Kaplan Turbine Research Articles

Hydro-abrasive erosion in Kaplan turbines: a case study

ABSTRACT Sediment in the flowing water causes hydro-abrasive erosion of hydraulic turbines and other underwater components. In the present study, erosion quantification in the Kaplan turbine of a low-head hydropower plant (HPP) on the Upper Ganga Canal, is considered in the study. The study uses the guidelines of the International Electrotechnical Commission IEC 62364: 2019 for quantifying erosion in the Kaplan turbine. This work extends the research of Rai and Kumar (2016) and uses their primary details of some suspended sediment and operating parameters. The shape and mineral composition of the suspended sediment were quantified using dynamic imaging and X-ray diffraction techniques, respectively. The annual average particle load at the study HPP is obtained to be 356.87 kg·h/m3. Based on the analysis, it is estimated that the erosion depth varies from 0.88 to 1.37 mm/year at the blade tip, whereas from 2.40 to 3.74 mm/year at the blade outlet. At the runner chamber, the erosion depth varies from 1.27 to 1.98 mm/year. The erosion depth varies from 0.01 to 1.53 mm/year in the guide vanes. The calibration factor corresponding to the maximum erosion in guide vanes is estimated to be 1.75 × 10−5.

CAVITATION EROSION IN FRANCIS TURBINES

The phenomenon of secondary flow is a global problem that causes cavitation erosion in hydraulic equipment. Cavitation is a phenomenon of localised corrosion of the metal surface leading to instability and highly uneven flow behaviour with a consequent excessive noise, vibration, and decreased efficiency in Francis, Kaplan, and other turbines. Both Kaplan and Francis turbines are reaction turbines. Francis turbines (FT) are used worldwide due to their relatively compact design, high efficiency, and operation underwater at heights ranging from 100 to 300 m with an efficiency ranging from 90% to 95%. The article analyses the latest relevant research conducted by various researchers on different turbine components. The analysis shows that this type of erosion depends on flow characteristics, surface, and properties of the material eroding. Tools for design optimisation, cavitation erosion, and well-conducted experiments will provide results for identifying and reducing erosion. Although some researchers conducted experimental work to study the effect of cavitation erosion, literature on computational fluid dynamics (CFD) is very scarce. Over the past two decades, experts have been applying CFD methods to detect cavitation by examining areas where the pressure is below the vapour pressure with a single-phase model. Most studies do not consider the impact of cavitation bubbles on the flow field. However, these methods cannot provide detailed information, such as the impact of cavitation on efficiency or a more accurate prediction of the cavitation bubble size. Some researchers use cavitation inducers and some of the latest visualisation methods as experimental tools to study cavitation phenomena. In the last decade, a numerical methodology has been widely used in research and experiments, yielding significant results. Studying cavitation erosion in hydroelectric turbine systems presents a complex challenge for future research. Many parameters and features still require further investigation. All the discussed studies have established that cavitation phenomena require state-of-the-art equipment for their detection and visualisation. Moreover, more work is necessary for the numerical assessment of cavitation. Keywords: hydroelectric turbine, cavitation erosion, computational fluid dynamics.

Vibration and Flow Characteristics of a 200 MW Kaplan Turbine Unit under Off-Cam Conditions

Kaplan turbine units can adjust their blades to achieve wider outputs without a significant loss of efficiency. The combination of guide vane angle (GVA) and blade angle (BA) is selected based on efficiency curves obtained from cam tests. However, the vibration characteristics are not considered in the test. The vibration and flow characteristics are complex with different combinations of guide vane and blade angles. Different cam relation selection principles lead to varying machine vibration and flow characteristics. In this research, the flow and vibration characteristics were obtained by means of field test and numerical simulation. Vibration, pressure pulsation, and other stability indicators have been extracted and investigated under off-cam conditions. The flow and variation rules of different indicators have been thoroughly researched. The findings suggest that the magnitude of vibration in the X direction surpassed that in the Y direction for the head cover, upper frame, and lower frame under 22 experimental conditions. The disparity between the head cover and upper frame in both directions was not significant, whereas a substantial contrast existed between the lower frame in the X and Y directions. The calculation results indicate that when the guide vane angle was small, vortices appeared near the high-pressure edge of the runner in the vaneless region and caused disorganized flow lines in the runner, and this complex vortex behavior led to multiple frequency components in the pressure pulsation frequency domain. The conclusions provide references for the designers of Kaplan turbine units and improves the operating safety of Kaplan turbine power stations.

