Siemens offers a comprehensive range of steam turbine products in the power output range from 90 to 1,900 mw. Us6761536b1 turbine blade platform trailing edge undercut. Siemens announced it has successfully tested power generation gas turbine blades produced entirely through metalbased 3d printing, also known as additive manufacturing. Michael hales presentation on the r4 turbine blade sealpin rca included a status report on design improvementssuch as the enlarged sealpin slot modification, blade springs, and optimized platform gap for the r4 blade.
The socalled r2 issue was the hot topic at the conferencethe subject of several presentations and much hallway and exhibithall chatter. Cracking of the ev combustor liner in early 2000 and deformation of the lowpressure turbine row two blade shroud in mid 2000. Retrofit options increase steam turbine efficiency power. The use of longer steam turbine laststage blades lsbs reduces the number of lowpressure casings and, thus, a turbines total installed cost. Analysis of superalloy turbine blade tip cracking during. It found a crack in one l0 blade while conducting an insitu ultrasonic inspection in accordance with the 25,000hr200start inspection interval. Pdf crack of a first stage blade in a steam turbine. Turbine blades in modern gasfired power plants are highperformance components.
The crack is located near the pitch cylinder mounting brackets on blade b. A significant number of l0 blades in lp turbine connected to the hp lp23 also had cracks but the lp turbine connected to the generator lp21 was crack free. Replacing the gearbox, the coupling, and the highspeed generator with a lowspeed generator eliminates twothirds of the conventional drivetrain arrangement. Major overhaul on a 300mw siemens steam turbine and increasing the. With over eighty years of experience we support and assist our customers with advanced engineering, production and quality expertise. At the macroscale the turbine blades considered are cmsx series nickel based single crystal super alloy. Siemens gamesa renewable energy sgre has begun construction of the worlds largest wind turbine blade test stand in aalborg, denmark. With over a century of experience and continuous development in our steam turbine technology, siemens is a prime partner for your business. Siemens successfully tests 3dprinted gas turbine blades. Through optimal application of technology and proven expertise, stork turbo blading is unmatched in its ability to produce the blades in. The failure probably is a result of cracks in the structural member of the. Life assessment of large gas turbine blades turbo expo.
Products of the sst6000 series consist of a highpressure turbine, an intermediatepressure ip turbine, and up to three lowpressure turbines for 50 and 60 hz. Siemens engineers successfully test new 3d printed gas. Failure analysis of gas turbine blades in a thermal power plant. Example of custombuilt probe to inspect row 9 blade siemens parson 580mw turbine. Degradation of the mechanical integrity of steam turbine. Low pressure blade lacing wire ge design and lashing lug westinghousesiemens cracking are common findings during. More than 120,000 steam turbines delivered worldwide prove that we are a reliable and experienced partner. Crack detection on wind turbine blades in an operating. R0 compressor blade failure has been the life limiting factor of rotors whose designed lives are 144,000 hours and 5,000 starts, according to engineers at.
L0 blade crack proves that although technical advisories age, they remain current. L0 blade crack proves that although technical advisories. Utility steam turbines steam turbines siemens global. In april, a siemens service technician discovered a b53 blade on the ground at the eclipse wind farm. The blades are 53 meters long and used primarily on swt2. Example of custombuilt phased array probe to inspect l1 steeple of alstom siemens 850mw turbine. An increasing number of lowpressure steam turbinesespecially at supercritical fossil unitshave experienced stress corrosion cracking in. The corrosion mechanisms active in turbines stress corrosion cracking, corrosion fatigue, pitting, flowaccelerated corrosion areshowninfigure1. In spite of superior processing and quality control, large turbine blades may contain manufacturing induced discontinuities such as porosities, segregation, chemical inhomogeneities, particles, etc in few of the manufactured parts. In the past years, we have carried out the refurbishment of more than 500,000 gas turbine blades for the siemens gas turbine fleet. Failure analysis of a first stage in738 gas turbine blade. Each blade costs as much as an automobile, and if the turbine is out of action for several days for repairs, the costs can quickly escalate.
On saturday 28nov15 the nacelle, hub and blades of a single siemens 2. Our industrial steam turbines are designed for easy constructability, fast startup and economical operation. Hulls siemens factory produces first batch of wind turbine. Siemens as the original equipment manufacturer holds the unique technical knowhow and more than 30 years of experience in refurbishment. The charge is related to inspecting and replacing bearings due to the early degradation in certain turbine models. Siemens steam turbines of the sst6000 series are widely operated in coalfired steam power plants with a power output up to 1,200 mw and an efficiency up to more than 46 percent. With more than 8,000 steam turbines in service worldwide we provide proven technology, adapted to the specific local conditions. The symmetrical casing with horizontal joint flange enable the sst400 to accept short startup times and rapid load changes. Siemens has made more than 2,100 turbine blades of the same. The turbine blade in a steam turbine has an important role to convert the kinetic energy of the steam into mechanical energy. A gas turbine blade having an airfoil to platform interface configured to minimize thermal and vibratory stresses is disclosed.
