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Transient Analysis of Hydropower Plants With Cross-Flow Turbines
Transient Analysis of Hydropower Plants With Cross-Flow Turbines
Transient Analysis of Hydropower Plants With Cross-Flow Turbines
ABSTRACT
Transients in hydropower plants are complex phenomena impacted by various factors such as turbine
characteristics, dimensions of penstocks, closing speed of turbine guide vanes, closing speed of main turbine
inlet valves and many others. Transient regimes can result in serious disturbances in hydropower plant
operation and even in damage of mechanical and civil components due to water hammer. The best way to
anticipate and prevent such adverse outcomes is to conduct a transient analysis based on a mathematical model
of a hydropower plant system. In this paper, based on the collected data on 270 hydropower plants with cross-
flow turbines, a regression analysis was performed to derive empirical equations which relate the specific
speed, turbine rated speed, runner diameter and runner width to the rated turbine head and discharge. The
collected data and the obtained regression equations were then used to assess the turbine hill diagrams and to
develop a mathematical model for transient analysis of hydropower plants with cross-flow turbines. Finally,
the obtained numerical results are validated trough the case studies.
Keywords: Cross-flow turbine, turbine hill chart, hydropower plant, hydraulic transient, water
hammer
ABSTRACT
Transients in hydropower plants are complex phenomena impacted by various factors such as turbine
characteristics, dimensions of penstocks, closing speed of turbine guide vanes, closing speed of main turbine
inlet valves and many others. Transient regimes can result in serious disturbances in hydropower plant
operation and even in damage of mechanical and civil components due to water hammer. The best way to
anticipate and prevent such adverse outcomes is to conduct a transient analysis based on a mathematical model
of a hydropower plant system. In this paper, based on the collected data on 270 hydropower plants with cross-
flow turbines, a regression analysis was performed to derive empirical equations which relate the specific
speed, turbine rated speed, runner diameter and runner width to the rated turbine head and discharge. The
collected data and the obtained regression equations were then used to assess the turbine hill diagrams and to
develop a mathematical model for transient analysis of hydropower plants with cross-flow turbines. Finally,
the obtained numerical results are validated trough the case studies.
Keywords: Cross-flow turbine, turbine hill chart, hydropower plant, hydraulic transient, water
hammer
1. Introduction
Operation of the hydraulic system in general can be steady or unsteady (e.g., transient). While the
steady operation is characterised by constant flow over time, the transient regimes are characterized
by dynamic change of pressure and flow in the system. Unsteady flow also results in dynamic change
of flow dependent hydraulic parameters such as pipe friction factor (see e.g., Riasi et al., 2010).
The intensity of pressure changes closely depends on the flow velocity change but also on a number
of system parameters such as pipe length and diameter, pipe material, compressibility of water, gas
content in water, characteristics of valves and hydraulic machines involved etc. In some cases, the
increase or decrease in pressure can be so intense that it causes serious damage within the system
i.e., burst of system parts.
Transient regimes in hydraulic systems can be triggered by various events which can be divided into
two groups: uncontrolled or unintentional events (e.g., sudden power failure) and controlled events
(e.g., hydraulic machine start-up or shutdown, change of speed of hydraulic machine, change in
control valve opening etc.). In both cases, the safety of a system must be considered and adequate
preventive measures must be provided.
A good example of the complexity of the transients in hydraulic systems is the study by Garg &
Kumar (2020) on water hammer in pipelines made of different materials. They have calculated and
measured lower water hammer pressures in pipeline made of Glass Reinforced Fibre Plastic (GRP)
compared to pipeline made of combination of GRP and Mild Steel (MS) and significantly lower
water hammer pressures compared to pipeline fully made of MS.
The hydropower plant is generally considered as a complex hydraulic system. The transient regimes
in hydropower plants occurs mostly during change in turbine operation or change in main inlet valve
opening. The research presented in this paper is focused on transients generated by changes in turbine
operation, particularly sudden load rejection.
2. Method statement
In transient regimes it is important to consider flow and pressure changes over time. In the case when
the transient regime is triggered by the changes in turbine operation, the hydraulic response of the
system depends not only on the opening/ closing time of the turbine guide vanes (wicket gate) but
also on the (variable) runner speed.
where the no, Po and Ho or n11o and Q11o refer to the point of maximum efficiency = max.
The specific speed is used for classification, comparison and scaling of turbines, but also as a starting
point in sizing of the turbine and assessing its performance characteristics if these characteristics are
not known.
In case of cross-flow turbines the lack of their performance characteristics (i.e., hill charts) is the rule
since the turbine manufactures generally avoid to provide them. This is a serious problem that
practically makes it impossible to analyse the operation of the cross-flow turbine, especially in
transient regimes. Moreover, in the design stage of the hydropower plant, in which it is necessary to
analyse both steady-state and transient operation of the plant, the only reliable data available to the
designer are the turbine design head and discharge.