Experimental Fitting of Efficiency Hill Chart for Kaplan Hydraulic Turbine

The development of hydroelectric technology and much of the “knowledge” on hydraulic phenomena derive from scale modeling and “bench” tests to improve machinery efficiency. The result of these experimental tests is mapping the so-called “hill chart”, representing the “DNA” of a turbine model. Identifying the efficiency values as a function of the specific parameters of the flow and energy coefficient (which both identify the operating point) allows us to represent the complete behavior of a turbine in hydraulic similarity with the original model developed in the laboratory. The present work carries out a “reverse engineering” operation that leads to the definition of “an innovative research model” that is relatively simple to use in every field. Thus, from the experimental survey of the degree of efficiency of several prototypes of machines deriving from the same starting model, the hill chart of the hydraulic profile used is reconstructed. The “mapping” of all the characteristic quantities of the machine, together with the physical parameters of the regulating organs of a four-blade Kaplan turbine model, also made it possible to complete the process, allowing to identify not only the iso-efficiency regions but also the curves relating to the trend of the angle of the impeller blades, the specific opening of the distributor, and the identification of critical areas of cavitation. The development of the hill chart was made possible by investigating the behavior of 33 actual prototypes and 46 characteristic curves derived from the same reference model based on practical experiments for finding the optimal blade distributor “setup curve”. To complete this, theoretical characteristic curves of “not physically realized” prototypes were also mapped, allowing us to complete the regions comprising the diagram. The study of the unified hill charts found in previous documentation of the most famous manufacturers was of great help. Finally, the validation of the “proposed procedure” was obtained through the experimental survey of the actual efficiency of the new prototype based on the theoretical values defined in the design phase on the chart obtained with the method described.

Dynamic Response Characteristics of Rotating and Fixed Components of the Kaplan Turbine under Low and Medium Heads

Dynamic Response Characteristics of Rotating and Fixed Components of the Kaplan Turbine under Low and Medium Heads

Assessing the potential for gas supersaturation downstream of hydropower plants in Norway, Austria and Germany

Hydroelectric power facilities can generate episodic total dissolved gas supersaturation (TDGS), which is harmful to aquatic life. We developed a decision tree-based risk assessment to identify the potential for TDGS at hydropower plants and conducted validation measurements at selected facilities. Applying the risk model to Norway's hydropower plants (n = 1696) identified 473 (28 %) high-risk plants characterized by secondary intakes and Francis or Kaplan turbines, which are prone to generating TDGS when air is entrained. More than half of them discharge directly to rivers (283, 17 % of total). Measurements at 11 high-risk plants showed that 8 of them exhibited biologically relevant TDGS (120 % to 229 %). In Austria and Germany, the analysis of hydropower plants was limited due to significant data constraints. Out of 153 hydropower plants in Austria, 80 % were categorized at moderate risk for TDGS. Two Austrian plants were monitored, revealing instances of TDGS in both (up to 125 %). In Germany, out of 403 hydropower plants, 265 (66 %) fell into the moderate risk, with none in the high-risk category. At a dam in the Rhine River, TDGS up to 118 % were observed. Given the uncertainty due to limited data access and the prevalence of run-of-river plants in Austria and Germany, there remains an unclarified risk of TDGS generation in these countries, especially at spillways of dams and below aerated turbines.The results indicate a previously overlooked potential for the generation of biologically harmful TDGS at hydropower installations. It is recommended to systematically screen for TDGS at hydropower installations through risk assessment, monitoring, and, where needed, the implementation of mitigation measures. This is increasingly critical considering the expanding global initiatives in hydropower and efforts to maintain the ecological status of freshwater ecosystems.

