Engineering Computations

Emerald Article: Analysis of dynamic stresses in Kaplan turbine blades

Lingjiu Zhou, Zhengwei Wang, Ruofu Xiao, Yongyao Luo
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Lingjiu Zhou, Zhengwei Wang, Ruofu Xiao, Yongyao Luo, (2007),"Analysis of dynamic stresses in Kaplan turbine blades", Engineering
Computations, Vol. 24 Iss: 8 pp. 753 - 762
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Analysis of dynamic stresses
in Kaplan turbine blades
Lingjiu Zhou
College of Water Conservancy and Civil Engineering,
China Agricultural University, Beijing, Peoples Republic of China, and
Zhengwei Wang, Ruofu Xiao and Yongyao Luo
Department of Thermal Engineering, Tsinghua University,
Beijing, Peoples Republic of China
Abstract
Purpose Some comparison of unsteady ow calculation and the measured stress showed that the
dynamic stresses in blades are closely related to hydraulic instability. However, few studies have been
conducted for the hydraulic machinery to calculate dynamic stresses caused by the unsteady hydraulic
load. The present paper aims to analyse the stresses in blades of a Kaplan turbine.
Design/methodology/approach By employing a partially coupled solution of 3D unsteady ow
through its ow passage, the dynamic interaction problem of the blades was analyzed. The unsteady
Reynolds-averaged Navier-Stokes equations with the SST k-v turbulence model were solved to model
the ow within the entire ow path of the Kaplan turbine. The time-dependent hydraulic forces on the
blades were used as the boundary condition for the dynamics problem for blades.
Findings The results showed that the dynamic stress in the blade is low under approximately
optimum operating conditions and is high under low-output conditions with a small guide vane
opening, a small blade angle and a high head.
Research limitations/implications It is assumed that there is no feedback of blade motion on
the ow. Self-excited oscillations are beyond the scope of the present paper.
Originality/value The authors developed a code to transfer the pressure on blades as a boundary
condition for structure analysis without any interpolation. The study indicates that the prediction of
dynamic stress during the design stage is possible. To ensure the safety of the blades it is
recommended to check the safety coefcient during the design stage for at least two conditions: the
100 percent output with lower head and the 50 percent output with the highest head.
Keywords Turbines, Fluid-mechanics, Stress (materials)
Paper type Research paper
1. Introduction
With the increasing unit capacity and runner diameter, the problem of unsteady ows
in hydraulic turbines has attracted considerable attentions. The energy transfer in a
turbine is accompanied by more or less pressure oscillations caused by vortexes,
cavitations and other complex unsteady ow phenomena in the ow path, which can
cause excessive blade vibration, leading to structural fatigue failures. Most of the
researches have focused on pressure uctuations in the ow path, such as caused by
RSI effects (Guedes et al., 2002; Wang et al., 2002), and vortex rope in the draft tube
The current issue and full text archive of this journal is available at
www.emeraldinsight.com/0264-4401.htm
The authors would like to acknowledge Shuikou Hydropower Plant for presenting the original
data of the research.
Dynamic stresses
in Kaplan
turbine blades
753
Received 15 March 2007
Revised 16 July 2007
Accepted 20 July 2007
Engineering Computations:
International Journal for
Computer-Aided Engineering and
