This document summarizes the design and analysis of a multi-stage steam turbine blade and shaft assembly. It describes modeling the turbine blade profiles and patterns as well as the shaft in CAD. Finite element analysis is then used to conduct structural, modal, and thermal analyses on the assembly with different materials to evaluate stresses, displacements, natural frequencies, temperatures and heat transfer. The results indicate that a zinc aluminum alloy with a zirconium coating provides better reliability than other materials due to lower stresses and displacement under thermal and static loads. This improved design can reduce maintenance needs and costs of the steam turbine.

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International Journal of Research and Innovation (IJRI)
International Journal of Research and Innovation (IJRI)
DESIGN AND ANALYSIS OF MULTI- STAGE STEAM
TURBINE BLADE AND SHAFT ASSEMBLY
K.Khishor Kumar 1
, D.Gopichand2
,
1 Research Scholar, Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India
2 Assistant professor , Department Of Mechanical Engineering, Mother Theresa Institute of Technology(mist) Khammam,India
*Corresponding Author:
K.Khishor Kumar,
Research Scholar, Department Of Mechanical Engineering,
Mother Theresa Institute of Technology(mist) Khammam,India
Published: Sep 22, 2014
Review Type: peer reviewed
Volume: I, Issue : III
Citation: K.Khishor Kumar, Research Scholar (2014)
DESIGN AND ANALYSIS OF MULTI- STAGE
STEAM TURBINE BLADE AND SHAFT ASSEMBLY
Problem Description
Steam turbines are generally used for power gen-
eration by using thermal energy (steam pressure)
to produce rotary motion which in turn converted
to electric power. In this process a set of turbine
blades and shaft are used to convert steam pressure
in to mechanical energy.
Generally in turbine the blades and shafts are sub-
jected to high amount of pressurized steam with
high temperature. This causes thermal and static
stresses which leads to effect daily maintenance
and replacement of blades rapidly.
The rapid replacement of blades causes less power
generation and expensive.
Solution Methodology
As per the directions and requirements of R&D de-
partment, analysis has to be done on entire assem-
bly of shaft and group of blades with variant materi-
als to suggest the best material and coatings which
can withstand the thermal and static loads.
Regular material EN24 stainless steel material and
new materials such as zinc aluminum alloy (zamak)
and cast iron C70 along with partially stabilized zir-
conium coating for surface protection for the mate-
rials are used.
Static, modal and thermal analysis is to be done
on above three materials to analyze the structural,
vibrational and thermal characteristics.
Abstract
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary
motion. A system of angled and shaped blades arranged on a rotor through which steam is passed to generate rotational
energy.
The blades are designed in such a way as to produce maximum rotational energy by directing the flow of the steam along
its surface. The blades are made at specific angles in order to incorporate the net flow of steam over it in its favor. The
blades may be of stationary or fixed and rotary or moving or types, and Shaft designed to work in extreme conditions,
hear it has to bear the temperature which is coming from the steam and loads(weight and centrifugal force) of the blades
assembly and other assembly parts.
The aim of the project is to reduce maintenance, product cost and improving quality / life.
Initially literature survey will be done to understand rectification methodology and approach.
3D models of blades set’s shaft will be prepared according to C.M.M data.
Assembly of shaft and blades will be prepared and exported into IGES (inertial graphical exchanging specifications) for-
mat to conduct further work in ANSYS.
Structural analysis will be carried out on assembly to evaluate structural characteristics.
Model analysis will be carried out on same to find natural frequency’s (for comparison with other results)
Thermal analysis will be carried out on to find thermal characteristic.
Various materials and ceramic coating will be implemented on ANSYS for evaluation.
Comparison tables will be prepared according to the obtained results from Ansys; Conclusion will be made according
to the above.
Key words: Multi Stage, Ceramic Coating’s, Thermal
1401-1402

