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Frontiers in Energy

ISSN 2095-1701

ISSN 2095-1698(Online)

CN 11-6017/TK

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Front. Energy    2016, Vol. 10 Issue (1) : 88-104    https://doi.org/10.1007/s11708-015-0387-1
RESEARCH ARTICLE
Structure improvement and strength finite element analysis of VHP welded rotor of 700°C USC steam turbine
Jinyuan SHI(),Zhicheng DENG,Yong WANG,Yu YANG
Shanghai Power Equipment Research Institute, Shanghai 200240, China
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Abstract

The optimized structure strength design and finite element analysis method for very high pressure (VHP) rotors of the 700°C ultra-super-critical (USC) steam turbine are presented. The main parameters of steam and the steam thermal parameters of blade stages of VHP welded rotors as well as the start and shutdown curves of the steam turbine are determined. The structure design feature, the mechanical models and the typical position of stress analysis of the VHP welded rotors are introduced. The steady and transient finite element analysis are implemented for steady condition, start and shutdown process, including steady rated condition, 110% rated speed, 120% rated speed, cold start, warm start, hot start, very hot start, sliding-pressure shutdown, normal shutdown and emergency shutdown, to obtain the temperature and stress distribution as well as the stress ratio of the welded rotor. The strength design criteria and strength analysis results of the welded rotor are given. The results show that the strength design of improved structure of the VHP welded rotor of the 700°C USC steam turbine is safe at the steady condition and during the transient start or shutdown process.
Keywords 700°C ultra-super-critical unit      steam turbine      very high pressure rotor      structure strength design      strength design criteria      finite element analysis     
Corresponding Author(s): Jinyuan SHI   
Just Accepted Date: 23 October 2015   Online First Date: 04 January 2016    Issue Date: 29 February 2016
 Cite this article:   
Jinyuan SHI,Zhicheng DENG,Yong WANG, et al. Structure improvement and strength finite element analysis of VHP welded rotor of 700°C USC steam turbine[J]. Front. Energy, 2016, 10(1): 88-104.
 URL:  
https://academic.hep.com.cn/fie/EN/10.1007/s11708-015-0387-1
https://academic.hep.com.cn/fie/EN/Y2016/V10/I1/88
Paramrter Stage
1 2 3 4 5 6 7 8 9 10 11 12
t0/°C 698.45 678.57 667.02 650.87 635.91 621.27 609.30 594.55 578.61 561.90 545.06 527.93
p0/MPa 34.30 30.85 29.08 26.76 24.74 22.92 21.42 19.78 18.14 16.54 15.04 13.63
t1/°C 682.12 671.95 658.51 641.65 628.57 615.29 601.22 585.94 569.92 553.05 535.59 518.14
p1/MPa 31.60 29.95 27.98 25.64 23.95 22.21 20.61 18.97 17.38 15.81 14.33 12.96
t2/°C 678.57 667.02 650.87 635.91 621.27 609.30 594.55 578.61 561.90 545.06 527.93 510.65
p2/MPa 30.85 29.08 26.76 24.74 22.92 21.42 19.78 18.14 16.54 15.04 13.63 12.33
Tab.1  Steam parameters of VHP blade stages
Fig.1  Cold startup of 700°C USC steam turbine
Fig.2  Warm startup of 700°C USC steam turbine
Fig.3  Hot startup of 700°C USC steam turbine
Fig.4  Very hot startup of 700°C USC steam turbine
Fig.5  Sliding pressure shutdown of 700°C USC steam turbine
Fig.6  Normal shutdown curve of 700°C USC steam turbine
Fig.7  Typical positions of stress analysis of VHP rotor of 700°C steam turbine
Fig.8  Calculation results of transient stress field of rotor original design structure at the cold start process of 19200 s
