STEAM TURBINE BLADE FAILURES, CAUSES AND CORRECTION by John S. Sohre Consultant Vernon, Connecticut Jn 8, Sobre graduated from the Siete nt Teel, Chem Germany in 1951. He is @ Professional Engine! in the sate of Peay Heise member of ASME ‘ins Sohres cxpertence Includes 9 years of hop work soon sembly me EE His neicering experience tater 8 Wee, Wechancl Dean and Engineer, ing Mechanic Section, Turbines and Compressors. He pent? trait he Tony Stam Turbine Conny os Che Eng eer being eqponseferdaxcopmento Try styelS neg turbines for high-speed, high-horsepower service. Since July 1570 he hs boenan independent conotan for Turbomacin. ory Design, instalation an problem covecton ABSTRACT ‘This paper is meant to help with failure investigation, presenting a review of the causes and effects involved when, blades fail. Included are descriptions of failure mechanisms (stress; resonance; environment) and ofthe conditions causing the failures (design; material; manufacturing: operation). Also Included are chapters on failure analysis, evaluation of circum- stantial evidence, faire history, and investigative procedures ‘A table coordinates causes and effect. ‘An appendix explains methods used to compare stress levels against allowable values. INTRODUCTION ‘The requirements of variable speed and of stating while under load impose much more severe conditions upon the blading of Mechanical-Drive (MD) turbines thas, those perienced with turbine generators. At this time, blade relia ity represents a limit of technology in the development of large turbines, and it thereby introduces limiting fators into the design of process plants Vertical hima: 1.0 Failure Mechanisms LI Excessive stress 1.2 Resonance 1.3 Environmental effects NOMENCLATURE © = Steam velocity see $= Blade foil with; chord or ail, at base C= Steam velocity, at norze exit S__ = Stimulus of excitation B_ = Diameter. Pitch (mean) diameter of blading SF = A stress-level factor, for comparative purposes unless otfecwise specified inches ou SF = Lo sol cosy © nor E = Modulus of elasticity; Hale, in Servative stess levels, 2.0 indicating posible hi A Soxaveaar eae ere stress conditions worth checking, Note that this f= multiple of a parts weight (1B weight at 10,000 a very crude indiator and conclusions should not pulls wth 10,000 Ibs). be based on it. All it ts meant to indieate eee ae Whether or not a detailed check appears advisable Seam How: u Pitch line speed: ftsec., = D x RPM/229 Heat drop acost stage, usualy entropies BTU YT ih tne pee Mee Mode response factor for resonant vibration ee Stage horsepower w Root width, axial; in. ook ee factory reatve to fil base: Kn = 1 fr wy, = Blade ext velocity, relative to arf fisec. est oye factor = 1.0 for top-quality, and pine. t-® Bladetoblade pitch, at pitch diameter oF root tree root, axl o¢ tangential entry (with restraining Z_—™ Number of pulses of excitation per revolution lips) @ = Load-dissipation doefficient for shroud and/or 2 = Blade length usually from tp to base of fn) lashing eres m= Mase bs sein, i, = Foil exit angle: degrees M_ = Mach number at blade exit = velocity/acoustie 7 = Specie weight sf in velocity 3 = Damping coeficient Rotor speed; RPM € Admission ratio [180° admission are 0 (e=.5)] n= Mode of resonant vibration; eps 1 = Eficieney P= Pressure; psi pi=nozde inlet pressure, pa=bucket_ ‘Resonant frequency of blade; cps ent pressure a= Stress. See Appendix for defntions RPM = Revolutions per minute0 PROCEEDINGS OF THE FOURTH TURROMACHINERY SYMPOSIUM Horizontal headings: 2.0 Engineering, Design, Service Conditions 2.1 Blade design 22 Material 2.3 Manufacturing elfects 24 Stage environment and operating conditions 2.5 Maintenance offects 3.0 Symproms anel Evidence 3.1 Failure location 3.2 Fracture analysis 3.8 Surrounding evidence 34 Fallure history 3S Operating symptoms 4.0 Investigative Procedures 5.0 Remedial Action ‘The tables attempt to show areas of possible interaction: 1= possible correlation 2= probable correlation 3=highly probable correlation ‘These indicators are not meant to reflect