International Journal of Research and Innovation (IJRI)

International Journal of Research and Innovation (IJRI)

1401-1402

DESIGN AND ANALYSIS OF MULTI- STAGE STEAM

TURBINE BLADE AND SHAFT ASSEMBLY

K.Khishor Kumar 1, D.Gopichand2,

1 Research Scholar, Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India
2 Assistant professor , Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India

Abstract
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary
motion. A system of angled and shaped blades arranged on a rotor through which steam is passed to generate rotational
energy.
The blades are designed in such a way as to produce maximum rotational energy by directing the flow of the steam along
its surface. The blades are made at specific angles in order to incorporate the net flow of steam over it in its favor. The
blades may be of stationary or fixed and rotary or moving or types, and Shaft designed to work in extreme conditions,
hear it has to bear the temperature which is coming from the steam and loads(weight and centrifugal force) of the blades
assembly and other assembly parts.
The aim of the project is to reduce maintenance, product cost and improving quality / life.
Initially literature survey will be done to understand rectification methodology and approach.
3D models of blades sets shaft will be prepared according to C.M.M data.
Assembly of shaft and blades will be prepared and exported into IGES (inertial graphical exchanging specifications) format to conduct further work in ANSYS.
Structural analysis will be carried out on assembly to evaluate structural characteristics.
Model analysis will be carried out on same to find natural frequencys (for comparison with other results)
Thermal analysis will be carried out on to find thermal characteristic.
Various materials and ceramic coating will be implemented on ANSYS for evaluation.
Comparison tables will be prepared according to the obtained results from Ansys; Conclusion will be made according
to the above.
Key words: Multi Stage, Ceramic Coatings, Thermal
*Corresponding Author:
K.Khishor Kumar,
Research Scholar, Department Of Mechanical Engineering,
Mother Theresa Institute of Technology(mist) Khammam,India
Published: Sep 22, 2014
Review Type: peer reviewed
Volume: I, Issue : III

Citation: K.Khishor Kumar, Research Scholar (2014)

DESIGN AND ANALYSIS OF MULTI- STAGE

STEAM TURBINE BLADE AND SHAFT ASSEMBLY
Problem Description

Steam turbines are generally used for power generation by using thermal energy (steam pressure)
to produce rotary motion which in turn converted
to electric power. In this process a set of turbine
blades and shaft are used to convert steam pressure
in to mechanical energy.
Generally in turbine the blades and shafts are subjected to high amount of pressurized steam with

high temperature. This causes thermal and static

stresses which leads to effect daily maintenance
and replacement of blades rapidly.
The rapid replacement of blades causes less power
generation and expensive.
Solution Methodology
As per the directions and requirements of R&D department, analysis has to be done on entire assembly of shaft and group of blades with variant materials to suggest the best material and coatings which
can withstand the thermal and static loads.
Regular material EN24 stainless steel material and
new materials such as zinc aluminum alloy (zamak)
and cast iron C70 along with partially stabilized zirconium coating for surface protection for the materials are used.
Static, modal and thermal analysis is to be done
on above three materials to analyze the structural,
vibrational and thermal characteristics.

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International Journal of Research and Innovation (IJRI)

Steam Turbine
Introduction
A turbine is a rotary mechanical device that extracts
energy from a fluid flow and converts it into useful work. A turbine is a turbomachine with at least
one moving part called a rotor assembly, which is
a shaft or drum with blades attached. Moving fluid
acts on the blades so that they move and impart rotational energy to the rotor. Early turbine examples
are windmills and waterwheels.
The word "turbine" was coined in 1822 by the
French mining engineer Claude Burdin from the
Latin turbo.Gas, steam, and water turbines usually
have a casing around the blades that contains and
controls the working fluid. Credit for invention of
the steam turbine is given both to the British engineer Sir Charles Parsons (18541931), for invention of the reaction turbine and to Swedish engineer
Gustaf de Laval (18451913), for invention of the
impulse turbine. Modern steam turbines frequently
employ both reaction and impulse in the same unit,
typically varying the degree of reaction and impulse
from the blade root to its periphery.

