Estudio de Durabilidad de Los Alabes Del Compresor de Aire

Durability Studies Results
and Plans for Completion
9FA Results
VX4.3A Results
Robert Dewey
Status Update: 9FA F-Class
• Year 1 saw completion of 1st row

bucket aerothermal analysis.
• Examined the 9FA+e version of the
bucket – with TBC and platform
undercut.
• Results consolidated and
submitted to EPRI in January 2006
as interim report.
• Have initiated examination of 2nd
row bucket based on reverse
engineered dimensions obtained in
2005.
• Row 2 analysis to be completed in
2006. Row 3 in 2007.
© 2006 Electric Power Research Institute, Inc. All rights reserved. 2
Features of the Model
9FA+e Model
• 95,000 elements.
• 200,000 nodes.
• 3 serpentine channels.
• 45 trailing edge slots.
• Showerhead film
cooling.
• Tip cooling.
• TBC coating
protection system.

Operating Conditions Considered
Normal Start
Four conditions
• FSNL: 430 seconds.
– Most critical at start of
process.
• Normal base load Normal Shutdown
• Shutdown: 2400 seconds

– Two step drop
• Full load trip: 32 seconds
– Sudden closure of inlet
Full Load Trip
vanes
– significant gradient
between internal and
external temperatures
Internal Cooling
Leading Circuit.
• ~25” long
• 2nd
Elbow of • HGP starts about
circuit
6.5 inches up from
inlet.
• 1st Elbow • Lead circuit ranges
of circuit
from 760oF (404oC)
to 1100oF (593oC).
• Minimum film
• Shank ends coefficient in shank.
• Maximum film
coefficient near first
elbow region.

Internal Cooling
Trailing Circuit
• ~33” long
• HGP starts about
6.5 inches up from
• 2nd
Elbow of inlet.
circuit
• Lead circuit ranges
from 760oF (404oC)
• 1st
Elbow
to 1130oF (610oC).
of circuit
• Minimum film
• Shank coefficient in shank.
ends
• Maximum film
coefficient near first
elbow region.

External Flow
Pressure/Mach No.
• Largest static
pressure 131.9 psia
on pressure side
surface.
• Maximum Mach
number near TE of
suction side
surface.
• Distinctive wake
observed.

External Film Coefficients
Mean diameter
• Stagnation point
on pressure side
surface.
• Maximum heat
transfer at this
location.
• Decreases
substantially to
1” back from
nose.

Temperatures
Ramp Up Temperature Delta: ~464oF (258oC)

• Thermal response
milder than on earlier
versions.
• Mainly attributed to
reduction in
acceleration rate.
• TBC further
moderates transient
response in airfoil.

Metal Temperatures
Steady State
• Maximum operating
metal temperature of
~1800oF (982oC)
– Occurs at platform
PS/SS and tip.
• TE cooling hole ~1470oF
(700oC).
– 80oF (27oC) lower
than FA+ design
Base Metal Temperatures (TBC Removed)

TBC Surface Temperatures
Temperatures on TBC at Mid-Span

Steady State
• TBC bucket now
TBC Surface
operates at higher
temperature.
• Temperature is reduced
in base metal.
• Mid-span gradient
across the TBC
• Ranges from 130oF to Interface & Base Metal
250oF (54oC to 121oC)

TBC Surface Temperatures
Steady State
• Compared to 9FA+
TBC reduces mid-span
temp by 100oF-150oF
(38oC-66oC).
• Corresponding metal
temperature lowered
about 60oF-110oF
(16oC-43oC)
• At these temperatures
any oxidation expected
to be marginal.

Temperatures
Shut down
• Under normal conditions, produces thermal transient
considered relatively mild.
Temperature Delta: ~282oF (157oC)

Temperatures
Full Load Trip Temperature Delta: ~206oF (114oC)

• TBC profoundly
affects thermal
response for trip.
• Reduces response
and moderates
temperature
gradient across the
metal.
• Principal benefit is
for airfoil where
cooling flow is
available.
Stress
Start Up Stress Delta: ~21 ksi (145 MPa)
• External metal
surfaces operate
in compression.
• Internal surfaces
operate in
tension.
• Stress during
start-up lower
than in steady
state condition.

