Pelton Turbine Research Articles

Damage analysis and restoring of structural integrity of Pelton runner after repair welding: case study

This paper presents the repair welding technology of a Pelton runner blade, including an analysis of damage caused by cavitation. Extreme exploitation conditions resulted in crack initiation followed by its propagation, with a length 200 mm, detected during regular annual maintenance, compromising Peltron turbine’s structural integrity. The base material of the Pelton turbine was steel X3CrNiMo13-4, and as well as the blade geometry itself, required special attention during the process of defining repair welding technology. An austenitic electrode was used for this purpose along with a welding technology defined in a way to counter the initiation of new cracks at the same location. Following the NDT, the Pelton runner was put back into exploitation, along with recommendations for its further monitoring.

Numerical simulation of multiphase flow and prediction of sediment wear in a large Pelton turbine

AbstractThe problem of sediment wear presents a significant challenge for hydraulic turbines operating in sediment‐rich rivers, particularly for high‐head Pelton turbines. In this study, the VOF model, SST k–ω model, and DPM model were employed to simulate the gas–liquid–solid three‐phase flow within a large Pelton turbine, which operates under a rated water head of 671 m and has a single capacity of 500 MW, at a hydropower station situated on a sediment‐laden river. The sediment wear prediction model, derived from the sediment wear test of the model turbine, was utilized to forecast the sediment wear on the flow components of the Pelton turbine at the hydropower station. The results show that there are obvious pressure and velocity gradients near the nozzle outlet of the Pelton turbine in the power station, and the wear of the nozzle surface is gradually increasing, and the wear in the downstream area of the nozzle is more serious. The wear rate at the needle tip surface reached 1.372 μm/h, while the socket ring surface exhibited a wear rate of 3.175 μm/h. he highest wear rate recorded for the water bucket is 0.940 μm/h. After a year of continuous operation, the maximum erosion observed was 5.62 mm on the runner bucket made of stainless steel and wear‐resistant metal, 8.23 mm on the spray needle, and 19.05 mm on the nozzle mouth ring, highlighting the severity of sediment wear on the Pelton turbine. It is recommended that surface treatment technology be applied to the flow‐through components of the Pelton turbine at this hydropower station to enhance the wear resistance of the turbine and extend the operational life of the unit.

Numerical analysis of cavitation characteristics on front surfaces of different Pelton turbine buckets

Abstract Cavitation may occur in the runner bucket of the Pelton turbine, which could lead to cavitation erosion on the bucket surface. In this paper, three types of bucket were selected to carry out transient multiphase flow simulation at the same operating point of a model Pelton turbine. The hydraulic performance and cavitation characteristics of different buckets were analysed. The 3 bucket models were developed for Pelton turbines operating under the middle-high and the high-water head range, respectively. Results showed that the participation of cavitation model in simulation would slightly affect the working process of the bucket. The cavitation on the front surface of three buckets all happened at the beginning stage of jet inflowing the bucket, among which bucket C had the most serious cavitation on the front surface. This work showed different cavitation characteristics among various types of bucket, and the relevant result suggested comprehensive design considering cavitation characteristics should be done on the front surface of the bucket for a specific range of water head.

Design and Performance study of Francis turbine for high head applications.

Abstract Francis Turbines are widely employed globally for their adaptability and operational versatility across a broad range of water flow rates and pressure heads. This study explores the design and optimization of a Francis turbine configured for exceptionally high heads, specifically targeting a design head of 700 m. Traditionally, Pelton turbines are favoured for such high heads, but this study investigates the viability of Francis turbines in this range. Through comprehensive testing, including the development of hill chart diagrams to evaluate performance under various conditions, the study demonstrates promising efficiency levels. Utilizing a simplified approach, the design process involves empirical relations and the Khoj program, resulting in turbine designs representing three different speed numbers: 0.32, 0.42, and 0.52. Efficiency and sediment erosion rates were computed for each and compared between the three designs. The comparison indicates that while the turbine with a speed number of 0.32 exhibits lower efficiency, it offers superior erosion resistivity. Conversely, turbines with speed numbers 0.42 or 0.52 show better efficiency, especially in handling fluctuations in operating conditions. The findings suggest a balance between efficiency and erosion resistivity, recommending the turbine designed for a speed number of 0.32 for superior erosion resistance, and the turbine with a speed number of 0.42 for greater efficiency and operational range. This study broadens the horizon for Francis turbines in high-head applications, offering insights into their potential and viability in extreme conditions.

