A

THESIS REPORT

ON

“Structural and CFD Analysis of Steam Turbine Blade”

Submitted in partial fulfillment of the

Requirements for the award of the degree

of

BACHELOR OF TECHNOLOGY

in

MECHANICAL ENGINEERING

by
Hritik Anand (Regn No - 18030490038)
Jyotsna Priyadarshi (Regn No- 18030490039)
Kushagra Kumar (Regn No- 18030490041)

DEPARTMENT OF MECHANICAL ENGINEERING

B.I.T. SINDRI

SINDRI – 828123 (INDIA)

MAY, 2022
 CANDIDATE’S DECLARATION

I hereby declare that the work carried out in this report titled “Structural and CFD Analysis
of Steam Turbine Blade” is presented on behalf of partial fulfillment of the requirements for
the award of the degree of Bachelor of Technology with specialization in Mechanical
Engineering submitted to the department of Mechanical Engineering, B.I.T. Sindri, India,
under the supervision and guidance of Prof. Pankaj Kumar, Assistant Professor, Mechanical
Engineering, B.I.T. Sindri, India.
I have not submitted the matter embodied in this report for the award of any other degree
or diploma.

Hritik Anand (Regn No - 18030490038)

Date: - 02nd June 22
Jyotsna Priyadarshi (Regn No- 18030490039)
Place: Sindri Kushagra Kumar (Regn No- 18030490041)

i
 B.I.T. SINDRI
(DEPARTMENT OF SCIENCE & TECHNOLOGY, GOVT. OF JHARKHAND, RANCHI)
P.O. SINDRI INSTITUTE, DHANBAD-828123

DECLARATION CERTIFICATE

This is to certify that the work presented in this thesis entitled "Structural and CFD Analysis
of Steam Turbine Blade" submitted by Hritik Anand(Regn No - 18030490038), Jyotsna
Priyadarshi(Regn No - 18030490039), Kushagra Kumar(Regn No - 18030490040) under
the supervision and guidance of Prof. Pankaj Kumar, Assistant Professor, Mechanical
Engineering, B.I.T. Sindri, India.

Prof. Pankaj Kumar, Prof. Manoj Kumar,

Assistant Professor, Head of Department,
Mechanical Engineering Mechanical Engineering

ii
 B.I.T. SINDRI
(DEPARTMENT OF SCIENCE & TECHNOLOGY, GOVT. OF JHARKHAND, RANCHI)
P.O. SINDRI INSTITUTE, DHANBAD-828123

CERTIFICATE OF APPROVAL

This is to certify that the thesis entitled "Structural and CFD Analysis of Steam Turbine
Blade" submitted by Hritik Anand(Regn No - 18030490038), Jyotsna Priyadarshi(Regn
No - 18030490039), and Kushagra Kumar(Regn No - 18030490040) in partial fulfillment of
the requirement for the award of Bachelor of Technology in Mechanical Engineering at BIT
Sindri is an authentic study and design work carried by them under my supervision. To the best
of my knowledge, the matter embodied in the thesis has not been submitted to any other
university/institute for the award of any master’s, degree or diploma.

Prof. Pankaj Kumar Prof Manoj Kumar

Supervisor HOD
Dept. of Mechanical Engineering Dept. Of Mechanical Engineering
BIT SINDRI, DHANBAD BIT SINDRI, DHANBAD

External Examiner

iii
CONTENTS:

Chapter Title Page no.

Abstract ix
Chapter 1 Introduction 1-4
1.1 Steam Turbine 2
1.2 Working Principle of Steam Turbine 2
1.3 Turbine Blades 3
1.4 Blade Design 3
1.5 Problem Definition 4
Chapter 2 Literature Review 5-6
Chapter 3 Objective and Methodology 7-8
3.1 Objective 8
3.2 Methodology 8
Chapter 4 Structural Simulation in Ansys 9-27
4.1 Finite Element Method 10
4.2 Analysis Procedure in Ansys 10
4.3 Meshing of Model 13
4.4 Assigning Material Properties 14
4.5 Static Structural Analysis 14
4.6 Modal Analysis 20
4.7 Response Surface (Twist Analysis) 24
Chapter 5 CFD Simulation in Ansys Fluent 31-35
5.1 CFD Analysis if Turbine Blade 31
Chapter 6 Conclusion 36
References 38

iv
LIST OF FIGURES:

Figure No. Figure Title Page No.

