Search Results (30)

The erosion of Pelton turbine components in mountainous areas with high sediment input is a major challenge for energy- and cost-efficient operation. Quantitative data on possible efficiency losses associated with local damage are needed. A systematic experimental study was carried out on a model turbine to determine the efficiency losses caused by damaged needles and seat rings. For this purpose, artificial patterns of erosion-like damage were generated on the surfaces of needles and seat rings. These patterns were gradually deepened, and hill charts were measured repeatedly. The combination of needle and seat ring defects was also studied, and the finding is that superimposing the individual efficiency losses of the needle and seat ring resulted in the same efficiency loss measured for both damaged parts. The results of the measurement campaign show that damaged needles should be replaced at an early stage of deterioration, as efficiency losses can quickly add up to several percent and become unacceptable at partial load operations of the turbines. Full article

Pelton turbines are susceptible to hydro-abrasive erosion from sediment-laden flows, resulting in a progressive loss of efficiency. Typical defect classes can be derived from the analysis of such damage observed in hydropower plants. A systematic strategy was developed to investigate the effect of locally damaged Pelton runners on the efficiency in laboratory tests using a model turbine. For this purpose, nine identical runners were fabricated and machined with an increasing size, depth, or number of different artificial defect types, such as splitter, rounded or sharp-edged, defects at the cutout, defects in the bucket base, and added ripples on the bucket sides. The processing steps, the efficiency measurement, and the extracted slopes of the efficiency drops are discussed in detail. The main findings are that the efficiency losses due to the various defects increase in a good approximation linearly with the machining depth and that the individual defect types can be superimposed. Defects at the splitter, bucket base, and bucket side dominate the losses at partial load of the turbine, while those at the cutout dominate at full load. Based on the results of this measurement campaign, power plant operators can estimate the magnitude of efficiency losses in their plant. Full article

In energy transition scenarios, hydropower remains the largest source of renewable electricity generation. However, with respect to other means of renewable energy exploitation, like wind turbines or photovoltaics, very few technological advancements are to be expected, due to the technological maturity of hydropower turbines. Therefore, an increase in power production of hydropower plants can only be possible thanks to an optimization of the operation and maintenance policies, leading to improved performance, reducing energy losses and downtimes. This work proposes a practical approach to the continuous monitoring of the operational conditions of hydropower plants through the non-invasive measurement of the electrical efficiency of the generator group. To achieve this, a heat-loss based method is introduced, which enables the measurement of both the electrical generator losses and the electrical input power, along with their associated uncertainties. This method is applicable for plants of any size, does not require a production shutdown, and, since it is applied to the electrical generator, can be used with different turbine types, including Kaplan, Francis, and Pelton. It also relies on relatively simple instruments such as thermo-cameras, thermo-resistances, thermo-couples, and flow meters to measure key variables, including cooling water inlet and outlet temperatures, electrical machine external and frame temperatures, undisturbed ambient temperature, electrical power absorbed, and cooling water flow rate. The proposed methodology has been tested and validated through the application to a laboratory test rig. In all test conditions, the heat loss-based method showed a smaller relative error than the standard efficiency measurement methods. Full article

Pelton turbines frequently encounter significant sediment wear when operating in sandy river environments. The runner bucket of these turbines is particularly prone to wear, which results in considerable reductions in turbine efficiency and operational stability. This research focused on a large-scale Pelton turbine with a 500 MW standalone capacity in a sandy river setting. Numerical simulations of sand–water flow within the runner bucket were conducted using the volume of fluid (VOF) model, shear stress transport (SST) k-ω model, and the discrete phase model (DPM). Additionally, a sediment wear prediction model, based on wear tests conducted on a model turbine, was utilized to estimate sediment wear within the Pelton turbine bucket. The results indicated a maximum bucket wear rate of 2.61 × 10⁻⁷ mm/s. Specifically, the 04Cr13Ni5Mo runner bucket, typically made from stainless-steel wear-resistant material, is expected to experience over 5.62 mm of wear after one year of operation under rated conditions, emphasizing the severity of sediment wear. To prolong the operational life of the unit, further investigations into surface wear resistance treatments for the runner water buckets are recommended. Full article

