JETIR2304485

© 2023 JETIR April 2023, Volume 10, Issue 4 www.jetir.
org (ISSN-2349-5162)
ANALYSIS ON STEAM TURBINE BLADE

E.Durgesh [1], B.Durga Bala Sai Charan [2], Y.Mohana Sesha Venkata Bharadwaj [3], Sk.Sai Suraj [4],
K.Dushyanth Sri Naga Sai [5], P.Eswar Pavan [6]
Assistant Professor [1], Students [2][3][4][5][6]
Department of Mechanical Engineering, Andhra Loyola Institute of Engineering and Technology, Vijayawada,
Andhra Pradesh, India
ABSTRACT
Steam turbines are crucial components of power generation systems, and their efficiency and reliability are
essential for optimal energy production. The blades in these turbines are subjected to high mechanical and
thermal stresses during operation, which can cause deformation and failure if not adequately analysed and
designed.
This study presents a comprehensive analysis of steam turbine blades for structural and thermal stresses.
Finite element analysis is used to simulate the blades' structural behaviour, considering the effects of material
properties, loading conditions, and boundary conditions. The thermal analysis is performed using
computational fluid dynamics to calculate the blades' heat transfer coefficients and temperature distribution.
The results of the analysis show that the blades experience high stresses, particularly at the root and tip
regions. The maximum stresses are caused by thermal gradients and non-uniform cooling of the blades. The
deformation of the blades due to these stresses can result in blade failure, leading to reduced efficiency and
costly downtime.
Based on the findings, recommendations are made to optimize the design of the blades to reduce stress
concentrations and improve their structural integrity. The proposed modifications include changes in blade
geometry and material properties. The results of this study can provide valuable insights into the design and
optimization of steam turbine blades to enhance their reliability and efficiency.
INTRODUCTION
Two 660 MW units experienced failures of their last-stage turbine blades, specifically in the low-pressure
turbines connected to the high-pressure turbine and generator. The blades failed due to cracks in their roots,
which initiated at the trailing edge of the steeple outermost fillet radius on the concave side. Laboratory
analysis confirmed the failure mechanism as high cycle fatigue (HCF).
To explore the reasons behind the failures of the last-stage blades, a failure evaluation was carried out. The
evaluation process involved several techniques such as metallographic analysis, natural frequency testing and
analysis, blade stress analysis, examination of unit operation parameters and events history, and fracture
mechanics and crack propagation analysis. This paper presents a summary of the failure investigation, which
revealed that the primary causes of the failures were torsional vibrations of the blades at around 120 Hz and
operational periods with low load and low vacuum.
JETIR2304485 Journal of Emerging Technologies and Innovative Research (JETIR) www.jetir.org e615
© 2023 JETIR April 2023, Volume 10, Issue 4 www.jetir.org (ISSN-2349-5162)
LITERATURE SURVEY
[1] “TRANSIENT THERMAL ANALYSIS OF THE TURBINE BLADE” By M. Yashwanth Kumar, Shaik
Himam Saheb & M. Venkata Ramana Reddy, Volume 20, Issue 3, Version 1.0, Year 2020. This article
presents the findings of a thermal analysis conducted on turbine blades using Ansys software. The study
evaluated the effects of temperature and heat flux on various alloys and determined that thermal stresses
induced in the turbine blade are significantly influenced by temperature. The research also discovered that the
highest temperature and heat flux were observed in the Aluminum alloy.
[2] “STUDY ON DESIGN AND ANALYSIS OF STEAM TURBINE BLADE TO FIND ITS FREQUENCY
AND DEFORMATIONS” By Ronanki Naidu, B. Hari Gopal, Vol-7 Issue-4 2021, IJARIIE-ISSN (O)-2395-
4396. This paper presents a modal analysis of four different materials (Niobium, Silicon Carbide, Titanium,
and Aluminum) to evaluate their frequency response. The structural performance of the turbine blade is
analyzed under mode conditions, and it is found that the stresses induced in the Niobium and Silicon Carbide
turbine blades are within safe limits. As a result, it is concluded that Niobium and Silicon Carbide are the best
suitable materials for the manufacturing of turbine blades in turbine engines.
[3] “THERMAL ANALYSIS OF A STEAM TURBINE BLADE” By Challa Murali, Kolamala Sreenivasulu,
International Journal of Research, Volume 04 Issue 01 January 2017. This article presents a thermal analysis
conducted on both Aluminum and composite materials to determine their respective heat flux and thermal
error.
[4] “DESIGN AND ANALYSIS OF GAS TURBINE BLADE” By Theju V, Uday P S, PLV Gopinath Reddy,
C.J.Manjunath, International Journal of Innovative Research in Science, Engineering and Technology, Vol. 3,
Issue 6, June 2014. 16. This paper aims to design and analyze a turbine blade for a jet engine using two
materials, namely, Inconel 718 and Titanium T-6. The study involved conducting a thermal analysis to
determine the direction of temperature flow under thermal loading, and a structural analysis to investigate the
stresses, displacements, and shear stress of the turbine blade under thermal and centrifugal loads. The findings
indicate that Inconel 718 is the most suitable material due to its favourable material properties at higher
temperatures and economical cost.
[5] “DESIGN MODIFICATION FOR FILLET STRESSES IN STEAM TURBINE BLADE” By Tulsidas. D,
Dr Shantharaja. M, Dr. Kumar, K IJAET, Vol. III, Issue I, January-March, 2012,343-346. This paper
describes an exploration into designing an optimal blade root geometry for turbo-machinery to reduce stress
concentration and ensure safe operation in all service conditions. Finite Element Analysis was utilized to
determine fillet stresses, and Peterson's Stress Concentration Factor chart was employed to alter the blade root.
The modification was essential due to complications in manufacturing the tang's butting surface, which grips
the blade to the disk crowns with a small contact area.
METHODOLOGY
PROBLEM IDENTIFICATION:
This study aims to investigate the structural and thermal stresses on the last stage Low Pressure (LP) steam
turbine blade, rotating at 3000 rpm, in order to analyze the material stresses at the root of the blade. The study
will analyze five materials (Haste alloy, Chrome steel, Inconel 600, Stainless steel, and Nimonic 80A) to
determine which material would be best suited for the steam turbine, thus improving its efficiency and
performance.
PROCEDURE
The following steps will be taken to achieve this aim:
 Develop a 3D model of the different blade designs using CATIA V5 software.
 Converting the model into an IGS file format and importing it into the ANSYS software.
 Conduct static analysis and thermal analysis on the designed turbine blade.
 After analyzing the results, determining which material is the most appropriate for the blade.
SCOPE OF THE PROJECT:

