Turbine Blade Construction

TURBINE CONSTRUCTION
TURBINE BLADES
Blade converts energy of steam to mechanical power.
The length of each row of turbine blades is governed by – volume flow, mean
diameter of flow path, the velocity of steam, and the active arc through which the flow
takes place. Length increases LP to HP.
The cross sectional area is increases and hence the blade is stronger and better
resistant to vibration. The increase thickness also allows a circular tang to be fitted for
attaching a shroud. Non circular such as square tangs require the shroud to be punched
rather than drilled which introduces residual stress, micro-cracking etc.
Blade stresses
The predominant stress in turbine blades is centrifugal and concentrated at the root.
Vibration is set up in blades due to fluctuations in steam flow. Particularly in impulse
turbines where partial admission is used
Further stress is caused by expansion and contraction as well as bending stresses due
to the action of the steam
In addition to these stresses occur during manoeuvring due to speed changes.
Properties required of the blade material

Blade should be of good quality and high surface finish
Blade material should be
Good tensile and fatigue strength;

Toughness and ductility at working temperature
Resistance to corrosion and erosion
Rate of expansion similar to both rotor and casing
Machinability
Low density
Good vibration dampening properties
Good creep resistance
Weld ability
Typical blade material is
11.5 to 13.5% Chromium
1% Nickel
1% Manganese
1% Silicon
0.12% Carbon
Trace Sulphur & phosphorus
Bull nosed blades
Standard blades have the same inlet and outlet angles. Bull nosed blades are capable
of accepting a wide range of steam angles without serious increase in blade losses.
Reasons for taper-twisting of the final stages of LP turbines

 Due to the change in centrifugal velocity with the increase diameter
towards the exhaust end the true vector velocity of the steam varies over the
length of the nozzle. The blade must be twisted to ensure the steam enters at the
correct angle
 The tip has an aerofoil section to increase the reaction to equalise the
flow of steam across it which would otherwise be non-uniform due to the
pressure difference between the tip and base due to centrifugal action
 The tapered blade design allows an increased distance between the blade
and nozzles. This gives water droplets more time to increase in speed driven by
the steam flow.
 In addition the tangential velocity is much greater than that of the axial
velocity and hence the rotating disc of steam tends to centrifuge out the water
droplets
 When viewed as a cantilever beam the tapered design is ideal from a
mechanical point of view to resist bending
Blade Sealing
May be end or tip tightening
End Tightening
This is seen particularly on reaction turbines. It requires accurate positioning of the
turbine rotor and is normally associated with lengthy warm up perios during which the
position of the rotor is carefully monitored. Operational limitations on rapid power
changes may be in place. The author has seen this system in use on very large but
compact turbo alternators which required a warm up period consisting of increaseing
the rotor speed in stages over one hour
Tip Tightening
Clearance is governed by maximum blade centrifugal stretch
TURBINE BLADE FIXING

Blade is attached to the rotor disc by various type of blade roots, the choice being
dictated by size of the centrifugal stress which will vary according to the rotational
speed of the turbine and size and weight of the blade
Fixed Blades
Although not subjected to centrifugal force, the fixed blades of curtis velocity
compounded turbines are subjected to vibration in a similar way to the rotating blades.
The root fixture must, by necessity, be secure to prevent fretting
Reaction Blades
Blades are rolled to correct shape then cut to length. Up to 50 blades are then
assembled in a jig of correct radiurwith a distance piece to give the correct spacing.
The root is drilled and the upper part machined so as to accept shrouding fro end-
tightening, or thinned for tip tightening. After assembly on the jig a hole is drilled
though the base and a wire passed through. The whole assembly may then be removed
and brazed or spot welded to form a solid curved section.
The arc is then machined to the desired root form. Shown below is a single blade
section of the arc showing typical root form.
The segment is dropped into position pushed axialy and a caulking piece fixed
A gate is formed in the final blade which receives a further thin section piece made of
copper which is caulked in.
The fixed blades in reaction turbines are made in a similar fashion except that the end
blades as held in by a screw and locking strip as the horizontal joint. ALso the root
may be of a simpler design due to the lack of centrifugal stress.
For higher speed, higher rated turbines the built up method may not be acceptable due
to the stresses.
These blades may then be made of soild individual sections. The blades enter through
a gate with the final blade being caulked into position.
The gates for each groove are staggered to assist balancing. The lacing wire/shrouding
is then fitted.
Impulse Blades
The most common form is the dove tail.
The groove is cut away to form a gate to allow the fitting of the blades. The final blade
is riveted in position.
Blades subjected to higher centrifugal stresses, for example the longer tapered blades
found in the final stages of the LP turbine, may have the fir tree root method which
allows increased contact area without weakening root or wheel rim.
To reduce centrifugal stress on the wheel straddle root form of blade fixing may be
used thinning the wheel rim. The straddle may be a simple fork design or of fir tree
root. Rivets are added for strength.
Inverted fir tree root
Fir tree root attachment is very strong but requires accurate machining and manual
blade fixing is not possible. The gate is filled with a machined block with no blade and
then riveted to secure.
Multiple forks
For very large blades, say at the end if the LP turbine, the root, and thus wheel rim,
would be required to be very large. Multiple forks may be used which are
comparitively easier to machine.
Straddle 'T'
Straddle 'T' used rather than inverted 'T' so that the holding faces on the rim can be
easily inspected for defects.
Stal Laval bulb root

The main advantage of this system is that the blades are introduced into the rim
axially. Therefore the individual fitting of the blades required with circumferential root
arrangements is unnecessary
Where the distances between the bulb becomes so small as to risk failure of the rim,
staggered bulb root depths are used with alternating short and long shank lengths.
For these types of blades the shrouds are part of the blade. On this shroud are two tabs.
A shrouding wire is passed around the circumference over the shroud and the tanbs are
bent over. This has the advantage that in the event of root failure some support is given
to the blade. Multiple shroud wires are filled rather than a singe one for ease of
manufacture allowing smaller tabs, and also to reduce mechanical stress. On more
modern designs the groove is moved to the end of the shroud and a welded shroud
wire fitted.
Sizing the rim

When the rim is first cut and the entrance gate formed, a test blade with slightly too
large root ( or feet) is carefully filed and then tapped around the rim. This blade is then
discarded. The real blades are then carefully filed and fitted taking into account the
wear on the rim. The nating face of the blades are filed to ensure even blade pitch. A
tight fit is essential with a steam turbine, if not then severe fretting and failure will
occur.

Turbine Blade Construction

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Turbine Blade Construction

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TURBINE CONSTRUCTION

Properties required of the blade material

Good tensile and fatigue strength;

Reasons for taper-twisting of the final stages of LP turbines

TURBINE BLADE FIXING

Stal Laval bulb root

Sizing the rim

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