In the following text, the new equations are proposed that relate the specific speed, turbine rated
speed and the runner diameter and width to the known rated or design head and discharge of an
arbitrary cross-flow turbine. Based on these equations the linear interpolation method was applied to
estimate the hill diagrams of arbitrary cross-flow turbine using known hill diagrams of three different
cross-flow turbines.
In practice, the specific speed is calculated in the first iteration using empirical equations based on
the known turbine head. The turbine rated or design head is generally used in these equations
assuming it is equal to the head at the maximum efficiency point. One such empirical equation,
proposed by Kpordze & Warnick (1983) is given as:
513.864
ns (5)
H 0.5047
Equation (5) is applicable to cross-flow turbines and was derived using regression analysis of the
basic data on 17 different cross-flow turbines.
H 0.53012
n nHD ( H , D) 35.385 1.00601
; ( R 2 0.95) (9)
D
Equation (8) relates the speed of the cross-flow turbine to the known rated head and discharge while
Eq. (9) relates the turbine speed to the rated head and the runner diameter, assuming the latter is
known or selected in advance. To calculate the turbine rated speed the result of the Eq. (8) or (9)
should be rounded to the closest integer or standard rpm.
In order to get an impression on the collected data dispersion, in Fig. 2a are plotted actual rated
speeds of the sample turbine units vs. turbine speeds calculated using Eq. (8). The straight line in the
Figure 2. Actual vs. calculated rated speeds: (a) no vs. nHQ(H, Q), (b) no vs. nHD(H, D)
Using the same sample data and the same methodology, two more regression equations were derived
Q 0.63989
B BHQ ( H , Q) 3.5993 ; ( R 2 0.92) (11)
H 0.58729
In Fig. 3a are plotted actual runner diameter of the sample turbine units vs. diameter calculated using
Eq. (10). The straight line stands for calculated diameter. Figure 3b has the same meaning but refers
to runner width and Eq. (11). The obtained results show very good agreement and high reliability in
the calculation of the width and diameter of the impeller; however, it should be emphasized that in
the case of high flowrates there is a slight dispersion, especially in the case of the width of the
impeller.
Figure 3. Actual vs. calculated runner diameters and widths given in mm:
(a) D vs. DHQ(H, Q), (b) B vs. BHQ(H, Q)
n11
n1 (13)
n11o
P11
P1 (14)
P11o
where the unit powers P11 and P11o are calculated using Eq. (3).
At this point some assumptions must be made regarding non-regular operational regimes of the
turbine. Namely, the hill charts given in Fig. 4 cover only regimes expected in normal steady-state
operation of the turbine. However, in transient operation e.g., after sudden power rejection, the
turbine also passes through the regimes that are outside the regular operating range. These, so-called
non-regular operating regimes, are particularly important from the aspect of mathematical modelling
and analysis of turbine behaviour in transient operation. By analysing the performance characteristics
of various cross-flow turbines found in the literature (Mockmore & Merryfield, 1949; Adhikari,
2016; Durgin & Fay, 1984) it can be concluded that the turbine performance characteristics on their
left and right boundaries may be estimated as:
at n11 ≈ 0 Q11 ≈ 0 and P11 ≈ 0;
nsT2 69 [Q2T2 ]( m,n ) fQT22 (nsT2 , ) and [ P2T2 ]( m,n ) f PT22 (nsT2 , )
nsT3 93 [Q3T3 ]( m,n ) fQT33 (nsT3 , ) and [ P3T3 ]( m,n ) f PT33 (nsT3 , )
where the dimensionless unit speed is always in the range 0 - 2 while the opening of the guide vane
is always in the range 0 – 1.
Step 2. Specific speed nsT of the considered cross-flow turbine (T) is calculated using Eq. (4) if all
the rated quantities (no, Po, Ho) are known or using Eqs (6) or (7) if only the rated head and discharge
are known.
Step 3. Out of three available cross-flow turbines of known characteristics, two (T1 and T2) are
selected whose specific speeds are nsT1 > nsT > nsT2.
The dimensionless unit characteristics of the considered cross-flow turbine (T) is calculated using
linear interpolation.