1.1 Cross-Section of an airfoil 3
3.1 Profile 1 11
3.2 Profile 2 11
3.3 Steam Turbine Blade CAD model views 12

4.1 Tetrahedral Meshed Model views 13

4.2 Total Deformation 14

4.3 Equivalent Stress 15

4.4 Equivalent Strain 16

4.5 Mode Shapes 17

4.6 Natural Frequencies 21

4.7 Total deformation vs twist angle of blade profile 26

4.8 Equivalent stress maximum vs twist angle 25

4.9 Safety factor vs twist angle 27

4.10 Equivalent Stress vs Rotational Velocity and Twist Angle 28

4.11 Equivalent Strain vs Rotational Velocity and Twist Angle 29

4.12 Equivalent Strain vs Rotational Velocity and Twist Angle 30

5.1 Pressure Contour of Base Profile 32

5.2 Velocity Streamline of Base Profile of Blade 34

5.3 Velocity Vector of Base Profile 34

5.4 Pressure Contour of Top Profile of Blade 34

5.5 Velocity Vector of Top Profile of Blade 35

5.6 Velocity Streamline of Top Profile of Blade 35

v
LIST OF TABLES:

Table No. Figure Title Page No.

3.1 Coordinates of profile 1 11
3.2 Coordinates of profile 2 11
4.1 Mechanical Properties of the three materials 14
4.2 Comparison of simulation results for different materials 19
4.3 Results of Modal Analysis 23
4.4 Sample Design Points from Simulation 24

vi
 ABSTRACT

With the ever-growing demand of electricity, turbomachinery has become more vital in
the energy generation sector. Almost 80% of the needs are fulfilled by generation through
turbomachinery. With the advent of technology more sophisticated turbines are being built to
enhance the efficiency and life of the turbine. One of the most important components of steam
turbine is turbine blade. Blades are responsible for guiding the heated steam entering the
turbine. The gliding of steam over the turbine blades causes them to rotate which further causes
the shaft to rotate and produce electricity. While designing the turbine blade it is important to
take into consideration the mechanical and aerodynamic structure. The blades must be
mechanically strong enough to tackle the stress due to centrifugal forces, dynamic steam forces,
thermal stresses and vibrations. Blades of last stage low pressure steam turbine incur greater
centrifugal stresses, bending moments and corresponding vibrational deformations. In the
following project we intend to perform structural and modal analysis of Low-Pressure steam
turbine blade to estimate the stress, strain, vibration and deformation in various parts of the
turbine blade in order to strengthen them further. Blade section has been designed based on
geometric dimensions specified in US Patent (1). On this geometry various analysis have been
done in Ansys to carry out detailed structural analysis of the design. Twist of blade profile
facilitates the increase in blade rotation speed. Response surface has been used in Ansys to
come vary twist angles and Response Surface Optimization (RSO) has been used to come to
conclusion as to what degree the blade profile can be safely twisted.
Keywords- Structural Analysis, Modal Analysis, Twist Analysis, Response Surface, RSO

vii
CHAPTER 1: INTRODUCTION

1
1.1 Steam Turbine

Steam turbine is an engine where heat energy from high pressure, high temperature steam is
converted into mechanical energy which is further converted into electrical energy. Steam is
expanded in the turbine in multiple stages which are high, intermediate and low-pressure
stages to generate the energy. Steam turbine is so designed as to extract maximum quantity
of energy from the working fluid into useful work by utilization of minimum cost, maximum
reliability, minimum utilization and minimum supervision. In turbine power is generated by
rate of change of momentum of high velocity jet of steam that impinge on the curved blades
of turbine. The energy of high temperature and high pressure heated steam is used to obtain
power by expanding through several rings of fixed and moving blades. A composite material
is a combination of different materials with considerably different.

1.2 Working Principle of Steam Turbine

The steam gets expanded in the turbine and its heat energy is converted into mechanical work.
This steam is generated in boiler and expands over a series of fixed and moving blades. Steam
turbine operates on thermodynamic cycle called “Rankine Cycle”.