Software
Vol. 24 No. 8, 2007
pp. 753-762
qEmerald Group Publishing Limited
0264-4401
DOI 10.1108/02644400710833288
( Jacob and Prenat, 1996; Bhan et al., 1988; Arpe and Avellan, 2002; Wang and Zhou,
2006) Most recently a few researchers have measured dynamic stress in the blades
( Pan, 2004). Some comparison of unsteady ow calculation and the measured stress
showed that the dynamic stresses in blades are closely related to hydraulic instability
( Wang and Zhou, 2006). However, few studies have been done for the hydraulic
machinery to calculate dynamic stresses caused by the unsteady hydraulic load. In this
present paper, the stresses in blades of a Kaplan turbine were analyzed. The prototype
studied here was a ZZA315-LJ-800 Kaplan (pitch-angle adjustable) turbine with a
specic speed of 22.6, a runner diameter of 8 m, rated output of 204 MW, rated head of
47 m and rated speed of 107 rpm. The stresses in blades were calculated under various
operating conditions to analyze the relationship between the dynamic stresses and
operating conditions.
2. The calculation of stress in blades by coupling solution of uid and
structure
There are two strategies for the coupled solution of dynamic of uid and structure
interaction. One is the loosely coupled method with the results of the dynamic forces
and structural displacement exchanged as boundary condition for each other at every
time step (Younsi et al., 2001; Filsinger et al., 2002; Herfjord et al., 1999; Gnesin et al.,
2004). The other is the fully coupled method, the uid and structure problem are solved
within the same code and the same grids (Slone et al., 2002; Chen and Zha, 2005).
Obviously, only the fully coupled model is rigorous in the physical sense. However, the
calculation based on a fully coupled uid structure interaction is CPU-expensive
due to the intensive iterations between the uid and structure system, especially for
the large-scale calculation for a prototype Kaplan turbine with runner diameter of 8 m.
Here the author adopted the partial coupling concept, which assumes that blade
vibrations causing unsteady effects are signicantly smaller than unsteady effects due
to instability of the ow and even neglectable. That is to say, there is no feedback of
blade motion on the ow. This hypothesis is reasonable since self-excited oscillations
are beyond the scope of the present paper.
The ow path was from the spiral casing inlet to the draft tube outlet. The whole
path was discretized with an unstructured hybrid mesh of hexahedron and tetrahedron
cells. Normally the uid simulation need ner grid than structure analysis. So the mesh
size was determined according to Ma and Zhous (2006) recommendation to meet the
requirement for uid simulation. The nal mesh had about 730,000 nodes (Figure 1).
Figure 1.
Calculation domain for the
uid and structure
inlet
outlet
(a) fluid domain of the whole flow path (b) solid domain of the blade structure
EC
24,8
754
In the course of the calculations, the runner zone mesh rotated at 107 rpm with the
relative positions of each node in this zone unchanged. The interfaces between the
guide vanes, the runner and the draft tube were modeled with sliding interfaces with
the ux transferred between neighboring zones.
The water was considered to be incompressible. A time-dependent Reynolds
average Navier-Stokes (RANS) simulation was performed to calculate the ow eld
in the Kaplan turbine path. The continuity equation and the momentum equations
for the uid within static frame (spiral case, stay vanes, wicket gates and the draft
tube) are:

