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a r t i c l e i n f o a b s t r a c t
Article history: This work investigates the unsteady pressure fluctuations in a hydraulic turbine that are observed during
Available online 22 December 2017 steep ramping. Although hydraulic turbines are expected to operate seamlessly during steep ramping,
the resulting pressure amplitudes are so significant that they take a toll on a machine's operating life.
Keywords: Objective of the present study is to investigate time-dependent pressure amplitudes in the vaneless
Hydropower space, runner and draft tube during power ramping-up and -down under variable-speed configuration.
Turbine
Novelty is to vary both discharge and rotational speed of a runner. The measurements are performed on a
Francis-99
high-head model Francis turbine. The investigations revealed that amplitudes of characteristics fre-
Pressure
Load variation
quencies, especially rotor-stator interaction, are small during steep ramping however, at the end of
Variable-speed transient cycle, the amplitudes quickly increased 30-fold. During steep ramping, blade passing frequency
was appeared in the runner, which is uncommon phenomenon in high-head Francis turbines. Strong
reflection of pressure waves towards runner from vaneless space (guide vane walls) may be one of the
causes for the appearance of blade passing frequency in the runner.
© 2017 Elsevier Ltd. All rights reserved.
1. Introduction variable discharge and (3) high flexibility- variable speed and
discharge. The first approach is used for run of river power plant
Electricity is produced using both continual and intermittent where guide vanes are fixed permanently (or no guide vanes) to
types of energy sources. Competitive electricity prices and the reduce the operating/maintenance cost. Turbines are operated for
inclination towards wind and solar energy have forced industries to the fixed load depending on available head/discharge and are not
utilize intermittent energy sources. This has resulted in power applicable to meet the real-time demand. The second approach is
imbalance and frequent grid disruptions [1]. For the stable and widely used due to high efficiency and low cost. Turbines are oper-
uninterrupted operation of a power grid, demand factor (i.e. elec- ated at the best efficiency point (BEP) except load picking hours.
tricity demand/generation) must be maintained within the allow- Such turbines experience dynamic instability when they are oper-
able limit [2]. Hydropower is considered as a vital alternative to ated at the off-design load, i.e. away from BEP [5e7]. Third approach
accommodate the real-time demand after the gas turbine. The gas provides moderate to high flexibility to meet real-time demand and
turbines have generally low efficiency and the cost per kWh is more stabilize the power grid when wind/solar power fluctuates rapidly
than the hydropower. The large-scale power plants such as thermal, [8,9]. Advantage of this approach is the flexibility of two variables, i.e.
nuclear and geothermal are operated at their maximum efficiency angular speed and discharge, which enables the wide range of power
point, and the response time is very low. output and two different combinations for the same load. Thus,
Hydraulic turbines have capability to change power output by dynamic stability can be maintained unlike the second approach.
1e25 MW per second, depending upon turbine type and the power Currently, research is inclined towards design and development
generation capacity [3,4]. Output power is regulated using one of of a variable-speed turbine [2], that will accommodate increased
three approaches: (1) low flexibility- Synchronous speed and con- numbers of transients cycles, i.e. start-stop/load-variation. Tradi-
stant discharge, (2) medium flexibility- synchronous speed and tionally, turbines are designed for certain numbers of transient
cycles during their operating life [10] and majority of them exceed
the limit within half of their life [11,12]. Each transient cycle costs
* Corresponding author. Vannkraftlaboratoriet, Alfred Getz vei. 4, NTNU, NO- runner life equivalent to certain numbers of operating hours
7491Trondheim, Norway.
[13e19]. Moreover, turbine operating cost increases with the
E-mail address: chirag.trivedi@ntnu.no (C. Trivedi).
https://doi.org/10.1016/j.renene.2017.12.040
0960-1481/© 2017 Elsevier Ltd. All rights reserved.
