LIFE PREDICTION AND EXTENSION OF LEGACY GAS TURBINE AERO ENGINES THROUGH REENGINEERING AND NOVEL TECHNIQUES: A SAFETY AND RISK-BASED ANALYSIS

Abstract

Gas Turbines are subjected to inherent degradation and deterioration due to their environmental & operational conditions, and Legacy Gas Turbine Aero Engines (LGTAEs) are no exception and more so with their increased age. This results not only in reduced performance but also in increased SFC, the cause of the emissions. Moreover, with no support from OEMs, the LGTAEs have almost all become obsolete and defunct leading to premature loss. The primary purpose of this paper is to analyze and improve the life prediction and extension of LGTAEs through Reengineering, novel techniques, and methods. The Reengineering in this context incorporates Novel Design, Manufacturing, and Maintenance techniques/methods wherever required. Exploratory and descriptive research analysis has been used to identify the Current and Novel Techniques that can be applied to accurately predict and extend the Life of LGTAEs. The paper identified the application of Current and Novel Techniques as an Integrated Approach to LGTAEs has a greater scope in accurate prediction and extension of LGTAEs. This is demonstrated by carrying out a critical analysis of the Novel Techniques and illustrating how these Techniques and Methods when applied in real- time incidents produce significant positive results. The Novel Techniques studied and analyzed in this paper are Engine Systems and Component Analysis, Gas Path Analysis, Reliability, Availability, and Maintainability (RAM) Analysis, Digital Twins, Risk Based Maintenance (RBM) Analysis, Fatigue Analysis, Safety by Inspection, and Corrosion Prevention Techniques. Finally, the paper studies and investigates the investment recovery of the investors and operators of LGTAEs through Reengineering, Novel Techniques/Methods, and Upgradation/Modification.