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Automatic identification of malfunctions of large turbomachinery during transient states with genetic algorithm optimization

Barszcz Tomasz, Zabaryłło Mateusz

Metrology and Measurement Systems

2022

Vol. 29, nr 1

175--190

Turbines and generators operating in the power generation industry are a major source of electrical energy worldwide. These are critical machines and their malfunctions should be detected in advance in order to avoid catastrophic failures and unplanned shutdowns. A maintenance strategy which enables to detect malfunctions at early stages of their existence plays a crucial role in facilities using such types of machinery. The best source of data applied for assessment of the technical condition are the transient data measured during start-ups and coast-downs. Most of the proposed methods using signal decomposition are applied to small machines with a rolling element bearing in steady-state operation with a shaft considered as a rigid body. The machines examined in the authors’ research operate above their first critical rotational speed interval and thus their shafts are considered to be flexible and are equipped with a hydrodynamic sliding bearing. Such an arrangement introduces significant complexity to the analysis of the machine behavior, and consequently, analyzing such data requires a highly skilled human expert. The main novelty proposed in the paper is the decomposition of transient vibration data into components responsible for particular failure modes. The method is automated and can be used for identification of turbogenerator malfunctions. Each parameter of a particular decomposed function has its physical representation and can help the maintenance staff to operate the machine properly. The parameters can also be used by the managing personnel to plan overhauls more precisely. The method has been validated on real-life data originating from a 200 MW class turbine. The real-life field data, along with the data generated by means of the commercial software utilized in GE’s engineering department for this particular class of machines, was used as the reference data set for an unbalanced response during the transients in question.

Concept of automated malfunction detection of large turbomachinery using machine learning on transient data

Barszcz Tomasz, Zabaryłło Mateusz

Diagnostyka

2019

Vol. 20, No. 1

63--71

Large turbosets constitute a major source of electric energy in the world. They are critical machines which are vulnerable to several malfunctions which can decrease their availability and degrade the operation of the national electric grid system. The best source of data for assessment of the technical state are the transient data, measured during run-ups and coast-downs. The size of this data is very large and its analysis can be only performed by highly skilled vibration experts. The goal of this paper is to propose a method, which can apply Machine Learning for automated fault detection. In order to improve the quality of the learning process the method is accompanied by the ‘Digital Twin’ approach, where the simplified analytical rotordynamic model is tuned to a particular turboset and used in the learning process.

Turbozespoły dużej mocy stanowią znaczną część źródeł energii elektrycznej na świecie. Są to maszyny krytyczne, które są wrażliwe na kilka rodzajów niesprawności. Mogą one obniżyć dyspozycyjność maszyn i wpłynąć negatywnie na prace całego systemu elektroenergetycznego. Najlepszym źródłem danych do oceny stanu dynamicznego są dane ze stanów przejściowych, mierzone podczas rozruchów i odstawień. Są to dane o bardzo dużych rozmiarach a ich analiza może być przeprowadzana tylko przez doświadczonych diagnostów. Celem artykułu jest propozycja metody, wykorzystującej metody uczenia maszynowego (Machine Learning) do automatycznego wykrywania uszkodzeń. W celu podniesienia jakości procesu uczenia metoda została uzupełniona o zastosowanie uproszczonego modelu analitycznego stanu dynamicznego turbozespołu. Model ten jest dostrajany do danego turbozespołu, a następnie stosowany do wygenerowania dodatkowych danych ze stanów przejściowych, które będą następnie użyte w procesie uczenia.