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Investigation into the flow details of runner region in a pump turbine at off-
design conditions

Article  in  Advances in Mechanical Engineering · February 2016


DOI: 10.1177/1687814016630727

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Special Issue Article

Advances in Mechanical Engineering


2016, Vol. 8(2) 1–15
Ó The Author(s) 2016
Investigation into the flow details of DOI: 10.1177/1687814016630727
aime.sagepub.com
runner region in a pump turbine at
off-design conditions

Ruzhi Gong1, Deyou Li1, Hongjie Wang1, Xianzhu Wei1,2


and Daqing Qin1,2

Abstract
Due to the rapid development of large thermal power stations and nuclear power stations, it requires that the power
grid should provide greater capability and flexibility. Security, stability, and economy in operation should also be taken
into consideration. The pumped storage power station which has double peak regulating capability is a good choice to
realize this goal. However, the existence of S shape characteristic of a pump turbine in generating mode at off-design
condition makes it difficult to connect to the power grid. So it is necessary to analyze the reason of S shape characteris-
tic in pump turbine by experimental investigation and numerical simulations. To achieve the above-mentioned object,
numerical simulations of a pump turbine’s internal flow field were performed. The generating mode was analyzed by
unsteady computational fluid dynamics simulation. The evolution of flow details in runner regions under the S shape
characteristic conditions was observed by changing the guide vane opening. The unsteady flow structure and load on the
blades in regions of S shape characteristic were obtained, which will contribute to the design of hydro-turbine.

Keywords
Hydraulic machinery, computational fluid dynamics, S shape characteristic, pump turbine, unsteady simulation

Date received: 16 June 2015; accepted: 5 January 2016

Academic Editor: Junwu Wang

Introduction Pumped-storage power plants have taken the task of


power-frequency control for the electrical grid.1 Some
Rapid developments of large thermal power plants— real machine tests and experiments indicate that the
either coal or nuclear—need more powerful and feasi- unstable operation problems are possible to come into
ble ability of the electrical system. It requires that the existence when the turbine subjected to S shape charac-
power grid should provide greater capability and flexi- teristics (Figure 1). Depending on the specific speed of
bility. Rigorous safe, stable, and economical strategy of
the electrical system is needed because of the random-
ness of the electricity between demand and supply. 1
School of Energy Science and Engineering, Harbin Institute of
Pumped-storage power plants have strong ability of Technology, Harbin, China
peaking and are convenient in starting, stopping, and 2
State Key Laboratory of Hydropower Equipment, Harbin Institute of
compensating. It can decrease the cost of electrical sys- Large Electrical Machinery, Harbin, China
tem construction and supply the need of peaking and
Corresponding author:
frequency adjustment, which increases the quality Hongjie Wang, School of Energy Science and Engineering, Harbin Institute
and reliability of the electrical supply and improves of Technology, Harbin 150001, China.
the operating conditions of electrical system. Email: wanghongjie@hit.edu.cn

Creative Commons CC-BY: This article is distributed under the terms of the Creative Commons Attribution 3.0 License
(http://www.creativecommons.org/licenses/by/3.0/) which permits any use, reproduction and distribution of the work without
further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/
open-access-at-sage).
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2 Advances in Mechanical Engineering

