Gas Turbine Engine Inspection - Laboratory Activity 2

Introduction
Gas turbine engines are of paramount importance in contemporary power generation,
marine, and aerospace sectors. These engines, which are renowned for their exceptional power
generation and efficiency, are critical for the operation of ships, aircraft, and power plants.
Therefore, it is critical to establish rigorous and systematic inspection protocols to ensure their
functionality and dependability. Regular and comprehensive evaluations are imperative for gas
turbine engines due to their complex structure and the demanding operational conditions they
encounter. It is of the utmost importance that these inspections promptly identify and resolve
any potential issues prior to their escalation into catastrophic failures. Through the
implementation of these inspections, we safeguard the operational soundness of the turbines
and augment their lifespan and productivity, thereby making a significant contribution to safety
and economic results.
Gas turbine engine inspections are critical for optimizing performance and adhering to
stringent regulatory standards. These inspections enable the prompt detection of deterioration
such as corrosion, erosion, and other forms that could potentially undermine the performance of
the engine. For example, components that are exposed to elevated temperatures and pressures
are susceptible to thermal fatigue and material erosion. Failure to promptly detect and address
these issues can result in substantial degradation of performance. Inspections are of utmost
importance in maintaining the mechanical soundness of critical components, thus averting
unanticipated periods of inactivity and costly repairs. This guarantees the uninterrupted
progression of activities at their peak efficiency. Furthermore, continuous adherence to
regulatory requirements via routine inspections is critical for maintaining certification and
operational licenses, which are fundamental for ensuring both legal and commercial viability
(Bohlin & Steinert, 2009).
The inspection of gas turbine engines is a critical component in the pursuit of improving
efficiency and maximizing performance. Consistency in component operation with
predetermined specifications is critical for maintaining the overall efficacy of the engine.
Consistent inspections facilitate the identification of degradations in performance, including
those caused by material depletion or component erosion, thereby enabling the implementation
of timely remedial actions. Adopting this proactive stance not only enhances fuel efficiency and
reduces emissions but also prolongs the engine's lifecycle, leading to significant long-term cost
benefits (TMI Staff, 2014).
Body
Gas turbines are intricate devices that necessitate immediate maintenance and
inspections to guarantee peak performance and avoid periods of inactivity. Gas turbines are
widely used in various applications, such as electricity generation and airplane propulsion.
Ensuring their optimal function and safety relies on parts inspection. Thus , listed below are the
kinds of inspection in gas turbine engines:
Inspections for Maintenance: The inclusion of a wide range of inspections,
evaluations, and diagnostics enables a cooperative and data-based examination of gas
turbine equipment and their supplementary equipment. The efficiency of a facility's
turbomachinery has a direct effect on the financial success of the company. In order to
effectively manage their assets and finances, businesses need to be knowledgeable
about the health criteria of their equipment and identify areas where it is not working
optimally and what the specific shortcomings are. The primary objective is to rectify any
shortcomings identified through inspections in order to minimize the likelihood of a
system failure due to unforeseen circumstances.

Figure 1. Maintenance Inspection

Combustion Section Inspection: The condition of the hot combustion section is a

crucial determinant of the operational lifespan of a gas turbine engine. This involves the
examination and purification of the heated combustion area, which consists of the
combustion liners and cans, end caps, fuel nozzle assemblies, crossfire tubes, and
transition pieces. Prior to disassembling the exterior combustion casing, it is necessary
to examine it for any indications of exhaust leaks, hotspots, or deformities. Once the
combustion casing is opened, it is necessary to examine the combustion chambers for
signs of localized overheating and erosion, excessive wear, or cracks. The inspection
typically encompasses the examination of the combustion chamber outlet ducts, covers,
and turbine fuel nozzle for any obstructions, fractures, cavities, or corrosion. Additionally,
it involves inspecting the first stage turbine blades and nozzle guiding vanes for any
deformations, fractures, or damage caused by foreign objects. Furthermore, in
applications involving high salt water or other chemicals, it is often advisable to do a
comprehensive washing of the turbine. Moreover, employing the chlorinated solvent
approach for cleaning guarantees that the parts are completely devoid of any moisture.
Also, If two cracks are discovered originating from a free edge and showing clear
indications of converging towards the center over time, it is necessary to replace or
repair the combustion chamber.

