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Solving the runner blade crack problem for a Francis hydro-turbine operating under condition-complexity

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  • Zhu, Di
  • Tao, Ran
  • Xiao, Ruofu
  • Pan, Litan

Abstract

Runner blade crack is a problem that affects the operation security of hydro-turbines. In this study, penetrating cracks were found by inspection on the runner blade of a Francis turbine near hub and shroud on trailing-edge. To solve this problem, prototype test was conducted to find the conditions under strong hydraulic instabilities. The turbine vibration region was classified based on the test and found mainly at small guide vane opening angles or low-head high-load conditions. In these regions, vibration was strong and the numerical-predicted flow regime was disordered. Analyzed by fluid-solid interaction method, stress concentrations were found on the blade-hub and blade-shroud connections on trailing-edge. By excluding the influence of resonance, the runner blade crack problem was found as the combination of concentrating static stress, hydraulic excited pulsating stress and residual stress. Triangle-blocks, which were helpful for eliminating the concentrating static stress, were welded on the blades after cutting-off the old crack sites. Polishing and buffing were conducted for reducing potential residual stress. After a long-time re-operation, the improved runner was found without runner blade cracks. Prototype re-testing showed no impacts on the efficiency. This study provided a good solution for the Francis turbine runner blade crack problem under condition-complexity.

Suggested Citation

  • Zhu, Di & Tao, Ran & Xiao, Ruofu & Pan, Litan, 2020. "Solving the runner blade crack problem for a Francis hydro-turbine operating under condition-complexity," Renewable Energy, Elsevier, vol. 149(C), pages 298-320.
    • Handle: RePEc:eee:renene:v:149:y:2020:i:c:p:298-320
    DOI: 10.1016/j.renene.2019.12.057
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    References listed on IDEAS

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    Cited by:

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    3. Jin, Faye & Wang, Huanmao & Luo, Yongyao & Presas, Alexandre & Bi, Huili & Wang, Zhengwei & Lin, Kai & Lei, Xingchun & Yang, Xiaolong, 2023. "Visualization research of energy dissipation in a pump turbine unit during turbine mode's starting up," Renewable Energy, Elsevier, vol. 217(C).
    4. Liu, Fuxiu & Li, Zhaojun & Liang, Minglang & Zhao, Binjian & Ding, Jiang, 2023. "Prediction method of non-stationary random vibration fatigue reliability of turbine runner blade based on transfer learning," Reliability Engineering and System Safety, Elsevier, vol. 235(C).
    5. Xing Zhou & Changzheng Shi & Kazuyoshi Miyagawa & Hegao Wu & Jinhong Yu & Zhu Ma, 2020. "Investigation of Pressure Fluctuation and Pulsating Hydraulic Axial Thrust in Francis Turbines," Energies, MDPI, vol. 13(7), pages 1-16, April.
    6. Li, Lin & Tan, Dapeng & Yin, Zichao & Wang, Tong & Fan, Xinghua & Wang, Ronghui, 2021. "Investigation on the multiphase vortex and its fluid-solid vibration characters for sustainability production," Renewable Energy, Elsevier, vol. 175(C), pages 887-909.
    7. Zhou, Xing & Wu, Hegao & Cheng, Li & Huang, Quanshui & Shi, Changzheng, 2023. "A new draft tube shape optimisation methodology of introducing inclined conical diffuser in hydraulic turbine," Energy, Elsevier, vol. 265(C).
    8. Fang Dao & Yun Zeng & Yidong Zou & Xiang Li & Jing Qian, 2021. "Acoustic Vibration Approach for Detecting Faults in Hydroelectric Units: A Review," Energies, MDPI, vol. 14(23), pages 1-16, November.

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