Fatigue Life Consumption for Turbine Blades-Vanes Accelerated by Erosion-Contour Modification
A new mechanism responsible for structural life
consumption due to resonant fatigue in turbine blades, or vanes, is
presented and explained. A rotating blade or vane in a gas turbine can
change its contour due to erosion and/or material build up, in any of
these instances, the surface pressure distribution occurring on the
suction and pressure sides of blades-vanes can suffer substantial
modification of their pressure and temperatures envelopes and flow
characteristics. Meanwhile, the relative rotation between the blade
and duct vane while the pressurized gas flows and the consequent
wake crossings, will induce a fluctuating thrust force or lift that will
excite the blade.
An actual totally used up set of vane-blade components in a HP
turbine power stage in a gas turbine is analyzed. The blade suffered
some material erosion mostly at the trailing edge provoking a
peculiar surface pressure envelope which evolved as the relative
position between the vane and the blade passed in front of each other.
Interestingly preliminary modal analysis for this eroded blade
indicates several natural frequencies within the aeromechanic power
spectrum, moreover, the highest frequency component is 94% of one
natural frequency indicating near resonant condition.
Independently of other simultaneously occurring fatigue cycles
(such as thermal, centrifugal stresses).
[1] Han, J., Dutta, S., Ekkad, S. "Gas Turbine Heat Transfer and Cooling
Technology", Taylor&Francis, New York, NY, 2000.
[2] Woisetschlager, J., Lang, H., Hampel, B., Gottlich, E. and Heitmeir,
F. Influence of blade passing on the stator wake in a transonic turbine
stage investigated by particle image velocimetry and laser vibrometry
Proc. Instn Mech. Engrs Vol. 217 Part A: J. Power and Energy, 2003.
[3] Sondak, D. L. and Dorney, D. J. Simulation of vortex shedding in a
turbine stage. J. Turbomach., 1999, 121, 428-435.
[4] Adami, P. and Martelli, F.. Three-dimensional unsteady investigation
of HP turbine stages. Proc. IMechE Vol. 220 Part A: J. Power and
Energy, 2006.
[5] Tofighi, M., Ali, S., Rezamahdi, N. "Failure Analysis of Gas Turbine
Blades", K.N. Toosi University of Technology, Paper 120, ENG 108,
Proceedings of the 2008 LAJC-IJME International Conference, Iran,
2008.
[6] ANSYS FLUENT 12.0 "Theory Guide"
[7] Maintenance manual MFT4-CID/LF Vol. 1 y Vol. 2.
[8] Dennis G. Zill, Cálculo con Geometría Analítica, Editorial
Iberoamericana, segunda edici├│n.
[9] Shih, T.-H., Liou, W. W., Shabbir. A., Yang, Z., and Zhu, J. A New k-
╬Á Eddy- Viscosity Model for High Reynolds Number Turbulent Flows
- Model Development and Validation. Computers Fluids, 24(3):227-
238, 1995.
[10] Fern Engineering, Inc., "Gas Turbine and Combined - Cycle Capacity
Enhancement", TR-102412, Generation & Storage Division, EPRI
Project Manager, Palo Alto, California, October, 1993.
[11] Haldeman, C. W., Mathison, R. M., "Aerodynamic and Heat Flux
Measurements in a Single-Stage Fully Cooled Turbine- Part I:
Experimental Approach", Journal of Turbomachinery,
Vol.130/021015-1, Columbus, OH., April 2008
[12] Cizmas, Paul and Subramanya, Ravishankar, Parallel computation of
rotor/stator interaction, Westinghouse Electric Corporation and
Pittsburgh Supercomputing Center, internal publication 1996.
[13] G├│mez-Mancilla, J., Sinou(est), Jean-Jacques, Nosov, V. R.,
Thouverez, F., Zambrano(est), A., "The influence of crack-imbalance
orientation and orbital evolution for an extended cracked jeffcott
rotor", COMPTES-RENDUS Mecanique, R.C., ISSN: 1631-0721,
editorial Elsevier, Vol. 332, 2004, Diciembre 2004, pags. 955-962.