Stress
On TBC
Steady State
• Stress in TBC layer
relatively low.
• Stress in base
metal somewhat
higher.
• Favorable trend On Base Metal
due to TBC
• Reduced airfoil
stress from 2-15
ksi (14-103 MPa)

Stress
Near Cooling Hole

Steady State
• TE cooling hole:
– Notable tensile
stress
– ~91 ksi (627 MPa)
– TMF in-phase
• Platform upstream side:On Platform
– High compressive
stress.
– TMF will be out-of
phase.

Stress
Shut Down/Trip Stress Delta: ~32 ksi (221 MPa)
• Reversed stress
state compared to
start-up.
• Lower during shut
down than during
steady state.
• Tensile stress from
trip is milder
compared to FA+
due to TBC.

Life Assessment
Coating Life
• For TBC, look at spallation
or delamination.
• Based on isothermal and
thermal cycle tests by
SWRI.
• Relies on interface
temperature and stress
between TBC and
bondcoat.
• Cracks are parallel not
perpendicular to surface.

Life Assessment
TBC life equation:

Coating Life
Oxidation/TGO, fatigue strength,
• For TBC, spallation or sintering effect – Young’s modulus
delamination. Nf ={σ*TBC(t)/ΔσTBC[1-(δ/ δ*)c]}1/b
• Based on isothermal
and thermal cycle
tests.
• Peak interface temp of
1800oF (982oC) and
stress between TBC
and bondcoat.
• Compared at two
different Gpa fatigue
strength coefficients. • @ 6 hours/cycle = 1800 cycles or 11,000 hours
• @ 100 hours/cycle = 550 cycles or 55,000 hours
Life Assessment
TMF at Cooling Hole

• Normal shutdown = ~250 cycles.
• Full load trip = ~100 cycles
TMF primarily in phase

Life Assessment
TMF at Platform
• Normal shutdown = ~270 cycles.
• Trip about same.
TMF out of phase

Life Assessment
Creep Life
• Reached 1% on platform in transverse direction of DS
material after 24,000 hours (1HGPI).
• TE cooling hole reached 1.3% after 48,000 hours (2HGPI)

Creep Life
Creep Life
• Separated into 3
phases.
• Tertiary = plastic
instability of
material (necking).
• Rupture considered
imminent.
• Design criterion (%)
to approximate
when tertiary is
reached.

Summary Remarks - 1
TMF Life
• TBC clearly helps to
moderate base metal
temperatures.
• TBC effectiveness
however, is limited
where no cooling is
present
• TMF still considered
life limiting at platform
and cooling hole.

Summary Remarks - 2
Creep Life
• Creep remains an issue
– TE cooling hole cracking
– Platform failures.

Advanced Field Repair: 1st Stage Bucket
• Several OEM’s have alternative strategies for mitigating the

damage to the trailing edge cooling hole.
• All involve undercutting platform to relieve stress near hole.

Undercut: 9FA+e 1st Stage Bucket
• EPRI devised
platform undercut
as an alternative
field repair for use
by members.
• Evaluated three
incremental depths
of a cut.
• Trended change in
temperature, stress
and life.

Undercut Study Objectives
• Reduce stress in cooling hole.

• Balance this against stress created within platform

Undercut Metal Temperatures
Only nominal increase

• For 1st undercut, slight
increase in metal
temperatures
– 70oF (21oC) at two
corners of trailing edge.
– Peak metal temperature
~1680oF (916oC)
• Increase not considered
excessive.

Conclusion Regarding Undercut
Case # 1 Optimum
• Reduced TE hole
stress 29%.
• Groove stress
increased by 80
ksi.
• Est. potential life
improvement from
250 to 1000 TMF
cycles.

Summary Conclusions: Row 1
• How effective is the TBC compared to metallic coating?

– Most beneficial to airfoil, less to platform.
• Has the TMF cooling hole cracking problem been resolved?
– Better creep life, but still remains vulnerable to TMF
• Is the TE hole cracking still a problem for base load units?
– Interaction with TMF still likely.
• Where is the next durability issue likely to appear?
– Platform cracking on pressure side due to TMF.

Conclusions: Row 1
• How effective is the TBC in protecting the platform?

– Temperature is marginal. Erosion vs. oxidation.
• Where do trips cause most damage to the buckets?
– Principally to the TE hole. ~2.5 times normal start.
• Does the TBC justify the reduced cooling of the FA+e?
– Lower heat transfer offset by thermal resistance
• How does operating DLN combustors affect life?
– Could be increasing temperatures at platform at tip.

