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Diagnostic and failure analysis in blades of a 300 MW steam turbine

Article in Engineering Failure Analysis · May 2017

DOI: 10.1016/j.engfailanal.2017.04.039

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 Engineering Failure Analysis xxx (xxxx) xxx–xxx

Contents lists available at ScienceDirect

Engineering Failure Analysis

journal homepage: www.elsevier.com/locate/engfailanal

Diagnostic and failure analysis in blades of a 300 MW steam

turbine
J.A. Segurab, L. Castroa, I. Rosalesa, J.A. Rodrigueza,⁎, G. Urquizaa, J.M. Rodriguezc
a
Centro de Investigación en Ingeniería y Ciencias Aplicadas (CIICAp-UAEM), Av. Universidad 1001. Col. Chamilpa, C.P. 62209 Cuernavaca,
Morelos, México
b
Centro de Ingeniería y Desarrollo Industrial (CIDESI), Alianza Sur No. 203 Autopista al Aeropuerto Km. 10, C.P. 66629, Apodaca, NL, México
c
Centro Nacional de Investigación y Desarrollo Tecnológico, Interior Internado Palmira S/N, Col. Palmira, C.P. 62490 Cuernavaca, Morelos, México

AR TI CLE I NF O AB S T R A CT

Keywords: A steam turbine from a thermoelectric central was put into maintenance due to a forced outage
Failure analysis for high vibrations. Visual inspection of the steam turbine of 300 MW showed blades fractured at
Turbine blades the last stage, L-0 and these affected other blades. Some operating parameters demonstrated to be
300 MW out of range such as flow steam, low vacuum, and several areas in blade result to be damaged by
Crack propagation
the implosions particle. Three blades were fractured and others with a considerable crack
presence were detected. The damage and fracture in the blades joints are attributed to high
vibrations stresses combined with high cycle fatigue. A metallographic study revealed that the
fracture was initiated from a cavity due to particle erosion. Numerical calculation results have
shown that stubs blades group are disconnected as a result of the firstly vibratory stresses during
startup and shutdown of the turbine. Resonance phenomena are present in the first blade when
this is a detachment of the group initializing a crack propagation process. Number cycles before
crack propagation in the blades of the last stage of a steam turbine of 300 MW were calculated.

1. Introduction

It is well known that thermoelectric power plants produce electricity from the heat energy released by the combustion of diesel,
natural gas, fuel oil or coal [1].The risks of failure in power generation equipment are due principally to their working conditions;
these failures are expected by fatigue, erosion-fatigue, breakdowns for fracture, corrosion, etc. [2–8]. In the operation of steam
turbines is important to know the behavior of all components in the involved processes, in order to avoid such failures and
consequently maximize the performance of equipment through good maintenance [9].
Turbines defects are generated by the degradation material over service time where the blades are exposed to extreme conditions
such as alternating loads due to unstable flow steam, harmonics, imperfections in the minimum throat etc. [10]. The blades of the
stages L-0 of low pressure (LP), are the most important components of all types of the turbine and therefore play an important role in
power generation [11].
The atmosphere inside of steam turbines and blades connections also has a negative effect on the useful life. The damage is caused
by a solid build up at the blade root that shifted a natural frequency into an interface region and changed the response characteristic
of the blade disk assembly. Other failures are related to torsional effects that induced high cycle vibration fatigue [12]. Some blades
of 725 mm length of the steam turbine were fractured at 125 mm of the root destroying some of their steep and high vibrations were

⁎
Corresponding author.
E-mail address: jarr@uaem.mx (J.A. Rodriguez).

http://dx.doi.org/10.1016/j.engfailanal.2017.04.039
Received 26 July 2016; Received in revised form 23 April 2017; Accepted 23 April 2017
1350-6307/ © 2017 Elsevier Ltd. All rights reserved.