[14] Machorro-Lopez(est), José M., Adams, Douglas E, G├│mez-Mancilla,
Julio C., Gul(est), Kamra, Identification of damaged shafts using
active sensing - simulation and experimentation, journal of sound
and vibration, Elsevier, Vol. 327, Noviembre 2009, pags. 368-390.
ISSN 0022-460X
[15] Gómez-Mancilla J., García illescas(est), Nosov V., Detection of
steady crack growth on rota-ting shafts, Procs. 2nd International
Symposium On Control And Stability Of Rotating Machinery,
ISCORMA-2, Gdansk Technologic University y Bently Press. Brg,
Gdansk, Polonia, Sept. 2003
[16] Machorro-L├│pez J.M.(est), Adams D.E., Gomez-Mancilla J.C., Crack
detection of shafts in rotating machinery using active sensing with an
external excitation on a bearing, Proceedings of the American
Society of Mechanical Engrs, ASME, SMASIS-08, ISBN 978-7918-
3839-6, copyright 2008 ASME, paper 467, Turf Valley, Ellicott City,
EEUU, 28-30 Octubre 2008.
[17] Adams, D. E., "Health Monitoring of Structural Materials and
Components: Methods with Applications," 2007, John Wiley & Sons,
Chichester, UK
[18] Haroon, M. and Adams, D., E., "Component-Level Damage
Evolution Laws for Mechanical Damage Prognosis," 2008, American
Society of Mechanical Engineering Journal of Applied Mechanics,
Vol. 74(2), DOI: 10.1115/1.2793137
[19] Douglas E. Adams, Health Monitoring of Structural Materials and
Components, Ed. John Wiley & Sons Ltd, USA 2007. ISBN 978-0-
470-03313-5
[1] Han, J., Dutta, S., Ekkad, S. "Gas Turbine Heat Transfer and Cooling
Technology", Taylor&Francis, New York, NY, 2000.
[2] Woisetschlager, J., Lang, H., Hampel, B., Gottlich, E. and Heitmeir,
F. Influence of blade passing on the stator wake in a transonic turbine
stage investigated by particle image velocimetry and laser vibrometry
Proc. Instn Mech. Engrs Vol. 217 Part A: J. Power and Energy, 2003.
[3] Sondak, D. L. and Dorney, D. J. Simulation of vortex shedding in a
turbine stage. J. Turbomach., 1999, 121, 428-435.
[4] Adami, P. and Martelli, F.. Three-dimensional unsteady investigation
of HP turbine stages. Proc. IMechE Vol. 220 Part A: J. Power and
Energy, 2006.
[5] Tofighi, M., Ali, S., Rezamahdi, N. "Failure Analysis of Gas Turbine
Blades", K.N. Toosi University of Technology, Paper 120, ENG 108,
Proceedings of the 2008 LAJC-IJME International Conference, Iran,
2008.
[6] ANSYS FLUENT 12.0 "Theory Guide"
[7] Maintenance manual MFT4-CID/LF Vol. 1 y Vol. 2.
[8] Dennis G. Zill, Cálculo con Geometría Analítica, Editorial
Iberoamericana, segunda edici├│n.
[9] Shih, T.-H., Liou, W. W., Shabbir. A., Yang, Z., and Zhu, J. A New k-
╬Á Eddy- Viscosity Model for High Reynolds Number Turbulent Flows
- Model Development and Validation. Computers Fluids, 24(3):227-
238, 1995.
[10] Fern Engineering, Inc., "Gas Turbine and Combined - Cycle Capacity
Enhancement", TR-102412, Generation & Storage Division, EPRI
Project Manager, Palo Alto, California, October, 1993.
[11] Haldeman, C. W., Mathison, R. M., "Aerodynamic and Heat Flux
Measurements in a Single-Stage Fully Cooled Turbine- Part I:
Experimental Approach", Journal of Turbomachinery,
Vol.130/021015-1, Columbus, OH., April 2008
[12] Cizmas, Paul and Subramanya, Ravishankar, Parallel computation of
rotor/stator interaction, Westinghouse Electric Corporation and
Pittsburgh Supercomputing Center, internal publication 1996.
