Deep Part Load Research Articles

A numerical study on the effect of spanwise installation of vortex generators on Francis runner blades

Abstract Hydro turbine operation far off from its best efficiency point introduces vortices and swirl that detaches flow from the blade surface. This break-off of flow accounts to loss in hydrodynamic lift accompanied by pressure fluctuations and vibration that leads to poor performance and mechanical failure of the turbine blades. Vortex generators (VGs) are efficient passive devices deployed to enhance aerodynamic lift of wind turbine blades and aircraft wings and can improve hydrodynamic lift on turbine runner blades as well. This study aims to investigate on the possibility of installation of VGs on the runner blade at leading edge, midspan and trailing edge of the runner blade. The study is carried out on a model Francis turbine developed at Waterpower Laboratory, NTNU. The numerical study is mainly focused on improving performance of the turbine at low speed as well as at the best efficiency speed. The operating head selected for the study is 11.94 m and the speed of the turbine is varied from 233 rpm to 433 rpm at an increment of 25 rpm. The turbine is simulated at different positions of guide vanes and hydraulic performance is calculated and the results of the analysis are compared with reference case without VGs. The results at deep-part load show major improvement in runner efficiency with increment in values up to 4%. The core purpose of the research is to develop effective techniques to operate traditional turbine runner at variable speed with cost-efficient minimal modifications in the geometry of the runner blades.

Numerical investigation on vortex characteristics in a low-head Francis turbine operating of adjustable-speed at part load conditions

In this paper, the vortex characteristics in a low-head Francis turbine operating of adjustable-speed at part load conditions are numerically investigated. First, the rules of fixed-speed and adjustable-speed operations are introduced in detail, aiming at operating limits extension. Second, comparative analysis on vortex rope is conducted, with emphasis on vortex rope volume, tail water excitation and spontaneous power swing. Finally, inter-blade vortex has been analyzed and successfully demonstrated, and its induced high amplitude pressure fluctuation characteristic is explored. It is found that at deep part load, vortex rope volume and power swing coefficient of adjustable-speed operation decreased by 69 % and 61 % respectively. The amplitude of Rheingans frequency decreased by 17 %, while the amplitude of blade passing frequency increased by 83 %. After decreasing runner speed, inter-blade vortex is stranded at blade suction surface leading-edge. In addition to low-frequency disturbance, pressure fluctuation shows high-frequency wide-band characteristics. It is concluded that adjustable-speed operation has beneficial effects on improvement of cavity cavitation and energy stability. As for hydraulic stability, the Rotor-Stator Interaction effect cannot be ignored. After changing runner speed, the inter-blade vortex becomes more serious, which could provoke low-cycle and high-cycle fatigue of the blades.

Experimental Investigation of Part Load Vortex Rope Mitigation With Rod Protrusion in an Axial Turbine

Abstract The present paper investigates the rotating vortex rope (RVR) mitigation on an axial turbine model by the radial protrusion of four cylindrical rods into the draft tube. RVR mitigation is of particular interest due to the unfavorable pressure pulsations it induces in the hydraulic circuit that can affect turbine life and performance. The protrusion lengths, which were the same among the four rods, were varied according to a predefined sequence. The experiments were performed under four part-load regimes ranging from upper part load to deep part load. Time-resolved pressure measurements were conducted at two sections on the draft tube wall along with high-speed videography and efficiency measurement to investigate the effect of the mitigation technique on the RVR characteristics and turbine performance. The recorded pressure data were decomposed and studied through spectral analyses, phase-averaging, and statistical analyses of the RVR frequency and peak-to-peak pressure amplitude distributions. The results showed different levels of pressure amplitude mitigation ranging from approximately 10% to 85% depending on the operating condition, protrusion length, and the method of analysis. The hydraulic efficiency of the turbine decreased by a maximum of 3.5% that of the best efficiency point (BEP) with the implementation of the mitigation technique. The variations in the obtained mitigation levels and efficiencies depending on protrusion length and operating condition indicate the need for the implementation of a feedback-loop controller. Thus, the protrusion length can be actively optimized based on the desired mitigation target.

