6716879

ANL/ES-101
£ A
R
Evaluation of
Advanced Hydraulic Turbomachinery for
Underground Pumped Hydroelectric Storage
Part 2. Two-Stage Regulated Pump/Turbines
for Operating Heads of 1000-1500 m
C. A. Blomquist, A. A. Frigo, and J. R. Degnan
prepared for
U.S. DEPARTMENT OF ENERGY

under Contract W-31-1 09-Eng-38
\USTRKIUTIOM Of THIS DllCUh1BIT ~8 UNLIIfiTEil
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an agency of the United States Government. Neither the United
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ANL/ES-101
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EVALUATION OF ADVANCED HYDRAULIC TURBOMACHINERY

FOR UNDERGROUND PUMPED HYDROELECTRIC STORAGE
Part 2.
TWO-STAGE REGULATED PUMP/TURBINES
FOR OPERATING HEADS OF 1000-1500 m
by
,\
Carl A. Blomquist, Arthur A. Frigo, and .John R. Degnan*

Energy and Environmental Systems Division
Systems Engineering and Technology Group
October 1979
Work sponsored by
U.S. DEPARTMENT OF ENERGY

Assistant Secretary for Conservation and Solar Energy
Office of Advanced Conservation technology
*Allis-Chalmers Corp., Hydro-Turbine Div., York, Pennsylvania; services

,, provided under Argonne Contracts 31-109-38-4301 and 31-109-38-5078
f$TRHIUHfHIJ Of THIS OOCUMEU tg IJNlPMtT~

···r
THIS PAGE
WAS INTENTIONALLY
LEFT BLANK
'!
CONTENTS
ABSTRACT . . . . 1
1 INTRODUCTION 2
1.1 Description of Two-Stage Pump/Turbine and Components. 2
1.2 Types of Two-Stage Pump/Turbines . . . . 4
1.3 High-Head Turbomachinery . . . . 4
1.4 Advantages and Disadvantages of Two-Stage Pump/Turbines 9
1.5 Two-Stage Pump/Turbine State of the Art . .9
1.6 . Choice of Regulated Two-Stage Pump/Turbines 15
1.7 Developmental Studies . . . . . . . . . . . 16
2 PRELIMINARY DESIGN RESULTS: TWO-STAGE, TOP-GATED PUMP/TURBINES. 18

2.1 Mechanical Characteristics. . . . . 18
2.2 Hydraulic Characteristics. . . . . . 28
2.2.1 Selection of Specific Speed. 33
2.2.2 Design and Performance Parameters: Allis--Chalmers
Two-Stage Pump/Turbines . . . . . . 36
3 DETAILED ANALYSIS OF WICKET GATE AND DISTRIBUTOR COMPONENTS. 49

3.1 Wicket Gate . . . . . . . . 49
3.1.1 Wicket-Gate Design for 1000-m Head·, 500-MW Pump/
Turbine -- Design Generated by IRIS Program ... so
3 .1.2 Finite-Element Analysis for 1000-m-Head Wicket Gate. 52
3.1.3 Finite-Element Analysis for 1500-m-Head Wicket Gate. 53
3 .1.4 Life-Expectancy Analysis 64
3.2 Distributor Components . . . . . 68
3.2.1 IRIS Program Analysis . . 70
3.2.2 Finite-Element Analysis. .. 75
3.2.3 Shafting System Analysis 85
4 ·coST ANALYSIS. ·- 91
5 CONCLUSIONS. 93
GLOSSARY . . 94
REFERENCES. 107
ACKNOWLEDGMENTS AND CREDITS 108
FIGURES
·1 Sectional View of an Unregulated, Two-Stage Pump/Turbine. 5

2 Sectional View of a Top-Gated, Two-Stage Pump/Turbine . . 6
iii
FIGURES (Cont'd)
3 Sectional View of a Double-Gated, Two-Stage Pump/Turbine, 7

4 Comparison of the Stay-Vane and Wicket-Gate Thickness for a
Machine with a 500-m Head and One with a 1000-m Head. 8
5 Horizontal Shaft Arrangement of the Escher Wyss "One +One,"
Two-Stage Pump/Turbine·. . . . . . . . . . . . . . . . . 11
6 Vertical Shaft Arrangement of the Escher Wyss "One +One,"
Two-stage Pump/Turbine . . ; . . . . . . . . . . . . . 12
7 Sectional View of the Neyrpic-Proposed, Double-Gated,
Two-Stage Pump/Turbine for 300 MW. at 900-m Head . . . 13
8 Sectional View of a Double-Gated, Two-Stage Pump/Turbine
for a Head Range of 700-1200 m -- Being Developed by Voest-Alpine 14
Y Comparison ot the J:'ump-Mode Relat1ve Etticiency of Two-Stage,
Reversible Pump/Turbines: Both Stages Gated vs. Top Stage Only . .16
10 Plan View of a T~o-Stage, Top-Gated Pump/Turbine:
500-MW Capac'ity at 1000-m Head . . . . . . . . . . . . . . . . . . . . . 20
11 Elevation View of a Two-Stage, Top-Gated Pump/Turbine:
500-MW Capacity at 1000:-m Head . . . . . . . . . . . . 21
500-MW Capacity at 1250-m Head . . . . . . . . . . 23
13 Plan View of a Two-Stage, Top-Gated Pump/Turbine:
500-MW Capacity at 15UU-m Head . . . . . . . . . . . . 24
14 Elevation View of a· Two-Stage, Top-Gated Pump/Turbine:
500-MW Capacity at 1500-m Head . . . . . . . . . . . 25
350-MW Capacity at 1000-m Head. . . . . . ·. . . . 26
350-MW Capacity at 1000-m Head . . . . . . . . . . . . · . .. . 27
350-MW Capacity at 1250-m Head. . . . . . . . . . · .. ... 29
·350-MW Capacity at 1500-m Head . . . . . . . . . . . . . . . 30
19 Elevation View of a Two-Stage, Top-Gated Pump/Turbin.e:
350-MW Capacity at 1500-m Head . . . . . . . . . •. 31
20 Shaft Seal Design.for High-Head Pump/Turbine. 32
21 Distribution of Pumping Inefficiencies . . · . . 35
22 Available Synchronous Speeds for· Power Range of 250-750 MW and
Head of 125-1000 m.for Two-Stage Pump/Turbine .... 36
23 Turbine Performance Characteristics: 500 MW, 1000 m,
Two-Stage Machine . . . . . . . . . . 39
iv
,FIGURES (Con t ' d)
24 Pump Performance Characteristics: 500 MW, 1000 m,

Two-Stage Machine . . . . . . . . 39
Two-Stage MachiDe . . . . . . . . 40
Two-Stage 'Machine . . . . . . . . 40
Two-Stage Machine . . . . . . . . • l"e • • • •• • • • • • • • • 41
'Two-Stage Machine . . . .. . . . . 41
Two-Stage ·Machine . . . . . . . . . ..... . ...... •. 42
Two-Stage Machine . , . . . . . . . 42
31 Turbine Perfonuance Charac-teristics: 350 MW, 1250 m,
35 Comparison of Pump Performance of a Single- and Two:-Stage
Pump/Turbine with a 500-:MW Capacity at a 1000-m Head. . - . 4.5
36 Comparison of Turbine Performance of a Single- and Two-Stage
Pump/Turbine with a 500-MW Capacity at a 1000-m Head . . 46
37 Transient Simulation of a Turbine Head Rejection for ·a
Two-Stage Pump/Turbine. . ........... . 47
38 Transient Simulation of a Pump Power Failure for a
Two-Stage Pump/T~rbine. 48
39 Typical Wicket Gate . . 50
40 Comparison of Stem Size and Gate-Leaf Height for a 76-m-
and 400-m-Head Wicket Gate . . . . . . . . . . . • ... 51
l1l IRIS Program Wick8t-Gate Optimization_Proceilur.e -51
42 IRIS Program Wicket-Gate Model for the 1000-m-Head,
Two-Stage Pump/Turbine. . . . . . . . . . . . . 53
43 Finite-Element Model of a 1000-m-Head Wicket Gate 57
44 Gate-Squeeze Condition for the 1500-m-Head Wicket Gate. 59
45 Gate-Squeeze Contact Line Loading for the 1500-m-:Head Wicket Gate .• . 61
v
FIGURES (Cant 'd)
46 Shear-Pin-Failure Condition for the 1500-m-Head Wicket Gate 62

47 Corrosion-Fatigue Strength of 13% Cr-4% Ni Cast Steel . . . 65
48 Fatigue-Analysis Reference Diagram for the 1500-m-Head Wicket Gate. 69
49 IRIS Program Head cover': Thickness, Height, and Diameter Locations. 74
50 Stay-Ring Spiral-Case Sections . . . ·. 75
51 ·IRIS Program: Stay-:Ring Spiral-Case Geometry Description 76
52 IRIS Program: Stay-Ring Loading and Stay-Vane Stresses 79
53 Headcover Localized Effects ........ . . 80
54 Finite-Element Model of the Distributor Section of a Two-Stage
Pump/Turbine: 1000-m Head, 500-MW Capacity, Equal Head Per Stage 81
55 Location of Major Distributor Component Deflec.tions and Rotations
in a Two-Stage Pump/Turbine: 1000-m-Head, 500-MW Capacity,
Equal Head Per Stage. 84
·56 Shafting System Model for the Critical-Speed Study of a Two-Stage
Pump/Turbine: 1000-m Head, 500-MW Capacity, 50/50 Head Split . . 86
57 Shafting System Model for the Critical-Speed. Study of a Two-Stage
Pump/Turbine: 1000-m Head, 500-MW Capacity, .60/40 Head Split 89
58 Relationship Between the Two-Stage Pump-Turbine Capacity,
Head, and Cost Per kW . . ...... ; . . . , , , ...... 92
TABLES
1 Comparison of Certain Parameters of Single- and Two-Stage

Pump/Turbines of Identical Capacity and Head Rating . . . 10
2 Principal Mechanical Parameters of the Six Two-Stage Pump/Turbines. 19
·3 Material Specifications for the Major Components of a
Two Stage Pump/Turbine. . . . . . . . . . . . . . 22
4
.
Hydraulic Design Parameters for Two-Stage Pump/Turbines 38
5 Reactions, Deflections, and Stresses for 1000-m-Head Wicket Gate
during a ~ondition ot Gate-Squeeze at Maximum Static Head --
Data Generated by IRIS Program. . . . . . . . . . . . . . . . . 54
6 Reactions, Deflections, and Stresses for the 1000-m-Head Wicket
Gate during a Condition of Closed Gates at Pressure Rise --
Data Generated by IRIG Program. . . . . ~ . . . . . . . . · . . . 5.5
7 Reactions, Deflections, and Stresses for the 1000-m-Head Wicket
Gate during a Shear-Pin-Bre~k Condition -- Data Generated
by IRIS Program . . . . . . . . . ·. . . . . . . . . . . 56
8 Selected Results of Finite-Element and IRIS Analyses of .the
1000-m Head, Two-Stage, Pump-Turbine Wicket Gate. 58
vi
TABLES (Cont' d)
9 Basic Load Cases for the DANUTA Program . . 58

10 Selected Results of Finite-Element Analysis of the 1500-m-Head,
Two-Stage, Pump~Turbine Wicket Gate . . . . . . . . . . 65
11 R:esults of Life-Expectancy Analysis for a 1500-m-Head Wicket Gate 71
12 Results ·of IRIS Program Headcover Analysis at Pump-Shutoff
Condition for the 1000-m-Head, 500-MW-Capacity, Two-Stage
Pump/Turbine. . . . . . . . . . . . . . ~ . . . . . . . . . 73.
13 Res~lts of IRIS Program Spiral Case/Stay-Ring Analysis for

the 1000-m-.Head, 500-MW-Capac ity, Two-Stage Pump/Turbine. . 77
14 Headcover Deflections and Angular Rotations of Single- and
Two-Stage Pump/Turbine: 1000-m Head, 500-MW Capacity . . . 83
15 Selected Maximum Distributor· Component Stresses in a Two-Stage
Pump/Turbine: 1000-m Head, 500-MW Capacity . . . . . . . . 85
16 Nodal Element Dimensions for the Critical-Speed Analysis of
a Two-Stage Pump/Turbine Shafting System: 1000-m Head,
500-MWCapacity, 50/50 Head Split . . . . . . . . . . . . .
17 Added Weights .and Inertias for the Critical-Speed Analysis of a
Two-Stage Pump/Turbine Shafting System: 1000-m Head,
500..;_MW Capacity, 50/50 Head Split . . . . . . . . . . . . . 88
18 Nodal Element Dimensions for the Critical-Speed Analysis
of a Two-Stage Pump/Turbine Shafting System: 1000-m Head,
500-MW Capacity, 60/40 Head Split . . . . . . . . 90
19 Estimated Cost of Two-Stage, Gated Pump/Turbines . . · . 91
. 20 Percentage of Total Cost of Each Major Component of a
Two-Stage Pump/Turbine. . . . . . . . . ·. . . . . . 91
Vl.l.
1
EVALUATION OF ADVANCED HYDRAULIC. TURBOMACHINERY

FOR UNDERGROUND PUMPED HYDROELECTRIC STORAGE
Part 1.
1WO-STAGE, REGULATED PUMP/TURBINES
·FOR OPERATING HEADS OF 1000-1500 m
by
Carl A. Blomquist, Arthur A. Frigo, and John R. Degnan
ABSTRACT
This UPHS report applies, like Part· 1, to Francis-·

type, reversible pump/turbines regulated with gating systems.
TI:le first report, however, covered single-stage regulation;
this ·report· covers two-stage regulation. Development of· a
two-stage regulated pump/turbine appears to be attractive
because the proposed single-drop UPHS concept requires
turbomachinery with a head range of 1000-2000 m. With
tu~bomachinery of this range available, the single-drop
scheme offers a simple and economic UPHS option.
Six different two-stage, top-gated pump/turbines have

been analyzed: three that generate 500 MW and three that
generate 350 MW. In each capacity,· one machine has an
operating head of 1000 m, another has a head of 1250 m, and
the _third has· a head of 1500 m. The rated efficiencies of
the machines vary from about 90% (1000-m head) to about 88%
(1500-m head). Costs in 1978 $/kW for the three· 500-MW units
are: 20.5 (1000 m), 16.5 (1250 m), and 13.5 (1500 m).
Corresponding costs for the three 350-MW units are 23, 18,
and 14 $/kW .
. The authors foresee no major turbomachinery obstacles

that could hamper development of these pump/turbines.
Further model testing and development are needed before
building them.
2
1 INTRODUCTION
This report 1s the second in a series of three on turbomachinery

applicable to underground pumped hydroelectric storage (UPHS). The first
report! identified the need for and benefits of pumped storage, presented
a brief history of pumped storage, set forth the UPHS concept, described
reversible Francis-type pump/turbines and the development of singie-stage
machines, and discussed the components and general design characteristic of
reversible pump/turbines.· Much of this information is applicable to two-
stage machines and will not be repeated, except where needed for continuity
and clarification. .
A pump/turbine is an axial-, radial-, or mixed-flow hydraulic machine

that operates in one direction as a turbine and in the opposite direction as
a pump. These discussions will be limited to the radial-flow.machines, which
are designated as. "Franc is-t'ype." Hence, the terms "Franc is-type" and
"reVersibie" wiil be implied whenever ·the term "pump/turbine" is used in this
report. These pump/turbines are similar to the'original non-reversible
Francis turbines (named after J.B. Francis, who b~ilt the first well-designed
inward-flow; reaction, hydraulic turbine in 1849) except t~e runner is
designed basically as a pump impeller rather than as a turbine runner. This
design is· used because a good centrifugal pump will perform quite well as a
turbine when the direction.·is reversed, while the reversal of a Francis tur-
bine does not yield similar satisfactory results. The overall dimensions of a
pump/turbine are greater than those of either an equivalent turbine or pump.
There is a greater possibility of cavitation in the pumping mod'e than in the
generating· mode, because the head loss in the draft tube decreases the net
positive suction head. To avoid cavitation, the required submergence (verti-
cal distance between· th'e impeller runner centerline and the tail-water level)
for a pump/turbine is greater than that of an equivalent Francis turbine.
1.1 DESCRIPTION OF TWO-STAGE PUMP/TURBINE AND COMPONENTS
A two-stage pump/turbine can be described as two single-stage machines

joined in series and enclosed in the same housing. In th.e generating mode,
water enters the pump-turbine spiral case from an intake penstock connected
to an elevated reservoir. Water then flows through the stationary guide
vanes (stay vanes) attached to the stay ring; then it either directly enters
a runner (if the machine is ungated) or first passes through aqjustable wicket
gates (if the ·machine is gated) before entering the runner. The runner
receives the water. in an approximately radial inwards direction and discharges
it in an axial direction. The water flow is changed in the interstage
distributor from axial to radially outward, and reversed 180 degrees to
radially inward; at this stage, the water passes through a second set of stay
vanes, and then either enters a second runner (ungated bottom stage) or
.!mother set of wicket gates (double-gated machine) before entering the fir.st_:
stage runner. Once again, the runner changes the water flow from radial
inward at entrance to axial at discharge·. The water then flows through the
draft tube, into the tailrace, and finally into the lower reservoir.
The purpose of the spiral case is to p'rovide an even drstr ibution of

water around the circumference of the unit while maintaining an approximately
constant water velocity. The case is usually manufactured from steel and in
3
a number of pieces, a process dictated by shipping limitations and economy of

fabrication. The case is welded to the stay ring, which has two main func-
tions to perform. It must efficiently direct the water from the case to the
wicket gates or runner. This direction is accomplished by stay van~s fixed
in position and shaped to conform to the natural streamlines, which are
essentially spiral. The water velocity increases during the passage thro'ugh
the stay vanes because of the decreasing cross-sectional area. The stay ring
must also effectively resist the loads imposed upon it by the water pressure
in the case, and part of the generator load. Steel is generally used for the
stay ring, which may be cast integrally with the spiral case for high-head,
small-capacity machines. For large units, the stay ring and spiral case may
be cast· in sections, then the sections machined and bolted together; or they
may be produced by a combination of casting and fabrication.
Wicket gates (movable guide vanes) are devices that provide effective
and efficient control of the amount of water entering the runner in the
turbine mode. The wicket gate angular position and. the related gate opening
is controlled by a speed governor. Water is accelerated in the space betw~en
the gates and given a proper tangential velocity as it enters the runner.
Wicket gates are usually machined from steel castings; however, stainless
steel is used for high heads or silty water.
The prime purpose of the components described so far is to guide the

