Flow behaviour analysis of reversible pumpturbine in "S" characteristic operating zone
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1 IOP Conference Series: Earth and Environmental Science Flow behaviour analysis of reversible pumpturbine in "S" characteristic operating zone To cite this article: S Q Zhang et al 2012 IOP Conf. Ser.: Earth Environ. Sci View the article online for updates and enhancements. Related content - Numerical simulation on the "S" characteristics and pressure fluctuation of reduced pump-turbine at start-up condition D M Liu, J S Zheng, G Z Wen et al. - Numerical analysis of unsteady flow behaviour and pressure pulsation in pump turbine with misaligned guide vanes Y X Xiao, D G Sun, Z W Wang et al. - Experimental and numerical study on inlet and outlet conditions of a bulb turbine with considering free surface Y P Zhao, W L Liao, H D Feng et al. This content was downloaded from IP address on 25/01/2018 at 16:19
2 Flow behaviour analysis of reversible pump-turbine in "S" characteristic operating zone S Q Zhang 1, Q H Shi 2 and K W Zhang 1 1 College of Energy and Power Engineering, HuaZhong University of Science and Technology,Wuhan, Dongfang Electric Machinery Co., Ltd, Deyang, Sichuan Province, hust_zsq@163.com Abstract. The pumped storage plant undertakes the task for peak regulation, frequency modulation, phase modulation and accident standby in the electric grid system. Since the design consideration of a pumped storage plant is different from the conventional hydropower plant, the "S" shaped characteristic of pump-turbine will appear in four quadrants characteristic curves, and this characteristic will lead to a series of instabilities while the pump-turbine start at low water head. This paper presents the CFD simulation results of a pump-turbine model with the full flow passage which are compared with model test results. Based on the comparison, the hydraulic reason of the "S" shaped characteristic is discussed and a new concept of partial reverse pump is put forward, i.e. the reverse flow at inlet of runner is the real hydraulic cause of "S" shaped characteristic of a pump-turbine when the unit discharge descends to a certain degree. With the decrease of unit discharge, the effect of partial reverse pump becomes more and more obvious, which leads to an increase of head and finally results the "S" shaped characteristic of a pump-turbine. 1. Introduction The pumped storage plant undertakes the task for peak regulation, frequency modulation, phase modulation and accident standby in the electric grid system. The main type of reversible pump turbine is capably bidirectional operating machine, which combines pump and turbine into one unit. When we design the runner, the bidirectional characteristic of the pump and turbine operating condition must be taken into consideration simultaneously. Under the turbine rotational direction, the differential pressure between the runner inlet and outlet is great smaller than that under the pump rotational direction, the smaller differential pressure, the more unstable flow in the runner. The flow direction changes immediately when the outside pressure fluctuated slightly, so the machine comes easily into reversible pump operating condition when the unit starts under turbine operating condition, moreover the flow direction uneasily upheaval when the unit starts under pump operating condition. Under the same water head and revolution speed, the diameter of reversible pump turbine is 1.4 times larger than conventional hydraulic turbine, the "S" shaped characteristic of reversible pumpturbine will appear in four quadrant characteristic curve. Generally, the reversible pump turbine with low specific speed has more obvious "S" characteristic. Because of this, the flow in the runner is extremely unstable nearby the zero capacity operating condition under turbine rotational direction, at the same time, under one rotational speed, there are more than two corresponding capacity values Published under licence by Ltd 1
3 (Figure 1), especially, one of them is positive. This characteristic will lead to a series of instabilities while the pump-turbine starts at low water head. Brake 11 an a02 a01 Turbine 1 2 M 11=0 Brake +n11 Pump Q11=0 Brake 11 Turbine +n11 Pump 3 Reverse Pump Reverse Pump Brake Q11=0 Figure 1. Four quadrants characteristics of a reversible pump turbine Aiming at the unstable problems while reversible pump turbine starts at low water head, modern pumped storage plant commonly adopts the method of MGV (Misaligned Guide Vane), i.e. beforehand opening two or more symmetrical guide vanes to increase the capacity, it will take into effect while the other guide vanes have comparatively small openings. By means of this, the unit can steadily get through the "S" characteristic zone if the unit was relatively stable with small guide vane opening. This MGV method is international trends recently, but there exist corrupt practices itself. Because the opening guide vanes destroy the hydraulic balance in runner, the unit vibration will greatly increase obviously which is harmful to the unit, at the same time, the MGV method makes complicated the gate operating mechanism. So the most essential measure is to avoid this MGV method by means of optimizing the runner hydraulic performance during the design term. 2. Model test results Choosing the model unit as research object, this paper numerically simulated the full flow passage of the unit model by means of CFD simulation method, analyzed the flow characteristics of the unit operating in the "S" characteristic zone. The model test results are followings: Figure 2. Capacity characteristic curve of a reversible pump turbine model 2