statistica prob- abilities, but rather t show us what areas 4 fook into, and the degree of likelihood thar 2 correlation exists. The indicators tlso show us in which areas we ean oxpect the most effective ieprovements. Only the most essential considerations are covered, in a simplified and condensed format, suitable for use during failure favestgation. The procedures are not meant to be used for design analysis, being too erude for this purpose GENERAL CONSIDERATIONS When a blade failure occurs, the fst reflex reaction is usually "Resonanco!”, and off we go, into a lengthy and costly exploration of all the possible (and sometimes impossible) ‘modes of resonant vibration. We are all aware ofthe exceeding- ly detrimental effects of resonance, but it may be # good idea to sit back a minute and to consider a few basic facts Operation on resonant frequencies, under load, and in telatvely poor steam, is a fect of life with most, mechanieal- drive turbines. This fs the reason wo have such difeultis building machines over, say, 60,000 HIP, while the generator drives are far bisger, having 30 in lades inning 200020 tipspeed. The fist resonant mode ofa ixestage Dade will be about 2000 to 6000 eps, while an 15” laststage lade will come ‘out around 100 9 150 cps. The intermediate stages wil eover ‘he spectrum between these values, Considering the many ‘mores of direct, harmonic and subharmome excitation fr each of these resonant mods, there can hardly be any doubt that wwe will in on some resonances while — and this may be more important —we wil also have to pas through some of the most destructive modes during each start. accumulating. quite a few thousand highstressejeles each tine. For constant speed and no-load starting we can tune blades to avoid resonances, but not so with varlable-speed MD turbines. Evidently, certain blades mast be strong enough 10 op- erate under resonant conditions, and feof hese resonances Sl be sever. Ifa non-defective blade fs under hese com tons, was obviouny ton weak fr this Kn of sre, and stresses most be reduced to make i survive Getting vt of a fevere resonance assuming this foe the main prable) i Se i ai yn eh ny ay any & rule, 4 very Iegthy operation, involving many nce {alnteswhich can resul repeat falures and plant shutdowns ‘The weakness ofa blade — or its exposure to highly detimental \workingeeonditions is often quite obvious, and in most eases itispossible to reduce stress by sch means as making the bad ing Stonger, using beter design and quality, and by adding damping by means of caulking strips and lashing, if resonance ‘ssuspected, Excitation en be educed by smoothing the steam path. Load dissipation canbe improved by means of shrovding tnd lashing, to name a few possiblities, Other important ia provements may be obtained by using a different material, providing better, less eorroive steam: giving more attention to tmode of operation (led, back-pressire, ete.) Many more redatly applicable measures are svalable It is important to remember that blading must have a generous safety margin, 0 survive the nay abuses to which it will be exposed. I flues have occarred, it proves beyond argument that the actual margin was insufficient, for whatever reason. Itis mandatory that stress, strength, load, ov environ- ment be improved by a known factor ofa feast 9, expecaly 50 incase of repeat fsures. A minor improvement, sy 20% — such as may be obtained by better surlace finish, shot-peening, caulking ete: — fg not adequate to establish «definite mini ‘nom level of reliability. Such minor improvements may well work in some eases, and they ae, of course, aways desirable, ‘bu they should never be regarded as satisatory solutions by themselves ‘One curious situation can be observed more often than not: Money and time are spent generously ow the analysis of the failed blade, but when the time comes to make the hard- ware stronger, people settle for the skimpiest kind of improve- ment ~for cost reasons! Wauld it not be better the other way around? Homever, should always be kept firmly in mind that