Crack evaluation and subsequent solution of the last stage blade in a low-pressure steam turbine

A crack of the last stage blade in a low-pressure steam turbine is studied. From non-destructive inspection, the crack was found at the trailing edge fillet of the last stage blade. On further examination using the replication of the crack and scanning electron microscopy, the crack was induced by stress corrosion cracking. The blade integrity is evaluated for several crack-removal conditions to repair the cracked blade. Finite element analysis is utilized to determine the stresses and dynamic characteristic of the blade for these conditions. The assessment of high cycle fatigue is performed by modified Goodman diagram. From the results, it is found that the crack-removal blade satisfies the design criteria for the fatigue life and has the sufficient margin from resonant condition of vibration. Repair for the cracked blade would be recommended on the basis of the careful analysis. For the repaired blade, periodic inspection is needed and replacement of the blade will be necessary when an indication is found. (C) 2010 Elsevier Ltd. All rights reserved.