Neural network monitoring system used for the frequency vibration prediction in gas

turbine

Mohamed Ben Rahmoune, Ahmed Hafaifa and Mouloud Guemana

Faculty of Science and Technology
Applied Automation and Industrial Diagnostics Laboratory
University of Djelfa, Algeria
Emails: benrahmounmohamed@gmail.com; hafaifa.ahmed.dz@ieee.org
Faculty of Science and Technology
Applied Automation and Industrial Diagnostics Laboratory
University of Médéa, Algeria
Email: guemana_m@yahoo.fr

Abstract— Rotating machines are widely used in the industry; all
these machines in operation produce vibrations phenomena
caused by dynamic forces generated in moving parts of these
equipments. This work propose the development of fault
diagnosis system for the vibration detection and isolation based
on artificial intelligence using artificial neural networks, applied
to a gas turbine system, in order to secure the vibration
frequency acquired by the sensors at bearings and then the
prediction of the behavior of the turbine shaft. The obtained
results are satisfactory and given the justification for the use of
artificial neural networks for diagnosis of rotating machinery.
Keywords— Diagnosis, defects, neural networks, modeling,
generation of residues, faults detection, faults isolation, vibration,
gas turbine.
I. INTRODUCTION
Fault detection in gas turbine systems, that is to say, their
diagnosis, was and remains an important topic dice
industrialists the appearance of modern automatic. Indeed in
many applications often it will, beyond purely economic
considerations to ensure the safety of people and to preserve
their environment [1-7]. In this work, we focus on the detection
method study and modeling of neural network based defects.
We are interested in detecting faults precisely monitoring the
frequency of vibrations in a gas turbine. These systems are
considered as posing a difficult to predict behavior in light of
significant changes that may be associated with parametric
variations.
Dice the importance of gas turbines in the oil facilities and
other industrial fields. This work proposes to study and analyze
this type of industrial system. Many shortcomings and
problems Affected such systems [10-14], which can cause
dangerous vibrations which degrades the operating state of the
turbine such that the unbalance, misalignment, bearing
vibration, surge…etc. Vibrations may then be viewed as
symptoms of failures that would translate the mechanical
condition of a gas turbine, this influencing the quality of gas
production and economic sheaths of companies.
This work attempted processed these vibrations through
support tools for the detection and diagnosis of faults. The need
for speed to detect and locate these failures in these gas turbine
systems was the subject of our work, and we made use of
artificial intelligence techniques. In this framework, it is
limited to the diagnosis of this industrial system based on
artificial neural networks in the vibration frequency of the
monitoring part of a gas turbine. The obtained results are
satisfactory and given the justification for the use of artificial
neural networks for diagnosis of rotating machinery.
II. GAS TURBINE VIBRATION
The vibrations may be rectilinear or rotary; it is the most
frequent phenomenon in a rotating shaft system. It is a kind of
periodic angular movement of trees with elastic circular rotors
rigidly attached. This type of vibration is particularly the gas
turbine rotors. In this work, the MS3002 gas turbine shown in
Figure.1 is examined. This is a mechanically driven machine
has dual overhead, simple cycle, using actual gas turbine
consists of an axial compressor 15 floors, 6 combustion
chamber arranged (90 °) payment has axial a High pressure
single stage turbine (1st floor), which drives the compressor
and auxiliary equipment, as well as a low pressure turbine
(second shaft) that causes the load. The assembly of the turbine
consists of three main elements: the axial compressor,
combustor, and turbine.
Figure 1. Examined gas turbine GE MS3002
Vibrations in the gas turbine can induce several defects
such as unbalance, misalignment, absolute shaft vibration ...
etc. And we are interested in more frequent failure to file the
