Sediment Erosion on Pelton Turbines:A Review

The Pelton turbine has been widely used to develop high-head water resources with sediments because of its advantages in life cycle costs.When a flood or monsoon season occurs,the sediment concentration in the river increases suddenly,causing severe erosion to the nozzle,needle,and runner of Pelton turbines.After decades of development,researchers have developed practical engineering experience to reduce the sediment concentration of the flow through the turbine and ensure the safety and efficiency of power generation.Research on the mechanism of sediment erosion,development of anti-erosion materials,and establishment of erosion prediction models have attracted scholarly interest in recent years.Extensive research has been conducted to determine a complete and valuable syndication erosion model.However,owing to the complexity of the flow and wear mechanisms,the influence of specific parameters of erosion and the syndication effect is still difficult to determine.Computational fluid dynamics and erosion monitoring technology have also been evaluated and applied.This paper presents a comprehensive review of the erosion of Pelton turbines,some of the latest technical methods,and possible future development directions.

Simulation of Unsteady Water Film Flow on Pelton Bucket

In order to simulate the complicated unsteady flow in Pelton bucket, it is necessary to apply the animated cartoon approach. In this paper, a free jet and the inner surface of a bucket is described by boundary fitted grid (BFG) with non-orthogonal curvilinear coordinates. The water flow is discretized in space and time for CFD (computational fluid dynamics). The moving grids of water film are successfully projected onto the bucket’s inner surface by a projection algorithm. The visualization result of the jet landing on bucket’s surface and the unsteady flow in the rotating buckets in 3D verifies the effectiveness of the proposed method.

船用燃料电池供氢系统压能回收过程模拟研究

针对高压氢气减压过程中能量耗散未有效利用的问题,在Pelton式膨胀机相关设计经验的基础上,以氢燃料电池船艇“蠡湖号”供氢系统为研究对象,提出并设计一种由拉伐尔喷管和双圆弧叶片叶轮组成的冲击式氢气膨胀机对氢压能耗散进行回收。为进一步研究氢气膨胀机内部流场形态、涡流损失和能量输出性能,利用Fluent软件,在船舶全速运行工况下,以氢气进口温度与出口背压为变量进行CFD仿真模拟。结果表明:膨胀机内部整体速度与温度梯度较大,气流喷射过程中有激波产生,喷管出口上沿存在压力真空,气流撞击叶片产生大小不一的涡旋;设定氢气喷管入口压力2 MPa,质量流量1.311 g/s时,装置对外输出的平均转矩为0.136 85 N·m;随入口温度上升,气体喷射速度提高,气体上扬趋势减弱;进口气温和背压变化对转矩影响较小,对转速影响较大。

冲击式水轮机泥沙磨损试验测试系统研发

冲击式水轮机在多沙河流上运行时会面临十分严重的泥沙磨损问题。针对目前国内缺乏冲击式水轮机泥沙磨损研究试验系统的情况,研发了一套冲击式水轮机泥沙磨损试验测试系统。该系统由管路及供水系统、沙水池及泥沙搅拌系统、水轮机试验机组、数据采集与测控系统等部分组成,可支持最高水头800 m、最大流量300 m^(3)/h和最高水轮机转速2500 r/min的冲击式水轮机泥沙磨损和性能试验,采用可编程控制器(PLC)和LabVIEW软件可实现供水泵启停、水轮机转速调节和管路阀门自动控制,同时能实时监测水轮机转速、水头、流量等关键参数。经过试验显示该泥沙磨损试验测试系统具有精度高(达0.3%)、自动化水平高、运行稳定、操作简单以及人机界面友好等特点。

500 MW级冲击式水轮机配水环管加工工艺研究

介绍了500 MW级冲击式水轮机配水环管的加工工艺以及厂内装配工艺研究。配水环管是冲击式水轮机的重要过流部件,配水环管设计为多节,每节配水环管厂内加工、整体预装完成后分节运输到电站进行装配焊接,各节配水环管的加工尺寸和管口角度对现场安装起决定性的影响,对后期机组的稳定运行有重大影响。通过对配水环管各节加工工艺研究,确定了配水环管制造加工工艺流程,保证了配水环管加工精度和质量,配水环管整体厂内装配,经过高精准测量,保证了配水环管装配后尺寸满足设计和安装要求。