Basic performance, cavitation and runaway investigations of a high specific speed Francis turbine with emphasis on cavitation analysis: A case study

The paper presents comprehensive experimental research on a high specific speed model Francis turbine with a characteristic runner diameter of 250 mm under the head of 12 m. Essentially, the turbine was designed for use at heads between 10 and 50 m, which are typical for installations with low specific speed Kaplan turbines. The basic performance, cavitation and runaway characteristics of the machine, which were determined as a result of the work, are quite rarely available in the literature in the case of high specific speed Francis turbines. The turbine achieved the maximum efficiency of 91%, kinematic specific speed of 82, and relatively wide operation range, so that it can be attractive as an alternative to the low specific speed Kaplan, semi-Kaplan or propeller turbines.In result of the basic laboratory tests, the performance characteristics of the machine operation in a wide range of guide vane opening angles between 9° and 36° as well as the shell efficiency characteristics were determined. On the characteristics plotted vs. rotational speed, the saddle effect was identified for the guide vane opening angles with values greater than the optimal one (22°). During the operation of the machine in the area of saddles, the change in the flow rate took quite surprising patterns. The share of the turbine thrust torque in the total torque was also determined, the characteristics of which are also burdened with a similar saddle effect.In the case of cavitation tests, a multi-aspect approach to cavitation diagnostics was used to characterize the cavitation phenomenon from the viewpoint of various criteria. Following this approach, the signals of the draft tube wall acceleration, acoustic emission at the draft tube cone upper flange, and pressure fluctuations inside the draft tube were used. The determined cavitation characteristics indicate little cavitation susceptibility of the Francis turbine blade system, despite the presented turbine having been designed to operate at higher flow rates than the classic high head Francis turbines with long interblade channels. The cavitating flow in the draft tube, directly below the runner, was also visualized during the cavitation tests. The paper presents the results of visualization for all cavitation states at five selected settings of the guide vane opening angle (two states in Partial Load, two states in High Load area and one state in the Best Efficiency Point), thanks to which it was possible to track the development of vortices during pressure reduction in the flow system.The runaway coefficient was determined as a result of the runaway tests. The value of 1.497 was reached at the optimum guide vane opening angle.Additionally, the work also presents in detail the efficiency scale effects to be expected at prototype turbines, i.e. those intended for operation at a higher head and with larger runner diameters. The efficiency of the machine with a runner diameter of 1.5 m and working at a head of 50 m reaches ∼93%. The influence of water viscosity on the change in efficiency of the prototype turbine is also shown.The presented methodology can be used for the proper selection of turbines intended for hydropower plants and for the proper installation of the runner in respect to the tailwater level in order to avoid the phenomenon of cavitation erosion.

Effect of runner tip clearance on hydraulic performance of Kaplan turbine

Abstract Due to its structural characteristics, the Kaplan turbine has a specific tip clearance between blade and chamber of the runner. This paper simulates effect of varied runner tip clearance on hydraulic performance of Kaplan turbine by CFD, and model tests validated the results. The results show that the efficiency and cavitation level of turbine will decrease with the increase of runner tip clearance within a specific range.

Investigation on hydraulic loss characteristic of Kaplan turbines based on entropy generation theory

Abstract In this paper, the hydraulic losses of a Kaplan turbine under optimal and rated operating conditions are investigated through the theory of entropy generation. The results show that hydraulic loss values calculated using pressure drop and entropy generation theory are similar. The hydraulic losses are mainly concentrated in runner and draft tube. However, when the operation condition of Kaplan turbines deviates from the optimal condition, the proportion of hydraulic loss in draft tube increases. The hydraulic loss in draft tube is mainly composed of entropy generation caused by turbulence fluctuation, which is the result of unstable flow induced by vortex rope. The hydraulic losses of other parts are mainly composed of entropy production caused by wall shear. The high entropy production of the runner concentrated on the shroud, hub, blade surface, and blade trailing edge, while entropy production caused by wall shear is concentrated on blade pressure surface and shroud near blades when the turbine strays from optimal operating condition.

