SAFE DIAGRAM - A DESIGN AND RELIABILITY

TOOL FOR TURBINE BLADING

Murari P. Singh
John J. Vargo
Donald M. Schiffer
James D. Dello
Dresser-Rand, Wellsville, NY, USA

ABSTRACT
The complex field of turbine blade vibration has long been in need of improved
tools to help predict the reliability of blading.

The SAFE interference diagram is presented as such a tool. It presents much

more information than the widely used Campbell diagram. In evaluating
interferences, the SAFE diagram compares not only the frequencies of exciting
harmonies with natural frequencies of blades, but also the shape of these
harmonics with the normal mode shapes of a completely bladed disc including
packeted blading. Examples are given of cases where the Campbell diagram
predicts a dangerous resonance while the SAFE diagram shows that no
resonances exist which are supported by experience. Examples are also
provided to show when the SAFE diagram can pinpoint what interference is likely
to cause the largest blade vibration. Finally, it is shown how a simple change in
packeting can be used to change the blade interference and to avoid dangerous
operation.

INTRODUCTION
To meet the objective of designing reliable and trouble free blading in
turbomachinery, the blade natural frequency analysis is of utmost importance.
This is due to the fact that almost all blade failures can be attributed to metal
fatigue, which is caused by variable aerodynamic loads acting on the blading.
Resulting dynamic stresses depend on the natural frequency and the mode
shape of the blade, the frequency and shape of the exciting force, and the
energy dissipating mechanism present in the system included as damping.
In the early days of blade design, the natural frequency analysis was based on
the assumption of a single beam cantilevered at the blade root. Prohl and
Weaver [1] showed that in the case of a packeted assembly where a group of
blades are connected by shrouding, many more natural frequencies and modes
exist which could not be predicted by a single blade analysis. This is due to the
fact that the group of blades behave as a system and are coupled through the
shrouding. The magnitude of frequencies and the number of modes depends on
the number of blades in the group and the stiffness of the shrouding. This type of
analysis has explained many blade failures and helped designers to build more
reliable blades.

The next important step in blade analysis was due to the realization that blades
are mounted on a disk which can influence the dynamic behavior of blades.
Calculations including the disk showed that frequencies can be affected and a
new large number of modes exist which cannot be predicted by using a single
packet analysis. In reality all blades and the disk constitute one system which
may or may not respond to an exciting force.

Singh and Schiffer [2] presented a finite element analysis for a packeted bladed
disk assembly. They showed and discussed the features of dynamic behavior
which is different than when the shrouding is 360 degrees.

Traditionally, a blade design is evaluated by using the Campbell Diagram. This

TOPIC_2

RankineCycler™
Advanced Micro Steam Turbine Power plant

GENERAL DESCRIPTION

The Turbine Technologies' RankineCyclerTm is a complete and

functional micro steam turbine power plant. It is delivered and
supported directly by the factory and can be readied to operate within
minutes of uncrating.

This micro steam plant allows students to readily view all components
and eliminates lengthy operational preparations. Special site
preparations are also eliminated.

RankineCyclerTm is not a simple demonstration piece, but a fully

interactive multiple experiment teaching device. Turbine load can
be varied, power input can be varied and 8 data points offer many
cycle analysis options. RankineCyclerTm can be set up and operated
virtually anywhere.

All components are mounted on a 48" by 28" tabletop stand. The

entire "power plant" weighs less than 100 pounds (dry weight). Major
components include a multiple pass flame-through boiler, an impulse
steam turbine and generator set, boiler feedwater pump, automatically
controlled gas burner with combustion blower and a condenser tower.

All sensors are routed to a dedicated PC data acquisition station for

data collection and analysis.

POWER PLANT COMPONENT DESCRIPTIONS:

Boiler

RankineCyclerTm multiple pass flame through boiler accurately models full

scale units. Its burner operates on natural or LP gas. Gas ignition and safety
valves comply with U.L. and CSA safety standards. The forced air blower,
ignitor, and gas valve are all automatically controlled for start, operation and
shut down. Operating pressure is maintained at a constant level via this
automatic regulation capability.

