DIAGNOSIS OF COMBINED CYCLE GAS TURBINE USING FEED FORWARD NEURAL NETWORKS 5. Camporeate, L. Dambrosio, A, Milella, M. Mastrovit, B. Fortunato Distec. ‘Sea Macchine el ners Politecnico di Ba Via Re Davia 200, 70125 BARI- ITALY Emil camporele@polbait ABSTRACT A diagnostic tool based on Feed Forward Neural Networks (FFNN) is proposed to detect the ‘rin of performance degradation in 8 Combined Cycle Gas Tusbine (CCGT) power plant [In such a plant, due the connection of the steam cycle tothe gas turbine, any deterioration of 28 turbine components affects the gas turbine itself but also the steam eyele. At the same time, fouling of the heat recovery boiler may cause the increase ofthe turbine back: pressure, reducing the gas turbine performance. Therefore, the fault variable set used for detecting Faults in the gas turbine can include measurements taken from the steam cycte The diagnostic tool is composed of wo FFNN stages the frst network stage pre-processes fault data in order to evaluate the influence of the single fault variable on the single fault condition. The second FFNN stage detects the fault condition. The influence of the set of ‘measurements chosen to constitute the neural network training is analysed, taking into account also the effect of uncertainties in the instrumentation, Tests with simulated data show thatthe diagnostic tool i able to recognize single faults onthe CCGT with a high rate of success, in case of fll fault intensity, even in presence of uncertainties in measurements, In case of partial fault intensity, faults concerning gas turbine components. and the superbeater are well recognized, while false alarms occut for the other steam plant ‘component faults, in presence of uncertainties in daa, Finally, some combinations of faults, belonging citer to the gas turbine or the steam plan, have been examined. In this case, the network is applied twice: in the frst step the amount ofthe faut parameters that originate the primary fault ae estimated; in the second step, the diagnostic tool curls the contribution of the main fault to the fault parameters, and the Aiagnostic process is reiterated. In the examined fault combinations, the diagnostic tool vas able to detect at leat one of the two faults, even in presence of uncertainty in measurements and partial Fault intensity. Norartoy G mtfowrac : [ N Fano ed Pome Abbrevitions pre ANN” Aiea! Ne Nework }petomane fr CCT Conined ye Gs Trine 1 Ener FANN Feo Fv Neal Nes Urea raster cot Gh Gos tain oreo HRSG Hen Recon Stam Gente Por meer IG Int Cade Vane SF CORED URALEAT-Gmenzot ISTLHV Low Heating Value sup supetheater RH Relative Humidity evap evaporator ST Steam Turbine econ economizer ‘TET Turbine Entry Temperature d— design point exh exhaust gas Subscripts is isentropic 0. ambient condition st steam mass Mow rate b fuel stack stack gas compressor T turbine CC combined cycle ced compressor discharge 1 INTRODUCTION ‘hn efficient diagnostic tool, able to detect fault conditions at the early stages of thei ‘panifestaion. assumes an essential role for condition monitoring in gas turbine power Plants. This kind of application allows t0 increase the plant components reliability and Frailabity because of the deterioration process results in loss of power and thermal efficiency which together contribute 10 lower revenue and to reduce profitability. Im Combined cycle and cogeneration power plants the degradation of gas turbine components involves not only the gas turbine engine itsel? but also the heat recovery system and the ‘ottoming steam eycle (Boccaeiti eta, 2000: Zovebek and Pilidis, 2001-pat.). ‘Various techniques have been proposed and are curently applied in onder to determine the health sate of stationary gas turbines on the basis of the data collected from the engine jnstrumentation, Some authors investigated the application of the “trend analysis" together ‘with “inverse design” techniques (Bettocchi and Spina, 1999 Bettocchi eta, 2001; Pinel ‘and Venturini, 2002: Benvenuti, 2001) ‘The atfiial ural networks are also very attractive for gas turbine diagnostic, due to their ability to recognize fault paterns, despite the presence of noise. In particular, due to its flexible and straightforward structure, the Feed Forward Neural Networks (FFNN) seem to bre very stitale for fault detection, DePold and Glass (DePold et al, 1999) investigated oural network methods for automated trend detection, Gluch proposed a neural network ‘with back-propagation earning algorithm for thermal turbines diagnosis (Gluch et al, 19%; Gluch etal, 1997) and Lu (La et al, 2001) investigated the isolation of single fault for an ‘ero engine using Artificial Neural Networks (ANN). Probabilistic Neural Network (PNN} ‘vith a feed! forward structure has been proposed for their capability (0 integrate statistical Jrformation about the engine faults (Romessis et al, 2001). A condition monitoring by jeans ofan ato