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Assembly Method of Pre Twisted Steam Turbine Blades

Conference Paper · December 2018

DOI: 10.1007/978-3-319-53556-2_84

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Assembly Method of Pre Twisted Steam
Turbine Blades

Dhanaji Chavan and Pravin Kachare

Keywords Fixture Pre twist FFT analyzer Natural frequency Steam turbine


Fork root

1 Introduction

The present theory relates to methods and systems for assembling blade having a
shroud and a fork root onto the rim of a turbine wheel, particularly to assure
complete accurate mechanical coupling between adjacent shrouds in final assembly.
Shrouded turbine blades used in steam turbines, require the shroud edges to be in
mechanical contact with one another, eliminating any gap between adjacent
shrouds. The shrouds typically support application of tip seals to provide improved
turbine thermal efficiency. High levels of mechanical reliability are also required
under service conditions. A shroud having a predominantly rhombic configuration
satisfies these design characteristics. Blades having integral shroud of rhombic
configuration with fork root in rotor disc. Blades having rhombic shaped shrouds
have been previously used in low, intermediate and high pressure turbine appli-
cations. Integrally shrouded blades, however, become increasingly difficult to
assemble as airfoil stiffness is increased, as airfoil aspect ratio (i.e., radial
height/axial width) is reduced, or as higher pre-twist stresses are required. Problems
associated with assembly of blade having rhombic configured shrouds and tan-
gential entry fork root. Generating adequately high tangential forces needed to
eliminate gaps between adjacent shrouds (i.e., to pack together) and to produce an
adequate pre twist of the blade airfoils. The level of pre-twist must be sufficient to
assure that the adjacent shrouds remain in contact, i.e. are mechanically coupled,
during all normal phases of turbine operation. Tangential assembly forces required
to adequately pack blades together on a turbine wheel can become very high for

D. Chavan (&)
P. Kachare

Department of Mechanical Engineering, SVERI’s College of Engineering,
Pandharpur 413304, Maharashtra, India
e-mail: dhanaji.chavan301@gmail.com

© Springer International Publishing AG 2018 819

P.M. Pawar et al. (eds.), Techno-Societal 2016,
DOI 10.1007/978-3-319-53556-2_84
820 D. Chavan and P. Kachare

blade of the size employed in large steam turbine applications. Also, as the blades
are packed together, the fork root undergoes rotation, which in turn reduces the
level of pre-twist applied to the blade airfoils. Fork root rotation must be limited to
assure an adequate assembly. Further, the blades in their packed configuration must
be constrained from backing away from each other as additional blades are installed
on the wheel. The tendency to back away is associated with the forces developed at
the shroud contact surfaces, and the orientation of these surfaces relative to the
tangential direction. Accordingly, there is a need for an assembly method and
system which will overcome the mentioned problems associated with assembly of
shrouded blades on a turbine rotor; and which will in turn permit the blades to
meet all efficiency and reliability objective.
Many researchers have done research on assembly method of pre twisted steam
turbine blades. Ramannagari et al. [1] invented a shrouded blade in a turbo
machine. Method and a blade for a turbine or, more generally a turbo machine are
described With the blade having at a top end a shroud segment designed to engage
With shroud segments of adjacent blades one an ring-shaped assembly at least
partly by means of assembling the blades With the shroud segment having a central
indentation along an engaging face. The moving blades are designed to have a root
at the bottom end to assemble with rotor and a shroud at the top end to engage with
the shrouds of adjacent blades forming a ring. The moving blades are assembled on
to the rotor having grooves in axial or circumferential direction. The axial grooves
can be straight or curved.
Tulsidasa and Shantharaja [2] studied effect of taper and twist in steam turbine
blades and found that centrifugal stress must be calculated because it is considered
as a main source of stresses in rotor blades. This study reveals that value of
centrifugal stress can be controlled by simply tapering blades and twisting the blade
can incorporate the moment which are developed in blades. Deallenbach et al. [3]:
invented relates to methods and systems for assembling blades having a shroud and
a tangential entry fork onto the rim of a turbine wheel, particularly to assure
complete accurate mechanical coupling between adjacent shrouds in final assembly.
Shrouded turbine blades, e.g. for use in steam turbines, require the shroud edges to
be in mechanical contact with one another, eliminating any gap between adjacent
shrouds. The shrouds typically support application of tip seals to provide improved
turbine thermal efficiency. High levels of mechanical reliability are also required
under service conditions. Guengant et al. [4]: studied Turbine blade assembly for
improving efficiency and safety in large steam or gas turbines leads to all or some of
the blades being made with a head, the heads of the blades in a given row being
adjacent, and thus forming a substantially continuous strip covering the blades at
the end opposite to their fixing feet. This arrangement gives a reduction in leakage
losses, an increase in the characteristic vibration frequency of the blades, and may
damp accidental vibration. The present invention also relates to a process for
placing these blades in position with an initial twist, hereinafter called the “ultimate
twist,” which process is particularly advantageous in the case in which all the blades
are similar and are fitted by being slid by the foot into circumferential grooves in the
periphery of the rotor element of the turbine.
Assembly Method of Pre Twisted Steam Turbine Blades 821