lade strength is, roughly, a linear function of cost, all things considered. This includes wheels and turbine length, critical speeds, ete., ete. There is no sense in asking for a stronger blade unless you are willing to foot the bill. Furthermore, in ‘any cases the problem originates with nozzles and flow irveg- tlarties. Good diaphragms are cery expensive! FAILURE INVESTIGATION 1.0 Failure Mechanisms 1.1.0 Excessive Stress ‘The total stress at any location of a blade consists of Cen- trifugal tension + centrifugal bending + steady’steam bending. + alternating bending. See appendix for stress criteria. Al- temating bending s the product of. steady bending x damping x stimulus of excitation x load dissipation (Shroud) x resonant response. LL Centrifugal Stress In steam carbines, contrifogal stress is never the principal ‘cause ofa lade failure, except inthe rare eases of turbine run- away (including reverse-rotation), or possibly with frequent start/stop service (low-oyele fatigue), Pare centrifugal stress failure would occur at 3 to 4 times normal design stress, or 15% to 100% overspeed. The failure appearance would be quite striking, being characterized by strong fracture elongation {about 20%) and area reduction in the critical areas, andlor by stripping of the rot serrations, the way threads are stripped ‘on overloaded bolts. However, centrifugal stress isan important contributing factor with fatigue failures, corrosion fatigue failures, and stressHART NO) Ore Ane FA Sx ae an Gc BATT |] amore a8) SIO axssmetng env a2ovs? a aloft Sapte. Pl] Il ml [| mal afol I alo] mo] [abl l ac lal ts | allt m)sdof | fal of | [ofl oll Tobe [l lols | at Hall = ras : a] afm i mt_[S m7 rstolroloa) 348 4 [half stata fe! |B a = Folland [REP |g ST Te =o) milo a4 fool] atta | fl col feal ralnfol _nlof all Fal _foot I feol nll ES) offs ole 5 ron aval TT t a im|ra| | a a IGS ralnlo ra Im ma] | SER ICSE ERCCEo N A al Tl Rall cs a alm a ial [ro alm 5 mal of af i coll saps a apal=bsalala || lal) [al sll ial = [al cofesfrol fl el fl ofa] vf fl] ml [ml gd dee . [ [ mm faim, _[m fa : ola) Gs He . 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IngsNvEL ~Im[al | |_| mf Ses RE SST [ol sisTad SER EER I asf Sfe[S[e hb) [>is malas Infroleofesfel fom st TS, alls] sles ROS eo[s EI Isle a = in |, Wad arTade Devnet iiped LaL a > jee) a) mc) mals Se ee = | | io TS. os EMEIEAEIES WOLWIOA TAVNOEIY 70 300K ENV ™| | T TIARA SY AO ~ KONI | =| [a] ml [slo mm] 9] oa] oa] ole] Stasiatate ates Palstotateteeieta[aietiatal pate ai | 9] ~[s] ~| 1.15}, even at normal operating conditions, i the blading is too short for the steam flow. Then, the exhaust pressure atthe blade throat is considerably higher than the condenser pressure, and the steam will expand again after leaving the bucket throat, as it enters into the exhaust hood behind the blades. This is essen- tially the same situation as would result from operation with excessive vacuum, but it is even worse because the throat pressure in the bucket is higher than designed, in addition to ‘possibly very high Mach Number. Usually the exhaust casing {s also built undersize with such machines. Ths ean be verified by checking the steam velocities across the horizontal split and at the exhaust Dange. If filures are caused by this mechanism and/or overload, the exhaust pressure can be increased so as to get Mz down to 115-135, -Non-condensing turbines Conditions are similar to condensing turbines, especially with respect to operation atthe proper backpressure. Too low a backpressure can eause the strongest buckets to fail. Warning devices for low backpressure would be very valuable, but are seldom used in practice. The lst stage blading of backpressure machines is often relatively short and there is a danger of ‘excitation at the nozale-passing frequencies as well a5 har- ‘monies or sub-harmonics thereof. Both steam stress and centrifugal forces are important. Corrosion fatigue is often a problem because the list stage may operate in the dry/wetSTEAM TURBINE BLADE FAILURES, CAUSES AND CORRECTION 5 region. If