基于谐响应分析的冲击式水轮机转轮共振预测

冲击式水轮机水斗的疲劳断裂与转轮的周期性振动密切相关。以六喷嘴冲击式水轮机模型机组转轮为研究对象,采用基于模态叠加的谐响应分析法,获取转轮在实际工作载荷激励下的形变与应力响应并评估薄弱部位,结合坎贝尔图确定共振转速。结果表明,在实际运行工况下转轮三阶模态振型最易被激发,最大形变值为21.50mm,位于水斗尖端;七阶与八阶频率下被施加最大简谐载荷的水斗等效应力值较大,从根部向水斗尖端缺口处递减,最大应力值出现在分水刃根部,发生明显的应力集中;坎贝尔图显示易发生谐共振的转速为587r/min、660r/min、785r/min,在实际运行中应进一步测试与避免。

冲击式水轮机转轮水斗汛期泥沙磨损特性分析

泥沙磨损是冲击式水轮机水力部件失效的主要原因之一,特别是在汛期时,过机泥沙含量会大幅增加,而转轮水斗表面的挟沙三相流动过程复杂,其磨损问题会更为严重。本文以规划建设的西藏紫霞电站冲击式水轮机为研究对象,根据设计院提供的电站实测泥沙特性数据,采用Mansouri磨损模型和欧拉-拉格朗日方法对泥沙颗粒在转轮水斗表面的流动过程进行了三相流动数值模拟,分析了电站在汛期高泥沙浓度下颗粒的流动特性以及水斗表面的磨损分布。预测的水斗表面磨损分布与文献中实测的较为一致,预测结果表明水斗主要磨损区分布在靠近水斗根部的出水边附近以及缺口边附近;磨损分布和冲击次数的分布相似度最高,冲击次数对泥沙磨损的影响很大。

喷针开度对冲击式水轮机转轮水力性能影响研究

冲击式水轮机是一种适用于中高水头段水力资源开发的流体机械,在我国西南地区高水头水力资源的开发中有着广阔的应用前景。本文以西藏紫霞水电站冲击式水轮机模型机转轮为研究对象,在5个不同的喷针开度下分别进行了转轮内部三维非定常多相流动数值模拟,分析了喷针开度对转轮水力性能与内部流动特性的的影响。预测结果显示转轮水力效率随开度上升而先上升后下降,在设计开度下水力效率最优。在0.75~1.60倍设计流量区间中,转轮水力效率的变化幅度小于1%。根据3个典型开度下转轮水斗内部非定常流动过程的对比分析,发现大开度工况时,水斗缺口处会发生水膜流的漏流现象,喷针开度越大时的泄漏量也越大,从水斗缺口处的漏流现象是其水力损失加剧的主要流动原因。研究为紫霞水电站230 MW大型冲击式水轮转轮水斗的水力优化设计提供了重要参考。

水斗式水轮机基准斗安放位置对水斗性能影响研究

常规水斗式水轮机在设计过程中主要依据比转速、水头等参数,结合水轮机型谱、经验公式进行选型设计,在设计过程中未对基准水斗安放位置进行限制。本文通过对水斗式水轮机的选型过程进行分析,发现基准水斗不同安放位置对水斗性能具有重要影响,应在设计中予以考虑。采用ANSYS CFX流体仿真软件分析表明:水斗分水刃顶点、圆心连线与水平轴夹角的改变将引起转轮扭矩的变化,增加转轮扭矩的波动程度,使水斗内流态、水斗表面压力场偏离原始水斗,易造成切水边工作面压力降低引起局部脱流,水斗背面附壁效应增强引起水斗局部空化。该研究结果可为大型水斗式水轮机选型设计提供理论指导,提升冲击式水轮机设计水平。

冲击式水电机组不同工况下孤网运行的稳定性分析

我国西南建有大量的冲击式水电机组的水电站,这些水电站与电网联系薄弱,孤网运行稳定性问题突出。对此建立了冲击式水轮机的数学模型、完善了冲击式水电机组孤网分析模型,研究了孤网条件下冲击式水电机组的控制参数稳定域。首先,根据电站实际情况建立冲击式水轮机的非线性模型。其次,根据李雅普诺夫第一方法开展稳定性分析,在不同运行工况点对冲击式水轮机进行线性化,获得相关传递系数,代入孤网分析模型建立状态方程,根据临界稳定条件求出稳定域。最后,通过非线性模型仿真对分析结果进行验证。结果表明,喷针开度变化时对运行稳定域的影响较大,不能忽视;调速器参数整定时,需对所有运行工况进行分析,按最小稳定域工况进行参数优化。

