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Francis Turbine Upgrade for the Lushui Generating Station by Using Computational Fluid Dynamics - A Case Study
J. Huang, Ph.D., Hydraulic Energy Group, Sustainable Buildings and Communities, CANMET Energy Technology Centre - Ottawa, Natural Resources Canada, Ottawa, Ontario, Canada Tel: 1-613-992-4379, fax: 1-613-996-9416, email: jhuang@nrcan.gc.ca J. Swiderski, P. Eng., Swiderski Engineering Inc., Ottawa, Ontario, Canada Tel: 1-613-829-8248, fax: 1-613-829-2160, email: jacek@keynetz.net J. Ji, Lushui Pivot Management Bureau, Changjiang Water Resources Commission of Ministry of Water Resources, Chibi City, Hubei, China Tel: 86-715-5259805, fax: 86-715-5259805, email: jijinting@163.com T. Tung, Hydraulic Energy Group, Sustainable Buildings and Communities, CANMET Energy Technology Centre - Ottawa, Natural Resources Canada, Ottawa, Ontario, Canada Tel: 1-613-996-6119, fax: 1-613-996-9416 M. Riley, Sustainable Buildings and Communities, CANMET Energy Technology Centre - Ottawa, Natural Resources Canada, Ottawa, Ontario, Canada Tel: 1-613-996-8151, fax: 1-613-996-9416, email: mriley@nrcan.gc.ca
Abstract Canada-China project Transferring Small Hydro technologies to China focuses on supporting environmentally sustainable development in China by improving technical and economic viability of small-hydro technologies to increase power production from small hydro and displace greenhouse gases emissions. The Turbine Design Enhancement is one of the Canadian technologies transferred in this project. A Francis turbine unit at the Lushui Generation Station of the Lushui Pivot management Bureau has been identified to apply this technology. The oversized generator and runner cavitation with turbines large head and flow variations at the dam were taken into consideration. Hydrological conditions of the site, the Computational Fluid Dynamics (CFD) design approach and methodology used to optimize the Francis runner design will be described. The appropriateness of CFD use for the design of small-hydro turbines, and the replication potential of this technology in China will be discussed. Keywords Francis turbine, Design enhancement, Turbine upgrade, CFD, Small Hydro
Natural Resources Canada Swiderski Engineering Inc. Changjiang Water Resources Commission of Ministry of Water Resources
turbine unit uses only marginal amount of water. The site has characteristics of a mountain-type with large possible fluctuations of the headpond or tailrace levels. Large upstream reservoir allows stabilizing and limiting headpond level fluctuations, although the flow-through capacity of the tailrace is limited and creates large fluctuations of the water elevation. This affects the operating conditions of the turbine in two ways: a) changing exposure to cavitation, as the suction head changes; and, b) changing turbine unit speed (n11), therefore varying runner inlet conditions.
Lushui G.S. Water level fluctuations
SWIDERSKI ENGINEERING INC.
60 55 TWL(Tail Water Level), HWL(Head Water Level) [m] 50 45 40 -4 35 30 25 0 1000 2000 3000 4000 5000 6000 -6 -8 -10 7000 TWL HWL Hs 0 -2 6 4 2 7000 River Flow 6000 Hgross
22 21 20 19 18 17 16 15 100%
Flow [cms]
Figure 1: Tail water level fluctuation (left) and flow-duration curve (right) at Lushui site.
Figure 2: All grids connected computational domain of the Lushui Francis turbine.
5000
Flow [cms]
Natural Resources Canada Swiderski Engineering Inc. Changjiang Water Resources Commission of Ministry of Water Resources
Flow simulation for the existing stationary components was conducted for a generic runner having close characteristics to the target design and for the custom optimized one for the Lushui project.
Figure 3: Flow chart of the optimization process Where: x : quality factor; x : active geometry parameter; x : rate of change of x ; and, : proximity of the solution ( ~ target /1000 ). Quality factors used in couple optimisation processes included (a) turbine efficiency, (b) draft tube stability, and (c) cavitation. The final design was created as a result of multiple runs of optimisation processes. The multi-parameter optimisation, proven to be the most productive in the past, was conducted in a couple of phases. Special emphasize was put on the draft tube stability and the cavitation-free operation. The first optimisation phase was performed for the following definition of quality factors: 1 = LE_Inlet 2 = * V_DT_Inlet Where: LE_Inlet : degree of uniformity of the flow field within the vicinity of the leading edge; : hydraulic efficiency of the turbine; and, V_DT_Inlet : degree of uniformity of the flow field at the draft tube inlet. (1) (2)
The final optimisation phase was performed for a more complex target definition, which consisted of three independent quality factors: 1 = LE_Inlet (3) (4) 2 = 3 = V_DT_Exit (5) Where: V_DT_Exit is the degree of uniformity of the flow field at the draft tube outlet.
Natural Resources Canada Swiderski Engineering Inc. Changjiang Water Resources Commission of Ministry of Water Resources
Figure 4: Leading edge flow for maximum net head Hnet = 27 m, design net head Hnet = 23.5 m and the minimum net head Hnet = 20 m (from left to right)
Natural Resources Canada Swiderski Engineering Inc. Changjiang Water Resources Commission of Ministry of Water Resources
Figure 7: Distributor flow at the optimum operating point (Hnet = 23.5 m).
OLD
1.2
1.0
Figure 8: (8a) Hill charts comparison of the turbine equipped with the existing (OLD) and the newly designed (NEW) runners; (8b) pressure distribution on runner surface of the newly designed turbine.
Natural Resources Canada Swiderski Engineering Inc. Changjiang Water Resources Commission of Ministry of Water Resources
Natural Resources Canada Swiderski Engineering Inc. Changjiang Water Resources Commission of Ministry of Water Resources
References
[1] [2] [3] [4] Francis Turbine Upgrade, J. Swiderski, Technical report to Public Works and government Services Canada, J. Swiderski, , Ottawa, August 2005 CFX TASCflow, Ver. 2.12, users manual, ANSYS, 2003 Design optimisation of replacement Francis runner CFD application in an optimization algorithm, J. Swiderski, 13th International on Hydropower Plants, Vienna 2004 Small Hydro Power: Chinas Practice, Tong Jiandong, China WaterPower Press, 2004