1466 CH Bieudron 423-Pelton-Runners en
1466 CH Bieudron 423-Pelton-Runners en
1466 CH Bieudron 423-Pelton-Runners en
INTRODUCTION
As scheduled, the new Swiss power station Bieudron 2 (3 x 423 MW, H = 1869 m) was successfully commissioned by the end of 1998 [1]. During the 1st year of operation until the end
of October 1999, the 3 units operated between 1500 and 2200 hours and the runner buckets
experienced up to 200 million load cycles by jet impingement. The extreme conditions in the
plant can be described, for example, by the maximum jet force which is only a little less than
1 Mega-Newton (1 MN). This value can best be envisaged as the deadweight of a modern
high speed locomotive which, however, would be hopping with high frequency from bucket
to bucket and not just rolling or resting on its rails. The question of how to design and manufacture runners for such demanding conditions is the main topic of this paper.
RUNNER DESIGN
Development of the turbines for Bieudron power plant meant a real step forward in the design of Pelton turbines [2]. The design requirements demanded new engineering and design tools, as well as a major extension of existing physical know-how on Pelton turbines.
Among a series of other special R&D tasks for Bieudron, three main studies may be mentioned:
1. On a single jet model turbine, a detailed experimental flow study was performed to develop the necessary knowledge for final selection of the basic turbine concept (three 5-jet
turbines instead of four 4-jet units) as well as for determination of the acceptable amount
of cavitation erosion [3, 4].
2. Optimisation of the complete turbine profile on a homologous vertical 5-jet model turbine;
determination of the prototype efficiency guarantees.
3. Detailed design study for all main turbine parts, mainly focused on the mechanical design
of the runners which is the main issue of this paper.
1
Richard Angehrn, Senior Engineer, VATECH ESCHER WYSS Ltd., Hardstr. 319 / P.O. Box, CH-8023 Zurich
Tel. (+41) 1 278 2406, Fax (+41) 1 278 2819, e-mail: [email protected]
Pelton turbine engineering and supply was by the Groupement Cleuson-Dixence, GCD, comprising Hydro Vevey
and the former Sulzer Hydro, now VATECH ESCHER WYSS, as consortium leader
3
1200 MW
423 MW
1869 m
428.6 min-1
756 min-1
25 m3/s
3993 mm
5
Outer diameter
Width of buckets
Number of buckets
Weight of runner
Weight of a bucket
Max. jet force
Centrifugal bucket force
at synchronous speed
Type of coupling
Material 3
4630 mm
620 mm
26
29000 kg
380 kg
944 kN
1470 kN
Friction type
stainless cast steel
G-X5 CrNi 13 4
Cast in 1991 at Georg Fischer, Schaffhausen, Switzerland, shortly before closing of their steel foundry
b
max = 40 MPa
max = 34 MPa
PELTBE is a computer programm for Pelton stress analysis based on beam theory
midway between the latter two. Keeping the explanations above in mind, this is understandable. The dynamic stress parts of FEA at the hot spot, mouth and rim are well equalised, this
being a quality label of the design. The PELTBE value, however, is at a 60% higher level. For
a better understanding, one has to be aware of the conservative PELTBE assumptions:
R=0
100
90
80
70
107
60
40
30
26.5
20
17 16.5
16
10
0
50
100
150
200
Mean Stress [MPa]
109
1010
1011
load
cycles
250
(b)
FEA rim
(c)
contractuel
limit of stress
amplitude
sa = 27 MPa
108
50
FEA mouth
300
Figure 4. Bucket
design stress results
at 1869 m net head
and 423 MW.
PELTBE vs. FEAresults. The Haighdiagram defines
fatigue limits for cast
steel G-X5CrNi13 4
based on tests of the
Darmstadt Betriebsfestigkeit Laboratory,
LBF [12]. Samples
are taken from near
surface zones. Load
cycle numbers > 1E8
are extrapolated.