water to the runner with a minimum reduction in total energy. The purpose
of the runner is to convert this energy into useful work in the most efficient
manner. To accomplish this, it must change the direction of flow from approx-
imately tangential where it enters the runner to approximately axial where it
leaves. This flow change produces an axial reaction force, which does not
contribute a useful ·output. The runner must also change the velocity of the
water between inlet and outlet in such a way as to produce a maximum circum-
ferential force that produces the shaft torque for driving the generator. The
water must exit from the runner with· a minimum circumferential velocity to
achieve maximum efficiency. Runners are usually steel .cast in one piece where
feasible, but also have been made from steel plate and cast-steel components
welded into a single unit. Stainless st~el is used for high-head applications
or for service with water containing suspended particles. Stainless steel is
also· used as an overlay on mild-steel runner-blade areas that are subject to
cavitation eros~on.
The interstage components occupy the region between the· stay ring and
the discharge ring. This section contains the water passages, with supporting
columns, that guide the flow from the discharge of the top-stage runner to
the entrance of the bottom-stage runner. The interstage components are
usually made from cast steel, either in one piece or in sections that are
machined and bolted together.
The discharge ring (bottom ring, lower stay ring) connects the inter-
stage components with the draft tube, and contains the fixed stay vanes .for
the entrance to the bottom-stage runner. When the machine is double-gated,
the discharge ring also provides the seat for the wicket-gate stem and a
mounting surface for the wicket-gate control mechanism. The discharge
ring is fabricated from cast steel either in a single. section or ~n multiple
sections that are machined and bolted together.
4
The function of the draft tube, aside from acting as a conduit to

channel the water from· the runner to the tailrace, is to decelerate the water
at the runner exit to the velocity required for exit from the system with a
minimum loss. The velocity head recovered in this way· forms a part of the
total effective head on the turbine. Various types of draft tubes have been
used iri the past; today, however, the elbow type is used almost exclusively.
Starting as a cone at the runner exit, the elbow tube changes to a rectangular
section while turning through 90 degrees and increasing in area from runner to
exit. A plate-steel liner is usually provided for a short distance below the
runner exit, the remainder being formed in concrete. For very high heads the
liner may extend around the elbow of the tube.·
The headcover must be rugged, resistant to vibration, and able to

withstand the stresses and deflections resulting from the internal water
pressure. The headcover not only seals the opening required for runner
installation but also provides a seat for the wicket-gate stems and a mounting
surface for the wicket-gate control mechanism on a top-gated machine. Still
another of its functions is to provide support for the shaft bearing and seal.
The headcover can be made of cast or plate steel.
Pump-turbine shafts are machined from integral steel forgings ~n all

but the very largest sizes. The shaft has a flange, for bolting it to the
generator shaft, and an enlarged diameter in the region· of the guide bearing.
The runner is connected to the shaft by bolts that are accurately ground to
fit the reamed holes in the runner.
1.2. TYPES OF TWO-STAGE PUMP/TURBINES
There are three different types of two-stage pump/turbines: 1) non-

gated; 2) only the top stage gated; and 3) both stages gated. Non-gated
machines (Fig. 1) afford a very simple and inexpensive mechanical design;
however, such machines cannot regulate turbine output power. Since these
machines fall under the category of multistage, ungated pump turbines, they
will not be discussed here, but in Part 3 of this report series. Turbines
with the top s.tage regulated by wicket gates (Fig. 2) .have the advantage
-of a relatively simple mechanical design but allow only limited power control
within the band of acceptable performance. Machines with both stages regu-
lated (Fig. 3) allow a wide range of power at acceptable efficiency levels
while maintaining constant head drops per stage. The obvious disadvantage of
a double-gated machine ~s its relatively complex and expensive mechanical
design. ·
1.3 HIGH-HEAD TURBOMACHINERY
With increasing developments ~n high-head, single- and multistage

pump/turbines, a_ logical extension to the technology is the two-stage, gated
pump/turbine. The single-drop UPHS concept requires turbomachinery with a
1000-2000-m head range. Presently this requirement can ·only be met by a
multistage ungated pump/turbine or by a tandem unit consisting of a Pelton
turbine and multistage pump. Both of the·se approaches, however, have dis-
advantages. The machinery they require is currently limited in capacity
because of component manufacturing and shipping restrictions; it is expensive;
5
SPIRAL
CASE
(
Lil.c;:r=====\\- - - - - - --\-
\
;
Fig. 1. Sectional View of an Unregulated (Non-Gated),

Two-Stage Pump/Turbine
6
STAY VANES
ljO
SCALE ·CM
Fig. 2. SeL:Liuual View of a 'l'op-t;ated, Two-Stage Pump/Turbine
and the power of the multistage pump/turbine cannot be regulated. The problem
with single-stage turbomachinery, on the other hand, concerns the practical
upper limit of its head nmge. The highest head, single-stage, regulatPtl
puutp/Lurbine in the world today is the 620-m-head unit being installed at the
Baj ina Basta Power Station in Yu~oslavia .1 ThPrP i ~ n0 th"oretical head
limit for single-stage reversible pump/turbines, but there are different views
on the upper limit for this machine. Flodl and Strohm~;>r2 state that the
head limitation for an economically justifiable application of a single-stage
arrangement will probably be at about /00 m; the unit capacity will exceed 500
MW. Chacour et al.3 believe that it is possible to supply reliable, single-
stage machines for heads of 1000 m. Amblard4 thinks that for heads beyond
600-700 m, multistage pump/turbines should be used.
The problems in designing high-head, single-stage machines are hydrau-

lic, mechanical, and construe tional. Hydraulic problems refer to the choice
of specific speed, losses, and cavitation. Pump-eye le specific speeds below
23 rpm (m3/s)0.5 (m)-0.75 are undesirable because the efficiency level is
low.5 At these speeds the ratio of the runner height to diameter is small and
the runner takes the shape of a flat disk. This shape results in significant
fluid frictional losses, and leakage losses in the labyrinth seal. If the
7
J
·
SPRAL
CASE
Fig. 3. Sectional View of a Double-Gated, Two-Stage Pump/Turbine
specific speed ~s increased to improve efficiency, problems may arise from

excessive flow velocities in the spiral case and runner; and also from the
higher rotational speeds of motor/generators, which may require water cooling
instead of air. Hydraulic losses will also result from the increased thick-
ness of the stay vanes and wicket gates (Fig. 4) . With high head s , seal
clearances become important. A de fleet ion of the headcover by a fe w tenths
of a millimeter increases the clearance at the wicket-gate faces, t hereby
increasing the losses within the machine. A further problem is pres en ted by
cavitation during the high-head machine's operation as a pump, bec au se the
intensity of ero si on varies with the 3rd power of the head. A pr essure
depression occurs at the runner blade inlet, and this is the most signifi-
cant factor causing cavitation. Therefore, careful attention must be paid to
the design of the runner-blade leading edges and to providing sufficient
submergence.
Mechanical problems are related to the static and dynamic loads

developed in the machine. To accommodate the higher stresses resulting from
high heads, the machine components such as the stay vanes, wicket gates,
runner blades, headcover, etc., must be thicker. Problems also occur during
8
_ _ _ 1000m
500m
STAY VANE
WICKET
Fig. 4. Comparison of the Stay-Vane and Wicket-Gate

Thickness for a Machine with a 500-m Ho?.ad
and One with a 1000-m Head
turbine runaway and pump braking, where intense pressure surges give rise to
high torque fluctuations on the wicket gates, to torque variations on the
shaft, and to varying radial thrusts acting on the runner. These pulsating
forces increase in proportion to the head.
Construction problems arise from the increased mass of the components.

To facilitate machining and shipping, components may have to be fabricated in
several sections; this causes additional design constraints, increases field
assembly work, and adds materially to the machine cost. For a given output,
the physical size of a pump-turbine runner decreases as the head increases.
The water passage height is reduced and its length is elongated, which pre-
sents problems in casting and surface finishing. Core deformation, which can
occur during casting of the runner, must be avoided at all costs. The small
water passages permit grinding of the blades to obtain the desired profile and
surface finish only at the extremities. To alleviate these problems, the unit
· capacity must be quite large. For a runner water passage height of 100 mm,
the capacity of a single-stage pump/turbine for a 1000-m head must be greater
9
than 280 MW for rotational speeds of less than 720 rpm.5 On the other hand,
it is very difficult to design one-piece headcovers for runner diameters
larger than 4 m; hence, an upper limit for the capacity results.
1.4 ADVANTAGES AND DISADVANTAGES OF TWO-STAGE PUMP/TURBINES
The two-stage, gated pump/turbine is the logical extension of single-

stage technology for high-head applications. When the head is divided over
two stages, the operating head range becomes twice that of a single-stage
machine. Limiting the head per stage leads to a more suitable choice of
specific speed. The submergence requirements and water velocities are
less than those of a single-stage machine. Both of these factors strongly
influence cavitation. The smaller submergence requirement also reduces
underground construction costs. Smaller pressures and pressure fluctuations
per stage reduce the dynamic forces acting on the runner, wicket gates, and
stationary components. The lower rotational speed of the two-stage machine
may result in the use of a conventional and more economical motor-generator.
When compared with multistage pump/turbines, which are inherently

unregulated, a two-stage unit allows power control in the turbine mode. In
the pumping mode, adjusting the wicket-gate opening allows a suitable head/
flow ratio, which is advantageous for plants with wide water-level variations.
Pump starting is easier with the wicket gates closed and the machine un-
watered. The power required for starting is about 15% of maximum, whereas for
an unregulated turbine the power requirement can be 65-70% of maximum.
Two-stage, gated units do have certain drawbacks. They require, for

example, that each stage be designed for pressures resulting from the total
head; their leakage losses exceed those of ungated multistage units; and they
have interstage efficiency losses. The main hydraulic problem is to find an
arrangement for and shape of the guide vanes and return vanes between the
first and second stages. That will give acceptable flow conditions and
efficiencies in both pump and turbine operating modes.
Table 15 compares two pump/turbines that have the same capacity and
head ratings (100 MW at 550 m) but different means of regulation -- one is
regulated in two stages, the other in a single stage. The two-stage arrange-
ment results in a reduced submergence and runner diameter, plus an increase in
efficiency. The 25% increase in price of two-stage regulation can often be
compensated for by savings in civil engineering costs, because this arrange-
ment requires only about half the suction head needed for single-stage
regulation.
1.5 TWO-STAGE PUMP/TURBINE STATE OF THE ART
A two-stage, gated pump/turbine has not yet been installed in service.

Based on European ideas dating back several decades in connection with storage
pumps, however, Escher Wyss5 has conducted investigations and completed essen-
tial model tests for a two-stage pump/turbine with adjustable wicket gates.
The wicket-gate system of the bottom stage, in the turbine-flow direction, is
designed so that the full head cannot develop between the top and bottom
stages. One set of wicket gates would simp! ify the mechanical design, but
10
Table 1. Comparison of Certain Parameters of Single-

and Two-Stage Pump/Turbines of Identical
Capacity and Head Rating (100 MW at 550 m)
Method of Regulation
Parameter Single-Stage Two-Stage
Speed, rpm 600 600

Speci fie speed, 26 40
Runner outside diameter, m 3.15 2.40

Net positive suction head, m 66 34
Efficiency change, % 0 +0.5
Cost differential, % 0 +25
the efficiency drop-off from the peak would be much steeper than with two-
stage regulation.
An earlier Escher Wyss proposal,6 called the "One + One" arrangement,

basically combines two single-stage reversible pump/turbines of proven
design in series to form a two-stage machine. In the horizontal shaft
arrangement (Fig. 5), the two pump/turbines are arranged on either side of
a common motor/generator, with overhung runners. The machines are connected
by a pipe leading from the volute discharge of the first-stage unit to the
inlet of the second-stage machine. The connecting pipe helps to even out the
flow, resulting in an acceptable flow pattern -- during both turbine and pump
operation -- at the entrance of the second stage. The overhung-runner
arrangement provides a very simple bearing design; eliminates the shaft
through the runner eye; requires only one shaft-seal arrangement per stage;
greatly reduces critical-speed problems because the motor-~PnPrRtor shaft can
be made extremely stiff; makes the machine very simple in its mechanical
layout; and provides optimum accessibility for repair and maintenance. In
addition, the symmetrical arrangement of the two units balances the hydraulic
thrust so that the problem of high axial thrust is reduced. A governor and
servomotor arrangement similar to tho~;;P <~pplied to multijet and multirunncr
~elton turbines would be used to guarantee simultaneous movement of both sets
of wicket gates. For safety reasons, both machines would be designed for the
full-pressure stresses.
A vert i r.Al shaft of the "One + One" arrangement (Fig. 6) requires that
both machines be separated from each other to facilitate accessibility and
to provide space for an intermediate bearing and wicket-gate mechanism. The
"One + One" arrangement requires more space than a gated, two-stage machine;
but the efficiency should be slightly higher because both stages are volute
stages and better flow conditions can be expected, especially in part-load
turbine operation.
ll
Fig. 5. Horizontal Shaft Arrangement of the Escher Wyss

"One + One," Two-Stage, Pump/Turbine
(Source: Escher Wyss Ltd.)
A double-gated, two-stage pump/turbine (Fig. 7) with a capacity of 300

Mw and a head rating of 900 m is proposed by Neyrpic. 4 The two runners and
distributors would be dismantled from below, because upward removal of the
second (top) stage would require the removal of the smaller-diameter motor-
generator stator. The spiral case is a double-shell type, which reduces the
length and consequently the weight of the stay vanes. This spiral-case
concept already has been used by Neyrpic on the Brommat Francis turbine
( 240-MW capacity, 255-m head, and 250-rpm speed). The shaft is supported
by four guide bearings, two for the pump/turbine and two for the motor-
generator. The preliminary design of each distributor was based on the
maximum head because the possibility cannot be excluded that the first
(bottom) stage of the wicket gates will be closed at the same time that one or
several or the wicket gates on the second (top) stage are partially open
because of an obstruction.
Electricit~ de France has placed an order with Neyrpic for design

and fabrication of a double-gated, two-stage, reversible pump/turbine (35-
40-MW capacity, 440-m head, 750-rpm speed) for its forthcoming Le Truel
Plant in the central mountainous region of France. The model of this unit has
been built and is undergoing testing.
Voest-Alpine2 has the goal of developing a double-stage, double-

controlled, reversible pump/turbine with a head range of 700 m to 1200 m.
This machine (Fig. 8) is basically two single-stage reversible pump/turbines
connected back-to-back. It is a variation of the "One + One" vertical shaft
arrangement (Fig. 6). There are 16 wicket gates in each stage, all of them in
pairs; the gates in each pair are rigid1y connected to each other by a tooth
coupling and a stretch screw. Tile gates are supported by five bearings and
are adjusted by one regulating ring, with two servomotors, to assure synchro-
nous control. The separate gate control of the "One + One" arrangement may
cause asynchronous problems. Wicket-gate torque vibration caused by the
pulsating flow at the runner circumference is reduced by bearing friction and
12
b'ig. 6. Vertical Shaft Arrangement of the Escher Wyss

"One +One," Two-Stage Pump/Turbine
(Source: Escher Wyss Ltd.)
13
~~
~-=- - 1- ~·
I
:. ·. ~ .'
· ... - ..
·, .:·.. ..•. ;...' , · :· ,,
'
' (.'..
. ~-·.- ..~ . : ..
. .. -..
·.
.-... .. '
I I
Fig. 7. Sectional View of the Neyrpic-Proposed Double-Gated,

Two-Stage Pump/Turbine for 300 MW at 900-m Head
(Source: Neyrpic)
14
Fig. 8. . 1 View of a b Two-Stage Pump /Turbine

b
Sectl.ona d Range of Dou le-Gated, .
__ Be 1.ng Developed y
for a Rea . (Source:700-1200 m · e AG)
Voest-Alpl.ne Voest-Alpl.n
15
by staggering the blades on both runners half a space circumferentially. Tbe

crown-to-crown arrangement of the two runners causes a reduction in axial
thrust, and the remaining amount is controlled by labyrinths. Hydraulic
radial forces are nearly compensated for by two spiral cases whose baffles are
staggered 180°. The spiral cases are embedded in concrete. Three guide
bearings are provided for the shaft which passes through both draft elbows.
Water is led from one stage to the other through a connecting elbow pipe which
equalizes the flow gives causes a large radial extension to the pump-turbine
configuration. The design provides easy access to the bearings, shaft
seal, and runner -- and makes the machine relatively easy to assemble and
disassemble. Startup of the unit in the pumping mode is with a dewatered
machine. Both stages are filled simultaneously, starting with the draft
elbow; air escapes from the upper part of the elbow pipe; water from the
penstock is used to fill the high-head stage.
After optimization of the components, the efficiency loss in the elbow

pipe connecting the two stages is estimated to be approximately 0. 5%. 1h is
loss is less than would occur in a more conventional two-stage, double-gated
pump/turbine, because the latter machine has higher friction and eddy losses
in its interstage diffuser.
1.6 CHOICE OF REGULATED TWO-STAGE PUMP/TURBINES
The two-stage pump/turbine, with both stages independently regulated

by a servomotor system · and a minicomputer, provides the ultimate in control
and gives higher efficiencies at all gate openings other than the peak-
efficiency gate opening. Two-stage regulation requires the most complex
and expensive design. The bottom gates, in addition, must have a positive
restraint to prevent closing past a set of minimum gate openings in order to
eliminate the possibility of the bottom stage undergoing a full pressure rise
during transients. Independent regulation of the wicket gates could result in
pressure pulsations if a small asynchronism occurs during control.
When only the top stage of a two-stage machine is gated, machine power
is controlled at acceptable efficiencies and the gate-operating system stays
relativPly simple. Gating the top stage will minimize the pressures seen by
the bottom stage during transients. The unregulated stage has the same
behavior as a conventional uncontrolled machine; each head corresponds to one
turbine output. The unregulated stage is rated for nominal load in both flow
directions, so that both stages are operating with the same head and output.
During the generating mode, decreasing flow adds · to rotational losses, and
therefore efficiency is reduced. During the pumping mode, the difference in
~::fficiency between top-gaterl ;mel clouble-gated pump/turbines is small, as
shown in Fig. 9 (where relative efficiency is the ratio of actual to maximum
efficiency).
The proper choice of machinery for a pumped-storage plant depends on

a number of factors, mainly the plant configuration (number of units and
total installed capacity) and the power demand imposed on it. Plants with a
total installed capacity of 350 to 1000 MW, and consisting of one or two
pump/turbines, will benefit from a daub le-gated design. For plants with
several units, the best compromise between design simplicity and operational
16
1.00
0.98
>-
(.)
z
UJ 0.96
(.)
u.
u. 0.94
UJ TOP GATED
UJ
> 0.92
t-
<
_J
UJ 0.90
a:
0.88
0.5 0.6 0.7 0.8 0.9 1.0
RELATIVE PUMP FLOW
Fig. 9. Comparison of the Pump-Mode Relative Efficiency

of Two-Stage, Reversible Pump/Turbines: Both
Stages Gated vs. Top Stage Only
flexibility appears to be the top-gated pump/turbine. The power output of

machines regulated in this way can be controlled by shutting off snme units
::md operating ulhers near their optimum efficiFmcy.
1.7 DEVELOPMENTAL STUDIES
Considering the requirements of UPHS facilities (>1 000 MW at 1000-

