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Conference Session B6 2214

Steam Turbine Blade Design


Zachary Stuck (zas31@pitt.edu), Stanley Schurdak (sas312@pitt.edu)
Abstract- This paper addresses the issue of steam turbine energy being produced by steam turbine generators, it is in
efficiency by discussing the overall design of steam turbine the best interest of society to make these generators as
blades with a specific focus on blade aerodynamics, efficient and as sustainable as possible. One of the key
materials used in the production of steam turbine blades, factors influencing the efficiency of these turbines is the
and the factors that cause turbine blade failure and design of the turbine blades. It was through a century of
therefore the failure of the turbine itself. This paper development and advancement in steam turbine blade design
enumerates and describes the currently available that steam turbine efficiency rose from a mere 60% to 90%
technologies that enhance the overall efficiency of the or better [2]. Thus, the better the design of the blade, the
generator and prevent turbine failure due to blade erosion more efficient the turbine will be; and the more efficient the
and blade cracking. In particular, this paper evaluates the turbine is, the more efficient the generator is and the better
effectiveness of certain titanium alloys and steels in resisting off society is. Therefore, it is beneficial to society to
creep and fracture in turbine blades. The effectiveness of implement advanced blade technology that enhances turbine
chemical and thermal coatings in protecting the blade efficiency.
substrate from corrosion when exposed to wet steam will
also be addressed. The stresses developed in the blade as a BLADE MATERIALS
result of steam pressure, steam temperature, and the
centrifugal forces due to rotational movement are The type of material used for turbine blades is based on the
delineated; current designs calculated to counter the fatigue stage of the turbine in which the blades will operate. There
caused by these stresses are presented. The aerodynamic are three such stages: high-pressure (HP), intermediate-
designs of both impulse and reaction turbine blades are pressure (IP), and low-pressure (LP), which are named
compared and contrasted, and the effect that these designs according to the relative pressure of the steam in the stage.
have on turbine efficiency are discussed. The pressures and temperatures of each stage limit the kinds
Based on the research presented herein, this paper of materials that may be used in them. For instance, HP and
presents a detailed summary of what modifications to IP stage blades are generally made from 12Cr martesitic
existing steam turbine generator blades can be made to stainless steels [3]. However, blades used in high-
increase turbine efficiency. Finally, the overall sustainability temperature (> 450 C) HP or IP applications may be made of
of steam turbine generators is discussed and the impact that austenitic stainless steels because they have better
the design of the blades has on the sustainability of these mechanical properties at high temperatures [3]. For example,
generators is presented. stainless steel type AISI 422 (a martensitic stainless steel) is
commonly used for HP and IP turbine sections, while AISI
Key words- Blade, efficiency, corrosion, design, failure, series 300 steels (austenitic) are used for high-temperature
steam turbine, stress applications [3]. LP blades are often, but not exclusively,
made from 12Cr stainless steels also. Common types of
INTRODUCTION stainless steel used in LP sections include AISI types 403,
410, 410-Cb, and 630; the exact type of steel chosen for a
Electrical power has become an essential facet of life in all particular LP application depends on the strength and
spheres of modern society. In the home, electricity is used to corrosion resistance required. Since the 1960s, titanium
power water pumps that provide running water, and heating alloys, especially Ti-6Al-4V, have also been used for LP
and air conditioning systems that provide a comfortable turbine stages [3]. These alloys are particularly suited to LP
atmosphere; electricity is used to power the network of stages for a number of reasons. First, the densities of
computer systems used extensively in commercial inventory titanium alloys are generally less than the density of steels;
organization, and in the computerized mechanisms that for example, Ti-6Al-4V has a density of only 4.43 g/cc
govern manufacturing processes in the manufacturing while stainless steel type AISI 410S has a density of 7.8 g/cc
industry. These are just a few examples that indicate how [4, 5]. This lower density makes it possible to lengthen the
much modern society relies on electrical power and how LP blades and thereby increase turbine efficiency without
important it is to society that a reliable source of electricity increasing stresses in the blades due to centrifugal forces.
be established. Second, titanium alloys have greater corrosion resistance
Currently, nearly 90% of the electricity produced in the than steels; this makes titanium alloys ideal for use in LP
United States is generated using steam turbines, while about stages where there are greater levels of moisture. Finally,
80% of that produced worldwide comes from steam titanium alloys are resistant enough to water droplet erosion
generators [1]. With such a substantial amount of electrical