initial unbalance vibration is generally distributed continuously
 Mi m III.
and one on the rotor, the position of each weight i is
Y r = Oi M i Oi
defined by its abscissa axis i , the distance i , now a data processing technique well understood and managed
being the center of the shaft section, as it is mounted on the
α
Figure 2, the angle i that is the position of the mass relative
to the rotating frame of reference.
Figure 2. Modeling the distribution of imbalance in the rotor
m
Upon rotation of the rotor, each mass i is connected to
the shaft in the deformed position; the motion vector and the
associated speed are shown in the Figure 3 and given in the
equations 1-3.
Figure 3.Setting unbalance
­u + ri sin(φ + α i ) ½
{Oi M i } = °®0 °
¾ (1)
°w + r cos(φ + α )°
¯ i i ¿R0
­, , ½
°u + φ ri cos( φ + α i ) °
{V } = d {Oi M i } = °®0
° °°
¾ (2)
dt ° , °
° , °
°¯w + φ ri sin( φ + α i )°¿ R 0
The kinetic energy of the unbalance i involved in the
construction of the vector excitation force is:
1 , ,
TB = mi riφ ( u cos( φ + α i − w sin( φ + α i )
2 neural network is loaded with data from sensors by the
When a shaft rotates, it can be subjected to transverse
oscillations if the tree is out of balance, the resulting centrifugal
force will push the shaft to vibrate. And when it rotates at a
speed close to its natural rate (clean) transverse oscillations, the
vibrations become large and aggressive throughout the
installation. It is in this context, it is necessary that such
equipment must be controlled by reliable monitoring systems.
ARTIFICIAL NEURAL NETWORK DIAGNOSIS
Neural networks NWA or simply RN neural networks, are
in several industrial fields, these techniques can extract, in
many situations, the maximum of relevant information from
the data it has: control processes, properties, predictions,
modeling functions, pattern recognition and other industrial
applications [11, 13, 14, 16 and 18].
Techniques from these approaches based on neural
networks are varied but not always effective. Indeed, industrial
processes are often complex system with strong non-linearity
in their operation, which causes problems in control of these
systems; this requires the operator to formulate a workable
model on order. Since the technical linearization’s around a
working point or the reduction of some of the methods are
performance degradations of the mathematical model of the
real system.
The advantage of the used of neural networks is their use of
interest for the diagnosis of failure for more quickly detecting
the vibrations of a shaft of the gas turbine, they are classified
according to two criteria: The architecture of the networks
(sigmoid radial ) and the learning strategy (supervised or
unsupervised).
A. Residues based on neural networks
The neural model generates a neural observer for the
modeling by artificial neural networks is to compare the
outputs of the process with their estimated (actual process
output with the output of the network to compare the outputs of
the process with their estimated (actual process output with the
output of the neural networks to associated). In the examined
case, the output of the estimated (networks) is calculated by a
neural model and the difference between the two outputs
generates a residual vector r( t ) , as shown on the “Fig. 4”.
Figure 3.General scheme of modeling
The application in this work is based on actual data
observed by sensors turbine bearings levels gas, the associated
(3)
objective to make the behavior during the learning phase
unbalance shaft and after learning we try to predict the future
behavior of the turbine shaft.
The diagnostic procedure based on the most commonly
used models, particularly in industrial applications in real time,
which is based on the approach of residues The procedure is
usually performed in two steps: the residue of generation and
evaluation of residue, shown in “Fig. 5”.
 IV. APPLICATION RESULTS
To estimate the maximum amplitude of displacement of the
rotating shaft of the gas turbine, several validation tests were
made in this work. The results depend mainly on the
mechanical characteristics of the shaft and the non-
homogeneity of its mass and also to the rotational speed. The
shaft vibration frequency variation clumsy turbine is shown in
Figure 6.
15