associative back propagation neural network has heen also proposed (Pong erat, 2000), Volponi (Valpon eta, 2000) compared the Kalman filter (KF) method with a puck propagation neural nctwork for engine diagnosis, The simplicity and the high level of ffeodom led the authors to propose a diagnostic tool, based on FTN theory to a heavy-duty gas turbine (Dambrosio era, 2001). ‘The main aim of the present paper is to analyse the problem of fault recognition in & combined cyele power plant composed by an heavy-duty gas turbine and a single pressure tottoming seam eyele. In the first past ofthe paper, the effects ofthe deterioration of gas forhine, heat exchangers and steam turbine components, on the measured parameters are tstimated, through a mathematical rode able to simulate the power plant under deteriorated Conditions Since the performance and measured variables depend on the operating poi the analysis has been caried out under the hypothesis that the gas turbine is suitably185 controlled by & system able to maintain constant the turbine exhaust temperature and the power output, Some selected faults have been modelled and the influence coefficient matix, {that collects the fingerprints of the selected faults, is presented and discussed In the socond part, the proposed FENN-based diagnostic tool is described and applied to detect the considered single fault and also two diferent fauls that occur contemporstiy ‘The capability ofthe diagnostic tool of recognizing the fault itensity is also analysed. The architecture and the complexity of the Arificial Neural Network (ANN) for the given Aiagnostc problem are firstly examined. The authors propose a FFNN-base diagnostic tol that requires limited computational resources to be trained, Such diagnostic tool is composed by a set of FFNNs organized in two stages, The fits stage is specialized to evaluate the influence of each fault condition on each fault variable. The second stage operates a post. processing ofthe output coming from the first FENNs stage and detects the CCGT faults, ‘The described FFNN-based diagnostic too constitutes the fst tool proposed bythe authors, A second tool, detiving from the first achieves the detection of combined fault conditions in {wo different steps, In such a two-step strategy the proposed diagnosis algorithm firstly «detects the mos likely fault condition, estimating also its intensity: secondly, the diagnosis ‘ool subtracts the influence of the detected fault condition from the global influence ofthe ‘combined fault condition and then the detection proces is reiterated, 2. FAULTS ANALYSIS ‘This section investigates the effects of degraded components of a CCGT povser plan. The Plant i composed of asingle-shatt heavy-duty zas turbine and a bottoming steam plant with a single pressure heat recovery steam generator. A sketch of the plant is where the measured variables are also schematically indicated, ‘The gas turbine modelled in this work is the PG6S4-B, manufactured by Nuovo Pignone (Nuovo Pignone, 1990) For simplicity, a single pressure HRSG has been ehosen, instead of 4 more efficent and often adopted double pressure scheme with deaerator. The knowledge of GT and HRSG characteristics is necessary to evaluate the off-design behaviour under Ueteriorated conditions. A preliminary power plant design has been carried out in onler to 82 the parameters needed forthe off-design analysis. As far as the gas turbine is concemed, 4 limited set of information is obtained from the manufacturer's technical pon (Neovo Pignone, 199%) and from commercial simulation tools like GateCycle (Enter Software Ine 1990), The numerical simulation of the gas turbine, under both on-design and offdesign conditions, has been earred out by means of a code, previously developed by two of the authors (Camporeale and Fortunato, 1998). A conventional design procedure, based on ‘signed values of pinch-point and approach point temperature deltas has heen adopted in ‘order to determine the heat exchanger surfaces of the HRSG, Global performance and min characteristics resulting from the design procedure, summarized in Tab. 1, are referred tothe ‘nominal working poi, For the off-design analysis, the compressor is modelled using a normalized map given in {Enter Software Ine. 1990), that provides correted mas flow rate and isentropic eficency 4 a function of corrected rotational speed and pressure ratio. To take into account the Position of variable inlet guide vanes (IGV), the data given by the normalized map are ‘modified according to the formulas given in the same previous reference, A view of the compressor map obtained by means of such a procedure is given in the Fig2, where the GV position effect is shown, The off-design expansion, instead, is examined by means of a siage-by-stage procedure hased on the velocity diagram evaluated at the piteh-line from onstructive data of blade angles and eeosssetional are.