Planned Work for 2006
• Currently examining latest version of 2nd row bucket.

Questions on 9FA+e Row 1 Studies?

Status Update: V94.3A-Class
• Year 2 saw completion of

3rd and 4th row blade
aerothermal analyses.
• Examined the V94.3A
version of the blades –
uncooled, no TBC
• Plan to initiate examination
of 2nd row blades based on
dimensions obtained in 2005.
• Row 2 analysis to be
completed in 2006, Row 1 in
2007.

Durability Issues: V94.3A 3rd and 4th Stage Blade
• Row 3 failure attributed to LCF. Cause: high number of full load trips and fuel oil operation with quick localized cooling. Severely damaged airfoil. Considered unique event.
• Row 4 Modified in 2003 to increase power output by 12%. Not aware of any in service failures to date.

Features of the Model
V94.3A Row 3
• 28,000 elements
• 35,000 nodes.
• 3 spanwise channels
• Turbulence
promoters (trip strips)
• Airfoil effective length
~17” (432mm)
• MCrAlY coating
(Sicoat 2453)

Operating Conditions – Row 3
Normal Start
Four Conditions
• Start: 1,600 seconds.
– ~50% load by 1600
• Normal base load
Normal Shutdown
– Steady state
• Shutdown: 1440 seconds
– Gradual till inlet vanes
close
Full Load Trip
– First 6 seconds most
severe drop

Internal Cooling – Row 3
Middle Path
• ~24” (61 cm) long
• HGP starts about
6.3” (16 cm).
• Ranges from 529oF
(276oC) to 675oF
(357oC).
• Minimum film
• Shank ends
coefficient in shank.
• Maximum film
coefficient near tip.

External Flow – Row 3
Pressure/Mach No.
• Largest static pressure 59.9 psia (0.413 MPa)
on leading edge.
• Maximum Mach number on lead edge.

External Film Coefficients – Row 3
Mean Diameter
• Stagnation point
on pressure side
surface ~0.2”
(5mm) from nose.
• Maximum heat
transfer at this
location.
• Decreases
substantially to 1”
back from nose.

Metal Temperatures – Row 3
Ramp Up
• Mild thermal response.
• FSNL: 96oF to 701oF
(36oC to 372oC) after 280 sec.
• Load: 701oF to 977oF
(372oC to 525oC)
• Rate of 3.5 MW per minute
(about half of GE’s rate)

Steady State
• Peak metal
temperature of
1614oF (879oC)
on trailing edge.
• 1423oF (773oC)
near tip.
• 1470oF (799oC)
on platform

Shut down
• Temperature gradients
again relatively mild.
• Maximum temperature
shifts from airfoil to
platform.
• 1660oF to 1019oF
(879oC to 548oC) in
1440 seconds.

Full Load Trip

• Trailing edge principally
affected.
• Hot spot shifts again to
platform.
• Drops 1555oF to 1314oF
(846oC to 712oC)
• Transient over in 40
seconds

Stress – Row 3
Start Up
• External metal surfaces
operates in compression.
• Internal surfaces operate in
tension.
• Stress during start-up lower
than in steady state
condition.
• Reach ~68 ksi (470 MPa) in
airfoil pressure side.
Delta: 65.8 ksi (453 MPa)

Stress – Row 3
Steady State
• Peak thermal
stress in inner
cooling passage of
93 ksi (641 MPa).
• At mid suction
side 72 ksi (496
MPa).
• Root stress 200
ksi (1379 MPa)

Stress – Row 3
Shut Down
• Stress state
reverses
compared to
start-up.
• Stress lower in
shut down than
during steady
state.
• Change in stress
is negligible

Stress – Row 3
Trip
• Originally concerned
about trailing edge.
• Change in stress
relatively low.
• From 81 ksi to 91 ksi
(556 MPa to 625
MPa) over the
duration of the trip
Delta: 10 ksi (69 MPa)

Dynamic Analysis – Row 3
Frequencies
• Mode A well
detuned.
• Frequency ratio
of Mode B
(11ND) = 0.89
• Frequency
Ratio of Mode C
(16ND) = 1.01

Resonant Stress – Row 3
Frequencies Mode B 11 Nodal Diameter Mode

• Mode B resonance:
– On pressure side
above mid span =
11 ksi (76 MPa)
– At trailing edge
above platform =
6.2 ksi (43 MPa).
• Could affect damage
tolerance.