fulures persist and temperatures are not too high, ‘itaniums blading may provide an answer in such eases 2.2 Material Quality is important, not just physicals and chemicals Material ofall failed blades should be identified, Not that high yield strength and hardness will not improve the endurance strength heyond a certain point, if corrosive environment is considered. Iyield strength is much above 90,000 psi, material ‘becomes susceptible to corrosion fatigue, 12% Cr Stainless, types 403 and 422 (hot region) are stan- dard, but do not overlook the possibilities of titanium in the lower temperature zones, especially below about 450°. It is by far the best way to get out of serious corrosion-fatigue and erosion problems, since it does wat require time-consuming design changes. 2.3 Manufacturing About all items listed occur frequently. with careless assembly, surface imperfections, and dimensional errors head- ing the list. 24 Stage Environment and Operating Conditions Most frequently, improvements can be made by avoiding ‘operating, upsets (don't “jockey” the machine at the slightest pretext), by providing elean steam and correct steam condi tions. It is sometimes incredible how much actual operating conditions (vacuum! vary from design. 2.5 Maintenance Frequent problems arse from Improper blade replacement procedures (locking pins not fited right, inserting slot elongated) -Not all blades of a wheel replaced afte a fatigue failure. ‘This is a frequent mistake. And then people are surprised when they have one failure ater another! “Abrasive blasting used to remove deposits. A very common problem. Itcan change the contours (trailing edges), leaving stress concentrations. Shot-peeninglayets will definitely be damaged, leaving the blades with residual stresses and ‘minus the considerable benefit of the peening-layer. 3.0 Symptoms and Evidence 8.1 Failure location (fatigue falures), on blade assembly ‘This ean provide good clues concerning the destructive smechanisin ¥ailure in shroud or lashing is proof that the shroud or lash ing assembly was too weak to perform its function to diss pate oscillating loads (by averaging the pulsations on each blade in sucha way a to cancel the total forthe entire packet as far as possible). This could be a result of design weak ness, unexpected resonances, corrosives, or menufacturing, deficiencies (shroud not pulled down). Usually several of these factors are involved “ALi base or root: With ong blades this indicates a prab- ability of resonance. With shorter blades, it is a sign of in sufficient shroud stiffness, or of a poor shroud dissipation factor (a, or of a weak blade design (too narrow, poor root) Always check for poor shroud design andlor assembly. and for rtting mark at sl contact porte, * “Poll ater than base: Higher mode resonance “At or near locking piece: Slot to0 long, pin improperly fitted, blade (ifused) at end of shroud packet (= high stress), disk vibration locking lade is source of excitation) ‘Wheel root: Very rare with straddled blades. Common is circumferential cracking of wheel rims with internal roots not having restraining lips to hold the rim together (a low performance design). See Figs. 17 and 18. These failures Indicate see-saw modes ofthe packets (which are encouraged by these weak rims) often in conjunction with disk vibra- tion, corrosive action, poor shrouding, Figure 17, Pull-test showing effectiveness of retaining lips, preventing rimbending. (6) Figure 18. Typical rim failure caused by axial vibrations and Tack of reteining ips (see Figure 17). Shims in crack are 4 mils thick. (8) 3.2 Fracture Analysis See “Failure Mechanisms” forcorrelations: One can get an Idea of fatigue damage accumulated in apparently healthy blades by holding the root of a blade firmly () in a vise, with top of jaws at failure location. Then bend blade with a long pipe andjor hit hard with a sledgehammer. This sometimes tells a Jot about remaining ductility. Some of these blades may break likea poor grade of cast-iron (especially the ones having cracks), showing very