Fatigue Failure Analysis of a Cooling Fan Blade: A Case Study

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1 Fatigue Failure Analysis of a Cooling Fan Blade: A Case Study Triloki Nath Kushwaha * NTPC Limited,Farakka,742236,india -tnkushwaha@ntpc.co.in Astract Cooling tower (CT) fan lade are long in size and made up of FRP(Fier reinforced plastic) ecause of their mass saving advantage, high stiffness-to-density etc. During fan operation, the lade undergoes many forces such as gravitational, centrifugal, forces due to fluid (Drag force) and in addition of it many un-design forces such as non uniform airflow through the fan caused y unevenness of lade pitch angle, difference in height of lades etc. These multiple forces cause loading and unloading of the lade numerous times per revolution and is cyclic in nature and causes fatigue failure of the lade. The failure of one lade also damage other lades, drive shaft and motor frame leg and hence causes huge financial impact as well as fan availaility. In this article, the author present a case study of fatigue failure analysis of the fan lade used in a 500MW unit of a thermal power plant. A 3D modelling of the lade has een developed y Pro-Engineer ased on dimensions of the actual lade used at site and same FEM analysis is carried out y Ansys software. Concurrence etween FEM results and oservations of failing pattern at site has een found. Key words: CT Fan, Blade, Fatigue failure, FRP, FEM 1. Introduction Thermal power plants use a significant volume of water to dissipate the heat of the hot water received from the condensers. Cooling tower (CT) are used in thermal power plant to cool the circulating water are an important part of power plants as it has direct impact on unit efficiency. Induced draft cooling tower as shown in Fig. 1 which required fan to create the daft across inlet and outlet of the tower IDCT fan availaility is vital for the power plant efficiency as well as to keep unit running. The fan assemly consists of fan lades, hu plate and holding V-lock gear ox and drive shaft shown in Fig. 3 Fig:-1.A top view of CT showing fan and stack Fig.:-2. Exploded view of The fan assemly

2 Fig:-3. Schematic representation of the cooling fan assemly, gear ox, drive shaft and motor The lades are made up of FRP (Fier reinforced plastics) the nature of FRP allows us to make any desired shape and twist of the lade as needed to achieve maximum performance. A properly designed fan lade will have a non-symmetrical air foil with a variale chord and twist to compensate for the peripheral change in speed from the lade tip to the wide chord. 2. Prolem Definition. Fig.:-4. Schematic representation of the cooling fan lade. The lade of IDCT fan of the 500MW thermal power unit was failing while in operating at its design point although the fan having its on line protection system for high viration (velocity aove 10mm/s) of its gear ox assemly. As lade having low RPM (105) and made up of FRP as shown in Fig.4 the pre failure symptom could not got acknowledge many times y accelerometer mounted at its gar ox casing. The damage of any one lade ecome primary reason of failure for the other components like drive shaft and motor leg as shown in Fig.-3a-e. The failure is in catastrophic in nature and hence causes huge financial impact as well as availaility of the fan a

3 c d e Fig. 3.Actual image of damaged Fan components(a)complete Fan Assemly with Gear ox () Failed fan lade (c)failed from its neck side (d)fan motor Damaged leg (e)damaged drive shaft 2. Material and method FRP composites are frequently used in such structural applications, Because of their excellent formaility, their mass saving advantage, their high stiffness-to-density and strength-to-density ratios and the greater freedom to use these properties in the desired orientation and position. Furthermore, these lightweight structural materials have some precise ojectives, which cannot e reached with some other conventional materials. The necessary raw materials for the fan lade include Fier Reinforced Epoxy Resin in various forms like chopped strand mat, ravings, woven ravings, cloth surface mat and resin (vinyl ester & polyester), catalysts, accelerator, hardener, pigments, surface treatment agents. The material property of Discussed FRP is given in Tale-1. Tale -1: Material Properties of FRP Composite Fig:-4 Actual image of FRP lade used at site 4. Forces on fan lade During its operation, the fan lade undergoes many forces such as gravitational, centrifugal and air resistance force (Drag force). These forces can cause the failure of the lade.many factors such as variation of the centrifugal stress, shut up/down of the cooling system and mass imalance make the fatigue to e the most proale cause of failure in cooling fan systems. The various forces acting during fan operation are shown in Fig.5 the primary component of the lade force on the air is directed axially from inlet to outlet. The lade force necessarily has an additional component in the tangential direction, providing the reaction to the driving torque. Since mounting orientation of cooling fan shaft is horizontal, weight of lades and its moment must e considered in analysis. From input data and detailed results for the fan type, weight, F w centrifugal, F c axial, F a and tangential, F t forecasting on lades are calculated as follows

