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Renewable Energy 115 (2018) 1075e1085

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Renewable Energy
journal homepage: www.elsevier.com/locate/renene

Numerical analysis of non-axisymmetric flow characteristic for a


pump-turbine impeller at pump off-design condition
Zhao Xiaoran a, Xiao Yexiang a, Wang Zhengwei a, Luo Hongying b, *, Ahn Soo-Hwang a,
Yao Yangyang a, Fan Honggang a
a
State Key Laboratory of Hydroscience and Engineering & Department of Thermal Engineering, Tsinghua University, Beijing, 100084, China
b
Water Conservancy and Civil Engineering College, Tibet Agriculture and Animal Husbandry College, Lingzhi 860000, China

a r t i c l e i n f o a b s t r a c t

Article history: The present paper analyzed the inner flow characteristic of a reversible pump-turbine at pump mode
Received 2 January 2017 with the optimal guide vane opening. An unusual asymmetrical feature of both pressure fluctuation and
Received in revised form flow pattern inside the rotating impeller was detected under a pump off-design condition, in which the
23 May 2017
flow rate is smaller than that of hump district. The steady and unsteady simulations were performed in
Accepted 25 June 2017
Available online 27 June 2017
ANSYS 16.0 with the SAS SST-CC turbulence model. The simulation results of pressure fluctuations show
that there exists a noteworthy difference of pressure amplitudes in each rotating flow passage, which is
not obvious under other conditions. Flow pattern analysis indicates that the impeller flow fields are
Keywords:
Pump-turbine
asymmetrical in different passages under this pump off-design condition, with significant flow separa-
Rotating impeller tion and vortexes. When exploring the possible causes for this particular flow pattern, it is revealed that
Asymmetrical flow the specific elbow structure has an impact on the flow distribution in the draft tube. Flow separation and
Pressure fluctuation reverse flow are discovered in the conical and elbow part of the draft tube, which leads to the uneven
Vortex flow flow pattern at the impeller inlet. It is demonstrated that there is a close relationship between unsteady
flow structures and asymmetrical pressure fluctuation characteristic.
© 2017 Published by Elsevier Ltd.

1. Introduction pump mode, the pump turbine units could enter the “S” charac-
teristic area on the characteristic curve, which would give rise to
During the past decades, the energy demand has increased unstable pressure pulsations and cause vibrations and mechanical
dramatically, followed by some important energy issues. One of damages to the unit [2e4]. When operated in either of pump or
them is the stability of the grids, which is influenced by the supply generating mode at the off-design conditions, several complex flow
and demand fluctuation. Pumped-storage power is a good com- phenomena are usually observed in pump-turbines, such as cavi-
plement to the other renewable energy resources for electrical tation flows, reverse flows, vortex flows and pressure fluctuations
balance [1]. Pumped storage power stations undertake the tasks of [5,6]. In pump mode, the hump characteristic is a major factor
grid peak shaving, frequency modulation, phase modulation and affecting the stability of pump-turbines, disadvantageously due to
valley filling in electric power system. Pump-turbines operated in the low specific speed [7,8]. These phenomena could result in the
pumped storage power stations are characterized by high hydraulic sudden disorganization on the passage flow and bring about large
heads and bidirectional operations at various working conditions. pressure fluctuations.
The present requirements demand the pump-turbines to be This study focuses on the flow characteristics in the impeller
used at off-design conditions. Thus, it is important to expand the under the off-design working condition, in which the flow rate is
operating range and to ensure working stability of pump-turbines. smaller than that of the hump district. The primary concern is the
In a transient operation process, while in starting process at flow structure and pressure fluctuation asymmetries. Several re-
generating mode, load-rejection condition and power-off process at searchers have concentrated on the unsteady flow phenomena in
Francis pump-turbines, experimentally and numerically. Jese
concluded that the attack angle and the radial gap would affect the
flow structures at the trailing edge of the impeller blades [9]. Erne
* Corresponding author.
carried out CFD simulations with several turbulence models and
E-mail address: lhy_xz@sina.com (L. Hongying).