Experimental and numerical investigation of vortex flows and pressure fluctuations in a high-head pump-turbine

Vortex flows and pressure fluctuations, especially in the draft tube and vaneless space, have crucial impact on stable and safety operation for a high-head pump-turbine due to be fast adjusted and frequently switched between pump and turbine modes and often down to the deep part load. To more accurately investigate the vortex flows and pressure fluctuations in a high-head pump-turbine with splitter blades runner, a reliable approach by combined experiments with numerical simulations is presented in this paper. Laser Doppler Velocimetry measurements and high-speed camera observations inside the draft tube have been conducted at all the investigated points. Velocity profiles, vortex ropes visualization, the instantaneous tangential velocity and pressure fluctuations in both measured and simulated are presented to validate the numerical simulations and classify the vortex flow patterns. Meanwhile, the relationship between formation, development and breakdown of the vortex rope, the processional frequency and swirl intensity has been linked up and experimentally validated. Variation regularity of pressure fluctuations along the flow passage at different operating conditions has been quantitatively substantiated with measurements and predictions. Validation of predicted results versus experimental data shows that the presented numerical simulations can give very good results of vortex structures and the predicted fluctuation's frequencies. The pressure fluctuations amplitude of both the measured and the predicted in turbine mode agree well in the vortex rope-free zone, but has relatively larger deviations out of the vortex rope-free zone. It also demonstrated that the runner with splitter blades can restrain development of vortex flow and decrease the amplitude of pressure fluctuations for a high-head pump-turbine. The presented approach has been applied to successfully developed the high-head pump-turbines for several Pumped Storage Power Plants in China and demonstrated very useful in hydraulic optimizations.

Broadening the operating range of pump-turbine to deep-part load by runner optimization

To cooperate with new energy sources such as wind and solar, pumped storage units are required to frequently change conditions and operate under part loads, leading to the problem of violent pressure fluctuation and unit vibration. To meet this challenge, the next generation of pump-turbine runners will therefore have to be designed differently. The goal of this article is to construct a framework for broadening the operating range of pump-turbine to deep-part loads. In this study, a multi-objective optimization strategy for the runner with wider output range is suggested, wherein the blade control parameters, specifically the blade loading and blade lean angle, are optimized to enhance the efficiency, anti-cavitation, and stability of the pump-turbine runner. A runner with turbine output range of 40%–100% is optimized for a specific power station. Next, the impact of runner control parameters on runner performance is evaluated, and the runner geometric characteristics for different optimizing priorities such as the pump peak efficiency, cavitation performance, turbine rated efficiency, and turbine partial load efficiency, are concluded. The mutual restriction mechanism between the pump peak efficiency and cavitation performance of pump mode, as well as the turbine-rated efficiency and partial load efficiency of turbine mode, is revealed. The main contributions of this paper include putting forward an effective optimization design process for wide output pump-turbine, and pointing out the relationship between runner geometric characteristics and performance. The results indicate that the present approach can significantly improve the efficiency and stability of runners operating in deep-part loads. The blade loading pattern with hub section aft-loaded and shroud section fore-loaded, combined with negative blade lean angle, is recommended for such runners. Blades with a smaller wrap angle and lower arch are conducive to improving the pump peak efficiency and turbine-rated efficiency, while the opposite geometrical features are advantageous for improving the runner cavitation performance and efficiency performance under part load conditions. These findings can serve as an important guide for the development of runners with a wider output range.

