Fatigue analysis in rotor of a prototype bulb turbine based on fluid-structure interaction

Abstract

Bulb turbine units are widely used in run-of river or dam projects with relatively low head, and can also be used for tidal energy utilization. Some types of bulb turbines have excessive vibration and fatigue failure problems, which threats their fatigue life. The model analyzed in this paper is a prototype bulb turbine rotor which suffered cracks, probably due to erosion and welding defects. The dynamic stress characteristics are analyzed under not only the non-cracked shaft condition but also the cracked one, to find possible causes of the failure.The computational fluid dynamics (CFD) simulation is performed to obtain reliable hydraulic load on the runner for performing the FEM analysis. The CFD results are verified by comparing with the site test for the prototype one. The linear elastic fracture mechanics theory combined with the fluid-structural interaction theory is applied to developing a cracked FEM model, to obtain the dynamic stress characteristics for the runner, shaft and rotor. The results reveal that the change in dynamic stress level on the shaft flange root significantly depends on the operating conditions, and the stress amplitude on the shaft mainly depends on the structural weight. The stress at the cracked zone could be up to 376.5 MPa in the best efficiency point, with only 1.5 years of fatigue life.Based on the numerical calculations and site inspection, it could be concluded that the insufficient sealing could lead to leakage flows with specific flow rates in flange root, which resulted in the occurrence of erosion; in addition, the welding at the flange root probably generated tiny defects. These two factors are likely lead to fatigue cracks and major failure of the shaft. Suggestions for solutions for the problems of the shaft are also discussed. Results of this study helps to find the reasons of the shaft fatigue failure. Furthermore, the analysis method could be used for an accurate calculation of fatigue life and providing guidance in future designs and operations of bulb turbine units.