Assessment of Fiber Bragg Grating sensors for monitoring induced strains on the draft tube cone of hydraulic turbines

Abstract In hydraulic turbines, several flow instabilities can take place inside the draft tube cone during off-design and transient operating conditions such as the rotating vortex rope which can severely damage the structure if sustained in time. In the frame of the AFC4Hydro H2020 research project, an extensive measurement campaign has been carried out to monitor and predict this rotating vortex rope phenomenon in a reduced scale Kaplan turbine model at the Vattenfall Research and Development facility in Älvkarleby, Sweden. The hydraulic turbine model has been operated in propeller mode with a fixed blade angle corresponding to its best efficiency point. Several sensors have been placed along the test stand to monitor vibrations, strains and pressures. Concretely, the present paper assesses the performance of using Fiber Bragg Grating sensors to measure the strains induced on the draft tube cone walls with high-spatial resolution in three different zones of influence: the upper and lower flanges and the vertical cone wall between the runner outlet and the elbow. To do so, a total of 3 arrays embedding a total of 48 Fiber Bragg Grating sensors were glued inside three grooves previously machined on these particular areas of the draft tube cone. Analysing the frequency response of the different Fiber Bragg Grating sensors, the strain patterns induced by the rotating and plunging components of the rotating vortex rope have been precisely determined. Moreover, their impacts at the different part load conditions tested have also been quantified.

Experimental study on draft tube of a model kaplan turbine

Abstract To obtain the flow characteristics inside the draft tube of the model Kaplan turbine, a model test method was developed and carried out in this paper. The method includes introducing the model test system, test method, and parameters of model Kaplan turbine. Subsequently, experiments are conducted under different operating conditions and the results are analyzed. The result shows that, for the same blade angle and unit speed, operating conditions with larger guide vane openings (GVO) generally have higher axial velocities and lower tangential velocities than those with smaller GVO. In addition, particularly at higher flow velocities, a low velocity or backflow zone can occur in the center of the draft tube. Vortex rope is found to have a significant impact on the turbulence intensity in the mid-section of the draft tube, resulting in an unstable flow state. Also, under higher unit speed operating conditions, the turbulence intensity in the middle of the measurement area is greater and has a larger sphere of influence. Finally, the tangential pulsation intensity at the same measuring point under the same operating conditions is larger than the axial pulsation intensity, showing that vortex ropes have a more significant influence in the tangential direction.

Inner Flow Analysis of Kaplan Turbine under Off-Cam Conditions

Kaplan turbines are widely utilized in low-head and large flow power stations. This paper employs Computational Fluid Dynamics (CFD) to complete numerical calculations of the full flow channel under different blade angles and various guide vane openings, based on 25 off-cam experimental working conditions. The internal flow characteristics of the runner blade and draft tube are analyzed, and a discriminant number for quantitatively assessing the flow uniformity of the draft tube is proposed. The results indicate that low-frequency and high-amplitude pressure pulsations occur on the high- and low-pressure edge of the blade when the opening is small, with pulsations decreasing as the opening increases. The inner flow line of the draft tube is disturbed when both the blade angle and opening are small. Additionally, the secondary frequency of the draft tube inlet is double that of the vane passing frequency. The discriminant number of the flow inhomogeneity approaches 0 under optimal flow conditions. The number increases continuously with the decrease in efficiency, and the flow in the three piers of draft tube becomes more nonuniform. The research results provide a reference for enhancing performance and ensuring the operational stability of Kaplan turbines.

Study on Structure Dynamic Characteristics for Internal Components of Kaplan Turbine Runner under Different Contact Modes

Study on Structure Dynamic Characteristics for Internal Components of Kaplan Turbine Runner under Different Contact Modes

Optimization of Elbow Draft Tubes for Variable Speed Propeller Turbine

The design of the elbow draft tubes is challenging due to the complexity of the flow. The whole turbine unit’s power output strongly depends on the draft tube function, especially for the low-head turbines. The article presents a novel approach to optimizing elbow draft tubes for a variable-speed propeller turbine designed for low-head applications. First, the study addresses the specifics of the propeller variable speed turbine by comparing the classical Kaplan turbine. Then, the grid scaling test is conducted to evaluate the uncertainty of the pressure regeneration. Further, a new approach to parameterising the elbow draft tube geometry is introduced. The study employs ANSYS CFX 2021 R1 software for numerical simulation to optimise the elbow draft tube geometry in the CAESES environment. After the sensitivity test and deselecting the non-sensitive parameters, we perform multi-objective genetic algorithm (MOGA) optimization. The optimization process results in a Pareto front of optimised elbow draft tube shapes with the best pressure regeneration for different draft tube construction heights, enabling the selection of suitable candidates for various locations. Minimal difference in the performance of the selected elbow draft tube shapes with the simple straight draft tube confirms a high-quality draft tube optimization achievement.

