Search Results (22)

This study investigates an inlet design for a gravitational vortex turbine (GVT), drawing inspiration from the ancient Nazca puquios. The puquios are ingenious subterranean aqueducts constructed by the Nazca culture (c. 100 BC–800 AD) in southern Peru, featuring spiral ojos de agua (water eyes) used to access groundwater and stabilize flow.The primary objective was to enhance vortex stability and overall GVT efficiency under low-head, low-flow operating conditions. A parametric Nazca-type inlet feeding a conical basin was defined by two controlling factors: the number of turns (N) and the inclination angle ($\theta$). The optimal geometry was determined through a $3^2$ full factorial design, computational fluid dynamics (CFD) simulations, and response surface methodology (RSM), with vortex circulation $(\Gamma )$ serving as the optimization metric. The best-performing inlet configuration ($N=4$, $\theta ={13}^{\circ }$) yielded $\Gamma =1.3459$ m²/s. This circulation level is comparable to that reported for optimized conventional wrap-around inlets at similar flow rates, but uniquely produced a broader and more symmetric vortex structure. Subsequently, two four-bladed runners (one with twisted blades and one with curved cross-flow blades) were evaluated numerically and experimentally using a laboratory-scale prototype operated at a consistent flow rate ($Q\approx 0.00143$ m³/s). CFD predicted maximum efficiencies of $15.37\%$ and $17.07\%$ for the twisted and curved runners, respectively, while experimental tests achieved $8.70\%$ and $11.61\%$, demonstrating similar efficiency ($\eta$) versus angular velocity ($\omega )$ characteristics. These results indicate reduced hydraulic effectiveness of the Nazca-inspired geometry for the GVT, with experimental efficiencies below those reported in the literature. Full article

Sediment erosion is a persistent problem that leads to the deterioration of hydro-turbines over time, ultimately causing blade failure. This paper analyzes the dynamics of sediment in water and its effects on a small Kaplan turbine. Flow data is obtained independently and transferred to a separate Lagrangian-based finite element code, which tracks particles throughout the computational domain to determine local impacts and erosion rates. This solver uses a random walk approach, along with statistical descriptions of particle sizes, numbers, and release positions. The turbine runner features significantly twisted blades with rounded corners, and complex three-dimensional (3-d) flow related to leakage and secondary flows. The results indicate that flow quality, particle size, concentration, and the relative position of the blades against the vanes significantly influence the distribution of impacts and erosion intensity, subsequently the local eroded mass is cumulated for each element face and averaged across one pitch of blades. At the highest concentration of 2500 mg/m³, the results show a substantial erosion rate from the rotor blades, quantified at 4.6784 × 10⁻³ mg/h and 9.4269 × 10⁻³ mg/h for the nominal and maximum power operating points, respectively. Extreme erosion is observed at the leading edge (LE) of the blades and along the front part of the pressure side (PS), as well as at the trailing edge (TE) near the hub corner. The distributor vanes also experience erosion, particularly at the LE on both sides, although the erosion rates in these areas are less pronounced. These findings provide essential insights into the specific regions where protective coatings should be applied, thereby extending the operational lifespan and enhancing overall resilience against sediment-induced wear. Full article

Francis turbines operating in sediment-laden flows experience efficiency loss and reduced service life due to abrasive wear. To enhance wear resistance, this study optimized the turbine at Mupo Hydropower Station in Sichuan Province. Using the Plackett–Burman design, three runner parameters were identified as most influential: blade number, inlet setting angle, and outlet setting angle. A central composite design based on response surface methodology was then applied to these factors. Multiple regression models linking the parameters to turbine head, efficiency, and wear rate were established, revealing a trade-off between hydraulic performance and wear resistance. Multi-objective optimization, a method that simultaneously addresses and balances multiple competing goals, was performed to minimize wear rate while maintaining the original head. The optimal parameter combination was obtained as follows: blade number Z₃ = 17, inlet setting angle ${\alpha }_1$ = 65°, and outlet setting angle ${\alpha }_2$ = 22°. Numerical results demonstrate a 32.3% reduction in runner wear under these parameters, with the head requirement satisfied, confirming a significant improvement in overall turbine performance. Full article