Figure 2. Inspection of Combustion Section

Hot Gas Path Inspection: The gas turbine engine's components that are exposed to
the high temperature gasses emitted from the hot combustion section are subject to
extensive surveillance and condition monitoring. Typically, a comprehensive hot gas
route inspection encompasses an examination of the combustion system components as
well as a complete assessment of the turbine nozzles, shrouds, blades, buckets,
bearings, rotor, cross-fire tubes, fuel nozzle sets, and turbine casing.
 Figure 3. Hot Gas Path Inspection

Borescope Inspection: Borescope examination provides a cost-effective means of

visually examining the internal components of a turbine, such as the gas channel, rotor,
or impeller blades. These locations would be extremely difficult to access and observe
without the necessity for lengthy and intrusive equipment disassembly. This process
often results in a significant interruption of the system or plant, as the complete turbine
casing needs to be removed. Borescopes are equipped with both rigid and flexible cable
options, a lighting and optical system, and an eyepiece or digital screen for viewing the
inspection track. They are available in lengths up to 30 feet, providing sufficient coverage
for inspections of that nature. By utilizing a flexible and articulating video borescope for
the necessary inspections, the need for manpower, rigging, and maintenance
expenditures associated with dismantling equipment of this magnitude is effectively
eliminated. Furthermore, a significant portion of the examination of the hot gas path and
combustion section can be carried out using a borescope inspection.

Figure 4. Borescope Inspection

Alignment and measurements: Accurate and precise measurements allow for the
development of targeted data-driven repair strategies or simple component alignments,
while also retaining the data for longer term trending. Some of the common
measurement and alignment scope includes:

● Internal alignment measurements and realignment involve assessing the internal

bore to verify the proper alignment of bearings, diaphragms, and stationary
turbine components. This is done to minimize excessive vibrations.
● Alignment of shafts and couplings, ensuring they are concentric and free from
runouts.
● Measurement of the evenness and smoothness of a shell casing
● Dimensional analysis of turbine shape and mapping of joint surfaces in both
horizontal and vertical orientations.
● The parameters of interest include the axial clearance of the turbine nozzle, the
clearance between the blade tip and the surrounding components, and the
clearances of the bearings, among others.
● Verification of critical dimensions, such as those found in journal bearings, by
tolerance checks.

Figure 5. Alignment and Measurements of Engine Parts

Non-destructive testing/examination (NDT/NDE): Advanced non-destructive testing

(NDT) and non-destructive evaluation (NDE) technologies enable the early detection of
material faults and defects with a high probability of detection (POD). Modern
technologies have the capability to identify even the tiniest imperfections in turbine
 components that have the potential to restrict equipment functionality and increase the
likelihood of additional damage to the asset. The testing methods are specifically
developed to identify prevalent failure modes in gas turbines, such as corrosion,
cracking, fatigue, weld defects, and leaks. This enables organizations to make important
asset management decisions by optimizing maintenance resources.

Figure 6. Non Destructive Testing

On the other hand, gas turbine engines are subjected to severe operating conditions,
including persistent exposure to elevated temperatures, pressures, and abrupt rotations. These
severe conditions can cause a variety of internal damages over time. The following are frequent
forms of internal damage discovered in gas turbine engines:
Corrosion: Hot corrosion is a distinct form of corrosion that happens in gas turbines as
a result of the existence of liquefied salts in the fuel or input air. At elevated
temperatures, these liquid salts have a chemical reaction with the metal, which leads to
an increased rate of corrosion and a decrease in the strength of the components.

Figure 7. Hot Corrosion

Erosion: It is the process in which particles, such as sand, dust, or ice crystals in aircraft
engines, collide with the surfaces of turbine blades and casings. The ongoing barrage
erodes the material, causing the blades to become thinner and less efficient.