448 C. Trivedi et al. / Renewable Energy 119 (2018) 447e458
The test rig available at the Waterpower laboratory of the Nor- The Francis turbine was equipped with all instruments required
wegian University of Science and Technology is used for the to carry out model testing according to IEC 60193 [48]. Additional
C. Trivedi et al. / Renewable Energy 119 (2018) 447e458 449
pressure sensors were mounted at different locations in the 2.3. Performance study
turbine. Fig. 2 shows the locations of the pressure sensors in the
turbine. Two sensors (VL1 and VL2) are in the vaneless space to Experiments at the steady-state operating conditions were
acquire RSI frequencies and amplitudes; four sensors (R1, R2, R3 carried out before the transient. The results were compared with
and R4) are on the runner crown, between two blades; four sensors the benchmark data to confirm repeatability of the test-rig. The
(DT1, DT2, DT3, and DT4) are on the wall of the draft tube cone to constant efficiency hill diagram is shown in Fig. 3. The BEP is
investigate the vortex breakdown from the runner outlet. Two located at a ¼ 9.9 , nED ¼ 0.18 and QED ¼ 0.15 where the hydraulic
sensors (IN1 and IN2) are mounted at the turbine inlet conduit to efficiency is 93.1 ± 0.2%.
monitor the water hammer.
Calibration and uncertainty quantification of all measuring nD
nED ¼ pffiffiffi ðÞ (3)
instruments and sensors were conducted. IEC 60193 was followed E
to quantify the uncertainties, which are shown in Table 1. The total
uncertainty (dhh)t,BEP includes both systematic and random Q
QED ¼ pffiffiffi ðÞ (4)
uncertainties (see Equation (2)). The systematic uncertainty is the D2 E
square-sum-root of the discharge (dQ), head (dH), torque (dT) and
runner angular speed (dn). Total uncertainty in the hydraulic effi- Table 2 summarizes the flow parameters at BEP, PL and FL used
ciency (dhht) is ±0.2%, which includes a random uncertainty (dhhr) of for the current study. The runner synchronous speed was 5.5 Hz.
±0.18% at BEP. The uncertainties of the pressure sensors located in Total 10 repetitions were made for each condition and the deviation
the vaneless space, runner and draft tube are ±0.12, ±0.26 was within the uncertainty. The repetition study showed no shift
and ±0.14%, respectively. Further, discharge through the upper from the trend line. This has confirmed that both turbine and test
labyrinth seal was measured to estimate the volumetric efficiency rig perform well under steady conditions and can be used for
of the turbine, and uncertainty of the seal discharge (dq1) transient measurements.
measurement was ±0.26%. Uncertainty in guide vane angular Transient characteristics of the turbine:
positioning (da) was measured as ±0.7%. A repeatability study was
conducted at BEP and PL operating conditions to check any - For constant guide vane aperture: discharge is inversely
deviations over a certain period. The maximum deviation in the proportional to the runner angular speed.
hydraulic efficiency at BEP and PL was less than ±0.05% and ±0.1%, - For constant speed: torque is directly proportional to the
respectively. Hence, random uncertainty is less than the total discharge (guide vane aperture).
uncertainty.
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2 2 2 2 2 2.4. Range of parameters
dhh s
¼ ± dQ s þ ðdH Þs þ ðdT Þs þ ðdn Þs þ dr;water s (1)
Fig. 2. Locations of pressure sensors in the turbine. Sensors R1, R2, R3 and R4 are in the runner; DT1, DT2, DT3 and DT4 are in the draft tube cone; VL1 and VL2 are in the vaneless
space.
Table 1
Computed uncertainties in the flow measurement. The uncertainties are in percentage of the measured value.
Fig. 3. Constant efficiency hill diagram of the investigated model Francis turbine. QED and nED are the dimensionless quantities of discharge and speed, respectively. nED ¼ 0.18 is the
synchronous speed of the turbine.
Table 2
Summary of the parameters observed at the steady-state operating conditions of the During the measurements, available pressure in the draft tube
turbine. was above the atmospheric pressure and water temperature was
OP a ( , %) Q (m3 s1) H (m) T (Nm) n (Hz) hh (%) QED () nED () 15 C. Therefore, cavitation was not occurred in the test rig and the
measurements correspond to cavitation free conditions.