If specific speed nsT of the considered cross-flow turbine (T) is less than nsT 69 :
nTs nTs1 T2
(Q1T )i , j (Q ) (Q1T1 )i , j (Q1T1 )i , j ,
T1 1 i , j
i 1, 2...m, j 1, 2...n (15.1)
T2
ns ns
nTs nTs1 T2
( P1T )i , j ( P1 )i , j ( P1T1 )i , j ( P1T1 )i , j , i 1, 2...m, j 1, 2...n (16.1)
nTs 2 nTs1
If Specific speed nsT of the considered cross-flow turbine (T) great than nsT 69 :
nTs nsT2 T3
(Q1T )i , j (Q ) (Q1T2 )i , j (Q1T2 )i , j ,
T2 1 i , j
i 1, 2...m, j 1, 2...n (15.2)
T3
ns ns
nTs nTs 2 T3
( P1T )i , j ( P ) ( P1T2 )i , j ( P1T2 )i , j ,
T2 1 i , j
i 1, 2...m, j 1, 2...n (16.2)
T3
ns ns
Step 4. Unit speed, discharge and power at the point of maximum efficiency of the considered turbine
(T) are calculated using Eqs (1), (2) and (3). If not known, the turbine rated speed can be assessed
using Eq. (8) based on the rated head and discharge while the diameter of the turbine runner can be
assessed using Eq. (10).
Step 5 (final). The unit characteristics of the considered cross-flow turbine (T) in matrix form is
calculated as follows:
n11
T
nT nT (17)
m,1 11o 1 m,1
Q11
T T T
Q11o Q1 (18)
m,n m,n
A hydropower plant with a Cross-flow turbine is mathematically modelled as a system of nodes and
sections. The sections represent the pipes between the nodes. The nodes represent the boundary
conditions (turbine, the series connection of two pipes, pipe branches, valves, etc.).
Transients in pipelines that occur due to sudden changes in flow caused by change in turbine
operation modes or turbine failures, opening/closing of turbine guide vanes, main inlet valves, etc.)
are characterized with a complex flow which can be described by a system of partial differential
equations (Obradović, 1981; Chaudry, 2014) of hyperbolic type, i.e., continuity equation (20) and
momentum equation (21):
H a 2 Q
0 (20)
t gA t
Q H
gA Q Q 0 (21)
t x 2dA
Eqs (20) and (21) represent a system of (simplified) hyperbolic partial differential. This system can
be solved using the method of characteristics in order to define the pressure and the flow in all points
inside a pipeline except the boundary ones.
3. Case studies
Based on the previously explained procedures, mathematical and numerical models, further on are
presented the calculations of transient regimes for three existing hydropower plants. The
mathematical models of the plants are derived from the provided plants characteristics.
The aim of the presented analyses is to compare the results of the calculation of transient’s regimes
with the measurement data of the existing plants in order to validate the usage of the mathematical
model in prediction of the plants behaviours in the broad ranges of the real operating regimes.
Specifically, the transient analyses are performed for the following hydropower plants: BELCI (river
Jošanica-Serbia), ZABUKH (Aghavno river, Armenia) and VELEŽ (Samakovska river-Serbia).
Basic data for hydropower plants are given in Table 1.
Installed Number of
Power Pipeline Pipeline diameter Gross head
flowrate turbine
plant length [m] [mm] [m]
[m3/s] units
Belci 1964 GRP DN1700 30.6 5.65 1
Zabukh 2 4510 Steel DN1500 92.6 4.5 1
Velež 1690 PEOD630 PN10 103.5 0.96 1
Table 1. Hydropower plants data
When comparing the results of the measurements (obtained from the acceptance tests after
commissioning and presented at Figure 5), three time zones are observed:
Figure 6 shows the results of the measurements performed on the hydro power plant and the results
obtained by the developed mathematical model.
Figure 8 shows the results of measurements taken at the hydro power plant and the results obtained
by the developed mathematical model.
Figure 10 shows the results of measurements performed on the hydro power plant and the results
obtained by the developed mathematical model.
Figure 10. Hydropower plant VELEŽ - Comparison of measurements and numerical results
The performed analyses show that the differences between the measured and the calculated values
are within acceptable limits, so it can be concluded that the applied mathematical model realistically
predicts the transient regimes of the analysed hydropower plants with Cross-flow turbines. The
results obtained by the measurements and the results obtained by the mathematical modelling are
illustrated in Figs 6, 8 and 10. From the aspect of transient regimes, the most important time interval
is that from TSA3 to TSA4 where the change of flow is the most intensive. This conclusion is based
on results presented in Figs 7, 9 and 11. Based on the obtained results, it is noticed that not only the
small deviations between the measurements and the results obtained on the basis of the mathematical
model, but also the tendencies of pressure change in the zone of the most intensive changes from
(TSA3 to TSA4) are almost identical. All the obtained results indicate that the developed
mathematical model very realistically describes the behavior of the System in transient regimes.
Acknowledgements
This research was financially supported by the Ministry of Education, Science and Technological
Development of the Republic of Serbia.
The authors would like to thank company CINK Hydro-Energy for providing test results.
Notation
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