CA2438429C - Method of re-building francis turbine runners - Google Patents

Method of re-building francis turbine runners Download PDF

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Publication number
CA2438429C
CA2438429C CA2438429A CA2438429A CA2438429C CA 2438429 C CA2438429 C CA 2438429C CA 2438429 A CA2438429 A CA 2438429A CA 2438429 A CA2438429 A CA 2438429A CA 2438429 C CA2438429 C CA 2438429C
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CA
Canada
Prior art keywords
crown
runner
new
blades
band
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA2438429A
Other languages
French (fr)
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CA2438429A1 (en
Inventor
Alain Demers
Andre Coutu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Andritz Technology and Asset Management GmbH
GE Infrastructure Technology LLC
Original Assignee
Andritz Technology and Asset Management GmbH
GE Infrastructure Technology LLC
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Filing date
Publication date
Application filed by Andritz Technology and Asset Management GmbH, GE Infrastructure Technology LLC filed Critical Andritz Technology and Asset Management GmbH
Priority to CA2438429A priority Critical patent/CA2438429C/en
Publication of CA2438429A1 publication Critical patent/CA2438429A1/en
Application granted granted Critical
Publication of CA2438429C publication Critical patent/CA2438429C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00Restoring or reconditioning objects
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03BMACHINES OR ENGINES FOR LIQUIDS
    • F03B3/00Machines or engines of reaction type; Parts or details peculiar thereto
    • F03B3/12Blades; Blade-carrying rotors
    • F03B3/125Rotors for radial flow at high-pressure side and axial flow at low-pressure side, e.g. for Francis-type turbines
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F03MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
    • F03BMACHINES OR ENGINES FOR LIQUIDS
    • F03B3/00Machines or engines of reaction type; Parts or details peculiar thereto
    • F03B3/12Blades; Blade-carrying rotors
    • F03B3/128Mounting, demounting

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Hydraulic Turbines (AREA)

Abstract

A hydraulic turbine power house or installation has a rotatably mounted runner having a crown, a band and a plurality of original runner blades extending between the crown and the band. A method of retrofitting the runner with improved performance comprises the steps of removing the runner from the turbine power house or installation, removing the original runner blades from the crown, machining the surface of the crown to smooth the surface adjacent the removed original runner blades, affixing new runner blades with improved characteristics to the crown, securing the band to the runner blades to complete the assembly of the retrofitted runner, and re-installing the retrofitted runner in the turbine power house or installation.

Description

METHOD OF RE-BUILDING FRANCIS TURBINE RUNNERS
Field of the Invention The present invention relates to a hydraulic turbine runner and, in particular, to a method of re-building a Francis turbine or pump turbine runner utilizing the existing crown of the runner.

Background Of The Invention The output performance of hydro-electric power houses or installations that are twenty or more years old in operation may be improved by replacing the existing runner with a new runner whose blade design improves the efficiency of operation of the turbine and/or the power output of the turbine.
Typically, after twenty or more years of operation, the turbine runner blades operate with less efficiency and power output due to wearing of the runner blades. Further, substantial improvements in blade configuration have been made in the last twenty years.

Replacement of the turbine runner at a hydro-electric installation typically involves removing the turbine runner from the power house and replacing the old turbine runner with a new runner. The new turbine runner comprises a crown, a series of blades attached to the crown and a band surrounding the blades. The construction and assembly of each one of these replacement runners is time consuming and costly. Further, the turbine power house typically has anywhere from two to six or more turbines operating within the power house. These turbines are replaced one at a time since it is necessary for the power house to continue to generate hydro-electric power for the electrical power grid.

Accordingly, there is a need to provide these power houses with turbine runners of improved output performance which are less costly to manufacture than complete newly assembled turbine runners and are more quickly manufactured to reduce the time required to replace all turbine runners in the power house.

Summary of The Invention The present invention relates to a method of retrofitting a hydraulic turbine runner for improved performance whose blade design has improved characteristics that improve the efficiency of operation of the turbine and/or power output of the turbine runner. The method involves retrofitting a hydraulic turbine runner for improved performance by removing the original runner blades from the crown of the turbine runner. The method subsequently affixes new runner blades with improved characteristics to the crown and secures a band to the new runner blades to complete assembly of a retrofitted runner. The band may comprise either a new band or the original band reworked and affixed to the runner blades. Accordingly, the method of the present invention provides retrofitting the runner with new runner blades while reusing the crown and optionally permitting reuse of the band.

In one application of the invention, when replacing the turbine runners in a power house, a first turbine runner may be replaced with a complete newly assembled turbine runner. This allows for the power station to continue to operate with all turbine generators operating and permits for the removed runner to be retrofitted with new runner blades. By re-using the crown, significant cost savings in the manufacture of the retrofitted runner is recognized and the assembly of the retrofitted runner is typically quicker than assembling a complete runner including a new crown. This permits the next runner to be replaced in the hydro-electric power house to be removed and replaced with the retrofitted runner. As can be appreciated, in a power house having four hydro-electric installations with four turbine runners, it may only be necessary to replace one of the installations with a new runner and the other three installations may be replaced with retrofitted runners thereby providing a substantial replacement cost benefit to the hydro-electric power plant.