PL 7, 65 0.131 12.14 337.9 5.5 91.2 0.09 0.18
BEP 10, 100 0.199 11.94 620.7 5.5 93.1 0.15 0.18
FL 14, 140 0.263 11.64 781.9 5.5 92.1 0.20 0.18
3. Analysis of transient results
~ðtÞ
p
~E ¼
p : (13)
ðrEÞBEP
The head loss between IN1 and IN2 is 0.5% before the load
change and is less than 0.1% after the load change. Effect of pressure
surge at 4.8 s can be seen clearly, and the total head rise was 0.4 m
during the transient period. Pressure oscillations are damped out at
15 s. Spectral analysis of the pressure data was carried out to study
frequency content and amplitudes. Fig. 7 (right) shows frequency
spectrum and corresponding amplitudes (peE RMS) in time domain at
IN2 location.
Fig. 4. Change of guide vane angle (a), runner angular speed (n), torque (T), power
output (P) and net head (H) during 30% load reduction from BEP. Time t ¼ 0 s corre-
sponds to start time of load change. ~ðtÞ pðtÞRMS
p
~E RMS ¼
p (14)
ðrEÞBEP
Before the load change, turbine was operating at steady BEP load
Ju where the highest amplitudes are associated to the blade passing
tstart ¼ ðsÞ (6)
T frequency (fb) 167 Hz and its harmonic.
The mechanical start time is dependent on the flywheel effect
(GD2) of the rotating structure, runner acceleration (u2) and power fb ¼ nZb ðHzÞ (15)
(P), During 2e4 s, amplitudes of blade passing frequency are
extremely small, which increases gradually after 4 s. Turbine inlet
GD2 u2 conduit was connected to the pressure tank which developed
tm ¼ ðsÞ (7)
P standing waves of different frequencies 15, 27 and 41 Hz depending
In addition to the inertial effect, change of torque value can be upon the flow condition. Low-frequency pressure pulsations,
explained using Euler equation and velocity triangles. Fig. 5 shows a 14.95 Hz, can be seen with high amplitudes, twice the amplitude of
blade passage, a guide vane passage and velocity triangles at the blade passing frequency.
runner inlet and outlet. Velocity triangles are shown for both For the current study, two pressure sensors VL1 and VL2 were
conditions, i.e. BEP and after 30% load reduction. Whirl velocity (cu), mounted in the vaneless space; VL1 was located between two guide
specific energy (e) torque (T), power (P) and efficiency can be vanes, and VL2 was located at the trailing edge. Amplitudes of blade
estimated using following equations; passing frequency at VL2 are 1.33 times that of VL1. Fig. 8 (left)
shows acquired pressure from VL2 location during load change, and
cu ¼ u cm cot b; (8) Fig. 8 (right) shows fluctuations from 4.88 s to 5 s at VL1 and VL2
locations. The amplitudes are within the limit of ±2s, where s is the
time-average standard deviation. Time of 0.02 s corresponds to
e ¼ c2m1 cot a1 ðcot a1 þ cot b1 Þ; (9) approximate 180 angular movement of the runner. The pressure
pulsations correspond to the blade passing frequency. When a
T ¼ mðcu1 r1 cu2 r2 Þ; (10) blade is front of the sensor, pressure pick is developed, marked as t1
in the figure. When the sensor position is in the middle of the blade
P ¼ T u ¼ mðcu1 u1 cu2 u2 Þ; (11) passage, pressure is low, marked as t2. Thus, simultaneous inter-
action takes place as runner advances. Phase difference between
cu1 u1 cu2 u2 VL1 and VL2 is 4.2 .
h¼ : (12) Spectral analysis was performed to investigate the frequencies
gH
and amplitudes in the vaneless space (location VL2). The ampli-
In the investigated Francis runner, inlet and outlet blade angles tudes were normalized using Equation (14). Three distinctive fre-
are 57 and 15 , respectively. The runner inlet and outlet radius is quencies were obtained. A frequency of runner angular speed
315 and 173.5 mm, respectively. Variation of whirl and tangential (5.5 Hz) and the second harmonic (11 Hz) were observed with
452 C. Trivedi et al. / Renewable Energy 119 (2018) 447e458
Fig. 5. A blade passage, a guide vane passage and the velocity triangles at the runner inlet and outlet of the investigated Francis turbine. Continuous and dotted line velocity
triangles correspond to the time before and after the load change, respectively. A-enlarged view of the guide vane movement, B-enlarged view of upper labyrinth seal and C-
enlarged view of lower labyrinth seal.
