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Copyright 0 1997 by ASME All Rights Reserved . Printed in U.S.A

LIFE ASSESSMENT OF GAS TURBINE BLADES AND VANES

111111 11111111111111 1111


John K. Hepworth John D. Wilson, James M. Allen
PowerGen plc, Power Technology Centre, Ratcliffe-on-Soar, Cosulting Engineer, EPRI
Nottingham, NG11 OEE, UK.

George H. Quentin George Touchton


Electric Power Research Institute, Patto Alto, California, USA.

ABSTRACT life. The blades are sophisticated castings of nickel-based superalloys


The hot stage components of a large industrial gas turbine and are expensive to replace.
engine operate under extremely arduous conditions and as a result
have a finite life. In particular, the first stage blades and vanes are In order to keep operating costs to a minimum it is necessary to
expensive to replace and there are strong financial incentives to maximise the useful life of the blades. Accuracy is needed, because
maximise their useful life and to refurbish them, where possible, to an over estimate of life could result in blade failure in service with
extend that life. In order to achieve this life extension, it is essential the resulting costs of machine damage and loss of availability,
to have a detailed knowledge of the conditions under which the whereas an under estimate would result in either unnecessary shut
blades operate and of their responses to those conditions. down or premature blade replacement To achieve the required
accuracy, a thorough knowledge of blade behaviour and life usage is
Detailed thermal and stress analyses have been carried out on essential.
the first stage blades and vanes of a large gas turbine, operating in a
combined cycle power generation plant. The boundary conditions for In this study, the results of an aerothermal analysis are used as
the analysis were taken from an aerothennal analysis of the engine. boundary conditions for a thermal, elastic finite element analysis of
From these, the finite element method was used to compute both the moving and fixed blades from a Siemens 94.2 machine.
temperature distributions and then stress distributions in both the From this analysis, temperature and stress distributions are obtained
blades and vanes. Consideration was given to the effect of thermal for the blades and these results can then be used, in conjunction with
transients and also to the effect of creep in allowing some appropriate material property data to draw conclusions about damage
redistribution of the thermal stresses. accumulation in the blades. In this paper, the general life assessment
approach is described and some broad conclusions drawn. Recently,
The resulting stress and temperature distributions were used to examination of blades removed from service has revealed serious
estimate damage accumulation in the material due to fatigue, creep problems of cracking in the internal cooling ducts, which threaten to
and, where appropriate, oxidation. These damage estimates have then reduce blade life. Particular attention is paid to the understanding of
been applied to predict crack initiation. Estimates have also been this form of damage.
made of likely crack growth behaviour. Damage predictions have
been compared with observations made on blades removed from 2. ANALYSIS OF MOVING BLADES
service. The damage accumulation has implications for the operation, The first stage moving blade is a casting of the nickel based
maintenance and blade replacement strategies for the engine. superalloy IN738LC, which contains interior passages for air cooling.
The cooling air enters the leading edge duct passing into a mid-
1. INTRODUCTION section duct and then into the trailing edge duct. The air is
In a large industrial gas turbine the first stage turbine discharged through a series of holes along the trailing edge. A finite
components are subjected to a very severe high temperature element model of the blade, consisting of quadratic, 20-noded brick
environment, which they are required to survive for long periods. As elements, was constructed as shown in figure I. The thermal and
a result, the turbine moving and fixed blades have a limited life and stress analysis work was carried out using the ABAQUS finite
may require refurbishment a number of times during their anticipated element suite, with PATRAN as pre- and post-processor.

