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Presented at the International Gas Turbine & Aeroengine Congress & Exhibition
Orlando, Florida — June 2–June 5,1997
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2.1 Thermal Analysis The two slower transients had rise times longer than the heat
The boundary conditions, for steady state, full load operation, transfer time constant of the blade wall and thus generated no
were obtained from an aerothermal analysis of the engine carried out increase in thermal stress above steady state values, The fastest
at Power Technology Centre, which provided gas temperature and transient, 0.2 sec, did provide an increase in stress on the outer
heat transfer coefficient at a set of points on the outer surface of the surface. Here the initial compressive stress was replaced by a modest
blade. This analysis assumed an inlet temperature of 1120°C and an tensile stress at the end of the temperature ramp as shown in figure 4.
inlet pressure of 10.78 bar. The resulting values were interpolated to Thus it can be concluded that only the very rapid transients give rise
provide the external boundary conditions for the model. An additional to additional fatigue damage.
analysis provided values of cooling air temperature and heat transfer
coefficients in the interior cooling ducts of the blade and the trailing 2.4 Effect of Creep
edge cooling holes, which were applied to the model via a specially A creep analysis of the moving blade was carried out with
writtensubroutine. The blade analysis was iterated to take better secondary strain rates derived using Monkman-Grant and stress
account of the influence of variations in metal temperature on the rupture data from the literature (Swaminathan, 1990). There is
cooling air temperature. considerable variability in the strain rate data, which means that the
results of the analysis can really only be interpreted qualitatively.
The results of the thermal analysis are indicated in the plot in They show that the thermal stresses relax under the influence of
figure 2, which shows steady state temperature contours in a section secondary creep, most rapidly where the stress and temperature are
near the middle of the aerofoil section of the blade under full load highest. The stresses also redistribute to maintain equilibrium. In
operation. As might be expected, the leading edge is the hottest part consequence, when the blade is off-load and at a uniform
of the blade, but the temperature does increase again towards the temperature, a residual stress will be generated, which will generally
trailing edge, presumably because the cooling air is heated as it have an opposite sign to the thermal stress. As the thermal stress
paRsPs through the labyrinth of the cooling ducts. The results of the range is insufficient to cause yielding, then the creep strain associated
analysis were found to show good agreement with temperature with this redistribution is effectively bounded by the elastic strain
estimates made from the metallurgical structure of an ex-service associated with the thermal stress. The stress range for fatigue is
blade. unaffected by creep, but the residual stress induces an offset, so the
mean stress is changed which alters the R ratio.
2.2 Stress Analysis
The temperatures calculated from the finite element analysis 3. ANALYSIS OF FIXED BLADES
were used as a boundary condition for the elastic stress analysis, The first stage fixed blade, or vane, has been analysed for steady
which also included the loading due to centrifugal forces. It was state, full load operation in a similar manner to the moving blade.
assumed that the blade platform provided complete restraint in the The cooling arrangements are different in the fixed blade, which is
radial direction, relative to the engine. Additional restraints were cooled by impingement of jets of cooling air from a perforated can
included only to prevent rigid body modes. The results of the analysis fitted inside the vane. Internal cooling heat transfer conditions were
are illustrated in figure 3, which shows the von Mises equivalent calculated on that basis. The results of the temperature analysis are
stress on the surface of a section from the middle part of the aerofoil. shown in figure 5. The highest temperatures are found at the trailing
The thermal stresses dominate and, as expected, are tensile on the edge, which is slightly hotter than the leading edge. Generally, the
inner surface and compressive on the outer surface. The magnitude of central part of the blade is the coolest. The thermal stresses
the thermal strecsps is well within the shakedown limit. calculated from these temperatures are shown in figure 6, where the
largest stresses appear on the suction side. Again the expected pattern
2.3 Effect of transients is found of tensile stresses on the inner surface and compressive on
The thermal transients caused by starts and shut downs give the outer. The temperatures and resulting thermal stresses are
significant contributions to fatigue damage in many types of power critically dependent on the cooling parameters. In particular, small
plant. This damage is often strongly dependent on the rate of changes in the hole size in the perforated inner can significantly alter
temperature change during a transient and is small for slow blade temperatures, with a consequent effect on life.
transients. In the case of cooled gas turbine blades, the steady state
temperature gradient means that any start-stop cycle will cause 4. DAMAGE ASSESSMENT
fatigue damage. The question then arises as to whether the rate of
change of temperature in the transient will affect the amount of 4.1 Preliminary Assessment
damage. The effects on the gas turbine blades were explored by The principal mechanical damage mechanisms in high
applying thermal transients to simulate such operations, which can temperature components are creep, fatigue and oxidation. In some
cause rapid variation in the gas temperature on the outside of the cases other forms of chemical attack may have to be considered, but
blade. The temperature range of the transients were between the full for a gas turbine fuelled on natural gas, with efficient inlet air
load gas temperature and half that value. Up and down shocks were filtration, such additional problems should not be significant.
examined with 2 and 5 second ramp times, with the heat transfer
coefficients held at the full load values. In order to accommodate the The first stage blades and vanes are cooled and this results in a
more refined mesh needed for the thermal gradients, the 2 second temperature gradient through the wall of the blade under normal
ramp was applied to a model consisting only of a section of the operating conditions. The operating temperature of the blades is high
aerofoil at mid height Under trip conditions, the gas temperature can enough for the blade to be in the creep regime. In both fixed and
fall in times of around 200 msec so an analysis was carried out for a moving blades, the thermal stresses due to temperature gradients in
0.2 sec down shock. This was applied to a model that consisted of a the blades will cause creep strain, which leads to redistribution of the
portion of the pressure side wall of the middle cooling duct. Boundary stresses. The creep strain involved in this redistribution is relatively
conditions were applied in the stress analysis to provide some small, being of the order of the elastic strain associated with the
influence from the surrounding structure. thermal stress. The creep analysis, which has been carried out,
confirmed that the thermal stresses slowly relax with only a modestt
7. ACKNOWLEDGEMENTS
This work was carried out at the Power Technology Caine of
Power:3c plc and was partly funded by the Electric Power Research
Institute. The work is published by permission of PowaGen plc.
75 -
50 -
2.0
-25 -
De tect depth, mm
-50
1.0
75
0 6 12 113
I 2'4 SO 36
Distance, mm
980 C
840 C
700 C
560 C