2000-m head), the development of a two-stage regnlAtPil pump/turbine appear::; Lu
be very attractive. Therefore, in 1978, Argonne National Laboratory initiated
preliminary engineering design and cost studies for these machines. The
Allis-Chalmers Hydro-Turbine Division, York, Penn., was commissioned to
conduct these investigations. The goals of the study have been:
• To develop the design technology for two-stage, regulated

pump/turbines operating under water heads of 1000, 1250,
and 1500 m and developing power capacities of 350 and
500 MW;
• To generate preliminary machine configurations for the
specified operating conditions, so that model designs and
model testing procedures and standards can be developed to
support future model-testing programs;
17
• To evaluate the major hydraulic and mechanical parameters

associated with the performance and design of these
machines; and
• To estimate the corresponding costs for fabricating these
machines.
Allis-Chalmers has determined that the top-gated machine ~s the most

applicable type of two-stage pump/turbine for UPHS facilities.
18
2 PRELIMINARY DESIGN RESULTS: TWO-STAGE,

TOP-GATED PUMP/TURBINES
2.1 MECHANICAL CHARACTERISTICS
Six two-stage, top-gated machines were designed and evaluated for this
study. Three machines, shown in Figs. 10-14, had the same 500-MW capacity and
different operating heads: 1000, 1250, and 1500 m. The other three machines,
shown in Figs. 15-19, had the same 350-MW capacity and different operating
heads: 1000, 1250, and 1500 m . Plan views have not supplied for the two
1250-m-head machines because of their similarity to the 1000-m-head machines.
The principal mechanical characteristics of these six pump/turbines are
presented in Table 2, and the materials specified for the major components are
1 is ted in Table 3. Design of some of the basic components such as gate-pin
circle, runner, wicket gate, and spiral case configurations was performed by
the IRIS computer program, 7 developed at Allis-Chalmers in 1975-76 specifi-
cally for the automatic design of high-head pump /turbines. Other components
such as Lhe stay ring, intermediate water passage, and the shafting were
designed by a careful layout coordinated with the IRIS-designed components.
Because of the small physical size of the 350-MW, 1500-m machine,

two new approaches were used in its design. First, because access to th e
inside of the headcover was impossible, a different design for the gate
bushing was required. Therefore, this machine is equipped with a special
bearing cartridge for gate placement and removal (Fig. 18). The cartridge
serves for both upper-gate journal bearings; it also provides thrust resist-
ance against the upper-gate collar. Second, because the 350-MW, 1500-m
machine has a small gate-pin circle, an outside gate linkage must be used
instead of the conventional inside arrangement used on the other five pump/
turbines. The main advantage of the insiclP l inkage arrnngcment i s iLo minimum
encroachment on the powerhouse struc tnrP And turbine pit area. The gate ring
also becomes a much larger and A more flexi.hle structure wl1ich affects the
space requirements in the pit region. The outside linkage configuration
requires a more complex servomotor anchorage into the power house, as well as
a more expensive pit-liner design. This design, although less convenient, is
certainly reliable and has been proved a viable mPRns of governing the gates
as an alternativE> when thP inside g.:tte ring is 110L practical.
In many multistage pump/turbine designs, there 1s a shaft extending

through the draft tube, and this arrangement can increase cavitation and
lower efficiency. The Allis-Chalmers design was chosen to eliminate the need
for, and the complications of, a gnicle bearing below the lowet runner; and
hence to eliminate a shaft extending through the draft tube of the lower
stage. The pump/turbines were initially designed to develop equal heads per
stage, thP. usual characteristic of multistage machines. BP.cause of the
additional shaft length and the high overhung mass of the runners at a rela-
tively largE> clistance below the guide bearing, the critical speeds of the
shafting system are lower than normally obtained with single-stage pump
turbines.
The runner and shafts of a pump/turbine must be carefully designed in

cooperation with the motor-generator manufacturer, because of the combined
19
Table 2. Principal Mechanical Design Parameters

of the Six Two-Stage Pump/Turbines
Head and Power Capacity

1000 m, 1250 m, 1500 m, 1000 m, 1250 m, 1500 m,
Mechanical Parameter 500 MW 500 MW 500 MW 350 MW 350 MW 350 MW
Shaft rotational
speed, rpm 450 600 720 514.3 720 900
Main shaft diameter, m 1.321 1.194 1.118 1.118 1.168 0. 927
Gate pin c ire le
diameter, m 5.192 4.356 3.962 4.552 3.632 3.195
Second (top) stage
runner outside
diameter, m 4.552 3.820 3.475 3.993 3.185 2.802
First (bottom) stage
runner outside
diameter, m 3.R30 3.216 2.921 3.365 2.680 2.367
Second (top) stage
distributor pad
height, m 0.318 0.269 0.229 0.291 0.229 0. 211
First (bottom) stage
distributor pad
height, m 0.375 0.318 0.274 0.338 0.268 0.249
Outside diameter of top
stage guide vanes, m 7.988 6.909 6.452 7.036 5.766 5.169
Number of runner blades 7 7 7 7 7 7
Spiral case inlet
diameter, m 1.873 1.588 1.391 1. 676 1.327 1 .219
Draft tube diameter
at bottom stage
discharge, m 2.101 1. 772 1.567 1.872 1.483 1.351
Number of wicket gates
(top stage) 20 20 20 20 20 20
Number of stay vanes
( t np ::;tage) 20 20 20 20 20 20
WICKET GATES
TOP STAGE
STAY VANES
N
0
BOTTOM STAGE
STAY VANES
l!jO
Fig. 10. Plan View of a Two-Stage, Top-Gated Pump/Turbine: 500-MW Capacity at 1000-m Head
SHAFT
II
WICKET 3ATES
1¥>
SCALE· CII
Fig. 11. Elevation View of a Two-Stage, Top-Gated Pump/Turbine: 500-MW Capacity at 1000-m Head
22
Table 3. Material Specifications for the Major Components

of a Two-Stage Pump/Turbine
ASTM Material Minimum Yield

Component Specification Point, MPa
Head cover A537 Class I 345

Stay ring A148 Grade 90-60 414
Spiral case A157 Class F 689
Runner (both stages) A296 Grade CA6NM 758
Wicket gate A296 Grade CA6NM 758
Shaft A668 Class D 259
Bottom stage embedded components A148 Grade 90-60 414
- -- -
effect of the turbine and generator loading, bearing stiffness, shaft length,
etc., on the shafting system characteristi~s. ThP m~ximum allowable toroional
shear stress is limited to 42 MPa in the main turbine shaft. The critical
speeds of a shafting system great~y depend on its stiffness and the distribu-
tion of its mass, both of which are established by the system configuration
and material properties. In the absence of the motor-generator information,
shafting lengths, stiffness, and bearing locations were selected on the basis
of static analysis and experience. A criticAl-speed analysis was performed on
the 1000-m machine with each stage generating eqna 1 power, and the lateral
critical speed was found to be 496 rpm; this value was uncomfortably close to
the normal operating speed of 475 rpm. ThPrPfnre, it was necessary to change
the stiffness and/or configuration of the tnrhinP Pnl'l of the shafting nyotcm.
The design criteria was changed to use stiffer bearings and concentrate as
much ov~Lhwtg r:unner mass as close as possible to the turbine guide bearing.
The result was a top (second) stage that develops 60% of the power and a
bottom (first) stage that develops 40%. Further critical-speed studies
revealed that the modified configuration was effective in increasing the
margin between the operating speed and the critical speed. These stud i ~s are
discussed later in the report.
The runner used in high-head pump/turbines is of heavy construction.

Great care was taken to match the crown, band, anrl blade thickness; this
permits each of the three members to carry its share of the loads and momPnts
without unnecessarily constricting the others. The matching is evident at the
outside periphery of the runner, where the crown and band are thinned down so
that they gradually correspond to the edge of the blade (see Figs. 11, 12, 14,
16, 17, and 19). Tapering of the band and crown periphery has eliminated
fatigue cracking problems at the discharge edge of the runners. The runner
torque is transferred to and from the shaft through heavy body-bound bolts
that are accurately ground to fit the reamed holes in the runner and are
prestressed during field assembly.
Shaft and runner seals require careful design to prevent leakage

losses, Which reduce the turbine output and therefore reduce efficiency. The
HEADCOVER
SPIRAL
CASE
DISCHARGE
RING
I¥J
SCALE ·CII
TOP STAGE
STAY VANES
/--t
BOTTOM STAGE
STAY VANES
'¥'
SCALE-CII
Fig. 13. Plan View of a Two-Stage, Top-Gated Pump/Turbine= 500-MW Capacity at 1500-m Head
SHAFT
1/
I
N
V1
lfjO
SCALE·CII
TOP STAGE
STAY VANES
0
I '¥>
SCALE-CM
Fig. 15. Plan View of a Two-Stage, Top Gated Pump/Turbine: 350-MW Capacity at 1000-m Head
-------·~SHAFT
.,
l (
9 l!jO
SCALE-CII
28
runner seal ~s located at the small diameter of the band on each runner.
During synchronous condensing operation, an appreciable amount of heat is
generated by the runner rotating in pressurized air; therefore, the tempera-
ture of the runner has to be closely controlled in order to limit its thermal
expansion within seal clearances. The shaft seal is a newly developed
mechanical seal (Fig. 20) that provides easy access to its parts and a
simplified alignment of the pump/turbine. Seal clearances are kept as small
as possible but are dictated by the deflection of the runner shaft system and
radial growth of the runner band at runaway speed. The seal clearance cannot
be specified because of the lack of design information on the motor-generator,
shafting, and associated bearings.
Due to the long overhung length of the turbine shafting below the
guide bearing in the headcovPr, large radial deflections may occur during
transient loading conditions; this condition must be accouuuudated without
compromisiu~ propt=>r l'lP.al ing nnn I:Jt!l. furmartce. Therefore' the interstage seal
was designed so that during transient loadings, it will serve as a secondAry
guide-bearing. A carhnn-impregnated malerial was deve loped whif'li nisioto
corrosion ~ud hA<~ varying deg1.ees of self-lubricating and load-carrying
capacity. If contact should occur nur ing ohort t1.ansient periods between this
stacionary-seal material and the rotating shaft, the seal can indeed function
as a self-lubricated guide-bearing .
Special stress and deflection studies were performed on the wicket

gate for the 1000-m machine. The same gate was checked for use in a machine
operating under a net water head of 1500 m. These results, along with the
analysis of the headcover and stay ring/spiral case, ace presented in Sec. 1.
2.2 ~YDRAULIC CHARACTERISTICS
When pumped storage plants are planned, thP time schedule fur pump and
turbine operaL.ion is generally based on thP- gr.id-loading plau. From this
time schedule, a desirable ratio between the turbine and pump capacity is
obtained. For regulated pump/turbines this performance ratio can be varied
only within certain limits. For a given pump power and head, the full-load
point is chosen so that it lies between the point of optimum efficienr.y and
the point o£ maximum wicket-gate openin~. The maximUlll capacity ratio lies
between 1.1 and 1.4, with a ratio between pumping and turbining heads of
approximately 1.2.
Selecting a pump/turbinP is to some e.x.Lent a matter of compromise as

to whether turbine or pump operation is favored. The l>eoc-effic.i.ency turbine
lu:wd is lal.'ger than the best-efficiency pump head. If pumping efficiency
is of particular importance; the machine will be designed optimally as a
pump, resulting in a somewhat lower efficiency when generating. As a rule,
however, economical operation requires the highest possible turbine effi-
e iency; therefore, the pumping head range should be fixed to the left of
the pump optimum efficiency.
Besides the criteria of capacity ratio and efficiency, the cavitation

behavior of the machine is a further parameter affecting design. Cavitation
erosion on the runner should be avoided as much as possible during pumping;
:: ;(SHAFT
I I
HEADCOVER
SPIRAL
WICKET GATES CASE
N
1.0
SEAL
0L______l
50_ 100
___L_
150
_J
\ SCALE -eM
w
0
TOP STAGE
STAY VANES
9 r>fl l<jO l'jO

SCALE-eM
Fig. 18. Plan View of a Two-Stage, Top-Gated Pump/Turbine: 350-MW Capacity at 1500-m Head
SHAFT
WICKET GATES
SPIRAL
CASE
I¥J
SCALE-CII
Fig. 19. Elevation View cf a Two-Stage, Top-Gated Pump/Turbine: 350-MW Capacity at 1500-m Head
32
STAINLESS STEEL
STATIONARY RING
ROTATING PHENOLIC
SEAL RING
MAIN
TURBINE
SHAFT
Fig. 20. Shaft Seal Desigu fur High-Head .Pump/Turbine
this calls for the highest possible net positive suction head (NPSII). On
the other hand, it is desirable for economic- -r:easons (excavation, lengllt ur
penstocks, layout of the cavern, etc.) to · install the machine as high as
possible. For the same total head, each stage of a two-stage pump/turbine
develops only a portion of the total head and the bottom stage requirements
are much less than those of a single-stage mac.hine. The high ambient pres-
sure at the entrance to the top Rt::tgc reducet; cav lll-1!: ion teuueucles so that
it is not a major concern in this stage. According to Knapp's law, the
intensity of cavitation varies approximately as the 6th power of the flow
velocity and thus as the 3rd power of the head. With this high inherent
potential for mPtAl removal, it is extrewely important that runners, wicket
gates, stay vanes, etc., b~ virtually free of impPrfectiou~ ur discontinuitie~
that could trigger cavitation bubbles.
The term used to describe cavitation 1s the Thoma cavitation coeffi-

cient, with o expressed as
H -H -H
0 = NPSH b v s (1)
H H
33
where:
H =net effective head on the pump/turbine, m

Hb =,b~rometric pressure head, m
Hs = elevation of the throat of the runner above
the tail~ater (Hs is negative if the runner
is located below tailwater level and 1s
referred to as submergence), m
Hv = absolute vapor pressure of the water, m
The a value, at which efficiency and pumping head drop suddenly and the onset
of cavitation begins, is frequently defined as the critical value, ac. In
practice this value is often difficult to determine exactly, and is usually
obtained from model studies and operating experience with similar pump
turbines. In order to avoid excessive cav it at ion, the pumped-storage plant
is designed to yield a cavitation coefficient that exceeds the critical
value. The larger the value of a-ac, the smaller the chance that cavitation
will occur during operation. Localized cavitation can occur at a values
higher than ac; therefore, an acceptable cavitation level must be determined.
Seldom do design and economic factors allow submergence values to be large
enough that operation without cavitation is assured for all conditions. Some
cavitation may be acceptable in portions of the operating range that are
entered only briefly or infrequently. In addition, some materials resist
cavitation damage· and can be used entirely or as overlays in regions subject
to cavitation. There is no universal definition concerning excessive erosion
of material due to cavitation. The Bureau of ReclamationS defines excessive
cavitation as the removal of 19.5 oo-5) kilograms of metal per operating
hour· per square meter of impeller/runner throat area. This amount is for
aluminum, bronze, and stainless steel. ·For carbon steel, the allowable rate
of metal removal is four times greater.
Another crucial factor affecting the installation level of a pump/

turbine is the pumpl.ng head ratio (maximum pump head/minimum pump head).
Yor two identical machines, the one with the higher pumping head ratio
requires a deeper submergence to achieve the s·ame cavitation level.
2.2.1 Selection of Specific Speed
Specific speed is a parameter that is used in the selection of turbo-

machinery; it is defined as the speed at best efficiency of a homologous
turbine (pump) of such size that it develops one unit of power (flow) under
one unit of head. For a multistage machine, the specific speed is given on a
per-stage basis,
The pump specific speed, Nsp• can be expressed by
N(Q )1/2
N = ---"-p--,:--r:- (2~
sp H 3/4
p
34
where:
N = rotational speed, rpm
Hp = developed head, m
.
Qp pump best e ff_ic iency discharge flow, m3fs
The turbine specific speed~ Nst• can be expressed by
N(P )1/2
t
N = ---=--:-~ (3)
·st (H )5/4
t
where:
Ht turbine head, m
Pt power developed at best efficiency, kW.
Note that the value of specific speed calculated from Eqs. 2 and 3 are
dimensional, i.e., Ns has units of (rpm)(m3/s)1/2j(m)3/4; and Nst has
units of (rpm) (kW) 1/2 I tm)5/4. The dimensional representation of speci fie
speed will be used because ·this 1s the well-established form used by the
pump-turbine industry~ Steps are being taken to use a dimensionless form of
specific speed, which is given in Ref. 8.
The selection of the specific speed for a pump/turbine requires care-

ful consideration. The distribution of pumping inPffi~i.enc.ies is shown in
Fig. 21, adapted from Stepanoff.9 . A simil:~r C1..1rve applies to the turbine
eye le. From Fig. 21, it can be seen that the maximum effi.ci.ency occurs at
a specific speed of ·about 40-60 and the efficiency decreases rapidly with
specific speeds less· than 30. Typically· lower specific speeds are used
with higher heads to minimize the required excavation depth . . The ratio of
pump-power input to turbine-power output will be greater w.lth a pump/turbine
of low specific speed beca\lee of the pump-power input rP.cplirPd :~t m.i.rd.mum
head. It is desirable that the pump-power input equal the turbine-power
output for motor-generator\economic reasons.
In addition to high efficiency, a high specific speed· will result

in a smaller machine (and possibly a smaller powerh.ouse); will reduce water-
hammer, because of a decrease in suppression of discharge at runaway speed;
and wi 11 provide a better balance between pump-motor input and generator
output. High specific speeds could result in a motor-generator synchronous
speed (120 times the frequency in Hz, divided by an even number of poles;
preferably a multiple of 4 for large machines) that is higher than current
design and manufacturing limits. In addition, with increasing head the
number of synchronous speeds available to the designer decreas~s -- this is
illustrated in Fig. 22. A high specific speed in a pump/turbine results in
reduced inertia in the motor-generator. The smaller inertia results. in a
reduced acceleration time during pump startup, which is particularly important
for pony motor starting.
35
100
95
~
~
> 90
0
z
-w
0
6
LL. 85.
LL.
w
I. MECHANICAL LOSSES
2. IMPELLER LOSSES
80 3. DISK FRICTION LOSSES
4. L.E AKA GE L 0 SSE S
5. CASING LOSSES
6. PUMP OUTPUT
75 •'
25 50 75 100 125
Fig. 21. Distribution of Pumping Inefficiencies
Increasing specific speed also caus·es Oc to increase, and thus the

submergence must be increased. Stelzer8 gives the following relation for
predicting the critical sigma for pumps:
(4)
Localized cavitation usually occurs at sigma values higher than Oc. The
sigma value at which cavitation is first observed in pump model tests 1s
designated as ob and, from Ref. 8, can be expressed by
(5)
Note that Eqs. ,4 and 5 should only serve as a guide to determining the sub-
mergenc~ from Eq. 1. Sigma values given in the literature are often not
exactly defined, ~ut generally are for the point of optimum efficiency or
for the . minimum Oc value. No allowance is made for the behavior of Oc at
other discharge rates."
36
1800.0
1200.0
900.0
720.0
600.0 I
::E
Q.
514.3
450.0
400.0
360.0
327. 3
300.0
I
a: 276.9
.......
N
257. I
J: 240.0
0
225.0
CD 211.8
200.0
(/) 89.5
c 80.0
w 71.4
w
Q.
(/)
63.6
56.5
(/) 50.0
::::::> 44.0
0 38.5
z 33.3
0
a: 28.6
J:
(.)
24.1
z 20.0
>- 116. I
(/) 112.5
109.1
' 105.9
102.9
100.0
97.3
94.7
92.3
90.~
87.
85.7
83.7
125 250. 500 750 1000
HEAD PER STAGE, m
Fig. 22. Available Synchronous Speeds for Power Range

of 250-750 MW and Head ·of 125-1000 m for
2.2.2 Design and Performance Parameters: Allis-Chalmers Two-Stage

