Blade Vibration Audit Technology | SwRI Page 1 of 5

Advanced science.  Applied technology. 

BLADE VIBRATION AUDIT

TECHNOLOGY
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›› Blade Vibration Audit Technology

HOW CAN WE HELP YOU?

✉ JUSTIN HOLLINGSWORTH

(/CONTENT/CLIENT-SERVICES-CONTACT-FORM?CSID=9097&URL=BLADE-
VIBRATION-AUDIT-TECHNOLOGY)

+1 210 522 2537 (tel:1 210 522 2537)

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DIAGNOSTIC METHODS TO DETECT

AND AVOID HIGH-CYCLE FATIGUE
DAMAGE

H
igh-cycle fatigue (HCF) is avoided in rotating turbine blades by controlling
vibratory stresses. Long blades are designed by tuning the lower natural
frequencies to avoid operating near strong excitations and high vibratory
stresses.

When the natural frequency variance is greater than an acceptable band, the
blades must be designed with sufficient stiffness to limit stresses when blades
operate at resonance. HCF failures can occur when these conditions are not met
or if excessive excitations occur because of:

• Vane damage
• Rotating stall
• Flutter
• Blade tip rubbing

The variability of blade fabrication can influence natural frequencies on assembly;

wear and erosion can reduce resonant frequency margins over time. Either of
these conditions can result in high-cycle fatigue damage.

BLADE AUDIT APPROACHES

There are several blade audit approaches used by Southwest Research Institute
(SwRI) that can provide information on frequency margins and stress levels for
turbine blades that have experienced HCF failures. Because these methods are
based on testing of the actual blades in service, they relate to the actual
installation and the mix of variables associated with fabrication, assembly, wear,
and such.

The blade vibration audit methods used by SwRI include the following:

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• Blade Frequency Audit provides experimental data for comparison with

excitation at integral order sources. The method requires impulse testing of
the blades installed in the turbine slots or of a set of blades mounted in a
bench top fixture. Frequency margins at operating conditions are deduced
by adjusting measured frequencies for temperature and centrifugal force
effects. The data are plotted on a Campbell diagram to illustrate the
frequency margins from integral order sources.
• Blade Modal Analysis provides a means to define the vibratory motion for
each blade natural frequency. This illustration is useful for redesign of blade
sets to avoid resonances. For example, the shrouds and lashing are features
that can be readily adjusted for grouped blade sets to affect their natural
frequencies. Modal analysis requires that a number of vibration points be
recorded for each test to clearly define the details of motion. The required
mass and stiffness changes to tune natural frequencies can be estimated
with acceptable accuracy.
• Excitation of Rotating Blades is caused by passage through stationary
wakes and flow distortions. Vector summation of modulating axial velocity
with constant tangential velocity results in modulation in velocity relative to
blade. Relative velocity modulation is used to calculate lift pulsation
(pressure modulation).
• Blade Vibratory Stress Audit provides experimental data for estimating
operating blade stresses. An "on resonance" stress analysis is applied to
high-frequency modes or to evaluate transient conditions of lower
frequency resonances. Blade transfer function data are recorded by impulse
testing with strain gauges mounted at suspected failure locations. Operating
stresses are calculated from the measured strain/force function, with
dynamic forces based on steady gas load and dynamic factor, frequency
margins, and damping. Calculated stresses are compared with the
endurance limits for the blade material to determine the prospects for HCF
damage.
• Probabilistic Analysis assesses the risk of failure of any one blade in a
group based on statistical information. Failure could be associated with the
probability that one blade will operate with less than adequate frequency
margin or the probability that vibratory stress will exceed the endurance
limit for some period of time. An accurate measure of probability of failure
or risk times the consequence of failure is useful for financial evaluations of
maintenance and repair options.
• Nonintrusive Monitoring is a technique developed by SwRI to detect shifts
in blade natural frequency margins that contribute to high vibratory

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stresses. The method requires sensitive, high-frequency accelerometers

mounted at the bearings that are calibrated to sense blade vibration
sources. Data are continually recorded, filtered, averaged, and analyzed for
synchronous multiples of running speed. Phase and amplitude trends are
monitored and diagnosed for resonance and damping using modal fitting
algorithms. The method will detect resonant frequency shifts for all blades
or blade groups in a stage. Multiple blade rows can be monitored if their
natural frequencies are separated by at least one rotational order.
• Telemetry Testing or Slip Ring Systems can be provided by SwRI when
blade resonant responses are required at rotating conditions to assure that
all blade-to-blade interaction and CF stiffening effects are included. Strain
gages are attached at critical stress locations, wires are routed along the
blade and rotor to a rotating transmitter, and the signals are received
through a stationary antenna to stationary recording equipment.

APPLICATIONS
All rotating blades, buckets, impellers; all stationary vanes, nozzles, and struts
used in gas turbines, steam turbines, compressors, fans, expanders, and similar
rotating equipment.

SUPPORTING TECHNOLOGY
• Full metallurgical laboratory is usually required when conducting a root
cause failure analysis (/node/8634) with capabilities to identify fracture
mechanisms, confirm material specifications, and evaluate environmental
contributions.
• Field monitoring and diagnostic services (/node/9006) to record and evaluate
machinery vibration, pulsation, strain, and performance, at site locations.
• Dynamic and thermal analysis (/node/9007) capabilities to evaluate
structural and fluid dynamics of disks, airfoils, attachments, and such.
• Fracture mechanics analyses (/node/9017) and life prediction.

SwRI can offer you a full range of capabilities and experience in gas turbine
technology including becoming an extension of your engineering department. To
contract with SwRI, please contact the Machinery Services Hotline at +1 210 522
3000.

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For more information, contact Justin R. Hollingsworth (/user/401/contact?

path=/blade-vibration-audit-
technology&page=QmxhZGUgVmlicmF0aW9uIEF1ZGl0IFRlY2hub2xvZ3k=) or call
+1 210 522 2537.

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