2 Method of Pre Twisted Steam Turbine Blade Assembly

In this method of assembling a plurality of blades on a rotor wheel wherein each

blades includes an airfoil terminating at opposite ends in a shroud and a fork root,
respectively, comprising the step of pre-twisting the shroud and airfoil of each
blades in a rotational direction about a generally radial axis in response to applying
a tangential assembly force to interference fit shroud contacting surfaces thereby
imparting a rotational bias to the airfoil enabling subsequent rotation of the shroud
and airfoil into final assembly with the shroud edges of adjacent blades in contact
with one another and gap between adjacent blades at root portion.
In a further preferred embodiment of the present invention, a method of
assembling a plurality of blades on a rotor wheel wherein each blades includes an
airfoil terminating at opposite ends in a shroud and a fork root respectively,
comprising the steps of: providing a lug on the shroud of each blades; releasable
securing a fixture on each lug carried by the shroud of each blades, the fixture and
lug of respective adjacent blades having generally complementary tapered surfaces
at acute angles relative to the tangential direction; and wedging the fixture carried
by the shroud of each blades being installed against the tapered surface of the lug
carried by the shroud of the adjacent blades previously installed on the rotor rim to
pre-twist the shroud and airfoil of the blades.
In a further preferred embodiment of the present invention, a turbine wheel and
blades assembly comprising a plurality of blades each including an airfoil, a shroud
adjacent the tip of the airfoil and a fork adjacent a root of the airfoil; a lug carried by
each shroud; a fixture releasable secured to each lug and having a projection
extending in a tangential direction for overlying a portion of a lug of a previously
assembled blades onto the wheel, the adjacent shrouds having interference fit
contacting surfaces; at least one of the lug and the fixture projection having a
tapered surface in contact with a surface of another of the lug and fixture projection
to pre twist the shroud and airfoil being installed.

3 System of Pre Twisted Blade Assembly

3.1 Detailed View of Blade Assembly

Various aspects and embodiments of the invention will now be described in con-
nection with the accompanying figures.

3.2 Drawing Description

Referring now to the drawings, particularly to Fig. 1, there is illustrated a turbine

rotor wheel including a wheel rim having a rib and groove configuration, i.e. a fork
822 D. Chavan and P. Kachare

Fig. 1 View illustrating

blade with rhombic shaped
shrouds

root configuration along opposite axial sides thereof about the circumference of the
wheel. Also illustrated in Fig. 1 is a plurality of blades generally designated each
blade includes an airfoil having a fork root projecting from the root of the airfoil
and a shroud adjacent the tip of the airfoil. It will be appreciated that the fork has a
mating corresponding rib and groove arrangement, i.e., a fork root configuration
complementary to the fork configuration of the wheel fork. Thus, the blades con-
stitute tangential entry blades whereby the blades are disposed in a radial slot shown
on the wheel and slightly disposed about the turbine wheel with contact faces of the
fork and contact edges of the shrouds in respective engagement with corresponding
parts of adjacent blades. Also illustrated in Fig. 1 is an anti-rotation key which
extends about the outer periphery of the fork of the rotor wheel and which engages
in a corresponding slot at the base of the fork to minimize or preclude rotation of
the fork and hence blade during assembly and operation. In Fig. 1, each of the
blades is illustrated as including a lug projecting radically outward from the forward
edge of shroud. The lug is preferably formed integrally with the shroud and is in
part removed from each blade and shroud after final assembly. Also illustrated in
Fig. 1 is a fixture mounted on each of the respective lugs and which fixtures project
axially forwardly. Each fixture is bolted to an associated lug by bolts.
As best illustrated in Fig. 2, the shrouds have a rhombic configuration. It will be
appreciated that in final assembly, the angled margins or tangential edges of the
shrouds about one another. However, those adjoining angled edges which typically
extend about to 60° relative to the tangential axis or direction have an extant
interference condition at their mating shroud contact surfaces when the blades are
Assembly Method of Pre Twisted Steam Turbine Blades 823