Pump/Turbines
Because of the potential critical-speed problems mentioned in Sec. 2.1,

the two-stage pump/turbines were designed ·for. a 60/40 head split between
the top (second) and bottom (first) stages. Equal heads per stage would have
permitted each stage to be designed for the same specific speed. The 60/40
split results in a different specific speed and a different runner design for
each stage, since both stages have the same flow and runner speed. Based on
the experience of single-stage pump-turbine designs and the discussion in
Sec. 2.2.1, a pump specific speed of about 35 rpm (m3fs)l/2f(m)3/4 per
37
stage was deemed suitable for the two-stage design. After adjustments were
made to match synchronous speeds available for the motor-generator, the design
parameters given in Table 4 were used for the two-stage machines. An attempt
was made· to obtain approximately equal specific speed per stage for each
machine. This speed selection maintains about the same efficiency for each
head, i.e., efficiency is only reduced due to thicker gates, guide and
impeller vanes; similar hydraulic designs can .be used for all the machines.
To determine the size of each stage, a set of crossplots of critical

design parameters for a sing le-st age, state-of-the- art pump-turbine des1gn
was used with suitable corrections for the two-stage machines. . Performance
e;,a.lua!= ion was obtained by usi~g two different Allis-Chalmers, single-stage,
pump-turbine designs that had specific speed ranges close to those ~sed
for each stage. The performance characteristics from both of these machines·
wer.e entered into the CORA computer programlO as a tandem set, i.e., exit
data for one stage is the input data for the second stage. CORA is a pro-
prietary Allis-Chalmers hydraulic-transients program based on ·the method
of characteristics. It was used to match flows in each stage at each head
condition for a large number of fixed gate openings. The performance curves
derived in this manner were then corrected for dissimilarities between the
two single-stage machines and a two-stage unit (draft-tube effects, losses
between stages, component modifications because of higher-head application,
higher velocities, etc.). The error band on these curves is ±1%.
The head ranges· for the pump and turbine cycle were picked to be
consistent with single-stage design. For th·e pump operation, the head range
is ±10% of the nominal ·head, e.g., 900 to 1100-m total dy'namic head for
the 1000-m machine. The turbine head range was obtained by dividing the pump
head by 1.13. This ratio of pump head to turbine head is typical of that
found in high-head pump/turbines. The actual ratio of pump head to turbine
head for a specific project must be evaluated by consideration of the pen-
stock configuration and head losses.
Based on Allis-Chalmers' experience ·and worldwide· practices, a plant

setting was chosen for· maximum head with a sufficient safety margin on the
first (bottom) stage. The pump and turbine hydraul ic-perfo~ance character-.
istics of the two-stage units are shown in Figs. 23-34. A comparison of the
s ingle-stage1 and two-stage pump/turbine performance for a capacity of 500 MW
at a 1000-m head is shown in Figs. 35 and 36. Having the fixed gate on the
bo.ttom stage of the two-stage machine ·has not lowered the pumping efficiency
from that which is· obtained with both stages gated. The turbine efficiency
of the top-gated machine is only 1% less than that of the double-gated unit.
Also, the top-gated turbine output (point "a" in Fig. 36) is slightly less
than the output of the double-gated machine (point "b" ·in Fig. 36).
The CORA programlO was expanded to accommodate the complexities

associated with the two-stage pump/turbines. The program can handle multiple,
double-controlled machines on the same penstock. Some typical transient
simulations3 for a turbine-load rejection and a pump-power failure are shown
in Figs. 37 and 38.
38
Table 4. Hydraulic Design Parameters for Two-Stage Pump/Turbines
Head and Power Capacit~
1000 m, 1250 m, 1500 m, . 1000 m, 1250 m, 1500 m,

Parameter 500 MW 500 MW 500 MW 350 MW 350 MW 350 MW
Shaft rotational 450 600 720 514.3 720 900

speed, rpm
Flowrate, .m3fs 51.5 40.8 33.6 35.7 28.6 23~8.
Submergence, m 75 85 100 75 100 125

First (bottom) stage 400 . 500 600 400 500 600
head, m
s·econd (top) stage 600 750 . 9.00 600 750 900
head, m
First stage specific 36.10 36.25 34.43 . 34.36 36.42 36.22
speed,
~rpm ~m3j s ) 1/2] m-3/4

Second stage specific 26.64 26.74 25.40 25.35 26.87 26.73
speed,
~rpm ~m3j s ) 1/2] m-3/4

Rated turbine 90.0 89.5 88.4 90.0 89.6 88.5
efficiency, %
Rated pump efficiency, % 90.6 89.6. '88.3 90.6 89.6 ·88.3
Pump flow'at minimum head l.Ul U.YY U.Y6 U.8.) 0.~8 0.81 .
Turbine flow at minimum
head and maximum power
PumE flow at maximum head 0.57 0.54 0.51 0.55 0.56 0.51
'
Turbine flow ~t maximum
head and power
..
Pump flow at minimum head 1.53 1.56 1.60 1.55 1.50 1.62
Pump flow at maximum head
39
92
·go
-
0~
88
86
975-m HEAD
>-
u
z 84
w
·u
LL: 82
u..
w
80
78
·76
100 200 300 400 700 800
TURBINE OUTPUT POWER (MW)
Fig. 23. Turbine-Performance Characteristics: 500 MW, 1000 m,

Two-Stage Machine
1100 92 ~-
>-
u
z
w
1060 u
LL:
u..
86 w
EI020
Cl
<l:
~ 980
940 a::
w
460 ~Q_
48 52' .. 56 58
PUMP DISCHARGE (m3/s)
Fig .. .24 ... Pump-Performance Characte~istics: · 500 MW, 1000 m,

Two-Stage Machine. ·
40
90
88
~
·o 86
>-
<...> 84
z
LLJ
<...> 82
LL.
LL.
LLJ 80
78
76
100 200 300 400 500 600 700 800
TURBI~E OUTPUT POWER (MW)
Fig. 25. Turbine-Performance Characteristics: 500 MW, .1250 m,

Two-Stage Machine
1400r---~----------------------~--~----------~
--
~
>-
<...>
-e13oo z
UJ
B
Cl
c:(. 86 . . LL.
LL.
Lol
:::t:l200 84 UJ
1100 520
0::
LLJ
3:::
440 ~
24 28 . 32 36 40 .44 48 52
Fig. 26. Pump-Performance Characteristics: 500 MW, 1250 m,

Two-Stage Machine
41
90
88
1460-m~ HEAD
·O
0'
84
>-
u
z 82
I..&..J
u
LL. 80
LL.
w
78
76
74
100 200 ,300 400 500 700 800
TURBINE OUTPUT POWER { MWl
Fig. 27. Turbine-Performance Characteristics: 500 MW, 1500 m,

Two-Stage Machine
1700 90 0~
88 >-
u
z
I..&..J
1600 86 u
LL.
LL.
84-
-E
~1500
-
I..&..J
I..&..J
~
520
. ·1400
480 ~
0:::
I..&..J
3:
440~
20 24 ' 28 32 36 40
PUMP DISCHARGE (m3/ s)
Fig. 28. Pump-Performance Characteris-tics: 500 MW, 1500 m,

Two-Stage Machine .
42.
90
88
86
84
oo;;O·
>-·
82
u
:z: 80
LLI
u
1.1- 78
1.1-
LLI
76
74
.72
150 200 250 300 350 400. 450
TURBINE OUTPUT POWER ( MW)
Fig. 29. Turbine-Performance Characterist~cs: 350 MW, 1000 m,

Two-Stage Machine ·
II00~--------------~------------~~----~--------- 92 0~
1080 90 >-
u
:z:
LLI
1060 88 u
L'-
1040 86 1.1-
lol
·el020
-;;;: 1000 360
c:x:
. ~ 980
960 320 a:::
LLI.
~
940 300 ~ ..
920 280
900~------~~--~--~----~--~~~~~----~
18 22 26 30 34 38
PUMP DISCHARGE (m3ts)
Fig. 30; Pump-Performance Characteristics: 350 MW, 1000 m,

Two-Stage Machine . ·
43 '
90.--------------------------------------------
88
~ 86
t;
:z
w
<...>
LL.
82
LL.
w 80
78
76~--~----~--~~--~----~--~----~----L---~
100 200 300 400 500 600 700 ' 800
Fig. 31. Turbine-Performance Characteristics: 350 MW, '1250 m,

Two-Stage Machine
1400 90 0~
88 >-
<...>
:z .
w
-1300 86 <...>
E
LL.
0 84 LL.
w
<(
~1200
~
2
340~
~
·0
CL.
16 20 24 28 32 36
PUMP DISCHARGE (m3/ sl
Two-Stage Machine
44
90~----------------------------------------------~
88
1460.-m HEAD
84 1195-m HEAD
0~
82
>-
u
z
LI.J
80
u
LL: 78
u..
LI.J
76
74 ~'
72
70
200 250 300 350 400 450
Fig. 33. Turbine-Performance-Characteristics: 350 MW, 1500 m,.
Two-Stage Machine
1700~------------------------------------------~ 90 0~
~\t~\,
~ 88 >- .
u·
z
~J\" . ILl
1600 86 <:3
u..
E
84 u..·
LI.J
-~1500
LI.J
:::I:
360
1400 340 :::!:
~
320~
300 ~
0...
280
10 14 . 18 22 . 26 ·30
Two-Stage Machine
45
'
Q/OPTIMUM Q
0.6 0.1 0.8 Q.9 1.0
>- 1.00
0
z
u.~· --- --
~ 0.98
u..
u..
UJ
UJ 0.96
>
......
~ 0~94
UJ DOUBLE STAGE
0::: <BOTH CONFIGURA TIONSl
0.92 - - SINGLE STAGE
1100
,...E.
0 1000
~
UJ
I
900
500
0::: 460
UJ
~·
0
Q. 440
. 420
.Fig. 35. Comparison of Pump Performance of a Single- and Two-Stage

Pump/Turbine with a 500-MW Capacity at a 1000-m Head
46
POWER CMW)
200 300 400 .. 500 600
1.00
~
0.98
!I"'I' " '~
N . ',\.
>- 0.96
u
z ItJ/ ·'
'~·
UJ
u
u..
u..
0.94 /I1/ ___.'~,, .--b·
UJ
UJ
> 0.92 I'
;,
I a
\.
1- I _ _ TWO-STAGE PUMP/TURBINE
<(.
..J·
w
I I <BOTH STAGES GATED>
a:: o.-9o ,' - - - - TWO-STAGE PUMP/TURBINE
/ <TOP STAGE GATED>
I
I I SINGLE STAGE
. 0.88 //
,' a OUTPUT OF TOP-GATED TURBINE
b OUTPUT OF DOUBLE-GATED TURBINE
0.86
Fig. -36. Comparison of Tu~bine Performance of a Single- and Two-Stage

Pump/Turbine with. a 500-MW Capacity at a lOOO-m Head
.....
e
'J
C!l
<t
w
0.
(!)
:E
a..
:I: l/1. 0:
1500 100 100
1000
50
500
HEAD BETWEEN TOP

DRAFT TUBE HEAD (m)
AND BOTTOM STAGES (m)
0
10 20 30 40 50 60
TIME (sec)
Fig .. 37. Transient Simulation of a Turbine Head Rejection for a Two-stage Puntp/Turbine
,...
·e
.....,
. .
0
<t
0 . .
~
w (!)
~ ~
1500 100
96-G.O.
50 500
<BOTTOM STAGE>
0
30 40. 50
MAIN SHAFT SPEED <RPM>
Fig. 38. Transient Simulation of a Pump Power Failure for a Two-Stage Pump/Turbine
49 '
3 DETAILED ANALYSIS OF WICKET GATE AND DISTRIBUTOR COMPONENTS
Along with the layout and hydra,ulic design of a pump/turbine, stress

and deflection· analyses are necessary to ensure the adequacy of the design.
The important stresses and deflections for some of the major components were
evaluated. to determine design· loading conditions and certain vibrational
charact·eristics. Vibrations may be induced from pressure fluctuations that
occur in all hydraulic machines, due to the finite number of blades in the
various cascades. Furthermore, in the turbine mode of operation, pressure
fluctuations occu_r in the draft tube above and below the range of peak
e'fficiency; the fluctuations result from a. whirl and vortex core downstream of
the runner outlet. If the natural frequencies of certain machine components
or parts of the complete plant are such that they favor vibrations -- or if
they are within the same range as the inducing frequencies, e.g., the pressure
fluctuations -- then resonance phenomena may occur which can affect the smooth
running of the machine or even make operation impossible within certain output
ranges. Special finite-element studies were conducted on a 50/50 head-split,
1000-m head design, in order to fully understand the mechanical behavior of
the two-stage pump/turbine components and their interact ion. Finite-element
studies were also carried o.ut· on the wicket gate for the final design of the
1 000-m head machine. This gate was. also analyzed for: use in the 1500-m head
pump/turbine. Life-expectancy studies were conducted in conjunction with this
1 atter analysis.
3 .1 WICKET GATE
The most stressed part of a high-head reversible pump/turbine is

the wicket gate (Fig. 39). During the pumping and generating mode, the
wicket gates are subjected to high pulsating flows, and these flows can cause
vibrations to occur. The intensity of the vibrations can be reduced by
increasing the distance between the runner and the wicket gates. A regular
rotation of the wicket gates is generally controlled by a system of levers and
links operated by a servomotor. A shear pin is usually incorporated in the
coupling-lever connection and is designed to allow operation of the mechanism
under all normal loads. However, if an obstruction lodged between any t:wo of
the gates prevents them from closing or opening, the appropriate pins will
shear, thus allowing the remaining gates to operate as required by the load
conditions. A gate-restraining mechanism is also generally incorporated into
the gate for two reasons: to prevent violent gate movement following a
shear-pin failure, and to help prevent potential resonant flutter with natural
frequencies in the system. The gates and their control mechanisms must be
able to withstand the torque which occurs during the transient phase of
load rejection anci speed reversal, and also during the special conditions
associated with starting. ·
A critical balance exists between the hydraulic and mechanical require-

ments of a wicket-gate system. It is essential to assure that neither the
hydraulic performance nor the mechanical considerations of long life and
reliability are compromised. It is interesting to note that resonance con-
siderations tend to govern gate sizing in lower-head applications, while for
higher heads the static-stress considerations tend to govern gate sizing.
50
LEADING
LENGTH
LOWER TRAILING
BEARING LENGTH
Fig. 39. Typical Wicket Gate
This tendency is due in part to the increased gate-stem stiffness and de-
. creased leaf mass inh.erently associated with high-head applications. There-
fore, as the strength characteristics of the gate are being upgraded to
satisfy the static-stress design criteria, the natural tors.ional frequency
is also increased. Gates designed for high-head applications will have
thicker leaves (Fig. 4) than those for lower heads; and thicker leaves reduce
performance. An additional comparison (Fig. 40)4 of the head effect on
pump-turbine gates shows that the g'ate-ieaf height is less for high than low
heads, that gate stem and trunion diameters are larger for high-head applica-
tions, and that the stem is longer because the head cove~ is thicker.
The wicket-gate leaf profile is essentially elliptical and of constant

cross section in the lower half of the distributor; its thickness increases
linearly in the upper half of the diitributor~ however, to accommodat~
. the higher loads· encountered' at the leaf-to-stem intersection. The advantage
of this concept is. that the elliptical cross. section efficiently accommodates
the loading while not adversely affecting the hydraulic performance.
3.1.1 Wicket-Gate Design for 1000-m Head, 500-MW Pump/Turbine-- Design

Generated by IRIS Program
The wicket gate system for the 1000-m head, 500-MW capacity, two-stage
pump/turbine was initially sized by the IRIS program. 7 Part of the IRIS
optimization process (Fig. 41) checks the static stresses and deflections in
the gate according to beam theory; i.e., the gate is represented by a beam of
variable cross section. Generally this classical method of analysis yields
adequate stress values in the stem region, but at the same time it misrepre-
sents the leaf and leaf-to-stem intersections.
51 '
HEAD=76m HEAD=400m
GATE LEAF
Fig. 40. Comparison of Stem Size and Gate-Leaf Height
for a 76-m~Head and a 400-m-Head Wicket Gate
DIMENSIONAL PARAMETERS OPERATIONAL PARAMETERS MECHANICAL PARAMETERS HYDRAULIC PARAMETERS
GATE PIN CIRCLE MAX STATIC HEAD MATERIAL PROPERTIES, STATIC & DYNAMIC
..•
GA.TE HEIGHT MAX TAILWATER HEAD STRESS CONCENTRATION GATE TORQUE ·
HEAD COVER COtFIOURATION MAX TRANSIENT HEAD a FORM COEFFICIENTS
• •• ••
•• • •
~ l l l
!
PRELIMINARY STRESS ANALYSIS,
INITIAL. STEM a LEAF GEOMETRY,
BEARING REACTIONS, TORQUES
.,.I •
LINKAGE OPTIMIZATION &
SERVOMOTOR SIZING
~
STRESS, DEFLECTIONS a INCREMENTAL GEOMETRY
REACTION CALCULATIONS CHANGE ON LEAF OR
FOR DIFFERENT CONDITIONS STEM ACCORDING TO
UNSATISFIED DESIGN
~ CRITERIA
~
CHECK LIMITING DESIGN CRITERIA
-STRESSES
-DEFLECTIONS
-SLOPE AT BEARINGS
-STEM ANGULAR ROTATION
-BEARING PRESSURES
.••
-TORSIONAL FREQUENCY
I
+
ALL CRITERIA SATISFIED?
.. NO I
~
' I YES
1
FINAL DESIGN - OUTPUT I
Fig. 41. IRIS Program Wicket-Gate Optimization Procedure.
52
The preliminary design of the wicket gate was achieved by incrementing

the gate geometry until all static and dynamic criteria (stress, deflection,
and torsional frequency) were satisfied. The allowable combined value of
torsional shear and bending stress is 1/3 the allowable yield-stress of the
gate material at the maximum design loading (gate-squeeze· condition, i.e.,
wicket gates closed and maximum design pressure on the spiral case). Consid-
eration was also given to the guide bearings qf the head cover and discharge
ring so that they are able to accept the slope of the wicket-gate stem -- this
prevents the gates from binding during their operation. · The design also
accounts for degradation of bearing clearances, a process that occurs because
the wicket gate and its guide bearings deform during all significant operating
conditions.· The dynamic criteria was chosen so that the first torsional
natural frequency of the gate is at least twice the forcing frequency imposed
by the runner blades as they pass each gate at runaway speed. The forcing
frequency is expressed by
N nb
r
·f = (6)
b 60
where:
fb = forcing frequency, Hz
Nr = runaway speed, rpm
nb = number of runner blades
The IRIS wicket-gate analysis provides a good criterion for the

development of a preliminary design, and until about five years ago was
considered a final design. Present-day analytical methods use digital-
computer solutions to· finite-ele~ent models, and these methods provide a much
more complete description of structural behavior. The wicket-gate model used
by the IRIS program for the 1000-m head pump/turbine is shown in Fig. 42. The
reactions, stresses, and deflections obtaine.d from this analysis are presented
in Tables 5-7. Table 5. presents data derived during a gate-squeeze conditi.on
at maximum static-head; Table 6 presents data derived during a closed-gate
maximum pressure rise (waterhammer); and Table 7 presents data derived during
a sheat·-pin-fai lure condition. The shear-pin-failure t:(md i tion occurs with
the wicket gates in near closed position and only two gates interacting due to
an obstruction being wedged between them. The most adverse loading occurs
when the debris ·is caught between the tops of the two gates, because the
torque transferred through the stem unloads on the leaf without the benefit of
the sate flexihility.
3.1.2 Finite-Element Analysis for 1000-m-Head Wicket Gate
Detailed wicket~gale analyses are essential for a high-head pump/

turbine. All of these analyses were made using the finite-element technique,
because the classical beam theory does not adequately represent the behavior
of the leaf and leaf-to-stem intersection. A three-dimensional finite-
.e lement model of the wicket gate was generated automatically by the IRIS
Program for execution by the DANUTA finite-element program:ll The model
(Fig. 43) consists of 372 elements, 707 nodes with 12 degrees of freedom
53
TOP MIDDLE LOWER

