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Abstract:
The low pressure steam turbine blade rows have a history of stress failure . They suffer from
tensile and bending stresses partly due to the centrifugal force as a result of high rotational
speeds and partly due to high pressure, temperature and speed steam loading. The centrifugal
force is one of the problems that face the designers of turbine blades especially the long ones.
The designer always aims at reducing these stresses. One way to do so is by the reduction of blade
mass. That is to make the blade of variable cross section stead in of straight. This paper presents
the method of reducing cross section. Analysis of such blade is also done as applied to the (P 23-
14A) steam blade.
:اﻟﺨﻼﺻﺔ
ﻓﻬﻲ ﺘﻌﺎﻨﻲ ﻤﻥ ﺍﺠﻬﺎﺩﺍﺕ ﺸﺩﻴﺔ ﻭ ﺍﻟﺘﻭﺍﺌﻴﺔ ﺠﺯﺌﻴﺎ" ﺒﺴﺒﺏ ﻗﻭﺓ.ﺍﻥ ﻟﺭﻴﺵ ﺍﻟﺘﻭﺭﺒﻴﻥ ﺍﻟﺒﺨﺎﺭﻱ ﺍﻟﻁﻭﻴﻠﺔ ﺘﺄﺭﻴﺦ ﻤﻥ ﺍﻟﻔﺸل ﺍﻻﺠﻬﺎﺩﻱ
ﺍﻥ. ﺩﺭﺠﺔ ﺍﻟﺤﺭﺍﺭﺓ ﻭ ﺍﻟﺴﺭﻋﺔ،ﺍﻟﻁﺭﺩ ﺍﻟﻤﺭﻜﺯﻱ ﺍﻟﻨﺎﺘﺞ ﻤﻥ ﺴﺭﻋﺔ ﺍﻟﺩﻭﺭﺍﻥ ﺍﻟﻌﺎﻟﻴﺔ ﻭﺠﺯﺌﻴﺎ" ﺒﺴﺒﺏ ﺘﺤﻤﻴل ﺍﻟﺒﺨﺎﺭ ﺍﻟﻌﺎﻟﻲ ﺍﻟﻀﻐﻁ
" ﺍﻥ ﺍﻟﻤﺼﻤﻡ ﺩﺍﺌﻤﺎ.ﻗﻭﺓ ﺍﻟﻁﺭﺩ ﺍﻟﻤﺭﻜﺯﻱ ﻫﻲ ﺃﺤﺩﻯ ﺍﻟﻤﺸﺎﻜل ﺍﻟﺘﻲ ﻴﻭﺍﺠﻬﻬﺎ ﺍﻟﻤﺼﻤﻡ ﻟﺭﻴﺵ ﺍﻟﺘﻭﺭﺒﺎﻴﻥ ﻭ ﺨﺼﻭﺼﺎ" ﺍﻟﻁﻭﻴﻠﺔ ﻤﻨﻬﺎ
ﻭ ﺫﻟﻙ ﺒﺼــﻨﺎﻋﺔ ﺭﻴﺸــﺔ ﺫﺍﺕ. ﺃﺤﺩﻯ ﺍﻟﻁﺭﻕ ﻟﺘﺤﻘﻴﻕ ﺫﻟﻙ ﻫﻭ ﺒﺘﻘﻠﻴل ﻜﺘﻠﺔ ﺍﻟﺭﻴﺸــﺔ.ﻴﻬﺩﻑ ﺍﻟﻰ ﺘﻘﻠﻴل ﺘﻠﻙ ﺍﻻﺠﻬﺎﺩﺍﺕ
ﻫﺫﺍ ﺍﻟﺒﺤﺙ ﻴﺴــﺘﻌـﺭﺽ ﻁﺭﻴﻘﺔ ﻟﺘﻘﻠﻴل ﻤﺴـــﺎﺤﺔ ﻤﻘﻁﻊ. ﻤﻘﻁﻊ ﻤﺘﻐﻴﺭ ﺒﺩﻻ" ﻤﻥ ﺍﻟﺭﻴــﺵ ﺍﻟﻤﺴــــﺘﻘﻴﻤﺔ
. ﻭﻜﺫﻟـﻙ ﺘﻡ ﺍﺴــــﺘﻌﺭﺍﺽ ﺘﺤﻠﻴل ﻟـﻬـﻜـﺫﺍ ﺭﻴﺸــﺔ.ﺍﻟﺭﻴﺸــــﺔ
i) The Nozzle (stator) , in which the steam s =spacing between two moving blades.
expands from a high pressure and a state of ρƒ = density of steam.
comparative rest to a lower pressure and a σcf = centrifugal stress.
state of comparatively rapid motion. σt =total stresses (tension and bending).
ii) The Blade (rotor), in which the stream vv 1, vv 2 , vv 3 =distances from the axis u to
of steam particles has its direction and points 1,2, and 3, respectively.
hence its momentum changed. A blade force uu1, uu 2, uu3 =distances from the axis v to
points 1,2, and 3, respectively.
results from the difference between the Iv =moments of inertia of axis vv.
momentum entering and the momentum Iu =moments of inertia of axis uu.
exiting the rotor blade row.