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that they can be used without erosion protection in certain of rotation in the direction away from the center of rotation
applications. of the mass m. The multiplication of m with the second cross
Overall, it is the material properties that make a blade product returns a vector whose magnitude is equal to the
reliable or doomed to failure. The yield strength, tensile second cross product multiplied by the scalar m and whose
strength, corrosion resistance, and modulus of elasticity all direction is the same as that of the second cross product.
play a role in determining whether or not a blade will fail This product is equal to the force vector F. This indicates
under operating loads. that the centrifugal force F acts on the point mass m in a
direction radially outward from the center of rotation.
BLADE LOADING Although this equation is reliable only for point masses, it
helps to illustrate the fact that centrifugal forces tend to
Steam turbines operate at similar speeds, usually in the range pull the objects out of their path of rotation. Figure 1
of 3000-3600 rpm for fossil-fired plants and 1500-1800 rpm illustrates this point. If a turbine blade is thought of as a
for nuclear-powered plants [3]. Because the speeds are finite collection of point masses, then the previous equation
similar, the stresses in the turbine blades, which arise may be applied to each point mass to find the resultant
because of their movement, are also similar. There are two centrifugal force acting on the blade. Thus, the centrifugal
main categories of stress that the blades experience: static force creates an overall tensile stress in the blade by
stresses, consisting of centrifugal tensile stresses, centrifugal pulling on the blade as it rotates [3].
bending stresses, and steam bending loads, and dynamic
stresses, arising from non-uniform steam flows and
synchronous resonance of the blade with the operating speed
of the turbine. However, the majority of blade stresses are
due to centrifugal forces [3].

Centrifugal Tensile Stress

Centrifugal tensile stress is the tensile stress induced in the


blade as a result of its rotational movement. According to
McCloskey [3], the magnitudes of these stresses are
proportional to the square of the speed:

!ct = ("op/"100)2 !100ct

where !ct is the centrifugal tensile load, "op is the rotational


speed of the blade, "100 is the design rotational speed, and
!100ct is the centrifugal tensile stress in the blade at the
design rotational speed. However, blades in the HP and IP
stages are shorter than blades in the LP stage; therefore, the Fig. 1 Centrifugal Force Illustration
centrifugal stresses in the HP and IP stages are relatively
small. Centrifugal forces have a greater effect on the LP !
stage blades due to the longer blade length. According to Centrifugal Bending Stresses
McCloskey, the steady-stresses in the last-row LP blades are
typically 0.5!y for about 50% of the blade length, and Centrifugal bending stresses arise if the centers of gravity
greater than or equal to 0.25!y for 80% of that length, where (centroids) of the blade cross-sectional areas at different
!y is the yield stress of the material [3]. heights do not lie in a straight line with the blade roots
To clarify the action of centrifugal forces, consider the center of gravity. Because the centrifugal force acts on the
simple equation for the centrifugal force, F, acting on a point centroid of the area and in a direction radially outward,
mass m that is rotating with an angular velocity " in a bending moments are produced where the centroids do not
circular path described by the vector r, whose magnitude r lie on the blades center of gravity line. This causes tensile
equals the radius of the path around a certain fixed point: stresses on one side of the blades center of gravity line and
compressive stresses on the other. However, blade designers
F = m"!("!r) [6] have exploited the effects of centrifugal bending to counter
the effect of steam bending. For example, if a steam-bending
The result of the first cross product, ("!r), is a vector in the load tends to bend the blade axially in the direction of steam
direction perpendicular to the plane of rotation. The result of flow, a blade designer can intentionally offset the centroids
of the blade areas that lie towards the tip of the blade in the
the second cross product, "!("!r), is a vector in the plane
direction of the steam load. The centrifugal force acting on