In this work, the NSGA-II multi objective genetic algorithm, numerical methods, and parametric design techniques found in the Autodesk Inventor professional 2023 CAD software were combined to perform the geometrical optimization of the Pelton bucket geometry. The validation of the proposed method was carried out with numerical simulations using the OpenFOAM CFD program and taking into account the case study turbine’s operating conditions, as well as the k-SST turbulence model. The CFD simulation results and operational data from the case study turbine from the “Illuchi N°2” hydrocenter have been compared in order to validate the proposed methodology. The implementation of the NSGA-II in the design process resulted in optimized bucket geometrical parameters: bucket length, width, inlet angle, and outlet angle. These parameters not only resulted in a 2.56% increase in hydraulic efficiency, but also led to a 0.1 [kPa] reduction in the maximum pressure at the bottom of the bucket. Further research will involve testing these parameters using 3D printing methods to validate their effectiveness. Full article

The Pelton turbine has been widely applied for the advantages of its simple structure, flexible mass flow rate, wide range of applicable heads and high efficiency. The nozzle and needle are a core part of the Pelton turbine injector. In this paper, the VOF (Volume of Fluid) model was used to simulate the jet flow behaviors and hydraulic performance for a Pelton injector with a needle tip with different breakage losses. Three types of needle tip breakage loss combined with normal needle tip were selected for numerical calculation and analysis, focusing on the influence of needle tip on the high-speed jet flow characteristics. An injector with normal needle tip hydraulic performance is compared with the model test. Finally, the injector hydraulic performance and the jet flow behavior changes with the needle tip shape were comprehensively analyzed. Results show that the needle tip shape almost does not affect the flow rate; when the tip breakage loss is larger than 0.1 of nozzle diameter, the jet efficiency will decrease rapidly and the jet will diffuse rapidly after outflow from the injector. The investigation provides a basis for the operation, maintenance and stability of the Pelton turbine. Full article

The Pelton turbine is an ideal choice for developing high-head hydropower resources. However, its cantilever-beam structure exposes the runner to intense alternating loads from high-velocity jets, causing localized high stresses, structural vibrations, and potential bucket fractures, all of which compromise safe operation. This study employs fluid–structure interaction analysis for the numerical investigation of a six-nozzle Pelton turbine to examine its unstable flow characteristics and hydrodynamic excitation under high-velocity jets. Our findings indicate that low-order frequencies primarily induce overall runner oscillations, while high-order frequencies result in oscillation, torsional displacement, and localized vibrations. Torsional displacement at the free end of the bucket induces stress concentrations at the root of the bucket and the splitter, the outflow edge, and the cut-out. The amplitudes of stress and displacement are correlated with the nozzle opening, with displacement typically in phase with torque, while stress fluctuations exhibit a phase lag. The stress and displacement values are higher on the bucket’s front, with maximum stress occurring at the bucket root and maximum displacement at the outflow edge, particularly in regions subjected to prolonged jet impact. The dominant frequency of the stress pulsations matches the number of nozzles. This study elucidates the dynamic response of Pelton turbines under high-velocity jets, correlating fluid load with runner dynamics, identifying maximum stress and deformation points, and providing technical support for performance evaluation. Full article

