Pump-turbine Unit Research Articles

Chaotic Analysis of the Reversible Pump Turbine Exhaust Process in Pump Mode Based on a Data-driven Method

Due to the important strategic position of Pumped Storage Power Plants (PSPP) in global energy upgrading, conducting in-depth research on the various operating conditions of pump turbine units is important for their safe and stable operation. This study sought to clarify the gas–liquid phase motion and the nonlinear chaotic characteristics of the process of exhaust and pressurization in pump mode; with the simplified objective model proposed here, a visualization of the process is achieved using data-driven methods, and the nonlinear characteristics of gas–liquid phase motion during the process are theoretically demonstrated. A method that combines data-driven and chaotic analysis is proposed to qualitatively and quantitatively analyze the force and torque time-series signals of the runner under different exhaust rates. The results indicate that the chaotic characteristics of the force signals and torque signals of the runner are not in a single linear relationship with the exhaust rates. Therefore, this research also provides guidance on exhaust rates with the aim of informing actual engineering practice, the purpose of which is to reduce the vibration amplitude caused by repetitive torque and improve the stability of the unit operations.

Modal characteristics analysis of a variable-speed pump-turbine rotor system: a perspective of resonance

Abstract The safety and stability of the rotor system is crucial to the pump-turbine unit. The present paper analyzed the modal characteristics of a variable-speed pump-turbine rotor system based on the rotor dynamics theory and FEM method. The results show that the bending mode of the rotor system exhibits the forms of forward whirling (FW) and backward whirling (BW). The added mass effect will reduce the natural frequency of the rotor system, and it is more obvious for the torsional mode Torsional 1. In addition, the critical speed analysis shows that both the critical speed of the dry mode and wet mode of the rotor system is greater than 700rpm, which proves the safety of the unit. The results of the analysis can be used as a reference for the optimized design of similar variable-speed pump-turbine rotor system, which is conducive to the improvement of the reliability and life of the rotor system.

Study on the dynamic characteristics of the head cover-bolts-stay ring of a variable-speed pump-turbine

Abstract The design and operation of variable-speed pump-turbine units is more difficult than that of conventional units due to their adjustable speed, frequent start stop, and forward and reverse operation. Due to the development of variable-speed pump-turbines towards variable-speed, high head, and large capacity, the vibration instability caused by frequent switching between turbine and pump operating conditions is more prominent. The study on the dynamic characteristics of the head cover-bolts-stay ring system is an important guarantee for the long-term safe and stable operation of the units. This article uses the finite element method to conduct modal analysis on the head cover-bolts-stay ring system of a variable-speed pump-turbine. The natural frequency and mode shape are analyzed, and resonance analysis is carried out in combination with the dynamic and static interference characteristics of the variable-speed unit. The research results show that the dynamic and static interference frequency of the unit during the variable-speed process may be close to the natural frequency of the head cover-bolts-stay ring system, which needs to be paid attention to during operation. The results and findings in this article provide theory and practical basis for the research and design of high head, large capacity, and variable-speed pump-turbine units.

Research on the clearance evolution of preloading filling spiral case and surrounding concrete

Abstract The embedment of steel spiral cases within concrete under a pressurized condition is a kind of construction approach that widely used in pump-turbines. There will be an initial preloading clearance between the spiral case and surrounding concrete after the construction. The clearance is directly determined by the preloading water head and changes with the variation in operational hydraulic pressure, which will effect the combined load transmission mechanism. This paper investigates the clearance evolution of preloading filling spiral cases and surrounding concrete under different internal pressure. The effect of the preloading water head on the initial clearance, the contact characteristics and the combined load transmission mechanism under different internal pressure are numerically studied. The results show that the initial clearance between the spiral case and concrete increases with the rise of the preloading water head. The maximum clearances are all located at the waist of the spiral case. The clearance during operation presents uneven distribution characteristics in spatial and temporal scales. Before the internal water pressure comes to the preloading water head, the inlet, outer part in the direction of 45° and the sectional area are the first to close, the outer part of the waist follows, while the outer area of the spiral case middle remains open when the pressure reaches the preloading water head. The contact pressure distribution is consistent with the contact status characteristic. The conclusion of this paper aims to improve the understanding of the effect of the clearance between the preloading filling spiral case and concrete, so as to provide theoretical reference for safe and stable operation of pump-turbine units.