The project aims to develop a three-dimensional model of a steam turbine blade and examine its static-thermal
behaviour using various materials through finite element analysis. To accomplish this goal, CATIA V5 will be
employed for drafting and designing and ANSYS software is used for analysis purposes.
LOAD CALCULATION
F = M × Vm
M = Mass of the steam flowing through the turbine
Vm = velocity of the steam in m/s
M = 1000.00kg/hr.
Vm = 1310.00m/s
F = 362.8701N
Blade Area = 23319.101mm2
Pressure = F/A = 0.0155601N/mm2
MATERIAL PROPERTIES
MATERIAL NIMONIC CHROME HASTE INCONEL STAINLESS

80A STEEL ALLOY 600 STEEL
Density g/cc 8.19 7.31 8190 8360 8025

Young’s 144 200 205 214 200
modulus(Gpa)
Poisson’s ratio 0.348 0.3 0.33 0.324 0.30
Tensile strength 1120 485 601.2 570 652
ultimate(Mpa)
Tensile strength 980 275 275 340 400

yield (Mpa)
Melting 1380 1365 1144 1370 1451

point( c)
o
Thermal 33.5 14.0 11.2 13.6 33.5

conductivity
(W/m/k)
Specific heat 0.448 0.418 0.427 0.419 0.410
capacity(J/g -c)
o
DIMENSIONS AND DESIGN PROCEDURE:

