Research on the technical improvement of the turbine runner of a power station based on improving stability

Abstract In view of problems such as the narrow efficiency area, large hydraulic vibration area, pressure pulsation, and serious sediment wear of turbines at the Futang hydropower station, the technical transformation of turbine runners was carried out by modifying the blade shape and increasing the blade thickness, and a combination of numerical simulations based on shear stress transport k–ω turbulence model and tests was adopted to improve the operational stability of power station units. Calculation and testing demonstrate an enlargement of the high‐efficiency zone. Specifically, the optimal efficiency of the runner increases by 0.37%, while the rated efficiency rises by 0.19%. Significant reductions are observed in pressure pulsation within the draft tube and vaneless area decrease of approximately 50%. There is a high‐frequency pressure pulsation in the vaneless zone and the runner under low‐load conditions, and the influence of dynamic and static interference gradually weakens with the increase of opening. The draft tube is prone to eccentric vortex bands under partial working conditions, which causes the unit to be affected by low‐frequency pulsation. This optimization also leads to a notable decrease in runner blade wear, with the maximum sand and water velocity reduced from 45 to 40 m/s, resulting in a 30% reduction in sand wear. Moreover, there is a substantial enhancement in the runner's stiffness, with the thickness of the blade near the high stress area of the upper crown and lower ring increasing by over 50%, and the weight of each individual blade increasing by more than 50%. These research findings validate that modifying the runner blade effectively improves flow patterns, reduces eddy current generation, minimizes pressure pulsation, widens the high‐efficiency zone, decreases wear, and enhances the operational stability of the unit. The technical transformation method and research results of this study have important guiding significance for similar technical transformation of other power stations