Analysis of Rotor-Stator Interaction in Turbine Mo
Analysis of Rotor-Stator Interaction in Turbine Mo
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Xianzhu Wei
Harbin Institute of Technology
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ABSTRACT
The highest-level fluctuations in large pump-turbines are usually originated from rotor-stator interaction
(RSI) in the vaneless region. Hence, the studies of RSI phenomenon and corresponding unsteady effects are
significantly important to reduce the pressure fluctuations. In this paper, firstly, RSI in a pump-turbine,
featuring 20 stay vanes, 20 guide vanes and 9 runner blades, is analyzed through diameter mode theory,
which has been used widely. Then, 3-D unsteady numerical simulations are performed under six guide vane
openings in turbine mode. The comparison including performance and pressure characteristics between
numerical and experimental results shows a good agreement. Finally, best guide vane opening 21° is chosen
to analyze the distribution of pressure fluctuations. The detailed investigation of numerical results shows that
frequencies in the vaneless region at best guide vane opening are mainly blade passing frequency (BPF) and
its harmonic frequencies caused from RSI. The variation of BPF and its harmonic frequencies is confirmed by
diameter mode theory. For this type of the pump-turbine, the amplitude of 2BPF (18fn) shows the highest
corresponding diameter mode k2=-2, which indicates two high pressure regions caused by the component of
18fn in the vaneless region. Furthermore, the two high-pressure regions rotate in the counterclockwise
direction with rotational speed of the runner blades. This research could provide a basic understanding of RSI
to have a further study for pressure fluctuations in pump-turbines.
Keywords: Pump-turbine; Rotor-stator interaction; Turbine mode; Vaneless region; Diameter mode.
NOMENCLATURE
were developed due to their quick respond ability to In this paper, 3-D unsteady simulations of a pump-
the variation of the load (Decaix 2015), especially turbine, featuring 20 stay vanes, 20 guide vanes and
for pumped storage power plants. Because of 9 runner blades were conducted using the SST k-ω
effective storage and flexible switch between turbulence model in turbine mode. Based on the
turbine mode and pump mode, pumped storage validation of the experimental data including
power plants have a rapid development. Pump- performance and pressure characteristics, best guide
turbine as for the key component, the current trend vane opening 21° is selected to study the causes and
is the increasing of the power, head, and speed propagation characteristics of RSI combing
either for building new plants or for upgrading diameter mode theory in the vaneless region. In
existing plants. It leads to an obvious rise in the addition, the distribution of the pressure
pressure and fluid velocities (Rodriguez 2007). A characteristics in the circumferential direction and
great number of studies were carried out on flow vertical direction is also presented.
characteristics (Yin et al. 2010, 2014), instabilities
such as hump characteristics (Li et al. 2015) and S 2. PUMP-TURBINE SPECIFICATIONS
shaped characteristics (Wang et al. 2011), and
corresponding pressure fluctuations in pump- A reversible pump-turbine model is investigated in
turbines. Pressure fluctuation is one of hot topics in this research, which is reduced 8 times of a
pump-turbines. The increase of pressure prototype in a pump storage power plant (see Fig.
fluctuations leads to the fatigue problems more 1). Main parameters of the pump-turbine in turbine
common. Generally speaking, pressure fluctuations mode are listed in Table 1. The five components are
of pump-turbines in turbine mode operating at as follows: the spiral casing, the stay vanes, the
normal conditions for full load come from RSI. At guide vanes, the runner and draft tube. All the
part load they are mainly caused by the vortex rope measurements are carried out on the hydraulic
in the draft tube cone. At extreme off-design system in Harbin Institute of Large Electrical
operating condition, the pressure fluctuations are Machinery.
due to draft tube instabilities, runner channel
vortices and flow separation (Magnoli 2012). These
pressure fluctuations not only generate lot of noises
and serious oscillations, but also introduce
unfavorable characteristics. Hence, it is very
important to understand the causes of pressure
fluctuations to improve the overall performance and
reliability (Wang et al. 2001).