Fig. 2 View of a pair of

blades as viewed looking
inwardly towards the radially
outer faces of the shrouds in
the course of assembly of the
blades onto the wheel

assembled to the turbine wheel and the adjacent fork faces contacts one another.
That is, there is an excess amount of material on the contact edges of the shrouds so
that the shroud edges would theoretically overlap one another when the fork faces
of adjacent blades are in contact one with the other.
Because of this shroud interference condition at the shroud contacting surfaces
32, the adjacent fork faces 34 cannot be brought into full flush contact with one
another until a rotation or twisting of the shroud 20 occurs. By rotating the shroud
about a blade radial axis, a change in the shroud cover tangential pitch occurs which
permits the blade assembly to accommodate the shroud interference condition. That
is, the excess amount of material forming the edges 30 of the adjacent shrouds is
taken up by rotation of the shrouds about generally radial axes of the blades to
produce a twisting of the shrouds as well as an elastic pre twist of the blade airfoils.
Because of the angle of the shroud edges 30, a twisting of the shroud reduces the
tangential width of the shroud as the shroud rotates about the generally radial axis
until all of the interference is taken up. By twisting the shroud, the airfoil acts as a
torsional spring, which serves to maintain the contact load between adjacent shroud
contact surfaces 32 at all normal operating conditions of the blade to pre-twist the
airfoil during assembly, a substantial tangential assembly force is required to
generate the required twisting moment, i.e., torque on the shroud which occurs
through the bearing forces on the shroud contact surfaces 32. The tangential
assembly force must also overcome the frictional forces associated with sliding one
contact surface 32 relative to the adjacent contact surface 32.
There is provided shroud contact surfaces having a shallow angle, i.e.,
approximately 15° relative to the tangential axis creates a wedging effect as the
blades are tangentially assembled. Large bearing forces are thus generated on the
shroud contact surfaces for the steep angle design and are oriented principally in
the axial direction creating a substantial twisting moment on the shroud. The
component of the assembly force in the tangential direction, however, is relatively
small compared to the axial component of force which minimizes the required
tangential assembly force necessary to overcome the tangential component of the
shroud force and frictional forces.
824 D. Chavan and P. Kachare

A rhombic configured shroud, however, having a substantially larger tangential

axis, i.e., on the order of about 40°–60°, reduces the wedging action between the
shroud contact surfaces as the blades are driven tangentially causing the required
tangential assembly force to be substantially greater than for the steep angle design
of the prior patent. This places limitation because of this shroud interference con-
dition at the shroud contacting surfaces. The adjacent fork faces cannot be brought
into full flush contact with one another until a rotation or twisting of the shroud
occurs. By rotating the shroud about a blade radial axis, a change in the shroud
cover tangential pitch occurs, which permits the blade assembly to accommodate
the shroud interference condition. Because of the angle of the shroud edges, a
twisting of the shroud reduces the tangential width of the shroud as the shroud
rotates about the generally radial axis until all of the interference is taken up. By
twisting the shroud, the airfoil acts as a torsional spring, which serves to maintain
the contact load between adjacent shroud contact surfaces at all normal operating
conditions of the blade to pre-twist the airfoil during assembly, a substantial tan-
gential assembly force is required to generate the required twisting moment, i.e.,
torque on the shroud which occurs through the bearing forces on the shroud contact
surfaces. The tangential assembly force must also overcome the frictional forces
associated with sliding on contact surface relative to the adjacent contact surface.
Referring to Figs. 2 and 3, each fixture includes a portion which projects in a
tangential direction from the lug to which the fixture is attached. The projection
includes, on each axial downstream face, a leading chamfer as illustrated in Fig. 3.
The size of step is adjusted based on the interference level at the shroud contact
surfaces. Additionally, as seen in Fig. 3, the axial admission face of the lugs also
include a chamfer complementary to the chamfer of adjacent blade, the chamfer
being located on an adjacent lug to the lug having a registering taper (Fig. 4).