Sediment erosion of hydraulic turbines is a significant challenge in hydropower plants in mountainous regions like the European Alps, the Andes, and the Himalayan region. The erosive wear of Pelton runner buckets is influenced by a variety of factors, including the size, hardness, and concentration of silt particles; the velocity of the flow and impingement angle of the jet; the properties of the base material; and the operating hours of the turbine. This research aims to identify the locations most susceptible to erosion and to elucidate the mechanisms of erosion propagation in two distinct designs of Pelton runner buckets. The Pelton runner buckets were subjected to static condition tests with particle sizes of 500 microns and a concentration of 14,000 mg/L. The buckets were coated with four layers of paint, sequentially applied in red, yellow, green, and blue. The two Pelton buckets, $D_1$ and $D_2$, were evaluated for their erosion resistance properties. $D_2$ demonstrated superior erosion resistance, attributed to its geometrical features and material composition, lower erosion rates, less material loss, and improved surface integrity compared with D1. This difference is primarily attributed to factors such as the splitter’s thickness, the jet’s impact angle, the velocity at which particles strike, and the concentration of sand. $D_2$ exhibits a great performance in terms of erosion resistance among the two designs. This study reveals that the angle of jet impingement influences erosion progression and material loss, which is important to consider during a Pelton turbine’s design and operating conditions. Full article

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. Full article

The sediment erosion of Pelton turbine components is a major challenge in the operation and development of high-head water resources, especially in mountainous areas with high sediment yield. In this paper, a study using numerical simulation was conducted with different sediment particle sizes in the fine sand range. And the erosion mechanism of the Pelton turbine injector was analyzed. The Eulerian Lagrange method was adopted to simulate the gas–liquid–solid flow. The Mansouri’s model was applied to estimate the injector erosion. The predicted erosion results were in accord with field erosion photographs. In particular, the asymmetrical erosion distribution on the needle surface was physically reproduced. With the sediment particle size increasing from 0.05 mm, the needle erosion rate decreased, while the nozzle casing erosion rate increased dramatically. In order to clarify this tendency, the characteristics of the three-phase flow were analyzed. Interestingly, the results show that with the rise in particle size, the separation of particles and water streamlines became more serious in the contraction section of the nozzle mouth. Consequently, it caused the enhancement of erosion of the nozzle surfaces and weakened the erosion of the needle surfaces. Significant engineering insights may be provided for weakening Pelton injector erosion with needle guides in the current study. Full article

Hydro-pneumatic energy storage is a form of compressed-air energy storage that can provide the long-duration storage required for integrating intermittent renewable energies into electrical power grids. This paper presents results based on numerical modelling and laboratory tests for a kilowatt-scale HPES system tested at the University of Malta. This paper presents measurements of the discharge cycle, in which energy stored in compressed air within a pressure vessel is hydro-pneumatically converted back into electricity via a Pelton turbine and fed into the national electricity grid. The tests were conducted using a hydraulic turbine operated under different fixed-turbine rotational speed settings, with the pressure being allowed to decrease gradually during the HPES system’s discharge cycle. The system’s overall efficiency accounted for flow losses, turbine inefficiencies, and electrical losses. The tests showed that this efficiency was practically independent of the compressed-air pressure of specific water turbine runner speeds, despite the water turbine operating at fixed speeds. A numerical model developed in MATLAB Simulink (R2022a) was also presented for use simulating the hydraulic performance of the system during the discharge cycle. The model used secondary loss coefficients for the hydraulic circuit and derived velocity coefficients from computational fluid dynamics (CFD) for the Pelton turbine nozzle. We achieved very good agreement between the predictions based on numerical modelling and the measurements taken during laboratory testing. Full article

The Pelton turbine has been widely regarded as the most efficient hydro turbine for high-head applications. However, the Pelton turbine buckets, especially the area commonly referred to as the ‘splitter’, are highly susceptible to erosion, drastically reducing efficiency over prolonged periods of time. This paper demonstrates a novel turbine idea that has been validated through both computational and experimental methods. This turbine addresses the issues associated with the erosion of the splitter through a redesign of the Pelton turbine to remove the need for a splitter and therefore potentially reducing downtime due to maintenance. The computational fluid dynamics (CFD) simulation results show that the turbine is capable of efficiencies greater than 82% with room for further improvement. The practical experimental results also show efficiencies within 6% of an optimized Pelton turbine. The results from this study indicate that through further optimization this turbine design could provide a means to produce power outputs similar to conventional Pelton turbines, with the added benefit of lower maintenance costs. Full article