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the centroids would then create a bending moment that tends small, and the stress does not exceed the yield stress of the
to bend the blade in the direction opposite that of the steam- material at a given amplitude, the blades experience high-
bending load [3]. Fig. 2 helps to illustrate this point [3]. cycle fatigue causing them to fail suddenly after a large
number of cycles. Larger amplitudes of stress fluctuations
will result in greater stresses in the blades and cause low-
cycle fatigue with blade failure occurring only after a
relatively small number of cycles. Blade vibrations are most
dangerous when the frequency of vibrations coincides with
the natural frequency of the blades [3]. When this occurs, the
blades resonate and fail from high-cycle fatigue in a short
period of time.

Creep

Turbine blades are constantly subject to high temperatures,


predominantly in the HP and IP stages, which tend to soften
the blade material. This, in combination with the centrifugal
forces exerted on the blades, serves to deform the blades,
and cause creep (the slow and continuous deformation of a
Fig. 2 Steam-Bending and Centrifugal Bending
material over time) [3, 7]. The rate of material deformation
(rate of creep) is highly dependent on both the temperature
of the material and the applied stress [7]. This is a
Steam Bending Loads particularly dangerous phenomenon because the blades are
manufactured according to stringent specifications based on
the loading and environment that the blades will operate
As the steam flows through the turbine blades, the steam
under. Any change in the geometry of the blade due to creep
pushes on the blades causing them to bend, thus creating
can result in catastrophic failure due to blade degradation or
what is known as steam bending. Like centrifugal bending,
sudden cracking. This is why it is imperative that the
steam bending causes the blades to be bent lengthwise,
materials chosen for the HP and IP blades retain high yield
creating regions of tensile and compressive stress in the
strengths at elevated temperatures.
blade. Although the movement of the steam does induce
The above information applies mostly to reaction turbine
blade bending, the effect of steam bending in moving blades
blading. Impulse turbines differ from reaction turbines in the
is not as pronounced as the effects of centrifugal forces. In
way that the blades are moved, which results in different
fact, steam-bending stresses are typically only about 10% of
the centrifugal stresses [3]. The stationary blades of a stresses in the different kinds of blades. In a reaction turbine,
the steam flows through fixed blades with no pressure drop
reaction turbine are more affected by the moving steam
and then flows through the moving blades that are shaped so
because the force of the steam on the stationary blades tends
as to form nozzles that serve to increase the velocity of the
to move the blades in the direction of the force. Because the
steam as it passes through the rotor and in doing so cause the
blades cannot be displaced by the applied force of the steam,
rotor to turn. In an impulse turbine, the steam is directed
they instead bend in reaction. Steam bending occurs in HP,
onto the rotor blades from fixed nozzles. The steam hits the
IP, and LP stages, but it is most pronounced in the HP stage
blade creating an impulse and causing the rotor to turn [8].
where the pressure difference across the blades is greatest.
However, it must be noted that in practice, there are no pure
However, steam bending is also significant in LP stage
impulse turbines, but only some considered low-reaction
blades because the LP blades are much longer than HP or IP
turbines [9]. Hence, with the possible exception of steam
blades [3].
bending stresses, the stresses found in impulse turbine blades
Dynamic Stresses may be assumed to be similar to stresses in reaction turbine
blades.
All of the stresses listed above will propagate cracks in
Dynamic stresses are induced in turbine blades when there is
the material, if there are any to begin with, or they will tend
some exciting force that causes the blades to vibrate.
to form cracks from dislocations in the material if there are
Exciting forces can arise from sources of non-uniform flows
no cracks initially present. This is dangerous not only
such as nozzle-wake interactions and structural features that
because it damages the structural integrity of the blade, but
interfere with the steam flow, as well as turbine operating
also because cracks serve as repositories for condensed
speeds [3]. Blade vibrations lead to fluctuations of stress in
steam, which can then react with the blade materials and
the blades, sometimes exceeding the yield strength of the
cause corrosion of the blade [10].
blade material. If the amplitude of the stress fluctuations is