Position Steady rated condition σ eq 2 / σ 0.2 t Cold start 19200 s σ eq 3 / ( 2 σ 0.2 t )
Original Improvement Criteria Original Improvement Criteria
A1 0.11 0.08 1 1.35 0.97 1
A2 0.35 0.33 1 0.72 0.72 1
A3 0.22 0.23 1 0.88 0.87 1
A4 0.32 0.25 1 0.65 0.57 1
A5 0.19 0.19 1 0.62 0.63 1
A6 0.21 0.21 1 0.13 0.13 1
A7 0.27 0.26 1 0.05 0.04 1
A8 0.13 0.16 1 0.03 0.01 1
Tab.2  Calculation results of stress of high temperature segment of original and improved structure of VHP welded rotor
Position Original σ eq 1 / σ 10 5 t Improvement σ eq 1 / σ 10 5 t Criteria
A2-A3 segment 0.46 0.40 0.56
B1-B3 segment 0.19 0.19 0.44
B10-B12 segment 0.24 0.30 0.44
Tab.3  Stress ratio σ eq 1 / σ 10 5 t of original and improved structures of VHP welded rotor
Fig.9  Calculation result of steady temperature field of improved structure of rotor
Fig.10  Calculation result of transient temperature field of improved structure of rotor at the cold start process of 19200 s
Fig.11  Calculation result of transient temperature field of improved structure of rotor at the warm start process of 10200 s
Fig.12  Calculation result of transient temperature field of improved structure of rotor at the hot start process of 3420 s
Fig.13  Calculation result of transient temperature field of improved structure of rotor at the very hot start process of 540 s
Fig.14  Calculation result of transient temperature field of improved structure of rotor at the sliding pressure shutdown process of 10500 s
Fig.15  Calculation result of transient temperature field of improved structure rotor at the normal shutdown process of 7200 s
Fig.16  Calculation result of transient temperature field of improved structure of rotor at the emergency shutdown process of 80 s
Fig.17  Calculation result of steady stress field of improved structure of rotor
Fig.18  Calculation result of steady stress field of improved structure of rotor at 110% rated speed
Fig.19  Calculation result of steady stress field of improved structure of rotor at 120% rated speed
Fig.20  Calculation result of transient stress field of improved structure of rotor at the cold start process of 19200 s
Fig.21  Calculation result of transient stress field of improved structure of rotor at the warm start process of 10200 s
Fig.22  Calculation result of transient stress field of improved structure rotor at the hot start process of 3420 s
Fig.23  Calculation result of transient stress field of improved structure of rotor at the very hot start process of 540 s
Fig.24  Calculation result transient stress field of improved structure of rotor at the sliding pressure shutdown process of 10500 s
Fig.25  Calculation result of transient stress field of improved structure of rotor at the normal shutdown process of 7200 s
Fig.26  Calculation result of transient stress field of improved structure of rotor at the emergency shutdown process of 80 s
Position σ eq 2 / σ 0.2 t σ eq 3 / ( 2 σ 0.2 t ) Criteria
Rated condition 120% rated speed Cold start 19200 s Warm start 10200 s Hot start 3420 s Very hot start 540 s Sliding shutdown 10500 s Normal shutdown 7200 s
A1 0.08 0.16 0.97 0.74 0.62 0.38 0.42 0.53 1
A2 0.33 0.28 0.72 0.59 0.51 0.38 0.43 0.56 1
A3 0.23 0.27 0.87 0.69 0.56 0.46 0.44 0.53 1
A4 0.25 0.18 0.57 0.38 0.23 0.27 0.39 0.41 1
A5 0.19 0.31 0.63 0.39 0.29 0.15 0.31 0.29 1
A6 0.21 0.27 0.13 0.04 0.01 0.13 0.19 0.17 1
A7 0.26 0.33 0.04 0.03 0.07 0.15 0.19 0.17 1
A8 0.16 0.22 0.01 0.04 0.05 0.08 0.11 0.10 1