Analysis of safety margin for pump-turbine “S” characteristics of Pumped-storage Power Stations

Abstract The pump-turbine is the “heart” of Pumped-storage Power Stations, and the “S” characteristics is an inherent characteristic of the routine Francis pump-turbine unit, which is an important factor affecting the safe and stable operation of the unit. There are three main methods for conducting research on the “S” characteristics: model testing, on-site testing, and CFD numerical simulation calculation. Based on the theoretical research of CFD numerical simulation calculation, this article compares and analyzes the results of model testing and on-site testing for specific practical cases, studies the differences between these two methods, and provides suggestions for the reasonable value of safety margin in the “S” area of the pump-turbine based on engineering practice, providing reference for the design of new or renovated power stations and the hydraulic optimization of pump-turbines.

Transient Flow-Induced Stress Investigation on a Prototype Reversible Pump–Turbine Runner

Pump–turbine units with high heads are subjected to strong pressure pulsations from the unsteady transient flow in fluid channels, which can produce severe vibrations and high stresses on the pump–turbine structural components. Therefore, reducing transient flow-induced stresses on prototype reversible pump–turbine units is an important measure for ensuring their safe and efficient operation. A high-head prototype reversible pump–turbine with a rated head of 440 m was used to investigate the transient flow characteristics and the flow-induced-stresses in this study. First, the flow passages of the pump–turbine unit and the structure of the reversible pump–turbine runner were constructed with CAD tools. Next, CFD simulations at the full load were performed to investigate the pressure pulsation characteristics of the pump turbine in both the time domain and the frequency domain. After this, the pressure files calculated by the CFD were exported and applied to a finite element model of the pump–turbine runner to calculate the transient flow-induced dynamic stresses. The results show that the pressure pulsations in the flow passage are closely related to the rotational speed, the guide vane number, and the runner blade number of the pump–turbine unit. The maximum flow-induced stresses on the pump–turbine runner at the full load were below 2 MPa and lower than the allowable value, which reveals that the designs of the pump–turbine runner and the flow passage are acceptable. The conclusions can be used as a reference to evaluate the design of high-head pump–turbines units. The approaches used to carry out the transient flow-induced stress calculations can be applied not only to pump–turbines units but also to other types of fluid turbomachinery such as pumps, turbines, fans, compressors, turbochargers, etc.

Three-Dimensional Numerical Simulation of Pumped Storage Unit No-Load operation with PID control before Grid-Connected

Abstract The “S” characteristic curve has been a persistent challenge for low-head grid connection of pump-turbine units. The stability of the no-load operation before grid connection directly determines the success of grid connection. In order to accurately simulate the characteristics of the no-load operation before grid connection, this paper applies a PID speed controller model to the full flow system 3D simulation of the pumped storage unit, using user-defined functions and dynamic grid technology. The calculation results were compared with the conventional transient calculation method and field test data, which verified the reliability of the calculation method and solved the shortcomings of the conventional transient calculation method, especially in terms of pressure pulsation. The application of this speed controller model provides a new method for studying the instability of the “S” characteristic curve in pump-turbine units.

Pressure Fluctuation analysis of pump-turbine in turbine mode under the same head condition

Abstract As the key technical part of pumped-storage power station, the efficient and stable development of pump-turbine units is of great significance for renewable energy power generation. However, pump-turbine units have the characteristics of complex and variable operation conditions. In addition, under different guide vane openings, operation conditions of pump-turbine units also show different flow patterns and pressure fluctuation characteristics. For the sack of studying the pressure fluctuation characteristics of pump-turbine units in turbine mode, a dynamic model of a pump-turbine unit is established in this research. Based on SST k-ω turbulence model, combined numerical simulation and experimental test, pressure fluctuation laws in vaneless region and draft tube under three typical guide vane openings are carried out. The results indicate that, by increasing the guide vane opening, the pressure fluctuation intensity of each monitor point is decreased. Furthermore, the pressure fluctuation at the monitor points in vaneless region between guide vane and the runner presents a periodic change rule, which is mainly due to the two-stage rotor and stator interference between guide vane and runner, and between runner and draft tube. The research further clarifies the pressure fluctuation law in turbine mode, and provides theoretical reference for long-term sustainable development of pump-turbine units.

