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ISSN 2250-3153
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M. Tech, Department of Mechanical Engineering, Godavari Institute of Engineering & Technology, Rajahmundry, (A.P), India.
Associate professors, Department of Mechanical Engineering, Godavari Institute of Engineering & Technology, Rajahmundry, (A.P), India.
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International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
IV. MATERIALS
It is generally known that rotors made of high CrMoV steels
(customary: 9% up to 12%Cr) show bad running behavior in
babbitted bearings. Therefore it is necessary to coat the journal
areas of such rotors with materials which prevent the known wire
whooping effect and improve the performance. For safety
reasons, those materials are normally applied by overlay welding.
A low alloy MnCr weld metal with an approximately 0,2 %
carbon content was selected as overlay weld material. To reduce
the carbon diffusion, butter layers made of a filler metal similar
to 16 Mo 3 were deposited on the 12 % Cr steel rotor prior to
depositing the MnCr surfacing electrode. In principle all these
welds are performed using the submerged arc welding process.
The only exception is axial bearing areas where the buffer layers
are performed with an automatic gasshielded welding unit.
i.Saturated steam turbine rotors, normally made of NiCrMoV
steel are susceptible to erosion corrosion especially in the area of
the shaft seal section. Due to the high steam flow rates, a material
which is strongly resistant to erosion corrosion is necessary. The
standard rotor material does not fulfill these requirements.
ii. Density = 7.8e-6 kg/mm3
iii.Poissons ratio Prxy = 0.3
iv.Youngs modulus EX = 1.6e5 N/mm2
Figure-4 2D wireframe
International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
rated power in about 2 hours and hot start (after shut down for 48 hrs) while the Rotor material is very close to steady state
temperature, facilitating turbine to produce rated power in less
than an hour Each start-up transient indicates variation of
different parameters like pressure, temperature, flow rate and
load with time from their starting level to the maximum values.
Shut down duration and starts up time vary with the rating of the
unit. Obviously, cold start will induce maximum stresses due to
thermal transient and is crucial for fatigue.
It was commissioned on 21st Aug 1989 and operated for 1,
69,396 hours (till Nov 2010). It is estimated that the casing has
been subjected to 518 hot starts, 322 warm starts and 95 cold
starts. Turbine rotor was replaced in 2004. Subsequently, it is
estimated that the rotor has been subjected to 165 hot starts, 105
warm starts 30 cold starts and operated for 55,116 hours. Steam
turbine rotor is subjected to high temperatures and pressures at
different sections of the rotor. These temperatures and pressures
are different values at various sections of rotor. We considered
the actual values of temperature and pressures, these and
temperatures and pressures are essential for analysis and we
considered these values as inputs for analysis.
International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
Section - 1 HP Inlet
KP Nos 62-90
0.1
2
10
20
40
70
100
115
140
160
180
215
250
300
350
400
535
535
535
535
535
535
535
535
535
535
535
535
535
535
535
535
Section - 2
0.1
2
10
20
40
70
100
115
140
160
180
215
250
300
350
3,655.16
3,841.54
3,948.12
4,108.67
4,343.93
4,458.39
4,619.78
4,860.80
9,645.46
44,282.94
59,918.52
72,930.03
72,930.03
72,930.03
72,930.03
72,930.03
KP Nos 90-37
466
466
466
466
466
466
466
466
466
466
466
466
466
466
466
287.82
289.75
304.87
315.48
332.15
345.94
369.81
381.27
764.01
3,476.20
4,685.48
5,690.04
5,690.04
5,690.04
5,690.04
Section - 3
0.1
2
10
20
40
70
100
115
140
160
180
215
250
300
350
400
KP Nos 37-28
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
426.9
Section - 4
0.1
2
10
20
40
70
100
115
140
160
180
215
250
300
350
400
326.32
336.19
345.73
370.18
384.76
395.16
418.37
433.04
856.60
3,893.93
5,249.58
6,376.97
6,376.97
6,376.97
6,376.97
6,376.97
KP Nos 28-72
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
366.2
440.83
500.09
576.14
654.99
709.09
771.01
842.92
909.21
949.84
4,279.97
5,745.50
6,973.28
6,973.28
6,973.28
6,973.28
6,973.28