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BLADE CORROSION formed surface crack provides an area for condensed steam
to accumulate and a place for impurities carried by the steam
Blade fractures and surface roughness, even on a to concentrate. The concentration of impurities, if high
microscopic scale, provide areas where deposits of highly enough, will corrode the material, thereby lessening the
concentrated aggressive solutions of admixtures [11] can be contiguous area of the blade. This will not only weaken the
formed. The subsequent reaction of blade materials with overall strength of the blade, but it will also increase the
these admixtures is extremely detrimental to the blade local stresses at the edge of the crack, thus propagating the
structure. These reactions propagate cracks by corroding the crack even further and presenting new areas for corrosion.
material around existing cracks and in doing so weaken the Eventually, if the crack grows to a critical size, the blade
blade. In essence, corrosion only occurs because of the will split at the crack location and fail. This example
presence of blade surface cracks. Furthermore, corrosion is illustrates the interconnectedness of stress, corrosion, and
accelerated by impurities in the steam. According to fatigue, and indicates that the effects of crack and defect
Ryuichiro Ebara, in his paper Corrosion Crack Initiation in accumulation are not insignificant.
12% Chromium Stainless Steel, over eighty different
compounds including oxide, silicate, and sulfide have been ACCUMULATION FAILURES
found in deposits on turbine blades [12]. These impurities,
depending on their nature and concentration, can lead to a Over the course of a turbines active lifetime, the cyclic
drastic decrease in blade fatigue strength. Ebara has shown loading experienced by its components will build up areas of
that NaCl and NaOH are very corrosive compounds and defects that can severely affect the integrity of the
therefore very effective in reducing blade fatigue strength. components. Such accumulations of defects increase the
For example, Ebara showed in his study, that even in small possibility of component failure and, if accumulation of
(3%-3x10-2%) concentrations of NaCl solutions the fatigue defects occurs rapidly, the operating lifetime of the turbine
strength of steel is greatly (~75%) reduced. will be significantly shortened. A peer-reviewed case study
Corrosion is of major concern mostly in the LP stage of describes the failure of an 8.25-MW capacity steam turbine
the turbine because of the lower temperatures, but it is an [14]. Although the turbine was designed to operate for years,
issue in any area where there is a phase transition it failed within three months of operation. A thorough
(condensation) of the steam. This is especially harmful examination of the turbine components revealed the
during turbine downtime when high-temperature stages of presence of macropores and extended cavities having
the turbine begin to cool, providing favorable conditions for branched cracks at their ends [14], as well as a build up of
condensation. When the steam condenses on the blade salt deposits in these cavities. From this investigation, the
surface, corrosion pits and dimples are formed. These are cause of failure was surmised to be a combination of
particularly harmful to the blade because they serve as stress corrosion, from the concentration of salt in the macropores,
concentrators. In the presence of normal loading and stress and stress corrosion cracking due to the concentration of
conditions, these concentrators often increase the local stress in the blade defects. In order to increase the reliability
stresses to many times the overall stress of the blade [13]. of turbine components, this study recommended that the
These localized increases in stress provide a means by which steam be regulated to ensure a minimum level of impurities,
dislocations in the materials crystal structure can be moved, especially chlorides, and that the manufacturing process be
resulting in blade deformation and crack propagation. improved to reduce macroporosities, segregate
Ultimately, stress, fatigue, and corrosion are inherently microporosities, and increase micro-structure uniformity
related: Stress induces dislocation movement in the blades throughout the material.
crystal structure; fatigue fluctuates the levels of stress in the Such catastrophes as this indicate the necessity of
blade, causing material dislocations to accumulate and form improved component designs to ensure component
cracks, thereby increasing local stress concentrations; reliability and improve turbine efficiency.
corrosion propagates cracks by reacting with blade material
around existing cracks, thus increasing the crack size, BLADE DESIGN
spreading the stress concentrations, and lessening the blades
overall strength [13]. Under constant cyclical loading, these Based on the information provided in the previous sections,
three factors combine to cause blade failure. For example, a an efficient and reliable blade design will satisfy the
blade experiencing cyclic loading and centrifugal force F, following requirements:
will have a stress of !tot, equal to the sum of all the stresses
(centrifugal, centrifugal-bending, steam-bending, and 1. The blade material must have a sufficient yield
dynamic stresses) acting on the blade. The stress !tot will strength to resist plastic deformation, and must be
tend to move dislocations in the material in the same able to retain such yield strength, or at least most of
direction. As the number of cycles increase, more and more it, at elevated temperatures.
dislocations are moved, and eventually a crack forms as the 2. The blade material must be able to be processed
dislocations reach the surface of the blade. This newly and worked with easily (this is one of the