4 F w = mg =(64 kg)x ( 9.81m/s 2 )= Fc = mr m w 2 = 64 kg x (1.93 m)x(10.9red/sec) 2 = N F a =Axial thrust/6 =9761/6= N Ft =Fan shaft power/6 x r A x w =123; 700 W Fig. 5 Applied forces on the cooling fan assemly. Where m is the mass of each lade and w is the angular velocity of lades. r m is the distance etween the origin of the coordinate in the centre of the hu plate and mass centre r A is the distance etween the origin of the coordinate in the centre of the hu plate and area centre of lades. After the lade is modelled, r m and r A are calculated using modelling software Pro-E. The directions of applied forces on lades of the cooling fan are shown in Fig. 5. It is noted that the condition of loading is multi axial. Among all forces, the only alternating force is weight force. Except the weight, all forces acting on the lades have fixed direction in relative coordinate system whose axes are rotating with the lade. To otain the stresses on the lades the forces are exerted to the lade, which contact with hu plate and V-lock.. Geometry modelling of the cooling fan including fan lades, hu plate and V-lock is shown in Fig Blade failure analysis A failure analysis of twisted FRP lade has een carried out points were oserved: at site y its failure pattern, following (a)fan lade is failing due to excessive deflection caused y crack initiation at its root ()The excessively deflected lade hits other fan components such as drive shaft got eaked. (c)as every time lade failed has some similarity aout weakest failing cross section. (d)failed lade indicates that its weakest cross-section is neck and at distance ¾ of its total length (L) from tip end. (e) Failure of any one lade ecomes primary reason of failure of other Fan components. 3. Finite element analysis of FRP lade Pro-Engineer software is used for geometry modelling of CT fan lade individually and as complete fan assemly with hu and V-lock as shown in Fig. 5. Force applied to the finite element model is according to the operating condition the fan model MPI1000. An axial fan lade can e considered as cantilever eam on which air pressure and centrifugal force are applied Blade failure due to different forces during its operation is analysed y fixing its one end at hu y V-lock as shown in Fig. 0 and setting the lade with 16 degree angle with horizontal.frp composite lade can e considered as a stepped, taper, continuous cantilever eam. The circular (ho) section of FRP lade has een fixed. Ansys simulation has een done y doing modal analysis using ANSYS Workench. A three dimensional model of lades has een generated in Pro-Engineer. The modal analysis in Ansys is carried out. In modal analysis, first refresh the material and geometry then do meshing, further in an analysis system select numer of modes required, Apply fixed support at circular section of the lade then, Find the solution. The Solution gave maximum principle stress, maximum shear stress and Total deformation.

5 a c d Fig. 6. (a) A 3D Blade modelled in Pro-E () Mesh generated in Ansys (c) Blade (FEM) showing maximum principle stress (d) shear stress distriution 5. Results and discussion On analysis of failed lade y Visual inspection revealed that the lade is failing repeatedly at mainly two point one at its shank/neck portion shown in fig.8a. and second near 1/3 of the lade length Fig.8. From its tip side.

6 a Fig. 7 FEM result showing distriution of the stress (a) At shank portion () Near 1/3 of the lade length from its tip end 5.1 Results of FEM Simulation In line with oservation from on site failing pattern and data analysis a FEM analysis of CT fan lade also carried out y use of Ansys software. It involves study of different modal parameters of system. Ansys simulation has een used to analyze the modal various parameters of FRP lades. Thus avoiding the need for carrying out several experiments which is time consuming and costly. The results presented ahead are the most stressed section of the lade from which proaility of lade failing is highest.the section of lade with higher stress is also shown in Fig.8 (a) and Fig.8 (). a Fig. 8. Image showing actual crack location of fan lade (a)crack at the neck/shank of the lade () Crack from L ¾ of lade from tip side 6. CONCLUSIONS Analysis of loading condition indicates that the lade is under multi axial fatigue. The finite element analysis shows that the nodes having the high stress values are near the neck/shank of the lade and L 1/3 length of the lade from its tip. As compared ANSYS results, with site failure pattern, it is eing oserved that Good agreement etween ANSYS results and experimental results has een found in the failure for a the FRP Composite lade. FEM results are close to the site results. Therefore the aove otained FEM failure analysis can e considered to increase the reliaility of the lade while designing it.

7 References [1]Y. Bedjilili, A. Tounsi, H. M. Berraah, I.Mecha, Natural frequencies of composite eams with a variale fier volume fraction including rotary inertia and shear deformation, Appl. Math. Mech. -Engl. Ed. 30(6), (2009). [2]Viration Analysis of Fier Reinforced Plastic Fan Blade Khandare R.S1, Londhe B.C.2, Ganore D.J.3 Fatigue failure analysis of holding U-olts of a cooling fan lade M. Reihanian a,, K. Sherafatnia, M. Sajjadnejad c [3] Brooks CR, Choudhury A. Failure analysis of engineering materials. 1st ed. USA: McGraw-Hill; [4] Technical data sheet and drawing of the CT fan [5] Operation and maintenance Manual of the cooling tower [6] Dowling NE. Mechanical ehaviour of materials. 2nd ed. USA: Prentice Hall; [7] Bhaumik SK, Sujata M, Venkataswamy MA. Fatigue failure of aircraft components. Eng Failure Anal 2008;15: [8] ANSYS CFX Theory Guide, (2012), ANSYS CFD, v15, ANSYS [9] Pro-E (wildfire 4.0)Theory Guide)

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