Research Papers: Gas Turbines: Combustion, Fuels, and Emissions

Prediction and Analysis of Impact of Thermal Barrier Coating Oxidation on Gas Turbine Creep Life

[+] Author and Article Information
E. A. Ogiriki

School of Aerospace, Transport
and Manufacturing,
Cranfield University,
Bedford, Cranfield MK43 0AL, UK
e-mail: ebitoski@yahoo.com

Y. G. Li

School of Aerospace, Transport
and Manufacturing,
Cranfield University, Bedford,
Cranfield MK43 0AL, UK
e-mail: i.y.li@cranfield.ac.uk

Th. Nikolaidis

School of Aerospace, Transport
and Manufacturing,
Cranfield University,
Bedford, Cranfield MK43 0AL, UK
e-mail: t.nikolaidis@cranfield.ac.uk

Contributed by the Combustion and Fuels Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received February 19, 2016; final manuscript received June 26, 2016; published online August 2, 2016. Editor: David Wisler.

J. Eng. Gas Turbines Power 138(12), 121501 (Aug 02, 2016) (9 pages) Paper No: GTP-16-1081; doi: 10.1115/1.4034020 History: Received February 19, 2016; Revised June 26, 2016

Thermal barrier coatings (TBCs) have been widely used in the power generation industry to protect turbine blades from damage in hostile operating environment. This allows either a high turbine entry temperature (TET) to be employed or a low percentage of cooling air to be used, both of which will improve the performance and efficiency of gas turbine engines. However, with continuous increases in TET aimed at improving the performance and efficiency of gas turbines, TBCs have become more susceptible to oxidation. Such oxidation has been largely responsible for the premature failure of most TBCs. Nevertheless, existing creep life prediction models that give adequate considerations to the effects of TBC oxidation on creep life are rare. The implication is that the creep life of gas turbines may be estimated more accurately if TBC oxidation is considered. In this paper, a performance-based integrated creep life model has been introduced with the capability of assessing the impact of TBC oxidation on the creep life and performance of gas turbines. The model comprises of a thermal, stress, oxidation, performance, and life estimation models. High pressure turbine (HPT) blades are selected as the life limiting component of gas turbines. Therefore, the integrated model was employed to investigate the effect of several operating conditions on the HPT blades of a model gas turbine engine using a creep factor (CF) approach. The results show that different operating conditions can significantly affect the oxidation rates of TBCs which in turn affect the creep life of HPT blades. For instance, TBC oxidation can speed up the overall life usage of a gas turbine engine from 4.22% to 6.35% within a one-year operation. It is the objective of this research that the developed method may assist gas turbine users in selecting the best mission profile that will minimize maintenance and operating costs while giving the best engine availability.

Copyright © 2016 by ASME
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Fig. 1

Integrated creep life assessment model

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Fig. 2

Schematic diagram of the blade and gas directions

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Fig. 3

Average radial temperature distribution profile at the inlet of a turbine rotor blade

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Fig. 4

Blade centrifugal forces

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Fig. 5

Temperature profile of a blade with TBC and film cooling

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Fig. 6

Layout of two-shaft aeroderivative engine

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Fig. 7

Strain effects on TBC life at different TBCs

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Fig. 8

Effect of TET on TBC life at different PCN

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Fig. 9

Ambient temperature effects on TBC life at different strain

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Fig. 10

Effect of TBC failure on blade temperature

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Fig. 11

Blade metal temperature deviation due to different TETs

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Fig. 12

TBC oxidation on blade creep life at different TETs and strain levels

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Fig. 13

Day temperature profile

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Fig. 14

PCN variation for different ambient conditions at constant power

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Fig. 15

TET variation for different ambient temperature at constant power

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Fig. 16

Creep variation during winter

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Fig. 17

Creep variation during summer

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Fig. 18

Creep and oxidation effects

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Fig. 19

Impact of TBC oxidation on the overall life usage




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