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International Journal of Research and Innovation (IJRI)
Steam Turbine
Introduction
A turbine is a rotary mechanical device that extracts
energy from a fluid flow and converts it into use-
ful work. A turbine is a turbomachine with at least
one moving part called a rotor assembly, which is
a shaft or drum with blades attached. Moving fluid
acts on the blades so that they move and impart ro-
tational energy to the rotor. Early turbine examples
are windmills and waterwheels.
The word "turbine" was coined in 1822 by the
French mining engineer Claude Burdin from the
Latin turbo.Gas, steam, and water turbines usually
have a casing around the blades that contains and
controls the working fluid. Credit for invention of
the steam turbine is given both to the British en-
gineer Sir Charles Parsons (1854–1931), for inven-
tion of the reaction turbine and to Swedish engineer
Gustaf de Laval (1845–1913), for invention of the
impulse turbine. Modern steam turbines frequently
employ both reaction and impulse in the same unit,
typically varying the degree of reaction and impulse
from the blade root to its periphery.
Steam turbine showing blade and shaft assembly
working of impulse and reaction turbine
Experimental Procedure
Generation of Pressure Distribution Data on the
Blade
Surface:
Last stage blade of steam turbine, which is
being analyzed, for stress and vibration is a high-
ly twisted blade due to the variation if the blade
speeds across the height of the blade. The deflection
in the blade passage also reduces from hub to tip
to vary the loading on each section. Thus the pres-
sure distribution on the suction & pressure surface
of the blade changes considerably from hub to tip
to match the loading at that suction .It is known
fact that the area of pressure distribution curve rep-
resenting the blade loading. Hence it has been de-
cided to generate the pressure distribution at all the
‘17’ blade sections.
The following procedure is allows to get the blade
surface pressure distribution with the help of Blade
Gen&Blade Gen plus package.
From the blade coordinate input data file for suc-
tion/pressure surface x, y, z, coordinate of surface
was generated as a loop with the following notations.
X-along the height of the blade.
Y- Meridional direction.
Z-along blade to blade
2. Profile curve is generated with above coordi-
nates of all sections placed one below the other is
sequence from section (1) to section (5 along the
height of the blade. The coordinates between two
section separated by ‘#’.
3. Hub & Shroud boundary is generated at the ap-
propriate heights with –Y negative Meridional axis
corresponded from LE (Leading edge). And positive
distance from Meridional distance from TE (Tailing
Edge).
4. Hub. Curve file is generated as follows
X, Y, Z
283.450000 0.000000000 -100.000000
283.450000 0.000000000 0.000000000
283.450000 0.000000000 100.000000
In between the values Comma is compulsory. (X, Y,
Z)
A profile contains total 60 points for all ‘5’ sections.

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International Journal of Research and Innovation (IJRI)
5. Profile. Curve file is generated as follows
X, Y, Z
#
283.45,-5.74,-22.92
283.45,-5.23,-23.25
283.45,-4.46,-23.36
283.45,-3.43,-23.22
283.45,-2.15,-22.82
283.45,-0.66,-22.12
283.45, 1.03,-21.11
283.45, 2.85,-19.72
283.45, 4.74,-17.91
283.45, 6.61,-15.62
283.45, 8.32,-12.78
283.45, 9.66,-9.39
283.45, 10.4,-5.53
283.45, 10.35,-1.43
#442.65, 15.21,-15.51
442.65, 15.64,-15.21
442.65, 15.81,-14.69
442.65, 15.74,-13.95
442.65, 15.44,-12.99
442.65, 14.91,-11.83
442.65, 14.19,-10.49
442.65, 13.26,-8.99
442.65, 12.14,-7.36
442.65, 10.79,-5.66
442.65, 9.23,-3.95
Introduction To Cad
Computer-aided design (CAD), also known as com-
puter-aided design and drafting (CADD), is the use
of computer technology for the process of design
and design-documentation. Computer Aided Draft-
ing describes the process of drafting with a com-
puter. CADD software, or environments, provide the
user with input-tools for the purpose of streamlin-
ing design processes; drafting, documentation, and
manufacturing processes. CADD output is often in
the form of electronic files for print or machining op-
erations. The development of CADD-based software
is in direct correlation with the processes it seeks to
economize; industry-based software (construction,
manufacturing, etc.) typically uses vector-based
(linear) environments whereas graphic-based soft-
ware utilizes raster-based (pixelated) environments.
Modeling of Turbine Blade and Shaft
The above image shows blade profile
The above image shows blades pattern model
The above image shows final shaft
The above image shows assembly of blades and shaft
pressure
Specified Initial Steam Pressure (s) 36 ata
Permissible deviation without Limitation
(1)
39 ata
Permissible deviation (2) 39 ata
Permissible deviation Instantaneously
For A Total Duration Of 12 Hours Per
Annam(2)
46.8 ata
Specified initial Steam Tem-
perature (%)
360 ˚C
Permissible Deviation without
Limitation (1)
380 ˚C
Permissible Deviation for
Longer Periods (2)
388 ˚C
Permissible Deviation for 400
hours per annum (2)
394 ˚C
Permissible Deviation for 80
hours per annum (2)
408 ˚C
Maximum Output 3769 KW
Design Rating (Economical
Rating)
3426 KW