Fig. 3 Detail of lug engagement with adjacent blade

Assembly Method of Pre Twisted Steam Turbine Blades 825

Fig. 4 Enlarged view of a

fixture for securement to the
lug on the shroud

3.3 Fixture Assembly

To assemble the blades on the rim of the rotor wheel, the fixtures are secured to the
lug, e.g. using the bolts. Each successive blade to be assembled is side around the
wheel rim to a location where the chamfer contacts the mating chamfer on the lug of
the preceding blade. Once contact is made, a tangential assembly force is applied to
the blade being installed to drive the blade toward the preceding blade. The fixture
thus initially slides along the wedge angle created by the mating chamfers and
causing a substantial twisting movement and corresponding rotation to occur at the
shroud as illustrated in Fig. 5 as well as a twisting action of the airfoil. It will be
appreciated that both of the mating blades will twist with the application of a
tangential assembly force. When the axial step between the faces of the two blades
equals the step size in the fixture, the flat surface of the fixture contacts the flat
axially forward face of the shroud lug. The magnitude of rotation at the shroud is
governed by the fixture step size and is set to slightly exceed the level of rotation
that would naturally be created by the interference condition at the shroud contact
surfaces. Thus, as the shroud twists and because of the angle of the shroud edges,
the tangential width of the cover as the shroud is rotated is taken up to the extent
that the faces of the fork surface of the blades contact one another. This enables the
adjacent blades to slide together to enable the fork faces to contact one another with
only the involved frictional forces resisting motion of the blades. Because of the
small angle between the fixture and lug, i.e., 10° chamfer and the contact between
flat and the adjacent lug, the frictional forces at such contact are larger than the
forces tending to drive the blades apart. The blades will therefore remain in the
partially assembled position after being driven together even when the assembly
force is removed. This in turn enables additional blades to be assembled and
likewise driven together without interference from the previously assembled blades.
826 D. Chavan and P. Kachare

Fig. 5 Illustrating a direction of rotation or twist of the shroud and airfoils in the course of the
assembly of the blades on the rotor wheel

3.4 Closing Blade Assembly

When all of the blades except for a closure blade have been applied about the
wheel, the closure blade is inserted into a radial opening in the wheel fork. The
assembly fixtures on the shrouds of the closure and adjacent blades aid in assembly
of the closure blade since a pre-twist of the closure blade shroud can be applied with
the fixtures. Thus, the closure blade is inserted and driven radially into the notch
opening. After assembly of the closure blade, the assembly fixtures are removed
from the shrouds. As the fixtures are removed, a rotation of the shrouds occurs in
the opposite direction from the initial pre twist (i.e., compare Figs. 5 and 6). This
opposite or negative rotation of the shrouds enables the contact surfaces of the
shrouds to come into full flush contact with one another. It will be appreciated that
the fork anti rotation key is in place during assembly of the blades to constrain fork
rotation. Thus, the level of pre-twist in the blade airfoil created by the shroud
rotation biases the shroud for rotation in the opposite direction into final assembly.
Outer portions of the lugs may then be removed by machining.
Assembly Method of Pre Twisted Steam Turbine Blades 827

Fig. 6 View similar to Fig. 5 with the fixture removed illustrating a counter-rotation of the shroud
and airfoil

Referring to Fig. 5, there is provided a relief groove on the shroud pressure side
surface. The relief groove provides a low stress transition between the shroud
contact and clearance surfaces.

4 Assembly Procedure

A method of assembling a plurality of blades on a rotor wheel wherein each blade

includes an airfoil terminating at opposite ends in a shroud and a fork, respectively,
comprising the step of pre-twisting the shroud and airfoil of each blade in a rota-
tional direction about a generally radial axis in response to applying a tangential
assembly force to interference fit shroud contacting surfaces thereby imparting a
rotational bias to the airfoil enabling subsequent rotation of the airfoil into final
assembly with the shroud edges of adjacent blades in contact with one another and
fork faces of adjacent blades in contact with one another. A method including
restraining rotational movement of the fork at the interface of the fork and rotor ring
when said tangential assembly force is applied. A method including the step of
wedging a fixture carried by the shroud each blade against a lug carried by the
shroud of the adjacent blade to pre-twist the blade shroud and airfoils.
A method including sliding each blade being installed along the rotor rim to
engage opposed contact faces of the forks as the shrouds and airfoils are being
pre-twisted in excess of the level of rotation created by the interference fit between
adjacent shroud contact surfaces.
828 D. Chavan and P. Kachare