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downsides of Titanium alloys as they are not easily presence or formation of cracks that allow corrosion is
welded and they are expensive to produce). practically inevitable. To this end, studies have been
3. Blade materials must exhibit a moderate elastic conducted to determine whether certain chemical coatings,
modulus so that the blade neither deforms when deposited on turbine blades, are effective in preventing
exceedingly nor breaks suddenly under normal blade corrosion [17]. E. K. Sevidova, et al, determined that
operating stresses. among three coatings (Ti+TiN, Cr+CrN, Cr+(CrTi)N) tested
4. Preferably, blade materials should be low-density in on 20X13 steel, the Cr+CrN coating proved to be most
order to decrease the centrifugal forces, and effective in resisting corrosion when exposed to a 3% NaCl
therefore centrifugal stresses, on the blades. solution [17].
5. The blades must be corrosion-resistant, even in the Water droplet erosion is also an issue in steam turbines.
presence of aggressive ionic solutions formed by Erosion of blade materials will distort the geometry of the
impurities in the steam. blade and cause a decrease in efficiency due to aerodynamic
6. Blades must be manufactured in such a way as to losses. In order to improve erosion resistance, coatings that
minimize initiation of cracks during the harden the surface of the blade have been investigated.
manufacturing process. Shun-sen Wang, et al, tested five different boride coatings,
three ion-plating CrN coatings, and three thermal-spray
Kiyoshi Segawa, et al, have developed a new rotor blade coatings on five different substrate steels [18]. They
for steam turbine plants [15]. The new blade design concluded that the thermal coatings had negligible effects on
optimized blade aerodynamics near the root section of the protecting the blade substrate from erosion when compared
blade, thus decreasing both profile and endwall losses. to the other coatings tested; that the protective coating must
Based on the results of 3-D stage and air turbine tests, the be a at least equal to some minimum critical value in order
new rotor blade was found to increase stage efficiency by to effectively protect the substrate from erosion; that
about 0.3%. In addition, the new blade design was found to improving coating thickness reduces the erosion rate of the
improve internal efficiency and reduce manufacturing costs coating; and that the erosion resistance of the coating is
by reducing the blade number by 15% [15]. strongly dependent on temperature.
Walker and Hesketh have determined that improvements Overall, an improved blade design consisting of strong,
in efficiency can be realized by the optimization of erosion and corrosion-resistant materials with optimized
aerodynamic parameters including stage heat-drop, blade aerodynamic parameters will result in a more efficient
velocity distribution, surface finish, and three-dimensional turbine.
design [9]. However, in order to optimize these parameters
the constraints imposed by manufacturing costs and TURBINE EFFICIENCY
mechanical limitations must be considered. For example,
reduction of blade stress can be realized with the Turbine efficiency is lost through defects accumulating in
implementation of lighter-weight materials, such as turbine components. As the turbine blades significantly
Titanium alloys. However, such alloys are not suitable for impact the overall efficiency of the turbine [2], defects that
use in regions of elevated temperatures and they are neither accumulate in theses components dramatically reduce the
easily nor cheaply manufactured. Thus, in order to improve efficiency of the turbine. At the worst, these defects can
turbine efficiency, a happy medium between cost and cause the failure of the turbine and necessitate the shutdown
performance must be established. of the generator; at best, these defects will increase turbine
A new blade design developed by Hideo Nomoto, et al, maintenance costs. When defects arise, such as blade
allows steam turbine blades to be more resistant to cracking and blade corrosion, the aerodynamic designs of
temperatures up to six hundred and thirty degrees Celsius the blades are severely compromised leading to inefficient
[16]. Thanks to advancements in computer fluid dynamics, interactions between the steam and the blades. This
blade design has allowed for a more efficient steam path. consequently increases the amount of fuel consumed to
The blade is now designed to optimize root and tip area, produce the steam, which increases operating costs, which
which in turn minimizes leakage from the steam path to the ultimately reflects increased the costs to the consumer.
blade. This allows for a more efficient system where steam Hence, to avoid, or at least diminish, elevated energy costs,
is not lost throughout. The introduction of integral snubbing the implementation of an improved blade design in existing
at the tip connects the blades circularly. This new blade turbines, consistent with the findings of this paper, should be
design aspect also reduces leakage, as well as vibration considered.
control. Both add to the efficiency of the steam turbine An increase in fuel consumption necessarily increases
system. This new blade design reduces the impact of thermal the amount of emissions from the generator plant. In the case
stress because of the improved efficiency of the system [16]. of fossil fuel-burning power plants, this indicates elevated
Effective corrosion resistance is key in improving blade amounts of carbon dioxide emissions. However, improved
design. Although the materials currently used in turbine turbine technologies that utilize cleaner, renewable fuels
blades have some degree of corrosion resistance, the have been developed, thereby lessening unwanted emissions.