Three-dimensional modelling and numerical analysis of Pelton turbine runner buckets

Three-dimensional modelling and numerical analysis of Pelton turbine runner buckets

CFD-based shape optimization of flashing converging-diverging nozzles in pelton turbines for domestic carbon dioxide heat pumps including off-design conditions

A path to enhance the coefficient of performance (COP) of domestic heat pumps is to replace the throttling valve with a turboexpander. Designing this component requires addressing supersonic flashing flows localized within the nozzle. In particular, two-phase flows prevent the application of the method of characteristics to design efficient converging–diverging shapes. To overcome this issue, we propose a shape optimization combined with a homogeneous equilibrium flow model as a design tool. Kriging models are used as surrogates of the objective function and constraint to reduce the overall computational burden associated with shape optimization. The infilling criterion to improve surrogate accuracy involves the maximization of the constrained expected improvement. A multi-point optimization is formulated, including design and off-design conditions in both objective and constraint, for a total of four relevant operating conditions. The off-design conditions are derived from system analysis, accounting for variations in the evaporator temperature and outlet gas-cooler temperature. The optimized nozzle results in a COP improvement of 7.6%, compared to a 6.6% increase when replacing the throttling valve with a baseline geometry designed as recommended by the literature. The adoption of a multi-point optimization strategy ensures that this enhancement in design conditions is not offset by off-design performance decay, which is 0.3 percentage points over the three off-design conditions. Overall, replacing the throttling valve with the optimized expander leads to an average COP improvement of 8.6%.

Numerical assessment of transient flow and energy dissipation in a Pelton turbine during startup

The Pelton turbine, known for its high application water head, wide efficient operating range, and rapid start-stop capability, is ideal for addressing intermittent and stochastic load issues. This study numerically analyzes the transient two-phase flow and energy dissipation during the startup of a Pelton turbine. Dynamic mesh technology controlled nozzle opening changes, and momentum balance equations managed runner rotation. Findings showed that the runner speed initially increased rapidly and then more slowly, and flow rate matched the nozzle opening variations. Runner torque first rose linearly, then decreased, with the fastest decline during nozzle closing. Hydraulic efficiency peaked early in nozzle reduction but then dropped sharply. Strong vortices formed due to upstream inflow and downstream backflow impact in the distributor pipe. The jet needle and guide vane improved flow in the converging section of nozzle, but flow began to diffuse with increased stroke. Initially, the jet spread fully on the bucket surface, but later only affected the bucket tips. Pressure fluctuations in the water supply mechanism were primarily due to jet needle motion, with higher amplitude during movement and lower when stationary. These fluctuations propagated upstream, weakening over distance. Reynolds stress work and turbulent kinetic energy generation, respectively, dominated energy transmission and energy dissipation, with their maximum contribution exceeding 96% and 70%. High-energy clusters corresponded to jet impact positions, highlighting jet-bucket interference as crucial for energy transport. This study established a performance evaluation method for Pelton turbine startups, supporting further investigation into characteristic parameters, flow evolution, and energy dissipation patterns.

Effect of sediment erosion on pressure pulsations in a large Pelton turbine

AbstractPelton turbines functioning in sandy river environments often encounter difficulties due to the swift movement of sediment particles, leading to erosion and damage to overflow components. These challenges can result in operational instability, particularly noticeable in large turbines. Pressure pulsation is crucial for turbine stability, and alterations in overflow component profiles caused by sediment erosion can worsen pressure pulsations. This study utilizes numerical simulations to analyze turbine pressure pulsations based on surface profile changes of runner buckets after 2 and 4 years of sediment erosion in a single 500 MW large‐scale Pelton turbine. Our findings reveal that erosion leads to a gradual decrease in pressure pulsation along the bucket's splitting edge from the notch to the root. After 4 years of erosion and wear, the relative pressure pulsation amplitude in the root region increased by more than 530%. Additionally, changes occur in the thickness of the water film in the erosion area on the working surface, disrupting the flow pattern and generating more vortices. This occurrence intensifies the relative pressure pulsation amplitude and reduces bucket stability. The study findings highlight the significant impact of sediment erosion on Pelton turbine pressure pulsation, posing a considerable risk to the unit's operational stability and safety.