LINK~ BEARING BEARING BEARING
445
- 74~ ~64 -
- 76 ~ I"'"'
~
-
- -·--·-·---
•
I2 3 5 6 8 9 10 11121314 15161718 115 20 21 22
-- 4
~~
•
7
.... ~~
--
1~·~50-0--·+i"-·2-2_9_s,j--·-2-8-2--·~i--·----~0-5-2--~--+i-·--3-0-5~·l~I·~----3-I-8------~·L~
'--
~OTE: DIMENSIONS IN mm
Fig. 42. IRIS Program Wicket-Gate Model for the 1000-m.,-Head,

represented at 371 corner nodes. This model reveals the structural behavior
(stresses, displacements, slopes, strains, and bearing reactions) through
simultaneous solution of 4452 equations (371. X 12). In the model, the gate
is constrained laterally at its three guide-bearing locations and rotation~lly
at· the top of tbe stem, where the linkage is connected. Selected results
of the analysis are presented in Table 8. Note that the stem is adequat.ely
sized by the beam analysis but the leaf and leaf-to-stem intersection requires
finite-element analysis to verify the design. Minor adjustments were made to
the gate torque and link loads between the preliminary and· final analyses' --
·'' ',
these adjustments account for the small discrepancy in the stem behav'ior .,
•'.;.
predicted by ~he two analytical methods. It. can be concluded that from th~
finite-element analysis, the general static behavior falls well within the
allowable 1 imits for these gates.
3.1.3 Finite-Element Analysis for 1500-m-Head Wicket Gate
As the stiffness of'the gate leaf approaches the stiffness of the stem,
the effect of hydraulic pressure (bending) and hydraulic unbalance (torsion)
on the leaf stresses and deflections should diminish. For this reason,
the same gate size and model (Fig. 43) presented in Sec. 3 .1. 2 were used
for the finite-element analysis of the wicket gate for the 1500-m, two-stage
pump/turbine. The design head was 2131 meters, which corresponds to the
maximum transient head from pressure rise. Fourteen different .basic load
cases (Table 9) are run separately by the DANUTA program for each finite-
element analysis.
The load values ·of these isolated components are chosen so that they
can be scaled up· or down; and then through superposition of all relevant
loading conditions, real operating conditions can .be simulated. The two most
important cases are the gate-squeeze and· the shear-pin-break conditions.
54
Table 5. Reactions, Deflections, and Stresses for 1000-m-Head

Wicket Gate during a Condition of Gate-Squeeze at
Maximum Static Head -- Data Generated by IRIS Program
Reaction Value
Top bearing, MN 0.59855

Intermediate bearing, MN -1 .'84887
Lower bearing, MN -1.761
Torsion at top gate, MN·m -0.29144
Leaf transverse bending stress, MPa 228.50
Stress, MPa
Fig. 42 Lateral Lateral · Torsional Combined
Point No. Deflection, mm Slope Twist, rad Bending Torsional Shear
1 -0.78943 0.00157 0.01037 0.00 0.00 0.00

2 -0.68879 0.00157 0;01037 .0. 00 62.55 62.55
3 -0.13539 0. 00ll8 0.00831 61.68 62.55 69.74
4 0.00000 0.00068 0.00764 79.97 60.42 72.57
5 0.10751 0.00051 0;00685 67.34 59.68 68.52
6 0.17084 0.00013 0.00586 . 49.24 57.80 62.82

7 0.1).242 -0.00027 0.00379 8.62 51-.00 51.19
8 0.01353 -0.00014 0.00172 26.21 51.00 52.66
9 0.00000 0.00025 0.00037 47.85 48.00 53.64
10 0.02165 0.00032 0. OOOll Y.35 45.67 45.91
ll 0.03862 0.00032 0.00046 14.37 41 .19 41.81

12 0.04355 0.00031 0.00000 20.54 ll.1 . 1 ') 42.45
13 0.05200 0.00028 a 28.53 0.43 14,?.7
14 0.06439 0.00021 a 44.50 0.38 22.25
15 0.07336 0.00007' a 56.33 0.33 28.16
16 0.07268 -0.00009 a 56.91 0.23 28.45

1/ 0.06.548 -0.00021 a 51.18 0.13 25.59
18 0.05774 -0.00028 a 56.25 0.06 28.13
19 0.05304 -0.00032 a 51.15 0.02 25.58
20 0.03549 -0.00034 a 31.46 0.00 15.59
21 0.00000 ·~O. 00039 a 0.00 0.00 0.00

22 -0.03694 -0.00039 a 0.00 0.00 0.00
a Less than 0.00001.

55
Table_.6 . . Reac;tions, .Deflections, and Stresses· for :the 1000-m-Head

Wicket Gate _during ~ Condition of Closed ~ates at Pressure
Rise (Waterhamme~) --.Data Generated ·by IRIS Program
Reaction Value
Top bearing,. MN 1.17083

Intermediate bearing, MN 2.67782
'Lower bearing, MN 1.29880
Leaf transverse ~ending stress, MPa· 263.49
Stress, MPa·
Fig. 42 Lateral Lateral Torsional Combined
Point No. De fleet ion, mm Slop~ Twist, rad . Bending · Torsi.onal Shear
.1 -0.74852 0.00150 0.01037 0.00 0.00 0.00

2 -0.65242 0.00150 0.01037 0.00 62.55 62.55
3 -0.12618 0.00111 0.00830 61.68 62.55 69·. 74
4 0.00000 0.00081 0.00763 79.97 -60.55 72.57'
5 0.09660 0.00044 ·. 0.00684 66.51 59.66 68.30
6 0.14675 0.00007 0.00585 47.38 .57. 78 62.45

7 0.06 768 -0.00029 0.00378 4.69 50.99 51.04
·8 -:-0.04811 -0.00007 0.00171 32.44 .50.99 53.50
9 o.ooooo 0.00039 o·.ooo37 55.24 47.99 55·.37
10 0.03184 0.00046 0.00010 4. 76 •, 44.99 45.05
q 0.05602 0.00045 0.00004 24.66 40.60 42.42

'12 0.06301 0.00043 .0.00000 32.74 40.60 43.76"
13 0.07601 0.00038 a 42.60 0.58 21.31
14 0.09213 0.00029 a 63.95 0.52 31.97
15 0.10430 0.00009 a 79.25 0.45 39.63
16 0. 1 0'289 -o:ooo14 a 79.25 0.31 39.63

17 0.09249 -0.00030 a 70.98 0.18 35.49
18 0.08149 -0.00039 a 77.94 0.08 38.97
19 0.07483 -0.00045 a 70.85 ·0.03 35.43
20 0.05003 -0.00048 a 43.57 0 .. 00 21.79
21 ·o .ooooo -0.00055 a 0.00 0.00 0.00

22 -0.05204 -0.00055 a 0.00 0.00 0.00
aLess than O.OOOOi.
56
Table 7. Reactions, Deflections, and Stresses for the 1000-m-Head

Wicket ~ate during a Shear-Pin-Break Condition --
Data Generated by IRIS Program
Reaction Value
Top bearing, MN 0.61207

Intermediate bearing, MN ·-2. 37394
Lower bearing, MN -1.43731
Leaf transverse bending stress, MPa 389.02
Stress, MPa
·Fig. 42 Lateral Lateral Torsional Combined
Point No. Deflection~ mm Slope Twist, Rad Bending Torsional Shear
1 -1.65831 0.00328 0.02076 0.00 0.00 0.00

2 -1.44824 0.00328 0.02076 0.00 125.10 125.10
3 -0.28869 0.00250 0.01663 123~35 125.10 139.48
4 0.00000 0. 00.191 0.01529 159.94 121.11 145.B
5 0.23620 0. OOll-5 0.01371 136.26 ll9 .40 137.48
6 0.38847 0.00038 0.01173 102.09 115.63 126.40

7 0.31177 -0.00052 0.00759 24.89 102.04 102.80
8 0.04004 -0.00040 0.00345 40.31 102.04 104.01
9 0.00000 0.00025 0.00075 81.34 96.04 104.30
10 0.02353 0.00037 0.00021 27.61 92.66 93.bH
11 0.04342· 0.00037 0.00009 8 '7L. 83.56 83.68

12 0.049JO 0.00037 0.00000 17.~5 83 '56 . 8'1 .01
13 0.060:;0 O.OOOJ4 a 29.72 0.58 14.87
14 0.07490 0.00026 a 51.20 0.52 25.60
15 0.08661 0.00010 a 67.78 0.45 34.06
16 0.08669 -0.00010 a 70.42 0.31 35.21

17 0.07848 -0.00024 a . 63.87. 0.18 31.25
18 0.06937 -0.00033 a 70.39 0.08 35.19
19 0.06375 -0.00038 a 64.03 0.03 32.02
20 0.04273 -0.00041 a 39.37 0.00 19:69
21 0.00000 -0.00047 a 0.00 0.00 o.oo

22 -0.04454 --0.00047 a 0.00 0.00 0.00
8 Less than 0.00001.
57
'
3.1.3.1 Gate-Squeeze
Condition z
The gate stem -is subjected to
the maximum torque (229.6 kN·m)
available at the closed position with
1 imi ted squeeze. The components of
the link load .. which develop this
torque are -272.7 kN in the X direc-
tion and 112.8 kN in the Y direction.
These .parameters are calculated in
the IRIS program and are based on the
torque required to seal the gates and
the optimum linkage configuration;
the latter configuration is based on
mechanical advantage being utilized
throughout the gate movement. The
magnitude of· the torque delivered to
the gate by the se~vomotor and
"linkage is determined by considering
the. hydraulic torque and bending
loads on the gate leaf. This torque
val'ue 1s obtained when the finite-
element results indicate that posi-
tive intergate sealing contact
exists along the entire length of .the
gate leaf. Whole-length intergate
sealing must occur in spite of the
leaf hydraulic pressure tending to
defot~ the nose and tail seals, which
would provide a leakage path through
the gates. The outer face of the
leaf, a line from nose contact to
tail contact (Fig. 44), is subjected
to a hydraulic pre~sure of 20.9 MPa;
this pressure results from the
maximum transient head of 2131 m.
To calculate the interreaction

between adjacent gates at the squeeze
condition, five pairs of coupled
points have been selected at differ-
ent levels along the nose and tail
contact line (Fig. 44). A unit load
acting in the transverse Y direction
has been applied to each one of these
points separately in the initial run.
Using the deflections caused by these
forces and imposing a condition of _X
equal, differential, t·ransverse
displacements. from level to level, a
set of simultaneous equations is
formed. The solution of this equa- Fig. 43.· Finite-Element Model of a
tion set" provides the magnitude of 1000-m-Head Wicket Gate-
58
Table 8. Selected Results of Finite-Element and IRIS Analyses of

the .1000-m-Head, Two-Stage, Pump-Turbine Wicket Gate
Results of Dual Analysis

in Two Behavioral Areas
Pressure Rise Shear-Pin-Failure
Finite Finite
Structural Characteristic Element IRIS Element IRIS
Stem rotation, rad 0.0106 0.0103 0.0235 0.0235

Maximum stem deflection, mm -0.69 -0.74 -1.56 -1.65
Maximum stem bending stress, MPa 83.8 80.0 108.5 159.9
Maximum stem torsional shear st~ess, MPa 45.4 62.6 lil.9 125.1
Maximum leaf transvese b'ending stress, MPa 137.9 263.5 401.2 389.0
Maximum leaf axial bending stress, MPa ~06.7 79.2 146.2 70.4
Maximum leaf-to-stem combined stress, MPa 181.4 42.5 400.9 83.6
Servomotor torque, kN·m 229.6 288.7 516.5 588.2
Table 9. Basic Load Cases for the DANUTA Program
T.n:=~ci C::=!SP Description Load
1 Bearing friction torque 706.4 kN·m

2 Link load 444.8 kN
3 Servomotor torque reaction ·262.8 kN·m
4 Hydraulic pressure on leaf face 13.9 MPa
5 Nose seal point reaction force at node 636 889.7 kN
7 Nose seal point reaction force at node 356 889 .'7 kN
9 Nose seal point reaction. force at node 695 889.7 kN
10 Tail seal point reaction force at node 612 889.7 kN
11 Tail seal point reaction force at node 273 889./ kN
14 Tail seal point reaction force at node· 671 889.7 kN
59
295.1 kN (LINK LOAD)
ROTATIONAL
~ 140 CONSTRAINT
en
w
120
~ 100
TRANSLATIONAL
~ 80 CONSTRAINT
w 60
1-
< 40
<!'
ffi 20 THRUST
CONSTRAINT
1-
z 0
1 2 3 4 5
LEVEL
TRANSLATIONAL
CONSTRAINT
20.9MPa
LEVEL
--- ,,,,..,------
........
......
)
TRANSLATIONAL
A--- CONSTRAINT
Fig. 44. Gate-Squeeze· Condition for the

1500-m-Head Wicket Gate
60
the interreactive forces at each level. These forces are used to obtain the
gate-squeeze-line contact forces (Fig. 45), from which it is ·concluded that no
leakage path exists for the 1500-m wicket gate.
The results of the finite-element analysis will be summarized l.n

Table 10, page 65. Scaling factors for the basic load cases giv~n in Table 9,
page 58, are:
Load Case Factor ·Load Case Factor

1 0.0 8 0.05515
2 0.86328 9 0.07300
3 0.87410 10 0.16485
4 1.50000 11 0.08903
5 0.16485 12 0.05759
6 0.08903 13 0.05515
7 0.05759 14 0.07300
3.1.3.2 Shear-Pin-Failure Condition
The gate stem is subjected to the maximum torque (516.5 kN·m) required
for the shear-pin break at or near a closed position. The link load -(Fig. 46)
to develop this torque. is 663.9 kN and its components are -613.5 kN in the X
direction and 253.7 kN in the Y direction. The magnitude of these loads is
chosen so that minimum fatigue damage will occur in the wicket gate as a
result of the adverse shear-pin-failure loading condition. The outer face
of the · leaf, a line from nose contact to tail contact, is subjected to a
hydraulic 'pressure of 20.9 MPa; this pressure results from the maximum
transient head of 2131 m. The corresponding hydraulic torque is 89.3 kN·m.
Shear-pin failure usually re~ults from a foreign object that sticks

between two gates during· closure. The position of the obstruction with
respect to the gate leaf greatly affects the stress and deflection pattern.
Several obstruction positions were investigated: the top. center. and bottom
of the leaf tail and nose. The highest stresses result from an obstruction
located at the upper tail end of the leaf.. In the analysis, the friction
moment (0.1 friction coefficient) created by the intermediate-bearing's
reaction is considered, but the friction moments at th~ upp~r and lower
bearings are neglected. Since the hydraulic torque tends to close the gates
when they are in the closed position, the following torque equation must be
satisfied:
(7)
where:
d = 392.2 mm = moment arm from the centerline of the wicket-

gate stem to the point where the obstruction
reaction force acts on the tail of the leaf
61
2200
2000
-·
E
E
.....
1800
1600
I
0
•I
316.7
-z
C!'
z 1400
0
c(
0 1200
...J
w
...... 1000
c(
C!'
a: 800
w
.....
z
600
400
200
0 ~--------._ ________._________ ~--~----~--------~---------L---J

~,
0 50 100 150 200 250 300

DISTANCE ALONG GATE LEAF (mm)
Fig. 45. Gate-Squeeze Contact Line Loading

for the 1500-m-Head Wicket Gate
Fr upper intergate reaction force due to an obstruction

Tf = intermediate bearing friction torque
Th = hydraulic torque from pressure on leaf
Ts = servomotor torque
In order to solve Eq. 7 for Fr, the torque due to friction (Tf) needs to
be determined. · The int.ermediate guide-bearing load, and correspondingly
Tf, results mostly from the link load, hydraulic unbalance on the leaf, and
the reaction load of the obstruction. Initially an obstruction reaction
is assumed, and ite·rative solutions for Tf from Eq. 7 were obtained until
the· calculated and assumed reaction force were .equal. The largest reactive
62
663.9kN
(LINK LOAD)
A--- ROTATIONAL
CONSTRAINT
TRANSLATIONAL
CONSTRAINT
THRUST
t----CONSTRAINT
1.385MN
TRANSLATIONAL
CONSTRAINT-
,-- - 20.9MPa
~
--...... ,-c:_.
--'~-
..... ' -----
'1
.
)
TRANSLATIONAL
A--- . CONSTRAINT
Fig. 46. Shear-Pin-Failure Condition for

the 1500-m-Head Wicket Gate
63
load due to an obstruction between the gates calculated in this manner is

1.385 MN. By applying this normal reactive load and a 0.1 friction coeffi-
cient, a realistic frictional load was determined, which in turn produces a
frictional torque of 62.6 kN·m. The loadings shown in Fig. 46 and the
following scale factors for the load cases listed in Table 9 were used for the
analysis, a summary of which is presented in the next section.
Load Case Factor Load Case Factor Load Case Factor