4 Figure 3. Torque characteristic curve of a reversible pump turbine model From the aforementioned model capacity and torque characteristic curve, we can find out that there exists obvious "S" shaped characteristic on the performance curve during the transient process of the operating condition from turbine to brake, i.e. under one rotational speed, there are more than two corresponding capacity values, especially, one of them is positive. This characteristic will lead to a series of instabilities while the pump-turbine start at low water head. 3. Turbulence and CFD simulation model 3.1. Selection of turbulence model All of the turbulence models have certain adaptable range, there isn't a turbulence model which is suitable for all flow condition in practical engineering application. The selection of turbulence model rests with a great many considerations, such as the flow physical mechanism, the existed simulation and test materials for a special type problem, required precision level, existing calculation resources as well as the numerical simulation time, etc. SST ( Transport of the Turbulent Shear Stress ) k-ω turbulence model was designed to give highly accurate prediction of the onset and the amount of flow separation under adverse pressure by the inclusion of transport effects of turbulence shearing stress into the formulation of the eddy-viscosity, so it is much more suitable to simulation the convective zone. Additionally, this model also takes into consideration of cross-diffusion term, which makes the formulation compatible near and far from the wall. This paper employed this model for the operating conditions simulation in "S" characteristic zone. The closure mode of SST k-ω is listed as follows: ( ρ t k ρ k) + ( kui ) = ( Γk ) + Gk Yk + Sk (1) xi x j x j t ω ( ρω) + ( ρωui ) = ( Γω ) + Gω Yω + Sω (2) xi x j x j where: G k represents the generation of turbulence kinetic energy due to mean velocity gradients. G ω represents the generation of ω. Г k and Г ω represent the effective diffusivity of k and ω respectively. Y k and Y ω represent the dissipation of k and ω due to turbulence. D ω represents the cross- diffusion term. 3
5 3.2. CFD simulation model and boundary conditions The CFD simulation domain include five components, which are spiral case, stay vane, guide vane, runner and draft tube ( Figure 4 ). Except the spiral case uses tetrahedron grid, the other simulation zones use hexahedron grid. In order to analyze the flow characteristic of the unit in "S" operating zone and the hydraulic reason of "S" characteristic, 10 guide vane opening was taken into effect for detailed simulation and analyze based on the model test results. The components mesh information is provided in table 1. Figure 4. Full flow passage model for CFD simulation Table 1. Model numerical simulation grid (y+ is evaluated under optimal condition) Component Nodes Elements y+ Grid type Spiral case Tetrahedron Stay vane Hexahedron Guide vane Hexahedron Runner Hexahedron Draft tube Hexahedron Total number The boundary conditions of simulation model were set like followings: the quality capacity was set to inlet boundary ( spiral case inlet), the opening condition was set to outlet boundary (draft tube outlet), the static pressure on outlet was 0Pa, the blade surfaces and the inner surface of spiral case, hub, shroud and draft tube were set to no-slip wall. The interface between static spiral case domain and rotational runner domain was set to frozen rotor model, which keeps the relative location between static and rotational zone by means of changing the reference coordinate. The interface between rotational runner and static draft tube domain was set to stage model, this model simulates the average interaction by means of forming an circumferential average flow on the interface. 4. Hydraulic reason of S-shaped characteristic 4.1. The flow figure characteristic in "S" operating zone Based on the research object and emphasis as well as the model test results, the operating points for CFD numerical simulation are confirmed in table 2, which mainly distribute in S-shaped zone. 4
6 Table 2. CFD simulation points in S-shaped operating zone Point number Capacity Q (L/s) Rotational Speed(rpm) Many references indicated that, comparing with conventional hydraulic turbine unit, the special flow condition in the non-blade zone of reversible pump turbine has extremely important influence to its hydraulic stabilities, especially the form of S-shaped characteristic. Here the non-blade zone is the domain between guide vane outlet and runner inlet. Figure 5. Streamline and velocity distribution on 50% flow surface (Q=120L/s) Figure 6. Streamline and velocity distribution on 5% flow surface (near hub, Q=20L/s) Negative Vr (flow into runner) Positive Vr (flow into guide vane) Figure 7. Streamline and velocity distribution on 50% flow surface (Q=20L/s) 5