Fig. 7. Time-average pressure variation and spectral analysis at the turbine inlet conduit during 30% load reduction from BEP. IN1 and IN2 are the locations of pressure mea-
surement, 0 s corresponds to start time of load reduction.
C. Trivedi et al. / Renewable Energy 119 (2018) 447e458 453
Fig. 8. Pressure variation at vaneless space during 30% load reduction. t1-the pressure sensor is exactly front of a blade. t2-the sensor is in between a blade and the neighboring
splitter. Time 4.88e5 s correspond to ~180 runner rotation.
Fig. 10. Pressure variation in the runner, locations R1, during load change. Right side plot shows pressure amplitudes of the guide vane passing frequency (fgv). Circle diameter is
normalized by the maximum amplitudes of fgv.
454 C. Trivedi et al. / Renewable Energy 119 (2018) 447e458
Fig. 11. Unsteady pressure variation in the draft tube during load reduction from BEP.
Time t ¼ 0 s corresponds to start time of load change.
Fig. 12. Pressure pulsation of vortex rope frequency (frh) during load reduction from PL. Dash line at 0 s indicates the start time of load reduction from PL.
C. Trivedi et al. / Renewable Energy 119 (2018) 447e458 455
Fig. 15. Time-average pressure variation in the vaneless space during load acceptance from 40% steady load. Dash line at 0 s indicates the start time of load change. VL1 and VL2 are
locations of the pressure measurement in the vaneless space.
guide vane passing was obtained at IN2 location. This is rare obtained at all locations in the runner with the amplitudes of 8% of
occurrence in a hydraulic turbine. However, the amplitudes were fgv. The amplitudes of fgv are shown in Fig. 16 (right), which are 1%e
small, i.e., 10% of the blade passing frequency. Presence of guide 0.3% of (rE)BEP for R1 to R4, respectively. However, during load
vane passing frequency may be due to the multiplier combinations change, the amplitudes were small, i.e., less than 0.4% of (rE)BEP.
of stay vanes (14) and guide vanes (28) in the turbine, and the Similar to the load reduction case, a frequency of blade passing was
reflection of travelling waves from the spiral casing. obtained in the runner. A frequency of vortex rope was obtained at
High amplitudes frequencies in the vaneless space were the R4 after 4 s as load approached to PL.
blade passing and the runner frequencies, including their har- Four pressure sensors were mounted to investigate the
monics. Time-average pressure variation in the vaneless space unsteady pressure pulsations associated with the vortex rope
(locations VL1 and VL2) is shown in Fig. 15. The pressure fluctuation frequency in the turbine. When proper combinations of runner
factor (peE) varied from 1.2 to 1.4, which was equivalent to 2% head speed and discharge were met, vortex rope began to develop
rise. Unsteady pressure amplitudes of the blade passing frequency steadily at 4.4 s (see Fig. 17). Tangential velocity of the swirling flow
for two revolutions can be seen in Fig. 15 (right). The pressure was increased with runner angular speed, and same time increase
amplitudes at 40% and 65% load were 1.3 and 1.2%, respectively. For of discharge added momentum. When the load was approximately
the second harmonic, the amplitudes were small (<0.1%), which 58% (at 3 s), vortex rope steadily developed. At DT1 and DT2 loca-
gradually increased to 0.5% at 70% load. More interestingly, tions, amplitudes gradually increase and the phase difference
amplitudes of vortex rope frequency were observed in the vaneless between them is 180 . As load approached to 65%, the frh was
space when the load was 58% (t ¼ 3 s). appeared clearly. To investigate the presence of synchronous
The trend of time-average pressure variation in the runner was component (axial), further analysis was carried out. Details about
similar to that observed for the vaneless space. However, the the synchronous and asynchronous components of vortex rope can
amplitudes of RSI frequencies were different. Time-average pres- be found in literature [49e52]. A pressure signal includes a
sure variation at R1, R2, R3 and R4 locations is shown in Fig. 16. synchronous, an asynchronous and a random component, i.e.,
Pressure loading at R1 location is maximum, which is approxi- ~E ¼ p
p ~E syn þ p
~E asyn þ p
~E rand . Both synchronous and asynchronous
mately 22%, and at other locations is less than 5%. Spectral analysis components can be decomposed as,
of the pressure pulsations showed frequencies related to runner
angular speed (n), guide vane passing frequency (fgv), blade passing
frequency (fb) and vortex rope (frh). The maximum amplitudes in p ~ E DT2
~E DT1 þ p
the runner corresponded to fgv and the second harmonic. The ~E syn ¼
p ; (17)
2
frequency of runner angular speed and the second harmonic were
Fig. 16. Time-average pressure variation (left) and amplitudes of guide vane passing frequency (right) in the runner loading load acceptance from 40% load. R1, R2, R3 and R4 are the
locations pressure measurement starting from runner inlet to the outlet. Time t ¼ 0 s corresponds to start time of load change.