The low-pressure edge of a pump-turbine runner blade is more prone to cavitation than other parts. The installation angle of the blade’s low-pressure edge is one of the key parameters affecting the cavitation performance of the pump-turbine. Based on the installation angle of the blade’s low-pressure edge obtained by the principle of normal outflow of the turbine runner, two other installation angles of the low-pressure edge are constructed by increasing the installation angle of the low-pressure edge toward the band direction. Three types of blades are designed based on the parametric design program of the pump-turbine runner. The Zwart cavitation model is adopted to carry out full-channel steady numerical simulations for the three runners. The efficiencies and internal flow fields of the draft tube under turbine operating conditions are compared. The cavitation characteristics in pump mode, the distribution of the turbulent flow field, and the pressure distribution on the blade surface are analyzed. The influence laws of the installation angle of the blade’s low-pressure edge on pump-turbine performance is summarized. A design method for anti-cavitation of Francis pump-turbine runners has been explored. The results show that the LP1 blade can achieve normal outflow under the turbine’s rated operating condition, but due to the large inflow attack angle under pump operating conditions, the cavitation performance in pump mode is very poor. By increasing the installation angle of the blade’s low-pressure edge toward the band direction, the efficiencies and cavitation performances of the pump mode can be improved. The LP3 blade reduces the inflow attack angle while optimizing the pressure distribution on the blade’s suction surface, thereby reducing the superimposed effect of two phenomena under large-discharge pump operating conditions with low cavitation numbers: flow separations on the pressure surface caused by inflow impact, and flow separations on the suction surface of adjacent blades caused by cavitation. As a result, the cavitation performance of the LP3 blade is significantly better than that of the LP1 and LP2 blades. The proposed anti-cavitation design method is simple and effective and can be applied to the research and modification design of Francis pump-turbine runners. Full article

As a core component in renewable energy systems for grid regulation, hydropower units are increasingly exposed to flow conditions that elevate the risk of cavitation and erosion, posing significant challenges to the safe operation of flow-passage components. In this study, model testing and computational fluid dynamics (CFD) simulations are employed to investigate the hydraulic performance and cavitation behavior of a bulb turbine operating under rated head conditions and varying cavitation numbers. The analysis focuses on how changes in cavitation intensity affect flow characteristics and efficiency within the runner region. The results show that as the cavitation number approaches its critical value, the generation, growth, and collapse of vapor cavities increasingly disturb the main flow, causing a marked drop in blade hydraulic performance and overall turbine efficiency. Cavitation predominantly occurs on the blade’s suction side near the trailing edge rim and in the clearance zone near the hub, with bubble coverage expanding as the cavitation number decreases. A periodic inverse correlation between surface pressure and the cavitation area is observed, reflecting the strongly unsteady nature of cavitating flows. Furthermore, lower cavitation numbers lead to intensified pressure pulsations, aggravating flow unsteadiness and raising the risk of vibration. Full article

Cross-flow turbines are widely used in microhydropower systems because of their cost-effectiveness, environmental sustainability, adaptability, and robust design. However, their relatively lower efficiency than other turbine types limit their application in large-scale projects. Previous studies have identified poor flow profiles as a significant factor contributing to inefficiency, with the number of blades playing a critical role in the flow behavior, efficiency, and structural stability. This study employed numerical simulations to analyze how varying the number of blades affects the internal flow characteristics and performance of the turbine at, and off, its best operating points. Configurations with 16, 20, 24, 28, 32, 36, 40, and 44 blades were investigated under constant low-head conditions, fully open valve settings, and varying runner speeds. Simulations were performed using ANSYS CFX, incorporating steady-state conditions, a two-phase flow model with a movable free surface, and a shear stress turbulence model. The results indicate that the 28-blade configuration achieved a maximum hydraulic efficiency of 83%, outperforming the preset 24-blade setup by 6%. Flow profiles were examined using pressure and velocity gradients to identify regions of adverse pressure. Due to the impulse nature of the turbine, the flow profile is more sensitive to changes in the flow speed than to pressure. The flow trajectory showed stability in the first stage but exhibited discrepancies in the second stage, which were attributed to turbulence, recirculation, and shaft flow impingement. The observed performance improvements were linked to reduced hydraulic losses due to flow separation and friction, emphasizing the significance of the number of blades and the regions of optimal efficiency under low-head conditions. Full article