Regarding Damage Tolerance
• For GT blades/buckets, effective operating life is

generally assumed to be when enough cycles can cause
cracks to form.
• Remaining life – propagation to rupture – traditionally
been considered as limited and high risk.
• Blades are special case – dynamic component (HCF)
always present due to vibration. Generally vibration is
marginal.
• Failures usually occur as a sequence. Different
mechanisms participate in the formation and propagation
of cracks.

Regarding Damage Tolerance continued
• Ultimately once a crack forms and grows, HCF

(vibration) takes control of the process and remaining life
is rapidly consumed.
• For latter stage blades, modal stresses represent
locations most susceptible to any initial damage. Good
places to inspect.

Life Assessment – Row 3
Coating Life
• Used equivalent base
alloy of IN738 and GT+29
as substitute for Rene 80
and SICOAT 2453.
• Applied peak temperature
at trailing edge mid-span
of 1614oF (879oC).
• Est. oxidation life of
~103,480 hours

TMF Inside Cooling Path

• Normal shutdown = ~3,700 cycles.
• Full load trip = ~3,700 cycles
TMF in phase

Creep Life
• Reached 0.29% on leading edge after 100,000 hours.
• Discounting aging effects, creep not life limiting.
• Effectively cooled.

Conclusions: Row 3
• What role does creep play in terms of limiting life?

– Not very pronounced, even on airfoil and platform.
• Why is the predicted creep low, compared to other rows?
– No shroud and plenty of cooling available.
• What role does oxidation play?
– Likely to occur by 3rd or 4th HGPI.
• What role does TMF play?
– Nominal damage. Estimated at ~3,700 cycles

Conclusions: Row 3
• Is there a reliability issue with row 3?

– Reported failure appears to be non-design related.
• Is there a potential damage tolerance issue?
– Mode B could become a problem over time.
• Could the present replacement interval be extended?
– Results indicate possibility with inspection and
recoating.

Questions on V94.3A Row 3 Studies?

Features of the Model – Row 4
V94.3A Row 4
• 14,000 elements
• 18,500 nodes.
• Hollow, ~60% up
from platform, no
forced cooling
• Turbulence promoters
(trip strips)
• Airfoil effective length
~26” (606 mm)
• Diffusion chromium
coating (Sicoat 1110)
Operating Conditions – Row 4
Only two conditions examined:

• Normal base load operating
– Steady state
• Large transient thermal stress not
expected:
– Low temperatures
– No internal cooling


Trip:
• Mild thermal
response.
• 1282oF to 1184oF
(694oC to 640oC)
after 40 sec.
• Row 3 thermal
differential was
2.5 times greater.

Steady State
• Peak temperature
of 1284oF (696oC)
on leading edge.
• 1187oF (642oC)
near tip.
• 1242oF (672oC)
on platform

Stress – Row 4
Delta: 48 ksi (331 MPa)

Trip:
• Transient stress from trip
relatively low.
– 165 to 117 ksi
(1138 to 806 MPa).
• Temperature ~300oF
(166oC) much lower than
row 3,
– Row 3 had borderline
TMF damage.
• Concluded TMF not likely
to have any consequence
for row 4.
Stress – Row 4
Steady State
• Peak thermal stress in
airfoil:
– Exposed to gas path
– ~85 ksi (586 MPa).
• Root stress:
– ~109 ksi (752 MPa)

Dynamic Analysis – Row 4
Frequencies Interference Diagram – Row 4

• Mode A and B
are detuned.
• Frequency Ratio
of Mode C
(11ND) = 0.996
Mode A Mode B Mode C

Resonant Stress – Row 4
Resonant Stress
• For Mode C (11ND) =
7.0 ksi (48 MPa)
• Occurs on leading edge
above mid span.
• Could affect damage
tolerance.

Low Cycle Fatigue

• Concern of fatigue
cracking in root.
• Due to centrifugal
force at full speed.
• Not directly in hot gas
path, so evaluate
separately from TMF.
• Based on 109 ksi (751
MPa) est. life is
essentially “infinite”.

