02_Anagnostopoulos

Development and laboratory testing of Development and laboratory testing of

improved Action and Matrix hydro improved Action and Matrix hydro

turbines designed by advanced analysis turbines designed by advanced analysis turbines designed by advanced analysis turbines designed by advanced analysis

and optimization toolsand optimization tools

77thth Framework Programme: ENERGYFramework Programme: ENERGY

ESHA Hydroaction Seminar, Brussels, April 13, 2011ESHA Hydroaction Seminar, Brussels, April 13, 2011

Participants and Key topics

Development of innovative design methodologythat can be easily customized at affordablemanufacturing costs for SME manufacturers

Identify current needs of SHP manufacturesfor the new design methodology

National Technical University of Athens, Greece (Coordinator)

Institut Polytechnique de Grenoble, France

ANDRITZ Hydro GmbH, AustriaANDRITZ Hydro GmbH, Switzerland

for the new design methodology

Application in three different turbine types:Pelton, Turgo and Matrix.

Assessment of economic and environmentalimpacts - Market penetration strategy

Training for engineers and workshops to informSMEs about possibilities of new design approachcole Centrale de

Lyon, France

Techniques Hydro Electriques, France

European Small Hydropower Association (ESHA), Belgium

WIP Renewable Energies GmbH, Germany

Research Platform

Advanced and new parameterization and Advanced and new parameterization and Advanced and new parameterization and Advanced and new parameterization and flow analysis methods (CFD Eulerian and flow analysis methods (CFD Eulerian and flow analysis methods (CFD Eulerian and flow analysis methods (CFD Eulerian and Lagrangian)Lagrangian)Lagrangian)Lagrangian)

Modern optimization framework (parallel, Modern optimization framework (parallel, Modern optimization framework (parallel, Modern optimization framework (parallel, multilevel evolutionary algorithms multilevel evolutionary algorithms multilevel evolutionary algorithms multilevel evolutionary algorithms ---- EASY, EASY, EASY, EASY, metamodels, artificial intelligence ).metamodels, artificial intelligence ).metamodels, artificial intelligence ).metamodels, artificial intelligence ).

Turgo runner Turgo runner

designdesignPelton buckets Pelton buckets

optimizationoptimization

metamodels, artificial intelligence ).metamodels, artificial intelligence ).metamodels, artificial intelligence ).metamodels, artificial intelligence ).

Exploitation of experience accumulated Exploitation of experience accumulated Exploitation of experience accumulated Exploitation of experience accumulated during years of small hydraulic turbines during years of small hydraulic turbines during years of small hydraulic turbines during years of small hydraulic turbines production.production.production.production.

Manufacturing of prototype turbine models Manufacturing of prototype turbine models Manufacturing of prototype turbine models Manufacturing of prototype turbine models and experimental analysis/verification of optimal and experimental analysis/verification of optimal and experimental analysis/verification of optimal and experimental analysis/verification of optimal designsdesignsdesignsdesigns

Matrix Matrix

runner runner

designdesign

Distribution Distribution

section and section and

injector injector

designdesign

Mapping the small-hydro sector in the EU

Main objectivesMain 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

Three-layer middleware:

1. Local resource management S/W: CONDOR.

Grid Computing or Robots-based Optimization

Metamodel-assisted EasThe Inexact Pre-Evaluation (IPE) Scheme

2. Grid deployment: GLOBUS Toolkit 4. Discovery and monitoring of resources: GANGLIA.

3. Exploitation of resources: GRIDWAY.

Multilevel optimization

EASY Applications

A. Hydraulic turbomachinery

B. B. Other areas

Water tank of 320 mWater tank of 320 m33

Lab. of Hydraulic Turbomachines, NTUA

Control board with real time Control board with real time monitoring and analysis of monitoring and analysis of measurements (LabView)measurements (LabView)

Lab. of Hydraulic Turbomachines

LHT - Software

0 0.01 0.02 0.03 0.04 0.05

Flow rate parameter,

0.4

0.5

0.6

0.7

0.8

0.9

T

u

r

b

i

n

e

e

f

f

i

c

i

e

n

c

y

FLS / Measurements

6 mm nozzle

12 mm

20 mm

32 mm

40 mm

6 mm nozzle

12 mm

20 mm

32 mm

40 mm

Fast Lagrangian Solver, FLSFast Lagrangian Solver, FLSSmoothed Particle Smoothed Particle

Hydrodynamics, SPHHydrodynamics, SPH

AArtificialrtificial compressibilitycompressibility &&Free surface adaptationFree surface adaptation

Commercial Software (Fluent, CFX)Commercial Software (Fluent, CFX)

Open source softwareOpen 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 .

JetJet--bucket interaction analysis: FLS model (left); SPH model (right)bucket interaction analysis: FLS model (left); SPH model (right)

New methodology: Flow simulation and Design optimization

Initial design Optimum design

Design optimization (EASY) resultsDesign optimization (EASY) resultsValidation Validation comparison with comparison with Eulerian model results (Fluent)Eulerian model results (Fluent)

Jet-runner interaction analysis

Flow pictures obtained by the Flow pictures obtained by the SPH modelSPH model

Piping and injectors system design


Surface Ptot (Pa) Losses (Pa)

Max helicity

Area (m2)

Welding Length (m)

pressure_outlet.18 1438.934 720.7506

pressure_outlet.19 1438.731 720.953 90 (reference)

velocity_inlet.17 2159.684

126 3.719709 8.090476

pressure_outlet.18 1448.735 511.4458

pressure_outlet.19 1449.423 510.7574 70


72.85 4.296013 8.146408

pressure_outlet.18 1441.313 379.2711

pressure_outlet.19 1438.368 382.2162 90o Curve 3


79.35 3.725127 9.141367

72

76

80

84

88

E

f

f

i

c

i

e

n

c

y

(

%

)

'Conventional' design

Optimum design

Improved runner performance

Real turbineReal turbine Improved Improved designsdesigns

0 0.4 0.8 1.2 1.6 2

Load (Q / Qdesign)

68

72

76

80

84

E

f

f

i

c

i

e

n

c

y

(

%

)

Lower injector

Upper injector

FLS results

0 0.4 0.8 1.2 1.6

Load (Q / Qdesign)

68

72 Optimum design

Optimum - Turgo adjusted

74 74767

880

81

82

8383

Flow rate (lt/sec)

N

e

t

h

e

a

d

(

m

)

20 40 60 80 100 120 14030

35

40

45

50

55

60

84,2

FLS resultsFLS results

Model turbine construction drawings

Model turbine computer views

Design of the casing and of the injectors of the model of Turgo turbine

Separate fabrication of runner parts (blades, hub and shroud)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

Runner fabrication

Internal blade surface polishing Final blade assembly with bronze welding Runner balancing

FeaturesFeaturesMore complex but more accurate construction methodologyEnhanced axial symmetry of the runnerCapability 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,

Thank you!Thank you!

www.hydroaction.orgwww.hydroaction.org

will contribute to the development of cost-efficient, tailor-made turbines for small hydro plants with optimum performance.

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02_Anagnostopoulos