Hamza Oui 2015
Hamza Oui 2015
Hamza Oui 2015
h i g h l i g h t s
The failure assessment in blades is optimized using articial neural network inverse (ANNi).
(ANNi) is a very effective modeling the useful life in blades of steam turbines.
Failure assessment in blades is optimized using articial neural network inverse.
a r t i c l e i n f o a b s t r a c t
Article history: The useful life (UL) of the failure assessment in blades of steam turbines is optimized using the articial
Received 30 June 2014 intelligence. The objective of this paper is to develop an integrated approach using articial neural
Accepted 23 September 2014 network inverse (ANNi) coupling with a Nelder Mead optimization method to estimate the resonance
Available online xxx
stress when the UL of the blades is required. The proposed method ANNi is a new tool which inverts the
articial neural network (ANN). Firstly, It is necessary to build the articial neural network (ANN) that
Keywords:
simulates the output parameter (UL). ANN's model is constituted of feedforward network with one
Inverse neural network
hidden layer to calculate the output of the process when input parameters are well known, then
Optimal parameters
Optimization
inverting ANN. The ANNi could be used as a tool to estimate the optimal unknown parameter required
Steam turbine failure (resonance stress). Very low percentage of error and short computing time are precise and efcient,
Life cycle assessment in blades make this methodology (ANNi) attractive to be applied for control on line the UL of the system and
constitutes a very promising framework for nding set of good solutions.
2014 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
1359-4311/ 2014 Elsevier Ltd. All rights reserved.
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
2 Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10
" !!# !
X
S X
K
Outputk yfkg purelin LWfk;sg $ tansig IWs;k $Ink b1s b2k (1)
s1 k1
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10 3
2 0 13
XS 66
B
B
C7
C7
6LW2;s $B 2
y2 6 B !! 1C 7
C7 b22 (2)
s1 4 @ PR A5
1 exp 2 r1 IWs;r $pr b1s
2 3
XS XS 66 2LW2;s
7
7
y2 b22 LW2;s 6 !!7 (3)
6 7
s1 s1 4 PR 5
1 exp 2 IWs;3 $p3 rs3 IWs;rs3 $pfrs3g b1s
where subscripts s is the number of neurons in the hidden layer; method approximately nds a local optimal solution with N vari-
subscripts r is the number of neurons in the input layer; l is the ables when the objective function varies smoothly. NeldereMead
number of neurons in output layer; S is the number of neurons in generates a new test position by extrapolating the behavior of the
the hidden layer; R is the number of input; Tansig is the hyperbolic objective function measured at each test point arranged as a sim-
tangent sigmoid transfer function; Purelin is linear transfer func- plex. Then, the algorithm chooses to replace one of these test points
tion; and IW, LW and b1s, b2l are the input and output weights and with the new test point. Thereby, a new simplex is generated with a
the biases, respectively. single evaluation of the objective. The numerical algorithm of the
The Eq. (4) is to be minimized to zero to nd the optimal input(s) NeldereMead simplex method has been described in detail by
parameter(s) in a general ANN, in this case, x is the p3 value to be Nelder and Mead [30].
computed to zero by an optimization method.
2 3
X
S XS 66 2$LW2;s
7
7
f x b22 LW2;s y2 6 !!7 (4)
6 7
s1 s1 4 PR 5
1 exp 2 IWs;3 $x rs3 IWs;rs3 $prs3 b1s
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
4 Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10
Fig. 2. Numerical procedure used for the ANN learning process, and the iterative architecture used by the model to predict the UL of the failure assessment in blades of steam
turbines (S is the number of the neuron in the hidden layer).
algorithms. LevenbergeMarquardt backpropagation training algo- Consequently, RMSE and R2 were used as the error function
rithm could have smaller mean square error (RMSE), on the other which measures the performance of the network. Therefore, the
hand, we found training with Levenberg Marquardt algorithm can network having minimum RMSE and maximum R2 was selected the
run smoothly in computer with lower expanded memory speci- best ANN model. More detail about neural network training was
cation (EMS), and the training time is quickly, than the other already described by Rodriguez et al. [4].
backpropagation algorithms. Because, the LevenbergeMarquardt
algorithm was designed to approach second order training speed
without having to compute the Hessian matrix. 4.2. Inverse neural network considering one neuron in the hidden
However, the performance of the ANN model was statistically layer in ANN model
measured by the root mean square error (RMSE) and regression
coefcient (R2), which are calculated with the experimental values In the case of one neuron in the hidden layer. The analytical
and network predictions as illustrated in Figs. 3 and 4. These cal- solution is performed as follow:
culations are used as a criterion for model adequacy, obtained as
follows: If tansig and purelin are considered as the hyperbolic tangent
v sigmoid and linear transfer function in the hidden layer and
u ! output layer, and k 1.
u P 2
u N 0 1
u n1 yn;pred yn;exp
t 2
RMSE (5) Out1 LW1;1 $@ 1A b2
N 1 exp 2$ IW1;r $pr b1
2 (7)
PN
n1 yn;pred yn;exp This can be transformed into:
R2 1 (6)
PN 2
0 1
n1 yn;exp ym
@ 2
Out1 b2 LW1;1 $ 1A
where N is the number of data points, yn,pred is the network pre- 1 exp 2$ IW1;r $pr b1
diction, yn,exp is the experimental response, ym is the average of
(8)
actual values and n is an index of data.