To begin the design process in CATIA, navigate to the sketcher workbench. Start by creating a blade shape
profile using arcs with radii of R55, R60, and R80. Once the profile is complete, apply a fillet with a radius of
R4.
After creating the fillet, switch to the part design workbench and apply a pad command to the blade shape.
Then, returning to the sketcher and creating a rectangle of dimensions 120*100. Apply the pad command of
25mm to this rectangle in the part design workbench.
Next, create another rectangle in the sketcher with dimensions of 85x100 and apply a pad of 25mm to this
shape in the part design workbench. Finally, create a rectangle with dimensions of 120x100 in the sketcher
and apply a pad of 25mm to this shape in the part design workbench.
Once all the pads have been applied, the steam turbine blade should be visible on the part design workbench.
Refer to the figure below for a visual representation of the final design.
Blade Dimensions Blade without Holes Blade with Holes
Steam Turbine in Catia workbench

PROCEDURE FOR ANALYSIS IN ANSYS:
After importing the pre-designed component from the Catia workbench into the Ansys workbench, then the
next step is to select the steady-state thermal analysis. The following steps should be followed:
 Specify the engineering materials and their corresponding material properties.
 Import the component's geometry.
 Model the component and apply meshing techniques.
 Set up the boundary conditions for the thermal analysis.
 Solve the problem and obtain the results.
 Finally, analyze and interpret the obtained results.
STATIC STRUCTURAL ANALYSIS:

The ANSYS WORKBENCH solver can be used to perform a static structural load analysis. This type of
analysis is used to calculate stresses, displacements, and forces in structures due to the loads that do not cause
significant inertia and damping effects. The analysis presumes stable loading and the response situations and
that the loads and structure response change at a gradual pace concerning time. Through static structural load
analysis, it is possible to acquire a comprehensive understanding of how a structure operates under different
loading conditions.
STEADY-STATE THERMAL ANALYSIS:

Steady-state thermal analysis is a type of analysis that determines the impact of steady thermal loads on a
system or component. Analysts often conduct this analysis before performing transient analysis, and it can
also serve as the final step of a transient thermal analysis. By conducting a steady state analysis, one can
determine various parameters such as temperature, thermal gradient, and heat flux in an object that do not
change with time.
MESH AND BOUNDARY CONDITIONS
Nodes:5031 P=0.01556N/mm2 Temperature:229

Elements:2680 Convection:0.0025
RESULTS
The purpose of this study is to assess the structural and thermal characteristics of a steam turbine blade,
including stress levels, deformations, heat flux, and temperature distributions. The study includes an analysis
of the blade with and without holes, using five different materials: Nimonic 80A, stainless steel, chrome steel,
and, Inconel 600, Haste alloy. The findings of the investigation are presented in the figures provided below.
Von-Mises stress in the blade (without holes)
Nimonic 80A Chrome Steel Inconel 600
Haste Alloy Stainless Steel
Von-Mises stress in the blade (with holes)
Total Deformation in the blade (without holes)
Total Deformation in the blade (with holes)
Chrome Steel Inconel 600

Nimonic 80A
Temperature Distribution in the blade (without holes)
Temperature Distribution in the blade (with holes)
Total Heat Flux in the blade (without holes)
Total Heat Flux in the blade (with holes)
Stainless Steel
Haste Alloy
COMPARISON OF VON MISES STRESS

The graph below illustrates the differences in stress variation between two designs, one with holes and the
other without holes, across five different materials: Nimonic 80A, Haste alloy, Inconel 600, Chrome steel, and
stainless steel. The material with the lowest level of stress was found to be Nimonic 80A.
COMPARISON OF TOTAL DEFORMATION

The graph below depicts the differences in total deformation variation between two designs, one with holes
and the other without holes, across five different materials: Nimonic 80A, stainless steel, Haste alloy, Inconel
600, and Chrome steel. It was observed that Nimonic 80A exhibited the least amount of deformation among
all the materials tested.
COMPARISON OF TEMPERATURE DISTRIBUTION

The graph presented displays the varying temperature distribution values between two different designs and
across different materials, including Nimonic 80A, stainless steel, Haste alloy, Inconel 600, and Chrome steel.
The results indicate that the Nimonic 80A material with holes exhibited the highest minimum temperature
distribution value.
COMPARISON OF HEAT FLUX

