Vibration based damage detection of rotor blades in a gas turbine engine

This paper describes the problems concerning turbine rotor blade vibration that seriously impact the structural integrity of a developmental aero gas turbine. Experimental determination of vibration characteristics of rotor blades in an engine is very important from fatigue failure considerations. The blades under investigation are fabricated from nickel base super alloy through directionally solidified investment casting process. The blade surfaces are coated with platinum aluminide for oxidation protection. A three dimensional finite element modal analysis on a bladed disk was performed to know the likely blade resonances for a particular design in the speed range of operation. Experiments were conducted to assess vibration characteristics of bladed disk rotor during engine tests. Rotor blade vibrations were measured using non-intrusive stress measurement system, an indirect method of blade vibration measurement utilizing blade tip timing technique. Abnormalities observed in the vibration characteristics of the blade tip timing data measured during engine tests were used to detect the blade damage. Upon disassembly of the engine and subsequent fluorescent penetrant inspection, it was observed that three blades of the rotor assembly were identified to have damaged. These are the blades that exhibited vibration abnormalities as a result of large resonant vibration response while engine tests. Further, fractographic analysis performed on the blades revealed the mechanism of blade failures as fatigue related. The root cause of blade failure is established to be high cycle fatigue from the engine run data history although the blades were put into service for just 6 h of engine operation.     

Blade protection and efficiency preservation of a turbine by a sacrificial material coating

In order to preserve the efficiency and power of a gas turbine, the clearances between rotating blades and the interior casing should be as small as possible. To obtain that, one sprays a sacrificial material by an atmospheric plasma spraying torch and obtains a coating layer. During their rotation, the blades scrape the coating and tear off fine layers, creating a functional gap between the blades and the casing seal. The combustion gases do not escape through the clearance and contribute to the power production. The aim of this work is to investigate the behavior of a particular sacrificial material and its effect on turbine blade wear under operating conditions. For this purpose, we use the abradability test rig in which three functional parameters are varied. Blade wear or material displacement is shown on various graphs and on the wear map, which indicates the other observed phenomena.     

Modeling Smart Structure of Wind Turbine Blade

With the increasing size of wind turbine blades, the need for more sophisticated load control techniques has induced the interest for aerodynamic control systems with build-in intelligence on the blades. The paper aims to provide a way for modeling the adaptive wind turbine blades and analyze its ability for vibration suppress. It consists of the modeling of the adaptive wind turbine blades with the wire of piezoelectric material embedded in blade matrix, and smart sandwich structure of wind turbine blade. By using this model, an active vibration method which effectively suppresses the vibrations of the smart blade is designed.     

Failure probability estimation of steam turbine blades by enhanced Monte Carlo Method

Steam turbines are designed to work in stable operating conditions, including speed and load, to avoid mechanical stress variations. However, sometimes failures occur in the turbine components. The components having major breakdowns for fracture, an average of 75%, are the blades of the Low Pressure (LP) stage steam turbine. These blades produce around 10% of the output power turbines and 15% in some applications of combined cycle; generally longs, with a relatively low stiffness and such blades may present problems of high stress due to centrifugal forces. In this work probabilistic design procedure was applied to the group of ten blades of the LP stage steam turbine of 110 MW, in order to compute the stress changes and reliability due to variations in: damping, natural frequencies, vibration magnitude and density. The computed vibration stresses were analyzed by applying probability distributions and statistical parameters of input and output to compute the useful life. Monte Carlo technique and stochastic finite element method (SFEM) were applied. The results show that the Monte Carlo technique and SFEM are a good approach to estimate the useful life and reliability design of those blades.     