Rear boiler door open during firing depicts flame tubes and flame
holder

Both the front and rear doors are insulated and open easily to reveal the
burner, flame tubes and general boiler construction. The boiler walls are also
insulated to minimize heat loss. A sight glass shows water levels and is
equipped with safety valves that instantly close in case of glass breakage.
Turbine/Generator set

The micro steam turbine consists of a flanged two piece housing and an axial
flow impulse turbine wheel. Steam condition (temperature and pressure ports)
are located on the turbine inlet and outlet. Load and measurement terminals
are provided and routed to transducers for data acquisition purposes. The DC
generator's output varies with turbine steam inlet conditions and the generator
winding is constructed for a safe low voltage output.
 Axial steam turbine housing image depicts steam inlet and outlet flanges

Axial flow impulse steam turbine wheel

Condenser Tower

Turbine outlet steam is piped to the condenser tower and is admitted

tangentially. The tower is constructed of stainless steel. Condensate is
returned to the boiler from the condesor tower sump via a custom
manufactured steam driven feedwater pump.

BOILER FEEDWATER PUMP

The feedwater pump is a fully functioning, dual-piston reciprocating pump. It
is independent of electric or other external power requirements and is driven
by boiler steam. An intensifier principle (large area steam piston/ small area
feedwater piston) comprises the basic design.

Water is drawn from the condenser tower sump and then routed through the
suction port and inlet valve of the feedwater cylinder assembly. The double
acting steam cylinder and feedwater pistons are mounted on a single
connecting rod. The reciprocating piston motion is controlled by a four way
steam valve.

INSTRUMENTATION/DATA ACQUISITION DESCRIPTION

Eight installed sensors allow for full Rankine Cycle analysis and study.
On screen data includes:

Boiler Temperature
Boiler Pressure
Turbine Inlet temperature
Turbine Exit temperature
Turbine Inlet pressure
Turbine Exit pressure
Generator amperage
Generator voltage

The computer is capable of logging all data points and replaying them
at a later time. Data can be viewed as collected in a strip chart type
presentation on the computer screen.

Data Acquisition Station:

Software related items:
68 pin rail mountable terminal
block
National Instruments data acquisition
16 channel signal conditioning
software
unit
Signal Conditioning Driver software
2-meter, 68-pin shielded cable
Windows 98
4 shelf cart with lockable castors
Microsoft Office 2000
17" color display
Norton Anti-Virus 2001
2-button Mouse
Keyboard
56.6 K PCI modem
64 Meg Ram 100 Mhz SDRAM
733 Mhz Intel Pentium III
processor
10 Gig hard drive
48XCD-ROM drive
Power protection/surge suppresser

RankineCyclerTm
 Specifications
Weight: 60 pounds dry weight

Dimensions: 48"L X 28"W 46"H

Power required: 120Vac (standard wall outlet)

Impulse turbine wheel diameter: 2.00 inches

Turbine housing O.D. 3.50 inches

Generator output: 100 W maximum

Fuel: LP or natural gas

Complete RankineCyclerTm system cost: $19,750 U.S.D. (FOB Factory)

 TOPIC_3

APPLYING STEAM TURBINES FOR PUMP DRIVES

John Elmore
Randy Palmer
Dresser-Rand, Wellsville, N.Y., USA

Steam turbines are well-suited for pump drive service for a number of reasons.
First is their ability to operate across a wide speed range. This enables them to
do two things: operate at the pump's most efficient speed and match the system
head curve at varying pump flows, thus reducing throttling losses. This can
make the turbine a good choice for marginal NPSH applications as it can avoid
drastic speed reductions. When operating at low speed, turbines reduce radial
reaction in centrifugal pumps operating at low flows.

Turbines also work well as pump drives because they can be used safely in an
explosive atmosphere, do not fail when overloaded, have high starting torque
(useful for positive displacement pumps), and are rugged and reliable.

