases,
fracture and surface distress. Secondly, experienced online data acquisition can be used.
troubleshooters think in a "diffuse" manner, i.e., their
reasoning is not necessarily "step-by-step". Diagnosis is 2. For each manifestation, the EVOKE operator would
made in general terms and then progressive refinements evoke a problem Set Pi.
are made until underlying causes have been identified.
Thirdly, problems in machinery may be classified in a 3. For each Problem Pi, lists A,B,C&D would be cre-
hierarchal structure in which certain class of problems may ated. These lists essentially indicate how close the
be a subset of a larger problem category. Moreover, often manifestations "match" the problem under consid-
times, problems of a certain class will give rise to similar eration. If a particular problem has been previously
or even the same manifestation. For example, oil whirl is evoked then the lists A,B,C&D would be updated.
a subclass of subsynchronous instability problems.
4. Hypotheses (regarding problems) are then screened
Abductive logic (method of hypothesis) is a means by which and a top few selected. Dominance of two Hypo-
a set of observations (manifestations of a problem) is used theses H1 and H2 is established by checking if the list
to evoke a set of hypotheses. As certain manifestations "A" for H1, less items explained by previous diag-
could evoke several hypothesis, a weighting procedure noses, is a subset of a similar construct of H2. If it
should be used. For example, in the Gas Turbine shown in is a subset, then H1 is dominant.
Figure 3, a drop in output power could be caused by
compressor fouling, internal seal leakages, external leak- 5. Once hypotheses have been narrowed down, by spec-
ages, drop in turbine efficiency, drop in combustor effi- ific tests or questions, an action recommendation can
ciency, etc. The most common (likely) hypotheses would be be developed by the engineer using the expert system.
compressor fouling, seal leakage problems or turbine
damage. For example, if we consider the case of a split shaft
turbine under constant power, the symptoms [12] shown in
Each of these hypotheses would then generate a set of Figure 5(a) will lead to the conclusion of a fouled
consequences. Then hypotheses would have to be grouped compressor. The case under constant speed is more
together into mutually exclusive subsets corresponding to difficult as the manifestations are qualitatively the same.
specific problem areas. Based on a structure proposed by The manifestations evoke hypotheses of "fouled comp-
Pople [11], a theoretical framework is now developed for ressor" and "increase in the area of the low pressure
diagnostics of a type of turbomachine. Three relations may turbine". In this event the expert system would request a
be defined: quantitative description which would allow discrimination
between compressor fouling and a drop in low pressure
1. E (M, P) This relates to the Evocative association turbine nozzle area. The case of constant speed operation
that Manifestation M has for a Problem P. is shown in Figure 5(b).
3
or EgVir','eYnt'res
IF
Change process
Run Machine Under Repair at Scheduled Routine Shutdown ..... conditions—flow, speed,
Close watch time temperatures, etc.
Figure 6 shows a conceptual hierarchal tree for a M.D. 2. Load decreased 16.5% (M2)
steam turbine showing how a manifestation of "insufficient
power" can be used to evoke a variety of problems. It can 3. First Stage Pressure increased 21.2% (M3)
also be seen that low efficiency is a problem caused by
another problem, fouling, gland seal leakage, etc. 4. HP Section efficiency dropped 12.2% (M4)
For example, based on a case reported by Cotton &
Schofield [13] is now presented. A turbo-generator started
losing output at a rate of 1.2 MW/day after operation for
21 months. All changes noted below were gradual:
1. Throttle flow rate dropped 17.2% (Manifestation M1)
Process
Problems
P2.4 Low Vacuum Noise
P2
Aerodynamic
Problems
P4.1 Damaged Blades St Vanes
P4
Foreign Object Damage. Symptoms would be an Damaged Turbine Blade. This results in a
increase in Turbine Inlet Temperature, a drop in Pressure vibration increase accompanied by an increase in the
Ratio and a reduction in Shaft Horsepower. exhaust temperature.