At the bucket root the section area and the area moment of inertia are calculated with a reduced profile width, namely with a width that corresponds to the thickness of the adjoining
disk. However, since the effective root stiffness at Bieudron is higher than usual the supporting width is larger than assumed.
Based on the stress analysis a runner lifetime of 80000 hours at full power, equivalent to
about 1010 load cycles, was indicated in the contract. Part-load hours are evaluated according to their reduced damaging effect compared with full power operation (Chapter 10).
The example shows a design optimisation step which was enabled by application of the
above-mentioned tools. The traditional method would not have allowed sufficiently deep insight into the problem to establish this improvement.
measured natural bucket frequencies (approx. 760 775 Hz, Fig. 9) have a 50 % higher order
number, namely i = 21 at 750 Hz and i = 22 at 785.8 Hz. Consequently, the relative amplitude
of the bending moment or stress at the bucket root is smaller (< 0.0003, Fig. 6). For this
reason, the dynamic stress characteristic (Fig. 7) contains less superimposed dynamic stress
than originally expected, thus increasing the runner safety. Nevertheless, careful detuning
was carried out, as explained in the following.
i =1
a=0
nd
Figure 5. Calculated frequencies of the first 6 natural modes of bucket bending vibration:
f1 = 508 Hz, f2 = 576 Hz, f3 = 706 Hz, f4 = 761 Hz, f5 = 761 Hz, f6 = 762 Hz. i = number of
mode, n = i 1 = number of vibration node diameters nd.
9 11 13 15 17 19 21 23
8 10 12 14 16 18 20 22
moment M
moment M
relative amplitude
0.1
0.01
integers i of harmonics
of basic frequency
f1 = n/60*Z0
f1 = i*f1
00
5-jets
72
0
72
time
time
1-jet
0.001
0.0001
Figure 6. Discrete Fourier spectrum of jet impingement force on prototype for 1 and 5-jet
operation (Z0 = 1 and 5), scaled up from model test. The frequency step for 1 and 5-jet
operation is 7.14 Hz and 35.72 Hz respectively.
DETUNING
The goal of detuning is to avoid resonance, in other words: to prevent a coincidence of the
natural frequencies of the bucket bending vibrations (Fig. 5) with multiples (or harmonics) of
the basic excitation frequency f1. Resonance would increase the superimposed stress B
(Fig. 7) since, due to low damping, a
B = superimposed
high dynamic magnification factor up
dynamic stress part
to 1000 is to be expected.
due to harmonic
A frequently asked question concerns
response
the added mass influence of the water.
J = dynamic stress part
This was investigated and answered
due to jets
during the course of earlier measure c = centrifugal stress
ments [13]. It was found that the added
a = stress amplitude
mass effect, lowering the natural frequencies, was compensated by the stif m = mean stress
fening effect due to the centrifugal
forces. Therefore, these effects are neFigure 7. Typical stress trace at a bucket root.
glected here.
The actual dynamic system, consisting
m3
m4
of 26 slightly different buckets coupled
m2
mass
m5
by the runner disk, is complex and difm1
ferent from the theoretically investigak3
k2
ted system in Chapter 6. In the past,
k4
k1
each bucket was regarded as a singlekc3
stiffness
k5
kc4
kc2
degree-of-freedom system, separated
kc5
kc1
from the others. Corrections of the
natural frequencies, if necessary, were
coupling
executed by grinding the rear of the
stiffness kci
bucket concerned. Subsequent checks,
however, sometimes revealed unexpected deviations. The reason is that the system cannot be separated as described
above. It must be analysed as a multidirection of the displacement cooridnate
degree-of-freedom system (Fig. 8).
Figure 8. The model for detuning is a multiTherefore, a new detuning procedure
degree-of freedom system
[15] was developed, initiated and sponsored by the former Sulzer Hydro. The aim was to optimise the process of final bucket grinding. Not only the natural frequencies should be regarded but also the final runner balancing
which has to meet the quality requirements of ISO 1940/1.