Cracking failure in gasturbine blades researchgate. The blade was made of 174 ph stainless steel and has been used for 12 years before failure. Gas turbine blades and vanes refurbishment by siemens. Bernd burbaum 40 has developed a new laser welding process that makes it possible to repair expensive gas turbine blades so they are as good as new. Your trusted partner siemens has been a major driver of innovation in the wind power industry since 1980 when wind turbine technology was still in its infancy. Since year 2017, siemens wind power as is no longer active. Numerous cracks were observed along the leadingedge and midchord regions of the pressure and suction surfaces. This configuration minimizes exposure to the conditions that are known to cause high cycle fatigue and low cycle fatigue cracks. As the major driver of innovation with more than 30 years of experience, siemens is the ideal business partner. The site will be capable of performing fullscale tests on the next generations of sgre rotor blades and is expected to be fully operational before the end of 2019. Independent turbine consulting turbine generator experts. The manufacturer was taken over by siemens gamesa renewable energy. Hi all, we recently found cracks in the hub casting on one of our swt2. They not only need to be capable of withstanding temperatures of up to 1,500 celsius and rapid temperature changes, they also need to handle other extremes.
Siemens unveils 75 m wind turbine blade materials today. Feasibility of automatic detection of surface cracks in. For power generation in upstream, midstream and downstream applications as well as mechanical drives for compressors and pumps, siemens gas turbines are proven and trusted in the industry. It is of particular concern for gas turbines because it causes cracking in areas under extreme stress, such as the bases of turbine blades. Abstract cracks on the surface of a wind turbine blade wtb can be a sign of current or future damage to the underlying structure. Crack of a first stage blade in a steam turbine sciencedirect. The blade was tested in a baseline condition with no cracks, and then with various cracks induced in it. Whichever kind of wind turbine or service you require we have what you need to maximize your return on investment. A case study of failure analysis of a 40 mw gas turbine blade made of udimet 500 is presented.
As an aerodynamic blade addon, it reduces the sound power levels by using a. Siemens hlclass gas turbines are paving the way to the next level of efficiency and performance. Additive manufacturing with selective laser melting duration. Samso turbine collapsed due to welding crack 4c offshore news. Industrial steam turbines steam turbines siemens global. Failure analysis of a first stage in738 gas turbine blade tip cracking in a thermal power plant. To determine the extent of disc cracking, all six of the lp rotors were inspected. General product information 3d design to power up the performance one of the innovative solutions offered by siemens to help you improve your operating plant competitiveness and profitability are the siemens innovative 3dimensional blades and vanes for the turbine stages. Manufactured using a directionally solidified nickel superalloy tailored for gas turbine parts the design uses a metallic bond coat applied by hvof and a tbc topcoat providing superior protection against oxidation and tmf cracking. This research presents a method of detecting cracks on wind turbine blades using the vibo. At siemens, stefan schmitt develops gas turbine blades and coordinates the work of developing blade vibration technology. The purpose is to enable the participants to assess the extent of blade laminate damage and perform surface and finish repairs to damage in the coat and laminate of siemens gamesa renewable energy blades. Our gas turbines are the heart of the most modern and efficient power plants.
Siemens refurbishment process maintenance, repair and. Using modal analysis for detecting cracks in wind turbine. Chris wetzl followed with a turninggear timereduction product developed by siemens. Siemens reveals root cause of turbine blade breaks north. In addition, crack growth and threshold behaviour of blades has been investigated in. Results from an analysis of cracked firststage blades or buckets from two general electric ms7001e industrialelectric utility gas turbines are presented. This turbine can also be equipped with a 120 m rotor, standard equipment for the siemens 3.
Siemens ag power generation, d45466 mulheim germany. The enhanced platform is siemens answer to our customers need for extended operating capabilities and improved economical solutions. R0 compressor blade cracking has curtailed the lives of many fclass gas turbine rotors. The research result shows that turbine blade tip is initially damaged by rubbing and corrosion over a period time, premature cracking of blade tip is caused by a combination mechanism of environment and thermal stress. Jul 05, 20 siemens reveals root cause of turbine blade breaks. Inservice inspection of steam turbine blades without. Hulls siemens factory produces first batch of wind turbine blades. Rotating lp turbine blades may be free standing not connectedtoeachother,connectedingroups,orallbladesinthe.