and the results coincided well with the experimental


results.11 The flow field in the turbine was described as
well.12 Tani and Okumura13 improved the efficiency of
the pump turbine under turbine status by applying the
CFD method to the turbine design. Blanc-Coquand
et al.14 analyzed the influence of blades’ number, flow
rate, and vaneless zone area on the rotor–stator interac-
tion by introducing unsteady CFD computation of the
pump turbine under both turbine status and pump sta-
tus. Backman15 simulated the three-dimensional (3D)
flow field of a pump turbine and studied the rotor–
stator interaction through analyzing the flow distribu-
tion, amplitude, and frequency of pressure fluctuations.
Pettersen and Nielsen16 proposed the mathematical
Figure 1. Complete characteristic curves of pump turbine. equations of pump turbine complete character curve
according to the mathematical theory of pump turbine
inner flow character. And ‘‘S’’ character was sketched
the pump turbine, the discharge-speed as well as according to the equation derivation and analysis.
torque-speed characteristics at constant guide vane Hasmatuchi17 found in the experiment that the pressure
opening can be ‘‘S-Shaped.’’2 In this case, the machine fluctuation of a turbine in the guide vane region will
operation may become strongly unstable at runaway increase, and the low frequency component in the pres-
speed and beyond, with a significant increase in struc- sure fluctuation will increase evidently when the turbine
tural vibrations and noise. Moreover, a stable runaway steps into the ‘‘S’’ region. Gentner et al.18,19 has evalu-
operating point is difficult to be reached and therefore ated several CFD procedures with different approaches
the synchronization with the electrical network in for the calculation of the described instabilities in pump
safety conditions becomes impossible.3 In this case, one and turbine operation. Sun et al.20 Studied the S char-
rotational speed may correspond to three discharge val- acter of a pump turbine with discrete-event simulation
ues, which will inevitably increase mechanical vibra- (DES) model. Borresen and Knutsen21 deeply studied
tions and noises to a larger extent. Most of all, it is the flow character under turbine status; however, the
difficult for the hydraulic machine to be synchronous flow character under runaway status and braking status
with the power network. The existence of S shape char- are less studied. The article carefully examined the flow
acteristic in low head start of a pump turbine is the field of a pump turbine under turbine mode, runaway
restriction of the pump turbine development. This will mode, and braking mode at different guide vane open-
induce large pressure pulsations and vibrations in ings. The mechanism of S shape characteristic of the
pump turbines.4–6 And this characteristic of reversible turbine was analyzed.
pump turbine will lead to severe difficulties in the tran-
sition process of generators cut-in.
The hydromechanical mode period depends on the Case description
rotating inertias, the penstock water inertia, and on the
local gradient of the turbine characteristic in the S The parameters of pump turbine model studied in the
shape as it is well described by Martin.7,8 To investigate article are shown in Table 1. Figure 2 shows the meri-
the reason of S shape characteristic, some researches dional sketch of the turbine runner. The scaled model
were carried out. Hasmatuchi2 found that by numerical parameters are provided by Harbin Institute of Large
simulations the pressure fluctuation in the stay vane machinery. The specific speed of the scaled model is
zone will increase from turbine status to runaway sta- nq = 29.58 r min21. The whole flow passage of the
tus. Anciger et al.9 described the rotating stall and cavi- scaled turbine is simulated in the article. The scale tur-
tation inception phenomena, which will lead to the bine model includes spiral casing, stay vanes, guide
instability of a pump turbine, using computational fluid vanes, runner, and draft tube (see Figure 3).
dynamics (CFD) simulations. Yin et al.10 investigated
the possible different flow patterns existing in pump
Numerical scheme
turbine under off-design conditions in pump mode. The
simulation result was compared with experimental data A time-dependent Reynolds-Averaged Navier–Stokes
and they showed good agreements. Velocity field ana- (RANS) model is chosen for the governing equations
lyzing in stay vanes and guide vanes found the ‘‘jet- of the flow, and numerical simulations are performed
wake’’ flow pattern in the pump turbine. And the S in order to obtain the flow field in the turbine flow pas-
shape characteristic of a pump turbine was predicted sage. Commercial CFD code CFX is used to carry out

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Gong et al. 3

Figure 2. Meridional sketch of the turbine runner.

Table 1. Geometrical parameters of scaled turbine.

Parameters Value

Runner low pressure diameter, D1 (mm) 274


Blades number, Z 9
Guide vanes distribution diameter, D0 (mm) 610.46
Guide vanes number, Z0 20
Guide vane height, B0 (mm) 45.84
Stay vanes number, Zs 20

Figure 3. Model of scaled turbine.