Steam Turbine Types can be classified based on various parameters as follows

According to the action of steam:

Impulse Turbine and
Reaction Turbine
Based on the number of pressure stages or impellers:
Single-stage Turbine and
Multistage Turbine

Major components of steam turbine are:

• Casing
• Rotor
• Blades
• Governor for speed control
• Servo Mechanism
• Oil Pump for lubrication

Multi stage turbines have stages that are grouped in different sections and depending on
pressure levels the sections are known as high pressure section, intermediate pressure section
and low-pressure section.

2
1.3 Turbine Blades

The rotor blades of the turbo machine are very critical components and the operation of
turbo machine as a whole depends on their reliable operation. Turbo machine rotor blades
are subjected to different types of loading such as fluid or steam forces, inertia loads and
centrifugal forces. Due to these forces various stresses are induced in rotor blades. So, stress
and strain mapping on a rotor blade provide a vital information concerning the turbo
machine design and lead to the detection of critical blade section.

The major cause of break down in turbo machine is the failure of rotor blade. The failure of
the rotor blade may lead to catastrophic consequences both physically and economically.
Hence, the proper design of the turbo machine blade plays a vital role in the proper
functioning of the turbo machine.

A good design of the turbo machine rotor blading involves the following:

• Determination of geometric characteristics from steam dynamic analysis

• Determination of steady loads acting on the blade and stressing due to them
• Determination of natural frequencies and mode shapes
• Determination of unsteady forces due to stage flow interaction
• Determination of dynamic forces and life estimation based on the cumulative damage
fatigue theories
•
Blades may be considered to be the heart of turbine and all other member exist for the sake
of the blades. Without blade there would be no power and the slightest fault in blade would
mean a reduction in efficiency and costly repairs. The following are some of the methods
adopted for production of blades.

1.4 Blade Design

While designing the geometry of blade, stagger angle, inlet and exit camber angles, camber
line and thickness distribution are considered. Blade profiles are airfoil in shape for better
aerodynamic performance.

Fig-1.1 Cross-Section of an airfoil

3
 Main parts of an air foil are:
Leading Edge: Leading edge is that portion which meets the steam first. If the airfoil has
to perform at high speed its leading edge would be sharp and if it has to generate higher lift
at relatively lower speed then it would be thick.
Trailing Edge: Trailing edge is the end of the airfoil. It is the point where the steam over
the upper surface and that flowing over the lower surface meet.
Chord: Chord is the line that joins leading edge to trailing edge.
Camber: Camber is the locus of all the midpoints of upper and lower surface. It determines
the amount of lift that can be produced by the airfoil.

Mach number is an important parameter while designing turbine blades. NACA-65 profiles
are used for low to intermediate subsonic Mach range. Double circular arc (DCA) and multi-
circular arc (MCA) profiles are used for intermediate Mach numbers. For turbine blades of
transonic Mach range, Controlled Diffusion profiles are used in order to reduce shock losses.
The design consideration involves achievement of maximum lift force , minimum viscous
force.

1.5 Problem Definition

Major challenge faced during turbine blade design is reducing the creep developed due to
thermal stress. Stream turbine blade gets damaged due to high temperature and mechanical
stress. As temperatures are increased in an effort to improve turbine efficiency, creep
becomes significant. In order to counter creep thermal-coating and super alloys with solid
solutioning strengths are used Using a thermal protective coating limits the temperature
exposure of the nickel super alloy. This reduces the creep mechanisms experienced in the
blade.
All modern steam power plants use impulse-reaction turbines as their blading efficiency is
higher than that of impulse turbines. Last stage of steam turbine impulse-reaction blades
very much directly affects the efficiency of plant. The long length of last stage steam turbine
blades exposes them to high level of stresses and strains, centrifugal stress, steam induced
stress, fatigue and thermal stress etc. Twisted blades increase the velocity and make the
blades more efficient but at the same time increase the exposure to stresses. An
understanding of the forces and stresses acting on the turbine blades is of vital importance:
therefore, in this work we will compute such forces acting on a last stage Low Pressure (LP)
blade of a large steam turbine rotating at high rpm in order to estimate the material stresses
at the blade root.