Validation of deep part load dynamic stresses for axial runners

To accommodate renewable energy production and load demand variability, hydropower plant owners need to increase their operating range regardless of their units’ original design load envelop. When this increased operating range is an issue for the fatigue life of the old runners, solutions need to be found with the design of a new runner to sustain those new challenging loads of the increased operating range. In recent years, many papers have been published to show the challenging loads on Francis runners at speed-no-load and deep part load conditions. Andritz demonstrated a good numerical prediction capability for stress levels at deep part load conditions for Francis runners. However, for axial units, very little has been published. Very recently, some papers showed good predictability by CFD of the flow behavior at deep part load including the vortices present at those conditions. This paper demonstrates the prediction capability of the numerical tools by comparing strain gage measurements on an axial runner to CFD-FEA stress predictions. The measurement campaign was conducted conjointly by the unit owner and the manufacturer for research purposes. In the deep part load operating zone under the effect of columnar vortices, frequency analysis of the measured vibrations and strain gage signals confirmed the flow behavior predicted by CFD, and the measured dynamic strain amplitudes were well predicted. Numerical prediction of dynamic stress in the complete range from 0-100% power of the measured unit as well as detection of high vibration zones was successful.

An engineering approach for the prediction of fatigue damage in the part load regime

Due to the volatile electricity received from solar and wind power plants, the energy market requires highly variable hydropower machines which are able to cope with fast changes of their operating regimes. With the need for flexible operation, Francis runners are exposed to various operating conditions outside the traditional operating range. Hence, the runners must be specifically designed for long time part load operation to meet hydraulic and structural requirements. Therefore, it is inevitable to have a reliable but also practical engineering approach in the design phase of the projects in order to ensure sufficient fatigue life of the Francis runners. Deep part load operation mainly consists of stochastic loads acting on the runner blades. Previous publications show that it is reasonable to normalize the Rainflow matrix of stress amplitudes to represent the characteristic behaviour at deep part load operation. Hence, it is feasible to utilize the normalized Rainflow matrix to predict the fatigue damage of Francis runner designs without prototype measurements. Within this paper, a scaling method to derive project specific fatigue results for deep part load is introduced and subsequently validated through an intercomparison of available strain gauge measurement data and prediction. Based on the results, the accuracy of the proposed engineering approach and possible impacts of different boundary conditions are discussed.

Numerical investigation of the impact of cavitation on the pressure fluctuations in a Francis turbine at deep part load conditions

Hydropower plants can play an important role to stabilize the electrical grid when the share of volatile renewable energies increases. This goes hand in hand with a more flexible operation of the turbines and longer operation in off-design operating points. The increased pressure fluctuations that occur at off-design conditions may reduce the lifetime of the turbines. Consequently, this should be considered within the design process to develop efficient but also robust turbines. To derive suitable simulation setups that can be used in the design process, it is crucial to have a deep understanding of specific flow phenomena. As pressure fluctuations are of main importance in terms of fatigue, it is important that simulations can capture them well. Within this study, a deep part load operating point of a Francis turbine at model scale is investigated. By using three different meshes the influence of mesh refinement on the predicted pressure fluctuations is analyzed. Furthermore, by means of single- and two-phase simulations it is investigated how the pressure fluctuations are affected by the occurrence of cavitation. The results show only minor differences between the different meshes, whereas significant differences are observed between a single- and two-phase treatment.

Towards accurate numerical fluid dynamics of pump-turbine runners in deep partial load operation

The operation of pumped storage power plants at off-design conditions requires an understanding of the flow field and the resulting damage to ensure a safe and economic operation. Within this study, CFD simulations are carried out for an existing pump-turbine at deep part load operation to enable calculating the damage in later structural analyses. Furthermore, this study includes the comparison between the SST and SBES turbulence model at different mesh sizes. The simulation results are compared with model test data regarding head, torque and pressure fluctuations at a bottom ring and draft tube cone sensor. Whereas all simulation setups are within a reasonable range to the available model test data, the pressure fluctuations on the runner blades as well as the resolved vortices within the runner blade channels show a qualitative difference between both models. The SBES turbulence model resolves more vortices and thus different pressure fluctuations. Subsequent structural analyses show higher accuracy of the SBES turbulence model compared with the SST model. A mesh refinement from 25 million nodes to 80 million nodes with the SBES model reveals a better resolution of vortices, but only local differences in pressure fluctuations.