Figure 4.Structure of diagnostic system based on residues

Amplitude Frequency um
10

In the diagnostic procedure, there are two static

characteristics are considered to characterize the residue: its
mean and standard deviation. The residue is zero in normal 5

operation and different from zero in the presence of a fault. The

neural network is among the best tools, it is able to collect the
information processed by the process. 0
0 200 400 600 800 1000 1200 1400 1600 1800 2000

The neural network architecture depends on user needs, in Temps H

this application we use the multilayer networks respectively

Figure 5. Response of the shaft unbalances
and has an input layer, one or more hidden layers and an output
layer. The hidden layer activation function of the type is
According to the complexity of real data collected by the
'sigmoid' and the type of output layer 'linear'. As we choose the
sensors we set the target 'Goal' to 1 for ease of learning
retro propagation algorithm, choose the retro propagation
networks. The input of our neural network 1200 are shaft
algorithm, we use a learning rule to minimize squared error
vibration frequency values of the turbine, in first place we try
given by the following equation:
to take the maximum of the shaft of the turbine behavior,
changes every time the number of iterations and the number of
2 hidden layers and number of neurons in each layer until the
E=
1
2 i
2 1
(
¦ (di − yi ) = 2 ¦i di ¦ wij x j ) (4) best networks, which is the learning stages.
After several thresholds for the best network architecture is
wij Δwij classified in “Table. 1”.
Involves changing each weight by an amount
proportional to the error gradient TABLE 1. NETWORK ARCHITECTURE

NN Input Hidden Output MSE

dE layer layer layer
Δwij = −η = η ¦i (di − yi )xi (5)
dwij
I 15 8 1 5.64
The weighted sum of inputs calculated using the following II 20 14 10 1 4.73
expression: III 15 10 12 1 4.89

a j = ¦ j =1,n wij x j (6) The results are satisfactory given the large number of items
to follow 1200 points and the complexity of the vibration
amplitude curve is a very good result and the only neural
From this value; the transfer function (activation function) networks that have the ability to track this type of signals.
calculating the value of the neuron state that it is sent to
downstream neurons. The most interesting step in neural networks is the learning
step shown in “Fig. 7”.
yi = ϕ (ai − θ i ) (7)

The gradient descent algorithm is a calculation technique

derivative of an entity with respect to all of its inputs, used to
solve the problem of calculating errors of outputs of the
neurons of the hidden layers, for each instance of the training
set.
 15

10

-5

-10

-15
0 200 400 600 800 1000 1200 1400 1600 1800 2000

Figure 6. Mean square error Figure 7. The error between the actual signal and associated networks

The turbine shaft characteristic has a small margin of In the first step we use neural networks output, shown in
vibration amplitude threshold (the interval characteristic of the Figure 11, to take the behavior of the real points. And in the
turbine shaft, shown in “Fig. 8”, has a small margin of second stage we exploited the networks prediction, shown in
vibration amplitude threshold (the tolerance interval) for that the Figure 12, for the analyze the future behavior of the shaft
the frequency amplitude must not exceed 10ȝm. gas turbine. The prediction is very important in expensive
processes such as gas turbines, steam turbine, and oil
15
Amplitude Frequency
machinery, to be ready to face the issues of whether there is
threshold
Neural Network damage and allows planning the proper maintenance plan.
12
Amplitude Frequency um

10
X: 2000
Y: 9.719
10

8
AmplitudeFrequency

4
0
0 500 1000 1500 2000
Time H 2

Figure 7. The threshold of the frequency

0
0 500 1000 1500 2000 2500
Temps H

From the shaft unbalance response and learning associated Figure 9. Output of the network
networks, take the two signals to determine the error, shown in
“Fig. 9”. 9.7

15 X: 2000
Y: 9.689
Amplitude Frequency
Neural network

9.65
AmplitudeFrequency
Amplitude Frequency um

10

9.6

X: 4000
5 Y: 9.567

9.55
2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000
Temps H

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Temps H
Figure 10. Predictive neural networks

Figure 8. The shaft and the associated response networks In remarks that in point H 2000, in the two figures is the
same, and also notes the appearance of the second is decreasing
After the response of the two signals, we determine the in other words, the vibration amplitude is helpless in between
error between the network and the actual signal, shown in 2000 hours - 4000 hours.
“Fig. 10”.
V. CONCLUSION
The importance of the gas turbine in the oil facilities and
other industrial facilities, requires a rapid and accurate
diagnosis simultaneously for the faults detected and repaired as
soon as possible For this purpose we use the neural approach
for their ability learning to detected defects due to shaft
vibration and make us predict the future behavior tree to be
ready to face the issues of whether there is damage and allows
planning the proper maintenance plan.
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