Nozzle Erosion (Power Turbine). -This would be [6] Tuft, R. H. "No! Our Condition Monitoring Techniques
indicated by a drop in Turbine Inlet Temperature, a drop in are Not Adequate". Editorial in Sound and Vibration,
Shaft horsepower and a drop in Pressure Ratio. Constant P. 5, April, 1984.
N1 speed assumed.
[7] Sohre, J. S. "Operating Problems with High Speed
Nozzle Erosion (Gas Generator Turbine). Symp- Turbomachinery, Causes and Corrections". ASME
toms would be an increase in Turbine Inlet Temperature, Petroleum Mechanical Engineering Conference, Dal-
increase in Shaft Horsepower, increase in Fuel Flow and a las, Texas, November, 1968.
drop in Pressure Ratio. Constant N1 speed assumed.
[8] Sohre, J. S. "Reliability Evaluation of Troubleshooting
CONCLUSIONS of High-Speed Turbomachinery", ASME Petroleum
Mechanical Engineering Conference, Denver, 1970.
Based on this study, expert systems in the field of
turbomachinery are being developed. These systems will be [9] Broekmate, A., "Diagnosis of Machinery Vibration"
for specific machine types and will be used to assist DSM Research and Patent Dept., Equipment Testing
troubleshooters in decision making. Time estimates for Center, Geelen, Holland.
developing a reasonable expert system for a generic class
of turbomachine is estimated to be about 2 to 3 man years. [10] Sohre, J. S. "Common Sense in Turbomachinery
Troubleshooting". Informal Keynote Address pre-
Expert systems developed, will be useful tools in helping sented at the Vibration Institute, Chicago, Illinois,
engineers troubleshoot a wide variety of problems. AI March 30, 1982.
techniques, coupled with development in areas such as
fuzzy set-theory, have the capability of providing very [11] Pople, H. E., Jr., Et. Al. "DIALOG: A Model of
powerful aids to diagnostic engineers. Diagnostic Logic for Internal Medicine". Proceedings
of the Fourth International Joint Conference on
ACKNOWLEDGEMENTS Artificial Intelligence, September, 1975. pp 848-855.
The author wishes to thank J. E. Broussard and H. T. [12] Saravanamutto, H.I.H. and McIsaac, B.D., "Thermo-
Sethna for their assistance in preparing this paper. dynamic Models for Pipeline Gas Turbine diagnostics".
ASME Paper No. 83-GT-235.
REFERENCES
[13] Cotton, K. C. and Scofield, 0. "Analysis of Changes
[1] Boyce, M. P. and Meher-Homji, C. B. "Aerothermal in the Performance Characteristics of Steam Tur-
Mechanical Health Monitoring and Diagnostics of bines". ASME Journal Engineering for Power, April,
Turbocompressors". Proceedings of the Eleventh 1971, pp. 225-237.
Turbomachinery Symposium, Texas A&M University,
December, 1982. [14] Zadeh, L. A. "Fuzzy Sets". Information and Control,
Vol. 8, pp. 338-353 (1965).
[2] Boyce, M. P., Meher-Homji, C. B. and Mani, G., Th e
Design and Development of Advanced Online Mon- [15] Gupta, M. M., "Fuzzy Information in Decision An-
itoring and Diagnostic Systems for Gas Turbines". alysis". IEEE Conference on Cybernetics and Society,
1983 Tokyo Joint International Gas Turbine Con- October 28-30, 1982, Seattle, Washington.
ference, Paper #83-Tokyo-IGTC-04. November, 1983.
[16] Zaba, T., "Losses in Gas Turbines Due to Deposits on
[3] Boyce, M. P., Et. Al. "Operating Experience With Blading", Brown Boveri Review, 12-1980, p. 716.
Health Monitoring and Diagnostics of MD Steam
Turbines and Centrifugal Compressors". ASME Joint
Power Generation Conference, Indianapolis, Sept.,
1983. ASME Paper #83-JPGC-PWR 28.