The pump turbine, as the core equipment of a pumped storage power plant, is most likely to operate in the hump zone between condition changes, which has a great impact on the stable operation of the power plant, and the high sedimentation of a natural river will lead to wear and tear in the overflow components of the equipment. Therefore, this paper is based on the Euler–Lagrange model, and seeks to investigate the distribution of vortices in the hump zone of the pump turbine and its effect on the movement of sand particles. The study shows that as the flow rate increases, the strip vortex in the straight cone section of the draft tube becomes elongated, and the cluster vortex in the elbow tube section gradually decreases. The strip vortex encourages the sand particles to move along its surface, while the cluster vortex hinders the movement of the sand particles. The accumulation areas of the sand particles in the straight cone section and the elbow tube section increase axially and laterally, respectively. The blade vortex in the runner gradually occupies the flow channel as the flow rate increases, and the blade vortex near the pressure surface encourages the sand particles to move towards the suction surface, resulting in the serious accumulation of sand particles on the suction surface. As the flow rate increases, the number of blades where sand particles accumulate increases and the accumulation area moves towards the cover plate and the outlet. The flow separation vortex in the double-row cascade decreases as the flow rate increases, which drives the sand movement in the middle and lower sections of the vanes. The area of sand accumulation in the stay vane decreases with increasing flow rate, but the area of sand accumulation between the guide vanes increases and then decreases. The vortex on the wall surface of the volute gradually decreases with the flow rate, and the vortex zone at the outlet first decreases, then disappears, and finally reappears. The vortex at the wall surface suppresses the sand movement, and its sand accumulation area changes from elongated to lumpy and finally to elongated due to the increase in flow. The results of the study provide an important theoretical reference for reducing the wear of pump turbine overflow components. Full article

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. Full article

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. Full article

The growing installation of intermittent renewable energy sources is forcing hydraulic turbines to work more frequently at speed no load when dangerous vaneless space vortex structures and stochastic flow phenomena can occur. An experimental campaign has been performed in a reduced-scale Kaplan turbine model at speed no load for different combinations of guide vane and runner blade angles under non-cavitation and cavitation conditions. Several simultaneous vaneless space vortex structures, all of them inducing torsional rotor vibrations, have been observed. Nonetheless, only one of them has been found to dominate over the rest depending on the blade and guide vane angles. Off-board pressures, torques and vibrations as well as on-board strains have been measured to characterize their nature, intensity, dynamic behavior and induced structural response. Their precession frequencies have been found to depend on the discharge factor, the number of vortices and their location inside the vaneless space. Under cavitation conditions, their dynamic behavior has not been significantly altered but the induced structural response has increased at the low-pressure side of the turbine. Full article

When an axial-flow pump is running, there is a very complex flow inside the runner. Based on the two-way fluid–structure coupling method, this paper simulated the forward and reverse operating conditions of an axial-flow pump and calculated the dynamic stress distribution on the blade surface. The stress load spectrum was loaded onto the blade, and fatigue characteristic analysis was carried out to obtain the fatigue life and damage of the blade. This research shows the following: under different working conditions, the dynamic stress is concentrated at the root of the blade, and its amplitude decreases with the increase in the flow rate; at the same time, the change in stress with time shows a periodic change law. Under the working conditions of the turbine, the main frequency is the rotational frequency, and the secondary frequency is composed of multipliers of the rotational frequency, which is obviously affected by the number of blades; the fatigue damage and stress distribution are consistent, and the damage is the most serious at the stress concentration point. The research results of this paper can provide theoretical guidance for the structural design and safe operation of axial-flow pumps. Full article

Inside the pump-turbine, energy is irreversibly lost due to turbulent pulsations in the high Reynolds number zone and actions of viscous forces close to the wall. The conventional differential pressure method cannot obtain specific details of the hydraulic loss within the machine’s flow passages; on the other hand, the entropy production method can provide accurate information on the location of irreversible losses and the spatial distribution of energy dissipation. Therefore, based on the entropy production theory, this study investigates the composition and distribution of hydraulic losses under different flow conditions for a prototype pump-turbine in pump mode. Study results indicated that total hydraulic losses significantly decreased, then slowly increased with an increase in flow rate. The entropy production rate caused by turbulence dissipation (EPTD), direct dissipation (EPDD), and wall shear stress (EPWS) displayed the same variation patterns as that of total hydraulic losses, with EPTD and EPDD being the most dominating. The location of hydraulic loss within the pump-turbine’s flow domain strongly depended on flow conditions. High hydraulic losses primarily occurred in the guide vanes (GV) and draft tube under low flow rates. Under high flow conditions, however, high hydraulic losses were mostly concentrated in the stay vanes (SV), spiral casing, and GV. Hydraulic losses at low flow rates were primarily caused by flow separation within the GV flow channels, vortices in the vaneless region, and inlet flow impacts on the runner blade’s leading edge. On the other hand, large vortices within the GV and SV flow channels, GV wake flow, and unsteady flow at the spiral casing were the main contributors to hydraulic loss under high flow conditions. EPDD was mainly caused by strain rate, so it was closer to the main vortex regions, whereas EPTD was affected by turbulence intensity and had a wider distribution range in the unsteady flow. Full article