[13] G├│mez-Mancilla, J., Sinou(est), Jean-Jacques, Nosov, V. R.,
Thouverez, F., Zambrano(est), A., "The influence of crack-imbalance
orientation and orbital evolution for an extended cracked jeffcott
rotor", COMPTES-RENDUS Mecanique, R.C., ISSN: 1631-0721,
editorial Elsevier, Vol. 332, 2004, Diciembre 2004, pags. 955-962.
[14] Machorro-Lopez(est), José M., Adams, Douglas E, G├│mez-Mancilla,
Julio C., Gul(est), Kamra, Identification of damaged shafts using
active sensing - simulation and experimentation, journal of sound
and vibration, Elsevier, Vol. 327, Noviembre 2009, pags. 368-390.
ISSN 0022-460X
[15] Gómez-Mancilla J., García illescas(est), Nosov V., Detection of
steady crack growth on rota-ting shafts, Procs. 2nd International
Symposium On Control And Stability Of Rotating Machinery,
ISCORMA-2, Gdansk Technologic University y Bently Press. Brg,
Gdansk, Polonia, Sept. 2003
[16] Machorro-L├│pez J.M.(est), Adams D.E., Gomez-Mancilla J.C., Crack
detection of shafts in rotating machinery using active sensing with an
external excitation on a bearing, Proceedings of the American
Society of Mechanical Engrs, ASME, SMASIS-08, ISBN 978-7918-
3839-6, copyright 2008 ASME, paper 467, Turf Valley, Ellicott City,
EEUU, 28-30 Octubre 2008.
[17] Adams, D. E., "Health Monitoring of Structural Materials and
Components: Methods with Applications," 2007, John Wiley & Sons,
Chichester, UK
[18] Haroon, M. and Adams, D., E., "Component-Level Damage
Evolution Laws for Mechanical Damage Prognosis," 2008, American
Society of Mechanical Engineering Journal of Applied Mechanics,
Vol. 74(2), DOI: 10.1115/1.2793137
[19] Douglas E. Adams, Health Monitoring of Structural Materials and
Components, Ed. John Wiley & Sons Ltd, USA 2007. ISBN 978-0-
470-03313-5
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:60013", author = "Julio C. Gómez-Mancilla and Luis M. Palacios-Pineda and Yunuén López-Grijalba", title = "Fatigue Life Consumption for Turbine Blades-Vanes Accelerated by Erosion-Contour Modification", abstract = "A new mechanism responsible for structural life
consumption due to resonant fatigue in turbine blades, or vanes, is
presented and explained. A rotating blade or vane in a gas turbine can
change its contour due to erosion and/or material build up, in any of
these instances, the surface pressure distribution occurring on the
suction and pressure sides of blades-vanes can suffer substantial
modification of their pressure and temperatures envelopes and flow
characteristics. Meanwhile, the relative rotation between the blade
and duct vane while the pressurized gas flows and the consequent
wake crossings, will induce a fluctuating thrust force or lift that will
excite the blade.
An actual totally used up set of vane-blade components in a HP
turbine power stage in a gas turbine is analyzed. The blade suffered
some material erosion mostly at the trailing edge provoking a
peculiar surface pressure envelope which evolved as the relative
position between the vane and the blade passed in front of each other.
Interestingly preliminary modal analysis for this eroded blade
indicates several natural frequencies within the aeromechanic power
spectrum, moreover, the highest frequency component is 94% of one
natural frequency indicating near resonant condition.
Independently of other simultaneously occurring fatigue cycles
(such as thermal, centrifugal stresses).", keywords = "Aeromechanic induced vibration, potential flowinteraction, turbine unsteady flow, rotor/stator interaction, turbinevane-blade aerodynamic interaction, airfoil clocking", volume = "5", number = "6", pages = "1095-7", }
