Research Papers: Gas Turbines: Turbomachinery

Partial Stall Effects on the Failure of an Axial Compressor Blade

[+] Author and Article Information
E. Poursaeidi

Department of Mechanical Engineering,
University of Zanjan,
Zanjan 45371-38791, Iran
e-mail: epsaeidi@znu.ac.ir

M. R. Mohammadi Arhani

Department of Mechanical Engineering,
University of Zanjan,
Zanjan 45371-38791, Iran
e-mail: mohammadi500@gmail.com

S. Hosseini

Faculty of Mechanical Engineering,
Tarbiat Modares University,
Tehran 14115-111, Iran
e-mail: hosseini.sana@gmail.com

M. Darayi

Department of Mechanical Engineering,
Arak University,
Arak 39455-38138, Markazi, Iran
e-mail: mech.mohsen@gmail.com

M. Arablu

Department of Mechanical Engineering and
Engineering Science,
University of North Carolina at Charlotte,
Charlotte, NC 28223
e-mail: marablu@uncc.edu

Contributed by the Structures and Dynamics Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received December 28, 2014; final manuscript received April 27, 2015; published online June 2, 2015. Editor: David Wisler.

J. Eng. Gas Turbines Power 137(12), 122602 (Jun 02, 2015) (6 pages) Paper No: GTP-14-1681; doi: 10.1115/1.4030515 History: Received December 28, 2014

This paper is aimed to show the effects of partial stall on the fracture of the first stage rotating blades of the gas turbine compressors of an onshore gas refinery. The first part of the paper deals with the results of finite element modeling (FEM) of stress distribution and stress concentration areas on the blades under its first to third natural frequencies. Comparison of the stress concentration areas with the fractured blades shows that the blades have been fractured due to resonance under the first and second natural frequencies. The second part of the paper deals with the computational fluid dynamics (CFD) simulation of air flowing through the blades to determine the most probable sources of vibrational loads as the aerodynamic forces. Results of CFD simulations show that the operation of the gas turbines under 40–50% of their nominal output power—which has been very regular in the history of operation of the turbines—increases the possibility of stall at the tip side of the first stages rotating blades. The vortices shedding due to downwash flow at the tip side of the blades causes flow instability and increases the aerodynamic vibrational forces on the blades, which finally makes them to experience a kind of high cycle fatigue (HCF).

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Fig. 1

Destroyed compressor

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Fig. 2

3D model of IGVs and first row rotor blades and stator blades

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Fig. 3

Stress distribution on the pressure surface of the blade which represents a stressful area at approximately its one-third height

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Fig. 4

Qualitative stress distribution on the blade under first three natural frequency vibrations

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Fig. 5

Comparison of stress distribution on the blades resulted from vibration analysis under frequency equal to second natural frequency with the fracture line of GTG C compressor blade

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Fig. 6

(a) Compressor operation curve under different controlling modes and the failure conditions and (b) output power versus exhaust mass flow rate, based on nominal engine operation [14]

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Fig. 7

The constructed geometry and the applied mesh in the CFX modules

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Fig. 8

Streamline over the tip section of the blades resulted from stage model

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Fig. 9

Streamline over the tip section of the blades resulted from frozen rotor model

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Fig. 10

Huge radial vortex at the tip section of the rotating blades causing local stalls at the downstream flow at the tip and hub sections of the stator blades




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