little ductility anda very coarse fracture surface This givesaclue about magnitude ofstress-levels involved, and their distribution asound the wheel and within the packets 3.3 Surrounding Evidence Most correlations wil be selfevident from the table. Neke that water slugging will bend the blades backwards,26 PROCEEDINGS OF THE FOURTH If blades are loose in the wheel, look for a disk vibration pattem, and for evidence of overspeeding (reverse rotation) Otherwise either poor fit or excessive stress, centrifugal oF steam. Can be eaused by water shigging or water washing, Axial rim rubs not uniform around the circumference of sim, shroud, o blading may indicate heavy disk vibration, Look for pattern. 9.4 Failare History Failure shortly after original start-up, or while bringing the plant to capacity, often indicate inadequate design andior construction, but also steam system problems. Failures may ‘occur after steam system modification (more load on boiler, new boiler onstream, pipe slope shifted and dumping water. 3.5 Operating Symptoms Blade failures give little or no warning, but sometimes one ean spot conditions which may lead to failure. & very high- pitched noise may indicate disk vibration. 150, it would dis- appear completely with a mince speed change (10-20 RPM), as these resonances have a very sharp peak ‘Taking avibration spectrum on shaft, case, or steam (noise) is probably the best way to get some data suitable for monitor ing, See Fig. 19 and Ref. (2) TRATIONS NERTASE Pade naTunac PEO er CRESS Ti SPL FREQUENCY He Figure 19. Excitation of lower blade natural frequencies as @ function of speed (Hydrocarbon Processing, April 1974). Compressor surging, if prolonged, ean be murder for the blades if it eauses speed cycling and/or govemor action, be cause it is very likely to eycle one or more stages through Note that water slogging ean be detected by watching the governor valves. As the water slows the unit down, the govern: or valves will open wide to maintain speed, then close, and finally come back to normal. A valve-position recorder (must be {fast — no \6-point recorders!) can be used to verify this, A ‘real fast thermocouple in the steam line can also be sed, but itis not as foolproof, ‘Water slugging is also a prime cause of rotor-bow, easing distortion, nozzle-bovwl-cracking and thrust fulures (always on active side). This gives another clue. 4.0 Investigation Procedure It is obviously not possible to cover all types of problems and possibilities. A few general rules are given below, for @ grass-roots type of investigation, See also notes on chart \BOMACHINERY SYMPOS! 4.1 Inspection Open turbine as soon as possible after fallure. Be present when eurbine is opened. -Keep away people with rags, scraping knives, and an uncon trollable urge to touch things — such as failure surfaces, coatings, ete ‘Take photos, notes, samples of deposits. Make sure to get precise condition and position of nozzles, windage shields flow obstructions. Wrap fractured blades in clean rags, then ppt in box with small bag of silica gel (‘De Mois,” available in hardware store), seal box with tape. -Spray thin film of clear lacquer on exposed fracture surfaces in rotor (later to be removed with acetone}. -Remove rotor to shop for disassembly, Don't let, people touch anything they don't have to handle! Don't allow blast-cleaning, oiling, or any surface treatment. Carefully inspect shroud assembly (check for clearance with Teelergauge) Take sumple of any deposits under shroud, cheek fr lesoness, rubs, snusalfowemarkingy.Gghness ctlokinganby, Check for ight ck heel Geer ge), Bomp-teet wheel (3) 0 get ania of ds equen: fies Note sound of wheel and blades when tapped. Ifwheel Sounds dul, make sure to. magnetcrpartce check for crac, especially Keyways,saltdsk fonction (integral), incertingelt area -Number each blade at top and bottom using electrie pene! Make map, to full scale, showing packet locations “Remove blades very, very carefully, paying special attention to inserting area. Be there to witness. Make sure to give complete