The new procedure is based on the principles of experimental modal analysis. Model identification is carried out by measurement of the dynamic flexibility matrix H. The elements hik of
the matrix H contain the response of the displacement coordinate i due to a unit excitation
(excitation with a unit force as amplitude) at the coordinate k with frequencies in the relevant
range. In practice, the matrix H is determined by
symm.
h ()11
hammering on a bucket in circumferential direction
h ()21 h ()22
and measuring the acceleration of the buckets in
H = H ()31 h ()32 h()33
the direction of the displacement coordinate. The
Fig. 9 shows the response curves derived from bucket dynamic flexibility measurement.
Multiple close resonances can be recognised which are caused by coupling of the slightly
different buckets. The model is identified by adapting the unknown parameters (masses and
stiffnesses) in a way which minimises the differences between measured and reconstructed
excitation. The difference (Fig. 9, 10) between the measured and calculated dynamic
flexibilities indicates the quality of the identified model. When the model is found to reflect
actual conditions sufficiently well, it can be used for predicting what happens if small mass
corrections are necessary by grinding, either due to imbalance of the runner or to correct
bad locations of the natural frequencies.
Detuning is mainly required on runners rotating at speeds higher than about 400 rpm in
turbines with 4 or more nozzles, where the bucket frequencies are relatively low (< 700 Hz).
Figure 9. Frequency response curves of
measured and simulated flexibility of a
bucket. Multiple close resonances can be
recognized which are caused by coupling
of the slightly different buckets.
Figure 10. The identification of the mathematical model is based on the adaption of
the unknown parameters (bucket mass,
stiffness) in a manner which minimizes the
differences between the measured and the
reconstructed excitation.
excitation
Pelton
runner
+ -
math.
model
deviation
response
NON-DESTRUCTIVE TESTING
The decision limits for NDT are strictly based on actual stress levels and on admissible flaw
size as determined by fracture mechanics. Quality control was carried out using UT, MT and
PT, whereas RT was applied only at the first quality control stage in the foundry.
Nine inspections by MT, three on each runner, were carrried out between commissioning in
1998 and the end of October 1999 without finding any inadmissible flaws or cracks.
1.0
effective hours
0.8
corresponding Pmax-hours
0.6
0.4
0.2
0.0
ad
MW
MW
MW
MW
no lo 0-100 1-200 1-300 1-420
0
0
0
1
3
2
l
tota
a) adapting the
number of jets
b) non-adapting
the number of jets
stress amplitude
at bucket root
higher
lower
inspection periods
shorter
longer
life time
shorter
longer
>0
bending moment
of turbine shaft
>0
>0
hydraulic efficiency
better
lower
1
1
Table 3. Consequences of
different part load
operation modes:
a) adapting and b) nonadapting the number of
jets.
5 jets
active
0.8
0.6
a)
b)
0.4
0.2
0
0
0.2
0.4
0.6
relative power, P/Pmax
0.8
evaluation factor
0.6
0.4
a)
(1)
b)
0.2
dN = da /(CY m Ds m a m / 2 ) (3)
0
0
0.2
0.4
0.6
0.8
relative power, P/Pmax
crack
length
a
Pmax
inspection
interval
da
dN
a2
P < Pmax
a1
a0
a2
(5)
a1
N0
N1
N2
number of cycles, N
10
The inspection
1st inspection
2nd inspection
3rd inspection
4th inspection
5th inspection
As a conclusion it can be said that the Bieudron runners have been designed on top-state of
the art engineering practice, and represent a milestone in Pelton technology.
ACKNOWLEDGEMENTS
The author would like to thank all his colleagues who contributed to the development of
these new tools and their successful application in the presented project.
REFERENCES
[1] Loth, P., A record breaker. Cleuson-Dixence will go on line ..., Part Hydromechanics, International Water
Power & Dam Construction, June 1998, Pages 22-24.
