Life Assessment of Steam Turbine Components Based on Viscoplastic Analysis

Abstract

Unsteady thermal and mechanical loading in turbine components is caused due to the transient regimes arising during start-ups and shut-downs and due to changes in the operating regime in steam power plants; this results in nonuniform strain and stress distribution. Thus, an accurate knowledge of the stresses caused by various loading conditions is required to ensure the integrity and to ensure an accurate life assessment of the components of a turbine. Although the materials of the components of the steam turbine deform inelastically at a high temperature, currently, only elastic calculations are performed for safety and simplicity. Numerous models have been proposed to describe the viscoplastic (time-dependent) behavior; these models are rather elaborate and it is difficult to incorporate them into a finite element code in order to simulate the loading of complex structures. In this paper, the total lifetime of the components of a steam turbine was calculated by combining the viscoplastic constitutive equation with the ABAQUS finite element code. Viscoplastic analysis was conducted by focusing mainly on simplified constitutive equations with linear kinematic hardening, which is simple enough to be used effectively in computer simulation. The von Mises stress distribution of an HIP turbine rotor was calculated during the cold start-up operation of the rotor, and a reasonable number of cycles were obtained from the equation of Langer.