Tab.4  Calculation results of stress of high temperature segment of improved structure of the VHP welded rotor
Position σ eq 2 / σ 0.2 t σ eq 3 / ( 2 σ 0.2 t ) Criteria
Rated condition 120% rated speed Cold start 19200 s Warm start 10200 s Hot start 3420 s Very hot start 540 s Sliding shutdown 10500 s Normal shutdown 7200 s
C1 0.22 0.38 0.15 0.11 0.09 0.19 0.13 0.17 1
C2 0.59 0.67 0.21 0.26 0.30 0.25 0.23 0.22 1
C3 0.34 0.37 0.16 0.21 0.24 0.17 0.16 0.18 1
C4 0.44 0.57 0.28 0.27 0.29 0.18 0.14 0.14 1
C5 0.01 0.06 0.23 0.22 0.24 0.13 0.13 0.19 1
C6 0.13 0.18 0.09 0.08 0.08 0.06 0.05 0.05 1
C7 0.09 0.12 0.01 0.01 0.01 0.06 0.07 0.08 1
Tab.5  Calculation results of stress of non-high temperature segment of improved structure of the VHP welded rotor
Position σ eq 2 / σ 0.2 t σ eq 3 / ( 2 σ 0.2 t ) Criteria
Rated condition 120% rated speed Cold start 19200 s Warm start 10200 s Hot start 3420 s Very hot start 540 s Sliding shutdown 10500 s Normal shutdown 7200 s
B1 0.30 0.23 0.23 0.21 0.18 0.22 0.19 0.24 0.8
B2 0.24 0.23 0.17 0.13 0.11 0.16 0.18 0.19 0.8
B3 0.18 0.21 0.23 0.17 0.13 0.16 0.18 0.20 0.8
B4 0.28 0.32 0.22 0.21 0.20 0.18 0.16 0.19 0.8
B5 0.29 0.31 0.09 0.07 0.07 0.19 0.18 0.19 0.8
B6 0.44 0.48 0.11 0.12 0.13 0.27 0.25 0.28 0.8
B7 0.25 0.30 0.21 0.20 0.20 0.17 0.15 0.17 0.8
B8 0.26 0.29 0.07 0.05 0.05 0.17 0.17 0.18 0.8
B9 0.40 0.45 0.06 0.08 0.10 0.25 0.24 0.26 0.8
B10 0.22 0.23 0.23 0.19 0.17 0.22 0.16 0.22 0.8
B11 0.27 0.32 0.14 0.11 0.10 0.17 0.19 0.20 0.8
B12 0.44 0.53 0.18 0.17 0.17 0.24 0.25 0.26 0.8
B13 0.40 0.45 0.13 0.15 0.16 0.24 0.22 0.25 0.8
B14 0.40 0.49 0.07 0.09 0.11 0.23 0.22 0.24 0.8
B15 0.61 0.72 0.17 0.19 0.20 0.33 0.29 0.31 0.8
B16 0.37 0.43 0.11 0.14 0.14 0.23 0.21 0.24 0.8
B17 0.37 0.46 0.05 0.08 0.09 0.22 0.21 0.23 0.8
B18 0.57 0.69 0.13 0.16 0.17 0.31 0.29 0.31 0.8
Tab.6  Calculation results of stress of welded seam and heat affected zone of improved structure of the VHP welded rotor
Fig.27  Calculation results of stress ratio σ eq 2 / σ 0.2 t of the high temperature segment of improved structure of the VHP welded rotor at the steady condition
Fig.28  Calculation results of stress ratio σ eq 2 / σ 0.2 t of the non-high temperature segment of improved structure of the VHP welded rotor at the steady condition
Fig.29  Calculation results of stress ratio σ eq 2 / σ 0.2 t of the welded seam and heat affected zone of improved structure of the VHP welded rotor at the steady condition
Fig.30  Calculation results of stress ratio σ eq 3 / ( 2 σ 0.2 t ) of the high temperature segment of improved structure of the VHP welded rotor during the start process
Fig.31  Calculation results of stress ratio σ eq 3 / ( 2 σ 0.2 t ) of the non-high temperature segment of improved structure of the VHP welded rotor during the start process
Fig.32  Calculation results of stress ratio σ eq 3 / ( 2 σ 0.2 t ) of the welded seam and heat affected zone of improved structure of the VHP welded rotor during the start process
Fig.33  Calculation results of stress ratio σ eq 3 / ( 2 σ 0.2 t ) of the high temperature segment of improved structure of the VHP welded rotor during the shutdown process
Fig.34  Calculation results of stress ratio σ eq 3 / ( σ 0.2 t ) of the non-high temperature segment of improved structure of the VHP welded rotor during the shutdown process
Fig.35  Calculation results of stress ratio σ eq 3 / ( σ 0.2 t ) of the welded seam and heat affected zone of improved structure of the VHP welded rotor during the shutdown process
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