To prevent lifetime shortening and premature failure in turbine runners, it is of paramount importance to analyse and understand its dynamic response and determine the factors that affect it. In this paper, the dynamic response of a Kaplan runner is analysed in air by numerical and experimental methods. First, to start the analysis of Kaplan runner mode shapes, its geometry is simplified and modelled as a bladed disk. Bladed disks with different blade numbers are investigated, by numerical simulation, in order to understand the influence of this parameter on its modal characteristics. Then, mode shapes extracted are characterized and a classification is proposed. Second, an existing Kaplan runner is simulated by Finite Elements Method (FEM) and its mode shapes are extracted. The obtained results are contrasted with the bladed disks mode shapes, in order to validate the classification proposed. The simulated Kaplan runner is also experimentally studied. A numerical modal analysis is carried out in the real runner. Different, global and local, mode shapes are identified. The global mode shapes extracted by numerical and experimental modal analysis are compared and discussed. Finally, the local mode shapes identified are commented and explained by means of numerical simulation. Full article

The role of hydropower has become increasingly essential following the introduction of intermittent renewable energies. Quickly regulating power is needed, and the transient operations of hydropower plants have consequently become more frequent. Large pressure fluctuations occur during transient operations, leading to the premature fatigue and wear of hydraulic turbines. Investigations of the transient flow phenomena developed in small-scale turbine models are useful and accessible but limited. On the other hand, experimental and numerical studies of full-scale large turbines are challenging due to production losses, large scales, high Reynolds numbers, and computational demands. In the present work, the operation of a 10 MW Kaplan prototype turbine was modelled for two operating points on a propeller curve corresponding to the best efficiency point and part-load conditions. First, an analysis of the possible means of reducing the model complexity is presented. The influence of the boundary conditions, runner blade clearance, blade geometry and mesh size on the numerical results is discussed. Secondly, the results of the numerical simulations are presented and compared to experimental measurements performed on the prototype in order to validate the numerical model. The mean torque and pressure values were reasonably predicted at both operating points with the simplified model. An analysis of the pressure fluctuations at part load demonstrated that the numerical simulation captured the rotating vortex rope developed in the draft tube. The frequencies of the rotating and plunging components of the rotating vortex were accurately captured, but the amplitudes were underestimated compared to the experimental data. Full article

The Karman vortex street is a common flow phenomenon. In hydraulic machinery, it is usually located downstream of the guide vanes and the runner blades, which reduces hydraulic performance and may also cause fatigue damage to the structure. The latest research suggested that the difference in velocity gradient on each side of the blade trailing edge may have a significant impact on the strength of the wake vortex. The current work aims to verify the above conclusion and further explore the influence of asymmetry of flow velocity on the wake vortex. A numerical model with the velocity ratio, α, between the two sides of the hydrofoil as the only variable was designed, and the wake characteristics were solved by a computational fluid dynamics (CFD) method based on the finite volume. The unsteady Reynolds-average Navier–Stokes (URANS) equations were numerically solved by coupling with a transitional shear-stress transport (SST) turbulence model. The results showed that with the increase of α, the vortex shedding frequency decreased first, and then increased after reaching the critical velocity ratio α_c1 ≈ 1.4. The vortex intensity first gradually decreased, and the vortex street suddenly disappeared after reaching the critical velocity ratio α_c2 ≈ 2.2. The value of α_c1 was affected by the thickness of the trailing edge, and α_c2 was affected by the thickness and the Reynolds number. Besides, the asymmetry of the flow velocity also affected the effectiveness of the trailing-edge trimming. This research can provide references for the design of hydraulic machinery and other submerged structures. Full article