Berhanu Mulu

Hydraulic axial turbines are more frequently utilized for grid regulation purposes. Sometimes, they must be operated at speed-no-load (SNL) conditions, which is characterized for some machines by a varying number of large vortical flow structures extending from the vaneless space to the draft tube, introducing detrimental pressure pulsations throughout the turbine. A recent study shows that the vortices can be mitigated by individually controlling the guide vanes. Since optimization of the distributor layout is linked with a large degree-of-freedom, machine learning is deployed to assist in finding an optimal setup cost-effectively. A reduced numerical computational-fluid-dynamics (CFD) model is built and used to generate input for Gaussian process regression surrogate models by performing 2000 steady-state simulations with varying distributor layouts. The surrogate models suggest that the optimal layout is to open seven out of 20 guide vanes in succession while keeping the remaining ones closed. However, this configuration induces large radial forces on the runner, and after implementing some modifications by trial and error, detailed time-dependent CFD simulations show that placing 4 + 3 opened guide vanes on opposite sides of the runner axis is better; it reduces the pressure peaks corresponding to a two- and three-vortex configuration, and the maximal pressure pulsations by as much as 88% in the vaneless space compared to regular SNL operation. Meanwhile, the radial force on the runner is reduced by more than 83%, and pressure pulsations on the runner blades by more than 55%, compared to the surrogate models' optimal layout prediction.

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.

Hydraulic turbines are operated more frequently at no-load conditions, also known as speed-no-load (SNL), to provide a spinning reserve that can rapidly connect to the electrical grid. As intermittent energy sources gain popularity, turbines will be required to provide spinning reserve more frequently. Previous studies show vortical flow structures in the vaneless space and the draft tube and rotating stall between the runner blades of certain axial turbines operating at SNL conditions. These flow phenomena are associated with pressure pulsations and torque fluctuations which puts high stress on the turbine. The origin of the instabilities is not fully understood and not extensively studied. Moreover, mitigation techniques for SNL must be designed and explored to ensure the safe operation of the turbines at off-design conditions. This study presents a mitigation technique with independent control of each guide vane. The idea is to open some of the guide vanes to the best-efficiency-point (BEP) angle while keeping the remaining ones closed, aiming to reduce the swirl and thus avoid the instability to develop. The restriction is to have zero net torque on the shaft. Results show that the flow structures in the vaneless space can be broken down, which decreases pressure and velocity fluctuations. Furthermore, the rotating stall between the runner blades is reduced. The time-averaged flow upstream the runner is changed while the flow below the runner remains mainly unchanged.

The rotating vortex rope, which can be decomposed in the rotating and the plunging modes, is the origin of pressure fluctuations in the draft tube cone when hydraulic turbines operate at part load, compromising the structural integrity and limiting the output load. A measurement campaign was carried out in a Kaplan turbine model which is a replica of the experimental 10 MW Porjus U9 prototype machine along a propeller curve to study the rotating vortex rope’s excitation levels and the induced structural responses. A complete set of sensors mounted on-board and off-board was used to measure pressures, forces, torques, accelerations, displacements, and strains. The characteristic frequencies and amplitudes of the pressure fluctuations and of the corresponding induced loads and vibrations associated with the two modes were quantified in a wide range of operating conditions at part load. The two modes are detected at different frequencies depending on the sensor position. Moreover, their frequencies change depending on the discharge and present different amplitudes depending on the mode. Particularly, the rotating mode shows higher amplitudes than the plunging mode in the majority of positions and directions measured.

The paper addresses unsteady pressure measurements on the blades and stationary parts of a Kaplan turbine model (Porjus U9) during load variation. The turbine was studied in various load acceptance and load rejection scenarios in off-cam mode to investigate the effect of the transients on the turbine performance. The formation and mitigation processes for the rotating vortex ropes and their effects on the forces exerted on the runner were also investigated. The results show a smooth transition during load variations between high load and the best efficiency point, at which no rotating vortex ropes form in the draft tube. However, load variation to part load resulted in a draft tube surge and the formation of a rotating vortex rope with two fluctuating components: rotating and plunging. The rotating vortex ropes began to form at the end of the draft tube cone during the closure of the guide vanes and travelled upstream with further guide vane closure. The plunging mode induced flow oscillation throughout the entire turbine conduit, whereas the rotating mode resulted in local pressure fluctuations. The rotating vortex ropes induced wide-band pressure fluctuations on the suction side of the runner close to the hub section. The formation of the rotating vortex ropes near the runner resulted in a sudden change in the pressure exerted on the suction side of the blades, whereas the rotating vortex rope mitigation process proceeded in a smooth manner.

This paper presents laser Doppler anemometry (LDA) measurements within the runner blade channels and at the runner outlet of a Kaplan turbine model. The model was investigated at six operating points located on two propeller curves of the turbine to study the flow condition during on-cam and off-cam operations. Main and secondary flows within and after the runner were analyzed, and the effects of the hub and tip clearances on the velocity fields within and after the runner were evaluated. Operation of the turbine at flow rates that are lower than the designed rate for the corresponding propeller curve resulted in vortex breakdown and the formation of a rotating vortex rope (RVR). The RVR formation produced an asymmetrical velocity distribution within and after the runner. The results demonstrated the occurrence of an oscillating flow with the same frequency as the vortex rope within the blade channels located upstream of the RVR. This results in an asymmetric flow through the runner and oscillating forces on the runner blades. The measured velocities indicated that the geometrical asymmetries in the runner manufacturing process resulted in various flow asymmetries at the measured sections. The asymmetries were up to 3% within the runner and 7% at the runner outlet.

This paper reports on unsteady pressure measurements on the runner blades of a Kaplan turbine model as well as torque and radial load bearing measurements on the corresponding prototype at several operating points to investigate the sources of periodic loads exerted on the runner when operating at the best efficiency point and off design. Pressure measurements on the model runner blades indicated that the spiral casing delivers a poorly conditioned flow to the guide vanes close to the lip-entrance junction, resulting in flow separation on the guide vanes. The asymmetric flow delivered to the runner induces large oscillations with respect to the guide vane passing frequency, runner frequency and its harmonics to the runner blades. The torque measurements on the prototype also revealed an asymmetric flow at the distributor outlet. The bearing radial load measurements performed on the prototype support the torque measurement results. The asymmetric hydraulic loads on the runner result in shaft wobbling, and the oscillatory forces exerted on the blades are transferred to the main shaft and bearings. Another source of oscillating forces exerted on the runner blades is the rotating vortex rope (RVR) formation that occurs at part-load operation of the turbine and induces pressure fluctuations at two sub-synchronous frequencies to the runner.