Steam turbine showing blade and shaft assembly

Experimental Procedure
Generation of Pressure Distribution Data on the
Blade
Surface:
Last stage blade of steam turbine, which is
being analyzed, for stress and vibration is a highly twisted blade due to the variation if the blade
speeds across the height of the blade. The deflection
in the blade passage also reduces from hub to tip
to vary the loading on each section. Thus the pressure distribution on the suction & pressure surface
of the blade changes considerably from hub to tip
to match the loading at that suction .It is known
fact that the area of pressure distribution curve representing the blade loading. Hence it has been decided to generate the pressure distribution at all the
17 blade sections.
The following procedure is allows to get the blade
surface pressure distribution with the help of Blade
Gen&Blade Gen plus package.
From the blade coordinate input data file for suction/pressure surface x, y, z, coordinate of surface
was generated as a loop with the following notations.
X-along the height of the blade.
Y- Meridional direction.
Z-along blade to blade
2. Profile curve is generated with above coordinates of all sections placed one below the other is
sequence from section (1) to section (5 along the
height of the blade. The coordinates between two
section separated by #.
3. Hub & Shroud boundary is generated at the appropriate heights with Y negative Meridional axis
corresponded from LE (Leading edge). And positive
distance from Meridional distance from TE (Tailing
Edge).
4. Hub. Curve file is generated as follows
X, Y, Z
283.450000
0.000000000
-100.000000
283.450000 0.000000000
0.000000000
283.450000
0.000000000
100.000000

In between the values Comma is compulsory. (X, Y,
Z)

working of impulse and reaction turbine

A profile contains total 60 points for all 5 sections.

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International Journal of Research and Innovation (IJRI)

5. Profile. Curve file is generated as follows

X, Y, Z
#
283.45,-5.74,-22.92
283.45,-5.23,-23.25
283.45,-4.46,-23.36
283.45,-3.43,-23.22
283.45,-2.15,-22.82
283.45,-0.66,-22.12
283.45, 1.03,-21.11
283.45, 2.85,-19.72
283.45, 4.74,-17.91
283.45, 6.61,-15.62
283.45, 8.32,-12.78
283.45, 9.66,-9.39
283.45, 10.4,-5.53
283.45, 10.35,-1.43
#442.65, 15.21,-15.51
442.65, 15.64,-15.21
442.65, 15.81,-14.69
442.65, 15.74,-13.95
442.65, 15.44,-12.99
442.65, 14.91,-11.83
442.65, 14.19,-10.49
442.65, 13.26,-8.99
442.65, 12.14,-7.36
442.65, 10.79,-5.66
442.65, 9.23,-3.95

The above image shows blades pattern model

The above image shows final shaft

Introduction To Cad
Computer-aided design (CAD), also known as computer-aided design and drafting (CADD), is the use
of computer technology for the process of design
and design-documentation. Computer Aided Drafting describes the process of drafting with a computer. CADD software, or environments, provide the
user with input-tools for the purpose of streamlining design processes; drafting, documentation, and
manufacturing processes. CADD output is often in
the form of electronic files for print or machining operations. The development of CADD-based software
is in direct correlation with the processes it seeks to
economize; industry-based software (construction,
manufacturing, etc.) typically uses vector-based
(linear) environments whereas graphic-based software utilizes raster-based (pixelated) environments.
Modeling of Turbine Blade and Shaft

The above image shows blade profile

The above image shows assembly of blades and shaft

pressure
Specified Initial Steam Pressure (s)

36

ata

Permissible deviation without Limitation

(1)

39

ata

Permissible deviation (2)

39

ata

Permissible deviation Instantaneously

For A Total Duration Of 12 Hours Per
Annam(2)

46.8

ata

Specified initial Steam Temperature (%)

360

Permissible Deviation without

Limitation (1)

380

Permissible Deviation for

Longer Periods (2)

388

Permissible Deviation for 400

hours per annum (2)

394

Permissible Deviation for 80

hours per annum (2)

408

Maximum Output

3769

KW

Design Rating (Economical

Rating)

3426

KW

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International Journal of Research and Innovation (IJRI)

The above image shows meshed model

Results :

