Numerical Simulation and Experimental Validation of a Kaplan Prototype Turbine Operating on a Cam Curve

Abstract

The role of hydropower has become increasingly essential following the introduction of intermittent renewable energies. Quickly regulating power is needed, and the transient operations of hydropower plants have consequently become more frequent. Large pressure fluctuations occur during transient operations, leading to the premature fatigue and wear of hydraulic turbines. Investigations of the transient flow phenomena developed in small-scale turbine models are useful and accessible but limited. On the other hand, experimental and numerical studies of full-scale large turbines are challenging due to production losses, large scales, high Reynolds numbers, and computational demands. In the present work, the operation of a 10 MW Kaplan prototype turbine was modelled for two operating points on a propeller curve corresponding to the best efficiency point and part-load conditions. First, an analysis of the possible means of reducing the model complexity is presented. The influence of the boundary conditions, runner blade clearance, blade geometry and mesh size on the numerical results is discussed. Secondly, the results of the numerical simulations are presented and compared to experimental measurements performed on the prototype in order to validate the numerical model. The mean torque and pressure values were reasonably predicted at both operating points with the simplified model. An analysis of the pressure fluctuations at part load demonstrated that the numerical simulation captured the rotating vortex rope developed in the draft tube. The frequencies of the rotating and plunging components of the rotating vortex were accurately captured, but the amplitudes were underestimated compared to the experimental data.

Keywords

• hydropower
• Kaplan turbine
• prototype simulation
• CFD
• rotating vortex rope