http://dx.doi.org/10.1016/j.renene.2017.06.088
0960-1481/© 2017 Published by Elsevier Ltd.
1076 Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085

compared the results with experimental data. The results indicated


that the reverse flow was generated in the draft tube core and the
static pressure distribution was asymmetric circumferentially,
which leaded to a low-frequency pressure fluctuation [10]. These
researches dedicated to figuring out the unsteady flow phenomena
involving the non-uniform flow structure and its asymmetrical
flow characteristic in Francis pump-turbines. However, the effects
of these phenomena on the flow patterns in the whole impeller
passage have still not been investigated. The exact relationship
between the non-axisymmetric flow pattern and the unsteady flow
characteristic should be analyzed in the impeller flow passage. Fig. 1. Simulation domains for a Francis pump-turbine.

The asymmetrical flow field caused by the flow disturbance in


the pump-turbine could increase the non-uniformity of the axial
Table 1
and radial forces in various degrees [11,12], thereby leading to noise Performance parameters of the Francis pump-turbine.
and vibration. Since stability and security issues in pump-turbines
Parameter Value
require more concern for operating conditions variability, the
mechanism of asymmetrical flow characteristic in the pump- Impeller diameter Dr 0.47 m
Number of impeller blades Zr 9
turbine under off-design conditions at pump mode needs to be
Number of guide vanes Zg 20
investigated more meticulously. Number of stay vanes Zs 20
Optimal opening of guide vanes Aopt 27 mm
1.1. Previous studies for centrifugal pumps Rotating speed n 1300 rpm
Design flow rate Q0 408 L=s
Design head H 51 m
Various studies are focusing on centrifugal pumps. It should be pffiffiffi
3:65n Q 158.8 m$PS
noted that Francis pump-turbines at the pump mode are similar to Specific speed ns ¼ H3=4
centrifugal pumps on the structure forms and the operating
methods. Therefore, researches on the asymmetrical flow charac-
teristic in centrifugal pumps would provide a foundation for them
on Francis pump-turbines. Pei performed 3D internal flow simu-
lations in a centrifugal pump and found out that the velocity and
static pressure distributions were not uniform circumferentially,
which was more obvious at the low flow rate condition [13]. Zhang
conducted a PIV experiment on the diffusion-type and contraction-
type sewage pumps. The asymmetric flow patterns appeared at the
impeller outlet in both pumps [14]. Some studies presented that the
asymmetric pressure fluctuation was associated with the volute
static pressure distribution. Guo carried out the experiment on the
pressure fluctuation and the vibration in a centrifugal pump. The
results showed that the pressure fluctuation in the impeller was
non-uniform circumferentially coupled with the volute static Fig. 2. Meshes of all simulation domains.
pressure under off-design conditions [15]. Zhu investigated the
pressure characteristic in a gap drainage impeller experimentally
and numerically. The findings revealed that the pressure pulsations analyzing the relationship between the pressure fluctuation and
were uneven at the impeller circumference, which showed the the unsteady flow pattern in the impeller passage, along with
tendency was consistent with static pressure in the volute [16]. taking the upstream flow structures into consideration. The present
Some researchers argued that the interaction between the impeller paper aims to find out the relationship between the non-
and the volute was the major reason for the asymmetrical flow axisymmetric flow phenomenon and the unsteady flow charac-
characteristic. Miner numerically modeled a centrifugal pump teristic, from the flow field analysis on the flow structure and the
under 0.75Q0 working condition. The results showed that each pressure fluctuation. 3D numerical simulations with a Francis
channel had a distinction on the flow rate in the impeller. For this
reason, there was an obvious asymmetric pressure distribution due
to the interaction of impeller blades and a tongue [17]. Cui simu-
lated the internal flow field in a low-specific-speed centrifugal
pump and explored that the amplitudes of pressure fluctuation
varied circumferentially owing to impeller-volute interaction [18].
Wang found out the asymmetric flow pattern in a multistage cen-
trifugal pump, which was caused by the vortex and reverse flows
[19]. Li demonstrated that the ring vortex band and the reverse flow
were generated in the pipe outlet under 0.4Q0 and 0.6Q0 conditions
in the centrifugal pump, which propagated to the impeller inlet and
brought about non-uniform flow patterns [20].

