Effect of Damping Element Damage under Erosion on Vibration Behavior of an Industrial Gas Turbine Group-Blades

Document Type : Research Article

Authors

Faculty of Mechanical and Energy Engineering, Shahid Beheshti University, Tehran, Iran

Abstract

The last stage blade rows of modern low-pressure gas turbines are subjected to high static and dynamic loads. The centrifugal forces primarily cause the static loads due to the gas turbine's rotational speed. Dynamic loads can be caused by stationary gas forces, for example. A primary goal in designing modern and robust blade rows is to prevent high cycle fatigue caused by dynamic loads due to synchronous or non-synchronous excitation mechanisms. Damping elements are one of the most common structures to alleviate excessive vibration amplitudes in turbomachinery applications. This paper deals with fracture investigations of the gas turbine blade of a 15 MW Gas injection station in the national Iranian South oil company in the southwest of Iran. Macroscopic and scanning electron microscopy images of the fracture section of the tube show two phenomena erosion and fatigue. Therefore, to more accurately identify the cause of the failure, stress and vibration analysis of the blade is performed individually and coupled with other blades by the connecting tube using ANSYS software. To validate finite element results, the modal test of a single blade and group of blades is done. According to the observation of fatigue at the section of the tube failure and the possibility of error in the design, the sensitivity measurement of the diameter and installation position of the tube is done.