Table 1
Comparison of 10 backpropagation algorithms with ve neurons in the hidden layer.
Backpropagation algorithm Function Root mean square Epoch Correlation Best linear equation
error (RMSE) coefcient (R2)
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10 5
0 1
2$LW1;1 LW
Out1 b2 @ LW1;1 A 1;1 Out1 b2
1 exp 2$ IW1;r $pr b1 exp 2 IW1;1 $p1 b1 (13)
Out1 LW1;1 b2
(9)
2$LW1;1 !
LW1;1 Out1 b2
Out1 b2 LW1;1
1 exp 2$ IW1;r $pr b1 2 IW1;1 $p1 b1 ln (14)
Out1 LW1;1 b2
(10)
!
1 LW1;1 Out1 b2
2LW1;1 IW1;1 $p1 b1 ln (15)
1 exp 2$ IW1;r $pr b1 2 Out1 LW1;1 b2
Out1 b2 LW1;1
(11)
!
1 LW1;1 Out1 b2
LW IW1;1 $p1 ln b1 (16)
1;1 Out1 b2 2 Out1 LW1;1 b2
exp 2 IW1;r $pr b1 (12)
Out1 LW1;1 b2
Let p{r1} would be the input parameter to be calculated when
As k 1, R 1, So one output parameter is required. Then:
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
6 Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10
LW1;1
exp IW1;1 $p1 b1 1 (21)
Out1 b2
LW1;1
IW1;1 p1 ln 1 b1 (22)
Out1 b2
LW1;1
b1 ln Out1b 1
2
p1 (23)
IW1;1
If logsig and purelin are considered as the logistic tangent sig- The experimental set up used in this work has been previously
moid and linear transfer function in the hidden layer and output described in detail elsewhere [4]. Failures of turbine blade usually
layer, and k 1 initiate at the zone of high stress concentration which occur in
metallurgical discontinuities or where corrosion is present or even
0 1 in regions of excessive wear. During operation of the turbine, the
1 cracks are frequently caused by erosion, corrosion or small imper-
Out1 LW1;1 @ A b2 (18) fections and then propagate into the fracture. However, these im-
1 exp IW1;1 p1 b1
perfections increase the fatigue stress concentration factor and of
LW1;1 course the stresses themselves. Turbine inspection revealed that
Out1 b2 (19) sets of 10 blades failure of the L-0 in low pressure stage of a 110 MW
1 exp IW1;1 $p1 b1
steam turbine were illustrated within 15 cm from the root. The
blades are signicantly affected by a crack practically is a fracture
LW1;1 observed in a blade root is shown in Fig. 5. The L-0 stage had 110
1 exp IW1;1 p1 b1 (20) blades of 0.6 m in length with groups of 10 blades. The blades of
Out1 b2
each group are connected in their top end by a shroud and two
wires as shown in Fig. 6. In addition, a visual inspection combined
with a revision of the turbine operation history was carried out into
system description and experimental data. Furthermore, a turbine
Fig. 5. The cracked leading edge of the L-0 blade. Fig. 6. Discrete models of blade group for the calculation of natural frequencies.
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10 7
2 0 13
XS 66
B
B
C7
C7
6LW1;s $B 2
UL 6 B !! 1C7
C7 b2 (24)
PR
s1 4 @ A5
1 exp 2$ r1 IWs;r $pr b1s
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
8 Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10
Table 3
Some samples of the experimental and simulated information of the system.
Test number 500 1000 2000 3000 4000 5000 6000 7000 8000 9000
Input
Mean stress 557.12 655.97 483.77 562.34 602.87 500.71 634.83 492.83 673.60 566.39
Frequency ratio 0.91 1.052 1.017 0.902 0.916 1.029 0.966 0.889 1.036 0.937
Dynamic stress 24.12 35.41 101.75 31.66 30.184 85.985 60.516 21.95 60.59 32.159
Damping 0.018 0.020 0.0201 0.023 0.0188 0.0201 0.0185 0.0201 0.0207 0.0198
Fatigue strength 1295.36 967.85 1186.33 977.33 923.95 1070.33 971.45 1128.079 883.3121 1038.347
Resonance stress_Exp 244 221 208 208 211.5 216 219 221 221.5 220
Output
[Useful Life]EXP 4.67E11 4.27E17 4.7855E10 5.38E14 6.87E14 3.19E14 1.54E14 4.18E14 6.03E12 3.04E13
[Useful Life]SIMANN 4.67E9 4.27E15 4.7855E8 5.38E12 6.87E12 3.19E12 1.54E12 4.18E12 6.03E10 3.04E11
stress. Whilst, the required output is the useful life. However, the
where resonance stress will be estimated by ANNi.