Study on the flow characteristic of pump turbine at partial load

Abstract Pump turbine adopts the same runner to realize forward pumping for pumping condition and reverse power generation for turbine condition, which is a widely used power equipment in pumped storage power station. Compared with conventional pump units or turbine units, the pump turbine has a complex internal flow, especially under part load conditions, and the vibration and noise problems of the structure are prominent. In this paper, the internal flow characteristics of the pump turbine at 60% load are studied by numerical simulation. The low-frequency pressure pulsation 3.5fn and 5.5fn that occur under this operating condition are analyzed. The results show that under partial load conditions, the opening of the guide vane decreases, the angle of attack of the water entering the runner increases, and the rotating stall phenomenon occurs in the pump turbine. The stall vortices show periodic variations on the blade inlet pressure surface and undergo the processes of vortex reduction, fusion, splitting and increase, respectively. The frequency of change is 0.5 times the runner rotation frequency (0.5fn ). The frequency of the corresponding monitoring points in the 7 blade rotor is 7 times (1fn -0.5fn ), which is 3.5fn .

Study of axial hydraulic thrust and radial force characteristics of a variable speed pump-turbine unit

Abstract When the pump turbine does variable speed operation, it can improve the operation efficiency in the turbine mode, and it can improve the automatic frequency adjustment efficiency in the pump mode. However, the hydraulic thrust will also change when the speed changes, and the magnitude of the hydraulic thrust is crucial for the safe and stable operation of the unit. The work of this paper is to analyze the changes of the axial hydraulic force and radial force with the change of the speed by numerical simulation method. It is found that the fluctuation of axial hydraulic thrust can reach about 34 t at 398.57rpm speed, 37 t at 412.16rpm speed and 21 t at 428.6rpm speed. the fluctuation of radial force can reach about 13.78 t, 14.4 t and 12.4 t. The purpose of this paper is to use the simulation results to understand the hydraulic thrust characteristics and ensure the stability of the unit to select the appropriate speed range, provide the basis for stable operation of the unit under design conditions.

The model test research of medium-low specific speed Francis pump-turbine

Abstract In the last few years, the pumped storage power station grows vigorously. As a result, the higher demand have been put forward in relevant technical fields. This article mainly discusses the model test research of medium-low specific speed Francis pump-turbine. Furthermore, the pump-turbine model test method of performance, cavitation, pressure pulsation, complex characteristics, and the rest auxiliary test is expounded and studied, with a view to optimizing pump-turbine model test method and further improving test rate. It can provide the favorable condition for the pump-turbine unit design and power station continuously operation.

Research on pressure pulsation characteristics of a pump-turbine in pump mode with rotating stall: Focus on the broadband frequency

To investigate the adverse effects of rotating stalls on the pressure pulsation characteristics of a pump-turbine in pump mode, an unsteady numerical simulation was carried out by applying the partially averaged Navier–Stokes turbulence model. The numerical methods were carefully verified, and the onset flow rate of the hump at the performance curve and heads were in good agreement with the experimental data. The rotating stall appeared in the guide vane when the flow rate ranged from 0.514 to 0.887 times the best efficiency point (QBEP), with a frequency of 11.7% times the rotational frequency. In the period of a rotating stall, a sudden intensive pressure pulsation in the guide vane channel was observed and named as the component of the broadband frequency, and its corresponding flow mechanism was explained as the vortex evolution between the adjacent guide vane blades based on the dynamic mode decomposition technology. There were three distinct characteristics of broadband frequency: (i) intermittent occurrence when the rotating stall cell propagated to the current flow channel, (ii) a wide range of the frequency varying with flow rate, (iii) a considerable amplitude, e.g., reaching 21.1%–42.2% times that of the rotating stall frequency. In addition, both the frequency range and amplitude of the broadband frequency gradually decreased as the flow rate increased to 0.887QBEP. This study clarified the internal flow mechanism and frequency behaviors of a sudden intensive pressure pulsation if a rotating stall occurred, which was important to assess the stability of pump-turbine units.