The blades are attached to the rotating
element of the machine or rotor shaft. The Forces on Rotor Blades:
resultant of blade forces is then converted
into shaft power to drive the load. On the
Turbine rotor blades are positioned
ather hand, the nozzles are attached to
in a very harsh environment .They the
the stationary part of the turbine (casing) ,
incoming , hot , fast and high pressure
as shown in
streams exiting from the nozzles. The
Fig (1-1).
loading on a rotating turbine blade is
The rotor blades facing the steam will carry
composed of:
most of the flow loading . Hence to design
i) centrifugal force due to rotation.
these blades , the flow has to be studied first ,
ii) bending force due to the fluid pressure
flow forces to be estimated and blade stresses
and
to be evaluated.
change of momentum.
iii) bending force due to centrifugal action,
Nomenclature: resulting from that the centroids of all
section do not lie along a single radial line.
Ar = cross section area of blade root.
Am = cross section area of blade middle.
At = cross section area of blade tip. Stresses:
Fcf = centrifugal force.
Rr = radius from shaft center at blade root. The steady state stress at any section of a
Rm = radius from shaft center at blade parallel sided blade is a combination of
middle. direct tensile load due to centrifugal forceb
Rt = radius from shaft center at blade tip. and the bending load due to steam force,
m = mass of blade. Both of which are acting on that portion of
Lb = blade height. blade between the section under
Mv = bending moment about the axes v. consideration and the tip section. The
Mu = bending moment about the axes u. direct tensile stress is maximum at the blade
ω = speed in radians per second. root. It is decreasing towards the blade tip.
ρ = density of blade material. The tensile stress (centrifugal stress)
cf2 =axial velocity at inlet. depends on the mass of material in the
cf3 =axial velocity at outlet. blade , blade length , rotational speed , and
Vw2 = whirl velocity at inlet. the cross sectional area of blade. Impulse
Vw3 = whirl velocity at outlet. blades are subject to bending stresses from
p2 =pressure at inlet to the moving blade. centrifugal force if the centroids of all
p3=pressure at outlet to the moving blade. sections do not lie a long a single radial line
169
and the tangential force exerted by fluid . The centrifugal stresses at the blade section
While Reaction blades have an additional are the centrifugal force in that section
bending stress that is due to the large axial divided by the area of the blade section, and
thrust resulting from the pressure drop can be written as :-
which occurs in the blade passages. The
bending stress is maximum at the blade F ( x )
σ cf (x)= cf
(1)
root. The combined tension and bending A ( x )
stress is also maximum at blade roots and
diminishes with radius. If an infinitesimal element (dz ) is separated
If the blade is tapered, the direct tensile in section (Z) shown in Fig (1-2) ,the force
stress diminishes rapidly towards the blade developed by this element during disc
tips , while the bending stress can be made rotation is :-
to increase at greater radii. It is therefore
possible to design the blade as a cantilever , 2
with constant tensile stress (centrifugal dF cf =dm. ω (Rr+z) (2)
stress ) and bending stress. The blade Where,
material is much more effectively dm=ρ. A (z). dz (3)
utilized there. Provision must be made in
the blade design to get a blade that Substituting Eq. (3) into Eq. (2) gives:-
withstands all these stresses encountered in
operation at an acceptable long service life. dF cf = ρ. ω
2
.A (z). (Rr+z) .dz (4)
Integrating gives :-
169
z
⎛ At ⎞ Lb
[
1 Ar.⎜ ⎟ .Rr.Lb
F cf (x)=ρω 2 [Rr(Lb - x) + (Lb 2 - x 2 )] (8) ⎝ Ar ⎠
2 F cf (x) = ρ.ω 2 +
⎛ At ⎞
ln⎜ ⎟
It is clear that at the tip of the blade, that is ⎝ Ar ⎠
when ( x = Lb ) , the force F cf ( Lb ) = 0 . z
⎛ At ⎞ Lb
On the ather hand the maximum centrifugal Ar.⎜ ⎟ .z.Lb
⎝ Ar ⎠ -
force is at the blade root, that is when ( x = 0
), ⎛ At ⎞
ln⎜ ⎟
the Centrifugal stress is determined by using ⎝ Ar ⎠
Eq. (6 ) , and Eq. (1) becomes:- z
⎛ At ⎞ Lb Lb
]
2
Ar.⎜ ⎟ ..Lb
Lb ⎝ Ar ⎠ x (14)
σ cf (x) = ρ . ω 2 . ∫ ( Rr + z ) dz (9) 2
⎛ ⎛ At ⎞ ⎞
x
⎜⎜ ln⎜ ⎟ ⎟⎟
where ( Z ) = A ( X ) = constant ⎝ ⎝ Ar ⎠ ⎠
It is clear that at the tip of the blade i.e at
When (x = Lb) at blade tip the centrifugal
( x = Lb) , the stress σ cf (Lb) = 0 . Whereas
force is zero, and at blade root (x = 0 ) the
the maximum centrifugal force is at the blade centrifugal force is maximum .