Please cite this article as: Segura, J.A., Engineering Failure Analysis (2017), http://dx.doi.org/10.1016/j.engfailanal.2017.04.039
J.A. Segura et al. Engineering Failure Analysis xxx (xxxx) xxx–xxx

Fig. 1. Damage in stubs of the blades.

generated. The blades are made of 17-4pH precipitation hardening stainless steel [13].
A finite element analysis (FEA) of the group of blades was performed. It was observed with this analysis that high vibrations
generated high stress concentration caused by the first natural frequency with the second harmonic. Resonance phenomena are
presented in all system [14]. These conditions are good enough to start the cracking process in the blades and its imminent failure.
In this work, the first step was to develop a diagnostic of failure and next step to determine the failure analysis for the cause of the
fracture in blades of L-0 stage in LP of the steam turbine of 300 MW and finally crack propagation was analyzed.

2. Experimental and numerical procedure

2.1. Failure inspection

The blades of the last stage of the turbine of 300 MW were removed allowing an initial evaluation of the failure. Three blades of
the last stage of LP were fractured destroying several blades and one more with a considerable crack. Like consequence probably,
high cycle vibration fatigue was produced affecting all steam turbine performance. The Fig. 1 shows the blades from the last stage of
the steam turbine. After physical inspection, it is observed that these blades were repaired at another time and the joints of blades
have the lack or incomplete penetration weld revealing evidence of damage. Such weld defects could easily decrease its useful life
and, depending on the conditions of the operation, this situation may cause a fracture in poor weld joints. These fractured stubs
released from the blades can be the main cause for large vibrational amplitudes in its first mode, producing also an increased steam
flow in the turbine operation.
Fracture in blades was produced by the high frequency fatigue originated from blades vibration. The direction of the crack
propagation was in the tangential direction [15]. Due to that, the crack started at the trailing edge of the blade than the first
tangential mode of vibration is suspected as a principal contributor to blade fracture.

2.2. Numerical modeling

Numerical modeling was performed by means of calculation of the number of cycles for crack propagation in the blades of last
stages of a steam turbine of 300 MW. This stage is formed by 120 blades which are connected in groups of five blades (see Fig. 2). The
software for CAD and numerical simulation was Ansys Research® V 16.1 and simulations were performed in Dell Precision® Intel (R)
Core (TM) i7-4800 MQ CPU @ 2.70 GHz.
According to previous studies [15], the present steam forces on the blades are located at half of each blade. Table 1 shows
maximum and minimum excitation forces produced on the blade [16].
Fig. 3 shows the crack in the blades where operating conditions were determined in point A.

3. Results and discussions

3.1. Diagnostic of failure

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Fig. 2. Discrete model; (a) 5 blades group, (b) lower joint, (c) upper joint.

3.1.1. Steady conditions

In order to obtain precise information about the stresses generation and to develop a diagnostic of failure, it was necessary
performed different calculations of cases studies [17]. Table 2 shows four principal cases. The rotational speed used in the calculation
is 3600 RPM.
The first case considered five blades joined. Fig. 4 shows the stress distribution in the group of blades, pointing stress
concentration. In this figure, it is presenting the maximum stress on the first blade, being the maximum value of 670.39 MPa.
The second case analyzed, shows the stresses distribution, determined by disconnecting of the lower joint from the first blade.
Fig. 5 shows that the maximum stress occurs in the fifth blade approximately to half the height, in the input limit. The magnitude of
stress is 677.62 MPa and is located according to Fig. 5.
In the third case, the stresses distribution were calculated by disconnecting of the upper joint from the first blade (see Fig. 6)
showing that the maximum stress occurs in the first blade at approximately in the lower joint in the output limit. The magnitude of
stress is 740.58 MPa.
In the fourth case, the first blade is separate of both joint of the rest of the blades group. The stress distribution occurs as is shown
in Fig. 7. In this case, the magnitude of the stresses is 904.73 MPa and is presented close to the lower connector blade.
According to the obtained results, it was not possible to determine crack initiation under these conditions in the first blade to
125 mm of the root, therefore it was necessary to perform another study.

