POWER March 2013 - 67

PLANT DESIGN
Steam Turbine Blade Reverse
Engineering, Upgrade, and
Structural Design
Steam turbine blade cracking often suggests the need for an upgraded blade
design. Follow the process of reversing engineering a failed blade to produce
a more reliable and efficient design.
By Eugene A. Chisley, PhD, PE and Eric Prescott, Alstom Thermal Services
B
lade reverse engineering is widely
recognized as a crucial step in the
product design cycle. Blade surface
reconstruction is an iterative process to develop
mathematical models from existing
physical objects for finite-element analysis
(FEA), computational fluid dynamics, and
rapid prototyping in order to reduce product
design lead time.
In this process, precise data point measurement
is important to create a valid shape.
Due to the complexity of blade shape, the resultant
model geometry change can lead to a
large alteration in turbine performance (see
sidebar). Therefore, blade shape control is
critical in the design process. In essence, the
blade is a complex cantilever beam, and generating
an accurate simulation result makes
turbine blade analysis challenging.
Finite-element analysis is the accepted
tool for turbine blade structural analysis.
Both the model development upgrades and
analysis will be discussed.
Turbine Blade Design Fundamentals
Turbine blade design involves blade solid
model development, thermo-aerodynamics,
and structural mechanics disciplines.
The process of reverse engineering begins
with determining the function of the machine
part (referred to as " capturing design
intent " ). The accuracy of reverse engineering
is limited by the applied measurement
and computer-aided modeling techniques.
A few of the major limitations are wear of
the part; numerical, sensing, and approximation
errors; and manufacturing methods.

http://www.powermag.com

POWER March 2013

Table of Contents for the Digital Edition of POWER March 2013

Contents
POWER March 2013 - Cover1
POWER March 2013 - Cover2
POWER March 2013 - Contents
POWER March 2013 - 2
POWER March 2013 - 3
POWER March 2013 - 4
POWER March 2013 - 5
POWER March 2013 - 6
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POWER March 2013 - Cover3
POWER March 2013 - Cover4
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