Characterization of energy loss in jet mechanism of a Pelton turbine

Characterization of energy loss in jet mechanism of a Pelton turbine

Evaluation of the jet distortion by sediment erosion in the needle in the Pelton turbines

Abstract In order to succeed in the transition to a more renewable energy sector, the hydropower industry must overcome multiple challenges in the coming decades, including the need for faster and reversible turbines to support emerging renewable energy sources. In addition, the location of new projects in tropical and semi-tropical areas poses unique considerations, as does the increase in sediment. Evaluating sediment erosion in turbines is a critical challenge, which may partly be addressed by analyzing the behavior of water jets from eroded nozzles in Pelton turbines. This paper presents an evaluation of the quality of the jet under various hydraulic conditions, focusing on needle erosion. The study is part of a research project conducted in the Waterpower Laboratory at NTNU, focusing on Pelton turbines. Furthermore, this paper investigates erosion patterns caused by sediments on the needle and explores the impact on jet performance. Through high-speed visualization and image processing, the behavior of a jet from the needle tip to a representative distance downstream has been investigated. The investigation revealed discernible differences between jets with eroded and uneroded needles in size and edge variation.

Experimental Study of Sediment Erosion in Pelton Turbine Bucket

Abstract In hydroelectric power plants (HPPs), sediment-laden water flows through entire turbines, causing components to be damaged over time. Pelton turbine components serve abrasive erosion from particle hardness, and rough surface when subjected to high flow velocities and various jet impingement angles. In this study, an experiment was conducted to examine the erosion-prone areas of a small-scale Pelton turbine bucket under actual flow conditions. For the experiment, the Pelton bucket was painted with four distinct layers of paint: red, yellow, green, and blue. These layers served as indicators, helping us to visually track the erosion process. The setup was specifically designed to inject sediment upstream of the nozzle. It operated for a significant period of 0- 30 minutes, and every 5 minutes, the erosion pattern was noted with the nozzle fully open at 10 l/s and a net head of 6m with jet impingement angle 75°, 90°, and 105°. After operating for 0-30 minutes in sediment-laden flow conditions, a pattern of erosion was revealed, showing the hot spots (areas more susceptible to erosion) during the investigation at jet angles of 75°, 90°, and 105°. The most severe erosion areas are in the bucket domain, specifically at the splitter region and the deeper upper and lower parts of the brim. The erosion mechanism was influenced by the jet diameter and impingement angle on the bucket splitter. The experiment revealed that the outer regions of the bucket, where the flow was directed outward, suffered the most severe erosion, providing evidence of particle separation at high accelerations.

Numerical Investigation of Effects of Ripple Type Needle Erosion on Pressure Inside a Pelton Nozzle

Abstract Pelton turbines, a commonly used impulse turbine for hydroelectric generation which converts the potential energy of the water into kinetic energy through a needle structure within the nozzle system. However, the exposure of the Pelton turbine components such as needle, seat ring, buckets to the sediment laden water can erode these components. The erosion on the needle can also lead to the efficiency degradation. This study aims to investigate the effect of needle erosion on the pressure dynamics within the Pelton nozzle system. For the study purpose, the nozzle system from Pelton rig at the Waterpower Laboratory, NTNU is used and a general erosion pattern is developed through literature and field information. The research focuses on analysing the difference in pressure distribution between the normal and eroded needles under different opening conditions, with the objective of understanding how erosion affects the nozzle performance. Single-phase 3-D simulations are performed with an unstructured ANSYS mesh and the CFX solver. This study examines the static pressure at the inner surface of the nozzle casing wall. The results show that for a constant head at the inlet boundary condition, the static pressure with eroded needles was significantly lower than that with normal needles. The pressure difference was around 1.88 kPa for a 60% nozzle opening and around 3.57 kPa for a 40% nozzle opening. The reduction in pressure is due to the increased area in the needle orifice and nozzle outlet caused by erosion, which is more pronounced at lower openings. The findings reveal a direct correlation between needle erosion and alterations in pressure distribution, highlighting the necessity for vigilant monitoring and timely maintenance. The study provides valuable insights into optimizing turbine performance in sediment-laden water conditions and underscores the importance of addressing needle erosion to maintain efficiency.

