Two-Objective Optimization of a Kaplan Turbine Draft Tube Using a Response Surface Methodology

Riccardo Orso, Ernesto Benini, Moreno Minozzo, Riccardo Bergamin and Andrea Magrini
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Riccardo Orso: Department of Industrial Engineering, University of Padua, Via Venezia 1, 35131 Padua, Italy
Ernesto Benini: Department of Industrial Engineering, University of Padua, Via Venezia 1, 35131 Padua, Italy
Moreno Minozzo: ZECO S.r.l., via Astico 52/c, 36030 Fara Vicentino, Italy
Riccardo Bergamin: ZECO S.r.l., via Astico 52/c, 36030 Fara Vicentino, Italy
Andrea Magrini: Department of Industrial Engineering, University of Padua, Via Venezia 1, 35131 Padua, Italy

Energies, 2020, vol. 13, issue 18, 1-13

Abstract: The overall cost of a hydropower plant is mainly due to the expenses of civil works, mechanical equipment (turbine and control units) and electrical components. The goal of a new draft tube design is to obtain a geometry that reduces investment costs, especially the excavation ones, but the primary driver is to increase overall machine efficiency, allowing for a reduced payback time. In the present study, an optimization study of the elbow-draft tube assembly of a Kaplan turbine was conducted. First, a CFD model for the complete turbine was developed and validated. Next, an optimization of the draft tube alone was performed using a design of experiments technique. Finally, several optimum solutions for the draft tube were obtained using a response surface technique aiming at maximizing pressure recovery and minimizing flow losses. A selection of optimized geometries was subsequently post-checked using the validated model of the entire turbine, and a detailed flow analysis on the obtained results made it possible to provide insights into the improved designs. It was observed that efficiency could be improved by 1% (in relative terms), and the mechanical power increased by 1.8% (in relative terms) with respect to the baseline turbine.

Keywords: Kaplan turbine; draft tube optimization; CFD analysis; DOE; response surface (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2020
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (2)

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