[2] Keck, H., Schrer, Ch., Cunod, R., Cateni, A., Pelton technology for new plants and modernization schemes,
International journal on Hydropower & Dams, Vol. 4, Iss. 2, 1997, pages 104-108.
[3] Bachmann, P., Schrer, Ch., Staubli, T., Vullioud, G., Experimental flow studies on one 1-jet model Pelton
Turbine, 14th IAHR Symposium, Belgrade, Yugoslavia, 1990.
[4] Bezinge, A., Bachmann, P., Vullioud, G., Das Projekt Cleuson - Dixence, VE/SEV/VDE/-Fachtagung
Wasserkraft - Regenerative Energie fr heute und morgen, Vienna, May 1992.
[5] Obretenov, V.S., Analysis of the Flow on a Pelton Turbine Bucket, Proc. of the Lenin Higher Inst. of Mechanical
and Electrical Engineering, Vol.41, Book 3, Sofia, 1987.
[6] Grozev, G., Obretenov, V., Trifonov, T., Investigation of the Distribution of Pressure over the Buckets of a Pelton
Turbine, Proc. of the Conference on Hydraulic Machinery, Turboinstitut, Ljubljana, Sept. 1988, Pages 119-125.
[7] Angehrn, R., Rettich, J., Schrer, Ch., Pelton runner design based on measured unsteady pressure distributions
in the bucket, Hydropower & Dams, Issue Six, 1999.
[8] Schneebeli, F., Baltis, E., Keck, H., New Technology Earns Acceptance, Sulzer Technical Review, No. 1, 1996.
[9] Kalberer, A., Krause, M., A Review of Experience with MicroCast Pelton Wheels, Hydropower & Dams,
Issue 1, 1996.
[10] Krause, M., Riedel, A., Innovationen bei der Fertigung und Reparatur von Wasserkraftanlagen MicroGussTM
und Beschichtungen, 9th Internat. Seminar on Hydro Power Plants, Wien, 1996.
[11] Grein, H., Schneebeli, F., Bantli, H., 3-Dimensional Surface Modelling - a Design and Manufacturing Tool for
Hydraulic Machinery, Sulzer Technical Review 2/1989.
[12] Ostermann, H., Rckert, H., Ausfallsichere Bemessung von Laufrdern fr Wasserkraftmaschinen aus rostfreiem Stahlguss unter Bercksichtigung von Korrosion und Gefgezustand, Abschlussbericht zum
Gemeinschaftsprogramm Stahlguss, BMFT-Industrie-LBF, Fraunhofer-Institut fr Betriebsfestigkeit, Darmstadt, Sept. 1983.
[13] Angehrn R., Dubas M., Experimental Stress Analysis on a 260 MW Pelton Runner, Proc. of the 11th IAHRSymposium, Amsterdam, 1982.
[14] Grein, H., Angehrn, R., Lorenz, M., Bezinge, A., Inspection Periods of Pelton Runners, Proc. of the 12th IAHRSymposium, Stirling, 1984.
[15] Schmied, J., Von der Schwingungsmessung zum Simulationsmodell, Technische Rundschau Nr. 17,
Bern, 1998.
[16] Fuchs, H.O., Stephens, R.I., Metal Fatigue in Engineering, Wiley & Sons, NewYork, 1980.
[17] Grein, H.L., Angehrn, R., Service Life of Pelton Runners under Corrosion Fatigue, International Symposium on Fluid Machinery Troubleshooting, ASME Winter Annual Meeting, Anaheim, California, Dec. 1986,
FED-Vol. 46/PWR-Vol.2.
The inspection periods definiton is coherent with the results of a crack propagation case study which was executed on a
260 MW-runner after a damage occured in 1981 [17]. As a consequence, stringent inspection periods were introduced
there and it can be reported about successful experience up to now.
11
VA TECH HYDRO
12
e/XX.XX.30 ZC-00