Because turbine blades are designed to experience a. However, silent wind turbines can produce more power, which results in lower lcoe. Siemens wins asme award for 3d printed gas turbine blades. The long and short of laststage blades power magazine. Causes and resolution of stress corrosion cracking in.
With more than 35 years of experience in the wind power business, when you choose siemens gamesa, youre choosing proven solutions and proven reliability. Example of sensitivity setting on fatigue crack for l0 blade westighouse 1,300mw turbine courtesy south texas project ngs. Simulation of crack growth in the internal cooling system of a blade in a siemens gas turbine has been studied by inserting and propagating cracks at. In this paper, the premature tip cracking of the hpt first stage blade is investigated. Sep 25, 2011 readers may recall the special report on 501f r2 blade cracking and liberation posted in ccj onsite during the 2011 meeting of the 501f users group back in february. The root cause of r0 blade failure has been identified as high cycle fatigue cracking and liberation due to erosion from fogging and compressor washing. Thus, cases of rotor blade failures were discovered in a generating gas turbine plant after operation for to 6000 h.
Ultrasonic technique for inspecting turbine blade roots in situ. That kind of damage is incredibly expensive, says stefan schmitt, a turbine expert at siemens. The use of longer steam turbine laststage blades lsbs reduces the number of lowpressure casings and, thus, a turbine s total installed cost. In this study, we tested a single wind turbine blade which was subjected to two types of material failures. Feb 03, 2017 siemens achieves breakthrough with 3d printed gas turbine blades. Repairing lowpressure rotors with cracked blade attachments. The failure of the first stage blade in a steam turbine of 55 mw was investigated. Blade root blade attachment inspection by advanced ut and.
Our steam turbines work as generator drives or as mechanical. Due to the high repair costs for wind turbine blades, it is especially important to detect initial blade defects before they become structural failures leading to other potential failures in the tower or nacelle. The turbine maker immediately curtailed all turbines using the b53 blades, the type involved in the two incidents. The 3dprinted turbine blade places siemens at the forefront of a technology trend that is spurring a global revolution in product. Learn how simulation tools from siemens plm software are helping power generation companies design gas turbines to meet the everincreasing worldwide demand for energy while simultaneously reducing co2 emissions in order to meet global climate goals. Gas turbines manufacturer power generation siemens. With siemens as a partner, you benefit from proven expertise and experience in oil and gas applications. To increase the reliability and efficiency of turbine, it is necessary to perform detailed investigations of the failed turbine blade. Feasibility of automatic detection of surface cracks in wind turbine blades huiyi zhang and john jackman dept of industrial and manufacturing systems engineering, iowa state university, ames, ia, 50011 u. Feasibility of automatic detection of surface cracks in wind. As the original equipment manufacturer, only siemens knows the parameters that count when refurbishing gas turbine blades and vanes. No turbine engine is immune from it, and since sulfidation tends to form in the blade root, shrouds, and to a lesser extent on the. Such blade failures were observed in aircraft, marine and stationary gas turbine plants.
Turbine blade failure occurs time to time in power plants. The root cause of r0 blade failure has been identified. Siemens achieves breakthrough with 3d printed gas turbine. The cause of failure is found to be intergranular cracks which. Simulation prevents turbine blades from cracking energy siemens. Even regular inspections cant totally prevent cracks from developing. Update siemens collapse at ocotillo caused by blade failure. Dont lose your tune with turbine blade damage tg advisers, inc. Hot gas sweeps past the blades at supersonic speeds, and the rotary forces are enormous when speeds reach several thousand rpm. Siemens has produced the first batch of its new 75 m long wind turbine rotor blades, which it claims are the worlds longest.
The fractographic study revealed a static cracking mechanism initiated at blade edges. A feasibility study of wind turbine blade surface crack detection using an optical inspection method huiyi zhang1, john jackman wind energy manufacturing laboratory dept. A solution to fclass r0 compressor blade failure turbomachinery. Sst400 steam turbine overview the sst400 is a single casing steam turbine, providing geared or direct drive to 50 and 60 hz generators, or to compressors and pumps. Fatigue failures of the turbine blades is one of the most vexing problems of turbomachine manufacturers, ever since the steam turbine became the main stay for power generating equipment and the gas turbines are increasingly used in air transport. Simulation prevents turbine blades from cracking energy.