Numerical theory and method on the modal behavior of a pump-turbine rotor system considering gyro-effect and added mass effect

The pump-turbine unit is the core equipment of pumped storage power station, and the rotor system is the key component of the pump-turbine unit. In this paper, the numerical method considering the gyro-effect and added mass effect is proposed, the effect of the added mass, gyro-effect and bearing stiffness are discussed, respectively, and a “transfer” phenomenon of the mode shape is found. A coupling influence coefficient is proposed to analyze the coupling influence of gyro-effect and added mass effect on the rotor system mode, and the nodal diameter (ND) mode of runner is discussed. For the forward whirling ND mode, the coupling influence coefficient increases with the increase of the rotational speed, while for the reverse whirling ND mode, the coupling influence coefficient decreases with the increase of the rotational speed. The results in this paper can provide a theoretical basis for revealing the complex dynamic behaviors of the rotor system, and provide scientific guidance for the research and development, design, and safe and stable operation of pump-turbine units.

Effect of different draft tube designs on the phase resonance in a pump-turbine based on compressible CFD simulation

An investigation into projects with significant noise issues during full-load turbine operation revealed a distinct draft tube elbow design difference compared to more successful projects. This prompted an initiative to explore the impact of draft tube shape on pressure pulsations within the pump-turbine during full-load operation. Various draft tube designs were tested on the same prototype-scale pump-turbine unit using 3D compressible transient simulations. Results indicated increased pressure pulsation amplitude in the spiral casing for the flat elbow draft tube, accompanied by phase shifts that rendered pressure pulsations close to zero at certain locations, converting direct pulsations into indirect ones. Moreover, phase variations in the opposing runner channel aligned with multiples of the rotation period, suggesting possible cancellation of pressure pulsation waves. These improvements were confirmed through contour analysis, which showed reduced negative pressure areas in the draft tube, minimized pressure differences, and more uniform and stable streamlines. This study analyses the influence of draft tube shape on internal flow field pressure fluctuations, offering theoretical insights for enhancing pump turbine stability and guiding further research.

Power Stabilization System with Unique Pumped Storage to Stabilize Momentarily Fluctuating Power from Renewable Resources (Counter-Rotating Type Pump-Turbine Unit Operated at Turbine Mode)

This serial research proposes the hybrid power stabilization system with the counter-rotating type pump-turbine unit, to stabilize momentarily fluctuating power from renewable energy resources. In this paper, the experiments are verified that this type pump-turbine unit is reasonably effective to stabilize momentarily/instantaneously the unstably fluctuating power from renewable energy resources. Furthermore, an optimization for improving the hydrodynamic performance at turbine mode of this pump-turbine unit is carried out by using numerical analysis based on three-dimensional Reynolds-averaged Navier-Stokes equations. As a result, the optimization yielded a maximum increase in efficiency of 2.68% at the best efficiency point compared to a reference design. Detailed internal flow fields between the reference and optimum designs are analyzed and discussed in this work.

The influence of optimization algorithm on the signal prediction accuracy of VMD-LSTM for the pumped storage hydropower unit

Pumped storage hydropower units, as a crucial type of energy conversion equipment, play a pivotal role in energy storage and balance. Predicting pressure pulsation signals in pump-turbine units can help anticipate potential unit malfunctions within the pump-turbine system. However, conventional prediction methods may be constrained by their ability to extract signal features and perform pattern recognition. With the continuous advancement in the realm of artificial intelligence, there has been a rise in the evolution of prediction involving variational mode decomposition (VMD) for time series decomposition and the utilization of genetic algorithms (GAs) for parameter optimization of long short-term memory (LSTM) networks has emerged. To address the fitness function issue in the context of genetic algorithms, this study employs three optimization algorithms to combine with the VMD-LSTM model. Three different prediction models are formed and compared with both the conventional LSTM and VMD-LSTM prediction methods. The results indicate that, in the prediction of pressure pulsation data at the three monitoring points of the pump-turbine, the predictive performance of the VMD-whale optimization algorithm (WOA)-LSTM model surpasses that of the conventional LSTM model and the VMD-LSTM prediction approach. Furthermore, the magnitude of prediction errors is reduced in comparison to the VMD-sparrow search algorithm (SSA)-LSTM and VMD-improved grey wolf optimization (IGWO)-LSTM prediction models.

