Avoidance of Gas Turbine Failure Using Metallurgical Analysis and Engine Health Monitoring as Predictive Tools Available to Purchase

Combining metallurgical analysis with performance analysis is a powerful tool for engine health monitoring and can aid in determining the root cause of component failure. A case study is presented for an industrial gas turbine engine operating at BP Watson Cogeneration Company in Carson, California where accelerated material aging and coating depletion were found in the first-stage turbine buckets after an engine up-rate to an increased firing temperature. After the material degradation was discovered, the engine was intended to be derated back to its original firing temperature, however, the performance analysis found the engine was still operating in a higher firing condition which would have continued to cause accelerated damage to the turbine buckets if not detected. Through combined analysis efforts, the error was found and corrected before the units failed from overheating.