Modeling of critical start-up and shutdown scenarios of a gas turbine engine for testing regulator protections

Abstract

This study presents a methodology for simulation-based modeling of critical start-up and shutdown scenarios of the TV3-117 gas turbine engine to test the electronic controller’s protection algorithms. The proposed approach uses a hardware-in-the-loop simulation test bench with an integrated mathematical engine model, enabling real-time emulation of engine dynamics without the need for actual equipment. Based on this model, an automated test utility was developed, allowing the construction of start-up, shutdown, and emergency impact scenarios using logical block diagrams. The utility’s algorithms offer flexible configuration of action sequences, parameter values, fault injection, and control system response evaluation under various conditions. Simulations were conducted for both nominal and critical modes, including temperature and overspeed limit violations, delayed ignition, sensor channel faults, communication failures, and emergency engine shutdowns. The protection logic of the controller was tested for various scenarios, such as overspeed protection, temperature limiting, emergency power mode switching in case of engine failure, power loss, and inter-module communication disruptions. System responses were recorded for each case, enabling the assessment of algorithm effectiveness. The utility also supports real-time signal and parameter logging with time stamps to facilitate detailed analysis. The modeling results demonstrated a high level of correspondence with expected controller behavior, including the system’s ability to stabilize parameters under fault conditions and overloads, as well as flexible adaptation of protection logic. The developed methodology reduces testing time and cost, minimizes risks at early development stages, and ensures high simulation credibility. The proposed solution is applicable throughout the entire life cycle of engine control system development – from design to certification testing. Moreover, the test utility can be adapted to other engine types, highlighting its universality and scalability in the field of aerospace propulsion system development.