1.2. Objective of study

From the above findings, the study on the asymmetrical flow


characteristic in pump-turbines could be also established with Fig. 3. Performance characteristic curves of both simulation and experiment [21].
Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085 1077

pump-turbine model were performed at off-design condition with chosen after the mesh-independent check, which was conducted in
the optimal guide vane opening in pump mode. our previous study [21]. It is composed with 2.8 million elements,
of which the maximum dimensionless wall distance yþ is less than
200. The volute domain consists of the unstructured tetrahedral
2. Simulation model meshes with 0.59 million elements. For the other domains, the
structured hexahedral meshes are applied, such as the impeller,
2.1. The reversible model pump-turbine stay vanes, guide vanes and draft tube domains, of which the
number of grid elements is 1.2 million, 0.29 million, 0.34 million
This paper simulates the whole passage flow of a reversible and 0.42 million, respectively. The generated mesh is finer for the
pump-turbine, with 9 impeller blades and a diffuser with 20 guide impeller, stay vanes and guide vanes than the others, to capture the
vanes and 20 stay vanes, as shown in Fig. 1. Performance parame- complicated and unsteady flow structures, as shown in Fig. 2.
ters of the pump-turbine are listed in Table 1. The final mesh is

2.2. Turbulence model and boundary conditions

Under the off-design condition, the internal flow in the high-


speed rotating impeller is quite unstable, which is strongly influ-
enced by the rotor-stator interaction. For this reason, the strong
shear flow would be observed at the blade-surface boundary layer,
by the large angle of attack. The SAS-SST-CC turbulence model is
adopted to simulate the flow field in the pump-turbine. This Scale-
Adaptive Simulation model (SAS) was proposed by Menter [22,23].
It is a hybrid turbulence model, which includes the v. Karman
length-scale in the transport equation of the turbulence eddy fre-
quency. Therefore, the SAS-SST turbulence model could provide the
better solutions for the off-design condition due to involving
various scale vortices. Curvature correction, based on the work of
Spalart and Shur, is a modification for improving the curving and
rotating flows on turbulence models [24]. It is employed to predict
the internal flow in the impeller passage more accurately.
The boundary condition for the draft tube inlet is set to the
Fig. 4. Layout of the rotating monitor points in the impeller. velocity condition on the specific working condition. Static pressure

Fig. 5. Apeaktopeak in each flow passage under 0.46e1.19Q0 working conditions.


