Modernization of vertical Pelton turbines with the help of CFD and model testing

The modernization of water turbines bears a high potential of increasing the already installed hydropower capacity. In many projects the existing waterways allow a substantial increase of the available flow capacity and with it the energy output. But also the upgrading onto a state of the art hydraulic, mechanical and electrical design will increase the available power considerably after the rehabilitation. The two phase nature of the flow in Pelton turbines requires for the hydraulic refurbishment special care in the application of the available design methods. Where the flow in the high pressure section of the turbine is mainly of one phase nature, CFD has been used as a standard tool for many years. Also the jet quality, and with it the exploration of the source of flow disturbances that cause poor free surface quality can be investigated with CFD. The interaction of the jet with the buckets of the runner is also examined by means of CFD. However, its accuracy with respect to hydraulic efficiency is, because of the two phase flow and the transient flow process, in very few cases good enough for a reliable and accurate prediction of absolute numbers. The optimization of hydraulic bucket profiles is therefore always checked with measurements in homologous scaled model turbines. A similar situation exists for the housing flow after the water is discharged from the runner. Here also CFD techniques are available to explore the general mechanisms. However, due to the two phase flow nature, where only a very small space is filled with moving water, the experimental setup in a model turbine is always the final proof for optimizations of housing inserts and modifications. The hydraulic design of a modernization project for a power station equipped with vertical Pelton turbines of two different designs is described in the proposed paper. It will be shown, how CFD is applied to determine the losses in the high pressure section and how these results are combined with the model tests carried out in the hydraulic laboratory. Finally a comparison is made in between the achieved model turbine results with measurements carried out in the prototype.