x
i
(~ u
i
) = 0 (1)
u
i
t
-

x
j
(u
i
u
j
) = 2
p
rx
i
-

x
j
(m -m
t
)
r
u
i
x
j
-
u
j
x
i
_ _ _ _
- f
i
(2)
where p is the pressure, r the density, u
i
the component of velocity vector ~ u(u
1
; u
2
; u
3
)
and f
i
the component body force vector
~
f( f
1
; f
2
; f
3
): m the laminar viscosity, m
i
the
turbulent viscosity which was closed by SST k-v turbulence model (Menter, 1994).
The continuity equation and the momentum equations for the uid in the rotational
frame (runner) are:

x
i
(w
i
) = 0 (3)
w
i
t
-

x
j
(w
i
w
j
) = 2
p
rx
i
-

x
j
(m -m
t
)
r
w
i
x
j
-
w
j
x
i
_ _ _ _
- f
/
i
(4)
where w
i
is the component of relative velocity vector ~ w(w
1
; w
2
; w
3
): f
/
i
the component of
force vector F
/
~
.
The two velocity vectors ~ u; ~ w are related by:
~ u = ~ w - ~ v ~r (5)
Force vector F
/
~
is written as:
~
F
/
= 22 ~ v ~ w 2 ~ v ( ~ v ~r) -
~
f (6)
Here ~ v is the angular velocity of the runner and ~r is the position vector in the rotation
frame. Only gravity was considered in vector f
~
.
The time-dependent RANS model was discretized using the control-volume
technique through the SIMPLEC scheme with a second-order upwind scheme used for
the convection terms and a central difference scheme for the diffusion terms in the
momentum equations. The time step was 0.0056 s, which is 1/100 of the runner
rotational period. This time step was validated to be enough for catching some main
pressure uctuation frequencies such as rotational frequency and blade passing
frequency.
The pressure conditions were set on inlet and outlet according to the head of
each operation condition and estimated velocity on the two boundaries. The initial
Dynamic stresses
in Kaplan
turbine blades
755
turbulence variables on the inlet and outlet were estimated according to the hydraulic
diameters and turbulence intensity, which was set to be 6 percent on the inlet and
7 percent on the outlet.
The structure mesh is shown in Figure 1. The mesh near blade pivot was carefully
generated to ensure the accurate representation of the llet corner in order to avoid
false stress concentration. The transient dynamic equilibrium equation for the stresses
in a linear structure is:
[M]{ u} - [C]{ u} - [K]{u} = {F
t
} (7)
where [M] is the mass matrix, [C] the damping matrix and [K] the stiffness matrix,
{u} i the nodal displacement vector, { u} the nodal velocity vector and {u } the nodal
acceleration vector, {F
t
} the node load vector, including gravity, centrifugal force and
pressure force that was transferred from ow analysis.
Equation (7) was discretized using the FEM method and solved using the Newmark
method. The iterative equation was (Hallquist, 1998):
1
aDt
2
[M] -
d
aDt
[C] - [K]
_ _
{u
n-1
} = {F
t
} - [M]

1
aDt
2
{u
n
} -
1
aDt
{u
_
n
} -
1
2a
2 1
_ _
{u

n
}
_ _
- [C]

d
aDt
{u
n
} -
d
a
2 1
_ _
{u
_
n
} -
Dt
2
d
a
2 2
_ _
{u

n
}
_ _
(8)
where a and d are the Newmark integration parameters and Dt = t
n-1
2 t
n
:
Equation (8) shows that the effects of the velocity and acceleration terms are
considered in the transient displacement computation. {u} was obtained from
equation (8) with {s} calculated at every time step from:
s = [D][B]{u} (9)
where [D] is the elastic matrix based on Youngs modulus and Poissons ratio for the
material, [B] the strain-displacement matrix based on the element shape functions.
The dynamic stresses in blades were computed based on the fourth strength theory.
The von Mises or equivalent stress, s
e
, was computed using:
s
e
=

