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1 INTRODUCTION
In modern day world, Application of steam turbine as a device that is used to
transform the thermal energy of the steam into mechanical energy by turning the rotor
blades. Steam turbines are used as prime movers in all thermal and nuclear power
plants to produce electricity, large ships, pumps and fans at petrochemical plants. The
majority of steam turbines have two essential components or sets of such components.
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They are Nozzle , Blade or Deflector, The Simple Impulse Steam Turbine is shown
diagrammatically in fig.1.1. The top bit of the figure demonstrates a longitudinal
segment through the upper portion of the turbine, the center bit demonstrates an
development of the nozzles and blading, while the lower part of the outline indicates
roughly how the absolute pressure end, the absolute velocity of the steam differ from
point to indicating the entry of the steam through the turbine.
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designers. Various alloy compositions are developed which have a good stability to
withstand the thermal stresses, these alloys have been modified to give good erosioncorrosion characteristics to the blade. Among these various materials, the few which
have found to be apt for use in blades are steels, titanium alloys and nickel-based
alloys. All the three types of alloys, which are mainly used, have variations in the
proportion of chromium and aluminum to improve the strength and corrosion at high
temperature. Nickel alloys have also been developed extensively and are currently
being used for steam turbine engine. These alloys have superior strength and
oxidation resistance even though nickel by itself has poor oxidation resistance. This
weakness is overcome by alloying with chromium. In alloys, chromium is generally
20 30 % and forms chromium oxide (Cr2O3) protective layer and chromium carbide.
Other elements generally added are aluminum, titanium and niobium to improve the
strength at high temperature. Current alloys also use cobalt, hafnium, boron,
zirconium, molybdenum etc.
Blades are mounted on a disc in series, hence care must be taken in design and
material selection to avoid the catastrophic failure of the disc, based on yield and
ultimate strength at different temperatures, resistance to creep relaxation and good
fracture toughness at ambient temperature conditions and operating temperatures.
Steel based alloy performed these characteristics and lower levels of sulfur and
phosphorous results in the attainment of a high strength, tempered, lower bainite
structures having high toughness. In the present work chromium vanadium steel alloy
with different proportion is used for Disc. The fig.1.3 shows a conventional bladed
disc assembly used in turbines.
R = 0
(1)
We know that, the differential equation of motion for rotating disk at equilibrium is
r 1
( r ) Rr 0
r r
Where
(2)
r
( r ) 2 r 2
r
(3)
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2 r 2
r
The compatibility equation for rotational disk is
After simplification of eq.3, we get
1
(4)
( r )
r
r
After substituting the Generalized Hooks law, the relations for the plane stress
condtion in the above equation,
1
( r )
E
r = Radial Strain, = Tangential strain
1
( r )
E
2 r 2
Er
r
2 2
r
E r
r
Radial strain
Tangential strain
dr r
C1
C
1
r 2
8
2
r
Where C1 and C2 are constant of integration and can be found by initial
conditions.
Substitute the Airys stress function in the above equation, we get
(3 ) 2 r 3
1
8
C1 C2
2 r2
1
8
C1 C2
2 r2
(5)
(6)
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At
r = a,
r = 0, and
r = b, r = 0
We can find the constant of integration i.e. C1 and C2.
1
a 2b 2
The Radial Stress induced is r (3 ) 2 (a 2 b 2 ) 2 r 2
8
r
1
8
(3 ) 2 (a 2 b 2 )
a 2 b 2 1 3 2
r
3
r2
the maximum radial stress ( r ) max and maximum ( ) max and minimum ( ) min
tangential stress for the rotating disk due to centrifugal load, Differentiating the above
equation with respects to radius r
The maximum radial stress at r = ab is
1
(3 ) 2 (a 2 b 2 )
( r ) max= 8
Induced Maximum tangential stress at r = a,
2
( ) max 1 (3 ) 2b 2 1 1 a
2
3 b
Minimum tangential stress at r = b i.e.
4
( ) min is
( ) min
1 b 2
1
(3 ) 2 a 2 1
2
4
3 a
2. NUMERICAL METHODOLOGIES:
2.1 Geometric Modeling of Blade and Disc Assembly
For the present analysis the blades of the HP stage row were considered. Generally
the HP stage blades are tip shrouded, because they have to resist huge bending forces
produced by the steam loads. The geometry of the blade disc sector is modeled using
commercially available modeling software CatiaV5. A minimum of 30 co-ordinate
points at each section are selected from the list to represent the geometry as accurately
as possible. These coordinates are used to generate the aerofoil surface. T-root of the
blade is reproduced with best possible fillet to avoid sharp corner of the blade for
analysis. The geometric model of HP stage bladed disc is as shown in fig.2.1.
Blade Dimention:
Blade height= 26.2mm
Thickness of leading edge = 3 to 5mm
Thickness of trailing edge= 0.19 to 0.2mm
Number of blades = 60
Sector angle = 60
Mean diameter = 250 to 350mm
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Fig.2.4 FE Model
of Blade Disc Sector
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i.e., normal contact with axial motion is restricted and sliding motion is possible with
other directions. In the analyses rotational speed of 6000 rpm and 7200 rpm is
considered for operating and over speed conditions respectively
Blade
(Cr 13MoV59)
2.18e5MPa
7750 Kg/m3
0.33
540Mpa
Disc
(28CrMoV55)
2.11e5 MPa
7800 Kg/m3
0.3
590Mpa
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Figure 3.5 Average Von-Mises Stress Distribution at Minimum Cross Section of Disc
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100% speed in
MPa
101.04
125.55
120% speed in
MPa
145.49
180.792
Design limit in
MPa
540
590
FOS at
100% speed
5.3
4.7
Mode1
(Hz)
Mode2
(Hz)
Mode3
(Hz)
Mode4
(Hz)
Mode5
(Hz)
1138
3242.9
3536.2
4767.5
5157.8
6000
1153.2
3258
3549.7
4771.6
5173.8
7200
1159.7
3265.1
3562.1
4775.9
5185.2
Mode1
Mode 2
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Mode3
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Mode 4
Mode 5
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considering size factor, shape factor, surface finish factor etc. The safety factor for the
blade and disc is as shown in fig.3.11 and fig 3.12 is varying from 2.3074 to 15. This
also ensures the safety of the blade at operating conditions.
Figure 3.13 Factor of Safety for Blade and Disc under Fatigue Loading
4. CONCLUSIONS
The considerations for structural, vibration and fatigue analysis is obtained the
following conclusions for the present work.
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1. The radial expansion of blade at operating conditions is safe and found within
the safe limit. Hence there is no wear and tear of blade with the turbine casing
even at higher speeds.
2. The average stress developed in the blade, neck and the minimum disc cross
section at 100% and 120% is also shows the complete safety of the blade and
the disc from total yielding point of view.
3. The calculated natural frequencies should not match with any of the forced
frequency resulting from the running speed of turbine, NPF (nozzle passing
frequency), partial steam admission in the turbine at operating speed.
4. The peak stress developed at blade root filet due to centrifugal spin as resulted
in the LCF of 1.917e5 and 1.8119e5 number of cycles in blade and disc
respectively by meeting the important design requirements from both local
stress-strain approach and stress based (Zero-Max- Zero) fatigue analysis.
Therefore, with this novel work gives an approach for evaluation of a HP stage
Blade in a steam turbine is established in a methodical way and an effort has been
made to formulate the best method to understand and apply the same procedures for
estimation of the strength of the blade and the disc in regular design practice.
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