The graph below illustrates the varying total heat flux values between two different designs and across
different materials, including Nimonic 80A, stainless steel, Haste alloy, Inconel 600, and Chrome steel. The
results indicate that the Nimonic 80A material with holes exhibited the highest total heat flux distribution
value.
CONCLUSION
The steam turbine blades were modelled using CATIAV5 software, with and without holes, and then imported
into ANSYS software for structural analysis to assess the quality of materials, Nimonic 80A, stainless steel,
Haste alloy, Inconel 600, and Chrome steel. The Von-Misses stresses deformation, temperature distribution,
and heat flux were obtained for each material, and when compared, Nimonic 80A with holes exhibited the
least amount of stress, deformation, minimum temperature distribution, and heat flux values. Based on the
results of the structural and thermal analysis, it is concluded that Nimonic 80A with holes is the most suitable
material for steam turbines.
REFERENCES
[1] Transient Thermal Analysis of the Turbine Blade, M. Yashwanth Kumar, Shaik Himam Saheb & M.
Venkata Ramana Reddy Volume 20 Issue 3 Version 1.0 Year 2020.
[2] Study on Design and Analysis of Steam Turbine Blade to Find Its Frequency and Deformations, Ronanki
Naidu, B. Hari Gopal, Department of Mechanical Engineering, Gokul group of institution, A.P, India. Vol-7
Issue-4 2021, IJARIIEISSN(O)- 392-398.
[3] Thermal Analysis of a Steam Turbine Blade, Challa Murali, Kolamala Sreenivasulu, International Journal
of Research, Volume 04 Issue 01 January 2017.
[4] Design and Analysis of Gas Turbine Blade, Theju V, Uday P S, PLV Gopinath Reddy, C.J. Manjunath,
International Journal of Innovative Research in Science, Engineering and Technology, Vol. 3, Issue 6, June
2014.
[5] Experimental Investigation on the Design of High-Pressure Steam Turbine Blade, Subramanyam Pavuluri,
Dr A. Siva Kumar, International Journal of Innovative Research in Science, Engineering and Technology, Vol.
2, Issue 5, May 2013.
[6] Design Modification for Fillet Stresses in Steam Turbine Blade, Tulsidas. D, Dr Shantharaja. M, Dr
Kumar. K, IJAET, Vol. III, Issue I, January-March, 2012,343-346.

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© 2023 JETIR April 2023, Volume 10, Issue 4 www.jetir.

ANALYSIS ON STEAM TURBINE BLADE

SCOPE OF THE PROJECT:

MATERIAL NIMONIC CHROME HASTE INCONEL STAINLESS

Density g/cc 8.19 7.31 8190 8360 8025

Tensile strength 980 275 275 340 400

Melting 1380 1365 1144 1370 1451

Thermal 33.5 14.0 11.2 13.6 33.5

DIMENSIONS AND DESIGN PROCEDURE:

Blade Dimensions Blade without Holes Blade with Holes

Steam Turbine in Catia workbench

STATIC STRUCTURAL ANALYSIS:

STEADY-STATE THERMAL ANALYSIS:

MESH AND BOUNDARY CONDITIONS

Nodes:5031 P=0.01556N/mm2 Temperature:229

Von-Mises stress in the blade (without holes)

Nimonic 80A Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Von-Mises stress in the blade (with holes)

Nimonic 80A Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Total Deformation in the blade (without holes)

Nimonic 80A Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Total Deformation in the blade (with holes)

Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Temperature Distribution in the blade (without holes)

Nimonic 80A Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Temperature Distribution in the blade (with holes)

Nimonic 80A Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Total Heat Flux in the blade (without holes)

Nimonic 80A Chrome Steel Inconel 600

Haste Alloy Stainless Steel

Total Heat Flux in the blade (with holes)

Nimonic 80A Chrome Steel Inconel 600

COMPARISON OF VON MISES STRESS

COMPARISON OF TOTAL DEFORMATION

COMPARISON OF TEMPERATURE DISTRIBUTION

COMPARISON OF HEAT FLUX

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