7 Figure 8. Streamline and velocity distribution on 96% flow surface (near shroud, Q=20L/s) The above figures indicated that the vortex and flow separation become more and more severe with the decrease of flow capacity, simultaneously, the flow conditions on different flow surface are variant, the flow in non-blade zone reveals the following characteristics: The radial velocity is positive and the flow direction is from guide vane to runner near the hub and shroud zone, which is the normal direction under turbine operating condition. The radial velocity is negative and the flow direction is from runner to guide vane in the middle of rotational runner zone. The aforementioned phenomena also exists even if the operating condition isn't into the "S" zone, meanwhile, this situation becomes more and more obvious with the decrease of specific capacity. The meridian flow shows that there exist two obvious vortex near hub and shroud Concept of partial reverse pump operating condition The refluence has appeared in partial non-blade zone before the operating condition isn't into the "S" zone yet, which makes two obvious vortex on meridianal flow, but the flow direction is from guide vane to runner adjacent to the runner blades, we call this phenomena as partial reverse pump. Figure 9. Radial velocity distribution on runner inlet and Vortex in non-blade zone (Q=40L/s) 6
8 Figure 10. Radial velocity distribution on guide vane inlet (Q=120L/s) Figure 11. Radial velocity distribution on runner inlet (Q=120L/s) Figure 12. Radial velocity distribution on guide vane inlet (Q=20L/s) Figure 13. Radial velocity distribution on runner inlet (Q=20L/s) The radial velocity distribution on guide vane inlet has obvious characteristic of guide vane blade numbers (the blade numbers of guide vane are 20, the same as stay vane), but on the guide vane outlet, the radial velocity distribution has the characteristic of runner blade numbers. Along with the decrease of flow capacity, this characteristic becomes more and more unobvious, under the Q=20L/s operating condition (see Figure 12, Figure 13), the flow in non-blade zone has influenced the guide vane inlet condition, which makes the radial velocity distribution on guide vane inlet without the evident characteristic of guide vane blade numbers no more, and the regularity too Hydraulic reason of "S" characteristic From the simulation results, the water head of unit increases along with decrease of flow capacity, under the same rotational speed, the specific speed decreases, in other word, the specific speed decreases along with the decrease of specific capacity, which finally form the "S" characteristic. 7
9 The simulation results also indicated that the range with positive radial velocity (flow out the runner) on the guide vane outlet becomes more and more large, detailed analyses show that the radial velocity adjacent to hub and shroud on the column face of guide vane outlet is negative (flow into the runner), but the vast majority of radial velocity in middle zone are positive, this condition becomes more and more obvious along with the decrease of flow capacity. Under most simulating points, the maximal radial velocity on guide vane outlet appears in middle of the flow domain between runner blades, at the same time, the periodicity of this distribution is evident. Additionally, on the guide vane inlet, the velocity distribution has obvious characteristic of guide vane blade numbers, but on the guide vane outlet, the velocity distribution has obvious characteristic of runner blade numbers, we can think that the action of runner is dominant to the flow situation in non-blade zone at this time. The partial reverse pump state appeared in the non-blade zone and runner zone before the operating condition points entering into the "S" zone, meanwhile, the action of partial reverse pump becomes more and more important along with the flow capacity decrease. This flow state makes the water head consequentially increase because the unit need to consume more energy under the same flow capacity, so the specific speed decrease under the same rotational speed, which makes the performance curve reverse bending as S-shaped. 5. Conclusions This paper simulated the full flow passage of a reversible pump turbine model using CFD method, analyzed the flow regularity in the S-shaped operating zone and the hydraulic reason forming the "S" characteristic of reversible pump turbine, the conclusions are as following: The flow state between the runner blades is satisfactory under the large flow capacity operating condition, along with the decrease of flow capacity, the vortex appear between the runner blades, meanwhile, the flow states are comparatively difference between on the flow surface adjacent to hub and shroud and on the middle flow surface. The refluence will appear even if the operating condition wasn't enter the "S" zone, which brings about a great deal vortex in the guide vane and runner zone. This partial reverse pump operating condition is the central hydraulic reason to the S-shaped characteristic of reversible pump turbine. References [1] Zhang L J, Wang Z W 2011 J.Transactions of the Chinese society for agricultural machinery 42(1) [2] Wang LQ, Yin J L and Jiao L May 2011 J.Science China (Technological Sciences) 54(5) [3] Wu Y, Liu S, Wu X 2010 Turbulent flow computation through a model Francis turbine and its performance prediction 25th IAHR Symp. on Hydraulic Machinery and Systems(Timisoara, Romania) [4] Kerschberger P and Gehrer A 2010 Hydraulic development of high specific-speed pumpturbines by means of an inverse design method, numerical flow-simulation (CFD) and model testingn 25th IAHR Symp. on Hydraulic Machinery and Systems(Timisoara, Romania) 8
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