Numerical investigation of flow around the injector of a Pelton turbine due to eroded needle

Abstract Injectors of Pelton turbines are prone to both sediment erosion and cavitation. This causes degradation of the surface morphology, which aggravates the quality of the jet, lowering the turbine’s performance. The study focuses on CFD analysis of a groove-shaped erosion pattern on the needle and analyses its influence on the quality of the jet at the three stages of erosion. The numerical model comprises of a nozzle with a cylindrical passage for modelling the jet. The research used the SST turbulence model and boundary conditions defined according to the turbine’s data, from which the model was obtained. This study explores the impact of silt erosion on pressure signals around the injector of a Pelton turbine. Needle pressure distribution curves were plotted at various erosion levels and openings, revealing that pressure deviation increases with increase in erosion. The effect turns out to be minimal during high opening levels but becomes substantial as opening levels decrease. Operating in part load conditions leads to a significant pressure drop due to the reduction in flow rate. The pressure distribution tends to become more uniform at full load, achieving optimal flow rates. However, a noticeable pressure drop is observed in the eroded region, reaching a minimum at the deepest eroded area. The pressure drop is further amplified with an increase in the level of erosion, indicating erosion’s disruptive impact on fluid flow. The findings highlight the complex interplay between erosion, needle pressure distribution, and jet diffusion.

Optimizing Pelton turbine performance: unveiling the power of three nozzles for maximum efficiency and sustainable hydropower generation

Water energy is one of the potential renewable energy, the problem so far has a low efficiency of the blade Pelton shape. So it takes a series of tools to know characteristics and performance of the Pelton turbine as a hydroelectric power plant in this research. Pelton turbines work by utilizing the potential energy of water stored at a certain head, which flows through a penstock/pipe that is equipped with a nozzle at the end. The high head causes the water to be under high pressure when it reaches the nozzle. The water coming out of the nozzle becomes kinetic energy in the form of a pressurized water jet, which is used to rotate the runner of the Pelton turbine. In this study, the effect of the number of nozzles used to rotate the Pelton turbine was analyzed, with the result that the number of nozzles is directly proportional to the efficiency of the Pelton turbine. Where the highest efficiency value is obtained by using 3 nozzles with a maximum efficiency value of 13.7 %, at 2 nozzles of 12.209 % and at 1 nozzle of 8.82 %.

Artificial Neural Network Model for Estimating the Pelton Turbine Shaft Power of a Micro-Hydropower Plant under Different Operating Conditions

The optimal performance of a hydroelectric power plant depends on accurate monitoring and well-functioning sensors for data acquisition. This study proposes the use of artificial neural networks (ANNs) to estimate the Pelton turbine shaft power of a 10 kW micro-hydropower plant. In the event of a failure of the sensor measuring the torque and/or rotational speed of the Pelton turbine shaft, the synthetic turbine shaft power data generated by the ANN will allow the turbine output power to be determined. The experimental data were obtained by varying the operating conditions of the micro-hydropower plant, including the variation of the input power to the electric generator and the variation of the injector opening. These changes consequently affected the flow rate and the pressure head at the turbine inlet. The use of artificial neural networks (ANNs) was deemed appropriate due to their ability to model complex relationships between input and output variables. The ANN structure comprised five input variables, fifteen neurons in a hidden layer and an output variable estimating the Pelton turbine power. During the training phase, algorithms such as Levenberg–Marquardt (L–M), Scaled Conjugate Gradient (SCG) and Bayesian were employed. The results indicated an error of 0.39% with L–M and 7% with SCG, with the latter under high-flow and -energy consumption conditions. This study demonstrates the effectiveness of artificial neural networks (ANNs) trained with the Levenberg–Marquardt (L–M) algorithm in estimating turbine shaft power. This contributes to improved performance and decision making in the event of a torque sensor failure.