超大容量水斗式水轮机水力特性数值模拟分析

为满足超高水头、超大容量水电站建设需求,提出了一种额定水头1000 m,单机容量接近800 MW的三转轮立轴串联水斗式水轮机方案。阐明了这种通过增多转轮来增大容量的设计理念和结构组成,给出了方案的理论设计参数,并应用CFD模拟预测了其水力特性、分析和优化转轮及转轮室流态。研究表明:三转轮水斗式水轮机的额定工况效率可达87%,工作特性曲线变化平稳。转轮室溅水干扰是影响效率的主要因素。通过优化各层转轮相对位置和喷嘴方位,可一定程度提高效率,减小力矩振荡,保证出力稳定。此初步尝试证明了概念的可行性,也发现溅水优化的重要性,能为后续优化研究提供参考。

A FAST LAGRANGIAN SIMULATION METHOD FOR FLOW ANALYSIS AND RUNNER DESIGN IN PELTON TURBINES

In the present work, an alternative numerical methodology is developed for a fast and effective simulation and analysis of the complex flow and energy conversion in Pelton impulse hydro turbines. The algorithm is based on the Lagrangian approach and the unsteady free-surface flow during the jet-bucket interaction is simulated by tracking the trajectories of representative fluid particles at very low computer cost. Modern regression tools are implemented in a new parameterization technique of the inner bucket surface. Key-feature of the model is the introduction of additional terms into the particle motion equations to account for various hydraulic losses and the flow spreading, which are regulated and evaluated with the aid of experimental data in a Laboratory Pelton turbine. The model is applied to study the jet-runner interaction in various operation conditions and then to perform numerical design optimization of the bucket shape, using a stochastic optimizer based on evolutionary algorithms. The obtained optimum runner attains remarkably higher hydraulic efficiency in the entire load range. Finally, a new small Pelton turbine （150 kW） is designed, manufactured and tested in the Laboratory, and its performance and efficiency verify the model predictions.

NUMERICAL PREDICTION OF DYNAMIC PERFORMANCE OF PELTON TURBINE

Different from the reaction turbines, the hydraulic performance of Pelton turbine is dynamic due to the unsteady flow in the rotating buckets in time and space. The dynamic energy efficiency of bucket ηεB and power efficiency of bucket ηPB within a short period can be predicted from the dynamic flow pattern of the free-surface sheet flow in the rotating bucket, whereas the dynamic discharge efficiency of bucket ηQB is defined as the resident discharge in the bucket at the respective moment. Under the operation of higher unit speed non than the optimum one, the power efficiency of bucket is deteriorated by the jet interference with the rear surface of bucket △Prear at the first stage of the dynamic performance, as well as the loss power due to the spilt flow from the cutout of bucket at the later stage of performance. Based on the dynamic performance prediction presented, the future possibility of the quantitative investigation for the negative scale effect of Pelton turbines was discussed.

Parametric optimisation of two Pelton turbine runner designs using CFD

This paper aims to develop a generic optimisation method for Pelton turbine runners using computational fluid dynamics （CFD）. Two different initial runners are optimised to achieve more generic results. A simple bucket geometry based on existing bibliography is parameterised and initially optimised using fast Lagrangian solver （FLS）. It is then further optimised with a more accurate method using ANSYS Fluent. The second geometry is a current commercial geometry with good initial performance and is optimised using ANSYS CFX. The analytical results provided by CFX and Fluent simulations are used to analyse the characteristics of the flow for different runner geometries.