456 C. Trivedi et al. / Renewable Energy 119 (2018) 447e458
Fig. 17. Unsteady pressure variation in the draft tube at DT1 and DT2 locations. Right side plot shows decomposed components of pressure pulsations.
5. Prospective study
4. Conclusions
The prospective study will focus on following three objectives:
Experiments were conducted on a high head Francis turbine
during load variation, i.e., load reduction and acceptance. In the
- Investigate the fatigue loading during load variation. Strain
previous work [47], we investigated pressure amplitudes by
gauges will be mounted on the blades where the compressible/
changing rotational speed of the runner only, and the pressure
tensile stresses will be measured.
amplitudes were moderate. In the current work, we included
- Investigate the flow field inside the turbine during these tran-
variation in discharge as well; both runner angular speed and
sient conditions, particularly vaneless space and blade passages.
discharge were changed. Because, inertia of the rotating masses is
Numerical study will be carried out where the guide vane will be
dependent on the rate of guide vane movement (i.e., instantaneous
operated using dynamic mesh technique.
discharge) and the runner rotational speed, which play key role
- Investigate the optimum blade loading for the selected transient
during steep ramping. For example, load can be changed instantly
conditions.
by changing the rotational speed where the inertia of rotating
masses can help. Mean time hydraulic torque can be changed
steadily by opening/closing of guide vanes that allow smooth blade Acknowledgement
loading and water hammer. However, for a load reduction (steep
ramp-down), the inertia can affect adversely. Decrease of runner Investigations are conducted under a research project
angular speed (to reduce the load) can increase torque (due to HydroCen-FME, which is supported by both The Research Council
inertia/momentum); consequently, reduction of load may be of Norway (257588) and industrial partners. One of the objectives is
negligible. The opposite behavior of torque could be associated how to reduce the fatigue loading, and find out the way for flexible
with the increase of velocity cu1, which resulted in the increase of turbine operation in order to cope with current trend of electricity
specific energy until the cm1 converged. The findings indicate that demand.
well-calibrated approach for the rate of change of runner angular
speed, discharge and the inertia (water mass at that load and the Nomenclatures
rotating structure) is essential while configuring the variable-speed
in a turbine. BEP Best efficiency point
To investigate the amplitudes of unsteady pressure pulsations, DT Draft tube
pressure sensors in the vaneless space, runner, draft tube and the FL Full load
conduit were mounted. The results indicated that, during ramping- GV Guide vane
up or -down, amplitudes of characteristic frequencies such as blade IN Inlet
passing and guide vane passing are small. However, at the last OP Operating point
phase of ramping, the amplitudes quickly increase, which are up to PL Part load
30-fold in the vaneless space and runner. We recommend smooth RMS Room mean square
closing/opening of guide vanes during last phase of ramping that RSI Rotor stator interaction
will reduce the instant increase of amplitudes. Results from the c Flow velocity (m s1)
runner pressure sensors showed presence of blade passing fre- D Diameter (m)
quency (which is rare occurrence in a high head turbine) during E Specific hydraulic energy (J kg1); E ¼ gH
steep ramping. If this is the case for other turbines, to avoid possible f Frequency (Hz)
C. Trivedi et al. / Renewable Energy 119 (2018) 447e458 457
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