Evaluating energy-efficiency improvement of variable-speed operation with the help of entropy: A case study of low-head Francis turbine

In this paper, the effect of operation at optimized rotational speeds on a low-head Francis turbine is investigated, focusing towards the energy-efficiency improvement. For forty-two different operating scenarios with and without considering the speed variations, energy losses of the turbine are evaluated with the help of entropy production method. A comparative analysis is carried out in terms of overall energy harvesting performance, entropy production distribution, and detailed distribution of local entropy production rate (LEPR). It is found that variable speed operation can improve off-design efficiency up to 10%. For deep part load condition, while providing the same power output, it can save up to 14% of discharge thanks to the increased efficiency. At the design point, as turbine already operates at its maximum efficiency, it is unlikely to generate any benefits. Meanwhile, model hill-chart is sufficient for a first inspection of variable speed operation, and preliminarily predicts the efficiency improvement of prototype turbine. The results are encouraging and prove that variable speed operation can work well for Francis turbine of low-head.

Flow-induced pulsations in Francis turbines during startup - A consequence of an intermittent energy system

Hydraulic turbines are increasingly responsible for regulating the electric grid, due to the rapid growth of the intermittent renewable energy resources. This involves a large increase in the number of starts and stops, which cause severe flow-induced pulsations and fluctuating forces that deteriorate the machines. Better knowledge of the evolution of the flow in the machines during transients makes it possible to avoid hazardous conditions, plan maintenance intervals, and estimate the costs of this new kind of operation. The present work provides an in-depth and comprehensive numerical study on the flow-induced pulsations and evolution of the flow field in a high-head model Francis turbine during a startup sequence. The flow simulation is carried out using the OpenFOAM open-source CFD code. A thorough frequency analysis is conducted on the fluctuating part of different pressure probes and force components, utilizing Short-Time Fourier Transform (STFT) to extract the evolution of the frequency and amplitude of pulsations. Low-frequency oscillations are detected during the startup, which are induced by the complex flow structure in the draft tube. A decomposition is performed on the draft tube pressure signals, and the variations of the synchronous (plunging) and asynchronous (rotating) modes are studied. The plunging mode is stronger at minimum and deep part load conditions, whereas the rotating mode is dominant during the presence of the Rotating Vortex Rope (RVR) at part load. The velocity field in the draft tube is validated against experimental data, and the complex flow structures formed during the startup procedure are explained using the λ2 vortex identification method.

Broadening the Operating Range of Pump-Turbine to Deep-Part Load by Runner Optimization

Broadening the Operating Range of Pump-Turbine to Deep-Part Load by Runner Optimization

Vortex Evolution and Energy Production in the Blade ‎Channel of a Francis Turbine Operating at Deep Part ‎Load Conditions

The blade vortex evaluation in Francis Turbine under deep part load conditions generates severe pressure ‎fluctuations in the runner. The complex flow in a model turbine is numerically investigated based on a ‎modified Partially Averaged Navier-Stokes method. The main emphasis is focused on revealing the ‎correlation mechanism of blade vortex evolution and energy production. The results indicate that the ‎modified PANS method shows significant advantages in hydro turbine’s simulation than the traditional ‎RANS method. At deep part load conditions, the vorticity formed at the leading edge of the suction ‎surface and the trailing edge of the pressure surface in the blade channels. The stretching term provides ‎the most vorticity increments while the dilation term inhibiting part which only provides a decrement of ‎the vorticity evolution. Based on the entropy production theory, the total entropy production distribution ‎is consisting with the distribution of vorticity. At deep part load condition, direct dissipation and turbulent ‎dissipation provide the most entropy, while at part load condition the proportion of these two-part ‎decreased‎.