This discussion mainly addresses single-stage turbines 3,500 hp and smaller, but
most comments apply to larger single- and multi-stage turbines as well. Below is
a review of steam cycle and turbine performance terms. You should be familiar
with these before trying to make performance comparisons and analyze selection
data.
Wheel Pitch Diameter
Hp/Rpm 14 inches 20 inches 28 inches
Steam Rate-lbs/hp-hr Steam Rate-lbs/hp-hr Steam Rate-lbs/hp-hr
300/3600 39.8 31.4 26.7
300/1800 High Exh. Velocity 53.4 41.2
300/1200 High Exh. Velocity 77.6 57.9
50/3600 43.1 35.3 36.5
50/1800 77.3 59.4 42.8
50/1200 111.2 87.1 69.6
Inlet: 600 psig @750°F; exhaust: 40 psig. Please keep in mind that the table reflects actual steam rates
based on turbine efficiency only. Turbine performance is only a component of the customer's steam cycle
performance (for the entire plant steam loop).
Table 1. Performance comparisons: wheel pitch diameter vs. speed (single-stage).
STEAM CYCLES
Non-Condensing Cycle
The non-condensing cycle (back pressure operation) involves taking medium-to-
high-pressure steam into the turbine and exhausting it to a process header
where the pressure is higher than atmospheric Cycle efficiency is high because
the turbine and process absorb most of the heat before the condensate returns
to the boiler. Turbine arrangement is usually straight non-condensing (no turbine
extraction), and it is the most commonly used cycle for pump drive service. For
pump ratings of 3,500 hp or less, steam turbines are usually single-stage.

Condensing Cycle
This cycle takes the turbine's exhaust steam to a condenser at below
atmospheric pressure. Because the condenser's cooling water absorbs most of
the heat, cycle efficiency is low. Condensing cycles are sometimes used when
taking low-pressure process exhaust steam (as low as 5 psig) to the turbine inlet
through a multi-stage turbine, or when waste fuel is burned in the boiler.
Condensing cycles are not often used for pump drive service. The cycle is not
very efficient, and the cost of a multi-stage turbine, condenser, condenser pump
and cooling water can be prohibitive. Condenser cooling water availability is also
a concern for many processes.

STEAM RATES
Theoretical Steam Rate (TSR)
This is the quantity of steam per unit of power required by an ideal Rankine cycle
heat engine, which assumes a no-loss (isentropic) expansion between turbine
inlet and exhaus. TSR is expressed as pounds of steam per horsepower hour
(or kg/kw-hr) and is universally recognized and used as a benchmark for
measuring steam turbine performance. You can look up TSRs in the latest
ASME Steam Tables (the easiest method) or derive them from a Mollier chart for
steam (which requires time and good eyesight).

Actual Steam Rate

The actual steam rate reflects turbine efficiency and is expressed in the same
units as the TSR. Manufacturers determine its value using pump and steam
conditions. The product of actual steam rate and pump horsepower is the steam
flow required to develop a given pump power.
FACTORS AFFECTING TURBINE PERFORMANCE
Steam Conditions

• Greater pressure drop across the turbine makes more heat energy
(BTUs) available.
• Less than 50 Btu/lb enthalpy drop through the turbine is not generally
workable due to low turbine efficiency resulting in high steam flows. (This
is a rule of thumb figure, not an exact one.)
• Imposing a wide range of steam conditions usually causes the turbine
manufacturer to provide excess inlet nozzle area than required for
normal operating point.

Handvalves

• These are used to reduce throttling across the governor valve when the
system is operated for long periods at above or below normal pump
power.
• Part-load performance can be improved by closing handvalve(s) to
decrease nozzle area.
• Maximum load/overload capability performance is improved by opening
handvalve(s) to increase nozzle area.
• Handvalves are set either full open or full closed. (They are not used for
throttling.)