1
2
(s
x
2s
y
)
2
- (s
y
2s
z
)
2
- (s
z
2s
x
)
2
- 6 t
2
xy
-t
2
yz
-t
2
xz
_ _ _ _
_
(10)
The blade material is cast steel Cr
13
Ni
5
M
o
with the properties listed in Table I.
The key problem was to transfer the pressure load p on the blades to the dynamic
analysis code. To do this the grids on blade surfaces and the hub were identical for both
uid mesh and structure mesh. Asmall code was developed to generate an index for the
interface nodes in the two domains for the purpose of transferring data at each time.
Density (kg/m
3
) Youngs modulus (Pa) Poissons ratio
7.85 10
3
2.06 10
11
0.3
Table I.
Blade material properties
EC
24,8
756
The advantage of this method is that the pressure on the blades can be precisely
transferred without any interpolation. The ow eld simulation started rst. For most
cases, the frequencies and amplitudes of the pressure oscillations on the monitoring
nodes changed very little after several rotational periods. Then the structure calculation
was conducted and the calculation results were recorded for several periods.
3. Calculation result
The calculations were performed for 13 operating conditions with operating
parameters listed in Table II.
During the calculations, two points on one blade pressure side ( p1) and the suction
side (s1) were selected as monitoring points (Figure 2). Pressure uctuations at the two
points are shown in Figure 3 for three typical conditions GK3, GK8 and GK10.
Under the conditions approximating the optimum point and those with large blade
angles and guide vane openings, the pressure on the blade uctuates with the runner
Operating condition
Net head H
(m)
Power N
(MW)
Guide vane opening GVO
(percent)
Blade angle BA
(8)
GK1 61 235 65.6 17.29
GK2 61 215 62.4 15.44
GK3 61 100 36.21 5.57
GK4 57.3 215 65.76 16.68
GK5 57.3 100 40.54 6.16
GK6 53 235 78.58 20.41
GK7 53 215 74.05 18.3
GK8 53 150 59.03 11.72
GK9 53 100 47.19 6.95
GK10 43.8 235 94.6 25.82
GK11 43.8 215 90.46 23.32
GK12 43.8 100 57.37 9.43
GK13 38 180 97.66 23.26
Table II.
Calculated conditions
Figure 2.
Recording points on one
blade with (a) viewed from
runner inlet to outlet;
(b) viewed from runner
outlet to inlet
(a) Recording point p1 on pressure side (b) Recording point s1 on suction side
P1
S1
Dynamic stresses
in Kaplan
turbine blades
757
rotation frequency, f
n
, as shown in Figures 3(b), (e), (c) and (f) for conditions GK8 and
GK10. However, for conditions with small blade angles and small guide vane openings,
the blade pressure uctuations are accompanied by increased turbulence and the
uctuations which does not show any obvious periodic feature, as shown in Figure 3a
and d for condition GK3. Figure 4 shows that the randomness pressure uctuations in
GK3 are related to the secondary ow across the ow path. There are obvious vortexes
near hub within no blade region between the guide vanes and runner blades for GK3
with small guide vane opening. The random movements of vortexes cause pressure
uctuations on blades. For the same reason, the pressure uctuation amplitude for
GK3 is greater than for the other two conditions.
Figure 3 also shows that the mean value and amplitude of the torque uctuations is
small for conditions near the optimum point (GK8, Figure 3h), is larger for large blade
angles and large guide vane openings (GK10, Figure 3i) and even larger for small
blade angles and small guide vane openings (GK3, Figure 3g), which was veried by
the power stations operating recordings. When the turbine was operating under
approximately optimum condition (for example, GK8) the operating oil pressure inside
the piston chamber was normal, but operating under approximate condition GK3 the
oil pressure inside the chamber was extremely high.
Figure 3.
Pressure uctuations and
torque on one blade for
three typical operating
conditions
420
15
960
920
880
840
800
50.5
145
150
155
160
51.0
51.5
52.0
52.5
10
5
0
5
10
pressure on pl, GK3
pressure on sl, GK3
turque on one blade, GK3 turque on one blade, GK8
turque on one blade, GK10
pressure on sl, GK8
pressure on sl, GK10
pressure on pl, GK8
pressure on pl, GK10
400
P
/
k
P
a
P
/
k
P
a
T
/
k
N
.
m
760
800
760
720
755
750
745
740
T
/
k
N
.
m
T
/
k
N
.
m
P
/
k
P
a
P
/
k
P
a
P
/
k
P
a
P
/
k
P
a
380
360
356.5
188
184
180
356.0
355.5
355.0
16.5 17.0 17.5
t/s
(a) (b)
18.0 18.5
16.5 17.0 17.5
t/s
(d)
18.0 18.5
t/s
(g)
16.5 17.0 17.5 18.0 18.5
16.5 17.0 17.5
t/s
(e)
t/s
(f)
18.0 18.5
16.5 17.0 17.5
t/s
(h)
18.0 18.5
16.5 17.0 17.5 18.0 18.5
t/s
(i)
16.5 17.0 17.5 18.0 18.5
16.5 17.0 17.5
t/s
(c)
t/s
18.0 18.5 16.5 17.0 17.5 18.0 18.5
EC
24,8
758
Figure 4.
Velocity vectors in no
blade region between the
guide vanes and runner
blades
(
a
)