RSI has specific characteristics that could be clearly
observed in frequency and has been studied widely
through different methods. Tanaka (1990), Guo and
Marua (2005), Franke et al. (2005), and Guo and
Okamoto (2014) have used excited diameter mode
theory which was proposed by Kutota et al. (1983)
to determine vibration characteristics combing the Fig. 1. The test rig of the pump-turbine model.
number of stationary and rotating blades. These
studies could provide a quick and simple result. Table 1 Parameters of the pump-turbine model
Meanwhile, lot of researchers predicted pressure Parameter Value Unit
fluctuation caused by RSI with a reasonable D1 482.5 mm
accuracy using CFD. Wang et al. (2001) predicted D2 240 mm
pressure fluctuations in 2-D unsteady Zr 9 -
incompressible flow by using a vortex method, D0 563.5 mm
which shows a good agreement with the
Zg 20 -
experimental data. Yan (2010) obtained the pressure
Zs 20 -
fluctuations in the vaneless region using a
compressible CFD simulation and conducted that
the compressibility of water might strongly
influence the pressure fluctuation. Similar work was 3. EXPECTED ROTOR STATOR
carried out by Yin (2013) to study the effects of BEHAVIOR IN VANELESS REGION
water compressibility on pressure fluctuations.
More recently, a conclusion was obtained that the Pressure filed caused by RSI in the vaneless region
rotating of guide vanes has an obvious effect on the could be considered as a combination of inviscid
amplitudes of pressure fluctuations in the vaneless flow (potential) and viscous flow (wake). With
region (Li 2015). respect to potential effect, flow field in the vaneless
region is periodically perturbed by the rotating
Although a great deal of research has been carried runner blades. As for the viscous effect, the
out to investigate pressure fluctuations, a systematic hydrodynamic phenomena, which play a major role
investigation of RSI in the vaneless region using in RSI, is non-uniformity of the velocity field in the
numerical simulation, experimental validation and spiral casing, non-desirable flow angle in the
diameter mode theory is limited. The mechanism of distributor, flow separations and wakes (Zobeiri,
RSI is not fully clear, especially for pump-turbines. 2006).
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p r r ,t B m cos n Z r r m (2)
m 1
p mn ,t A mn cos n Z g s n (3)
cos m Z r r m
a)
Amn
pmn s , t
2
cos mZr t mZr nZg s n m
A
mn cos mZr t mZr nZg s n m
2
(6)
Eq. (6) indicates the pressure fluctuation induced by
b) potential interaction in the stationary system, which
is the function of time and space. One defines two
diameter modes k1 and k2, which can be expressed
as Eq. (7) and Eq. (8).
k1 m Z r n Z g (7)
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experimental data. The turbulence parameters are experimental and numerical results mainly come
specified in terms of turbulence intensity and from the following. Firstly, 13.4° guide vane
hydraulic diameter of the inlet. Static pressure (0 opening is small opening, which is an off-design
Pa) is set at the draft tube outlet (turbine mode). operation condition, in which the flow pattern is
Considering the recirculation and backflow, the extremely unstable and accompanies with flow
type of pressure outlet is opening. In addition, separation, vortex motion and secondary flow. So
smooth no-slip wall conditions are imposed for the the differences at this operation condition show the
rest of solid surfaces. Boundary function is adjusted highest. Secondly, leakage and gap losses as well as
to the low Reynolds number wall function. All the dis friction are neglected in the usual CFD set up.
cases are investigated for the energy characteristics Thirdly, the turbulence model based on URANS,
without considering the cavitation. which consists many empirical parameters, cannot
predict all kinds of flow. In this research, SST k-ε
4.3 Numerical Scheme turbulence model is chosen, and the differences for
torque, head and efficiency are less 5%, 3% and
All the simulations are conducted through ANSYS 2%, respectively, which satisfy numerical accuracy.
module CFX. 3-D incompressible unsteady A further analysis could be carried out based on the
Reynolds-averaged Naiver-stokes (URANS) validation above.
equations and mass conservation equations are
solved using finite volume method. Two-equation
turbulence model SST k-ω is chosen for closing
equations. In addition, the high resolution scheme is
used for the advection term and 1st order upwind
scheme is chosen for other terms. A time step
1.6×10-4s is set corresponding 1.2° of runner
rotation. Namely, a revolution for the runner needs
300 steps. The interface between rotor and stator is
Transient Rotor-Stator.
b)
Fig. 6. Monitoring points in the vaneless region
a) circumferential direction, b) vertical direction.