Life Assessment
Creep Life
• Reached 0.77% mid span suction side after 80,000 hours.
• Reached 1.00% at about 120,000 hours.

Conclusions: Row 4
• What is life limiting mechanism for Row 4?

– Creep on mid-span suction side. ~20% longer than OEM
replacement interval
• Is coating oxidation a concern?
– Oxidation starts being a problem ~1600oF (871oC).
Maximum temperature on Row 4 of 1268oF (687oC).
• Is TMF considered a problem?
– TMF is marginal compared to 3rd row.
• Is LCF considered a problem?
– Estimate indicates thousands of cycles could be
accommodated.

Questions on V94.3A Row 4 Studies?

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Durability Studies Results

and Plans for Completion

• Year 1 saw completion of 1st row

© 2006 Electric Power Research Institute, Inc. All rights reserved. 3

• Shutdown: 2400 seconds

© 2006 Electric Power Research Institute, Inc. All rights reserved. 5

© 2006 Electric Power Research Institute, Inc. All rights reserved. 6

© 2006 Electric Power Research Institute, Inc. All rights reserved. 7

© 2006 Electric Power Research Institute, Inc. All rights reserved. 8

Ramp Up Temperature Delta: ~464oF (258oC)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 9

Base Metal Temperatures (TBC Removed)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 10

Temperatures on TBC at Mid-Span

© 2006 Electric Power Research Institute, Inc. All rights reserved. 11

© 2006 Electric Power Research Institute, Inc. All rights reserved. 12

Temperature Delta: ~282oF (157oC)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 13

Full Load Trip Temperature Delta: ~206oF (114oC)

Start Up Stress Delta: ~21 ksi (145 MPa)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 15

© 2006 Electric Power Research Institute, Inc. All rights reserved. 16

Near Cooling Hole

© 2006 Electric Power Research Institute, Inc. All rights reserved. 17

Shut Down/Trip Stress Delta: ~32 ksi (221 MPa)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 18

© 2006 Electric Power Research Institute, Inc. All rights reserved. 19

TBC life equation:

TMF at Cooling Hole

© 2006 Electric Power Research Institute, Inc. All rights reserved. 21

© 2006 Electric Power Research Institute, Inc. All rights reserved. 22

© 2006 Electric Power Research Institute, Inc. All rights reserved. 23

© 2006 Electric Power Research Institute, Inc. All rights reserved. 24

© 2006 Electric Power Research Institute, Inc. All rights reserved. 25

© 2006 Electric Power Research Institute, Inc. All rights reserved. 26

• Several OEM’s have alternative strategies for mitigating the

© 2006 Electric Power Research Institute, Inc. All rights reserved. 27

© 2006 Electric Power Research Institute, Inc. All rights reserved. 28

• Reduce stress in cooling hole.

© 2006 Electric Power Research Institute, Inc. All rights reserved. 29

Only nominal increase

© 2006 Electric Power Research Institute, Inc. All rights reserved. 30

© 2006 Electric Power Research Institute, Inc. All rights reserved. 31

• How effective is the TBC compared to metallic coating?

© 2006 Electric Power Research Institute, Inc. All rights reserved. 32

• How effective is the TBC in protecting the platform?

© 2006 Electric Power Research Institute, Inc. All rights reserved. 33

• Currently examining latest version of 2nd row bucket.

© 2006 Electric Power Research Institute, Inc. All rights reserved. 34

© 2006 Electric Power Research Institute, Inc. All rights reserved. 35

• Year 2 saw completion of

© 2006 Electric Power Research Institute, Inc. All rights reserved. 36

© 2006 Electric Power Research Institute, Inc. All rights reserved. 37

© 2006 Electric Power Research Institute, Inc. All rights reserved. 38

© 2006 Electric Power Research Institute, Inc. All rights reserved. 39

© 2006 Electric Power Research Institute, Inc. All rights reserved. 40

© 2006 Electric Power Research Institute, Inc. All rights reserved. 41

© 2006 Electric Power Research Institute, Inc. All rights reserved. 42

Temperature Delta: ~881oF (472oC)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 44

Temperature Delta: ~595oF (331oC)

© 2006 Electric Power Research Institute, Inc. All rights reserved. 45

Full Load Trip

Temperature Delta: ~241oF (134oC)