1078 Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085

condition is adopted to the volute outlet boundary. In unsteady the passage. For example, the rvP91 locates at inlet of the pressure
simulations, the angular resolution is 2 , which is 1/180 of a rota- side in Passage 9.
tion period. The results of the last 8 revolutions are sampled for the Time-domain analysis on pressure fluctuations is adopted at the
further analysis in this paper. 216 monitor points in the impeller. A dimensionless value is
defined as Apeak-to-peak to describe the relative amplitude of pressure
2.3. Numerical results validation and simulation working condition fluctuations, as shown in Equation (1). The relative deviation of
selection Apeak-to-peak in each flow passage is defined in Equation (2) in order
to display the diversity of pressure fluctuations in different passage
Steady flow simulations with the optimal guide vane opening (Passage 7 is set as the base data).
were performed in the previous paper to verify the numerical
settings [21]. The maximum flow rate is 1.34Q0 and the minimum DH
Apeaktopeak ¼  100% (1)
flow rate is 0.46Q0, where Q0 is the optimum discharge condition. H
The simulation results of performance curve were compared to the
experimental results, as shown in Fig. 3. The simulation errors in Apeaktopeak; Passage N  Apeaktopeak; Passage 7
the efficiency are less than 4.52%, which shows the simulation re- DAN ¼  100%
Apeaktopeak; Passage 7
sults are reliable. From this result, the simulation method was
verified. The hydraulic performance of this pump-turbine at pump (2)
mode has a hump characteristic. There are some complex flow
DH is the peak-to-peak value of the pressure fluctuation, of which
structures, which could be observed clearly in the experiments.
the unit is converted to the length, and H is the head of the pump-
In order to understand the flow characteristics at the whole
turbine at pump mode. Besides, N represents the passage number.
working conditions on the performance curve for the optimal guide
The results in Apeak-to-peak at mid-passage under 0.46Q0, 0.69Q0,
vane opening, unsteady flow simulations are carried out at 0.46Q0,
0.85Q0, 1.0Q0 and 1.19Q0 working conditions are shown in Fig. 5. The
0.69Q0, 0.85Q0, 1.0Q0 and 1.19Q0 working conditions. The results
relative amplitudes of pressure fluctuations are less than 7% and the
show that the flow non-uniformity is stronger as the flow rate gets
smaller. (The detailed analysis is mentioned in part 3.1) The
circumferential asymmetry is a typical and noteworthy phenome-
non at the 0.46Q0 condition, in which the flow rate is smaller than
the pump hump district. Therefore, this paper aims to analyze the
asymmetrical flow behavior in the rotating impeller at 0.46Q0
condition under the optimal guide vane opening.

3. Asymmetrical flow analysis in rotating impeller

3.1. Pressure fluctuation analysis on nine blade passages

For investigating the unsteady flow features in 9 blade passages


and their asymmetries on the flow behavior, the pressure data are
saved at 216 rotating monitor points inside the impeller during the
unsteady simulations. For the purpose of recording the general
pressure variation inside the impeller, we select the revolution
surface of 0.5 span to set the monitor points. They are uniformly
arranged near the pressure side and suction side boundaries and
the mid-passages in the 9 channels, as shown in Fig. 4. Here, rvP,
rvM and rvS represent the points at the pressure side, the suction
side and the mid-passage, respectively. The first number is the
passage number and the second represents the radial location in Fig. 7. Pressure fluctuation spectrum at rvM91~rvM98.

Fig. 6. Changing trend of DAN in each flow passage.


Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085 1079

differences between each passage are not obvious under 0.85Q0, the mid-passage points in Passage 9 are presented in Fig. 7. The
1.0Q0 and 1.19Q0 working conditions. However, the difference of relative frequency is defined as f/fn where fn represents the rotating
relative amplitudes becomes remarkably significant when the flow frequency of the impeller. In this figure, the frequency 20fn is
rate decreases. Under 0.46Q0 working condition, the maximum induced by the rotor stator interaction, which has the larger
relative amplitude of pressure fluctuations is more than 60%. amplitude at the vicinity point of the vanes (rvM98). The detected
Therefore, we conduct the analysis mainly on the flow character- first dominant frequencies are lower than fn. The amplitudes at the
istic under 0.46Q0 working condition. lower frequencies are significantly larger relative to the high fre-
The results in DAN at the pressure side, the mid-passage and the quencies, and for the point near the vanes they are especially higher
suction side under 0.46Q0 working condition are compared sepa- than the other points.
rately, as shown in Fig. 6. The distribution of relative amplitudes in Pressure fluctuation spectra of monitor points at the same radial
9 blade passages is obviously uneven. The changing trends in the position in each passage are compared to explore the asymmetrical
streamwise direction vary in different passages, which indicates characteristic in pressure signals. Fig. 8 shows the comparison of
that each passage has the discrepancy in the flow structure. them in rvPx1~rvPx8 where x represents the passage number. The
Fast Fourier transform (FFT) was used to analyze pressure sig- dominant frequencies are generally the same at each blade passage,
nals of all 216 monitor points. The dominant frequencies are almost while the amplitudes have obvious distinctions. At rvPx4~rvPx6,
the same in 9 passages. To show the pressure spectra in the the amplitudes at Passage 5, 7, 8 and 9 are higher than other pas-
impeller, the fluctuation amplitudes and the relative frequencies at sages. At rvPx7 and rvPx8, the frequency diagrams seem to be