1 -0 ..08858 6 0.0 11 0.0
2 1.49238 7 0.0 12 b.o
3 1.96673 a· 0.0 13 0.0
4 1.50000 9 0.0 14 0.0
5 0.0 10 1.55673
3.1.3.3 Selected Results
The results of. the finite-element analyses are the stresses and dis-
placements for the 371 corner nodes. The displacements in the X, Y, Z, radial
and tangential directions were determined and are relative since the bearing
level at the stem top is fixed rotationally. Stresses in the X, Y~ and Z
directions; shear stress in the XY, YZ, and ZX planes; and the three princi-
pal stresses were also evaluated. Prine ipal stresses are defined as the
normal stresses on the three mutually perpendicular planes through a point on
which· no shearing stresses occur. Maximum normal stress, minimum normal
stress, and normal stress (a value between maximum and m'inimum) are the three
princ-ipal stresses. The final stress value produced by the finite-eiemen.t
program is the stress obtained from the maximum distortion-energy theory (von
Mises, Huber, Hencky). ·
This theory ·assumes yielding. occur~ when the distortion .. energy -:-
defined as that portion of the total energy which causes distortion rather
than volume change -- equals the energy in simple tension at yield. This
stress can be compared to the material properties obtained from a tension test
and is calculated by
•2 2 2 2 . 2
Sv = Vo.5[(Sx- Sy) . + (Sy - Sz) + (S z - Sx)2] + 3.0 (Txy + Tyz + Tzx) (8)
or
Sv =Vo.5 (Sl s )2 + (S - s )2 + (S - s )2 (9)
2 2 3. 3 1 .·
where:
Sv = von Mises stress
Sx = stress in X direction
Sy = stress in 'i direction
Sz = s.tress in z direction
64
sl = maximum princip.al stress
Sz = intermediate principal stress
83 = m~n~mum principal stress

Txy = shear stress ~n XY plane
Tyz = shear stress in yz plane
Tzx = shear stress in zx plane
Selected results of the finite-element analysis for gate squeeze and shear-pin
failure are presented in Table 10. The results of this analysis indicate
that the gate. designed for the 1000-m-head pump/turbine would also suffice
for the 1500-m machine except· for the size.
3.1.4 Life-Expectancy Analysis
Basically, all stress analyses are fatigue analyses, the difference

being in the number of applied stress cycles. For example, dead load may
·be treated as single. cycle or used to obtain the mean stress in components
subjected to alternating stresses. A prerequisite for fatigue design is
an accurate knowledge of· the working loads, their mode and frequencies of
application, the re.sul tant stress field and the material fatigue· character-
i sties.
There are numerous methods for the prediction of fatigue life, .. and
fundamentally they all involve the concept of the gradual accumulation of
damage during the process of loading. The differences among the methods
appear from the emphasis placed on some particular aspect or formula for
the representa~ion of either or both the applied loading spectra or the
allowable stress-eye le data. In this anal:ys is, Miner·':; 1 inear rule: of cum,~la
tive damage will be used. Miner's rule is based on l:.ht! linear summation
of the fractions of the :fatigue damage, wh-ich is expressed in t~I:tns of the
cycle ratio (n/Nf) where
n = numberof loading cycles experienced for each

mode of loading
Nf = number of cycles required to cause fatigue failure
at ·any point of the component under the evaluated
mode of loading
Failure is hypothesized when ~(n/Nf) = 1. A conservative approach is to limit

the summation of the fatigue damage fraction to an order of magnitude below
the failure level or ~(n/Nf) <O.l.
The corrosion-fatigue strength data (Fig. 47) for 13% Cr-4% Ni cast
steel {used typically for· high-head, pump-Lurblne wicket gates) are adapted
from Ref. 12. In Fig. 47, R ~s defined as ··
sm
R =1 (10)
sa
65
Table 10. Selected Results of Finite-Element Analysis of the

1500-m-Head, Two-Stage, Pump-Turbine Wicket Gate
Results of Analysis
· Structural Characteristic Gate Squeeze Shear-Pin Failure
Stem rotation, rad 0.01134 0.02427

Maximum stem deflection, mm -0.696 -1.56
Maximum stem bending stress, MPa 84.0 188 .6·
Maximum stem torsional stress, MPa 45.5 102.2
Maximum leaf transverse bending stress, MPa 179.9 436.6
Maximum leaf axial bending stress, MPa 158.4 197.9
Maximum leaf-to-stem combined stress, MPa 249.5 463.6
Servomotor torque, kN·m 229.6 516.5
PURE REVERSE BENDING PURE PULSE BENDING
Sm
R=1--
s.
N 1 ==~~BfRREgFF8JCLE S
UJ
300 FATIGUE FAILURE
Q
..._,
::I
Ill.
::::E
~ 200
en
en
UJ
...a:en
_,
UJ 100
m
...
~
D.
w
0
0
~
0 100 200 300 400 500 600
MEAN STRESS, Sm (MPa)
Fig. 47. Corrosion-Fatigue Strength of 13% Cr-4% Ni Cast Steel

66
where:
Sa = alternating stress
Sm = mean stress
Pure. reverse bending occurs when R = 1 and corresponds to the case when the
alternating stress fluctuates about a zero mean stress. When R = 0, the
a~ternating stress fluctuates around a particular mean stress; equal in
magnitude to the alternating stress; this condition l.S called pure pulse
bending, since the sense of the stress. is constant. The general case is
·defined as O<R<l and generally describes the wicket-gate stress behavior.
The mean stre·ss is determined from the static-stress behavior at a. point
in the wicket gate, while the alternating stress is determined from the
dynamic-stress behavior of the gate.
3.1.4.1 Operating Conditions
The static and dynamic torques for all the steady-state and transient
operatiqg conditions were extrapoiated from the gate-toique curve of a
recent ·pump-turbine model (500-m head, 257-MW capacity). The most severe
static-dynamic torque· com~ination for each mode of operation was chosen for
use in the wicket-gate life-expectancy analysis: The operating conditions
considered are:
Condition Torque Static~ Dynamic, kN·m
Pump start 100 . 8 .:!:. 114 ~ 7

Pumping (maximum torque) 1 i 4. 7 ~ 1 00 . 8
Turbining (ma~imum torque) 141.2 ~ Rt.. 7
Runaway-speed c.ondition 331.0.:!:. 220.6
Energy-dissipation pumping mode 144.4.:!:. 86.6
The loading at the runaway-speed condition corresponds to the extreme condi-

tion of runaway speed with the gates stuck open at the transient head. of
2131 m. The energy-dissipation pumping mode is the condition that occurs
during the reversal of the direction of flow .in the penstock due to a pump
power failure at a head of 1575 m.
3.1.4.2 Number of Loading Cycles
The number of wicket-gate loading cycles for seven operational condi-

tions will be estimated very conservatively for a 50-year minimum life. The
following definitions and assumptions are used:
67
no = number of ope rat ions

:N = opez:ating speed = 720 rpm
Nb = number of runner blades = 7
Nr = runaway speed = 1008 rpn
t = durati'on of operation, m1n.
td = number of operational days per year = 365
tw = number of operational weeks per year = 52
ty = minimum years of operation = 50
• Shear-Pin Break: .The .·number of loading eye les for
the· ext·remely improbable assumption of one shear-pin
failure per gate per year is nl = 50.
• Gate-Squeeze Condition: For eight daily closing

cycles the number of loading cycles is
• :Runaway-Speed Condition: The number of loading .

cycles resulting from the gates being stuck open
for 30 seconds once each week is
30 6
n
3
= N (Nb)(t)(t )(t ) = 1008(7)
60
(52)(50) = 9.173 (10 0.
r . w y . .
• Pump-Power Failure: For one power failure per ~~ek

wh,ich lasts 30 seconds, the number of loading cycles is
30 ·c1· o 6 ).·.·
N(Nb)(t)(t )(t )
w y
= 720(7) 60' (52)(50) = 6 . 553
• Pump Start: The number of loading cycles for four
pump starts per day for a duration of 1.5 minutes each is
n
5
= = 5.5l9(lo8).
• Pumping (Largest Loads Attained): For 12 hours ·of

pumping daily, the number of loading cycles is
n
6
= N(Nb)(tHtdHt) = 720(7)(60 x 12)(365)(50) = 6.623(lolO).
. y .
• 'Turbining (Largest Loads Attained): The number of

loading cycles obtained for ten hours per day of
t'urbining is
.n = N(Nb)(t)(td)(t ) = 720(7)(10 x 60)(365)(50) - 5.'519(1010).

7 y
68
3.1.4.3 Results
Using the operating conditions, Fig. 47, and the number of loading
eye les described earlier, the fatigue-damage eye le ratio was determined for
selected nodes (Fig. 48). The determination was made from a finite-element
stress analysis of the 1500-m wicket gate. These eye le ratios and the
accumulated-damage ratio are given in Table 11 for 16 points located in the
probable areas of fatigue failure based on stress level. All stresses for
node 30 (stem top) were multiplied by a stress-concentration factor of 1.5 to
compensate for the round key located in this region. Note that the "Mises"
combined stresses were used in the fatigue calculations because·they represent
the total stress behavior at the point in question.
Despite the extreme conditions of operation assumed in this anatysis,

the maximum accumulated damage is 0.01029 for a period of 50 years, or about
0.1% of the damage required for fatigue failur~. TIH~.tefore, a near--infinite·
life can be expected for these gates when. subjected to the normal design
loads.
3.2 DISTRIBUTOR COMPONENTS
The spiral case, stay ring, and headcover for a 500-MW-capacity,

1000-m, equal-head machine were optimally sized by the IRIS program. The
interstage and discharge ring were initially configured, using manual
engineering design techniques, around the water passageways as defined by
hydraulic considerations. The 1000-m machine was selected for the structural
analysis because a similar analysis was performed for a. 1<;>00-m single-stage
pump/turbine with the same service char-acter is tics (power, head, etc.). Thus
a common base for comparison is provided. The structural analysis was for the
initial design of a machine that developed an equal head 'for each of the two
stages. Because of critical-speed problems, the final design of the two-stage
pump/turbine uses a 60/40 power split. This design was not structurally
analyzed because of time and funding limitations; however, no problems are
expected in accommodating the additional loading on the stationary machine
components.
A mixed axisymmetric, two-dimensional, plane-stress, finite-element

model of the distributor was prepared for analysis of stresses; foundation
loads; deflection patterns in the assembly; required bolt prestressing; and,
in general, the intercomponent reaction forces. The mechanical design
parameters were chosen to limit static stress and deflections as well as to
check for potential resonance of component~ suhjec~ to high vibration-type
loading.
For pump/turbines, the headcover is normally sized by limiting the

maximum hoop stress and axial deflection in the top deck at the guide-bear lng
support. The angular rotation of the top deck is one of the most important
headcover criteria, and its magnitude is inversely proportional to the head-
cover rigidity. Experience with single-stage pump/turbines has shown that
the angular rotation should be less than 0.0009 radians, at normal running
conditions, to assure sat is factory performance. The runner periphery and
the gate-pin circle are two major geometric constraints on the design.
69
~- t TOP BEARING
.I
__ .,,,..,,,..,.-
,-
---- ,\
Fig. 48. Fatigue-Analysis Reference Diagram for .

the 1500-m~Head Wicket Catc
70
Another critical part When designing a high-head reversible pump/

turbine is the stay ring; the dimensions of the stay vanes influence the
hydraulic characteristics as well as mechanical strength. The resultant axial
stay-vane stresses for each section have been chosen as the criteria for
optimizing the stay-ring structural design. For each section, iterative
calculations are , performed with the IRIS program by adjusting the spiral
case connection location to the stay ring so th.at the maximum r~sultant
axial-vane-tension stresses at pressure rise and pump shutoff conditions
are nearly equivalent. In this way, both pumping and turbining design
loadings were considered in the optimization process.
Sections of the spiral case are assembled in the workshop within

transportation limitations, While the remaining sections ar·e welded to the
stay ring at the site. The load on the stay ring is c~used by the spiral
case and the head cover. The stay ring is designed so th<~t: the location
of the forces is close to the centroid in order to obtain low stre~:;s levels.
The frequent change from pumping to turbining also requires cyclic loading
considerations.
In a sing le-st age pump/turbine, the discharge ring provides the

foundation of the machine and transfers part of the headcover load to the
powerhouse. The remainder of the load is internally compensated by the
pump/turbine. In. a two-stage machine the discharge ring (lower stay ring)
must accommodate connection to the interstage components. In this design,
every effort was made to locate the bolted flange connection of the discharge-
ring crown to its adjacent component such that the moments delivered to the
vane by both crowns are nearly equivalent.
3. 2.1 IRI.S Program Ana1ys is
3.2.1.1 Hcadcovcr
The IRIS program was used for the initial design of the headcuver
for the 500-MW-capacity, 1000-m-head, two-stage pump/turbine. The operating
condition is for pump shutoff and the total headcover load is 254.1 MN.
Pump shutoff occurs during a pump start after the release of the pressurl.zed
air. The pressure on. the outside of the wicket gate is equal to the maximum
static head. The' pressure between the wicket gate and the runner periphery
is equal to the maximum shutoff head. This pressure decreases from the
periphery of the runner to the runner seals according to a forced-vortex
parabolic law that assumes a mass of water is rotating at half the speed of
the runner. The pressure inside the runner seals ,is equal to the maximum
tail-water head. The required bolt preload for the headcover-stay-ring flange
connection is 637.4 MN. This pressure distribution is more severe than the
actual values recorded in the field for similar machines. The pressure inside
the wicket gates does not exceed /5% of the theoretical pump shutoff head used
.in the calculations, because of the large amount of pressure head trans formed
into kinetic energy. Therefore, a degree of conservatism is imposed into the
design, and this conservative approach is desirable for high eye lie loading
conditions. ·The analysis assumes 40 bolts, each of them 171.5 mm in diameter
and 149.4 nun in shank diameter. Because of prestress problems, the bolt
71
1 i
Table 11. Results of Life-Expectancy Analysi~ for a 1500-rn-Head Wicket Gate
Shear-Pi~ Failure Gate Squeeze Runaway Speed Pump-Power Failures Pump Start Pumping Turbining
n1 = 50 Cycles n2 = 1.46 (105) Cycles n3 9.173 (106) Cycles n4.= 6.553 (106) Cycles ns = 5.519 (108) Cycles n6 = 6.623 (lolO) Cycles n7 = 5.519 (lolO) Cycles
Fig. 48 Alternating. Alternating
Stress, MPa Stress, MPa n4 Stress, MPa Stress, MPa Stress, MPa
Node Stress, Stress,
Number MPa MPa Mean Alternating Mean Alternating Nf Mean Alternating Mean Alternating Mean Alternating
30 203.3 0.0 135.5 .7.300(10-6) 174.9 116.6 p.Ol02 76.4 45.8 0.0 53.3 60.6 0.0 60.6 53.3 1.325(10-~) 74.6 .44.7 6.899(10-~· 1.029(10~2)
37 199.4 0.0 88.8 0.0 4·8.5 32.4 0.0 21.2 12.7 0. 0 14 .8~: 16.9 o.o· 16.9 14.8 0.0 ':. 20.7 12.5 0.0 0.0
111 303.2 6.333(10~6) 177.3 1.437(10-4) 77.4 51.6 0.0 33.7 20.3 0.0 23.5 26.9 .0.0 26.9 23.5 0.0 33.0 19.8 0.0 1. soooo-4)
219 428.9 8.333(10-5) 163.8 2.920(10-5) 71.6 47.8 0.0 31.3 18.7 o.o· 21.8 24.8 .o.o 24.8 21.8 0.0 30.6 18.3 0.0 1. 12s <lo-4)
248 171.9 0.0 86.1 0.0 7.3 4.9 0.0 3.1 1.9 0. 0 2. 3 2.5 0.0 2.5 2.3 0.0 3.1 1.9 0.0 0.0
231 451.3 5.123(10-4) 180.7 .1.327(10-4) 72.7• 48.4 0.0 31.8 19.0 0.0 22.2 25.2 0.0 25.2 22.2 0.0 31.0 18.6 0.0 6.450(10-4)
508 312.1 8. 336 oo-6) 113.9 0.0 73.0 48.7 0.0 31.9 19.1 0.0 22.3 25.3 0.0 25.3 22.3 0.0 31.2 18.7 0.0 8.3330o-6).
510 463.6 6.250(10-4) 249.5 2,086(10-3) 50.1 33 .'4 0.0 21.9 13.1 0.0 15.3 17.4 0.0 17.4 15.3 0.0. 21.4 12.8 0.0 2. 7uoo-3)
512 319.6 1.111(10-5) 164.2 2.290(10-5) 73.2 48.8 0.0 32.0 19.1 0. 0 22.3 25.4 0.0 25.4 22.3 0.0 31.3 18.7 0.0 4.031(10-5)
211 73.1 0.0 26.3 0.0 73.0 48.7 . 0. 0 31.9 19.1 0.0 22.2 25.3 0. 0 25.3 22.2 0.0 31.2 18.7 0. o' 0.0
247 84.2 0.0. 63.2 0.0 12.7 8.4 0. 0 5.5 3.3 0.0 3.8 4.4 0.0 4.4 3.8 0.0 5.4 3.2 0.0 0.0
239 . 101.9 0.0 47.9 0.0 72.1 48.1 0.0 31.5 13.9 0. 0 22.0 25.0 0.0 25.0 22.0 0.0 30.8 18.4 0.0 0.0
500 126.6 0.0 84.7 0.0 76.6 51.1 0.0 33.4 20. 1 0.0 23.3 26.6 0.0 26.6 23.3 0.0 32.7 19.6 0.0 0.0
498 230.8 o.o 171.1 3.650(10-5)· 62.2 41.5 0.0 27.2 16.3 0.0 18.9 21.6 0.0 21.6 18.9 0.0 26.5 15.9 0.0 3.650(10-5)
520 111.7 0.0 75.2 0.0 76.9 51.3 0.0 33.5 20.1 0. 0 23.4 26.7 0. 0 . 26.7 23.4 0.0 32.9 19.7 0.0 0.0
103 73.8 . 0.0 72.9 0.0 81.0 54.0 0.0 33.3 21.2 0.0 24.6 28.0 0.0 28.0 24.6 0.0. 34.5 20.7 0.0 0.0
' .
73
diameter was later changed to 180 mm with a shank diameter of 162.5 Due mm.
to the split flanges of the headcover, only 38 bolts with the same spacing as
40 could be used. During field erection, the 38 bolts would be prestressed
higher to accommodate the loading. The results of this analysis is shown in
Table 12 -- the thickness (T), height (l:i), and diameter (D) dimensions in the
table are referenced to Fig. 49. The maximum hoop stress occurs at the inner
radius of the top .deck. Angular rotation is based on the classical assump-
tions that rib rigidity is infinite and that the headcover rotates as i rigid
body.
3.2.1.2 Stay Ring/Spiral Case
The IRIS calculations·performed for obtaining the optimum configuration

of the stay ring/spiral case assumes.a symmetric stay-ring structure about the
centerline of the vane as designed for the single-stage machine. Because of
interstage component connections, however, symmetry is not entirely possible
for the two-stage pump/turbine. The structural optimization process divides
the stay ring/spiral case into 18 sections, numbered sequentially in a clock-
wise manner (looking down on the machine) and starting at ·the horizontal
centerline of the machine nearest the water inlet (Fig. 50). The locations
of the spiral-ca.se sections and the spiral case to stay-ring intersection
Table 12. Results of IRIS Program Headcover Analysis at

Pump·-shut.off Condition for the 1000-m-Head,
500-Mw-Capacity, TWo-Stage Pump/Turbine
Thickness (T) Height (H) Diameter (D)

Symbol Value (mm) Symbol Value (mm) Symbol Value (m)
T1 146.1 H1 139.7 D1 5.109

T2 ·222.2 H2 781.1 D2 6.077
T3 298.4 H3 647.7 D3. 2.496
T4 374.6 H4 1962.2 D4 1.962
TS 120.6 HS 743.0 DS 5.594
T6 108.0 D6 5.759
TB 108.0 D7 5.886
T9 133.4 DB 4.598
TlO 95.2 D9 2.702
Tll 209.6 D10 6.890
T12 80.5 Dll 6.375
Maximum hoop stress, MPa 122.3

Maximum angular rotation, rad 0.00078586
MBximum deflection ·at bearing support, mm 1. 525
74
DI I --+----+-J----:t
H4
2-- T I 2 CRIB
THICKNESS> I
.-
T4
I
TG -DIO__J 1
TH3
TIO H5
HI
Fig. 49. IRIS Program Headcover: Thickness (T), Height (H),

and Diameter (D)' Locations
are identified in Fig. 51. The dimensions for each section are given in
Table 13, along with the vane loading and vane stresses for the normal-
running, pump-shutoff, pressure-rise, and pressure-test conditions. The
normal-running condition corresponds to the machine operating at maximum
static lead. The pressure distribution inside the runner periphery follows a
forced-vortex parabolic law that assumes a mass of water is rotating at half
the speed of the runner. The maximum tailwater 4ead is applied at the inside
of the runner seals. The pressure-rise condition occurs with the wicket gates
closed and represents the normal turbine shutdown operation. The maximum
pressure rise acts outside the wicket gates and the maximum tailwater head
acts inside the wicket gates. The pressure-test. condition corresponds to
hydrostatic testing at 150% of design .Pressure before the spiral case/stay
ring is embedded in concrete.
Stay....:.ring loading and stay-vane stresses are represented in Fig. 52.