An in-depth numerical analysis of transient flow field in a Francis turbine during shutdown

Power production from intermittent renewable energy resources, such as solar and wind, has increased in the past few decades, leading researchers and engineers to establish techniques to preserve a stable electrical grid. Consequently, hydraulic turbines are being used more frequently in transient operating modes to regulate the grid. The present work provides a comprehensive numerical study on the transient flow field of a high-head Francis turbine model throughout the shutdown sequence. The computations were performed using OpenFOAM, utilizing the SST-SAS turbulence model. A Laplacian smoothing scheme is employed to conduct the mesh deformation of the guide vane domain. The time-averaged draft tube velocity field at the steady Best Efficiency Point (BEP) is validated against experimental data. Then different aspects of the transient flow field in the shutdown sequence are carefully assessed and explained for the first time. Short-Time Fourier Transform (STFT) analysis is carried out on the fluctuating part of the static pressure and force signals. High-amplitude low-frequency oscillations, due to the formation of a Rotating Vortex Rope (RVR) were observed during a specific period of the shutdown sequence. Thereafter, at deep part load conditions, the RVR vanishes and, a wide range of stochastic frequencies are identified at minimum load. A signal coherence analysis was accomplished to distinguish the deterministic and stochastic frequencies. The variation of the velocity field in the draft tube is described in detail with the help of velocity triangles. An in-depth explanation of the formation and variation of vortical structures during the whole sequence is presented. The physical mechanism of formation and destruction of the RVR is thoroughly explained.

Generation of Twin Vortex Rope in the Draft-Tube Elbow of a Francis Turbine During Deep Part-Load Operation

Abstract This paper focuses on the generation of twin vortex rope in the draft-tube elbow of a Francis turbine at deep part-load operation through analyzing the results of model tests along with numerical simulations. Model tests, including pressure fluctuations measurements, are conducted over ten speed factors. By considering the frequency of the pressure fluctuations with respect to the swirl intensity at the runner outlet, the part-load operating range is divided into three regimes, with two clear transitions between each occurring at swirl numbers 0.4 and 1.7. For operating conditions with a swirl number S > 0.4, a linear correlation between the frequency of the precessing vortex core and the swirl number is established. During the deep part-load regime (S > 1.7), low-frequency pressure fluctuations appear. Their frequency features another linear correlation with the swirl number. Unsteady computational fluid dynamics simulation of the full domain is performed to elucidate the generation mechanisms of the low-frequency fluctuations. By tracking the center of the vortical structures along the draft-tube, generation of three vortices in the elbow responsible for the pressure fluctuations at the lowest frequency is highlighted: the main precessing vortex core (PVC) hits the draft-tube wall in the elbow resulting in its break down into three vortices rotating with half the rotational speed of the PVC. Two of the vortices rotate with opposite angular position, constituting a structure of twin vortices. The periodic rotation of these three vortices in the elbow induces low-frequency pressure fluctuations.

Shear and vortex instabilities at deep part load of hydraulic turbines and their numerical prediction

For all types of turbines, deep part load operation (DPL) poses a challenge. An example of a dynamic phenomenon due to vaneless space vortices occurring at DPL is presented for three turbine types: a diagonal, a propeller and a Francis turbine. The backflow region occurring at DPL is often considered to be a main factor in these phenomena. Our results confirm that these backflow regions play an important role, but other factors also seem to be significant in specific cases. In our example of a diagonal turbine, the intersection of the backflow region with the leading edge of the blades seems to generate particularly high pressure pulsations and vibrations. In the case of the propeller turbine, large vaneless space vortices are found in CFD, but vibrations on the prototype machine are well within acceptable levels. Inspecting the flow at an operating point before large vaneless space vortices occur, shows high shear levels near the inner head cover that generate the high-intensity vortices at an even lower load. In the Francis turbine, half the number of strong vaneless space vortices interact with equally strong inter-blade vortices with vorticity of opposite sign to result in high dynamic blade torque. CFD simulations are well capable of capturing these phenomena, allowing them to be considered in the mechanical design of the turbine components for safe operation.