the numerical simulations. The code solves the incom-
pressible unsteady time averaged Navier–Stokes equa-
tions in a primitive variable form. No-slip condition is
assumed on all the solid walls. The effects of turbulence
are modeled using the shear stress transport (SST)
model.10 The flow near the wall area will be calculated
by transport equation, and automatic near-wall treat-
ment is introduced in the model. Boundary function
will shift to the low Reynolds number wall function in
the near-wall region, so that the continuity equation
and momentum equation can be solved in the sub-
layer. The mesh for simulations is generated by ICEM
grid generator (see Figures 4–7).
Three different grid densities (fine-G1 with grid
number of 9.96 million, medium-G2 with grid number
of 6.62 million, and coarse-G3 with grid number of Figure 4. Mesh in spiral casing.
4.43 million) were used to carry out the grid sensitivity
check. The type G3-type mesh was the coarsest mesh in uncertainty in the grid convergence were estimated
the simulation. The subsequent mesh was updated by using the GCI method:22 the computed flow para-
1.5 3 in the grid number. The grid quality was taken meters are established in Table 2, and Figure 8 shows
into consideration at each step of grid creation so that the grid check results. The approximate and extrapo-
the mesh nodes did not correspond exactly to a 1.5 3 lated relative errors are estimated as
increase. The simulations were performed at the 45.5%
 
guide vane opening, and operating condition G 1  G 2 
21
ea =    ð1Þ
n11 = 35.529 r m1/2 min21, Q11 = 0.3194 m1/2 s21, for all G1 
grid types. The grid convergence index (GCI) method  21 
was used to evaluate the numerical uncertainties and Gext  G2 
e21 =   ð2Þ
grid convergence. The extrapolation values and
ext  G21 
ext

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4 Advances in Mechanical Engineering

Figure 5. Mesh in stay vanes and guide vanes.

Figure 7. Mesh results in draft tube: (a) mesh in draft tube and
(b) mesh at the cross section of draft tube.

Table 2. Computed flow parameters.a

Parameter Turbine head (H) Turbine efficiency (h)

r21 1.5 1.5


r32 1.5 1.5
G1 14.89 90.71
G2 14.87 90.78
G3 13.94 91.31
21
Gext 14.890439 90.69935
e21
a 0.0013432 0.000772
e21
ext 0.0000295 0.000117
GCI21fine 0.0000369 0.000147
GCI32med 0.0017182 0.001111
a
Experimental head is 14.92 and experimental efficiency is 85.51 for the
validated condition.

Figure 6. Mesh results in runner: (a) mesh in runner and (b) The GCI from G2 to G1 was very low compared to
mesh at blade inlet.
the GCI from G3 to G2. And the turbine head and effi-
(r21 G1  G2 ) ciency with the fine grid are closer to the experimental
21
Gext = ð3Þ results. The converged solution with the fine grid
(r21  1)

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Gong et al. 5

Figure 9. Hydraulic turbine test rig in Large Electrical


Machinery.

Figure 8. Grid sensitivity check.


Zhou et al.24,25 proposed that the imaginary part of
Table 3. Grid information. complex eigenvalue of velocity gradient tensor can dis-
play the vortex structure and quantize local vortex
Components Nodes number (3105) Average y+ intensity, and the parameter is defined as the swirling
strength. Adrian et al.26 state that the method is a
Spiral casing 16.8 11.3
Distributor 38.5 1.48
responsible method to identify and count vortexes in
Runner 31.819.2 3.47 flow field.
Draft tube 12.3 7.6
Total grid 99.6 –
Results discussion
(G1 with grid number of 9.96 million) was used for fur- The computations are carried out at the guide vane
ther simulations at different operating conditions. opening of 22.7%, 45.5%, and 145.5% (with respect to
The grids near the wall are specially treated. And the best efficiency point guide vane opening,
the grid information of each part is shown in Table 3. aBEP = 22 mm, set as 100% opening) under the condi-
According to the recommendations of Versteeg and tion of first quadrant in the turbine character chart.
Mlalasekera,23 y+= 11.63 can be regarded as the edge Several operating conditions are simulated under each
of boundary layer. guide vane opening. During the data process, time
The inlet is set as mass flow inlet, the outlet of the averaged results are used for efficiency (h), head (H),
turbine is set as pressure outlet, and the runner speed is torque (T), and flux rate (q). Instantaneous results are
attained for contours, streamlines, and pressure
set as the experiments. The interface between spiral cas-
profiles.
ing and stay vanes was simulated by general grid inter-
Experiments are carried out on the hydraulic plat-
face (GGI); the interface between guide vanes and
form of Harbin Institute of Large machinery. The
runner was simulated by transient frozen rotor; and the
accuracy of the platform is designed to accord with
interface between runner and draft tube was simulated
standard of IEC 60193. Figure 9 shows the test rig in
by transient frozen rotor.
Harbin Institute of Large Electrical Machinery.
Swirling strength method is applied to analyze the
Figure 10 shows the numerical results and experi-
flow field in the article. Swirling strength method is an
mental results under the guide vane opening of 22.7%,
analysis method based on the critical point of local
45.5%, and 145.5%. From the results we know that
velocity gradient. The swirling strength is defined as
there is no S shape characteristic at the guide vane
the imaginary part of complex eigenvalue of velocity
opening of 22.7%, that S shape characteristic in the
gradient tensor
character chart of 45.5% guide vane opening is not
very evident or has slight S shape characteristic, and
lei = max
     that there is evident S shape characteristic at the guide
∂vx ∂vy 1 ∂vx ∂vy 1 ∂vx ∂vx ∂vy ∂vy vane opening of 145.5%.
0,   + +
∂y ∂x 2 ∂x ∂y 4 ∂x ∂x ∂y ∂y The operating conditions chosen to be analyzed are
ð4Þ listed in Table 4. They are selected to be stable state
(without S shape characteristic), limit of stability state
where x, y are x and y coordinates, respectively (m), (with less S shape characteristic), and unstable state
and vx, vy are velocities in x and y directions, respec- (with evident S shape characteristic). The three points
tively (m s21). are located on the different positions of ‘‘S’’ zone of the