Failure of last-stage turbine blades in a geothermal power plant

This paper presents an investigation into causes of failure of geothermal steam turbine blades. Several L-0 blades of geothermal steam turbines of 110 MW capacity suffered failures, causing forced outages of the turbines. To assess the causes of failure, the natural frequencies of the blades installed on the rotor were measured in the laboratory. The measured frequencies were compared with the natural frequencies calculated through a finite-element analysis (FEA) of the blade. The FEA was also used to calculate the vibratory stresses on the blade numerically. Also, the investigation analyzed the operational data and the history of the blade failures on several rotors of different units from the same system. The results of previous repairs were reviewed, and metallurgical investigations were conducted to identify the mechanical and metallurgical modes of failure. The results of the investigation showed that the fracture of two blades was attributed to installation and manufacturing errors and aggravated by general deterioration of the blades. The deterioration was caused by the erosion and corrosion process that resulted from moisture condensation in the steam.     

Erosion failure mechanisms in turbine stage with twisted rotor blade

Blades of steam turbine are very important elements in power plant turbo aggregates. If blades of turbine fail, this will provoke further failures and high economical losses. Therefore, it is crucial to perform detailed research on reasons for failure of turbine blades to increase the reliability of turbine systems. The present paper deals with numerical simulation and research of erosion over blades in a low pressure stage of K-1000-6/1500 steam turbine working in a Nuclear Power Plant. Attention is paid to the effect of the amount of moisture in the stage; to the impact of droplets' diameter, their mass flow rate and forces acting on blade surfaces, to their aerodynamic behavior and influence on the energy conversion efficiency.Specific trajectories of water particles, reasons for the occurrence of erosion wear and erosion of certain parts of the streamlined surfaces are established and discussed. An approach to obtain incidence time to erosion effects appearance is formulated and implemented in the code. Research methodology and obtained results are applicable to determine specifics of erosion effects over streamed complex surfaces; replace expensive measurements campaigns; introduce approaches to decrease wetness in the last stages of condensation turbines and prolong the reliability of blades operated in wet steam conditions.     

汽轮机叶片动频的转子调频非接触测量法

叶片的共振断裂是叶片损伤的主要形式,为了避免叶片共振,如何准确地测得叶片的动频是保证叶片安全工作的关键。本文提出采用转子调频非接触测量法测量汽轮机叶片的动频。采用该方法只需要在叶片顶部固定支架上安装两只光学传感器及在转子的适当位置安装一只转子旋转同步传感器,就可以测量工作轮上所有叶片的动步,从而克服了传统接触应变片法仅能测量某几个叶片动频、应变片寿命短等缺点,同时也避免了安装多只传感器工艺复杂、费用较高等问题。本文通过实验验证了该方法的可行性。     

Non-linear dynamic analysis of a wind turbine blade

ABSTRACT

Wind turbine blades’ dynamic behavior must be well investigated during the design process in order to avoid resonance. Modal analysis and nonlinear dynamic analysis of a rotating wind turbine blade are presented in this paper to study the effects of rotation speed on the natural frequencies and displacements. Accordingly, an enhanced finite element formulation based on uncoupled translational and rotational displacements’ kinetic energy was developed. A twisted wind turbine blade was discretized using beam elements with different cross sections; each has six degrees of freedom per node. At rest, the model results were validated using ABAQUS software. Furthermore, the effects of geometrically non-linear phenomena produced by blade displacement on the vibration characteristics of the rotating blade have been discussed. The blade non-linear problem was solved by applying the Newmark method combined with the Newton-Raphson schema. Results show that the blade natural frequencies and displacements increase under angular rotation speed augmentation. This work highlights the significant sensitivity of the blade vibration characteristics to the geometric non-linearity. Accordingly, a modal and a linear analysis are insufficient to precisely estimate the dynamic behavior of a rotating turbine blade.     