These stresses were chosen as the criteria for optimizing the stay-ring
structural design, as mentioned earlier, and are expected to be among the
highest in the stay-ring structure. For the pressure-rise and pump-shutoff
conditions, they are less than the 138 MPa allowable stress, thus indicating a
sound design.
75
16
n4NLET WATER
HORIZONTA.L
CENTERLINE
11 SECTION I
Fii. 50. Stay-Ring Spiral-Case Sections
3.2.2 Finite-Element Analysis
Distributor comp6nents for a 500-MW-capacity, 1000-m~head, two-

stage, equal-head-per-stage, pump/turbine were analyzed with a mixed, two-
dimensional, axisymmetric, finite-element model. This approach mathematically
reduces a three-dimensional axisymmetric representation to a more manageable
two-dimensional representation. The great reduction in problem size resulting
from this simplification permits the quick analysis of very large structural
assemblies. which could not be handled economically using three-dimensional
models. Any associated reduction in accuracy of the results is minimal, with
the greatest effects occurring in localized areas where the representation of
single-plane stiffness does not account for the third dimensional distribution
. '
76
INTERSECTION
. RADIUS .
PLATE
THICKNESS
f
INTERSECTION
SECTION
ELEVATION /RADIUS
GCCTION CENT!R
I
TO UNIT CENTERLINE
Fig. 51. IRIS Program: Stay-Ring Spiral-Case Geometry Description
of stiffness. The simplification procedure thus results in an averaged.

behavior being obtained. An example of this localized structural behavior
not being fully predicted is in the ribbed connections, or reinforced hoops,
where stress concentration might be expected. Negligible accuracy difference
can be expected between two- and three-dimensional analyses for the axisym-
metric components and for plane-stress components remote from their interface
with the axisymmetric components. There are, however, some limitations
·resulting tram the assumptions and simplifications used in this approaGh, and
they have to be properly understood and taken into consideration when prepar-
ing the model and interpreting the results.
3.2.2.1 Limitations of Two-Dimensional Axisymmetric Representation
In the two-dimension a 1 axisymmetric repre sen tat ion-, the boundary

nodes located at the intersection of the two-dimensional and axisymmetric.
elements are tied together for displacements and rotations while the direct
strains are kept independent. The "in-plane" stiffness, of the ribs is
distributed equally along the circumferencP. of thP. rine PlPmPnts, Th~
"bridge" bending ring load occurring between the ribs (or vanes) is not
considered.· In a headcover, for example, the local bending between ribs at
the water passage deck, resulting from the hyd raul 1c pressure, is not repre-
sented (Fig. 53b, Section A-A). The deformation of the ring elements is
assumed to be perfectly axisymmetric, while the true deformation· follows a
cyclic symmetrical pattern. . This effect· on the headcover bolting flange
subjected to radial loads is shown in Fig. 53c, Section B-B. The analysis-
also neglects the stress concentration due to holes and openings located in
the top and.bottom.decks (Fig. 53d, Section c-c). These limitations of the
mixed-plane stress, axisymmetric analysis do not affect the validity of the
77
Table 13. Results of IRIS Program Spiral Case/Stay Ring Analysis for
the 1000-m-Head, 500-MW-Capacity, Two-Stage Pump/Turbine
Component Dimensions in Stay Ring/Spiral Case, by Section
Coni pon'e n t 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Sect ion radius, mm 944.2 919.8 894.8 868.9 842.3 814.6 785.8 755.9 724.5 691.6 656.8 619.8 575.0 537.0 489.5 436.0 373.6 315.8
Section center to unit centerline, m 4.587 4.565 4.543 4.521 4.498 4.475 4.451 4.426 4.401 4.357 ·4.348 4.320 4.291 4.261 4.229 4.195
Section area, m2
4.607
2.554 2.. 417 2.279 2.142 2.005 1.867 1.730 1.593 1.455 . 1.318 1.181 1.043 0.906 I 0. 768 0.631 0.493 0.356
4.107
0.219
Plate thickness, mm 73.2 71.1 68.9 66.7 64.5 62.2 59.7 57.3 54.7 52.0 49.2 46.2 43.0 !39.7 36.0 31.8 27.1 22.7
Intersection radius, m 3.824 3.827 3.831 3.835 3.839 3.844 3.848 3.854 3.859 3.865 3.872 3.880 3.889 j 3.899. 3.910 3.924 3.942 3.944
Intersection elevation, mm 526.9 519.2 511.5 503.1 494.2 484.6 474.1 462.9 450.7 437.5 422.5 406.3. 387.7 366.3 341.6 311.7 274.2 270.1
.·Specific Vane Loading or Numerical Value of the Component Loading or Stress, by Section
Stress, by Operating Condition (Each Value Corresponds to a Section Number Above)
Normal Running:
Total vane mo~ent, MN·m 13.069 12.827 12.734 12.556 12.445 12.274 12.044 11.890 11.77.5 11.611 11.366 11.229 11.035 I )0.813 10.617 10.404 10.168 19.986
Total vertical load, MN 561.60 564.30 557.88 551.42 544.80 538.11 531.35 524.37 517.25 509.91 502.51 494.79 486.90 478.76 470.29 461.47 454.23 428.37
Tension stress, MPa 91.90 90.90 89.86 88.82 87.76 86.88 85.54 84.47 83.32 82.14 80.95 79.70 78.43 77.12 75.76 74.33 72.85 69.00
Outer diameter bending stress, MPa _;12.79 -12.55 -12.46 -12.28 -12.18 -12.01 -11.78 -11.63 -11.47 -11.36 -11.12 -10.99 -10.80 :-10.58 -10.39 -10.18 -9.95 -19.55
·Inner diameter bending stress, MPa 13.29 13.04 12.95 12.77 12'. 66 12.48 12.25 12.09 11.92 11'.81 11.56 11.42 11.22 '· 11.00 10.80 10.58 10.34 20.33
Outer diameter resultant stress, MPa 79.11 78. 35" 77.41 76.54 75.58 74.67 73.81 72.83 71.85 7.0.78 69.83 68.72 67.63 66.54 65.37 64.16 62.90 49.45
Inner diamet'er resultant stress, MPa 105.19 103.94 102.81 101.59 100.41 99.16 97.84 96.50 .. 95.24 93.95 92.50 91.12 89.65 ' 88.12 86.55 84.92 83.19 89.33
Pump-Shutoff:
Total vane moment, MN·m 23.310 22,068 21.976 21.797 21.686 21.515 21.285 21.131 20.966 20.852 20.601 20:.4 70 19.259 . 20.054 19.858 ·19. 645 19:409 29.222
Total vertical load, MN 603.35 598.05 591.63 585.18 578.55 571.87 565.10 558.12 551.01 543.66 536.26 528.54 520.65 512.51 504.04 495.22 485.98 462.12
Tension stress, MPa 97.33 96.34 ':13.92 94.26 93.19 92.12 91.03 89.90 88.76 . 87.57 86.37 85.14 R.1. R7 82.56 81,19 79.77 78.28 74.44
Outer diameter bending stress, MPa -21.83 -21.59 -21.50 -21.33 -21.22 -21. OS -20.82 -20.67 -20.51 -20.39 -20.16 -20.03 -18.46 '-19.62 -18.05 -19.22 -18.97 -28.59
Inner diameter bending stress, MPa 22.69 22.44 22.35 22.17 22.06 21.88 21.65 21.49 21.32 21.21 20.98 20.82 20.62 . 20.40 20.20 19.98 19.74 29.72
Outer diameter resultant stress, MPa 75.51 74.75. 73.80 72.94 71.98 71.07 70.20 69.23 66.87 67.18 66.22 65.11 64.03 . 62.94 61.76 60.55 59.29 45.!\4
Inner diameter resultant stress, MPa 120.02 118.78 117.24 116.43 115.25 107.10 112.68 111.39 110.08 108.78 107.34 105.96 104.49 '102.95 101.39 99.75 98.02 104.16
Pressure-Rise:
Total vane moment, MN·m -17.228 -17.553 -17.677 -17.915 -18.064 -18.294 -18.602 -18.808 -19.029 -19.182 -19.510 -19.694 -19.954 '-20.251 -20.514 -20.7.99 -21.115 -7.960
Total vertical load, MN 637.50 629.20 620.59 611.95 603.08 594.12 585.05 575.70 566.17 556,32 545.52 536.07 516.59 514.59 503.24 491.42 479.05 44 7. 07
Tension stress, MPa 102.69 101.35 99.97 98.57 97.14 95.70 . 94.24 92.74 91.20 89.62 88.02 86.35 84.65 82.89 81.06 79.16 77.17 72.01
Outer diameter bending stress, MPa 16.85 17'. 17 17.29 17.53 17.67 17.90 18.20 18.40 18.62 18.77 19.09 19.27 19.52 )19. 81 20.07 20.35 20.66 7.79
Inner diameter bending ctress, MPa -17.52 -24.7 5 -17.98 -18.22 -18.37 -18.60 -18.72 -19.13 -19.35 -19.51 -19.84 -20.03 -20.29 •;-20.60 '-20.86 -21.15 -21.4 7 -8.10
Outer diameter resultant stress, MPa 119.53 118.53 117.26 114.7.2 114.82 113.60 112.44 111.14 109.82 108.38 107.11 105.62 104.17 l02.70 101.13 99.51 97.69 79.80
Inner diameter resultant stress, MPa 85.17 83.50 78.54 80.35 78.77 77.10 75.32 73.61 71.85 70.11 68.18 52.53 64.35 I 62 .3o 60.20 58.01 21.22 63.92
Pressure-Test: I
Total vane moment, MN·m -79.859 -80.447 -80.734 -81.194 -81.519 -81.9.68 -82.534 -82.949 -83.387 -83.724 -84.323 -84.705 -85.203 ~85.757 -86.259 -86.791 -87.368 -67.800
Total vertical load, MN 703.86 691.28 678.37 655.40 652.09 638.65 625.04 610.99 596.73 581.97 567.08 551.59 535.72 .519.37 502.34 484.61 466.05 418.06
Tension stress, MPa 113.36 111.35 109.27 107.19 105.04 102.88 100.69 98.43 96.12 93.74 91.35 88.85 86.29 83.66 80.93 78.06 75.07 67.35
Outer diameter bending stress, MPa 78.13 78.71 78.99 79.44 79.75 80.19 80.75 81.15 80.20 80.39 82.50 82.87 83.36 83.90 84.39 84.91 85.48 66.33
TnnPr rliamP.ter bending stress, MPa -81.22 -81.82 -82.11 -82.57 -82.91 -83.36 -83.94 -84.36 -84.81 -85.14 -85.76 -86.15 -86.65 ;;-87. 22 -87.73 -88.27 -88.85 -68.95
Outer di.amP.ter resultant stress, MPa 191.49 190.06 . 188.26 186.62 1!!4.!!0 . l!lJ.UJ 181.43 179.58 177.70 175.66 173.85 . 171.72 169.65 1'!67. 56 1fi~.11 162.97 160.55 133,68
Inner diameter resultant stress, MPa 32.14 29.54 27.17 24.61 22.14 1':1·. 51 16.75 14.07 11.32 8.GO 5. 59 2.71 -0.36 ; -3.55 -6.81 -10.?,0 -13.78 -1.61
HEAD COVER
UPLIFT
HEADCOVER R .I I\DIAL
INTERACTIVE FORCE
TOTAL VANE MOVEMENT

~
TENSION
I-'---'--L-L-..I.--'--L--L--'-.....I-...L-.L.-L.-J4- S T RE S S
BENDING
0 tlJrJ.::Z:::P---==<:::::::z:._.L_..J.-L-L-t- S T R E S S
DISCHARGE RING
RESULTANT
RADIAL INTERAC T IVE
0 P--.L-..-..L-L--L---L-L_J__J__t__L....JL...L-4- S T RE S S
FORCE
HEADCOVER VANE INNER VANE OUTER
U PL IFT RE ACTION DIAMETER DIAMETER
Fig. 52. IRIS Program: Stay-Ring Loading and Stay-Vane St r esses

80
--1
I
I
I
II
I
l
___,.,/
SECT A-A
A
lbl
SECT 8-8
lei
Fig. 53. Headcover T.ocRl i?.Pcl F.ffPrts
general structural behavior of the 1000-m machine components; they explain why
more details on localized structural behavior are not presented, e.g., at
ribbed connections or where stress concentrations might be expected. . Such
details can be accommodated through weld geometry, local reinforcement, or
further three-dimensional structural analysis. The magnitudes of hoop stress,
foundation loading, intercomponent radial interactive forces, required bolt
prestresses, etc., are very accurately predicted.
3.2.2.2 Model Description
The finite-element model of a mixed distributor assembly is shown in

Fig. S/1, where the shaded at:8~ ~:~i.gui.fi.es axisymmetric elements while the
non-shaded area signifies two-dimensional plane -stress elements. There are
1017 elements and 1500 corner nodes, having six degrees of freedom, which
gives 9000 0500 x 6) simultaneous equations. The model includes the dis-
charge ring, spiral case, stay ring, headcover, bearing support, intermediate
water passages and vanes, and connecting bolts. Experience has shown that the
inclusion of the discharge ring in the distributor analysis is essential for a
81
AXISYMMETRIC ELEMENTS
TWO-DIMENSIONAL
D PLANE STRESS ELEMENTS
X
Fig. 54. Finite-Element Model of the Distributor Section
of a Two-Stage Pump/Turbine: 1000-m Head,
500-MW Capacity, Equal Head Per Stage
82
proper understanding of the rolP of this important component and for a

calculation of the foundation loads.
The analysis will provide the following information:
• A general understanding of the deflection pattern 1n the

assembly;
• A good evaluation of the interactive forces between
components, e.g., at bolted flanges;
• The calculation of the bolt prestress required to elimi-
nate fatigue; and
• The foundation loading.
Reactions to the assumed foundation constraints and friction forces

at four locations are also shown in Fig. 54. Loadings used in this analysis
pertain to the normal running condition with the following prPRRure distribu-
tions:
• The top-stage stay vanes and wicket gates are subjected to

a pressure, P0 = 11.28 MPa, from the 1150-m headwater.
• The pressure distribution between the first-stage runner
periphery and seal varies parabolically as a function of
P0 , Ro, N2, r2 -- where N = 450 rpm and is the runner
speed; R0 = 2.108 m and is the runner radius, and r =
position radius.
• The interstage components and bottom-stage stay vanes are
subject to a pressure, P0 1 = 6.37 MPa, from the 650-m
interstage head.
• The pressure distribution between the bottom-stage runner
periphery and seal varies parabolically as a function of
Po, Ro, N2, r2.
• The region below the bottom-stage runner is subjected to a
pressure of 1.47 MPa from the 150-m tallwater.
3.2.2.3 Results
The results of the distributor analysis indicate that a majority of the

loads developed by the two-stage machine are compensated within the machine to
a greater degree than in a single-stage pump/turbine. During normal opera-
tion, the foundation has to withstand a 21.2 MN compression and a 7.1 MN
tension load. In contrast, the single-stage pump/turbine foundation must
accommodate a 44.1 MN load in both tension and compression.! Headcover
detlections and angular rotations for several positions identified in Fig. 55
are given in Table 14. Also included are the corresponding values from the
1 000-m, 500-MW-capac ity single-stage, pump-turbine preliminary design .1 The
distributor height growth, G, is an acceptable value since the additional
clearances can be filled by the wicket-gate end seal to limit leakage and wire
drawing. The largest axial deflection in the head cover occurs at the shaft
seal bolted connection, location J in Fig. 55. One of the most important
83
Table 14. Headcover Deflections and Angular Rotations

of Single- and Two-Stage Pump/Turbines:
1000-m Head, 500-MW Capacity
Deflection Rotation
Two-Stage Single-Stage Two-Stage Single-Stage
Parameter Value (mm) Value (mm) Parameter Value (rad) Value (rad)
A 0.9704 0.9797
a = IA-cl 0.00053 0.00061
B 0.3018 0.3959
o'
c 0.1675 0.0937
D 0.3427 0.3320 _ID-Ej
s - o" 0.00041 0.00045
E -0.3573 -0.3031
F 0.3684 -0.2034
G 1.2655 0.9095 e= S/a 0.77382 0. 73770
H 1 .4954 1.1618
headcover criteria is the angular rotation of the top deck, a, and its
magnitude is inversely proportional to the headcover rigidity. Single-
stage pump-turbine experience has shown that a should be less than 0. 0009
radians at normal running conditions to assure a satisfactory performance.
The wicket-gate bearing angular rotation, S , is an indication of the head-
cover rigidity and is used as a criteria to prevent gate-movement binding.
The maximum value of S should be 0. 0009 radians. The ratio of the gate-
bearing rotation to headcover top deck rotation, e = S/a, is an indication
of the efficiency of the transfer, by the ribs, of the shear load between
the headcover top and bottom decks. An infinitely rigid ribbing corresponds
to 8= 1.0; it is not unusual for high-head pump/turbines under normal
operation to have a value of e = 0. 75.
Some selected values of the maximum stress 1n the distributor com-

ponents are given in Table 15.
Early in the design process of the two-stage pump/turbines, it was

deemed important to attain the normal operational behavior of all the inter-
acting major components by finite-element structural analysis because the
operating loads are beyond present experience. The results of this analysis
have shown that an acceptable mechanical design was developed. Only a few
minor adjustments in the area of the interstage and lower . stay vanes are
necessary. These two components will require carefully designed fillets at
their connection to their upper and lower axisymmetric decks so that the
transition stresses do not reach unacceptable levels. The final configuration
of the thinner downstream edges of these two stay vanes must also be carefully
controlled to maintain the desired thickness.
Remember that this analysis is for a machine that develops equal

head per stage and that the shafting system analysis, to be discussed in
84
I• 8' = 152. 90cm ~

