In recent years, large-capacity, high-head pump–turbine units have been developed for pumped storage power plants to effectively utilise water energy and store large amounts of electricity. Compared with the traditional Francis turbine unit, the radial distance between the trailing edge of the guide vanes and the leading edge of runner blades of high-head pump–turbine unit is smaller, so the rotor–stator interaction and the corresponding pressure fluctuations in the vaneless space of pumped storage units are more intense. The pressure fluctuations with high amplitudes and high frequencies induced by rotor–stator interaction (RSI) become the main hydraulic excitation source for the structures of the unit and may cause violent vibration and fatigue damage to structural components, and seriously affect the safe operation of the units. In this paper, the RSI of a high-head pump–turbine in turbine mode of operation is studied in detail by means of site measurement and full three-dimensional unsteady simulations. The results of RSI-induced pressure fluctuations in turbine mode are analysed experimentally and numerically. The accuracy of the numerical calculations is verified by comparing with the measured results, and the variation law of RSI is deeply analysed. The results show that the pressure fluctuations in the vaneless space are affected by the wake of the guide vane, the rotating excitation of the runner, the low-frequency excitation of the draft tube, and the asymmetric characteristics of the incoming flow of the spiral case, and shows significant differences in spatial position. The findings of the investigation are an important and valuable reference for the design and safe operation of the pumped storage power station. It is recommended to design the runner with inclined inlets to reduce the amplitudes of RSI-induced pressure fluctuations and to avoid operating the pump–turbine units under partial load for long periods of time to reduce the risk of pressure fluctuation induced severe vibration on the structures.

Reversible pump-turbine units of pumped storage power stations can generate power in turbine mode and store electric energy in pump mode for load balancing of the electric power grid. During the start-up transient process in pump mode of a reversible pump-turbine, the flow pattern and the pressure distribution in the flow channel change dramatically with the increasing opening angle of guide vanes. The unsteady pressure of the flow passing channel can cause severe vibration on the head-cover, bottom ring, and other stationary structures around the impeller. In this paper, a coupled 1D/3D co-simulation approach is developed to investigate the pressure distribution characteristics of the flow field during the start-up transient process in pump mode for a large prototype reversible pump-turbine unit. The entire model of flow channel from spiral casing to draft tube is constructed and the flow characteristics of key fluid fields such as spiral casing, stay vanes, guide vanes, impeller, and draft tube are analyzed. The simulation results show that under the condition of minimum guide vane opening the flow is insufficient and vortices occur on the impeller blades. The pressure distribution results of the flow channel from 3D fluid dynamic analysis during the start-up transient process in pump mode are exported as boundary conditions for the subsequent fluid-structure coupling analysis of the head-cover vibration investigation.

Pumped storage-power plants play an extremely important role in the modern smart grid due to their irreplaceable advantages in load peak-valley regulation, frequency modulation, and phase modulation. The number of start-stops per day of pump-turbine units is therefore also increasing. During the start-up transient process in turbine mode, the complex flow in runner passage, crown and band chambers, and seal labyrinth is able to induce severe vibration of non-rotating structures such as head cover, stay-ring, and pose a threat to the safe operation of the pump-turbine unit. In this article, the flow-induced vibration of the structures of a pump-turbine unit during its start-up process in turbine mode is studied. In the first place, this investigation establishes a three-dimensional model of the full flow passage and carries out a full three-dimensional CFD calculation based on one-dimensional pipeline calculation results for the start-up transient process. In the next place, by applying the fluid–structure interaction calculation method, the finite element analysis of non-rotating components of the pump-turbine unit is carried out. The flow-induced stresses and deformations of head cover, stay-ring, etc., are obtained and analyzed. The results reveal that the maximum deformation of the non-rotating structures is located at the inner edge of the head cover while the maximum stress appears at the trailing edge fillet of a stay vane. In summary, the dynamic stress of the non-rotating structures changes largely during the start-up process. The stress is strongly related to the axial thrust caused by the fluid flow. The achieved results can provide guidance for further fatigue life assessment of non-rotating structures and contribute to the structural safety design of pump-turbine units.

During the load rejection transient process of the prototype pump turbine units, the pressure fluctuations of the entire flow passage change drastically due to the rapid closing of guide vanes. The extremely unsteady pressure distribution in the flow domains including the crown chamber and the band chamber may cause a strong vibration on the stationary structures of the unit and result in large dynamic stress on the head cover, stay ring and bottom ring. In this paper, the numerical fluid dynamic analysis of the entire flow passage of a reversible prototype pump turbine during load rejection was performed. The flow characteristics in the runner passage, crown chamber, band chamber, seal labyrinths and balance tubes are analysed. The corresponding unsteady flow-induced dynamic behaviour of the head cover, stay vanes and bottom ring was investigated in detail. The analysed results show that the total deformation of the inner edge of the head cover closed to the main shaft is larger than that of other stationary structures of the unit during the load rejection. The maximum stress of the stay ring is larger than that of the head cover and the bottom ring and the maximum equivalent stress is located at the fillet of the stay vane trailing edge. The fluid–structure coupling calculation method and the analysed results can provide guidance for the design of stationary components of hydraulic machinery such as pump turbines, Francis turbines and centrifugal pumps with different heads.

In order to ensure stable grid operatiFon and improve power quality, active or passive load rejection of pumped storage power stations (PSPS) inevitably occurs from time to time. The rapid closing of the guide vanes will cause drastic changes in pressure pulsations in the flow channel of the pump-turbine (PT) unit. The high-level pressure pulsations during load rejection transfer to the entire flow passage of the PT unit and generate strong vibrations on the head-cover and the connecting bolts. In this study, the 1D/3D joint simulation of the pipeline in a pumped storage power station and the turbine flow channels including the flow domains of the runner, crown chamber, band chamber, upper and lower labyrinths and pressure balance tubes is carried out first. Then, by applying the calculated pressure loads on the head-cover, stay vanes and bottom ring of the PT unit, the flow-induced dynamic behavior of the structures including the head-cover bolts is analyzed in detail. The results demonstrate that pressure loads on head-cover bolts change dramatically during the load rejection process. The flow-induced deformation of the inner head-cover during the load rejection is larger than that of other structures, and the flow-induced displacement and stress of different head-cover bolts are not uniform. The achieved conclusions in this study can be a useful reference for the design and operation of head-cover bolts for other PT units and high-head Francis turbine units.