3.1.2. Resonance conditions

A specific analysis was realized under resonance conditions. It was carried out a vibrational analysis on the group of blades
without fracture between joints, simulating operational conditions that may occur during turbine startup or shutdown (resonance
phenomena), to identify the areas of highest stress concentration. The points are shown in Fig. 8, located near the rotation speed
between the three natural frequencies and their harmonics. Table 3, shows the critical speed with the resonance point, natural
frequency and their harmonic [12]. Fig. 9 shows the stress distribution. It can be seen that the areas of highest stress concentrations
occur close to the joints between the blades. This condition may produce detachment of joints in both stubs of the blades.

Table 1
Excitation Forces of the blades.

Forces Maximum (N) Minimum (N) Average (N)

Total Ft 542.109 443.544 492.90

Tangential Fy 416.02 340.28 378.20
Axial Fz 347.71 284.49 316.10

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Fig. 3. Fracture blade and the representation of the crack location.

In the fourth case with one blade separate from the group and stubs disconnect. The first natural frequency intersects the second
harmonics near the speed of operation of the turbine, Fig. 10. The speed at which resonance occurs is 3323.77 RPM. This speed is
very near to the operational speed of the steam turbine.
However, although normally the resonance is presented in the startup and shutdown of the turbine. Fig. 11 shows the distribution
of vibratory stresses of the first natural frequency and the second harmonic in agreement with Campbell diagram of Fig. 10. As can be
seen that the maximum stress is located in the area where the crack is nucleated in the first blade [18]. The alternative stress at this
point is 90.645 MPa. The nominal value for the principal stress due to centrifugal force and stable steam power is 363.94 MPa.

3.2. Failure analysis

The results for diagnostic of failure in steady conditions shown that the stresses levels are below the yield strength of material for
Cases 1 and 2. There were an increase of stresses for Cases 3 and 4 regarding the first two cases. However, the zone of maximum stress
is not located where crack initiated in Fig. 3. The four cases were submitted in resonance condition. Therefore, under this condition,
only for the last case, the stresses increase and the zone is located where crack initiated to 125 mm from the root of the blade, Fig. 3.

3.3. Crack propagation analysis

The crack propagation in the blade L-0 of the turbine of 300 MW was carried out in high cycle fatigue. The blades group worked in
resonance between its first vibration mode and the second harmonic at 120 Hz, Fig. 10 [13]. Natural frequencies of the above cases
changed when the blades presented cracks to different sizes, between 5 and 100 mm of length. The mathematical equation that
describes the behavior of the crack propagation is Eq. (1) [4].

K = β BFSβ FFSβw βCFC∗σ πa [MPa√m] (1)

In which K is Stress Intensity Factor, β is the geometry factor relationship with consistent structural dimensions. The σ is the
nominal stress away from the crack. The symbol π is a mathematical constant and a is crack size. The various boundary effects are due
to back free surface (BFS), front free surface (FFS), width (w), and crack front curvature (CFC). These boundary effects are neglected
and then Eq. (2) is.

Table 2
Four cases of analysis.

Case 1 Five blades joined

Case 2 Disconnecting of the lower joint from the first blade

Case 3 Disconnecting of the upper joint from the first blade
Case 4 The first blade is separated of both joint of the rest of the blades group

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Fig. 4. Case 1: Stress distribution in blades group (a) concave side from the first blade (b) convex side from the fifth blade.

K = βσ πa [MPa√m] (2)

where β = 1.
The Paris law was applied for calculating the cycles of crack propagation during the crack growth, Eq. (3).
da
= C (ΔK )m [mm cycle]
dN (3)

where C and m are the material constants and ΔK is the range of the Stress Intensity Factor.
Fig. 12 shows the numerical model of the group of blades meshing with the crack.

Fig. 5. Case 2: Stress distribution with disconnecting of the lower joint from the first blade.

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Fig. 6. Case 3: Stress distribution with disconnecting of the upper joint from the first blade.

Table 4 shown the resonance zones of the different sizes of cracks and the corresponding Stress Intensity Factor (SIF). Fig. 13
shown the stresses distribution in the crack tip at a size of 100 mm crack, it also presents in detail the behavior of the Stress Intensity
Factor for different cracks sizes.
The Eq. (4) calculate the blade excitation frequency to which the failure take place.

