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Saji Kumar S.,Hindustan Aeronautics Ltd | Muthu S.E.,Hindustan Aeronautics Ltd | Dileep S.,Hindustan Aeronautics Ltd | Mishra R.K.,Regional Center for Military Airworthiness Engines
ASME 2013 Gas Turbine India Conference, GTINDIA 2013

Compressor washing is commonly used in gas turbine engines to retrieve engine power. Severity of fouling should be known to decide on mounted or uninstalled washing and also to optimize the time and money. The present study aims to develop a system for predicting and scheduling the washing process. One 1 MW turbo shaft engine has been taken as the model for this study. The deviations in performance parameters have been quantified based on test data over a period. Deterioration of engine health parameters namely efficiency and flow capability of compressor, gas generator turbine and power turbine are considered for analysis. Sensitivity analysis and ranking of the measurements were done using a correlative technique suggested by Stamatis. The interdependency and observability of the measurements were checked. The fault signatures of selected measurement set on component degradations were isolated and estimation charts were formed to predict the optimum time intervals for compressor washing. The study forms a base platform to apply techniques like artificial neural networks for the accurate forecasting of optimum cleaning intervals for turbo shaft engines. Copyright © 2013 by ASME. Source

Mishra R.K.,Regional Center for Military Airworthiness Engines | Thomas J.,Hindustan Aeronautics Ltd Engine Division | Srinivasan K.,Hindustan Aeronautics Ltd Engine Division | Ahmed S.I.,Aeronautical Quality Assurance Engines
Journal of Failure Analysis and Prevention

Failure of low-pressure compressor rotor blade in an aero gas turbine engine is analyzed to determine its root cause. Forensic and metallurgical investigations are carried out on the blade failed. The failure of the first stage rotor blade is found to be the first in the chain of events that led to the engine failure. The mode of failure in the blade is found to be fatigue and has originated from the mounting lug fillet region due to high stress concentrations. The failure has caused extensive damages in low-pressure compressor module and also in downstream modules as a secondary effect. Remedial measures are also suggested to prevent such failures. © 2014 ASM International. Source

Mishra R.K.,Regional Center for Military Airworthiness Engines | Thomas J.,Hindustan Aeronautics Ltd
Journal of Failure Analysis and Prevention

During altitude maneuver loud bang sound was observed followed by rapid winding down of engine rotation and jet pipe temperature. Compressor casing top half was found severely ruptured and broken into many pieces. On viewing through the ruptured area compressor rotor blades were found sheared at the root. Systematic investigation revealed that the failure of compressor casing was due to sudden overload. Analyzing the possible reasons of sudden overload it could be concluded that the rupture of compressor casing was most probably due to surge during the maneuvers. Remedial measures are suggested to address such failures. © ASM International 2014. Source

Mishra R.K.,Regional Center for Military Airworthiness Engines
Journal of Failure Analysis and Prevention

This paper deals with the study carried out on fouling and corrosion problems in an aero gas turbine engine which operates from coastal environment. Various parameters responsible for such problems are presented in the paper which causes deterioration in performance and leads to failure of the components. Prevention and control procedures for fouling and corrosion are also highlighted. Compressor washes such as performance recovery wash and desalination wash are found to be very effective in addressing these issues. The frequency of compressor wash is to be judiciously worked out from the corrosion rate and performance deterioration points of view. © 2015, ASM International. Source

Mishra R.K.,Regional Center for Military Airworthiness Engines | Beura C.,Hindustan Aeronautics Ltd
Journal of Failure Analysis and Prevention

This paper deals with the performance study and life consumption assessment of a long range civil aircraft engine with respect to take-off variables like airport altitude, ambient temperature, thrust levels, and flight duration. The component selected for lifing analysis is the first stage high pressure turbine blade/disk of a 430 kN thrust engine. Performance tools like TURBOMATCH and HERMES are validated against the published data, with deviation less than 4%. Based on failure modes like low cycle fatigue, creep, and oxidation, the integrated lifing tool is used to estimate the severity indices at various offdesign conditions. It is observed that creep is the main criteria in blade failure due to extreme high temperature gas coming from combustor, whereas for disk it is fatigue due to repeated stresses with varying shaft speeds. With increase in airport altitude, the blade and disk severity increases with respect to that at sea level conditions. As the ambient temperature goes up, blade severity also increases as well but the change in disk severity is not as much due to less change in spool speed. Operating with reduced thrust, both the blade and disk severity decreases with deratings. As flight duration increases with reference to a standard mission, both the component damages go up but the blade severity is more pronounced than the disk due to exposure to high temperature for a long time. As a whole, the total damage severity of disk and blade assembly increases with rise in altitude, outside air temperature, and mission duration and decreases with engine deratings. © ASM International 2014. Source

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