4
CHAPTER 2: LITERATURE REVIEW

5
O F Ogunbiy et al.[1] study the thermos-mechanical simulation of turbine blade using
Ansys.In the analysis it was found that the maximum principle stress is located at the root of
the blade on the trailing edge. This signifies that crack initiation will take place from roots
T. Tanuma[4] has vividly described the development of last stage steam turbine blade and
various forces that determine the design parameters. This paper focuses on forces on last
stage steam turbine blade due the large annulus area of these blades. Due to increased area
these blades are subjected to much larger centrifugal forces and bending moments.
Mechanical design as well as aerodynamic performances have been considered.The
procedure and specifications of steam turbine blade have studied on. In order to increase the
annulus area last stage blade length and pitch circle diameter are designed to be as large as
possible.
L. Witek et al.[5] have carried out experimental vibrational analysis of prototype of turbine
blade in laboratory. Further modal analysis has been performed in software to find out
different vibrational mode shapes and the two, experimental analysis and software
simulations have been compared to find the differences.
A M Kokong et al[6] 2021 in their journal has evaluated the natural frequency of last stage
steam turbine. Using FE , different mode shapes and associated natural frequencies have been
found at corresponding RPMs.
Abolaji Joseph Omosanya et al.[7] have performed analysis with different twist angles for
turbine blades. Increseing the twist angle increases the velocity of turbine howver also blades
are also subjected to higher stresses. Therefore designer needs to arrive at an optimum twist
angle
Shivkumar Pennaturu et al. [8] have performed CFD analysis and turbine blade in order to
visualize and analyse the flow of steam around the turbine blade and lift generated by steam

6
CHAPTER 3: OBJECTIVE AND METHODOLGY

7
3.1 Objective

Based on the conclusions of the conducted literature survey, the following are research
objectives.
• To make a 3D model of steam turbine blade and study the structural - thermal
behaviour of the steam turbine blade with different materials by performing the
finite element analysis.
• To perform modal analysis and find out fundamental frequencies and mode
shapes.
• To perform CFD analysis to visualize and analyze the steam flow over the blades
of turbine.

3.2 Methodology

The methodology followed in the work is as follows:

A. 3D model of the steam turbine blade is to be designed using Design Modeler in Ansys.
B. Meshing of the geometry is done and boundary conditions are applied
C. Static and thermal analysis on the steam turbine blade is to be performed
D. Stress, strain and deformations distributions are to be obtained. Graphs are to be studied.

The scopes of this proposed project are

1. To generate 3-dimensional geometry model in CAD software of the steam turbine
blade.
2. To perform structural analysis on the model to determine the stress, shear stress,
deformation, of the component under the static- thermal load conditions.
3. To compare analysis between three different materials of steam turbine blade.
4. To perform modal analysis to evaluate natural/fundamental frequencies and mode
shapes of the blade
5. To perform response surface optimisation to find out optimum twist angle of
steam turbine blade

8
CHAPTER 4: STRUCTURAL SIMULATION IN ANSYS

9
4.1 Finite Element Method

In finite element method the model is discretized into finite numbers of small elements by
meshing. Further the boundary conditions in terms of loads and displacements are applied
on the meshed model and governing equations are solved on these elements which are
then interpolated on the whole body to obtain simulation. The discretized body consists of
nodes and elements. Nodes are the boundary of elements and connect them. In FEA the
CAD model is converted into a mathematical model consisting of partial differential
equations.

4.1.1 FEA Equations

The set of nodal displacements with minimum total potential energy is found in order to
arrive at the state of equilibrium of the physical body. This leads to the formulation of
FEA equations for static analysis:
K*d = F (5.1)
where the body is discretised in the form of spring mass system. K is the stiffness matrix;
F is the known vector of nodal loads and d is the vector of unknown displacements. The
equation is a set of linear algebraic equations to be solved by the solver. Displacements is
found out and stress, strain values are determined thereof.

4.2 Analysis Procedure in Ansys

After geometry creation and meshing, static structural, modal analysis and response
surface optimization are carried out in Ansys. Analysis procedure in Ansys involves pre-
processing, solution and post-processing. Steps followed in the software are:
➢ Assigning material properties
➢ Creating or importing geometry
➢ Model creation (applying meshing)
➢ Setup (boundary conditions)
➢ Solution
➢ Results

10
 Following are the steps performed:

The model was created in Design Modeler of Ansys Workbench by importing the
coordinates of blade profile.