大型冲击式水轮机球型分岔配水机构水力特性及磨蚀预测

随着冲击式水轮机向大容量发展,配水机构的水沙气多相流特性和泥沙磨蚀受到广泛关注。为此,提出一种月牙肋球型分岔六喷嘴配水机构,采用RANS-ELES混合紊流数值模型模拟了配水机构的水力特性,水气交界面采用VOF模型进行追踪,并分析了不同肋宽比对流场和泥沙磨蚀的影响。结果表明:小肋宽比能改善配水机构射流质量,并有利于配水环管分叉部位抗泥沙磨蚀。研究成果可为类似冲击式水轮机的设计与运行提供借鉴。

Pelton turbine: Identifying the optimum number of buckets using CFD

A numerical case study on identifying the optimum number of buckets for a Pelton turbine is presented. Three parameters： number of buckets, bucket radial position and bucket angular position are grouped since they are found to be interrelated. By identifying the best combination of the radial and angular position for each number of buckets it is shown that reduction in the number of buckets beyond the limit suggested by the available literature can improve the efficiency and be beneficial with regard to the manufacturing complexity and cost perspective. The effect of this reduction in the number of buckets was confirmed experimentally.

冲击式水电机组孤网调节特性仿真与试验

水电机组由于多种原因可能进入孤网运行模式,保证孤网运行的稳定性是保障供电和加快电网恢复的重要前提。为有效地开展冲击式水轮机调速系统的调节特性和控制策略研究,本文建立了冲击式水电机组调节系统分析数学模型,仿真分析了孤网下小负荷扰动与大负荷扰动的冲击式水电机组调节特性,通过突甩负荷仿真验证了不同折向器投退策略的效果,并开展了冲击式水电机组孤网调节的现场试验,验证了本文所述数学模型的正确性。合适的折向器投入与退出频率设置和合理的调速器的控制参数是保障孤网运行稳定性的重要保障。

水斗式水轮机喷射机构水力性能研究

水斗式水轮机喷射机构的主要作用是将水流的压力能转换为动能并形成高速射流,高速射流的质量直接影响着水斗式水轮机的能量转化效率。采用无网格运动粒子流方法对不同喷针开度下水轮机喷射机构的流量特性、喷针尖受力特性以及喷嘴出口射流流态分布特征等进行数值模拟研究。研究结果表明:随着喷针开度的增加,喷嘴出口流量逐渐增大,其增长率逐渐减小,喷针尖所受水推力逐渐增大;喷嘴出口射流自由液面逐渐出现发散现象,其表面变得不光滑。这与水力模型试验结果是相符的,验证了该方法的有效性,同时给水斗式水轮机的水力设计者提供了新思路。该方法可大大提高水力优化设计效率,具有一定的工程应用价值。

大型冲击式转轮机器人电弧增材制造技术应用研究

随着冲击式机组容量参数越来越大,机组核心部件转轮的尺寸不断增大,受制于锻件厂家设备制造能力和性能保障工艺,厚大马氏体不锈钢锻件质量风险巨大,成为大型冲击式机组能否研制成功的关键因素。而外部水斗结构复杂,锻件加工时材料利用率低,制造成本高,人工焊接时气孔、夹渣等缺陷不易控制,焊接质量风险大。本文通过基于电弧增材制造工艺结构设计、机器人电弧增材制造系统集成及工艺研究,开发出了一套适用于大型冲击式转轮制造的增材工艺,并成功应用于冲击式转轮的制造,大幅压缩了中心体锻件的规格,释放了厚大马氏体不锈钢锻件的制造风险,提高了外部水斗的材料利用率和焊接质量。

500MW冲击式水轮机关键技术研究

西藏扎拉水电站需装设2台500 MW冲击式水轮发电机组,是目前全球在建单机容量最大的冲击式水轮发电机组。为提升大型冲击式水轮机制造水平,基于试验和数值模拟分析总结了扎拉电站水轮机在高效率转轮模型水力开发、重大不锈钢转轮锻件制造、大型冲击式转轮制造等方面存在的技术难点。结果表明:(1)在高效率转轮模型水力开发方面,可采用定常的气液两相流CFD分析配水环管、喷嘴,采用非定常两相流CFD分析转轮;扎拉水电站水轮机转轮内部流动均匀合理,整体具有良好的水力性能。(2)在重、大不锈钢转轮锻件制造方面,关键技术主要在于钢材冶炼、锻造和热处理这3个过程中材料化学成分的优化、锻件锻造载荷和锻造温度控制及热处理工艺;扎拉水电站水轮机的重、大转轮轮毂不锈钢锻件的质量可行。(3)在大型冲击式转轮制造方面,扎拉水电站水轮机转轮采用锻焊结构,合理选择了水斗和轮毂的分瓣位置及焊接工艺,实现了转轮焊接接头疲劳寿命与水斗根部的疲劳寿命等同。