The method may further comprise machining the surface of the crown adjacent the original runner blades to smooth this surface prior to the step of affixing the new runner blades with the improved characteristics.

In an embodiment where the runner blades have lengths that are larger then the original runner blades, additional material is added to the surfaces of the crown so that the crown continues to lay over and support the runner blades.

In one embodiment a new band is utilized and in another embodiment, the original band is utilized and additional material may be added so that the original band lays over and supports any changes in the size of the replacement runner blades relative to the original runner blades.

In another embodiment a hydraulic turbine power house has a rotatably mounted runner having a crown, an original band and a plurality of original runner blades extending between the crown and the original band.
The method of retrofitting the runner for improved performance comprises of the steps of:

removing the runner from the turbine power house;

removing the original runner blades from the crown adjacent a surface of the crown;

machining the surface of the crown to smooth the surface adjacent where the original blades have been removed;

affixing new runner blades with improved characteristics to the crown;
securing one of the original band and a new band to the new runner blades to complete assembly of a retrofitted runner; and, re-installing the retrofitted runner in a turbine power house.
It should be understood that retrofitting may include re-building which may include repair and/or dismantling and reassembly with improved parts for a single turbine runner.

Brief Description of The Drawings For a better understanding of the nature of the present invention reference may be had to the accompanying diagrammatic drawings in which:
FIG. 1 is an elevational view, partially in cross-section, of a Francis turbine installed in a turbine installation of a power house;

FIG. 2 is an illustration of a Francis-type turbine shown removed from the power house; and, FIG. 3 is a partial sectional view showing the re-built runner.
Detailed Description Of The Invention The present invention relates to a hydraulic turbine runner and, in particular, to a method of re-building a Francis turbine or pump turbine runner utilizing the existing crown of the runner. It should be understood that any reference to turbine throughout the specification and claims may also equally refer to a pump-turbine.

Referring to FIG. 1 a portion of a turbine installation 10 of a power house is illustrated for use in the generation of hydroelectricity. It should be understood that in a power house, several turbine installations are typically located beside each other. This could range from two to six and more turbine installations 10 in the same power house or adjoining power houses at one hydro-electric power site.

Each turbine installation 10 has a water passageway 12. Water flows from an inlet 14 of passageway 12 to an outlet 16 located at a lower elevation. The water passageway 12 passes through a Francis turbine 18 having a turbine runner 20 and a draft tube 22. The runner 20 is secured by bolts 24 to a shaft 26 transmitting energy to a generator (not shown). The turbine 18 is mounted in a stationary casing 28 having a head cover 30 and a bottom discharge ring 32. The head cover 30, discharge ring 32 and draft tube 22 are embedded in concrete foundation 34. The draft tube 22 is also shown to diverge outwardly as the draft tube 22 extends in the downstream direction.

It should be understood that installation 10 includes other components such as, for example, stay vanes and wicket gates which are not shown.
Runner 20 is rotabily mounted in casing 28. The runner 20 has a crown 36 and a plurality of circumferentially spaced original runner blades 38 extending therefrom to an enclosing band 40. The runner 20 is better shown in FIG. 2 as a one piece assembly of the crown 36, runner blades 38 and the band 40. The original runner 20 may be assembled by welding or may have been formed as a one-piece casting.

In accordance with a preferred aspect of the method of the present invention, the runner 20 is removed from the installation 10 and shipped back to a turbine manufacturer for retrofitting. The retrofitting is accomplished by removing the runner blades 38 by cutting these blades from or adjacent the surface 60 of the crown 36.

The crown 36 is then machined so that its surface 60 is smoothed adjacent to where the runner blades 38 were previously affixed; thereby removing any excess blade material not removed from the crown 36 when the blades 38 are removed from the crown 36.

Next, new runner blades 80 as shown in FIG. 3, are attached to the surface 60 of the crown 36 by means of welding. As shown in FIG. 3, each new runner blade 80 has trailing and leading edges 50, 52 which are displaced downstream and upstream of corresponding trailing and leading surfaces 46 and 48 of the removed runner blade 38 as represented by broken lines in FIG. 3. As a consequence, the crown 36 has material added to its outer periphery 41. This material may be added by welding and is shown at 42. The material 42 is provided so that the refurbished crown 36 lays over and supports the new blade 80.

In FIG. 3, the original band 40 is also utilized and affixed to the new blade 80 by means of welding. The original band 40 also has additional material 44 added to one end of the band 40. It should be understood that in an alternative method, a new band of material may be affixed, by welding, to the blade 80 to complete the assembly of the new or retrofitted runner 82.
Further, it should be understood that the shape of the new blades 80 may differ from the shape of the original blades 38 whereby the new blades have improved characteristics.

The retrofitted runner 82 is then shipped back to the power house where it is re-installed.

While the invention has been described in connection with the above detailed description, it is to be understood to those skilled in the art that various modifications and arrangements may be made without departing from the scope of the invention described and claimed.