Power and Speed

• Generally, higher powers and speeds result in greater turbine

efficiencies.
• Speeds slower than 1,800 rpm usually require attention to whether there
is sufficient steam flow availability, the high exhaust temperature and the
type of lubrication.
Wheel Pitch Diameter

• Larger pitch diameters perform well at higher power ratings and lower
operating speeds than smaller wheels.

• Small pitch diameters are best at low power ratings (under 100 hp) and
high exhaust pressures. They also produce less exhaust loss.
Inlet and Exhaust Nozzle Size

• Keeping steam velocities below limits specified by NEMA Standards can

minimize friction losses.
• NEMA Standard SM-23 velocity limits are 175 ft/sec at turbine inlet and
250 ft/sec non-condensing exhaust (450 condensing).

TURBINE BASIC SELECTION DATA REQUIRED

• Minimum requirements:
o inlet steam pressure and temperature
o exhaust steam pressure
o pump power (rated max.-min.)
o pump speed (rated max.-min.) and maximum allowable over-
speed for trip
o speed control (manual or type of process signal)
o site conditions: indoor/outdoor and ambient conditions
o cooling water data (pressure, temp and cleanliness)
• Any off-normal steam or pump operating conditions:
o affects turbine steam path areas and ability to make power
o low power conditions create high exhaust temperature (affects
lubrication method)
• Type of pump and service:
o centrifugal or positive displacement
o normal or quick start
o continuous or standby duty
o site electrical rating (if electrical accessories are involved)
• Specifications:
o customer required scope and turbine shop tests
o API-611/612-3rd or 4th editions (API data sheets required)
o steam cost evaluation
o sound level requirements

Reprinted from Pumps and Systems Magazine.

Refer questions to:
Contact D-R
 TOPIC_4
FREQUENCY EVALUATION OF A STEAM TURBINE BLADED
DISK
Jim Dello
Dresser-Rand, Wellsville, NY, USA

Unplanned and untimely shutdowns of critical turbomachinery is costly-for both

the user and original equipment manufacturer. Therefore, it is very important that
the turbomachinery be designed and operated to assure trouble-free operation.
This is not always easily accomplished. Because turbomachinery components,
specifically airfoils, are subjected to high variable loads that can cause failure,
designing reliable components requires in-depth vibration and stress analysis.

Identification of when the frequency of variable force match component's natural

frequencies is the traditional method to design around potential blade failures.
The identification of matching frequencies-the force with the structure-is
commonly shown on a Campbell diagram. However, the Campbell diagram lacks
some information when used to analyze the possibility of blade failure. To further
help bladed disk designers, Dresser-Rand has initiated the use of the SAFESM
(Singh's Advanced Frequency Evaluation) diagram.

Natural Frequency and Mode Shape

Natural frequency is the frequency at which an object vibrates when excited by a
force, such as a sharp blow from a hammer. At this frequency, the structure
offers the least resistance to a force and if left uncontrolled, failure can occur.
Mode shape is the way in which the object deflects at this frequency. An
example of natural frequency and mode shape is given in the case of a guitar
string. When struck, the string vibrates at a certain frequency and attains a
deflected shape.

The frequency can be noted by the pitch coming from the string. Different string
geometries (length and diameter) lead to different natural frequencies or notes.

By nature of its structure, a turbine bladed disk, shown in figure 1, usually has
many natural frequencies and associated mode shapes. These frequencies and
mode shapes are somewhat further complicated by the use of a shroud to
connect groups of blades together. Shrouding groups of blades together serves
two purposes-one is for aerodynamical reasons to reduce losses and the other is
for blade strength required to sustain steam forces. Blades are banded in
brackets with varying numbers in one packet. At Dresser Rand, a 6-blade packet
is most commonly employed. The knowledge of packeting arrangements of
blades into groups is very important when analyzing packeted-bladed disk
vibration.

Figure 1
Vibrational behavior or typical deflection mode shapes of a packet containing six
blades is shown in figure 2. Natural frequency values will change depending on
blade geometry; a tall and narrow (i.e., less stiff or more flexible) blade will have