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6 Advances in Mechanical Engineering

Table 4. Simulation conditions.

Guide vane n11 (r m1/2 min21) Q11 (m1/2 s21) Head, h (m) Condition mode
opening, b (%)

22.7 38.996 0.1018 12.316 Turbine status


22.7 43.562 0.0724 10.373 Runaway status
22.7 45.454 0.0072 9.453 Braking status
45.5 35.516 0.3194 14.925 Turbine status
45.5 48.634 0.1433 7.548 Runaway status
45.5 48.276 0.0458 8.023 Braking status
145.5 53.034 0.5230 6.008 Turbine status
145.5 50.874 0.3065 5.849 Runaway status
145.5 50.533 0.0917 6.420 Braking status

the same runner phase are selected, for example, the


runner at the same position relative to spiral casing and
draft tube.
The runner is the components for a turbine to realize
the energy transfer, which greatly affects the efficiency
and stability of a turbine. Figures 11–13 show the
streamline principle in turbine runner at the guide vane
opening of 22.7%, 45.5%, and 145.5%, respectively.
There is almost no vortex in the runner under tur-
bine operating status. The vortex has emerged in the
runner under runaway operating status. There are more
vortexes in the runner under braking operating status
than under runaway operating status, and the vortex
will block up the flow passage. The larger the guide
vane opening, the smoother the streamline distribution,
and the later the vortex movement emerge under run-
away operating status and braking operating status.
The vortex intensity will be weaker and the influenced
region will be smaller. The reason is that the vanes pro-
duce larger prevention to backflow of vaneless zone
under smaller guide vane opening, which makes the
vortex develop rapidly when the turbine step into run-
away or braking operating status. While under larger
guide vane opening, backflow in vaneless zone will
transfer to the guide vane passage smoothly, which
slows down the development of vortex at the runner
inlet.
Figure 14 described the pressure surface, suction sur-
face, leading edge, trailing edge, and rotational direc-
tion of the turbine runner blades in the form of cascade
expansion which will be analyzed in Figures 15–20.
Figure 10. First quadrant character of pump turbine under Figures 15–17 show the streamlines distribution at
different guide vane openings: (a) n11–Q11 profile and (b) n11–T11 the guide vane opening of 22.7%, 45.5%, and 145.5%,
profile. respectively. The cutting planes analyzed are the middle
stream surface in each condition. At the guide vane
opening of 22.7%, two vortexes will be produced at the
character curve. Runaway conditions are the operating runner inlet, and the rotational direction of two vor-
conditions in which the torque of the runner is zero. texes is opposite to each other. Under braking status,
And breaking conditions are the operating conditions the two vortexes at the runner inlet will merge and
in which the torque of the runner is below zero. The almost block the flow passage. The fluid at the inlet
shown results below are instantaneous ones. States with region cannot flow into the middle and tail part of the

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Gong et al. 7

Figure 11. Streamlines in runner at 22.7% guide vane opening: (a) turbine status (t = 0.36 s), (b) runaway status (t = .0352 s), and
(c) braking status (t = 0.353 s).