A method according to any preceding claim including providing a lug on the

shroud of each blade, releasable securing a fixture on each lug carried by the shroud
of each blade, the fixture and lug of respective adjacent blades having generally
complementary tapered surfaces at acute angles relative to the tangential direction,
wedging the fixture carried by the shroud of each blade being installed against the
tapered surface of the lug carried by the shroud of the adjacent blade previously
installed on the rotor rim to pre-twist the shroud and airfoil of the blade. A method
for each blade removing the fixture from the lug to enable rotation of the shrouds
and airfoil, in the opposite rotational direction into final assembly.

5 Natural Frequency Test of Pre Twisted Blades

The natural frequency test results conducted to stage-7 turbine blades mounted on
the rotor. Condition was that Blade was mounted on the turbine rotor and sensor
mounted along the center axis of the blade 1/4th the distance from the blade
tip. Weight of the accelerometer plus mounting stud used was 5 g.

5.1 Measurement System

The following instruments and measurement system were used for the study.
1. DI 440 FFT analyzer, Diagnostic Instruments make
2. Accelerometer: B&K make (Weighing 5 g) with 93 mv/g sensitivity
3. Polymate software for analysis and report generation.

5.2 Measurements

Following are the measurement parameters used while taking the data
• Frequency Spectrum 10–2000 Hz frequency bandwidth, 1600 lines of resolu-
tion was selected and the data collection was made.

5.3 Procedure

The vibration signatures were Fourier analyzed in the FFT analyzer to get the
frequency spectra and was transferred to polymate software for detailed analysis of
the signatures.
Assembly Method of Pre Twisted Steam Turbine Blades 829

5.4 Comparison of Natural Frequency of Old Rotor

Assembly and New Rotor Assembly

Natural frequency of pre twisted blades measured by using FFT analyser. Below is
the following frequency measurement reading of Old and New rotor assembly
(Figs. 7 and 8).

S. No. Old rotor stage-07 blade New rotor stage-07

frequency blade frequency
F1 F2 F3 F4
1 703 763 674 741
2 703 761 674 741
3 702 761 674 741
4 702 763 675 741
5 701 765 675 741
6 703 766 674 741
7 704 762 674 741
8 702 761 686 747
9 704 761.76 686 747
10 703 775 686 747
11 703 771 686 747
12 704 779 686 747
13 704 776 686 747
14 705 774 686 747
15 702 769 686 747
16 702 768 686 747
17 703 769 686 747
18 703 768 686 747
19 704 776 686 747
20 704 775 686 747
21 704 770 686 747
22 702 770 686 747
23 703 771 685 747
24 705 771 685 747
25 704 770 686 747
830 D. Chavan and P. Kachare

Fig. 7 Showing NFT spectrum recorded on blade-1 of 7th stage, first predominant natural
frequency 674 Hz

770

750
Y-Axis -Frequency

730
F1
710
F2
690
F3
670
F4
650
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Blade Number

Fig. 8 Comparison of natural frequency of old rotor assembly and new rotor assembly
 Assembly Method of Pre Twisted Steam Turbine Blades 831

6 Conclusions

This system for blade assembly is successfully used for rhombic shroud and fork
root blades. Blades are pre twisted to get shroud edges to be in mechanical contact
with one another due to this gap between adjacent shroud edges is eliminated. It
observed that the frequency values of the 7th stage blades are in the range of about
674–688 Hz. These values are in acceptable range. Steam leakages are eliminated.
Thermal efficiency of turbine is improved. High level of mechanical reliability is
increased.

References

1. Ramannagari DP, Masserey PA, Fleming RB, Calcagni C et al (2013) Shroud for pre twisted
airfoils. Alstom Technology Ltd., United State Patent Application No. 2013/0323053A1, 5 Dec
2013
2. Tulsidasa D, Shantharaja M (2015) Effect of taper and twisted blade in steam turbine. Int J Sci
Technol 04
3. Deallenbach RE et al Methods and systems for assembling shrouded turbine blade and
tangential entry fork. Europian Patent No. EP 1 731 713 A2
4. Guengant P, Drancy, France, Assignor to Aktiengesell Schaft Brown, Boveri & Cie., Baden,
Turbine blading. United State Patent Office, July 1967

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