Fig. 8. Pressure fluctuation spectrum at rvPx1~rvPx8 (x represents for the passage number).
1080 Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085

complicated, and the amplitudes of the dominant frequency are


remarkably large. Here, the frequency of 20fn is significant, which is
induced by the interaction between impeller and guide vanes. And
the pressure amplitude variation trend is not as same as the other
monitor points, that is, the amplitudes at Passage 5, 7, 8 and 9 are
not the highest. It means that the internal flow near the vanes is
complicated in the impeller under the low flow rate condition. It
could be influenced not only by the rotor-stator interaction phe-
nomenon but also other factors. The asymmetrical phenomenon
could result from vortexes distribution in different rotating
impeller passages, and it will be described in the next section.
Fig. 9 shows the comparison of the pressure fluctuation char-
acteristic in rvSx1~rvSx8 at the suction side. Like the pressure side,
the frequencies are similar at the same radial positions and the
amplitudes vary at different passages. However, the amplitudes at
the points of rvSx1 are distinguishable from the others, where the Fig. 10. Vortex flow structures in the impeller (l2 ¼ 400000m2 ).

Fig. 9. Pressure fluctuation spectrum at rvSx1~rvSx8 (x represents for the passage number).
Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085 1081

Fig. 11. Streamline on a 0.5 span plane in the impeller.


1082 Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085

amplitudes of Passage 1, 3 and 7 are significantly higher. It is passages, in an instantaneous flow field. From Fig. 10, it can be
demonstrated that the inlet flow obviously has the asymmetrical known that there is a significant asymmetric flow phenomenon in
characteristic at the suction side. Compared to results at the points the impeller, especially near the hub.
of rvSx2, pressure amplitudes of rvSx1 are obviously larger. It is due For exploring the changing trend of flow structures over time,
to the rotor-stator interaction between rotating impeller and static flow streamlines on a revolution surface at 0.5 span of the impeller
suction pipe. Under the low flow rate working condition, there during one rotating period are presented in Fig. 11. The inner flow
could exist a reverse vortex pattern flowing from the impeller inlet structure is uneven at each moment owing to the complicated
to the suction pipe outlet, which will interfere with the rotating vortex structures. There, various scale vortices can be observed,
blades. In the previous study on centrifugal pumps [25], this especially near the blade tip and the blade leading edge. Taking two
interaction was also detected, and it brought about the formation of obvious vortex structures as an example, at the pressure side in
ring vortex band and a more complex flow structure. This phe- Passage 8 and the suction side in Passage 3, the temporal and
nomenon could have an influence on the pressure fluctuations. spatial variations on the vortexes are discussed, and two taken
vortices are marked in Fig. 11. The two structures rotate around the
axis of the rotating impeller, of which relative positions are almost
3.2. Analysis of flow pattern in rotating blade passages
not be changed, while the swirling flow area between two marked
vortices changes temporally.
The l2 -criterion, proposed by Jeong and Hussain in 1995 [26], is
From the comparison of the flow structures in the whole
used to display the vortex structures in the impeller. The l2 -crite- impeller at different moments, it could be observed that the blade
rion has been used by several researchers for the detection of the inlet vortexes near the suction side only present in Passage 1, 3, 4, 5,
vortex core [27,28]. When the effect of disturbance and viscosity is 6 and 7 in a period. For the trailing edge vortex, when each rotating
ignored, the symmetrical parts in gradient of the incompressible impeller blade reaches near the volute tongue region (the upper
Navier-Stokes equation can be expressed as follow. Define the ei- right corner in the figure, as shown in Fig. 11(k)), the vortexes
genvalues of the symmetric tensor as l1 , l2 and l3 , then appear at the middle of the pressure side. At that moment, the flow
l1  l2  l3 , l2 < 0. separation at the middle of the pressure side in Passage 5, 7 and 8 is
more evident among the 9 passages. And the swirling streamline
1
S 2 þ U2 ¼  VðVpÞ (3) area with low velocity, which can be defined as the vortex regions,
r accounts for almost 50% of the whole passage and is larger than the
As shown in Fig. 10, vortexes mainly appears at the trailing edge other passages. The complex flow patterns nearby cause blockages
of the pressure side and leading edge of the suction side in several and disorder in the Passage 5, 7 and 8 for longer periods of time.