instructions. Don't allow lubricants (penetrating oil) unless there is absolutely no other way. Inspect eac! blade as it comes out. Put in special, fat, clean box in same circle as original assembly, print of map on bottom. Check teach blade for tightness of assembly before removal. If blades are shrouded, cut fils in half in lathe ar band saw (preferred). This is why we need two numbers per bade. Have all blades magnetic-particle inspected for eracks (Dye check is no good for this). Mark location of cracked blades on map, with details. Check failure pattern for signs of wheel vibration (90 and 180” or 30.60-120". Break cracked blades. First try to break at room tempera ture, noting signs of embrittlement and loss of strength, mark thison map. 1ftoo tough, coo! blades in liquid nitrogen and try again, using impact ‘Immediately register (and photograph) any coloration of the fatigue portion of the fracture surface, other then silver, or rey. Preserve blades in dry-box, fr immediate metallur- ‘ical inspection Go through complete final inspection, including surfaces, dimensional accuracy, metallurgy, etc Go through operating logs, inspect installation, boilers, feedwater apparatus, piping, condenser, drains, plant his- tory, turbine history, history of other turbines and steamSTEAM TURBINE BLADE FAILURES, CAUSES AND CORRECTION a sor PyLe -FEST, EXAMPLE: | TORT RERPORT RGR RAE ETRY PBR] arennt, "03, by "8000 Pe el [cece rae sremp (40) face etait poo os vile) ae Ripwaariaw, wee au L Figure 20. Pull test of axial-entry, Bland pinetree root, mounted in a wheel rim section Note successive loading and unloading, for the purpose of finding yield point. Ref (3) (7) 5.0 Remedial Action Regardless of the type af failure, a few improvements cean usually be made. This list describes possibilities in se- {quence of effectiveness. The obvious improvements of quality of hardware, steam and operation are not listed. Neither are solutions requiring re-design, Of course, stresses must be checked and adequate procedures used. a. Hardware If in cold end, vse titanium blades, with vacuumavelded shroud “If blades are 1” or less in width, silver-solder shrouds to blade tips. New blading only, as it requires surface prepara tion, Requires careful metallurgical control. Steel tempera- tures not toexoced = 1300" , coo! very slowly to prevent ait hardening, “Use heaviest possible shrouding. Consider titanium shroud. Check centrifugal stress. Cannot make shroud heavier if s-load is over ~ 35,000. -IF centers of gravity of root, fel, and shroud ate not in a racial line, or with packer-type blades, get correctly propor= tioned, integral blades made, with same root, airfoil, ete to fit the existing disk. -lnstall additional lashing wires, if blade is long. Install damping wites or strips in root, possibly in shrowd On existing assemblies, install axial damper-pins (1/6 to YS" Dia) through root platforms, between blades. ». Operational If first stage, throttle on TET valve until governor is nearly ‘wide-open, This increases steam consumption but lowers pressure-drop across frst stage to the minimum. Make sure ‘TET fs suitable for continuous throttling and that it wil trip reliably in part-open position (some don't). Always Sart on T&T and don't go on governor until fll continuous ‘operating speed is reached, Then open T&T very, veryslow Ty, taking about % to one hour to open T&T, after full speed and load has been reached. Don't “spin the valve open!” Its bad in many ways. Lf last stage, check blade exit velocity, adjust backpressure to stay at a Mach Number of = 1.15. Ian intermediate stage isin trouble, go for lowest possible steam flow. APPENDIX BLADE STRESS EVALUATION PROCEDURE, AT ROOT OR FOIL ‘This method is based on Traupel (6), but has been exten sively modified and ‘condensed. The procedures for single nozales were added. 