open-air laboratory for a new isokinetic turbine prototype

HES-SO Valais-Wallis Sierre, September 22nd, 2016

Open-air laboratory for a new isokinetic turbine prototype

Vlad Hasmatuchi Haute Ecole d’Ingénierie

Institut Systèmes industriels Groupe Hydroélectricité

HES-SO Valais-Wallis

Vlad Hasmatuchi – Open-air laboratory for a new isokinetic turbine prototype

Objectives of this “pilot & demonstrator” project

Design and construction of a first prototype of isokinetic turbine for artificial channels with a power of 1 kW

Evaluation of its hydraulic performances in the tailrace canal of the Lavey run-of-river powerplant (Rhône river)

Validation of the numerical simulation results

Preparation of an industrialization phase to exploit this energetic potential in Switzerland and abroad



Motivation

Estimation of artificial waterways energetic potential

Hydroelectricity statistics Isokinetic energy potential of tailrace canals

Type of powerplant Installed power [MW]

Annual production [GWh]

Installed power [kW]

Annual production [MWh]

Lave

y

Run-of-river 90 400 25 140

Suis

se Run-of-river 3854 17’022 1’070 5’957

Storage 8'081 17’297 2’244 6’053

Pumped-storage 1'383 1’594 0 0

Total 13’318 35’908 3’314 12’010

Estimation of Swiss small-hydro

potential: 1.3 TWh

1% of small-hydro potential



Available isokinetic technologies

Power coefficient:

Betz limit:

Tip speed ratio:

2 31

12ρπ

=P

e o

PCR C

16 59.2%27PC = =

o

RCωλ =

*Khan et al. 2009



Services industriels de Lausanne

Access to the pilot site

Stahleinbau GmbH

Fondation The Ark

Financial support

Construction of a 1kW isokinetic turbine and evaluation of its hydraulic performances into the tailrace canal of the Lavey power plant

HES SO Valais // Hydroelectricity Group Project management, Design, Manufacturing & Performance measurements

OFEN P&D

Financial support

Project management



Pilot site

Tailrace canal of the Lavey run-of-river power plant (Rhône River)



Pilot site

Free-surface flow numerical simulations have been performed to investigate its isokinetic potential



Pilot site – hydrokinetic potential

Numerical simulations validated with in situ velocity measurements on three cross sections



Pilot site – hydrokinetic potential

Nominal mean flow velocity : 1.4 m/s

Potential of mean flow velocity: 0.5 ÷ 1.7 m/s

𝑘𝑘𝑡𝑡 =𝑇𝑇(𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑)3 ∙ 365 100 %



Hydraulic profile of a 1 kW turbine optimized with steady incompressible monophasic turbulent flow numerical simulations

5 stator blades and 3 runner blades

Mesh: Ansys ICEM CFD commercial software

Hydraulic profile design and optimisation

Component Domain Mesh type Number of nodes

Box Stationary Structured 1’630’098 Duct in Stationary Structured 1’342’488 Stator Stationary Structured 1’609’160 Turbine runner Rotating Structured 2’375’304 Duct out Stationary Structured 1’211’783

Full domain Structured 8’168’833



Numerical simulation: Ansys CFX 16.2 commercial software

Numerical setup:


Numerical method Finite volume Numerical scheme 2nd order Simulation type Steady Turbulence model SST

Fluid method Monophasic

Interfaces Direct connection method

Rotor-stator interaction Stage

Convergence criteria RMSmax < 10-4 Simulation duration >1’000 iterations



Convergent-divergent duct to exceed the Betz limit

The variable speed should ensure an optimal operation under different inflow conditions

Power coefficient:

Tip speed ratio:


𝐶𝐶𝑃𝑃 =𝜔𝜔 ∙ 𝑇𝑇

12 ∙ 𝜌𝜌 ∙ 𝜋𝜋 ∙

𝐷𝐷𝑒𝑒24 ∙ 𝐶𝐶𝑟𝑟𝑒𝑒𝑟𝑟3

−

𝜆𝜆 =𝜔𝜔 ∙ 𝐷𝐷𝑒𝑒2𝐶𝐶𝑟𝑟𝑒𝑒𝑟𝑟

−



Sealed bulb housing including the variable speed generator, the encoder, the speed multiplier and the mechanical coupling

1kW compact permanent magnet synchronous generator

Coaxial gear speed multiplier with a factor of 1:16

Mechanical shaft sealing: resistant to suspended sediment conditions

Electro-mechanical concept



Open-air testing platform

Dedicated to hydraulic performance measurements on the isokinetic turbine prototype

Allows the immersion of the prototype at the desired water depth

Give an easy and secured access to the machine for handling, instrumentation and control



Open-air testing platform - characteristics

≈ 1.7 t

≈ 3.6 t

≈ 3.9 t

≈ 1.0 t

Total : ≈ 11 t



Open-air testing platform - anchoring



Open-air testing platform - installation

1. Base positioning

2. Pillars assembly

3. Base immersion

4. Platform installation 5. Turbine installation 6. Lifting system installation



Instrumentation

Mechanical power measurements Indirect torque measurement method (from the electrical generator Itrms values ) Incremental encoder (Heidenhein ECN 1325)

Hydraulic power measurements Reference flow velocity measurements

TeleDyne ADCP (Acoustic Doppler Current Profiler) system

Operating conditions measurements Water temperature, water depth, etc.

Local flow condition measurements Flow velocity measurements inside the machine (custom-made miniature Prandtl probe)

𝑃𝑃ℎ =12∙ 𝜌𝜌 ∙ 𝜋𝜋 ∙

𝐷𝐷𝑒𝑒2

4 ∙ 𝐶𝐶𝑟𝑟𝑒𝑒𝑟𝑟3 𝑊𝑊

𝑃𝑃 = 𝜔𝜔 ∙ 𝑇𝑇 𝑊𝑊



Instrumentation

Platform: Acquisition/control system River boat equipped with an ADCP system Electrical multimeter

Onboard instrumentation: Incremental encoder Moisture sensor Temperature sensors Water level sensor 3-axis inclinometer Miniature Prandtl probe



Perspectives

Experimental validation of the 1st prototype - Proof of concept - Feed-back for optimisation

Development of a serial industrial version - Tests of endurance - Water-to-wire solution - Island or network connected electrical solution

Large scale industrial deployment - Artificial waterways - Energy production - Supply of deployed instrumentation in isolated area

2016 – 2017 2017 – 2019 2020 – …



Acknowledgements

Partners of the Hydro VS – WP4 project:

Development team:

Project manager : C. Münch Hydraulic development : V. Hasmatuchi, A.Gaspoz, C. Münch Mechanical development : A.Gaspoz, J. Amacker, L. Rapillard with the support of N. Brunner (Stahleinbau GmbH) Electrical development : S. Richard, S. Chevailler

open-air laboratory for a new isokinetic turbine prototype

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