A Comparative Analysis of Distributor and Rotor Single Regulation Strategies for Low Head Mini Hydraulic Turbines

Tubular axial turbines (TATs) play a crucial role in mini and micro hydropower setups that require simplified yet reliable solutions. In very low head scenarios, single regulation in TATs is common, due to economic impracticality of the sophisticated mechanisms involved in the conjugate distributor–rotor regulation typical of the Kaplan turbines. Distributor or rotor single regulation strategies offer operation flexibility, each with distinct advantages and disadvantages. Stator regulation is simpler, while rotor regulation is more complex but offers potential efficiency gains. The present paper analyzes energy losses associated with these regulation strategies using two approaches: 1D mean line turbomachinery equations and 3D Computational Fluid Dynamics (CFD). The 1D mean line approach is used for understanding the conceptual fluid dynamic aspects involved in the two different regulation approaches, thereby identifying the loss-generation mechanisms in off-design operation. Fully 3D CFD simulations allow for quantifying and deeply explaining the differences in the hydraulic efficiencies of the two regulation strategies. Attention is focused on the two main loss contributions: residual tangential kinetic energy at the rotor outlet and entropy generation. Rotor regulation, even if more complex, provides better results than distributor regulation in terms of both effectiveness (larger flow rate sensitivity to stagger angle variation) and turbine operating efficiency (lower off-design losses).

Solar-hydro cable pooling – Utilizing the untapped potential of existing grid infrastructure

Over the years, the coupling of various variable renewable energy sources has emerged as a convenient way to partially or fully overcome their highly intermittent nature and low-capacity factors. In literature as well as in practical implementations, the coupling of solar and wind power systems is gaining special attention thanks to their advantageous complementarity in time. However, an area of yet not well-documented potential is the coupling of solar PV plants with non-dispatchable run-of-river hydropower plants. In this study, Poland, which still has significant untapped hydropower potential, is used as a case study. The objective of the work is to quantify the coupling potential with special attention paid to the unavoidable curtailment of solar generation due to the limited grid connection capacity. A simulation model was developed that uses input runoff, irradiation, and temperature hourly data covering the period 01.01.2008–31.12.2022 for 236 selected sites in Poland. Hydrological data were obtained from field measurements, while the remaining meteorological parameters were downloaded from the ERA5 reanalysis database. Hydropower generation was simulated assuming a constant head and a Kaplan turbine operating at different efficiencies depending on the flow rate through the turbine. The available flow was calculated considering environmental flow (e-flows) constraints. The design flow was determined based on the average multi-year flow in the considered river. The complementarity in time of these two renewable energy sources in each location was assessed by considering the grid connection capacity and resulting curtailment in case of too high simultaneous generation from both sources. The analysis showed that the average PV curtailment is about 10.7 % (or 13.2 % when it is solar PV capacity weighted) when the ratio of solar to hydro is equal. Still, it can be as high as 19.7 % in individual cases. To ensure that PV curtailment is no more than arbitrarily (in that case) selected threshold of 5 %, the solar-PV capacity should be between 58 % − 120 % of the designed hydropower plant capacity. The curtailment threshold can be further investigated as an expansion of a techno-economic analysis that fell out of the scope of this work. The additional analysis conducted by means of daily flow data showed a significant underestimation of solar curtailment in individual cases (i.e., up to 7 pp.) and, on average, lower by 0.24 pp. could be expected. Due to interannual flow variations, although the expected mean solar curtailment can be no more than 5 %, there are individual years when it is as low as 2 % and as high as 12 % of this year’s solar generation. The lessons learned from this study shed light on the potential maximization of local power generation through coupling with PV systems and the simultaneous reduction of environmental impacts by releasing higher quantities of e-flows offset by the integration of PV systems.

