Robust Control Design for Kaplan Turbine

The paper presents the dynamic model of a Kaplan turbine coupled to a DC generator, which is part of the H112D didactic system. A robust controller is designed using two different techniques: H ∞ mixed sensitivity and Quantitative feedback Theory (QFT). The robustness of the controller was analysed with three indicators: analysis of parameter uncertainties, transient response given a variable reference signal and robustness against disturbances.

A Brief History of the Kaplan Turbine Invention

One of the most important milestones in the history of hydropower is the invention of the Kaplan turbine. It is a machine stemming from the Francis turbine, which Viktor Kaplan was originally trying to improve. However, it gradually developed into the creation of a completely new solution of an impeller with an axial flow rate and adjustable blades. The first patent relating to the new invention dates from 1913. Shortly afterwards, the Kaplan turbine became the most widely used type of device for the use of low heads and variable flow rates. That meant a significant expansion of the potential of economically usable hydropower. The article briefly introduces the history of turbine development. The overall picture is then completed by a few less-known historical documents.

Numerical Model on the Dynamic Behavior of a Prototype Kaplan Turbine Runner

Experimental and numerical investigations of the modal behavior of a prototype Kaplan turbine runner in air have been conducted in this paper. The widely used roving accelerometer method was used in the experimental modal analysis. A systematic approach from a single blade model to the whole runner has been used in the simulation to get a thorough understanding. The experimental results show that all the detected modes concentrate their displacements on the impacted blade. The numerical results show that the modes of the single blade form different mode families of the runner, and each mode family corresponds to a narrow frequency band. Harmonic response analysis shows that, at the response peak point, the single blade excitation can only get mode shapes with concentrations on the exciting blade due to the superposition of the close modes in each mode family, which explains the experimental results well, while the mode superposition can be avoided by the order excitation method. With the reduction of the connection stiffness between the blades and hub/control system, the frequencies of most modes change from insensitive to more and more sensitive to the connection stiffness change, which results in a sensitive area and an insensitive area. Through comparison with the experimental results, it is indicated that the natural frequencies of the runner can probably be predicted by merging the runner into a whole body.

Performance of Kaplan Turbine Operating at Design Condition

Design and optimization using computational fluid dynamics to enhance the hydro turbine’s performance are becoming gradually more common because of its flexibility, minor detailed flow description, and cost-effectiveness. These features are not easily achievable in model testing. k–ω simulations conducted in OpenFOAM 7 characterize the flow structure inside an industrial-sized Kaplan turbine module operating at the peak design flowrate. The power signal, velocity, vorticity, and pressure field are presented over the blades and throughout the draft tube. Additionally, pressure fluctuations were probed along the draft tube wall. The simulation shows a tip vortex rope in the narrow gap between the blade tip and turbine casing. The strong influence of the swirl leaving the runner had a negative impact on the flow pressure fluctuation. Also, high vortical activity was presented near the draft tube wall, leading to turbine instability. It was demonstrated that the turbine generates 14.923 MW of average power. The power signal showed minor fluctuations induced by the vortical activity close to the runner region and the corresponding pressure fluctuations. The Fast Fourier Transform showed the system is dominated by low frequency, high amplitude fluctuations.

Numerical Investigation of the Trailing Edge Shape on the Added Damping of a Kaplan Turbine Runner

Hydraulic turbine runners experience high excitation forces in their daily operations, and these excitations may cause resonances to runners, which may induce high vibrations and shorten the runner's lifetimes. Increasing the added damping of runners in water can be helpful to reduce the vibration level during resonances. Some studies have shown that the modification of the trailing edge shape can be helpful to increase added damping of hydrofoils in water. However, the influence of blade trailing edge shape on the added damping of hydraulic turbine runners has been studied in a limited way before. Due to the difficulties to study this problem experimentally, the influence of blade trailing edge shape on a Kaplan turbine runner has been studied numerically in this paper and the one-way FSI method was implemented. The performances of three different turbulence models, including the k − ϵ , k − ω SST , and transition SST models, in the added damping simulation of the NACA 0009 hydrofoil were evaluated by comparing with the available results of the two-way FSI simulation in the references. Results show that, unlike the significantly different performances in the two-way FSI method, the performances of all the turbulence models are very close in the one-way FSI method. Then, the k − ϵ turbulence model was applied to the added damping simulation of a Kaplan turbine runner, and results show that the modification of the blade trailing edge shape can be helpful to increase the added damping to some extent.