1.0 Inpat Data 1.1 Stresses; all are without stress concentrations 6, = Caused by pure centrifugal tension, without any moments Oye = Centrifugal bending (eg offset) oy; = Average, ideal steam bending stress for the free- standing blade, caused by steady driving fore. Any Toad reduction aused by shroud or lashing, or vibea- tory amplieaton, wil be reflected in o+ 04 = Averge steam bending stress, including stifening effect of shroud and lashing, + 0,= Bending stress amplitude (=ouiV S a H) for vibratory bending 1.2 Crush stresses on Tands; all are average stresses. By = Caused by pure centrifugal tension Byc= Caused by pure centrifugal bending (¢. offet) yj = Caused by pure, ideal steam bending, equivalent to Fy = Caused by pure steam bending, including sien a effect of shroud and lashing, equivalent to os e By ~ Caused by vibratory bending stress amplitude os 1.9 Stress correction factors K,= Geometric stress concentration factor, tension (Peter- son 1] p. 113, Figs. 105 to 107) Kj= Geometric stress concentration factor, bending (Peterson. 113 & Fig. 108) = Notch sensitivity factor (Peterson p. 9 & 10, Figs 8,9, & 10, Eqo. 14) K=aK/-DA \ Kak, Dt1 Stress concentrations including notch sensitivityPs ROCEEDINGS OF THE FOURTH TURBOMACHINERY SYMPOSIUM b = Surface roughness factor: RMS| b (non-reversing stress) for 90,000=c7, Ithigher os, 63 | 85 subtract 0.015 3298) for each 10,000 psi over 90,000. K,= Crush stress distribution factor, pass = 1.5 See Fig. AS fi, = Temperature correction factor, applied to material strength 1.4 Material properties 0, = Uhimate strength, at opertaing temperature. 4g, ~ Yield strength, at operating temperatue. 2.0 Stress Evaluation; Full Admission Stages Criterion #1: ‘To be determined for both trip speed (om += 0) and for most unfavorable operating speed. max < 2fy oy Figure A-1, Relationship of centrifugal and alternating stress “The peak stress, at the stress concentration, must not ‘exceed twice the yield strength of the material.” ‘This prevents reversing yield and consequent material embrittlement. Stress concentration factors are applied to all stresses, statie and dynamic. max = Kyo + Ky (Ope + o * %) Chterion #2 ‘At most on hhvorble combination oral [Aut hye, < 065% Om +n) ation, and ment “Combined static and dynarnic stress at the peak of the ceyole must not exceed 65% ofthe corabined static and dynamic endurance strength of the materia.” ‘Thiscriterion protects against fatigue failure. Note thatthe 0.65 safety margin is applied to both static and dynamic strength, givinga considerably higher margin to the endurance portion, 9m = %* Oe + Op = Statiomean stress, without stress con- Gem = Endurance strength of material, read at mean stress om from the Goodman diagram, for the applicable environment and corrected for temperature, See Fig. L Criterion 8: At trip speed and at most un: favorable combination of Prax < fy0y load, speed and vibration “The maximum crush load on the root projections (lands) ust not exceed yield strength.” Since, with normal dimen soning, max. shear stress (in the 45° planes) isa direct function ‘of max. crush, this protects against shear induced failures (low cycle fatigue, embrittlement caused by reversing veld, conse- ‘quent reduction of fatigue strength). Prnax = Kp (Pe + Poe + Py * Pa "Note: The crossoaderiteria safeguard agin excesive shear stress inthe 45 maximum shear plane AC. This sony appl {able if plane A-Chasminimem dimensions as shoo at ht Sr conto Ie Contour It would be insu, requ sation stress comections. Contour Liss wed in Peterson tests Figure A-3. Location of important stresses in a root projection (land). (6)STEAM TURBINE BLADE FAILURES, CAUSES AND CORRECTION 2 Criterion #4 Both at tmp speed and most unfavorable operating speed. Prnax < Bf (Pm tem “The maximum crush load on the lands, at the peak of the cycle, mst not exceed the combined static/dynamic endurance strength of the material.” This protects against shear fatigue. An appropriate safety factor is inherent in the derivation of this relation | Prax =same as for #3, including various operat- ing conditions, but also including environment. Pm * em is determined in the same way as Oy + qx) for #2, disregarding the theoretically negative sign compression) for Py, Pa = Kp @t+ Boe +P) 3.0 Stress Evaluation, Stoges with Individual Nozzles ‘andlor Partial Admission If represented as under 2.0 the bottom of the non- resonant cycle would be below the centrifugal stress level which, for non-amplified conditions, is not reasonable. Evidently, the steam bending stress os must be multiplied by Ki for this ease, to find the correct mean stress. 