Optimization and reconstruction of pelton buckets based on statistical techniques, artificial neural networks and CFD modelling

During operation Pelton turbines suffer from erosion and cavitation wear, which decreases the hydraulic efficiency. Welding repair is a cost-effective method for recovering the original bucket geometry but requires templates to ensure proper results. However, those templates may be unavailable for Pelton units with decades of operation. This is the case of one of the 2.8 MW Pelton units at Nima II, a small hydropower plant in Colombia that began operation in 1942. This paper presents the redesign and optimization of the bucket. First, the bucket is rebuilt following both, technical recommendations, and Design of Experiments (DOE) to verify the effects of the basic dimensions on the hydraulic efficiency. Experimental measurements on the eroded turbine validate the two-phase computational fluid dynamics (CFD) modelling to be applied in the optimization process. Second, the best inner surface is found by using a multi-objective optimization based on Artificial Neural Networks trained by the previous DOE and a genetic algorithm. At the end, the CFD results suggest a total hydraulic efficiency recovery of 8 %. Further experimental tests on the optimized runner showed a difference of 0.7 % from the predicted value.

Simulation of a Pelton turbine using the moving particle simulation method: application to two challenging situations

ABSTRACT Simulation of the flow in a Pelton turbine is a challenging task for mesh based methods due to the air/water mixture and the rotation of the runner. Meshless based methods are better suited for such flows and take advantage of the graphical power unit to speed up the calculation. Simulations of a Pelton turbine are carried out using the software Particleworks based on moving particle simulation, which is a meshless method. The efficiency drop due to the ‘falaise’ effect and the erosion of the splitter are computed and compared with either experimental measurements or the literature. The results show that this method is able to capture the tendency of the efficiency drop in agreement with the available data and at a lower computational cost than the mesh based methods. These encouraging results should motivate the community to test and validate such an approach.

Performance Evaluation of a Pelton Turbine with Fiberglass Composite Blades Using Three Nozzles in Different Positions

Performance Evaluation of a Pelton Turbine with Fiberglass Composite Blades Using Three Nozzles in Different Positions

On the Water Jet Quality at Part-Load Operation of Pelton turbines

Abstract Pelton turbines with multiple nozzles are characterised by their excellent performance over a wide operating range of mass flow rates. Thus, Pelton turbine manifolds must also be designed to deliver good flow quality to the nozzles at part-load operating conditions to accomplish the expectations. A reduced number of nozzles are opened at low mass flow rate operating conditions, where the choice of the open nozzles depends on the water jet quality generated at the individual nozzles. We investigate the flow phenomena occurring in the manifold with the operation of a reduced nozzle number employing numerical simulations to analyse beneficial nozzle opening selections. The turbulent two-phase flow is predicted by the Volume-Of-Fluid (VOF) approach and the k–ω SST turbulence closure model. Different nozzle operating scenarios are simulated, and the implications on the water jet quality, i.e. deviation and shape deformation, are reported. The results show that the free water jet quality criteria can change drastically at individual nozzle operating conditions because of the velocity changes at the branch line junctions.

Analysis of the bucket surface cavitation characteristics of a model Pelton turbine

Abstract The internal flow in the rotating bucket of high-head Pelton turbine is complex problem with features of multiphase flow and free surface. As the runner rotating, high speed water jets continuously impact the buckets, which would cause the cavitation on the bucket surface. As proved by field practice, cavitation and cavitation erosion surely exists in the Pelton turbine, which is harmful for the hydraulic performance and the unit. This paper investigated the unsteady 3D water-air-vapour multiphase cavitation flow on the bucket surface of a model Pelton turbine under a high operating head. Results showed cavitation occurred during the process of the bucket cut into the water jet on both sides of the bucket cutout edge. The cavitation on the bucket front surface last for about 20 transient steps with a maximum vapor volume fraction of about 3%, while severe cavitation occurred on the rear surface of the splitter with the duration twice of that on the front surface and a maximum vapour volume fraction of approximately 100%.