G
K
3
(
b
)

G
K
8
(
c
)

G
K
1
0
Dynamic stresses
in Kaplan
turbine blades
759
Typical pressure distribution and the von Mises static stress distributions in blades are
shown in Figure 5 for condition GK3. The maximum stress is near the blade root for all
cases. This was consistent with general knowledge on static stress distributions in
Kaplan turbine blades. The dynamic stresses at the node with maximum stress are
plotted in Figure 6 for the three typical conditions.
Figures 3 and 6 show that the dynamic stresses in blades are closely related to the
pressure uctuations in the ow path. For most cases, the main pressure uctuation
frequency and dynamic stress frequency is the runner rotation frequency f
n
. The mean
stresses and the dynamic stresses amplitudes (with 95 percent probability) at the node
with the maximum stress are shown in Figure 7 for all calculated conditions. The mean
stress increased with head and decreased with blade angle. This is due to the fact that
Figure 5.
Pressure distribution on
blades and stress
distributions in blades on
condition GK3
Pressure
5.792e+005
154895 0.294E+08
0.148E+08 0.440E+08 0.732E+08 0.102E+09 0.132E+09
0.586E+08 0.879E+08 0.117E+09
3.959e+005
2.126e+005
2.931e+004
1.540e+005
[Pa]
(a) Pressure distributions (Pa) (b) Stress distributions (MPa)
Figure 6.
Dynamic stress at the
node with the maximum
stress (condition GK3,
GK8, GK10)
136
120.2
104
102
100
120.0
119.8
132
s
e
/
M
p
a
s
e
/
k
P
a
s
e
/
M
N
.
m
128
124
GK3
GK8
GK10
16.5 17.0 17.5
t/s
(a)
18.0 18.5 16.5 17.0 17.5
t/s
(b)
18.0 18.5 16.5 17.0 17.5
t/s
(c)
18.0 18.5
Figure 7.
The maximum mean
stress levels and dynamic
stresses amplitudes
(plotted with error bars)
for 13 conditions
140
Head=61 m
Head=57.3 m
Head=53 m
Head=43.8 m
Head=38 m
Head=61 m
Head=57.3 m
Head=53 m
Head=43.8 m
Head=38 m
130
120
s
e
/
M
P
a
s
e
/
M
P
a
110
100
140
130
120
110
100
4 8 12 16
Blade angle () Guide vane opening (%)
20 24 28 40 60 80 100
EC
24,8
760
the overall pressure difference between the pressure side and suction side of one blade
increases with head, and the bending effects increase with the decrease of blade angle.
Dynamic stress amplitude is low within 60-80 percent opening, and is higher at high
opening of above 90 percent with low head (GK10, GK11, GK13) and is the highest at
low opening (36 percent) with high head (GK3).
The maximum dynamic stresses amplitude is 8.6 MPa, which is less than the
limited stress of blade material. So blades are safe in practical application. In fact, the
runner has been operating for more then ten years without any cracks.
4. Conclusions
The dynamic stresses in the blades of a Kaplan turbine were analyzed for 13 operating
conditions using the CFD analyses in ow system coupled with the stresses analysis
in the runner. The stress distributions in blades show that the highest stress was
located near the blade root. The mean stress increases with head and decreases with
blade angle. The dynamic stresses in blade are closely related to the pressure
uctuations inside the ow path, which are low within 60-80 percent opening, are
higher at 90 percent opening (full output) with low heads and are the highest at low
opening (36 percent) with high head. The present study indicates that the prediction of
dynamic stress during design stage is possible. To ensure the safety of blades it is
recommended to check up safety coefcient during design stage at least for two
conditions, the 100 percent output with lower head and the 50 percent output with the
highest head.
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Corresponding author
Zhengwei Wang can be contacted at: wzw@mail.tsinghua.edu.cn
EC
24,8
762
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