Bulb turbine operating at medium head: XIA JIANG case study

Abstract

With lots of references for 4-blade bulb turbines, such as these of Wu Jin Xia (4 units-36.1 MW per unit-9.2 m rated head), Chang Zhou (15 units-46.7 MW per unit-9.5 m rated head) and Tong Wan (4 units-46.2 MW per unit-11 m rated head), ALSTOM Power Hydro is one of the major suppliers of bulb turbines operating under medium head for the Chinese market. ALSTOM Power Hydro has been awarded in November 2010 a contract by Jiang Xi Province Xia Jiang Water Control Project Headquarters to equip Xia Jiang's new hydropower plant. The power dam is located on the Gan Jiang river, at about 160 km away from Nan Chang town in South Eastern China. The supply will consist in 5 bulb units including the furniture of both the turbine and its generator, for a total capacity of 200 MW, under a rated net head of 8.6 m. The prototype turbine is a 7.8 m diameter runner, rotating at 71.4 rpm speed. For this project, ALSTOM has proposed a fully new design of 4-blade bulb runner. This paper outlines the main steps of the hydraulic development. First of all, a fine tuning of the blade geometry was performed to enhance the runner behaviour at high loads and low heads, so that to fulfill the demanding requirements of efficiencies and maximum output. The challenge was also to keep an excellent cavitation behaviour, especially at the outer blade diameter in order to avoid cavitation erosion on the prototype. The shape of the blade was optimized by using the latest tools in computational fluid dynamics. Steady state simulations of the distributor and the runner were performed, in order to simulate more accurately the pressure fields on the blade and the velocity distribution at the outlet of the runner. Moreover, draft tube computations have been performed close to the design point and at higher loads. Then, a model fully homologous with the prototype was manufactured and tested at ALSTOM's laboratory in Grenoble (France). The model test results confirmed the predicted ones: the expected weighted average efficiency is higher than the guaranteed value and the maximum output was reached with a comfortable safety margin. A comparison of the experimental and numerical velocity probings under the runner is also proposed as an insight into the prediction of flow behaviour at the inlet of the draft tube. © 2013 Published under licence by IOP Publishing Ltd.