Fig-4.1 Profile 1 Fig-4.2 Profile 2

Profile 1 Profile 2
Coordinates(x,y) Co-ordinates(x,y)
-37.825, -22.10 -39.250, -6.371
-36.727, -25.93 -38.771, -6.795
-1.969, 17.462 -6.929, 5.568
6.027, -0.430 4.076, -1.554
62.120, -28.937 60.551, -6.213
60.824, -30.53 60.213, -7.167

Table-4.1 Coordinates of profile 1 Table-4.2 Coordinates of profile 2

The coordinates of base and the top profiles are imported to respective airfoil surfaces and
then skin/loft command is used to create the 3D model.

The geometry is then used for further analysis process.

11
a. b.

c. d.

Fig-4.3 Steam Turbine Blade CAD model views

12
4.3 Meshing of the model

After geometry creation, meshing of the model is done to discretize it and further carry out
analysis. Turbine blade is meshed with a mesh size of 5 mm and mesh geometry is
tetrahedral.

b.

Fig-4.4 Tetrahedral Meshed Model views

13
4.4 Assigning Material Properties
Following materials are created in the Ansys system and their properties are assigned

S.No. Material Variables Stainless Titanium Chrome Steel Units

Steel Alloy
1 Density 7750 4620 7810 Kg/m3
2 Coefficient of thermal 1.7x10-5 9.4x10-6 1.4x10-5 C-1
expansion
3 Young’s Modulus 1.93x1011 9.6x1010 2.06x1011 Pa
4 Poisson’s Ratio 0.31 0.36 0.30
5 Bulk Modulus 1.693x1011 1.1429x1011 1.7167x1011 Pa
6 Shear Modulus 7.3664x1011 3.5294x1010 7.9231x1010 Pa
7 Tensile Yield Strength 2.07x108 9.3x108 7.35x108 Pa
8 Compressive Yield 2.07x108 9.3x108 7.35x108 Pa
Strength
9 Tensile Ultimate 5.86x108 1.07x109 8.8x108 Pa
Strength
10 Isotropic Thermal 15.1 21.9 28 W.m-1C-1
Conductivity
11 Specific Heat 480 522 J.kg-1
12 Isotropic Resistivity 7.7x10-7 1.7x10-6 1.25x10-7 Ω.m
Table-4.3 Mechanical Properties of the three materials

4.5 Static Structural Analysis

In static structural analysis we evaluate the stresses, strains, displacements in various parts of
the structure and identify the critical parts in the model. Static loading analysis were carried
out on the steam turbine blade for three different materials Chrome Steel, Stainless Steel, and
Titanium Alloy (Ti-6Al-4V). The three different materials were subjected to the same
boundary conditions. The effect of steam on the blade of last stage turbine were analyzed.
The base of the blade is the hub which used as fixed constraint. Contour plots for different
materials are presented to compare for stress, strain and deformation.

4.5.1 The comparative results of stress, strain and deformation of different materials
are as follows:

14
Total Deformation

a. Stainless Steel

b. Chrome Steel

15
 c. Titanium Alloy
Fig-4.5

Equivalent Stress

a. Stainless Steel

16
b. Chrome Steel

c. Titanium Alloy
Fig-4.6

17
Equivalent Strain

a. Stainless Steel

b. Chrome Steel

18
 c. Titanium Alloy

Fig-4.7

4.5.2 Results and discussion

Properties Titanium Alloy Stainless Steel Chrome Steel

Maximum Von- 305.49 434.63 436.71
Mises stress(MPa)
Maximum 0.003535 0.008240 0.008236
Equivalent Strain
Maximum 2.6335 3.0442 3.8048
Deformation(mm)
Table- 4.4 Comparison of simulation results for different materials

After analysis it was found that for Stainless Steel , maximum von-mises stress is greater
than its yield strength which means that the blade of this material will fail under this
operating condition. Also Titanium alloy has minimum von-mises stress.The result shows
that out of the three materials Titanium Alloy is the superior one and very much suitable
and sustainable and further analysis have been done with Titanium alloy as the material.