The Influence of Hydraulic Characteristics on Structural Performance in a Pump-Turbine under No-Load Conditions

The operating state of a pump-turbine unit under no-load conditions is directly related to its safe and stable operation. In order to probe into the influence of hydraulic characteristics on structural performance, a pump-turbine assembled in China is selected for research by using CFD (computational fluid dynamics) and unidirectional FSI (fluid–structure interaction) methods. The vortex distribution and the law of pressure pulsation propagation are analyzed to capture the peculiar flow phenomena. The results show that the vortex distribution in the runner channel appears initially at the suction side of the blades but then propagates toward the pressure side with GVO. This produces rotating stall frequencies (0.7fn) and a combination of the RSI, asymmetry of the water ring in vaneless space, and high-amplitude pressure pulsations in the downstream channel close to the runner inlet and elbow section of the draft tube. This, in turn, is associated with the structural stress of the runner and guide vane. The stress level of the guide vane becomes alleviated under no-load conditions with large GVO, but the stress distribution of the runner is no longer symmetrical, which aligns with the vortex evolution in the runner passage. The stress concentration that develops further along the blade root increases the structural failure, which is also captured and verified as a crack in the prototype runner. The phenomena suggest that the RPT should avoid operating under no-load conditions with large GVO as far as possible. Therefore, in the design or optimization of the pump-turbine unit, the structures of the guide vanes and runner could be treated as a whole to investigate the resulting internal flow and structure characteristics.

Numerical Study on the Flow and Structural Characteristics of a Large High Head Prototype Pump-Turbine under Different Operating Conditions

During the operation of pumped storage power stations, complex operating conditions can lead to different internal flow characteristics, which can cause different vibration characteristics or even damage to the structural components of the pump-turbine units. The time–frequency characteristics of the structural components’ response are of great significance for the safe operation of the unit. In this study, a three-dimensional flow field and structural field model of a large high head prototype pump-turbine is built in order to study the flow and the flow-induced dynamic response characteristics in different turbine operating conditions. The analyzed results show that the maximum deformation occurs at the inner head cover, and the maximum value of stress is located at the fillets on the outlet side of the stay vanes. Under the 50% load condition, the vortices in the runner caused by changes in the opening of the guide vanes result in the main response frequency of 4 fn of the stationary components. The research results can provide references for the structural optimization design of other pump-turbine units.

Optimal scheduling and management of pumped hydro storage integrated with grid-connected renewable power plants

Pumped hydro-energy storage will become a fundamental element of power systems in the coming years by adding value to each link in electricity production and the supply chain. The growth of these systems is essential for improving the integration of renewables and avoiding dependence on fossil fuel sources, such as gas or oil. This paper presents the modeling and application of an optimal hourly management model of grid-connected photovoltaic and wind power plants integrated with reversible pump-turbine units to maximize the monthly operating profits of the energy system and meet electricity demand. The techno-economic dispatch model is formulated as a mixed-integer optimization problem. To assess the proposed model, it is applied to a Spanish case study system, and the results are obtained for an entire year. The combination of renewable energy and pumped hydro energy storage reduces energy dependence by decreasing energy costs by 27 % compared with a system without storage to satisfy the required electricity demand. The findings confirm that storage plays a key role in energy transition to ensure the security and stability of power systems with a higher share of renewable generation.

Visualization research of energy dissipation in a pump turbine unit during turbine mode's starting up

Identifying the precise location of flow energy dissipation (FED) in pump turbines is crucial for enhancing the stability of pumped storage power stations. In this study, the transient process of the turbine mode's starting up in the pump-turbine has been simulated to examine the FED locations by using the one-dimensional and three-dimensional (1D-3D) coupled computational fluid dynamics (CFD) method. This analysis pinpoints high FED locations in each component of the pump-turbine. The observations reveals that the trailing edge of the guide vane consistently demonstrates high FED values, while wall shear stress, axial and radial forces had a significant effect on flow characteristics. Moreover, high FED sites correspond to high turbulence kinetic energy locations. Continuous wavelet transform (CWT) has been applied to examine the time-frequency characteristics during this process. Low frequency (fc = 0.12) has been identified as the dominant frequency in the volute. In the draft tube, the wavelet magnitude of the double blade passing frequency (fc = 18) is 30.4% of that under the dominant frequency (fc = 9). Regional visualization of FED offers a valuable method for the in-depth understanding of energy dissipation in pump turbines and improving operational stability in pumped storage power stations.