The sst800 is a single casing steam turbine with center steam. The companys first commercial wind turbine had a capacity of 30 kw and 5 m long blades, for a 10 m rotor diameter. Nov 19, 2016 michael hales presentation on the r4 turbineblade sealpin rca included a status report on design improvementssuch as the enlarged sealpin slot modification, blade springs, and optimized platform gap for the r4 blade. Turbo expo 2017 turbomachinery magazineturbomachinery magazine. Chemically the crystals are 2% chromium, 3% cobalt, 0. The modular package design allows a wide variety of. Analysis siemens acts to fix bonding issue behind blade breaks. North american windpower serves decisionmaking professionals involved in all aspects of wind energy generation and distribution. Our dedicated blades department and highly specialized technicians are here to h. Using modal analysis for detecting cracks in wind turbine blades surendra n. Large gas turbine nickel based superalloys blades are typically manufactured using an investment casting process.
Siemens engineers successfully test new 3d printed gas turbine blades, manufactured at siemens owned materials solutions. In such a system, differences between monitored modal parameters and. Each wind turbine blade weighs 28 tonnes and is made of balsa wood and fibreglass. Older steam turbines are prone to stress corrosion cracking of the turbine blades for a number of reasons and understanding the causes and potential solutions can help to minimize downtime and improve reliability. They provide low power generation costs, flexible and short startup times as well as high efficiency, and will make your business even more profitable. In april, a siemens service technician discovered a b53 blade.
The turbine combines the proven turbine casing of the siemens sst400 as well as the steam turboset accessories gears, generator, base frame with the geothermal steam path and. Dec 19, 2019 r0 compressor blade cracking has curtailed the lives of many fclass gas turbine rotors. As a market leader for industrial steam turbines, we offer a comprehensive range of reliable and versatile steam turbines for the power output range from 2 to 250 mw. Itc was started in 2010 and has quickly filled an urgent industry need for qualified, experienced turbine generator field engineers to provide technical direction, consulting, and. A typical lowpressure steam turbine blade dovetail damaged by stress corrosion cracking, which can cause extensive damage if the condition is not quickly corrected. Field application demonstrations ken maynard 1 and martin trethewey 2 1 applied research laboratory, the pennsylvania state university 2 dept. Jul 20, 2012 the launch of the new 75 m blade signifies a 200fold growth in the energy capture area and the turbine capacity of siemens turbine products over the last 30 years. A feasibility study of wind turbine blade surface crack. Sst400 steam turbine up to 65 mw industrial steam turbines.
The 75 m blades will be used on siemens 6 mw the mould for the b75 blade consists of two parts. The next generation of industrial steam turbines siemens. A feasibility study ken maynard 1, martin trethewey 2, ramandeep gill 2, brian resor 2 1 applied research laboratory, the pennsylvania state university 2 dept. Independent turbine consulting itc is a group of turbine engineers specializing in gas and steam turbine consulting, maintenance, repairs, projects, and outages. This turbine can also be equipped with a 120 m rotor, standard. A typical example for this is a turbine blade design.
It brings the entire siemens industrial steam turbine product range under one common umbrella and incorporates new stateoftheart features. Smooth repair for gas turbine blades inventors of the. Derived from proven siemens hclass technology in an evolutionary development step, the next generation of siemens advanced aircooled gas turbines uses a series of new, but already tested technologies like superefficient internal cooling features for blades or vanes and an advanced. Advanced two piece exhaust atp was designed to address all known issues such as outer diffuser cracking, tangential strut deformation and cracking, and baffle seal cracking on the twopiece exhaust cylinder tpex and enable the cylinder configuration as a dropin replacement. Top flight german turbine maker, siemens booked a 223 million write down ie loss in 2014 due to the fact it had to replace bearings in a fleet of turbines that were less than 2 years old. Blade failure in a steam turbine is a prevalent occurrence and has a strong correlation with the forces acting on the blade, which are centrifugal forces, centrifugal bending, steady steam bending, unsteady centrifugal forces due to lateral shaft. Results for blades of different sizes, surface conditions and materials have been evaluated. Incredible wind turbine blade technicians dont watch if. In a 2012 wind turbine overview for the world bank, ge presented its 1. The very best features of the siemens steam turbine. Siemens is as a trusted project partner for utilities, municipalities and independent power producers. The site will be capable of performing fullscale tests on the next generations of sgre rotor blades and is expected to be. Aug 21, 2017 superalloys, coatings, failure analysis, repair, vane liberation, filtration, hrsg fouling and blade cracking by drew robb keynote speakers and asme gas turbine executives during the opening address at the 2017 turbo expo the 2017 turbomachinery expo in charlotte, north carolina, drew more than three thousand people to hear hundreds of presentations from top academics and researchers.
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