root ( x = 0 ).The maximal centrifugal The Centrifugal stresses are determined by
stresses for a constant cross-section area dividing Eq. (14) by Eq. (12) as follows:
blade are. Fcf ( x )
σ cf (0)= ρ . ω 2 .Lb. ( Rr+ Lb ) (10) σ cf (x) = (15)
2
A(x)
or Case C
σ cf (0)= ρ . ω 2 .Lb .Rm (11) If the variable cross–sectional area of the
moving blade follows the relation [6]:
Case B z ℜ
In this case the blade is assumed of variable A(z) =Ar- (Ar –At ) ( ) (16)
Lb
cross–sectional area . To find the centrifugal
where,
force acting on the rotor blade, it is
Ar − At
necessary to find an equation describing the ln( )
change of cross-section with blade height . A ℜ = Ar − Am (17)
relation of the form [5] is used: ln 2
z To determine the centrifugal force acting on
⎛ At ⎞ Lb the blade, Eq. (16) and Eq. (5) become:-
A(z) = Ar . ⎜ ⎟ (12)
⎝ Ar ⎠ Lb
z ℜ
For the determination of the centrifugal force F cf (x) = ρ ω 2
∫
[ Ar- (Ar –At ) (
Lb
) ]
use Eq. (12) and Eq. (5) , then:- x
Lb z ( Rr + z ) dz (18)
⎛ At ⎞
F cf (x) = ρ ω 2
∫ [ Ar . ⎜ ⎟
⎝ Ar ⎠
Lb
].
2 2
( Ar − At )
x
F cf (x)=ρ.ω [Ar(Rr.z+ z )-
(Rr +z) dz (13) 2 Lb ℜ
ℜ +1
Rr .z z ℜ + 2 Lb
( + )] x (19)
After Integration it becomes:- ℜ +1 ℜ+2
169
For the entrance or leading edge of the blade Fig (1-4) shows the variation in cross-
the stress is: sectional area with blade height for cases A,
B, and C. It is noticed that the blade area of
Mv ∗ vv1 Mu ∗ uu 1 case C is less than that for case B is less than
σ b 1 = + (33) that for case A. One can imagine the amount
Iu Iv
of area removed by comparing cases A and
While for the exit or trailing edge, it is:
C.
Fig. (1-5) shows the variation in centrifugal
Mv ∗ vv 2 Mu ∗ uu 2 force with blade height for the three cases.
σ b 2 = −
Iu Iv It shows that for all cases the centrifugal
(34) force reduces with blade height. However,in
case A a blade of (constant cross-sectional
And for a point located at the intersection of area) produced larger centrifugal force. while
the v axis and the back of the blade which of case C produce the minimum centrifugal
course is subjected to compression stresses is: force. The variation is linear. This is due to
the fact that the centrifugal force is a
Mv ∗ vv 3 function of blade height. With blade
σ b 3 =− height increase, the remaining mass of
Iu blade trying to pull away the blade from its
(35) root is reduced , hence producing less
centrifugal force. Comparing case A with
Where the negative sign stands for case C, it is noticed that the centrifugal force
compression: in case C reduces to less than one half of the
Total Stresses: centrifugal force for case A, this is because
The total stress at a given point on a the area of rotor blade is reduced.
turbine blade may be found by adding the Fig (1-6) shows the variation in centrifugal
centrifugal stress at that point to the stress with blade height for the three cases.
bending stress . This figure shows a similar trend to that for
It is clear that since the leading edge of the the centrifugal force shown in Fig. (1-5). The
blade is in tension from the bending force centrifugal stress is function of centrifugal
and the centrifugal stress, the maximum force and cross-sectional area. It again shows
stress will be found at the leading edge as that case C produces less than one half the
follows: centrifugal stress of case A as when
The total stress in leading edge point (1) is:- calculated at blade root (section of
maximum stress ). This is mainly due to the
σ t1 = σ cf + σ b 1 (36) reduction in centrifugal force.