Fig. 5. Comparison for performance
characteristics between the experiments and
simulations. 4.5 Validation for Pressure Fluctuations
From Fig. 5, the difference between experimental Figure 6 shows the locations for monitoring points
and numerical results for all performance in the vaneless region. Fifty monitoring points are
characteristics curve is less than 5%. The maximal set in the vaneless region (between the runner inlet
differences for the head, torque and efficiency and guide vane outlet) close to the band (see Fig. 6-
between the experimental and numerical results are a) to investigate the pressure characteristics in the
observed at 13.4° guide vane opening, which are - circumferential direction. Five (A, B, C, D and E)
4.17%, -2.46% and -1.75%, respectively. The groups of monitoring points are set along the flow
minimal differences appear at 29° guide vane direction to investigate pressure characteristics in
opening. In a sum, the differences at large guide the flow direction. For each group, the distance of
vane opening show less than the ones at small guide every two monitoring points is equal. All the
vane opening, and the relative differences turn out monitoring points are equally copied four times in
much larger off the best guide vane opening (21°). the vertical direction (see Fig. 6-b) to obtain the
variation of pressure fluctuations in the vertical
The reasons for the differences between direction.
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The calculation results of last 2048 steps are used to The amplitudes close to the runner inlet show
study the pressure characteristics compared with obviously higher than the ones at the guide vane
experimental data. The frequency resolution is 3Hz. outlet, which indicates the effects of RSI are the
Dimensionless parameter ΔH/H is used to represent most serious close to the runner inlet.
how much the pressure fluctuation corresponding to
relative head. ΔH is peak-to-peak value during the
observing time. Point VL26 is an experimental and
also a numerical monitoring point in the vaneless
region. Fig. 7 gives the difference between the
experimental and numerical results for point VL26.
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The wave trough points are located between the two field. When to t4=1.00TB, at this moment there
guide vanes. The fluctuations mainly come from appears another wave peak, so variation of pressure
potential interaction, so the amplitudes are fluctuation enters the next period.
relatively low.
b)
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a) b) c)
d) e)
Fig. 13. Contour of pressure for point VL1 at different time a) t1=0TB, b) t2=0.18TB, c) t3=0.52TB, d)
t3=0.70TB, e) t4=1.00TB.
a) b)
a) b)
Fig. 14. Frequency spectrum for different monitoring points a) VL1, b) VL15, c) VL26, d) VL39.
wave propagation in the circumference. between the guide vanes and the runner blades. For
point VL1, the first main frequency is 18fn, with an
Then, a Fourier analysis of all the pressure time amplitude of 1.73; the second main frequency is 9fn,
data is performed to determine the prevailing with an amplitude of 1.23. The amplitudes of 27fn,
frequencies at different locations (see Fig. 14). 36fn, and 45fn, are relatively small and show a
Where, f is real frequency, fn is rotational frequency, descending trend. This is the same with the results
20.87Hz; frequency resolution is 0.146fn. obtained through diameter mode theory.
It can be obtained that the main frequencies are However, the frequency characteristics of VL26
blade passing frequency and its harmonic show different from the other three monitoring
frequencies, such 9fn, 18fn, 27fn, 36fn, …. So the points. The amplitudes of 9fn and 18fn are much
frequencies in the vaneless region at best guide lower than those of other points, while the
vane opening are originated potential interaction
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amplitudes of 27fn and 36fn show relatively high. It 0.15fn, fn, 4fn, 5fn. These frequencies are not
indicates pressure field of different frequencies produced by RSI and may come from other
components features different distribution and wave components, such as vortex motion, rope vortex in
propagation characteristics. the draft tube. A further study could be continued to
validate the sources of these frequency components.
6. CONCLUSION
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