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International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
Section - 5
0.1
2
10
20
40
70
100
115
140
160
180
215
250
300
350
400
KP Nos 72-06
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
Section - 6
0.1
2
10
20
40
70
100
115
140
160
180
215
250
300
350
400
9.70
10.41
11.91
13.05
14.89
16.71
18.07
20.14
25.86
116.49
156.51
190.06
190.06
190.06
190.06
190.06
KP Nos 06-01
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
353.4
7.96
8.04
8.32
8.71
9.09
9.42
9.97
10.51
20.74
97.90
132.07
158.60
158.60
158.60
158.60
158.60
Key point
number
Pressure
(N/mm2)
Key point
number
Pressure
(N/mm2)
2
3
4
5
6
6
64
67
7
8
9
10
11
12
13
14
15
16
17
18
19
20
69
71
72
72
21
73
22
74
23
75
76
24
25
77
98
26
78
79
27
28
28
80
81
29
82
3.068
3.068
3.068
3.068
3.068
3.068
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
4.792
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
6.617
8.949
8.949
8.949
8.949
8.949
83
31
32
33
34
35
36
37
37
38
84
85
86
39
40
87
41
42
88
43
89
44
90
90
45
46
91
47
92
48
49
94
50
51
95
52
53
96
54
55
56
57
58
59
97
60
61
8.949
8.949
8.949
8.949
8.949
8.949
8.949
8.949
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
3.068
1.392
1.392
1.392
1.392
1.392
1.392
1.392
1.392
0.431
0.431
0.431
0.431
0.431
0.431
0.152
0.152
0.152
0.152
0.152
0.152
0.0106
0.0106
0.0106
0.0106
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International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
www.ijsrp.org
International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
www.ijsrp.org
International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
Experimental stress
Computational stress
% Error
21587.49
41658.72
44007.19
47905.75
74021.33
21041
2.53
1.93
2.21
0.42
0.33
40852
43034
47702
73777
252.52
61.73
194.55
141.78
133.27
8.31
5.91
5.63
5.2
5.52
58.076
183.59
134.4
125.91
509.72
373.43
258.71
156.99
95.48
346.59
249.91
151.52
87.468
% Error
% Error
2.63
7.18
3.4
3.48
8.39
Experimental stress
Computational stress
% Error
42942.75
43555.33
44009.72
48901.16
50196.58
40855
4.86
1.19
1.77
2.44
2.95
43037
44793
47705
48713
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International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
26.09
234.57
18.96
20.42
20.96
231.53
18.814
18.99
19.81
6.33
1.29
0.77
7.01
5.48
501.06
374.52
259.48
157.69
90.85
346.55
249.88
151.5
87.459
0.95
7.46
3.69
3.92
3.73
Avg value
No. of cycles
Stress
computational
No. of cycles
Stress
Experimental
66.007
30682
52469.2
72694
92332
9063100
73777
47702
45281.2
43034
40852
21041
63.80803
28848.25
47475.1
63935.29
85071.52
8571259
75021.33
48905.75
46836.1
45007.19
42658.72
22587.49
10
Uf= n/N
Where, S is the alternating stress range (= S range /2)
n is the actual number of stress cycles experienced by the
component, and
N is the maximum number of stress cycles that the component
can withstand from S-N curve.
Fatigue factor
Uf= 120/52469.2
Uf=0.002287
Time
264350
314750
Avg value 448970
460350
548150
657250
Stress
computational
48713
47705
45020.6
44793
43037
40855
Time
190171
254942
403944.5
499514
522233.5
552862.5
Stress
Experimental
50196.58
48901.16
45921.11
44009.72
43555.33
42942.75
International Journal of Scientific and Research Publications, Volume 2, Issue 8, August 2012
ISSN 2250-3153
60000
11
XI. CONCLUSION
50000
40000
computation
al
30000
20000
Experimental
10000
Creep factor
Uc= 55116/448970
Uc=0.122761
Residual Life
Residual life= 0.5-0.002287-0.122760986
Residual Life=0.374952*10^5 Residual Life is 37495.2 hours
Residual Life of the Turbine Rotor is 37495.2 hours.
REFERENCES
[1]
AUTHORS
First Author : K.Venkatesh, M.Tech, Department of
Mechanical Engineering, Godavari Institute of Engineering &
Technology, Rajahmundry, (A.P)-533296, India.
venkateshkolusu@gmail.com.
Second Author :P. Veer Raju, M.Tech, (Ph.D),Associate
professor, Department of Mechanical Engineering Godavari
Institute of Engineering & Technology.Rajahmundry, (A.P)533296, India.veeraraju1951@gmail.com.
Third Author :T.Jayananda Kumar, M.Tech, (Ph.D), Associate
professor, Head of the Department,Department of Mechanical
Engineering,Godavari Institute of Engineering & Technology,
Rajahmundry, (A.P)-533296, India. jktatipaka@yahoo.com
Corresponding Author :K.Venkatesh,
Contact number - 9951053538, 9030355455.
Email id - venkateshkolusu@gmail.com
venkateshkolusu@yahoo.com
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