Stress Analysis and Life Assessment of the Steam Turbine Rotor During Peak Shaving Transient Processes

Abstract To achieve the net-zero emissions targets, the global share of renewable energy is rapidly increasing. The high penetration of intermittent and variable renewable power necessitates that coal-fired power plants enhance their operational flexibility for peak shaving and frequency regulation. Frequent and rapid start-ups, shutdowns, and peak shaving processes pose significant safety challenges to the steam turbine rotors. This paper investigates the impact of flexible operation on rotor stress. Firstly, an online monitoring model was developed and verified using a finite element model of a steam turbine high-medium pressure rotor. Secondly, the online calculation model was integrated with a dynamic coal-fired unit model developed using the JTopmeret software on the GSE platform, a well-established dynamic simulation tool for nuclear and fossil fuel power plants. Finally, a rotor low-cycle fatigue life assessment model was developed, and the von Mises stress and fatigue life loss under various load variation rates and ranges were determined. As the load variation rate increases, the life loss increases significantly, with maximum von Mises stress amplitudes of 5.2, 6.5 and 7.8 MPa at 1%, 2% and 3% Pe min−1 load variation rates, respectively. Conversely, as the load variation range increases, the life loss decreases substantially, with maximum von Mises stress amplitudes of 9.2 and 5.0 MPa during load variation processes of 50%–75% and 75%–100% THA, respectively. This study provides detailed guidance for optimizing the safe operation and control strategies of coal-fired power plants.