Optimising the blades of a hydroelectric turbine for maximum efficiency, with strain gage measurements helping to find the right answers.
The "Iron Gate" / Djerdap Gorge dam. Source: Shutterstock
After being in operation for more than 30 years, the revitalization project of six turbines started in Serbia in 2009. The aim was to increase the installed power as well as the efficiency by 10%. The installed turbines on Đerdap1 are old Kaplan turbines with adjustable blades, and the old design needed change and optimization. The target was to determine, through extensive tests of operational states, where the ratio of produced electricity and consumed water was the largest. For this purpose, IEENT (The Institute of Nikola Tesla in Belgrade) in cooperation with MFB (The Faculty of Mechanical Sciences, University of Belgrade) and TRC PRO (Technical Research Center) designed a concept of how to measure the efficiency in real-time under working conditions. To gain the highest effort and increase, the power production of the turbine and the mechanical design of the turbine blades were calculated and designed according to the latest standards.
Team of technical experts performing the measurement. Image: TRC
Turbine runner is being prepared and reconstructed with new blades. Source: TRC
Axis 1
Axis 2
Axis 3
Axis 4
Shaft connecting turbine wheel and generator (where strain gauges are installed)
Protected measuring point (one out of four) with telemetry system.
Electric cabinet with PMX
In the second step, the desired and relevant information had to be calculated in real time. This can be done with the Smart Functions of PMX, which can be used by the operator very easily without having extensive software skills. They offer several mathematical functions, like a pocket calculator, logical functions, and process evaluations up to controller functions like PID-controller. To calculate the mechanical power, the following formula can be used:
Units: P: W; M: Nm; n: rpm.
PMX webserver overview with measuring signals, calculated signals, and I/O signals.
PMX web server with the power calculations
Screenshot from HBK catman application for torque and axial force measurement during data acquisition with PMX
Screenshots from catman application for torque and axial force measurement during data acquisition with PMX
Recording in HBK catman with startup of the turbine A4: Torque, axial force, rotational speed, and calculated power
Turbine and generator number A4, where measurements are performed (source: TRC PRO)
Team of technical experts performing measurements
Their multidisciplinary team is made up of top experts from various technical and technological sciences, qualified to efficiently and with top quality solve research and development and practical professional and engineering tasks in the areas of strategic studies in the power industry.
Faculty of Mechanical Engineering is an institution of national importance, basis for the development of mechanical science and industry.
A very helpful tool for parameterization, setup and control we found the PMX web server. We didn’t need any additional software and could use the standard web browser on our PC’s tablet or smartphone. And it is permanently available in real-time over the whole power-plant area
Strain gauges (often also referred to as strain gages) are the key asset for measuring fatigue and testing materials for better and safer products. Whether it is in structural durability testing, structural health monitoring, or the production of OEM transducers, HBK's optical and electrical strain gauges are the first choice.
Whether your application, is mobile or stationary, on a test cell or under extreme environmental conditions, HBK has the right measurement data acquisition system for your needs. Benefit from the unique "made by HBK" precision and reliability while enjoying the best possible price-to-performance ratio.
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