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1st stage
<View from steam inlet side> <View from steam outlet side>
First stage wheel : Broken blade at one location. No damage on other components.
2. Observations during overhaul (2/3)
steam outlet side Damaged Blade
Blade root
Good Blade
One blade damaged out of 78 blades, and fracture was located at the 1st bearing
portion of blade root. Other components (2nd and 3rd stage) not damaged
2. Observations during overhaul (3/3)
Failed blade
No.70 blade root
No.11 No.22
Crack Crack
Convex side, Steam inlet side Concave side, Steam inlet side
Crack indication No.40
Crack indication was
Crack detected on No.11, No.22
Failed blade and crack indicated
and No.40 blade root in
blades were located on the
Concave side, MT inspection.
first/last of shroud.
Steam outlet side
3-1. Fracture surface observations
This portion was cut
Concave side
Ratchet mark
Ratchet mark
A
Ratchet mark was observed on fracture surface, so the crack has multiple origin.
Rough surface was observed around crack origin.
Crack was started from rough surface.
No corrosion pit was observed.
Chemical components and hardness were satisfied the required specification.
Initial crack was initiated by fretting fatigue, and blade failed from high cycle low
stress fatigue.
3-2. Fracture surface observation result
The followings are observed from fracture surface of No.70 blade.
90
0 0
2014/2/25 5:45 2014/2/25 6:43 Feb. 2014
2014/2/25 7:40 2014/2/25 8:38 2014/2/25 9:36 March. 2014
2014/2/25 10:33
Date
60 300
Inlet Flow
The temperature changed from approximately from 500 degree C to 410 degree C in
40 200
roughly 20 minutes and then recovered to rated temperatures in approximately
Torque meter
30 minutes.
This20event had occurred approximately 1 month before the failure of the turbine 100
blade.
5. Possible cause (1/2)
PHENOMENON ANALYSIS OF FAILURE PHENOMENON HOW TO VERIFICATION Result & Assessment
Vibratory stress
Step 2 High cycle low stress cause crack
Rated Operation
fatigue propagation even
with no slip
6. Heat transfer stress analysis (1/2)
<Analysis Model> <Analysis condition table>
Blade & Shroud Steam Temp. Operating Time Operating
Surface of Blade & Shroud Reduction Reheating Reduction Reheating Total Speed
Steam Temperature Nor.
-4 /min +2.4 /min 22 min 38 min 60 min
(4700 rpm)
Disc
Front & Back of Disc
Heat Insulated
Circumferential Section
Heat Insulated
Rotor
Surface & Inside of Rotor
465 (Constant)
(Initial /
Steady state) Steam Temperature Condition
Analysis Model & Thermal Boundary Condition
6. Heat transfer stress analysis (2/2)
Pa m/s
0deg 90deg 90deg 180deg 0deg 90deg 90deg 180deg
Rated temperature
High
180deg 270deg 270deg 360deg 180deg 270deg 270deg 360deg
0deg
The contact area shifts from 1st bearing surface to 3rd bearing surface on end blades 270deg 90deg
180deg 270deg 270deg 360deg
Contact force
Contact force
Cracked point
3rd brg.
Contact force
Fnominal
Fvib: Blade side
Vibratory
force Movement force
Evaluation portion
Contact stress
(based on experimental data in OEM). Fretting
zone
Relative slip S is, No
fretting
zone
Relative slip S
Schematic of fretting crack Fvib > Fnominal Slipped
Contact pressure
Fvib < Fnominal Not Slipped
Fnominal
Image of contact pressure distribution
Groove side
Direction y
Fnominal
Crack propagation Fvib Blade side
Stress
amplitude Slip Adhesive Slip
Movement force
region region region
(Not slip)
7. Fretting stress analysis (2/2)
Result Rated speed: 4700 rpm
Steam inlet 3600sec
Fretting zone
Temp.
Contact stress
500
Commonly, cyclic number for fretting fatigue crack initiation is 104 ~ 105 cycle.
Enough time to initiate fretting crack
8. Solution to avoid fretting (1/2)
Vibratory stress can be reduced about 50% due to GV opening location change for No,2 and 4.
Original
External No.1 No.3 No.2 No.4
force
Rotating direction
2 time external force occurs on blade during one rotation
After modification
External
Rotating direction
1 time external force occurs on blade during one rotation
v = Ab
v: Shock stress
b: Bending stress
8. Solution to avoid fretting (2/2)
Comparison of fretting evaluation
Fretting analysis result Fretting analysis result
Original case Improvement case
Contact stress
Relative slip Relative slip
2. Slip between rotor disk and blade was possible as the vibratory forces exceeded
contact pressure on blade root during temperature excursion event.
3. Temperature event combined with number of cycles during low temperature excursion
was adequate to cause fretting and to initiate fretting cracks.
Where:
Y - Yield strength
EA - Fatigue limit in pure steam
T Actual breaking stress
Thank you for your attention