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

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accumulation of creep strain. Typically, the peak tensile stress on the The effect of rapid transients also need to be taken into account
inner wall of the middle duct has been reduced to around 50% of its In the analysis, it was shown that the metal temperature gradients and
initial value in about 6000 hours, though the exact time scale is very hence thermal stresses were essentially independent of ramp rate for
dependent on the creep strain rate data used in the analysis. As all but the very rapid transients associated with trips. These transient
redistribution proceeds, the stresses relax reducing the driving force typically have a time scale of around 200 milliseconds and give rise to
for creep. In the moving blades, creep is also caused by the a moderate additional stress peak of around 60MPa , which would
centrifugal stress and here there is no scope for stress relaxation, so cause some additional fatigue damage, though not enough to cause the
this stress will ultimately cause creep failure of the blade. In practice, observed incidence of cracking. In order to provide an adequate
cracking has been found on the v84.2 blades after service periods explanation of the behaviour of blades in service, a model which
below 1000 hours when creep damage should be negligible. On includes the effects of oxidation has been developed.
v94.2 blades which operated with few shutdown, cracking was found
after some 14000 hours (23000 equivalent hours) 4.2 Oxidation Fatigue Damage Model
Examination of blades removed from service has shown
Fatigue damage is produced by the changes in strain when the cracking, particularly in the inner walls of the cooling ducts, at times
machine is started or shut down: The major contribution here comes when creep damage will be small. This cracking occur after far fewer
from the thermal stress. Because the outer surface is hotter, the cycles than would be expected for initiation under pure fatigue. It is
thermal stress is compressive on the outer surface and tensile on the therefore concluded that the cracking, which is found on uncoated
inner cooled surfaces. If there were total relaxation by creep of the parts of the duct walls, is due to some form of oxidation enhanced
thermal stress, then the same changes in stress and strain will occur fatigue. A number of studies have been reported in the literature
on start up and shut down, resulting in residual stresses in the cold which consider the combined effects of oxidation and fatigue in
blade that are tensile on the outer surface and compressive on the Nickel based superalloys (for example Bernstein et al (1993), Remy
inner surface. The effect on fatigue is to change the mean stress and (1993), Reuchet & Remy (1983) „Miller et al (1992) ). In view of the
hence influence damage through the R-ratio. On the outer surface, spread of data on fatigue damage, it would be difficult to establish
relaxation will change the cycle from • cool zero stress - hot defuntively which model provides the best description, but they all
compressive to cool tensile - hot zero, which will increase the damage appear to give reasonable descriptions of the experimental data they
accumulation rate. On the inner surface the damage rate is reduced as seek to explain. Additional evidence that oxygen has a deleterious
the cycle change from cool zero stress - hot tensile to cool effect on the damage related mechanical properties of nickel based
compressive - hot zero. In the time scale for blade cracking, moderate superalloys is provided by Woodford (1990). The current work is
amounts of stress relaxation take place, but the associated creep essentially based on the model due to Remy (1993) of oxide
strains are small and the influence of creep damage can be neglected. penetration of grain boundaries. This was chosen because
metallurgical examination of ex-service blades appears to show oxide
The operating temperatures of the first stage blades are penetration as a precursor to cracking.
sufficiently high for the blade material to oxidise. The outer surfaces In outline the model used assumes oxide penetration of grain
are coated to protect the blade from oxidation and other forms of boundaries according to a fourth power law, with an Arrhenius
corrosion. While the coating remains intact, oxidation of the base temperature dependence (Reuchet & Remy, 1983). This growing
metal is prevented. However, coatings have a limited life and, when oxide spike give rise to stress and strain enhancement locally, causing
the coating is breached, oxidation of the base metal will begin. The enhanced fatigue damage. The length of the oxide spike is given by
blades are cooled by air flowing through the interior. It is not the
normal practice to coat the interior of the blades and, even though the = ao t exp(—Q / RT) .(l)
metal temperatures are lower here than on the outer surfaces,
oxidation does occur. Oxidation can damage the blade in two main where aox is a material constant, t is the time, Q is the activation
ways. First, there is the direct effect of removal of material from the energy, R is the gas constant and T is the absolute temperature. The
blade. Second, the oxide can cause enhancement of fatigue damage stress concentration factor is taken as
and it is this effect that appears most significant in blades removed
from service. An exception to this might occur, for example, in blades
that have been seriously overheated or in blades that have been K, =1+2 rT
/c ir (2)
damaged due to poor environmental control during processing.
where r is the tip radius of the oxide spike. Strictly, this factor is
For all the damage mechanisms, the rate of damage for primary loads and does not in general apply to thermal loads,
accumulation is determined by some combination of the stress, or which are strain controlled. In this case because of the very small
strain, and the temperature, so the first requirement for assessing size of the spikes involved, this expression can be used as a good
damage is an accurate knowledge of the temperature and stress, approximation to the true stress, or strain, concentration factor. The
obtained from the analyses previously described. damage, which varies from zero in the initial, undamaged state to
unity, which crack initiation is taken to occur, can then be expressed
When the results of the blade analysis are used in a as
straightfonvard way, employing standard values of creep rupture and
fatigue data from the literature, life estimates are obtained which 1
imply that blade damage should not be serious problem under normal D =s+Dfatigue (3)
service conditions. Assuming there were no problems with the inn
coatings, the creep life of the 94.2 blade would be in excess of 1000
hours and fatigue cracking would not be expected until after several where (toot is the assumed initiation depth and Da tive is the
hundred cycles, even when allowance is made for creep fatigue fatigue damage given by a summation of all the fatigue cycles
interactions. In practice, blades are being scrapped after much less
service, so additional factors need to be included in the assessment.