4 , Sy sercante sores f ess Figure A-4, Stress versus time, round jets. (7) Procedure: 3.1 Partial admission Criteria #1, 3, & 4: Not affected, but paw must be cal culated for top-ofeyele loading, Criterion #2: Same relation, but &: é or + ole + Koon, xt DeIVINE FORCE to mere wee | puncrive Figure A-5. Stress versus time for partial admission nozzle Blocks and diaphragms. (7) 3.2 Individual jets, non-vibratory (Fig. AS) 1. round jets (dilled-and-reamed), procedure: Get driving force per nozzle, assuming 100% blade eff ‘Find active blade/nozale = nozzle £./blade pitch, and get avernge driving foree/blade, “Max. driving force/blade = 1.3 x average, at center of steam-jet ellipse The stress amplitude resulting from % of this force, ml tiplied by Kb, represents both Kiew and the non-vibra- tory eyeling stress amplitude Oy = G+ Ope +R, = Kay Use equations in the usnal manner. Vibratory ampliica- tion and/or load dissipation (shroud) will apply to the vibra- tory component of o— especially shroud dissipation a: For non-resonance @i=ow VS a H becomes at, alll other factors being 1.0. In case of vibration, the bottom of the cycle wil extend below the stress existing between jets ot ote ‘The second row of the Custis stage must be calculated the same way, because the jet from the nozzles will essen: tially permeate the frst row and reversing row, giving the same basie Toad pattern, plus another exciting frequency from the reversing blades. . Squate nozzles (milled oF cast) Use same procedure, but do nat multiply average div ing forvefblade by 1.3. REFERENCES 1. Barer, R. D., and Peters B. F., “Why Metals Fail” Gordon and Breach, Science Publishers, New York — London — Paris, 1970. 2. Wachel, von Nimitz, Szenasi. “Case. Histories of Spe- cialized Turbomachinery Problems.” Proceedings of the Second Turbomachinery Symposium, Texas A&M Uni versity, College Station, Texas 1973, 3.Sohre, J. S., "Guidelines for Testing of Mechanical- Drive Turbines in Factory and Field, 40 pp. 1973, Re- vised, 1974 4. Campbell. “Protection of Steam Turbine Disk Wheels from Axial Vibration.” And "Tangential Vibration of Steam Turbine Buckets.” ASME Paper No. 1820 and 1995. Reprint by General Electric Company 5.*Sohre, J. S., “Operating Problems with High Speed ‘Turbomachinery Causes and Correction.” ASME Paper, Presented at the ASME Petroleum Mechanical Engi neering Conference, September 1968, Dallas, Texas, Revised, November 15, 1968. 6. Traupel. “Thermische Turbomaschinen.” Springer, Berlin, 1968, Vol. Il, 2nd edition, 7. Sobre, J. 8. “Steam Turbine Explanatory Manual.” Sponsored, internal Publication 8. Kraft, E. A., "Die Dampfturbine im Betricbe.” Spring. er-Verlag, Berlin, Goettingen, Heidelberg, 1952, 2nd Edition, "Copies available from author.20, . 12, 13 PROCEEDINGS OF THE FOURTH TURBOMACHINERY SYMPOSIUM Probl. “A Method for Caloulating Vibration Fre: queney and Stess of a Banded Group of Turbine Buckets.” Trans. ASME 0, 1958 No. 1 p. 163-180 ‘Owczarke. “On a Wave Phenomenon in Turbines.” ASME 66.GT-99. Peterson, R. E. “Stress Concentration Design Factors.” John Wiley & Sons, Ine. New York, 1953. Weaver & Probl. Steam Turbine Buckets.” ASME 0 (1958) p. 189, Kantorowier, “On Steam Tysbine Wheel, Batch and Blade Vibrations.” N-E. Coast Inst. of Engt- neers & Shipbuilders. Trans 79, 1963, page 51 to 93 High Frequency Vibration of uM 15, 16. Mr. Woods et. al. “The Formation of a Shock Wave in the Blade Passage of a Partial Admission Turbine. ASME 65:FE25. Lefeort. “An Investigation Into Unsteady Blade Forces in Turbomachines.” ASME 64 WAICTP-3, Heymann. “Turbine Blade Vibrations Due to Nozzle Wakes.” ASME. 68-WA/PWR.L Armstrong, E. K. “Recent Blade Vibration Tech- niques.” ASME 66.WA/GT-14