Figure 12. Streamlines in runner at 45.5% guide vane opening: (a) turbine status (t = 0.359 s), (b) runaway status (t = 0.369 s), and
(c) braking status (t = 0.36 s).
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8 Advances in Mechanical Engineering

Figure 13. Streamlines on the runner mid-span at 145.5% guide vane opening: (a) turbine status (t = 0.379 s), (b) runaway status
(t = 0.401 s), and (c) braking status (t = 0.385 s).

runner because of the blockage of the two vortexes.


Contrariously, the fluid will flow back to the vaneless
zone. Under turbine status, the flowback area is small
and the vortex is weak. The flow is relatively steady
and smooth. Under runaway status, the water will flow
into the cone spirally because of the influence of two
vortexes in the flow passage. Under braking status, the
flow passage will be blocked by a vortex at the inlet,
and another new vortex at the middle region of the
flow passage will emerge. At the guide vane opening of
45.5% and 145.5%, similar principle will appear. The
unsteady condition comes later or the turbine flow is
more stable under large guide vane opening than that
under small guide vane opening.
Figures 18–20 show the vortex intensity distributions
in runner zone. Vortex with high intensity mainly distri-
butes at the inlet and the outlet of the runner. The
intensity of vortex at the outlet of the runner is larger
than that of the vortex at the runner inlet. The increas-
ing of guide vane opening will enlarge the flux differ-
ence between turbine status and braking status, which
leads to a higher flow rate at which the vortexes appear
Figure 14. Description of turbine runner blade. under a larger guide vane opening. The vortex intensity

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Gong et al. 9

Figure 15. Streamline distribution in the runner at the guide vane opening of 22.7%: (a) turbine status (t = 0.36 s), (b) runaway
status (t = .0352 s), and (c) braking status (t = 0.353 s).

Figure 16. Streamline distribution in the runner at the guide vane opening of 45.5%: (a) turbine status (t = 0.359 s), (b) runaway
status (t = 0.369 s), and (c) braking status (t = 0.36 s).

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10 Advances in Mechanical Engineering

Figure 17. Streamline distribution in the runner at the guide vane opening of 145.5%: (a) turbine status (t = 0.379 s), (b) runaway
status (t = 0.401 s), and (c) braking status (t = 0.385 s).

Figure 18. Vortex intensity distributions at 22.7% guide vane opening: (a) turbine status (t = 0.36 s), (b) runaway status (t = .0352 s),
and (c) braking status (t = 0.353 s).
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Gong et al. 11

Figure 19. Vortex intensity distributions at 45.5% guide vane opening: (a) turbine status (t = 0.359 s), (b) runaway status
(t = 0.369 s), and (c) braking status (t = 0.36 s).

Figure 20. Vortex intensity distributions at 145.5% guide vane opening: (a) turbine status (t = 0.379 s), (b) runaway status
(t = 0.401 s), and (c) braking status (t = 0.385 s).
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12 Advances in Mechanical Engineering

Figure 21. Pressure profile on the blade at 22.7% guide vane opening: (a) turbine status (t = 0.36 s), (b) runaway status (t = .0352 s),
and (c) braking status (t = 0.353 s).