Von Misses Stress

The thermal readings are taken from the thermal images
taken for the turbine
Introduction to Fea
Finite Element Analysis (FEA) was first developed in
1943 by R. Courant, who utilized the Ritz method of numerical analysis and minimization of variational calculus
to obtain approximate solutions to vibration systems.
Shortly thereafter, a paper published in 1956 by M. J.
Turner, R. W. Clough, H. C. Martin, and L. J. Topp established a broader definition of numerical analysis. The
paper centered on the "stiffness and deflection of complex structures".
Displacement

Structural Analysis Steam Turbine

The above image shows imported Model from creo2.0

(Pro/Engineer)

Frequency Analysis on Steam Turbine

Displacement

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International Journal of Research and Innovation (IJRI)

Thermal Analysis on Steam Turbine

Nodal temperature

Conclusion

Thermal gradient

A PT2001 turbo dine steam turbine is optimized for

to reduce maintenance. Initially static and thermal
conditions are evaluated using Infra-red thermometer and digital vibrometer. Those readings are taken
for simulation inputs from ATICS
A FEA model is developed according to given drawing.
Static analysis is carried out on FE model using
AISI steel (present material), cast-iron C70 with
zirconia coating and zinc aluminum alloy (Zamak)
with zirconia coating.

Thermal flux

Result Tables And Graphs

s.no

Material

Stress

Strain

Displacement

Castiron
C70with coating

308.6

0.0023

0.2036

AISI 4130 Steel

301.4

0.00078

0.765

Zamak

192.9

0.0012

0.123

Modal analysis is carried out to determine the vibrations due to geometry and property of material.
Thermal analysis is carried out to determine the
thermal behavior like thermal gradient and heat
flux.
Partially stabilized zirconium is mainly used as a
surface coating to prevent the thermal effect on surface and also it reduces the corrosive effect.
As per the analytical results ZAMAK material along
with partially stabilized zirconia coating will improve reliability of turbine shaft and blades due to
less stress, negligible displacement and strain values, also ZAMAK is having good level of thermal
gradient(heat transfer rate) and sufficient heat flux
rate which in turn improves the power generation
rate by reducing the maintenance.
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International Journal of Research and Innovation (IJRI)

References

Author

1) SPEED CONTROLLER DESIGN FOR STEAM

TURBINE [1], Rekha Rajan, Muhammed Salih. P,
N. Anilkumar, PG Students [I&C], Dept. of EEE,
MES College of Engineering, Kuttippuram, Kerala,
India
2) 3D Finite Element Structural Analysis of Attachments of Steam Turbine Last Stage Blades[2],
Alexey I. Borovkov Alexander V. Gaev Computational Mechanics Laboratory, St.Petersburg State
Polytechnic University, Russia
3) Design of a Constant Stress Steam Turbine Rotor Blade[3], Asst. Prof. Dr. Arkan Kh. Husain AlTai, Mechanical Engineering Department, University of Technology, Baghdad, Iraq
4) Simulation Modeling Practice and Theory[4], Ali
Chaibakhsh, Ali Ghaffari * Department of Mechanical Engineering, K.N. Toosi University of Technology
5) Development of New High Efficiency Steam
Turbine[5], EIICHIRO WATANABE, YOSHINORI
TANAKA
6)Theoretical and Numerical Analysis of the Mechanical Erosion in Steam Turbine Blades[6], Fernando Rueda Martnez, Miguel Toledo Velzquez,
Juan Abugaber Francis,

K.Khishor Kumar,
Research Scholar,
Department Of Mechanical Engineering,
Mother Theresa Institute of Technology(mist)
Khammam,India

D.Gopichand,
Assistant professor,
Department Of Mechanical Engineering ,
Mother Theresa Institute Of Technology(Mist)
Khammam,India

7)DESIGN OPTIMIZATION AND STATIC & THERMAL ANALYSIS OF GAS TURBINE BLADE[7],
Ganta Nagaraju , Venkata Ramesh Mamilla,
M.V.Mallikarjun
8)ANALYSIS OF LIQUID DROPLET EROSIONFOR STEAM TURBINE BLADES OF COMPOSITE MATERIAL[8], Sandeep Soni

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