The development of modern gas turbines is accompanied by an extensive prototype testing. To evaluate performance, the engines are fitted with a substantial number of sensors measuring pressures, temperatures, shaft speeds etc. The test data is analyzed by procedures calculating data that is not directly measured, e. g. component efficiencies and turbine temperatures. Engine manufacturers usually apply such procedures for a detailed analysis after the test (offline) as well as to ensure a safe and efficient engine operation during the test (online). Especially for the latter application, a fast and reliable assessment of the performance of the engine and its components as well as a fast and reliable detection of measurement faults is required. The paper describes a fully automated performance analysis procedure for offline as well as for online applications. Basis of the procedure is a full thermodynamic model representing the expected behavior of the engine to be tested. By such a model-based analysis procedure a comparison between test data and the expected engine behavior is performed. The way the comparison is done allows detecting and isolating measurement faults and component malfunctions. In case of a detected measurement fault, the measurement will be excluded automatically from the analysis. At MTU Aero Engines GmbH the procedure is regularly applied for online and offline test data analysis of different engine types. Compared to the procedures used so far, a lot of measurement faults can be detected quickly and reliably.

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