Fig. 7. Case 4: Stress distribution with rupture of the lower and upper joint from the first blade.

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Fig. 8. Campbell diagram of blades group.

Table 3
In terms of resonance points, the three natural frequencies with the harmonics near operation speed.

Resonance point Natural frequency Harmonics Critical speed

(Hz) (rpm)

1 147.32 Third 2946.18

2 227.66 Fourth 3415.497
3 257.66 Fifth 3091.966

Fig. 9. Relative vibratory stresses distribution.

Δa Δt
f= [Hz]
da dN (4)

where f is the blade excitation frequency, Δa is the depth of the cover segment hole, Δt is the time of the fracture propagation and da is
crack size increment [19].
According to the Eq. (4) [19], the excitation frequency between 83 and 119 Hz corresponds to the crack size increment average,
1.5 μm. This excitation frequency is similar to the calculate numeric and obtained when the blade is completely separated from blades
group. The cracks sizes for this are between 5 and 100 mm. The time crack propagation until 100 mm was between 8 and 10 min with

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Fig. 10. Campbell diagram with blade separate from the blades group.

Fig. 11. Vibratory stresses distribution with the first blade completely detached from the group.

66,000 cycles.
Metallographic analysis performed on the fractured blade of Fig. 3 is showed in Fig. 14. In this image is observed a crack series on
the surface blade, where two cracks are observed initializing from a surface pore (marked by an arrow) therefore this fact make the
relation with the assumption that crack initiation it is produced due to the impact of the external particles over the blade surface in
combination with the high vibratory stresses by resonance condition between the first natural frequency of the blade and the second
harmonic.
When the blade is connected at both junctions, the Stress Intensity Factor is below of the fracture toughness values of the material.
Under these joint conditions, the blade will not be fractured within 100 mm crack size, it also shows that the Stress Intensity Factor
when the blade it is completely detached, the fracture occurs at 93.7 mm. from the root.

4. Conclusions

The steam turbine of 300 MW has shown an evident fracture in the blades of the last stage, L-0. Operating parameters
demonstrated to be out of range such as: excessive flow steam, low vacuum, and the area nozzle result to be affected by the
implosions particles. A metallographic study revealed that the fracture initiated from a cavity due to erosion. Three blades were

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Fig. 12. Discrete model of blades group with crack and meshing around the crack, from the last stage of 300 MW turbine.

Table 4
Critical speed and Stress Intensity Factor at resonance points at the different crack size.

Crack sizes Natural frequency Resonance points (RPM) SIF, K

(mm) (Hz) (MPa-m1/2)

Blade completely detached

5 110.38 3311 17.97
37 104.44 3133 48.34
70.5 87.611 2629 121.63
100 74.273 2229 160.04

Connected both joints

5 152.24 3046 33.39
37 151.10 3023 84.82
70.5 149.45 2990 98.00
100 148.55 2972 105.23

fractured and other one present a considerable crack presence (about 100 mm).
The group blades could be susceptible to generate cracking during startup and shutdown of the turbine at the welded joints, with
poor or little penetration of the filler metal and caused the separation of the blades. Results suggested that high vibrations stresses
may produce a fracture in the blade joints. Numerical calculation results have shown that stubs blades group are disconnected as a
result of the first vibratory stresses during startup and shutdown of the turbine. Resonance introduced high stress concentration to the
first blade caused by the first natural frequency and the second speed harmonic, initializing a crack propagation process and resulting
in a catastrophic turbine failure. When the blade is connected at both junctions, the Stress Intensity Factor is below of the fracture
toughness values of the material; under these conditions, the blade will not be fractured within 100 mm crack size. The Stress
Intensity Factor when the blade it is completely detached, the fracture occurs at 93.7 mm of crack size according to numerical results.

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Fig. 13. Vibratory stress distribution from blade group with 100 mm of crack size, from the 300 MW last stage turbine.

Fig. 14. Blade surface with a series cracks propagation due to impacts of external particles.

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