Keywords

Main Subjects


[1] M. Schubert, J. Tusche, Development of a Robust LP Blade Family for Variable Speed Applications, in:  Turbo Expo: Power for Land, Sea, and Air, American Society of Mechanical Engineers, 2018, pp. V008T029A030.
[2] J. Szwedowicz, T. Secall-Wimmel, P. Dünck-Kerst, Damping performance of axial turbine stages with loosely assembled friction bolts: The nonlinear dynamic assessment, Journal of Engineering for Gas Turbines and Power, 130(3) (2008).
[3] R. Drozdowski, L. Völker, M. Häfele, D. Vogt, Experimental and numerical investigation of the nonlinear vibrational behavior of steam turbine last stage blades with friction bolt damping elements, in:  Turbo Expo: Power for Land, Sea, and Air, American Society of Mechanical Engineers, 2015, pp. V008T026A007.
[4] J. VoldÅ™ich, J. Lazar, P. Polach, Nonlinear Vibration Analysis of Steam Turbine Rotating Wheel Equipped with the LSB48 Blades, in:  The 14th IFToMM World Congress, 2015, pp. 48-55.
[5] E. Ferhatoglu, S. Zucca, D. Botto, J. Auciello, L. Arcangeli, Nonlinear Vibration Analysis of Turbine Bladed Disks With Mid-Span Dampers, in:  Turbo Expo: Power for Land, Sea, and Air, American Society of Mechanical Engineers, 2020, pp. V011T030A020.
[6] E. Petrov, D. Ewins, Effects of damping and varying contact area at blade-disk joints in forced response analysis of bladed disk assemblies,  (2006).
[7] D. Charleux, C. Gibert, F. Thouverez, J. Dupeux, Numerical and experimental study of friction damping blade attachments of rotating bladed disks, International Journal of Rotating Machinery, 2006 (2006).
[8] E. Petrov, D. Ewins, Analytical formulation of friction interface elements for analysis of nonlinear multi-harmonic vibrations of bladed disks, J. Turbomach., 125(2) (2003) 364-371.
[9] C. Siewert, L. Panning, J. Wallaschek, C. Richter, Multiharmonic forced response analysis of a turbine blading coupled by nonlinear contact forces, Journal of Engineering for Gas Turbines and Power, 132(8) (2010).
[10] D. Laxalde, F. Thouverez, J.-P. Lombard, Forced response analysis of integrally bladed disks with friction ring dampers, Journal of Vibration and Acoustics, 132(1) (2010).
[11] S. Zucca, C.M. Firrone, M. Facchini, A method for the design of ring dampers for gears in aeronautical applications,  (2012).
[12] K.Y. Sanliturk, D.J. Ewins, A. Stanbridge, Underplatform dampers for turbine blades: theoretical modeling, analysis, and comparison with experimental data, J. Eng. Gas Turbines Power, 123(4) (2001) 919-929.
[13] E. Cigeroglu, N. An, C.-H. Menq, Forced response prediction of constrained and unconstrained structures coupled through frictional contacts, Journal of Engineering for Gas Turbines and Power, 131(2) (2009).
[14] S. Zucca, C.M. Firrone, M. Gola, Modeling underplatform dampers for turbine blades: a refined approach in the frequency domain, Journal of Vibration and Control, 19(7) (2013) 1087-1102.
[15] M. Klein, G. Simpson, The development of innovative methods for erosion testing a Russian coating on GE T64 gas turbine engine compressor blades, in:  Turbo Expo: Power for Land, Sea, and Air, 2004, pp. 347-352.
[16] A. Kochetov, D. Korzh, A. Egorov, Lowering the erosion wear of long blades of the last stages by optimum hanging, Power Technology and Engineering, 41(1) (2007) 41-46.
[17] G.I. Ilieva, Erosion failure mechanisms in turbine stage with twisted rotor blade, Engineering Failure Analysis, 70 (2016) 90-104.
[18] M.S. Khan, C. Sasikumar, A water droplet erosion-induced fatigue crack propagation and failure in X20Cr13 martensitic stainless-steel turbines working at low pressure, Engineering Failure Analysis, 139 (2022).
[19] Y. Mollapour, E. Poursaeidi, O. Pedram, Study of pitting corrosion under actual operating conditions of a first stage compressor blade, Engineering Failure Analysis, 131 (2022).
[20] P. Yang, W. Yue, J. Li, G. Bin, C. Li, Review of damage mechanism and protection of aero-engine blades based on impact properties, Engineering Failure Analysis, 140 (2022) 106570.
[21] D. Qi, P. Petrie-Repar, T. Gezork, T. Sun, Establishment of an open 3D steam turbine flutter test case, in:  12 th European Conference on Turbomachinery Fluid dynamics & Thermodynamics, EUROPEAN TURBOMACHINERY SOCIETY, 2017.
[22] C. Fuhrer, D.M. Vogt, On the impact of simulation approaches on the predicted aerodynamic damping of a low pressure steam turbine rotor, in:  Turbo Expo: Power for Land, Sea, and Air, American Society of Mechanical Engineers, 2017, pp. V008T029A007.
[23] R. Rzadkowski, V. Gnesin, L. Kolodyazhnaya, Aeroelasticity analysis of unsteady rotor blade forces and displacements in LP last stage steam turbine with various pressure distributions the stage exit, Journal of Vibration Engineering & Technologies, 6 (2018) 333-337.
[24] P. Wang, X. Wu, X. He, Vibration-Theoretic Approach to Vulnerability Analysis of Nonlinear Vehicle Platoons, IEEE Transactions on Intelligent Transportation Systems,  (2023).
[25] D. Graciano, J. Rodríguez, G. Urquiza, M. Tecpoyotl-Torres, Damage evaluation and life assessment of steam turbine blades, Theoretical and Applied Fracture Mechanics, 124 (2023) 103782.
[26] Y. Wang, D. Luo, Y. Huang, Y. Peng, X. Wang, X. Yan, H. Xiao, Z. Huang, Nonlinear dynamic model of a turbine blade considering vibration and crack coupling, Journal of Theoretical and Applied Mechanics, 62(1) (2024) 75-88.
[27] P. Hu, Q. Meng, W. Fan, W. Gu, J. Wan, Q. Li, Vibration characteristics and life prediction of last stage blade in steam turbine Based on wet steam model, Engineering Failure Analysis,  (2024) 108127.
[28] X. Kan, B. Zhao, A New Method of Reducing the Vibration Localization of the Multi-packet Whole Mistuned Bladed Disk System Using Bladed Packets, International Journal of Aeronautical and Space Sciences, 22(4) (2021) 857-865.
[29] A. Chatterjee, Lumped parameter modelling of turbine blade packets for analysis of modal characteristics and identification of damage induced mistuning, Applied Mathematical Modelling, 40(3) (2016) 2119-2133.
[30] A. Chatterjee, M.S. Kotambkar, Modal characteristics of turbine blade packets under lacing wire damage induced mistuning, Journal of Sound and Vibration, 343 (2015) 49-70.
[31] G. Ma, M. Xu, L. Dong, Z. Zhang, Multi-point suspension design and stability analysis of a scaled hoop truss antenna structure, International Journal of Structural Stability and Dynamics, 21(06) (2021) 2150077.
[32] X. Kan, K. Wang, B. Zhao, Dynamic characteristics of vibration localization of mistuned bladed disk due to shroud and blade damages, Journal of Low Frequency Noise, Vibration and Active Control, 43(1) (2024) 405-417.
[33] Chapter 10 - Advances and Innovations in LNG Industry, in: S. Mokhatab, J.Y. Mak, J.V. Valappil, D.A. Wood (Eds.) Handbook of Liquefied Natural Gas, Gulf Professional Publishing, Boston, 2014, pp. 437-464.
[34] B. Salehnasab, E. Poursaeidi, S.A. Mortazavi, G.H. Farokhian, Hot corrosion failure in the first stage nozzle of a gas turbine engine, Engineering Failure Analysis, 60 (2016) 316-325.
[35] J. Zhang, P. Shan, K. Cheng, D. Ye, Comparison of Blade Tip Timing With Strain Gauge Data for Evaluation of Dynamic Characterization of Last Stage Blade With Interlocked Shroud for Steam Turbine, in:  ASME Turbo Expo 2018: Turbomachinery Technical Conference and Exposition, 2018.