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TURBINE SUSTAINABILITY with the incineration of garbage. Most prominent among the
problems resulting from the burning of trash is the release of
Sustainability, the ability of a technology to perform while toxins to the atmosphere. This not only pollutes the air, but
conserving natural resources and having no significant also poses serious health risks to humans. It has been found
adverse environmental impact, has become a major concern that waste incineration produces dangerous compounds such
as reserves of fossil fuels (on which modern society heavily as dioxin, sulfur dioxide, and nitrogen dioxide as well as
relies) begin to fall. Steam turbines have become a very many other substances of varying toxicity [21]. This has led
sustainable technology due to advances in cogeneration and to strict emission-level requirements which, whether
renewable fuel technologies. Cogeneration, the sequential intentionally or not, has caused the shutdown of some such
generation of two different forms of useful energy, typically facilities [22]. However, advancements in emission control
mechanical and thermal, from a single fuel input, [19] has technologies and incineration techniques have reopened the
been utilized by various manufacturing industries across the door to the possibility of using waste as a major source of
globe [19]. This utilization not only reduces operating costs energy production [21].
due to smaller amounts of electricity consumed by the The implementation of robust turbine blades, designed in
manufacturer from the grid, but it also lessens the accordance with the latest material technologies and able to
manufacturers impact on the environment. Coupled with the withstand the most trying of circumstances, in combination
use of renewable fuels, cogeneration provides an even more with the use of clean, renewable fuels presents an efficient
sustainable technology, sometimes with additional benefits method of generating substantial amounts of electricity. An
over and above a smaller environmental impact. For improved blade design, focused on resisting the effects of
example, M. A. Mujeebu, et al, conducted a case study on stresses, corrosive agents, and creep-inducing temperatures,
the utilization of a rice paddy husk-fueled cogeneration will elevate the turbine efficiency, consequently leading to
system in a South Indian rice mill [19]. It was found that if an increase in the power plants overall efficiency, a
such a system were implemented rice production would reduction of the amount of fuel consumed, and ultimately a
increase by at least 30 tons per day and that the system could decrease in operating costs. The use of renewable fuels, such
yield an annual savings of $0.12 million [19]. Aside form as waste, in addition to a more efficient blade design, will
the immediate monetary and manufacturing benefits of this serve to reduce operating costs even further and lessen the
system, additional benefits could be gained from the burning environmental impacts of steam turbines. Overall, such a
of the husk. As the content of the husk is mostly (91%) combination of technologies would benefit society by
silica, amorphous silica can be retained if the burnt husk is providing an efficient, viable, and sustainable means of
heated up to 700 C [19]. From this, pure silicon, which is generating electrical energy.
used extensively in computer chips and other electronic
devices, can be obtained. Additionally, sodium and REFERENCES
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tt_main&it=r&p=AONE&sw=w

Twelfth Annual Freshman Conference 7 April 14, 2012