Adj3 Calculation of Main Shaft (A7)

Ecuador Coca Codo Sinclair (CCS)

Hydropower Project
FATIGUE AND STRESS CALCULATION OF TURBINE
MAIN SHAFT TRADUCIDO

(A7)
Marzo 2013
Beijing, China

SLJ-EGDECA-005
Fatigue and stress calculation of main shaft
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Fatigue and Stress Calculation of Turbine Main Shaft

1 Purpose
This note calculated the stresses and the fatigue of the main shaft. The purpose of this note is
to check if the main shaft could meet the requirements. In this report there are three cases
considered, maximum output case (192.85MW), runaway case and maximum output (transient)
case (209.2MW).
2 General data
Maximum output (transient) 209.2MW
Maximum output 192.85MW
Rated output 188.266MW
Rated speed n 300r/min
Runner weight M 25.14T
Outside diameter of main shaft D 1000mm
Internal diameter of main shaft d 500mm
Radius of flange root R 80mm
Distance between runner center and flange L1 455mm
Distance between flange and section (B-B) L2 345mm
Distance between flange and section (C-C) L3 2050mm
Maximum flow Qmax 35.4 m 3 / s
Number of jets Z0 6
Maximal head Hmax 616.74m
Runner diameter D1 3349mm
Balance precision class of runner G G6.3
Speed of water leaving the injector C1 107.7m/s
Speed of runner at diameter (D1) U1 52.6m/s
This document contains proprietary information of Harbin Electric Machinery Co., Ltd.（HEC）and it can not be used in any way or
disclosed to others without the written permission of HEC.
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Unbalanced force because of runner mass imbalance:

G  9.55  M 2
Fu1=  =4971N
n  1000
Force of one jet of water:
F= 2    Qmax  C1  U 1  / Z 0 =650.66kN
When the output is 209.2MW or 192.85MW, all the six jets must be open. When six jets are
open, the theory hydraulic imbalance force is zero, but in fact it is a small value. In this report, we
choose the hydraulic imbalance force Fu2=F/2=325.33kN.
Then the total unbalanced force Fu= Fu1+ Fu2=330.3kN
Material and allowable stress of main shaft are shown in Table 1.
Table 1 Material and allowable stress of main shaft
Material property Allowable stress (MPa)
Material
UTS(MPa) YS(MPa) Tensile stress(YS/3) Shearing stress(YS/6)
20SiMn 470 255 85 42.5
In maximum output case (192.85MW), the allowable combination stress is 63.75MPa (YS/4);
in runaway case, the allowable combination stress is 170MPa (2YS/3); In maximum output
(transient) case (209.2MW), the allowable combination stress is 63.75MPa (YS/4). The maximum
output case (209.2MW) is short-term overload case, when the generator power factor is 1.
Main shaft is designed according to infinite life, and fatigue safety factor should be greater
than 1.5, according to experience of HEC.
3 Load calculation of main shaft in maximum output case (192.85MW)
When calculated the main shaft, the torque due to output power, the axial pull due to runner
gravity and bending of moment due to hydraulic imbalance force are considered. Three dangerous
section is calculated: the root of flange(A-A), supporting position of water guide bearing(C-C)and
the boss between flange and water guide bearing(B-B), the position of the three section is shown
in Fig.1.
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1）the torque due to output power:

p 2n
M  
 60
M  6.14  10 6 Nm
2）the axial pull due to runner gravity:

F=246372N
4 Calculation at section (A-A) in maximum output case (192.85MW)
4.1 Calculation of stress (A-A)
F 
1）Tensile stress  max 1 ：  max 1  , A  ( D 2  d 2 )  0.589m 2
A 4
 max 1  0.418MPa
M
2）Shearing stress  max 1 ：  max 1 
Wt1
D 3 d
Wt1  (1   4 ) =0.184 m 3 ， 
16 D
 max 1 =33.4MPa<42.5MPa
M W1
3）Bending stress  w1 ：  w1  , M W 1  Fu  L1
W1
D 3
W1  (1   4 )
32
 w1 =1.63MPa
4）Combined stress  1 ：
 1  ( max 1   w1 ) 2  3 2 max 1 =57.84MPa<63.75MPa
4.2 Calculation of fatigue safety factor

According to fatigue limit calculation formula of structural steel in alternating load
 1  0.27( s   b ) ，get the fatigue limit of main shaft  1  196MPa
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Theory bending stress concentration factor： K w  1.85
Effective bending stress concentration factor： K ' w = 1  q( K w  1)  1.595
Influence coefficient of material to stress concentration：q=0.7

Average stress：  max 1  0.418MPa ；alternating stress：  w1  1.63MPa
 1
n1  =37.3>1.5
K w w1
'
  max 1

Size coefficient：   0.57
Surface processing coefficient：   0.9
Average stress influence coefficient：  0.4
5 Calculation at section (B-B) in maximum output case (192.85MW)

5.1 Calculation of stress (B-B)
F 
A 4
 max 2  0.418MPa
M
2）Shearing stress  max 2 ：  max 2 
Wt 2
D 3 d
Wt 2  (1   4 ) =0.184 m 3 ， 
16 D
 max 2 =33.4MPa<42.5MPa
3）Bending stress  w 2 ：
MW 2
 w2  , M W 2  Fu  ( L1  L 2)
W2
D 3
W2  (1   4 )
32
 w 2 =2.87MPa
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4）Combined stress  2 ：
 2  ( max 2   w 2 ) 2  3 2 max 2 =57.89MPa<63.75MPa

