Computation of erosion in a hydro turbine

PurposeThis study aims to investigate the trajectories of sand particles and erosion wear in a hydraulic turbine model.Design/methodology/approachThe Lagrangian-based approach is used to track large numbers of sand particles and determine their impact through the hydro turbine components. The tracking procedure includes the stochastic eddy interaction model and the squeeze film effect. The number of particles, sizes and release positions are conformed to the particle concentration and size distribution. The impact locations, frequency and conditions of impacts are used to estimate the erosion rates and thereby the eroded mass from the distributor vane and the rotor blade and their deteriorated geometry.FindingsThe patterns of erosion in the stationary and rotating parts differ significantly and the effect of the initial position of the runner blade is elucidated. The distributor vane is characterized by a widespread of erosion over the pressure side. Typically, the surface beyond the throat and the root and tip junctions are the regions prone to erosion wear. The entry region of the runner blade is subject to a high number of impacts resulting in high erosion rates visible from the forepart of the blade pressure side.Practical implicationsThe erosion patterns and geometry deterioration may serve to evaluate the drop in the hydraulic performance and to select the appropriate surface coating to extend the lifetime of the turbomachinery parts and reduce the maintenance cost.Originality/valueErosion developments reveal a strong dependence on the blade position against the distributor vane and the particle size and concentration level.

Analysis of Stress-Strain State and Contact Pressures on Surfaces of Kaplan Runner Blade Bearing Bronze Bushes

An analysis of the existing and prospective blade seal designs for Kaplan runners was performed. The selected design type provides the maximum ecological safety for Kaplan runners. A 3D model of runner hub sector with the trunnion, inner and outer bushes of blade trunnion was generated taking into account the cyclic symmetry of the runner design based on the modern automated design engineering system. A diagram of application of external loads from the blade and lever to the given 3D model of the Kaplan runner hub segment was developed. The contact problem was formulated to determine the stress-strain state as well as the contact pressures at the inner and outer bronze bushes of the Kaplan runner blade trunnions in different operating conditions. The problem was formulated for the finite element method, taking into consideration the diagram of external load application and contact restraints to the given 3D model of the Kaplan runner hub sector in the software package for engineering calculations. Using calculation results, principal stress distribution diagrams and the distribution diagram for the contact pressure at the outer and inner bronze bushes of blade trunnions were obtained. Strength calculation results were processed using the data of principal stress distribution diagrams, and the contact pressure values at the inner and outer bronze bushes of blade trunnions were determined. A methodology for further use of the given analytical model in the evaluation of stress-strain state of Kaplan runners involving modern automated design engineering systems and software package for engineering calculations was developed. The comparison of stress-strain states of the blade trunnion bushes was performed for the old and new designs of the Kaplan runner seal.

Leakage Vortex Progression through a Guide Vane’s Clearance Gap and the Resulting Pressure Fluctuation in a Francis Turbine

A clearance gap (CG) between guide vanes (GVs) and facing plates exists at both ends of a Francis turbine and allows the opening angle to be adjusted for varying operating conditions. Leakage flow is induced through this gap due to the pressure difference between the two sides of the guide vanes. While some research works have used qualitative approaches to visualize and predict the strength of a leakage vortex (LV), this paper presents a method for quantifying vortices along a trajectory. In this paper, a prototype high-head Francis runner with specific speed of 85.4 is considered as a reference case. A systematic investigation across both space and time is carried out, i.e., analysis of the spatial temporal progression of LV for three operating conditions. While travelling from the CG to runner leading edge, LV evolution and trajectory data are observed and the values of vorticity and turbulent kinetic energy are calculated for the LV trajectory. Frequency spectrum analyses of pressure oscillations in the vaneless space, runner blade, and draft tube are also performed to observe the peak pressure pulsation and its harmonics. Unsteady fluctuations of the runner output torque are finally studied to identify the patterns and magnitudes of torque oscillations.

Prediction of the Cavitation over a Twisted Hydrofoil Considering the Nuclei Fraction Sensitivity at 4000 m Altitude Level

Cavitation phenomenon is important in hydraulic turbomachineries. With the construction of pumping stations and hydro power stations on plateau, the influence of nuclei fraction on cavitation becomes important. As a simplified model, a twisted hydrofoil was used in this study to understand the cavitation behaviors on pump impeller blade and turbine runner blade at different altitude levels. The altitudes of 0 m, 1000 m, 2000 m, 3000 m and 4000 m were comparatively studied for simulating the plateau situation. Results show that the cavitation volume proportion fcav increases with the decreasing of cavitation coefficient Cσ. At a specific Cσ, high altitude and few nuclei will cause smaller size of cavitation. The smaller Cσ is, the higher the sensitivity Δfcav is. The larger Cσ is, the higher the relative sensitivity Δfcav* is. On the twisted foil, flow incidence angle increases from the sidewall to mid-span with the decreasing of the local minimum pressure. When Cσ is continually decreasing, the size of cavitation extends in spanwise, streamwise and thickness directions. The cavity is broken by the backward-jet flow when Cσ becomes small. A tail generates and the cavity becomes relatively unstable. This study will provide reference for evaluating the cavitation status of the water pumps and hydroturbines installed on a plateau with high altitude level.

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.