Early detection of thermo-mechanical degradation in industrial frame-size gas turbine compressor blades under variable temperature and rotational speed

Abstract This study investigates the necessity of enhanced protection mechanisms under operational conditions to mitigate potential risks and prevent catastrophic failures. The motivation for this work arises directly from operational issues observed in real field applications. During turbine operation, exceeding prescribed limits of rotational speed, pressure, and temperature can induce significant thermo-mechanical deformations in compressor blades. These deformations primarily manifest as blade elongation, which may lead to unintended blade–casing interactions. Such rubbing phenomena can result in severe mechanical damage, reduced efficiency, and, in extreme cases, forced turbine shutdowns. In this study, the effects of variations in temperature, pressure, and rotational speed on compressor blade behavior are systematically analyzed. Coupled thermal and structural analyses are performed under multiple operating scenarios, and the resulting stress distributions and deformation patterns are evaluated. Based on the numerical findings, a set of preventive and protective recommendations is proposed to minimize blade–casing interference and enhance operational safety. The outcomes of this study are expected to provide valuable guidance for the protection of high-capacity gas turbines, contributing to improved reliability, extended service life, and reduced maintenance costs.