Excessive vibrations experienced in a Kaplan turbine at speed no load

A Kaplan turbine unit from a new powerplant experienced high levels of vibrations and noise during the acceleration of the unit to nominal speed. These levels remained very high at speed no load. A first analysis seemed to indicate a possible blade resonance phenomenon as the highest vibrations were measured on the head cover. Nevertheless, after some modifications on the root of the blades, the vibrations remained high and the commissioning of the unit was delayed several months. To determine the origin of these vibrations, an array of sensors was installed in the machine. Different types of tests were performed. Experimental modal analyses of the runner head cover were conducted. Furthermore, experimental tests to determine the transmission of vibrations from the runner blades to the rest of the unit were carried out. Finally, the unit was tested during the acceleration phase to speed no load. Thanks to these tests, the origin of the high amplitude vibrations and loud noise perceived close to the head cover of the turbine was found. A solution to mitigate this problem was implemented by modifying the diameters of the air admission openings and their distribution, according to the up-to-date design rules. Both vibrations and noise amplitudes were drastically decreased. After this, the subsequent steps of the commissioning tests were performed and the unit started the commercial operation without major issues.

Turbomachinery GPU Accelerated CFD: An Insight into Performance

Driven by the emergence of Graphics Processing Units (GPUs), the solution of increasingly large and intricate numerical problems has become feasible. Yet, the integration of GPUs into Computational Fluid Dynamics (CFD) codes still presents a significant challenge. This study undertakes an evaluation of the computational performance of GPUs for CFD applications. Two Compute Unified Device Architecture (CUDA)-based implementations within the Open Field Operation and Manipulation (OpenFOAM) environment were employed for the numerical solution of a 3D Kaplan turbine draft tube workbench. A series of tests were conducted to assess the fixed-size grid problem speedup in accordance with Amdahl’s Law. Additionally, tests were performed to identify the optimal configuration utilizing various linear solvers, preconditioners, and smoothers, along with an analysis of memory usage.

Feasibility study for test rig assessments of fish passage conditions in a Kaplan turbine

The assessment of fish passage conditions in hydroelectric turbines consists of identifying and quantifying physical magnitudes leading to increased risks of injury of fish passing through turbines in operation. Such assessments are usually carried out either with the use of computer-based methods during design or with field testing of live fish and sensors passing through prototypes. A method in between consists of test rig experimentation, which is critical for testing fish-focused design concepts and offers the opportunity for implementing the most effective design measures for improved fish survivability. However, fish-related assessments in test rigs are not sufficiently documented for industrial applications. This work presents the main findings of an experimental campaign to quantify fish-related hydraulic magnitudes in a physical model of a Kaplan turbine in a commercial test rig. Two operating conditions were tested by releasing miniaturized autonomous sensor devices (termed Sensor Fish Mini) at the turbine intake flow, passing them through the runner in motion and recovering them at the draft tube exit. During passage, time series of acceleration, absolute pressure and rotational velocity were recorded. The recordings were then interpreted to determine the magnitude and likely location of hydraulic stressors hazardous to fish. The statistical tests on the reported measurements indicated that low pressure, collisions on the runner and rotations in the draft tube were not different between the two tested operating points. On the other hand, pressure drop and collision rates on the distributor differed considerably as a function of net head. The outcomes of this investigation showed that test rig evaluations of fish-related properties with Sensor Fish Mini can contribute to an evidence-based development of turbine geometries designed for providing safer passage conditions. Future work will investigate the scaling of test rig measurements to hydraulically equivalent magnitudes in the prototype and their biological consequences.

A Comparative Study on the Cam Relationship for the Optimal Vibration and Efficiency of a Kaplan Turbine

Kaplan turbines are generally used in working conditions with a high flow and low head. These are a type of axial-flow hydro turbine that can adjust the opening of the guide vanes and blades simultaneously in order to achieve higher efficiency under a wider range of loads. Different combinations of the opening of the guide vanes and blades (cam relationship) will lead to changes in the efficiency of the turbine unit as well as its vibration characteristics. A bad cam relationship will cause the low efficiency or unstable operation of the turbine. In this study, the relative efficiency and vibration of a large-scale Kaplan turbine with 200 MW output were tested with different guide vane and blade openings. The selection of the cam relationship curve for both optimal efficiency and optimal vibration is discussed. Compared with the cam relationship given by the model test, the prototype cam relationship improves the efficiency and reduces the vibration level. Compared to the optimal efficiency cam relationship, the optimal vibration cam relationship reduces the efficiency of the machine by 1% to 2%, while with the optimal efficiency cam relationship, the vibration of the unit increases significantly. This research provides guidance for the optimization of the regulation of a large adjustable-blade Kaplan turbine unit and improves the overall economic benefits and safety performance of the Kaplan turbine power station.