考虑风速分布的叶片MPC气弹控制

作为叶片失效的重要原因,颤振一直是风电领域研究重点。以抑制叶片工作过程中的颤振为目的,建立分析模型时应充分考虑实际风速分布特别是风切变和塔影效应对叶片振动的影响,并在离散化后求取平均输入风速。针对小型风力机叶片气动弹性稳定性问题进行综合分析,根据实体结构建立叶片气弹模型,考虑非线性气动力作用时叶片大攻角、大风速工况下产生的高频、高幅失速颤振,模拟典型截面仿真振动位移。通过模型预测控制的滚动优化和误差矫正控制叶片挥舞、摆振两个运动方向的振动频率和幅值,结果表明振动形式实现控制后可在短时间内达到稳定且静差可接受。     

Investigation of Fatigue Failures of Titanium Alloy Blades Used in Compressor Modules of Aeroderivative Industrial Gas Turbines

Gas turbine axial compressor blades are designed to withstand cyclic stress loading resulting of modal vibrations. However, when surface suffers from foreign object damage, a fatigue crack is likely to initiate. In this paper two failure case-studies of titanium alloy used for aeroderivative gas turbine compressor blades are presented. Both are related to a failure of first stage compressor blades coming from different turbine power ranges. Observed cracks were found at blade spans corresponding to modal vibrations.     

Experimental-numerical investigation of the dynamic stability of flexural-torsional vibrations of compressor blades under conditions of attached and separated flow. part 3. mutual aerodynamic couplings

The paper considers the results of a study of mutual aerodynamic couplings which give rise to nonstationary aerodynamic interactions between the translational and angular components displacements of neighboring ring blades in the case of variation of attack angle, reduced vibration frequency and the geometric parameters of the blade cascade. The effect of mutual aerodynamic couplings between neighboring blades on the aerodynamic stability of flexural-torsional vibrations of the blades of the peripheral section of the shrouded fan blade ring of gas turbine engine for an attack angle of 15° has been estimated.     

5号汽轮机叶片断裂原因分析

对某热电厂5号汽轮机的断裂叶片进行了宏观形貌、化学成分、金相组织以及扫描电镜形貌和元素成分能谱分析。结果表明,叶片失效性质为腐蚀疲劳断裂;叶片拉筋孔处的点蚀坑是裂纹源;造成叶片发生点蚀的原因是蒸汽中含有的氯、硫等介质。     

Coupled mechanical,metallurgical and FEM based failure investigation of steam turbine blade

Steam turbine blades are the critical component in power plant, specifically low pressure blades are generally found to be more susceptible to failure. A mechanical, metallurgical and FEM based coupled methodology is used in the present failure investigation of low pressure steam turbine blade. The results of each investigation of turbine blade failure were then interpreted that leads to find the location of primary failure, sequence of failure and the root cause of its failure. All the three aspects of failure investigation are important in answering the questions raised for the failure and to avoid any future miss-happening.     

Failure of the J79 Engine Compressor Blade Due to Stall

The fractured and damaged compressor rotor blades of a J79 engine have been examined. Optical, stereoscopic, microhardness testing, and SEM examinations were carried out to find out the causes of the fracture. The material of the blades was STS403 and blades were used without coating. From the 15th through the 17th compressor stages the rotor blades, stator vanes, combustion, and turbine sections were damaged. The fractured surface of the 17th blade show multiple origins, secondary cracking in the blade’s convex surface, and extensive propagation before separation and rougher surfaces. The metallographic analysis of the microstructure suggested work hardening. Based on the results, the cause of the fractured blade was high-amplitude fatigue, due to severe stall. After normal engine usage of 5 months, the blade fractured and blade fragments hit the other compressor blades, stators, and casing, and caused damage in both combustion and turbine sections.     

离心泵作透平流体诱发外场噪声特性及贡献分析

以某离心泵作透平为研究对象,对流体诱发的外场噪声特性进行了数值计算和试验研究。在典型流量下,采用雷诺时均方法获取壁面偶极子声源,并利用FEM/AML方法求解出叶轮和壳体偶极子源作用的流动噪声,基于声振耦合法计算出流体激励结构振动产生的外场流激噪声,分析不同性质噪声源的频谱特性,同时评估外场声源在各个频段下的贡献量。借助模态试验对透平壳体结构的模态参数进行了识别。结果表明,计算与试验振型近似,固有频率平均相对误差小于4.60%。结构的影响使得外场五阶叶频处声压最高,二阶叶频处次之。壳体偶极子作用的流激噪声对外场噪声的贡献最大,其次是壳体偶极子作用的流动噪声,叶轮偶极子作用的流激噪声对外场噪声贡献最小。研究结果为低噪声叶轮机械设计提供了一定的参考。     