As the world strives towards its goal of net zero carbon emissions, it is vital that renewable energy sources be optimized to their full potential. A key source of renewable energy is hydropower, more specifically, the Pelton turbine—a highly efficient, widely used, and well-researched piece of turbomachinery. This review proposes a methodology that will aid future research on Pelton turbines and compares relevant literature to assess effective ways to improve upon the Pelton design. The methodology evaluates how both experimental and computational analysis can be utilized in parallel to accelerate the progress of research, giving an example of the adopted workflow presented in a case study. The literature study in this paper focuses on how a variety of bucket parameters can be optimized to improve the efficiency of a Pelton turbine and analyses the accuracy of CFD compared to experimental data from previous research involving Pelton and Turgo turbines. The findings revealed that a water exit angle of 169°–170° proved to be optimal, while modifications to the depth and internal geometry of the bucket seemed to have the greatest impact on the efficiency of Pelton turbines. A short discussion on the potential for utilizing the strengths of both Pelton and Turgo turbines is included to highlight the need for further research in this field. A combination of both simulation and experimental results running in parallel with each other during optimization is found to be beneficial due to advancements in rapid prototyping. By comparing experimental data with simulated data throughout the optimization process, mistakes can be realized early on in the process, reducing time in later stages. Having experimental data throughout the turbine’s development aids the computational process by highlighting issues that may have been missed when only using CFD. Full article

When a Pelton turbine operates in sand laden water, the abrasive wear of its overflow components by high-speed jets is serious. Based on the VOF (volume of fluid) multiphase flow model, the SST (shear stress transfer) k-ω turbulence model, the particle motion Lagrangian model, the generic wear model, and the SIMPLEC (Semi-Implicit Method for Pressure Linked Equations Consistent) algorithm, the liquid–air–solid three-phase flow in the key overflow components of a Pelton turbine were simulated, the abrasive wear was predicted, and the internal sand-water flow characteristics and the abrasive wear of the overflow components were analyzed. The results show that the trailing edge at the root of the runner bucket, the leading face of the bucket near the root, the notch, and the splitter are severely worn. The abrasive wear of the splitter and the notch is more severe than that of the leading face of the bucket. The wear rate from the splitter to the trailing edge increases first and then decreases. The wear pattern of the needle tip is mainly “dotted”, while that of the nozzle opening is “flaky”, and the abrasive wear of the nozzle opening is more severe than that of the needle. The predicted results are consistent with the actual conditions at the site of the power station. This study provides a technical method for the prediction of abrasive wear of the Pelton turbine and a technical basis for the operation and maintenance of the power station. Full article

During the operation of a Pelton turbine, the centerline of the nozzle jet may deviate from the bucket pitch circle due to the low installation and maintenance accuracy, which will reduce the operating efficiency and the stability of the turbine and even cause severe vibrations and damages. Based on the VOF (Volume of Fluid) two-phase flow model and the SST k-ω turbulence model, the flow characteristics of a Pelton turbine were simulated with the nozzle jet deviating from the bucket pitch circle. The pressure pulsation inside the bucket and the force distribution of the runner were obtained, the turbine oscillation and efficiency were measured before and after the jet deviation, and the effects of the radial and axial deviations on the stability and efficiency of the Pelton turbine were analyzed. The results show that both the radial and axial deviations of the jet cause a significant increase in the axial force and the pressure pulsation amplitude of the turbine; the radial and tangential forces on the runner are slightly reduced; the maximum axial force on the runner is increased by 4 times and 2 times, respectively, after the axial and radial deviations within the maximum value allowed by the industry standard; and the efficiency of the turbine is reduced by 0.4% and 0.3%, respectively. The maximum relative amplitude of pressure pulsation in the radial offset case appears in the center of the bucket blade, while the axial offset case causes uneven pressure distribution on both sides of the diverter blade, uneven force on the bucket blade of the runner, and fatigue damage. By comparing the operation of the runner under the two offset cases, we can find that the axial offset of the jet has a greater impact on the stability of the runner than the radial offset, and the unit is more prone to vibration, increasing the risk of the unit lifting. Full article