19
4.6 Modal Analysis

Modal analysis comes under dynamic analysis .Modal anlysis is used for finding out natural
frequencies and Assistantd shapes of vibration of the body. When a body vibrates under
the absence of any external damping and excitation forces it is known as free vibration and
the corresponding ferquncies of vibration are called as natural frequencies. If an external
excitation force applied on a body coincides with its natural frequencies then the
phenomenon of resonance takes place and the amplitude of vibration is high enough to
cause large deformations and destruction.Each mode and its Assistantd shapes denotes
the situation when stiffness forces cancel out with inertial forces.

Since modal analysis is a dynamic analysis the governing mathematical model equation
involves damping and intertial effects and load is a function of time.

Equation for dynamic analysis:

Md’’ + Cd’ + Kd = F(t)
where
M – mass matrix : known
C – damping matrix: known
K – stiffness matrix: known
F – vector of nodal loads: known
d – vector of nodal dispalcements: unknown

For modal analysis the vibration is free and undamped where [F(t)] = 0 (no excitation force)
and [C] = 0 (no damping). The simplified equation is:
Md’’+ kd = 0
Unsupported 3D model has first six rigid body modes with zero frequency(or very close to
zero because of discretization error) corresponding to three translational and three
rotational directions.Partially supported or pre-stressed model returns as many zero
frequnecy modes as there are rigid motions in the body

4.7 Modal Analysis of Steam Turbine Blade

To avoid mechanical resonance the fundamental frequency of turbine generators must be
kept into consideration.If rotaing machine spins near any of the funadmental frequencies
resonance might occur causing vibrational damage.In the following analysis vibration
mode, corresponding frequency were found out for the blade of last stage steam turbine
blade. Pre-Stressed modal analysis has been done to evaluate the vibration characteristics
of the steam turbine blade. Pre-Stressed conditions hacve been applied from the static
structural bounday conditions.

Following are the mode shapes and first six natural frequencies at 3000 rpm:

20
a. Mode Shape 1

b. Mode Shape 2

c. Mode Shape 3

21
d. Mode Shape 4

e. Mode Shape 5

f. Mode Shape 6
Fig-4.8

22
 4.7.1 Results and Discussion
Following are the natural frequencies which must be kept into consideration while
designing the blade in order to account for the excitaion forces of correspoding
frequencies.

Fig-4.9 Natural Frequencies

Total Total Total Total Total Total

Object Total
Deformation Deformation Deformation Deformation Deformation Deformation
Name Deformation
2 3 4 5 6 7
State Solved
Scope
Scoping
Geometry Selection
Method
Geometry All Bodies
Definition
Type Total Deformation
Mode 1. 7. 8. 9. 10. 11. 12.
Results

Minimum 225.94 mm 0.10422 mm 1.7952 mm 1.2045 mm 0.93582 mm 1.3752 mm 1.3885 mm

Maximum 814.92 mm 1455.9 mm 1497.6 mm 2157.8 mm 1444.4 mm 1579.1 mm 2439.7 mm

Average 449.93 mm 394.32 mm 403.1 mm 413.83 mm 425.13 mm 408.07 mm 390.27 mm

Frequency 0. Hz 84.617 Hz 225.77 Hz 295.98 Hz 313.57 Hz 432.85 Hz 589.6 Hz

Table-4.5 Results of Modal Analysis

23
4.8 Response Surface for Twist Analysis

To study the effect of twist aangle on turbine blade we perform response surface
optimisation in Ansys.
The response for the output variables – the equivalent shear stress, total deformation and
factor of safety for the Titanium Alloy blade were analysed for different twist angles in
different ranges. Different design points are employed to capture corresponding changes
in output variables.Below is the table for values.

Table-4.6 Sample Design Points from Simulation

24
4.8.1 Results and Discussion

Relation between different parameters are analysed.

➢ Total Deformation vs Twist Angle

Following graph states the relation between total deformation and twist angle.With increase
in twist angle total deforamtion increases.

Fig-4.10 Total deformation vs twist angle of blade profile

25
➢ Equivalent Stress Maximum vs Twist Angle

According to the following graph stress increases with increase in twist angle.

Fig-4.11 Equivalent stress maximum vs twist angle

26
➢ Safety Factor vs Twist Angle

The following graph shows realtion between safety factor and twist angle and as curve
depicts safety factor decreases with increaing twist angle.