Theory bending stress concentration factor： K w  2.02(r=50)
Effective bending stress concentration factor： K ' w = 1  q ( K w  1)  1.71

Average stress  max 2  0.409MPa；alternating stress  w 2  2.87MPa
 1
n1  =20>1.5
K w w 2
'
  max 2

Size coefficient   0.57
Surface processing coefficient   0.9
Average stress influence coefficient   0.4
6 Calculation at section (C-C) in maximum output case (192.85MW)

6.1 Calculation of stress (C-C)
F 
A 4
 max 3  0.418MPa
M D 3 d
2）Shearing stress  max 3 ：  max 3  , Wt1  (1   4 ) =0.184 m 3 ，  
Wt1 16 D
 max 3 =33.4MPa<42.5MPa
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MW3
3）Bending stress  w3 ：  w3  , M W 1  Fu  ( L1  l3 )
W3
D 3
W3  (1   4 )
32
 w3 =9MPa
4）Combined stress：
 3  ( max 3   w3 ) 2  3 2 max 3 =58.56MPa<63.75MPa

Theory bending stress concentration factor： K w  2.1(r=30)
Effective bending stress concentration factor： K ' w = 1  q ( K w  1)  1.77

Average stress  max 3  0.418MPa ；alternating stress  w3  9MPa
 1
n1  =6.3>1.5
K w w3
'
  max 3

Size coefficient   0.57
Surface processing coefficient   0.9
Average stress influence coefficient   0.4
7 Stress calculation in runaway case and maximum output (transient) case

In runaway case the forces on main shaft are hydraulic imbalance force Fu and runner weight.
In maximum output (transient) case the forces on main shaft are hydraulic imbalance force Fu,
runner weight and the torque due to output power (209.2MW).
The stress of main shaft in the two cases is shown in Table 2.
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Table 2 Stress in runaway case and maximum output (transient) case

Stress Runaway case (MPa) Maximum output (transient) case (MPa)
Tensile Shearing Bending Combined Tensile Shearing Bending Combined

Position
A-A 0.418 0 1.63 1.85 0.418 36.2 1.63 62.8
B-B 0.418 0 2.87 3.29 0.418 36.2 2.87 62.8
C-C 0.418 0 9 9.41 0.418 36.2 9 63.4
8 Conclusion
1) The fatigue safety factor at the root of flange (A-A) is 37.3. The fatigue safety factor at
boss (B-B) is 20. The fatigue safety factor at supporting position of water guide bearing
(C-C) is 6.3. Since all the safety factors above are greater than 1.5, fatigue strength has
enough safety margin.
2) The stress of main shaft is lower than allowable stress, which can meet the requirement.
9 Explanation
In HEC’s experience it is chosen 1.5 as the safety factor. In the power stations we have
applied 1.5 as the safety factor standard are Three Gorges Project(in China), Murum Hydraulic
Power station(in Malaysia), Daryan Dam and H.P.P Project(in Iran) and Pushihe pumped storage
power station(in China).
In the report, the least safety factor is 6.3, which is larger than 1.5.
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Fig.1 Geometry of main shaft and position of three dangerous section

Adj3 Calculation of Main Shaft (A7)

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Ecuador Coca Codo Sinclair (CCS)

Fatigue and Stress Calculation of Turbine Main Shaft

Maximum flow Qmax 35.4 m 3 / s

Unbalanced force because of runner mass imbalance:

F= 2    Qmax  C1  U 1  / Z 0 =650.66kN

20SiMn 470 255 85 42.5

1）the torque due to output power:

2）the axial pull due to runner gravity:

 1  ( max 1   w1 ) 2  3 2 max 1 =57.84MPa<63.75MPa

4.2 Calculation of fatigue safety factor

Theory bending stress concentration factor： K w  1.85

Effective bending stress concentration factor： K ' w = 1  q( K w  1)  1.595

Influence coefficient of material to stress concentration：q=0.7

Average stress influence coefficient：  0.4

5 Calculation at section (B-B) in maximum output case (192.85MW)

 2  ( max 2   w 2 ) 2  3 2 max 2 =57.89MPa<63.75MPa

5.2 Calculation of fatigue safety factor

Theory bending stress concentration factor： K w  2.02(r=50)

Effective bending stress concentration factor： K ' w = 1  q ( K w  1)  1.71

Influence coefficient of material to stress concentration：q=0.7

Size coefficient   0.57

Surface processing coefficient   0.9

Average stress influence coefficient   0.4

6 Calculation at section (C-C) in maximum output case (192.85MW)

6.2 Calculation of fatigue safety factor

Theory bending stress concentration factor： K w  2.1(r=30)

Effective bending stress concentration factor： K ' w = 1  q ( K w  1)  1.77

Influence coefficient of material to stress concentration：q=0.7

Average stress influence coefficient   0.4

7 Stress calculation in runaway case and maximum output (transient) case

Table 2 Stress in runaway case and maximum output (transient) case

Tensile Shearing Bending Combined Tensile Shearing Bending Combined

Fig.1 Geometry of main shaft and position of three dangerous section

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