基于叶尖定时技术的叶轮叶片动态监测研究现状

叶轮作为旋转机械的核心部件之一,在复杂恶劣的工况中容易使叶片产生振动,进而引发疲劳断裂等失效形式,因此对叶片振动进行状态监测具有重要意义。非接触式的叶尖定时技术具有同时监测整级叶片的优势,为叶片振动及损伤诊断提供了有效方式。本文从叶尖定时传感、叶片振动及损伤监测等三个方面对国内外研究现状进行综述,总结了当前研究中存在的不足,并就叶尖定时技术及叶片健康监测的发展方向进行了展望。     

混流式水轮机转轮叶片流激振动分析

结合小变形弹性理论和不可压缩粘性流体的最大功率耗散原理构造流体-叶片系统的功率泛函,通过广义变分原理建立了混流式水轮机转轮叶片在非定常湍流场中考虑流体-结构相互作用(FSI)的有限元模型,计算叶片在FSI情况下的流激振动。数值计算采用分离迭代格式,流动用大涡模拟(LES),叶片振动用直接积分法。试验模型以某型水轮机为原型设计制作,在一片叶片的正面和负面上分别装有5只Kulite的压力传感器,在另一片叶片上装有3只微加速度传感器。计算得到的叶片自振频率、频谱曲线以及加速度时程与试验实测结果是吻合的。     

叶尖定时旋转叶片实时振动测量技术

设计了一套基于叶尖定时传感的旋转叶片振动测量系统。系统主要由光电传感系统、数据采集与预处理系统、叶片振动数据处理系统三部分组成。叶尖定时传感器采用单根光纤发射、多光纤接收的 Y 型结构,并用高性能专用集成芯片完成弱光信号的放大检测,使传感器信噪比大于500,信号带宽大于 50MHz。利用 CPLD 和 DSP 技术,实现了叶尖定时信号的高速实时采集与处理;建立了同步共振条件下叶片振动的数据处理模型,实现了叶片振动的实时监测。整套测量系统在现场某大型压气机上进行了原理性验证,在转速高达 9210rpm的情况下测得的同步共振最大幅值为 0.4231mm,接近于同等条件下国外的测量结果,从而验证了整套测量系统的可靠性。     

Vibration of turbomachinery rotating blades made-up of functionally graded materials and operating in a high temperature field

Summary. The vibration of turbomachinery rotating blades made-up of functionally graded materials and operating in a temperature field is considered. In this context, the blade is modeled as a thin-walled beam mounted on a rigid hub at a presetting angle, rotating with a constant angular velocity, and exposed to a steady temperature field of a prescribed gradient through the blade wall thickness. The effect of the initial twist of the blade is also taken into consideration. Results are presented for two constituents, metal-ceramic based materials that are assumed to be temperature-dependent and graded in the thickness direction according to a simple power law distribution. Numerical results highlighting the effects of the volume fraction in conjunction with those of the presetting and pretwist angles, temperature gradient, rotating speed and hub radius are presented, and pertinent conclusions are outlined.     

变面积电涡流传感器带冠叶片振动测量

为实现对各种带冠叶片的振动的非接触式测量,提出一种基于变面积型电涡流传感器的带冠叶片振动测量技术。当转子叶片进行高速旋转时,叶片扫过电涡流传感器,会使感应面积发生变化,后接高速数据采集分析处理系统,将面积变化信号进行处理,从而获得带冠叶片振动参数。在某型汽轮机末级带冠叶片上进行振动试验,试验结果表明变面积型电涡流传感器测振技术可以在转子高速旋转的情况下,准确测量带冠叶片振动情况,得到振动的幅值和频率,可以应用在实际带冠叶片的振动测量中,为转子叶片健康状况评估提供依据。