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Research Papers: Gas Turbines: Turbomachinery

A Damage Evaluation Model of Turbine Blade for Gas Turbine

[+] Author and Article Information
Dengji Zhou, Tingting Wei, Huisheng Zhang, Shixi Ma, Shilie Weng

Gas Turbine Research Institute,
Shanghai Jiao Tong University,
Shanghai 200240, China

1Corresponding author.

Contributed by the Turbomachinery Committee of ASME for publication in the JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received December 4, 2016; final manuscript received February 5, 2017; published online April 11, 2017. Editor: David Wisler.

J. Eng. Gas Turbines Power 139(9), 092602 (Apr 11, 2017) (9 pages) Paper No: GTP-16-1565; doi: 10.1115/1.4036060 History: Received December 04, 2016; Revised February 05, 2017

Current maintenance, having a great impact on the safety, reliability and economics of a gas turbine, becomes the major obstacle for the application of gas turbines in energy field. An effective solution is to process condition based maintenance (CBM) thoroughly for gas turbines. Maintenance of high temperature blade, accounting for the most of the maintenance costs and time, is the crucial section of gas turbine maintenance. The suggested life of high temperature blade by original equipment manufacturer (OEM) is based on several certain operating conditions, which is used for time based maintenance (TBM). Thus, for the requirement of gas turbine CBM, a damage evaluation model is demanded to estimate the life consumption online. A physics-based model is built, consisting of thermodynamic performance simulation model, stress estimation model, thermal estimation model, and interactive damage analysis model. Unmeasured parameters are simulated by the thermodynamic performance simulation model, as the input of the stress estimation model and the thermal estimation model. Due to the ability to analyze online data, this model can be used to calculate online damage and support CBM decision. Then the stress and temperature distribution of blades will become as the input of the creep damage analysis model and the fatigue damage analysis model. The interactive damage of blades will be evaluated based on the creep and fatigue analysis results. To validate this physics-based model, it is used to calculate the lifes of high temperature blade under several certain operating conditions. And the results are compared to the suggestion value of OEM. An application case is designed to evaluate the application effect of this model. The result shows that the relative error of this model is less than 10.4% in selected cases. And it can cut overhaul costs and increase the availability of gas turbines significantly. Finally, a simple application of this model is proposed to show its functions. The physical-based damage evaluation model proposed in this paper is found to be a useful tool to tracing the online life consumption of a high temperature blade, to support the implementation of CBM for gas turbines, and to guarantee the reliability of gas turbines with lowest maintenance costs.

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Figures

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Fig. 1

A simplified flow diagram of the online damage evaluation model

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Fig. 2

Scheme of gas turbine simulation model

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Fig. 3

Structure of the high temperature blade of gas turbine

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Fig. 4

Heat transfer in the ith compartment

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Fig. 5

Schematic diagram of the forces on the blade

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Fig. 6

S–N curve of a certain superalloy

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Fig. 7

LMP–stress curve of a certain superalloy

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Fig. 8

Gas turbine configuration of this case study

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Fig. 10

The stress of the back of the first stage rotational blade in the process of cold startup and shutdown

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Fig. 11

The stress of the leading edge of the first stage rotational blade in the process of cold startup and shutdown

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Fig. 9

The stress of the 3/4 height of the first stage NGV in the process of cold startup and shutdown

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Fig. 12

Damage evaluation result of the rotational blade

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Fig. 13

Damage evaluation result of the NGV

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Fig. 14

Effects of power load and fouling extent on damage evaluation result of the rotational blade

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Fig. 15

Cumulative damage process of the rotational blade in the cold startup and shutdown

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Fig. 16

Cumulative damage result of the rotational blade in the process of cold startup and shutdown under different fouling extents

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