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Documente Profesional
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GT2012
June 11-15, 2012, Copenhagen, Denmark
GT2012-69103
John R. Scheibel
Electric Power Research Institute
Palo Alto, California, USA
Within the same wheel/disc, the damage mechanisms differ In the case of turbine discs, the failure mechanisms may be
depending on the location. For example in a compressor crack initiation and growth from the bore area due to thermal
wheel, the near bore area is subject to high tangential and CF fatigue stresses, creep crack initiation and growth from the rim,
stresses. Even a relatively small flaw located in the near bore neck and dovetail locations (Figure 1). Thus a condition and
region could become a critical crack size leading to sudden remaining life assessment study of a gas turbine rotor should
failure most likely during a cold start condition. At the take into account these numerous failure mechanisms. NDE
periphery blade attachment locations the damage mechanisms inspection methods, in-situ condition assessment steps, material
could be high-cycle fatigue crack initiation and propagation, sampling and properties determination, structural analysis and
corrosion pitting, crevice corrosion and stress corrosion the selection of appropriate life assessment models, require
cracking. Examples of corrosion pitting on a compressor disc careful consideration of the various damage mechanisms for
and dovetail cracking is shown in Figure 3 [1]. the integrity and remaining life assessment. Of course, the past
operational history and future duty cycles of the turbine are
required in this integrated life assessment procedure.
6
5
4
1
2
. 3
Results of the Charpy impact tests reveal that the disc material
Figure 8. Miniature surface scoop sampling from MS5001 is embrittled significantly in service with a fracture appearance
turbine discs for material condition and property transition temperature (FATT) above 400F (204C) at the bore
assessment. region. The estimated FATT increase (ΔFATT) from the initial
material condition is 225F (107C). Such material
In the absence of such data, one must assume conservative embrittlement reduces the safety margin due to reduced fracture
properties which could lead to overly conservative toughness, decreased damage tolerance and increased risk of
recommendations. Many of these properties are a strong brittle failure in the presence of a crack or defect [3,5].
function of temperature. Small specimen versus large specimen
property correlations are being established to facilitate the Extensive metallurgical evaluation of the first and second stage
extraction and use of miniature specimen to obtain the disc blade attachment serrations was conducted on
necessary material properties from the actual rotor being metallurgical samples as shown in Figure 10. Sections were
evaluated. cut from the inlet, mid span and exit faces of the blade
attachment serrations, mounted and polished for examinations
Under the current rotor life prediction technology development via optical and SEM microscopes. Sporadic MnS inclusions,
projects, EPRI has acquired retired rotor discs after long term typical for this vintage steel were observed. No evidence of
service from various turbine models. Destructive sectioning of creep damage was found on both the Stage 1 and Stage 2 disc
these discs and mechanical testing to obtain the various serrations (dovetail posts).
Figure 12. A logic flow chart for the remaining life analysis
of GT rotors and discs.
Dimensional Characterization
The dimensional characterization is an important part of the life
assessment process. This step provides the geometric
definition for the analysis, as well as describing abnormal wear,
corrosion or other dimensional defects of the rotor components.
Dimensional characterization was performed using laser
scanning coordinate measurement machines (CMM) and other
techniques. These results are used to produce a detailed 3-D
CAD model of the turbine as shown in Figure 15. External as
Figure 13. Disassembly of a MS 5001 rotor using differential
heating and cooling method well as internal bore dimensions were measured very
Structural Analysis
A finite element analysis is performed to assess the structural
capability of the turbine rotor. The analysis identifies the
critical regions for inspection and is the basis for the life
assessment and reinspection interval definition. An ANSYS
analysis was performed by AccTTech of the Frame 5001
turbine rotor as shown in Figure 17. A 2-D axisymmetric
analysis is used to assess homogeneous sections of the rotor
such as the bore and neck regions. The more complex regions
such as the bolt holes and rim dovetail posts require advanced
analysis treatments such as cyclic symmetry methods. Modern Frame 18. Example of transient stress versus time in a turbine
ANSYS analyses include the capability to model contact disc during a cold start at a various distances from the bore
regions such as blade and disc attachment, friction, rabbet surface.
interference fit and other important local loading conditions.
ACKNOWLEDGEMENT
The authors acknowledge the sponsorship of EPRI
Combustion Turbine O&M Program (P79) – a collaboration of
operators/owners of power generation turbines and combined
cycle plants.
REFERENCES