Claims (27)

1. A method of retrofitting a hydraulic turbine runner for improved performance, the turbine runner having a crown and a plurality of original runner blades extending between the crown and an original band, the method comprising the steps of:

removing the original runner blades from the crown adjacent a surface of the crown;

affixing new runner blades with improved characteristics to the crown;
and, securing one of the original band and a new band to the new runner blades to complete assembly of a retrofitted runner.
2. The method of claim 1 further including the step of:

machining the surface of the crown to smooth the surface adjacent where the original runner blades have been removed.
3. The method of claim 1 wherein the step of securing the band to the new runner blades comprises securing the original band to the new runner blades.
4. The method of claim 1 wherein the step of affixing the new runner blades to the crown comprises welding the new blades to the surface of the crown.
5. The method of claim 1 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
6. The method of claim 2 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
7. The method of claim 3 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
8. The method of claim 4 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
9. The method of claim 3 further including the step of adding material to the original band to modify the original band to lay over and support the new runner blades.
10. In a hydraulic turbine power house having a rotatably mounted runner having a crown, an original band and a plurality of original runner blades extending between the crown and the original band, a method of retrofitting the runner for improved performance comprising the steps of:

removing the runner from the turbine power house;

removing the original runner blades from the crown adjacent a surface of the crown;

machining the surface of the crown to smooth the surface adjacent where the original runner blades have been removed;

affixing new runner blades with improved characteristics to the crown;
securing one of the original band and a new band to the new runner blades to complete assembly of a retrofitted runner; and, re-installing the retrofitted runner in the turbine power house.
11. The method of claim 10 wherein the step of securing the band to the new runner blades comprises securing the original band to the new runner blades.
12. The method of claim 10 wherein the step of securing the band to the new runner blades comprises securing a new band to the new runner blades.
13. The method of claim 10 wherein the step of affixing the new runner blades to the crown comprises welding the new blades to the surface of the crown.
14. The method of claims 10 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
15. The method of claims 11 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
16. The method of claims 12 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
17. The method of claim 11 further including the step of adding material to the original band to modify the original band to lay over and support the new runner blades.
18. The method of claims 17 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
19. In a hydraulic turbine installation having a rotatably mounted runner having a crown, an original band and a plurality of original runner blades extending between the crown and the original band, a method of retrofitting the runner for improved performance comprising the steps of:

removing the runner from the turbine installation;

removing the original runner blades from the crown adjacent a surface of the crown;

machining the surface of the crown to smooth the surface adjacent where the original runner blades have been removed;

affixing new runner blades with improved characteristics to the crown;
securing one of the original band and a new band to the new runner blades to complete assembly of a retrofitted runner; and, re-installing the retrofitted runner in the turbine installation.
20. The method of claim 19 wherein the step of securing the band to the new runner blades comprises securing a new band to the new runner blades.
21. The method of claim 19 wherein the step of affixing the new runner blades to the crown comprises welding the new blades to the surface of the crown.
22. The method of claims 19 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
23. The method of claim 20 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
24. The method of claims 21 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
25. The method of claim 20 further including the step of adding material to the original band to modify the original band to lay over and support the new runner blades.
26. The method of claim 25 wherein the method further includes the step of adding material to the crown to modify the crown to lay over and support the new runner blades.
27. The method of any one of claims 1 to 26 wherein the hydraulic turbine runner is one of a Francis hydraulic turbine runner and a pump turbine runner.
CA2438429A 2003-08-22 2003-08-22 Method of re-building francis turbine runners Expired - Lifetime CA2438429C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA2438429A CA2438429C (en) 2003-08-22 2003-08-22 Method of re-building francis turbine runners

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA2438429A CA2438429C (en) 2003-08-22 2003-08-22 Method of re-building francis turbine runners

Publications (2)

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CA2438429A1 CA2438429A1 (en) 2005-02-22
CA2438429C true CA2438429C (en) 2013-01-08

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Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA2512126C (en) * 2005-07-14 2013-11-12 General Electric Canada Split francis turbine runner
FR2935761B1 (en) * 2008-09-05 2010-10-15 Alstom Hydro France FRANCIS TYPE WHEEL FOR A HYDRAULIC MACHINE, A HYDRAULIC MACHINE COMPRISING SUCH A WHEEL AND A METHOD OF ASSEMBLING SUCH A WHEEL
FR2974394A1 (en) * 2011-04-20 2012-10-26 Alstom Hydro France WHEEL FOR HYDRAULIC MACHINE, HYDRAULIC MACHINE EQUIPPED WITH SUCH WHEEL AND ENERGY CONVERSION INSTALLATION COMPRISING SUCH A HYDRAULIC MACHINE
CN103987956B (en) * 2011-10-23 2018-06-22 安德里兹水利有限公司 For the method for the compact blade and configuration runner of Fa Shi turbine discs
EP2942518B1 (en) * 2014-05-08 2019-03-20 GE Renewable Technologies Double-regulated turbine, installation for converting hydraulic energy and process for the rehabilitation of a double-regulated turbine

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