Fig. 12. Normal Eigen helicity distribution on Z ¼ 0.15 m plane in the draft tube.
Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085 1083

Besides, at several moments, there exist vortexes at both the middle flow characteristic in the impeller. In Fig. 12, normal Eigen helicity
of the pressure side and the trailing edge. However, this phenom- method is applied to analyze the vortex flow inside the draft tube.
enon is not discovered in other passages. Meanwhile, vortexes are The illustrated figures are at the cross-section plane Z ¼ 0.15 m in
alternately generated at the impeller outlet near the pressure side the draft tube, as shown in Fig. 12(e). The Helicity method uses the
in each passage. From the results on the unsteady flow pattern and normalized helicity Hn to extract vortex core lines [29]. Hn is the
the pressure fluctuation characteristic, it is demonstrated that the cosine of the angle between the velocity ! v and the vorticity vector
internal flow is disorganized and asymmetric in the impeller, at the !
u ¼V! v , as follow:
low flow rate working condition.
!v $! u
3.3. Analysis of influence factor on asymmetrical flow in impeller Hn ¼ ! ! (4)
j v jj u j
The internal flow in the draft tube is also analyzed in order to This method has been applies in many researches and been
investigate the influence of upstream flow on the asymmetrical proved as an useful tool to display the vortex distribution [30,31]. It

Fig. 13. Flow structure and analysis in the draft tube.


1084 Z. Xiaoran et al. / Renewable Energy 115 (2018) 1075e1085

reveals that the flow on the cross-section near the draft tube outlet flow area becomes larger and the flow blockage phenomenon is
is uneven circumferentially and changes over time. The flow more evident. It is investigated that there exist vortexes and reverse
pattern near the interface between the impeller and the tube has an flow at the elbow part of the draft tube, which bring about the
impact on the velocity distribution at the impeller inlet. This asymmetrical vorticity distribution at the conical part. In addition,
asymmetrical flow characteristic could lead to numerous problems the special formation of draft tube contributes to the uneven dis-
such as the secondary flows involving vortexes at the impeller inlet. tribution, when comparing to the condition in centrifugal pumps.
The asymmetrical flow at conical part results from the complex Therefore, the non-uniform inner flow of draft tube has an influ-
upstream flow, as the elbow part of the draft tube. There appear ence on the asymmetrical flow characteristic in the impeller.
different scale vortexes and reverse flows in the draft tube, as
shown in Fig. 13(a). The asymmetric geometric structure of the Acknowledgments
draft tube has an influence on flow patterns at pump mode under
the off-design condition. In this figure, the flow passing through the Special thanks are due to the State Key Program of National
draft tube inlet is smooth without any flow separation. Since the Science of China (Grant No. 51439002), National Natural Science
radius of side A is larger than that of side B at Plane I, the pressure Foundation of China (No. 51479093), Special Funds for Marine
decreases gradually from the wall of side A to that of side B due to Renewable Energy Projects (Grant No. GHME2012GC02), State Key
the centrifugal force, when the flow passes the elbow part. There- Laboratory of Hydroscience and Engineering (Grant No. 2016-E-01),
fore, the flow velocity near the side A is smaller than the side B, as The National Key Research and Development Program of China (No.
shown in Fig. 13(b). The velocity distributions at Plane I and Plane II 2017YFC0404200), Chinese National Sci-Tech Support Plan (Fund-
at t ¼ 1.754s moment were shown in Fig. 13(c) (d). At Plane I, the ing NO. 2012BAD10B01) for supporting the present work.
velocity near side B is much larger than that near side A, while at
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