Development and laboratory testing of improved Action and Matrix hydro turbines designed by advanced analysis and optimization tools 7th Framework Programme: ENERGY ESHA Hydroaction Seminar, Brussels, April 13, 2011
Participants and Key topics National Technical University of Athens, Greece (Coordinator)
Development of innovative design methodology Institut Polytechnique de Grenoble, France
that can be easily customized at affordable manufacturing costs for SME manufacturers
ANDRITZ Hydro GmbH, Austria ANDRITZ Hydro GmbH, Switzerland
Identify current needs of SHP manufactures for the new design methodology
Application in three different turbine types: Pelton, Turgo and Matrix.
Assessment of economic and environmental impacts - Market penetration strategy École Centrale de Lyon, France
Training for engineers and workshops to inform SMEs about possibilities of new design approach
Techniques Hydro Electriques, France
WIP – Renewable Energies GmbH, Germany
European Small Hydropower Association (ESHA), Belgium
Research Platform
Pelton buckets optimization
Turgo runner design
Advanced and new parameterization and
flow analysis methods (CFD Eulerian and Lagrangian) Modern optimization framework (parallel, multilevel evolutionary algorithms - EASY, metamodels, artificial intelligence ).
Exploitation of experience accumulated during years of small hydraulic turbines production.
Manufacturing of prototype turbine models
and experimental analysis/verification of optimal designs
Matrix runner design
Distribution section and injector design
Mapping the small-hydro sector in the EU Main objectives
Mapping the small-hydro sector in the EU
Parallel CFD & Optimization Unit, NTUA
The EASY Platform EASY: Evolutionary Algorithms SYstem
Enriched & customized for the needs of the Hydroaction Project
The EASY Platform Grid Computing or Robots-based Optimization Three-layer middleware: 1. Local resource management S/W: CONDOR. 2. Grid deployment: GLOBUS Toolkit 4. Discovery and monitoring of resources: GANGLIA. 3. Exploitation of resources: GRIDWAY.
Metamodel-assisted Eas The Inexact Pre-Evaluation (IPE) Scheme
Multilevel optimization
EASY Applications A. Hydraulic turbomachinery
B. Other areas
Lab. of Hydraulic Turbomachines, NTUA Water tank of 320 m3
Lab. of Hydraulic Turbomachines
Control board with real time monitoring and analysis of measurements (LabView)
LHT - Software Fast Lagrangian Solver, FLS FLS / Measurements
0.9
6 mm nozzle 12 mm 20 mm 32 mm 40 mm 6 mm nozzle 12 mm 20 mm 32 mm 40 mm
Turbine efficiency
0.8
0.7
Smoothed Particle Hydrodynamics, SPH
0.6
0.5
0.4 0
0.01
0.02
0.03
0.04
0.05
Flow rate parameter, Ă–
Artificial compressibility & Free surface adaptation
Commercial Software (Fluent, CFX)
Open source software
Turgo turbine design
New methodology: Prototype model
New methodology: Parameterization
Parametric design Quadratic variation of the blade angle along meridian stream lines Use of Bezier polynomials and interpolation techniques. Introduction of 12 free variables for wide shape modifications Addition of hub and shroud axisymmetric surfaces .
New methodology: Flow simulation and Design optimization
Jet Jet--bucket interaction analysis: FLS model (left); SPH model (right)
Initial design
Optimum design
Design optimization (EASY) results
Validation – comparison with Eulerian model results (Fluent)
Jet-runner interaction analysis
Flow pictures obtained by the SPH model
Piping and injectors system design
Piping and injectors system design
90째 (reference)
70째
90o Curve 3
Surface
Ptot (Pa)
Losses (Pa)
pressure_outlet.18
1438.934
720.7506
pressure_outlet.19
1438.731
720.953
velocity_inlet.17
2159.684
pressure_outlet.18
1448.735
511.4458
pressure_outlet.19
1449.423
510.7574
velocity_inlet.17
1960.18
pressure_outlet.18
1441.313
379.2711
pressure_outlet.19
1438.368
382.2162
velocity_inlet.17
1820.584
Max helicity
Area (m2)
Welding Length (m)
126
3.719709
8.090476
72.85
4.296013
8.146408
79.35
3.725127
9.141367
Piping and injectors system design
Improved runner performance Real turbine
Improved designs 88
Efficiency (%)
84
80
76 'Conventional' design Optimum design Optimum - Turgo adjusted
72 84
68 0
0.4
80
1.2
1.6
60 76
72
Net head (m)
Efficiency (%)
0.8
Load (Q / Qdesign)
Lower injector Upper injector FLS results
68 0
0.4
0.8
1.2
1.6
2
Load (Q / Qdesign)
FLS results
83
55
83
50
84,2
45 82
40
80
35 30 20
40
60
81
78
74
80
74
100
Flow rate (lt/sec)
76
120
140
Model turbine construction drawings
Model turbine computer views
Design of the casing and of the injectors of the model of Turgo turbine
Runner fabrication
Separate fabrication of runner parts (blades, hub and shroud) Hub and Shroud with precision machining. Proper slots for blades fitting. Prototype blade constructed by composites using 3D-printing Use of plastic prototype to produce aluminium prototype Blades fabrication by bronze casting Internal blade surface polishing Final blade assembly with bronze welding Runner balancing Features More complex but more accurate construction methodology Enhanced axial symmetry of the runner Capability for particular mechanical manufacturing of the hydrodynamic profile of each separate blade if necessary
Test rig construction / adaptation
Closure
HYDROACTION develops a methodology for optimizing the design of hydro turbines up to 5 MW, with regard to productivity and cost. The standardisation and application of the methodology will contribute to the development of cost-efficient, tailor-made turbines for small hydro plants with optimum performance.
Thank you! www.hydroaction.org