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x--• 1 operating temperature the thermal stresses on the outer surface
Digigue — ( N e j) ) ( 4) are compressive, which would be expected to reduce damage.
If the coating failed by cracking, rather than by thinning, then
the coating crack could provide stress enhancement and thus
where ) is the number of cycle to fatigue crack accelerate fatigue damage accumulation. A similar model can
initiation for strain range j taken from tests where the load be used to assess damage on the outer surface, taking these
frequency is sufficiently high for no significant oxide additional factors into consideration.
penetration to occur.
5. CRACK GROWTH
In applying this model to predict crack initiation in blades, Once a crack has initiated, the consequences depend on the rate
equation 1 is used to estimate oxide penetration during the on of growth of the resulting crack. It is therefore important to atenc the
load part of the cycle. Equation 2 is then applied to obtain an likely growth rates of cracks on the cooling duct walls of the moving
effective strain range from the FE predictions of strain and this blades. A detailed investigation of crack propagation would be time
effective strain is used to determine fatigue damage during the consuming, involving finite element determination of stress intensity
shut down to start up sequence, from appropriate material data. factors for a range of crack sizes. In order to obtain a preliminary
estimate of the likely behaviour of cracks on the cooling ducts of the
This procedure is repeated for each cycle, the fatigue damage
moving blades, a simple approximate method has been used, based on
summed over all the load cycles, equation 4, and the total the fracture mechanics program R6-Code (1994). Basically, the
damage estimated from equation 3. Crack initiation is assumed geometry is represented by a cracked plate and influence coefficients
to occur when the damage from equation 3 is greater than or from that geometry used to estimate the stress intensity factor, K,
equal to unity. from the stress that has already been calculated for the uncracked
blade. The boundary conditions used to establish the influence
This model gives reasonable predictions of the cracking coefficients have a major effect on K and hence on crack behaviour.
observed on plant and therefore provides an appropriate basis These conditions could range from load control, which is the most
for comparing blade life under a range of operating scenarios. severe, to displacement controlled conditions, where crack growth can
give rise to stress relaxation and loads may not be transferred to the
In the middle duct of a v94.2 blade, cracking is predicted to
remaining ligament. In the case of thermal stresses, displacement
initiate within the service time and number of cycles and the loading is a more appropriate model. Displacement loading acting
areas of greatest density of cracking correspond with the over a long range provide the next most onerous conditions and the
earliest predicted initiation. Quantitative comparisons of severity reduces with decreasing effective range of the displacement
initiation time are difficult as it has not proved possible to loading. The cracks are oriented parallel to the axis of the blade,
obtain reliable experimental estimates of when the observed which is the radial direction in the engine. In this direction, the
cracks initiated. In order to get better comparison, it will be driving stress for the cracks is almost entirely the thermal stress. Thus
necessary to make calculate crack growth rates and work to displacement boundary conditions are appropriate, but it is not
achieve this is in progress. There is still a need for more possible in a simple way to estimate the equivalent effective range. In
order to explore crack behaviour two ranges were considered,
accurate values for some of the material constants involved,
described by cracked plates with length, 1, to width, w, ratios of 4 an
which will be obtained from material testing and by 16. There are relatively few data on fatigue crack growth in 01738.
comparison of cracking predictions with further observations Paris law constants of 6.7x1( - 9 nun/cycle and 3.5 were used (
on ex-service blades. The oxidation rate in this model gives a Holdsworth & Hoffelner, 1982). For 1/w=16, which provides the more
time dependence of el% which is in reasonable agreement with severe loading as the stress will act more as a primary stress, shows
the time dependence of the empirical model of Bernstein et al the crack propagating at an increasing rate, becoming unstable after
(1993). about 130 cycles. For the lower aspect ratio case where the thermal
stress behaves as a secondary stress and is effectively relaxed as the
One problem with this model is that, if it is viewed crack propagates. The crack growth initially increases, reaches a
maximum and then, after around 200 cycles, the propagation rate
simplistically, it would imply that all grain boundaries in a
begins to decrease slowly, as illustrated in figure 7.
region with similar temperature and strain range should crack,
but this is not found to be the case. Clearly the process of oxide More detailed studies are in progress to determine more precise
penetration has some statistical element due to local variations values of stress intensity factor (K) and hence obtain a better estimate
around each surface breaking grain boundary of composition of crack growth rate. It is clear, though, that the results so far do show
and particle distribution. Strictly, the model should provide a that cracks are likely to grow. This correlates with the observation on
probability distribution for oxide penetration. Similar local ex-service blades, where cracks are found with a range of depths.
variations will also apply to the fatigue part of the model.
However, at this stage the deterministic model gives sufficient 6. CONCLUSIONS
information for the required purpose of estimating crack There are a number of significant points which arise.
initiation in the uncoated cooling passages. Metal temperatures calculated using finite element analysis are
in agreement with values estimated from the metallurgical structure.
For cracking on the outer surfaces, which are coated,
additional considerations apply. The life of the coating should The thermal stresses predicted using finite element analysis are
be a major part of the crack initiation life in these parts. When well below yield and the blades are well within the shakedown limit.
the coating fails, fatigue is further modified by the fact that at