The optimization method nds the minimum of a scalar func-
A UL b21 LW1;1 LW1;2 LW1;3 (30) tion of several variables, starting at an initial estimate. However,
this is generally referred to as unconstrained nonlinear optimiza-
tion. However, the optimization method starts at the initial value
X11 2 IW1;2 V2 IW1;3 V3 IW1;4 V4 IW1;5 V5 and nds a local minimum V1 described in Eq. (29). On the other
hand, Table 3, shows some samples of the experimental and
IW1;6 V6 b11 (31) simulated information of the system as shown in Fig. 7.
An example of this application is shown to calculate the
required resonance stress (V1) considering the experimental data
X22 2 IW2;2 V2 IW2;3 V3 IW2;4 V4 IW2;5 V5
reported by Rodriguez et al. [34,35], which values are obtained
from experimental test database showing in test number 1000,
IW2;6 V6 b12 (32)
thus only, we want to calculate the resonance stress value (V1):
Mean stress (V6) 655.97 [MPa];
Frequency ratio (V2) 1.052;
X33 2 IW3;2 V2 IW3;3 V3 IW3;4 V4 IW3;5 V5
Dynamic stress (V3) 35.41 [MPa];
IW3;6 V6 b13 (33) Damping (V4) 0.020;
Fatigue strength (V5) 967.85 [MPa];
The weights (IW and LW) and biases (b1 and b2) of ANN's model Resonance stress (V1) ?
are showed in Table 2 and the input parameters are reported by And an output value, UL 4.27E 17 [Min]
Rodriguez et al. [4] in order to minimize to zero the Eq. (29), an According to the weights and biases of Table 1 and optimization
optimization method (NeldereMead Simplex Method) is used to method of the NeldereMead, it is possible to calculate the optimum
calculate the resonance stress (V1). Where, the Input of ANN are Resonance Stress (V1), which is: Resonance Stress
frequency ratio; dynamic stress; damping; fatigue strength; mean ANNi V1ANNi 224 [MPa].
Fig. 7. Architecture of the articial neural network inverse for determining the optimum resonance stress.
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10 9
However, to validate this value, a test was performed with 6. Comparative results
different data to optimize the resonance stress in different condi-
tions to demonstrate the feasibility of this method about ANNi. The remarkable thing is that, according to Fig. 9, there is good
However, the simulation outcomes were then compared with agreement between the predicted values for useful life of the fail-
experimental data in order to check the accuracy of ANNi. This error ure assessment in blades of steam turbines by ANN and ANNi
is given by: models with experimental data. Indeed, it has been an outstand-
ingly successful models in predicting the experimental results.
jExp Simj
Err 100 (34) Consequently, the UL error between the experimental and simu-
Exp lated by ANNi is 0.7%.
That means Resonance Stress estimated by ANNi is compared to These models: articial neural network (ANN) and articial
experimental resonance stress of the experimental data using Eq neural network inverse (ANNi) prove to be very effective in
(34). In Table 2, within the test number 1000, the experimental modeling the useful life of the failure assessment in blades of steam
value of Resonance Stress is V1EXP 221 [MPa]. Whilst, the error is turbines. The smaller RMSE and larger R2 mean better performance
given by Eq (34). Therefore, in this case, an error of 1.5% is obtained [5]. However, the performance of the ANN and ANNi on modeling
which is very acceptable. On the other hand, the elapsed time to UL of the failure assessment in blades of steam turbines is pre-
calculate this Resonance Stress from this methodology (ANNi with sented in Fig. 9, where the two models are trained using the same
Nelder Mead Simplex) is only 35.17 s. It's seem that this time is good training datasets and validated by the same datasets (fresh data). In
enough to control the process. In addition, Fig. 8, illustrates that practice, however, the calculation required for system are so
there is a good agreement between the experimental resonance complicated, that's why, all the calculations were carried out on
stress and resonance stress estimated by ANNi. In the meantime, LINUX system, Intel D CPU 2.80 Ghz, 2.99 GB of RAM. According
the tting quality is so good. It has been an outstandingly successful to Fig. 9, we can distinguish the following results: The ANN model
models in estimating experimental results by ANNi. has smaller error for datasets than the ANNi (about 0.85%). In this
Fig. 9. UL versus number of test patterns for failure assessment of steam turbines.
Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065
10 Y.El. Hamzaoui et al. / Applied Thermal Engineering xxx (2014) 1e10
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Please cite this article in press as: Y.E. Hamzaoui, et al., Optimization of operating conditions for steam turbine using an articial neural network
inverse, Applied Thermal Engineering (2014), http://dx.doi.org/10.1016/j.applthermaleng.2014.09.065