Fig-4.12 Safety factor vs twist angle

27
➢ Equivalent Stress vs Rotational Velocity and Twist Angle

The following surface graph depicts how stress changes with different values of rotaional
velocity and twist angle both taken into account.

Fig-4.13 Equivalent Stress vs Rotational Velocity and Twist Angle

28
➢ Equivalent Strain vs Rotational Velocity and Twist Angle

The following surface graph depicts how strain changes with different values of rotaional
velocity and twist angle both taken into account.

Fig-4.14 Equivalent Strain vs Rotational Velocity and Twist Angle

29
➢ Safety Factor vs Rotational Velocity and Twist Angle

The following surface graph depicts variation of safety factor with different values of
rotaional velocity and twist angle both taken into account.

Fig-4.15 Equivalent Strain vs Rotational Velocity and Twist Angle

30
CHAPTER 5: CFD SIMULATION IN ANSYS

31
5.1 CFD Analysis of Turbine Blade
CFD simulation is done to analysis the behaviour of fluid around solid.The simulation of flow
of steam over the blade enables to visualise velocity changes and pressure changes over the
blade. This would help to better understand the momentum and velocity and pressure
being caused by the flow of steam over the blades of turbine.
Ansys Fluent has been used to carry out the simualtion.Boundary conditions of inlet and
outlet pressure have set on previously meshed cad model of turbine blade and then solved
in fluent .
Following are the contou plots, streamline plots and vector plots of velocity and pressure
distribution around the blade profile.

Fig-5.1 Pressure Contour of Base Profile

32
Fig-5.2 Velocity Streamline of Base Profile of Blade

Fig-5.3 Velocity Vector of Base Profile

33
Fig-5.4 Pressure Contour of Top Profile of Blade

Fig-5.5 Velocity Vector of Top Profile of Blade

34
 Fig-5.6 Velocity Streamline of Top Profile of Blade

There is lift being created by the steam flow as is visible in the velocity streamline diagram.

35
CHAPTER-6 CONCLUSION

36
Modelling and analysis of steam turbine blade is done considering different materials.
Obtained von mises stress, shear stress, deformations, and temperature distributions are
compared to arrive at the best material. After simulation, Titanium alloy is found to be the
best material for the design of last sage steam turbine blade. Different twist angles of blade
have been analysed to arrive at the best design. Following are the allowable twist angles
with minimum stress and deformation. Design would be safe and efficient with the
following values:
Twist angles of 32 degrees, 35 degree and 30 degrees have been found to be safe for
designing of blade with minimum deformations, minimum stress and maximum factor of
safety.
CFD analyses enabled to visualise the flow of steam around the turbine blade.
Modal analysis has helped to find different modes shapes associated with destructive
vibrational modes.

37
References
[1] O F Ogunbiy, “Thermo-mechanical simulation of steam turbine blade with spark
plasma sintering fabricated Inconel 738LC superalloy properties”, IOP Conf. Ser.:
Mater. Sci. Eng. 655 012046,2019
[2] Paul M. Kurowski, “Finite Element Analysis for Design Engineers”, Second Edition,
SAE International.
[3] “Technical Data for the BHEL 500 MW Steam Turbine”, McGrawHill Edication
[4] T. Tanuma, “Development of last-stage long blades for steam turbine”,Japan
[5] L. Witek and F. Stachowicz, “MODAL ANALYSIS OF THE TURBINE BLADE AT
COMPLEX THERMOMECHANICAL LOADS”, Strength of Materials, Vol. 48, No.
4, July, 2016
[6] A M Kokong, “Natural Frequency Evaluation of Last Stage Steam Turbine Blade
Power Plant Using Finite Element Method”, IOP Conf. Ser.: Mater. Sci. Eng. 1096
012092, 2021
[7] Abolaji Joseph Omosanya, “Static Analysis of the Last Stage Low Pressure Steam
Turbine Blade to Improve Blade twist Angle”, IOP Conf. Ser.: Mater. Sci. Eng. 1107
012056, 2021
[8] Sivakumar Pennaturu, Dr P Issac prasad, “Evaluating Performance of Steam Turbine
using CFD”, International Journal of Latest Trends in Engineering and Technology
(IJLTET), Vol. 4 Issue 2 July 2014

38