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Thermomechanical fatigue damage is virtually independent of R6 Code, 1994, Nuclear Electric plc, UK.
the rate of change of temperature during Start/stop transients, except
for °rattly fast tnmsients, as encountered in trips, which cause S R Holdsworth and W Hoffelner, 1982, 'Fracture
stress excursions and some additional damage. Mechanics and Crack Growth in Fatigue, High
Temperature Alloys for Gas Turbines, Liege Belgium.
Creep relaxation of thermal stresses can modify fatigue publ.
behaviour through the R-ratio, but causes negligible creep damage.
As relaxation proceeds, the fatigue damage rate changes from being
greater on the inner surface to the outer surface.

Simple creep-fatigue damage estimation predicts excessively


long lives compared with service experience. 41111
An oxidation-fatigue damage model has been used to give
Nib/
realistic estimates for internal crack initiation.

A simplified analysis implies that internal cracking is likely to DIM


propagate in service.
oho • ..
:==
The ability to predict damage accumulation in blades enables Ito ,;;:,
blade life usage to be optimised. It provides a sounder basis for „
In.1111111 A INIIMISEWIR
decisions about whether to refurbish blades or run them to the end of
life and better estimates of when these actions would need to be
amstruuti:
taken. This has important economic benefits by saving the costs
associated with premature refurbishment or replacement. There are of CM11071:1111 1!
course the very serious consequences of blades failing in service. . 11•11=211111111 1 I
I L I ;;; .--"=;;;
.=;wi
Damage assessment should permit the probability of this happening ill 1;11, ■.=r
— tom.;;;;;
to be minimised, though further work, currently in hand, is required ;;
to establish the amount of damage that can be safely tolerated. I ;;;;;; •
Pro
*

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.

8. REFERENCES Figural Finite Element Mesh of Moving Blade


V P Swaminathan, T R Sharron and 3 M Allen, 1990, 'URI
Supaalloy Database for Hot Section Gas Turbine Blade, Life
Assesra•ent and Repair Technology for Combustion Turbine Hot
Section Components, ASM/EPRI, EPRI s-7031, pp 129-136
Figure 2 Temperature Distribution of Moving
H L Bernstein, T S Grant, R C McClung and J M Allen, 1993, BIBS at 1410-heigM
Prediction of Thermal-Mechtmical Fatigue Life for Gas Turbine
Blades in Electric Power Generation', Thermomechanical Fatigue
Behaviour of Materials, ASTM STP 1186, pp212-238.

L Raw, 1993, 'Fatigue Damage and Lifetime Prediction in Alloys


for Gas Turbine Components submitted to Themial Transients',
Behaviour of Defects at High Temperatures, ESIS 15 MEP,
London, pp167-187.

Fteuchet and L Remy, 1983, ' Fatigue Oxidation Interaction in a 860 C


Superalloy - Application to Life Prediction in High Temperature 800 C
Low Cycle Fatigue', Met. Trans. A, 14A, ppI41•149.
740 C

M P Miller, D L McDowell and R L T Oelunke, 1992, A Creep- 680 C


Fatigue-Oxidation Miaocrack Propagation Model for 620 C
Thennomechnical Fatigue', Trans ASME, 3 Engng Math. Tech.
114, pp 282-288.

D A Woodford, 1990, 'Gas Phase Embrittlement of Superalloys -


Implication for Life Assessments, Life Assessment and Repair
Technology for Combustion Turbine Hot Section Components,
ASM/EPRI, FYR1 a-7031, pp 97-102.

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Figure 3 Mises Equivalent Stress Distribution of
Moving Blade at Mid-height

75 -

50 -

2.0

-25 -
De tect depth, mm

-50
1.0

75
0 6 12 113
I 2'4 SO 36

Distance, mm

Figure 4 Transient Stress In Moving Blade


due to 200 maw Transient
100 200 300
Cycles

Figure? Esthnate of Crack Growth from


Figure 5 Temperature Distribution of Moving Slade inner Surface
Fixed Blade at Mid—height

980 C

840 C

700 C
560 C

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