Figure 8. Erosion

Thermal Fatigue: It is a form of damage that arises from the repetitive process of
heating and cooling. During the operation of the turbine engine, its components undergo
periodic expansion and contraction. Repetitive motion can lead to the development of
cracks, particularly in regions characterized by abrupt contours or intense stress
concentrations.

Figure 9. Thermal Fatigue

Fouling: It refers to the accumulation of deposits on the turbine blades and other
internal components. These deposits might originate from combustion byproducts, such
as soot, or from impurities present in the incoming air. Fouling diminishes the flow of air
and the transfer of heat, resulting in a decline in engine performance and efficiency.
 Figure 10. Fouling

Foreign Object Damage (FOD): It is the term used to describe any object that enters
the engine and is not part of the normal airflow. Possible examples of foreign objects on
the runway may include avian species, fragments, or even equipment inadvertently
abandoned during maintenance activities. FOD, or Foreign Object Damage, has the
potential to inflict substantial harm to the blades and other internal components.

Figure 10. Foreign Object Damage (FOD)

To ensure the safe and efficient operation of the engine and avert catastrophic failure,
early detection of these damages is vital. Consistent maintenance and inspections are critical in
order to detect these issues in their initial stages and implement rectifying measures. Moreover,
to ensure the highest level of reliability for turbomachinery equipment, such as turbines, it is
crucial to establish and implement a well-designed and comprehensive maintenance program.
The maintenance priorities for turbines and their auxiliary components can be classified into
three primary categories:
Preventive maintenance (PM): It is a program that is planned, centered around
reliability, and based on maintenance. Failure mechanisms are recognized and risk
mitigation methods are undertaken by taking proactive measures such as replacing and
inspecting components.
Inadequate maintenance: A program focused on preventing failures. Identifying repairs
or problems and planning appropriate solutions is done at the next available time, such
as during a planned outage.
Corrective maintenance: It refers to a program and technique that is reactive and
based on failures. Component failure accompanied by collateral damage to other
components, typically resulting in a forced outage (whole system malfunction) and
subsequent repair work.
Conclusion

Examining gas turbine engines is an essential aspect of guaranteeing their

dependability, effectiveness, and durability in a range of demanding uses, such as aerospace,
power production, and marine propulsion. Due to the complex structure and harsh operating
circumstances of gas turbines, it is necessary to conduct thorough and frequent inspections in
order to rapidly identify and resolve possible problems before they develop into significant
failures. By implementing thorough inspection processes that include visual, non-destructive,
and advanced diagnostic tools, it is feasible to ensure the operational integrity of these engines,
improve their performance, and attain significant cost advantages.
Regular maintenance inspections are crucial for detecting and resolving issues such as
wear, corrosion, thermal fatigue, and other types of degradation that might jeopardize engine
performance and safety. Inspections are crucial in maintaining the mechanical integrity of
important parts, which helps to avoid unexpected periods of inactivity and expensive repairs.
Ensuring compliance with regulatory standards through systematic inspections is crucial for
maintaining the legal and commercial sustainability of gas turbine operations.
Inspections are essential not only for maintenance considerations but also for optimizing
performance and efficiency. Inspections play a crucial role in identifying performance declines
and enabling prompt corrective measures. This leads to enhanced fuel efficiency, decreased
emissions, and prolonged engine lifespan, resulting in substantial cost savings over time.
Utilizing modern inspection techniques, including borescope inspections, alignment measures,
and non-destructive testing, enables accurate and efficient evaluation of turbine components
without the need for substantial disassembly.
To ensure the ongoing safe and effective functioning of gas turbine engines, it is crucial
to address common internal issues such as corrosion, erosion, thermal fatigue, fouling, and
foreign object damage (FOD). Developing and executing a meticulously planned maintenance
schedule, which encompasses preventive, subpar, and corrective maintenance approaches,
guarantees optimal reliability for turbomachinery equipment.
The thorough examination and upkeep of gas turbine engines are essential for achieving
their maximum performance, ensuring safety, and maintaining economic feasibility. By
continuously improving inspection procedures and technologies, stakeholders may guarantee
the ongoing dependability and effectiveness of gas turbine engines, thus supporting their crucial
function in contemporary industrial applications.
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