will be larger and the vortex region will be wider. The develops to the downstream caused by the increase in
‘‘misplacement’’ and the difference of flow rate at which backflow area, which will lead to the lower pressure
the vortex appear may be the reason of S-shaped char- drop between pressure surface and suction surface. The
acter. At the guide vane opening of 145.5%, the vortex torque on the runner is ‘‘0’’ under runaway status, while
will appear at the inlet and outlet of runner from run- the torque on the runner is negative under braking
away status to braking status, and the vortex will be status.
enhanced during the processing. The flow stability will
become worse.
The load on the blades will be influenced a lot by Conclusion
flow profile in the runner. Figures 21–23 show the load The article studied the flow field of a pump turbine at
on the blades under different conditions. At the inlet the guide vane opening of 22.7%, 45.5%, and 145.5%
and outlet of the runner, the pressure on the pressure under turbine status, runaway status, and braking sta-
surface of a blade is lower than that on the suction sur- tus. The first quadrant character of the turbine is
face due to the vortex at inlet and backflow at outlet obtained through unsteady simulations for the men-
under turbine status with guide vane opening of 22.7% tioned conditions. It is found that when water receives
and 45.5%. The fluid will obtain energy from the blades power from runner blades in the inlet region, braking
in this region. Some water with increasing energy will torque will appear, which indicates that the turbine
flow back to the vaneless zone, which will lead to the deviates from the turbine status. When the braking tor-
pressure increase. At the other location of a blade, the que enlarged and the whole torque on the runner
pressure on pressure surface of a blade is higher than becomes ‘‘0,’’ the turbine will step into runaway status.
that on the suction surface because the blades will When the pressure drop between pressure surface and
obtain energy from fluid. The fluid will obtain energy suction surface becomes nearly ‘‘0,’’ the turbine will
from blades only at the inlet and there is no backflow at step into braking status. Different ranges of vortex and
the outlet with the guide vane opening of 145.5%. backflow will exist in the runner under different operat-
Under runaway status and braking status, the region ing conditions at small guide vane opening, and the
where the water receives power by runner blades vortex and backflow mainly distribute at vaneless zone,

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Gong et al. 13

Figure 22. Pressure profile on the blade at 45.5% guide vane opening: (a) turbine status (t = 0.359 s), (b) runaway status
(t = 0.369 s), and (c) braking status (t = 0.36 s).

Figure 23. Pressure profile on the blade at 145.5% guide vane opening: (a) turbine status (t = 0.379 s), (b) runaway status
(t = 0.401 s), and (c) braking status (t = 0.385 s).

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14 Advances in Mechanical Engineering

runner inlet, and runner outlet. At larger guide vane 8. Martin CS. Instability of pump-turbines with S-shaped
openings, the vortex and backflow will appear in the characteristics. In: Proceedings of the 20th IAHR sympo-
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rotating stall and cavitation inception in pump turbines.
respect to that under small guide vane openings. The S-
IOP C Ser Earth Env 2010; 12: 12013.
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Declaration of conflicting interests
on the ‘‘S’’ characteristics of a reduced pump turbine
The author(s) declared no potential conflicts of interest with model. Sci China Tech Sci 2011; 54: 1259–1266.
respect to the research, authorship, and/or publication of this 13. Tani K and Okumura H. Performance improvement of
article. pump-turbine for large capacity pumped storage plant in
USA. Hitachi Rev 2009; 58: 98–202.
Funding 14. Blanc-Coquand R, Lavigne S and Deniau JL. Experimen-
tal and numerical study of pressure fluctuation in high
The author(s) disclosed receipt of the following financial sup- head pump-turbine. In: Proceedings of the 20th IAHR
port for the research, authorship, and/or publication of this symposium on hydraulic machinery and systems, Charlotte,
article: This work was supported by Foundation for NC, 6–9 August 2000.
Innovative Research Groups of the National Natural Science 15. Backman G. CFD validation of pressure fluctuations in a
Foundation of China (Grant No. 51121004) and the National pump turbine. Luleå: Luleå University of Technology,
Natural Science Foundation of China (Grant No. 51176040). 2008.
16. Pettersen K and Nielsen TK. An explanation to the steep
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r32 mesh ratio (G3/G2)


Appendix 1 T torque on the runner (N m)
T11 unit torque (N kg21), T11 = rDT3 H
Notations 1

vx velocity in x direction (m s21)


a guide vane opening (mm) vy velocity in y direction (m s21)
B0 guide vane height (mm) x x coordinate (m)
D0 guide vanes distribution diameter (mm) y y coordinate (m)
D1 runner diameter (mm) y+ dimensionless wall distance (–)
e21
a approximate relative error Z blades number (–)
e21
ext extrapolated relative errors Z0 guide vanes number (–)
21
Gext extrapolated value for G1 and G2 grid Zs stay vanes number (–)
type
21
GCIfine grid convergence index for the fine grid b guide vane opening in percentage respect
(G1) to aBEP (%)
32
GCImed grid convergence index for the medium r density (kg m23)
grid (G2)
H head (m)

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