A Turbulence Model Assessment for Deep Part Load Conditions of a Francis Turbine

Today, hydropower plants received increased attention as they have the ability to stabilize the electrical grid. However, this is accompanied by more start-stop sequences as well as operation in off-design conditions. One big task is to develop improved runner designs that can resist the increased pressure fluctuations. In the scope of this study, a Francis turbine is simulated for a deep part load operating point with the use of the SAS model and the more recently developed SBES model with ANSYS CFX. Both turbulence models are hybrid RANS-LES models. The simulation results are compared against model test data from a measurement at high cavitation number. For the evaluation of the pressure fluctuations comparison is furthermore made against experimental data at low cavitation number. All in all, SAS and SBES model predict similar flow characteristics. Both, the velocity profiles in the PIV measurement plane and the predicted pressure fluctuations, show only minor differences. The comparison against experimental data shows that the amplitude of the broadband frequency spectrum, which results from the occurrence of vortices, is overestimated at the investigated locations on the runner blades.

Model test with sensor equipped Francis runner for Part Load Operation

With the need for flexible operation Francis runners are exposed to various operating conditions outside the traditional operating range. These machines have to be designed for long time Part Load Operation to meet hydraulic and structural requirements. Deep Part Load Operation mainly consists of stochastic loads on the blades. Calculation methods for the dynamic stress at Full Load Operation are well established, whereas the calculation of the dynamics during low load operation are in the focus of the current research to increase the predication accuracy. Through a model test of a Francis runner with multiple sensors in the rotating frame, knowledge is gained about low load operating conditions. The sensors consist of both pressure transducers and strain gauges. On the basis of the results for multiple operating conditions a comparison between pressure sensors and strain gauges is made and connected to flow phenomena. Prototype strain gauge data is utilized to prove the feasibility of the data gained in model size.

Simulation of the structural behavior of a Francis runner in Deep Part Load Operation

With the need for flexible operation, Francis runners are exposed to various operating conditions beyond the traditional operating range. These machines have to be designed for long time Part Load Operation in order to meet hydraulic and structural requirements. Deep Part Load Operation (DPL) mainly consists of stochastic loads on the blades. Whereas calculation methods for the dynamic stress at full load operation are well established, calculation of the dynamics during low load operation are in the focus of current research to increase the prediction accuracy. An unsteady flow simulation has been performed for a deep part load operating condition with the goal to derive the time-dependent pressure distribution in the runner. Based on the results, a FEA simulation with a 360° model is performed for multiple time steps to calculate the structural behavior. For a subsequent comparison to a strain gauge measurement, relevant characteristics with regard to material fatigue are identified. In addition, the calculation time in relation to the accuracy of the main characteristics of the flow induced stresses will be discussed.

Investigation into Pump Mode Flow Dynamics for a Mixed Flow PAT with Adjustable Runner Blades

The adoption of pumps as turbines (PATs) in both small-scale hydroelectric plants and water supply systems has brought about various advantages, the most recognized being cost-effectiveness compared to other hydroturbines. However, due to their lack of flow control ability, their intolerance to off-design operations constitutes a tough shortfall. Moreover, since this technology is new, PAT flow dynamics are not yet well understood. Therefore, this study intends to numerically investigate the mixed-flow PAT’s pump mode flow dynamics for five operating conditions from optimum (1 QBEP) to deep part-load (0.41 QBEP) conditions. Moreover, the effect of runner blade angle on them is investigated, considering three angles, namely −2°, 0°, and 2°. PAT flow stability was found to deteriorate as the flow decreased, where associated pressure pulsation level worsened at different flow zones. In addition, the blade angle increase led to correspondingly increasing flow unsteadiness and pressure pulsation levels, where the pulsation frequencies from rotor-stator interactions were dominant for most flow zones. This study’s findings are of crucial importance to both scientific and engineering communities as they contribute to a thorough understanding of PAT flow dynamics.