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International Journal of Research and Innovation (IJRI)
The thermal readings are taken from the thermal images
taken for the turbine
Introduction to Fea
Finite Element Analysis (FEA) was first developed in
1943 by R. Courant, who utilized the Ritz method of nu-
merical analysis and minimization of variational calculus
to obtain approximate solutions to vibration systems.
Shortly thereafter, a paper published in 1956 by M. J.
Turner, R. W. Clough, H. C. Martin, and L. J. Topp es-
tablished a broader definition of numerical analysis. The
paper centered on the "stiffness and deflection of com-
plex structures".
Structural Analysis Steam Turbine
The above image shows imported Model from creo2.0
(Pro/Engineer)
The above image shows meshed model
Results :
Von Misses Stress
Displacement
Frequency Analysis on Steam Turbine
Displacement

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International Journal of Research and Innovation (IJRI)
Thermal Analysis on Steam Turbine
Nodal temperature
Thermal gradient
Thermal flux
Result Tables And Graphs
s.no Material Stress Strain Displace-
ment
1 Castiron
C70with coating
308.6 0.0023 0.2036
2 AISI 4130 Steel 301.4 0.00078 0.765
3 Zamak 192.9 0.0012 0.123
Conclusion
•A PT2001 turbo dine steam turbine is optimized for
to reduce maintenance. Initially static and thermal
conditions are evaluated using Infra-red thermome-
ter and digital vibrometer. Those readings are taken
for simulation inputs from ATICS
•A FEA model is developed according to given draw-
ing.
•Static analysis is carried out on FE model using
AISI steel (present material), cast-iron C70 with
zirconia coating and zinc aluminum alloy (Zamak)
with zirconia coating.
•Modal analysis is carried out to determine the vi-
brations due to geometry and property of material.
•Thermal analysis is carried out to determine the
thermal behavior like thermal gradient and heat
flux.
•Partially stabilized zirconium is mainly used as a
surface coating to prevent the thermal effect on sur-
face and also it reduces the corrosive effect.
•As per the analytical results ZAMAK material along
with partially stabilized zirconia coating will im-
prove reliability of turbine shaft and blades due to
less stress, negligible displacement and strain val-
ues, also ZAMAK is having good level of thermal
gradient(heat transfer rate) and sufficient heat flux
rate which in turn improves the power generation
rate by reducing the maintenance.

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International Journal of Research and Innovation (IJRI)
References
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India
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tachments of Steam Turbine Last Stage Blades[2],
Alexey I. Borovkov Alexander V. Gaev Computa-
tional Mechanics Laboratory, St.Petersburg State
Polytechnic University, Russia
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Author
K.Khishor Kumar,
Research Scholar,
Department Of Mechanical Engineering,
Mother Theresa Institute of Technology(mist)
Khammam,India
D.Gopichand,
Assistant professor,
Department Of Mechanical Engineering ,
Mother Theresa Institute Of Technology(Mist)
Khammam,India