Fig (1-7) shows the variation in bending
stress with blade height for the three cases as
The total stress in trailing edge point (2) is:- calculated for point no. (1). It shows that the
bending moment is maximum at blade root,
σ t2 = σ cf + σ b 2 (37) and reduces with blade height for the three
cases. It also shows that(26) the case A is
And the total stress in point (3) is:- producing less bending stress as when
compared to the other two cases. This can be
σ t3 = σ cf + σ b 3 (38) understood referring to the equation used to
Discussion: calculate the bending stress and the
misalignment of blade axis.
169
Fig (1-8) shows the variation in the bending 3. The use of variable cross sectional
stress of the three cases for point no. (2). It area can reduce the centrifugal force
shows that the stress increases with radius to and the centrifugal stress.
about the middle section and them starts to 4. The bending stress is greater for
drop back to zero at the blade tip. It can be variable cross sectional area blades
seen that case A gave the least stress all when compared with straight blades.
along. Again this can be understood referring 5. The total stress depends mainly on
to the mathematical expression used and the centrifugal stress and takes its trends.
misalignment of axis of the blade.
Fig (1-9) shows the variation in bending References:
stress with blade height of the three cases 1- Kostyok A. and Frolov V. ,"Steam and
for point 3. It shows that case A gaves the Gas Turbine ", English translation, Mir
minimum stress all along the blade height as publisher, Moscow, 1988.
when compared to the other two cases.
Fig (1-10) shows the variation in the total 2- Church Edwin F. ., "Steam Turbines",
stress of the three cases for point no. (1). It revised edition, McGraw-Hill book
shows that case A gives the highest stress at company Inc., London, 1987.
blade root, and all cases give a diminishing
total stress with blade height. This is due to 3-.Lee John F., "Theory and design of
the fact that the centrifugal stress is more steam and gas turbines", McGraw-Hill
dominant than the bending stress. And that book company Inc., London, 1999.
the blade of case A has the greatest mass than
the other two. And that as the radius increases 4-Mukherjee D. K., "Stresses in turbine
this mass reduces. blades Due to temperature and load
Fig (1-11) shows the variation in the total variation", ASME paper no.78-
stress of the three cases for point no. (2). GT,1988,pp.158.
Again the same discussion presented for Fig.
(1-10) can be presented here. 5- ШУбенко-ШУбИН Л. A.,
Fig (1-12) shows the variation in total stress "Прочност паровых
along the blade for point 3. It is noticed that турбин",М.,Машиностроение,
the effect of the bending stress on total stress Москва, 1993.
can not be seen. This is due to the difference
in the order of magnate of the two stresses. 6- Җирицкий Г.С., Стрункин B. A.
"Конструкции и расчёт на прочность
Conclusions: Деталей паровых и ґазовых и
The following concluding remarks can be турбин" м. машґиз, 1988.
made:
1. In the mechanical design of rotor
blades , the centrifugal force, and
hence, the centrifugal stress are
dominant as when compared with
bending.
2. The centrifugal force is maximum at
the blade root. To carry this load the
blade root cross-sectional area is
made larger as when compared to
other sections.
169
case (A)
160
case (B)
case (C)
140
120
80
60
40
20
0
0 10000 20000 30000 40000 50000
100
blade height (Mpa)
blade height (m m )
100
80
80
60
60
40
40
20
20
0
0
0 0.0002 0.0004 0.0006 0.0008
0 20 40 60 80
cross-section area (m2)
centrifugal stresses (Mpa)
169
case (A)
160 case (B)
case (A) case (C)
160
case (B)
140
case (C)
140
120
120
100
100
80
80
60
60
40
40
20
20
0
0
-8 -6 -4 -2 0
0 1 2 3 4 5
bending stresses (Mpa)
bending stresses (Mpa)
100 120
80
blade height (mm)
100
60 80
40 60
20 40
0 20
169
case (A)
160
case (B)
case (C)
140
case (A)
160
case (B)
120
case (C)
140
blade height (mm)
100
120
80
b lad e height (m m ) 100
60
80
40
60
20
40
0
0 20 40 60 80
total stress (Mpa) 20
0
Fig (1-11) Variation in total stress with 0 20 40 60 80
169
169