~ tJ' q c
DATUM LINE
II
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f-~ "- L
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tl
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Fig. 55. Location of Major Distributor Component Deflections and
Rotations in a Two-Stage Pump/Turbine: 1000-m Head,
500-MW Capacity, Equal Head Per Stage
85
Table 15. Selected Maximum Distributor Component Stresses in a

Two-Stage Pump/Turbine: 1000-m Head, 500-MW Capacity
Figure 55 Stress
Parameter Location (MPa)
von Mises stress 1n head cover K 112.6

von Mises stress 1n discharge ring L 98.4
von Mises stress in interstage component M 103.4
von Mises stress in stay ring N 117.7
Hoop stress in headcover p 76.7
Circumferential stress in spiral case Q 164.6
(tension)
Axial stress (tension and bending) at the R 97.2
centerline of top-stage stay vane (tension)
Axial stress at centerline of interstage stay vane s 162.7
(tension)
Axial stress at centerline of lower-stage stay vane T 155.9
(tension)
the next section, resulted in a final design of the 1000-m machine with
the top stage carrying 60% of the total power and the bottom stage . carrying
40%. Hence, the top-stage runner outside diameter is 330-mm larger than the
one used in the 50/50 machine. No problems are anticipated in accommodating
the additional loading on the stationary components. Although an analysis of
the 60/40 pump/turbine would be an asset in providing positive verification of
the final design, limitations of time and expense could not justify this
study. Such studies would be conducted for a particular application, and it
is believed that only minor modifications would be required.
3.2.3 Shafting System Analysis
The shafting system of a two-stage pump/turbine is more prone to

a lower critical speed than an equivalent single-stage machine. This tendency
results from the longer shafting required to support both stages and the
overhung runner masses at relatively large distances below the guide bearing.
For this reason, a special critical-speed analysis was performed for the 50/50
machine. The model used for this study is shown in Fig. 56 and dimensions of
the nodal elements are given in Table 16. The added weights and inertias
used for the lateral, longitudinal, and torsional vibrations are listed in
Table 17. For the lateral case, stiffnesses of k1 = 2.627 GN/m, k2 = 1.751
GN/m, and k3 = 175.1 MN/m were added at nodes 22, 32 and 39 as shown in
Fig. 56. Critical-speed calculations were performed by the NATHALIE computer
program, a shaft-and-beam analysis program that performs lateral, longitu-
dinal, and torsional dynamic analyses on systems having any number of bearings
of specified stiffness and additional masses. The program will calculate the
86
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Fig. 56. Shafting System Model for the Critical-Speed Study

of a Two-Stage Pump/Turbine: 1000-m Head, 500-MW
Capacity, 50/50 Head Split
87
Table 16. Nodal Element Dimensions for the Critical-Speed Analysis

of a Two-Stage Pump/Turbine Shafting System:·
1000-m Head, 500-MW Capacity, 50/50 Head Split
Fig. 56 Outside Inside Outside Inside

Element Length Diameter Diameter Element Length Diameter Diameter
Number (mm) (mm) (mm) Number (mm) (mm) (mm)
1 325.1 2489.2 2133.6 23 904.0 1320.8 304.8

2 294.6 2616.2 1980.7 24 726.9 1320.8 304.8
3 127.0 3276.6 1294.4 25 240.0 1879.6 304.8
4 114.3 4267.2 1979.2 26 240.0 1879.6 304.8
5 203.2 2489.2 304.8 27 823.0 1320.8 304.8
6 167.6 3276.6 304.8 28 823.0 1320.8 304.8
7 91.4 4267.2 304.8 29 823.0 1320.8 304.8
8 101.6 17 78.0 304.8 30 823.0 1320.8 304.. 8
9 535.9 1143.0 304.8 31 480.0 1320.8 304.8
10 434.3 114-3 .o 304.8 32 582.9 2180.8 304.8
11 292.1 3048.0 2387.1 33 823.0 3911.6 3693.2
12 203.2 3048.0 2387.1 34 823.0 3911.6 3693.2
13 152.4 3505.2 2670.6 35 823.0 39U.6 3693.2
..
14. 12 7.0 4267.2 3495 .o 36 411.5 960.1 0.0
. 15 165.1 2418.1 304.8 37 474.2 960.1 0.0
16· 165.1 2921.0 304.8 38 460.5 960.1 0.0
17 114.3 4445.0 304.8 '39 260.1 960.1 0.0
18 345.4 2109.2 304.8 40 257.3 1213.9 0.0
19 381.0 1320.8 304.8 41 267.5 397.8. 366.0
20 350.5 1320.8 304.8 42 372.4 397.8 366.0
21 284.5 3171.6 304.8 43 372.4 397.8. 366.0
22 569.2 1371.6 304.8 44 372.4 397.8 366.0
natural frequencies as well as the dynamic response of the system to periodic

loading. The following critical speeds were obtained:
• Lateral first critical speed 496 rpm

• Longitudinal first critical speed 4636 rpm
• Torsional first critical speed 1220 rpm
Since the lateral critical speed is close to the normal operating speed
of 450 rpm, the design was changed to increase the bearing stiffness ·and
88
Table 17. Added We"ights and Inertias for the Critical-Speed Analysis
of a Two-Stage Pump/Turbine Shafting System: 1000-m Head,
500-MW Capacity, 50/50 Head Split
Weight Concentrated Norma.l Polar Inertias·

to Centerline, N kN·m2
Node Lateral Longitudinal Torsional
Number Vibrations. Case Vibrations Case Vibrations Case
33 1.027 106 1.027 . 106 43.27

34 ~.027 . 106 1.027 .. 106 . 43.27
35 1.027 106 1.027 106 43.27
36 1.027 106 1.027 . 106 43.27·
44 667.2 667.2
45 667.2 667.2
to utilize a larger top-stage runner; this change lumps as much overhung

mass as close as possible to the main-shaft guide bearing, thus fncreas-ing the
bearing IS Stability and decreasing the deflection Of the lower runner seal ..
This change resulted in the top stage carrying 60% of the total power ~nd the
bottom stage carrying the rem~ining 40%~
The shafting system for the 60/40 power split was analyzed for cr iti-
cal speeds with the model shown in Fig. 57. Dimensions of the nodal elements
are given in Table 18 and the added weights and inertias used for the lateral~
longitudinal,. and torsional vibrations are the saine as those used for the
50/50 head split listed in Table 1 7'. For the lateral case, stiffnesses of
k1 = 2.977; GN/m, k2 = 5.008 GN/m, and k3.= 810.9MN/in·were added at nodes
22, 32, and 39 --as shown in Fig. 57. 1he critical speeds calculated from
this dynamic analysis are: ·
• Lateral first critical speed 780 rpm

• Longitudinal first critical speed 4903 rpm
• Torsional first critical speed 1402 rpm
The added stiffness and the con6entraiion of the runner mass at the top
stage (clo~est to the guide bearing} have increased the critical speed
to a safe margin above the normal operating speed.
The maximum torsional shear stress in the shaft is 26.9 MPa, ·which
.is less than the maximum allowable value of 42 MPa.
89
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Fig. 57. Shafting System Model for the Critical-Speed Stuqy

of a Two-Stage Pump/Turbine: 1000-m Head,
500-MW Capacity, 60/40 Head Split
90
Table 18. Nodal Element Dimensions for the Critical~Speed Analysis

of a Two-Stage Pump Turbine Shafting System:
1000-m Head, 500-MW Capacity, 60/40 Head Split
i
Fig. 57 Outside In.side Fig. ·57 Outside Inside

Element Length Diameter Diameter Element Length Diameter Diameter
Number (mm) (mm) (mm) . Number (mm) (mm) (mm)
1 121.9 2367.3 2113.3 23 904.0 1320.8 304.8

2 177.8 2367.3 1971.0 24 726.9 1320.8 304.8
3 238.8 2529.8 2214.9 25 240.0 1879.6 304.8
4 139.7 2875.3 2052.3 26 240.0 1879.6 304.8
5 106.7 3840.5 2865.1 27 823.0 1320.8 304.8
6 12 7 .Q 2042.2 304.8 28 823.0 1320.8 304.8
7 152.4 2540.0 304.8 29 823.0 . 1320.8 304.8
8 88.9 2773.7 304.8 30 823.0 1320~8 304.8
9 86.4 3860.8 304.8 31 480.1 1320.8 304.8
10 203.2 1432.6 3Q4.8 32 582.9 2180.8 304.8
11 492.6 1280.2 304.8 33 823.0 3911.6 3683.0
12 304.8 1089.7 304.. 8 34 823.0 3911.6 3683.0
13 218 .ll 3820.2 JOl1,8 ·35 823.0 3911.6 3683.0
. 14 157.5 2824.5 304.8 36 411.5 960.1 0.0
15 106.7 2824.5 304.8 37 474.2 960.1 0.0
16 162.6 3037.8 304.6 38 460.5 960.1 '0. o.
17 114.3 ll4-80. 6 304.8 39 260.1 960.1 0.0
18 335.3 2123.4 . 304.8 40 257.3 1213.9 0.0
. 19 91.4 1585.0 304.8 41 267.5 397.8 366.0
20 711.2 . 1320.8 304.8 42 372.4 "397.8 366.0
21 304.8 1371.6 304-.8 43 372.4 397.8 366.0
22 569.2 1371.6 304.8 44 372.4 39/.8 . 366.0
91
4 COST ANALYSIS
A cost estimate for designing and manufacturing each of the six pump/
turbines described in this report was prepared. The prices are given in
Table 19 and are based on mid-1978 costs and a typical 2000-2100-MW installa-
tion .. The cost data for the 500-MW-capacity, 1000-m and 1500-m machines -- as
we 11 as for the 350-MW-capacity, 1250-m pump/turbine -- have been increased
from the values reported earlier in Ref. 13. The relationship between the
·pump-turbine capacity, head, and cost per kW is shown in Fig. 5.8. A very
approximate breakdown of percentage of total cost for each major component of
the two-stage pump/turbine is given in Table 20~ _From Ref. 4, the cost of a
double-gated, two-stage pump/turbine would be approximately 8% higher than the
single-gated machine.
Table 19. Estimated Cost of Two-Stage, Gated

Pump/Turbines
Head Power Cost per Unit Specific Cost

(m) (MW) . (1978 $106) (19.78 $/kW)
1000 500 10.250 20.5

1250 500 8.250 16.5
1500 500 6.750 13.5
1000 350 8.050 23.0
1250 350 6.300 18.0
1500 350 4.900 14.0
Table 20. Percentage of Total Cost of Each

Major Component of a Two-Stage
Pump/Turbine
Percentage of
Component Total. Cost
Pit Liner 5.0

Draft Tube Liner 8.0
Head cover 9.5
Stay Ring 14.3
Spiral Case 11.0
lntcratagc Components 8.3
Discharge Ring 6.5
Runners 13.0
Wicket Gate and Mechanism 8.0
Shaft 4.6
Miscellaneous 11.8
100.0
92
23.00
22~00
21.00
.
20.00·
19.00
~
~
.....
0 18.00
t- -
C/) 17.00
0
0
~6.00
15.00
500 MW
1. 4.00
13.00
12.00
1000 1250 1500

HEAD,m
Fig. 58. Relationship between the Two-Stage Pump-Turbine
Capacity, Head, and Cost per kW
93
5 CONCLUSIONS
A gated, two-stage pump/turbine has not yet been installed in service,

but this machine has a number of advantages . for high-head p~mped-storage
applications -- especially . for the proposed UPHS facilities. Three European
manufacturers of pump/turbines (Escher Wyss, Neyrpic, and Voest Alpine)
, have
conducted studies and some model testing on double-gated machines. Electri-
c ite de France has placed an order with Neyrpic, for a 35-40-MW capacity,
400-m. head, double-gated, two-stage pump/turbine for the Le True 1 plant.
Allis Chalmers has . conducted preliminary studies for Argonne National

Laboratory on six different two-stage, top-gated pump/turbines suitable for
UPHS service. These studies have shown that the concep_t is feasible from the
mechanical, hydraulic, and economic standpoint for at least the specified
service conditions: to 500-MW power at a maximum nominal head of 1500 m.
Sound m.echanical design has been demoqstrated through the static

and dynamic structural analyses of major components presented in the report.
With the good hydraulic performance predicted (overall efficiencies around
90%), the authors of this report foresee no major turbomachinery obstacles
which could hamper the development of these machines. Of course, extensive
model testing, in combination with further development work, is r-equired
before such machines can be built.
94
GLOSSARY
alternating current electric current that reverses direction flow

periodically in a sinusoidal pattern
armature that part of an· electric rotating machine that includes ·the ma.in
current-carrying winding (the coil in which electromotive force, produced
by magnetic flux rotation, is induced); may be rotating or stationary
axial hydraulic thrust in single-stage and multistage pumps, the summa-
tion of unbalanced impeller forces acting in the axial direction
axisymmetric symmetrical about an axis
back. up reserve generating capacity of a power system
band shroud ring at the bottom of a Francis-type runner to which the
blades are attached
baseload that part of the total load of an electric power system which -
·is applied, where possible, by· the most efficient, connected generating
S'tations; minimum load of a power generator over a given period of time.
bifurcation division into two branches
blade that part of a rotating fan or propeller arm that has an airfoil
shape
bottom deck. lower part of the headcover of an hydraulic turbine
bucket a cup on the rim of a Pelton wheel against which water impinges.
bulb tur.bine an axial-flow turbine situated in a straight-through water
passage; the generator is enclosed in a streamlined water-tight bulb
located in the water passageway, either on the upstream or downstream
side of the runner
bulkhead gate a gate installed at the entrance of a fluid passage and
used to dewater the passage for inspection and maintenance; always
opened or closed under balanced pressure
bus a set of two or more electric conductors that serve as common
connections between load circuits and the source of electric power
busbar a heavy, rigid metallic conductor used to carry a large current
or to make a common connection between several electrical circuits
capacitor a dielectric device that momentarily absorbs and stores
electrical energy
capacity the maximum power that can be developed by the generators of a
hydroelectric plant, at normal head with full flow
capacity factor the ratio of average power of an electric power plant
to its rated capacity
capacity interchangP in power pooling, transactions resulting from the
assignment by participating utilitfes of reserve or excess ·generating
capacity for common use
capitalize to convert into an equivalent capital sum; to compute,
appraise, or estimate the present value of
95
cascade an arrangement of separation devices that multiply the effect

of each individual device
cavitation formation of vapor-filled cav1t1es (bubbles) 1n motion, brought
on when the motion causes a local reduction of liquid pressure
central-station service electric energy supplied from a central electrical
system rather than by self-generation
charge/discharge ratio ratio of the average pumping load to the rated
generating capacity
coincident demand any demand for power that occurs simultaneously with any
other demand; also, the sum of any set of coincident demands
cold reserve reserve generating capacity, based on the availability of
generating equipment not actually in operation
critical speed the angular speed at which a rotating shaft becomes dynam-
ically unstable with large lateral amplitudes, due to resonance with
the natural frequencies Of the Shaft Is. lateral Vibration
critical streamflow the amount of water available for hydroelectric power
generation during the most adverse streamflow period
crown top portion of a Francis-type runner to which the blades are attached
deflection shape change of a structural member from its origina~ shape
degree of freedom any one of the number of ways in which the space
configuration of a mechanical system may change
demand the rate at which electric energy is delivered.to a system
demand factor ratio of the maximum demand for electric power of a system,
or part of a system, to the total connected load
Deriaz turbine ·a diagonal-flow turbine with a propeller-type runner whose
blades are adjustable; the axis of the blades is at an angle with the
axis of the shaft
dewatering removing or draining water .from an enclosure or a structure
diffuser a duct, chamber, or· section in which a high-velocity, low-pressure
stream of fluid (usually air) is converted into a low-velocity, high-
pressure flow
discharge ring that part of a pump/turbine, located below the runner
and stay ring, which provides the foundation for the machine and the
lower bearing surface for the wicket gates ·
disk friction loss energy loss in a machine due to hydraulic friction
be~ween the liquid and the rotating faces of the runner
dispatching the operating control of generating units, transmission lin~s,

and other facilities; includes ·assigning generator outputs as needed,
controlling maintenance and switching operations, and scheduling energy
transactions with other utilities
distortion-energy theory theory that assumes yielding occurs when the
distortion energy equals that .in simple tension at yield
96
distributor those components (headcover, stay ring, and discharge ring)

of a pump/turbine whose purpose is to contain and guide the water from
inlet to exit
diversity the differences among individual electric loads resulting from
the maximum customer demands not all occurring at the same time
diversity factor ratio of the sum of the individual maximum demands for
the various subdivisions of a system, or part of a system, to the _max1mum
demand of the whole system (or the part under consideration)
draft tube a conical tube connecting an hydraulic turbine runner to the
tailrace; its diverging sides decelerate the flow discharged from the
runner so that the remaining kinetic energy may be regained by conversion
into suction head
drag resistance caused by friction in ·the direction opposite that of the
motion of the center of gravity of a moving body in a fluid
drawdown rate of fall of water level in a reservoir when depletion
exceeds the rate of replenishment
eddy a vortexlike motion of a fluid running contrary to the main current
efficiency, hydraulic for a turbine, the ratio of net head to gross head
(vice versa for a pump); accounting for hydraulic friction and eddy
losses through the spiral case, stay ring, wicket gates, runner,· and
·draft tube of a pump/turbine~- as well as for kinetic energy of the
water, at draft tube exit, Which has not been converted into useful work
for a turbine
efficiency, mechanical for a turbine, the r·atiu of power available 'at the
shaft to that exerted by the water on the runner (vice versa for a pump);
accounting for bearing and disk friction, and fur drag on the runner in
the r: le~r~nrP spRr.PR
efficienc.y, overall hydraulic etticiency multiplied by the product uf Llu::
mechanical and volum.etric efficiency (f9r either a turbine or a pump)
efficiency, volumetric for a turbine, the ratio.of the quantity of water
that produce.s useful work to the total quantity of water supplied to the
turbine (vice vcroa for a pump); accounting for thP 1 nss nf P.ffi r.i.ency
due to water leaking past the runner through clearance spaces (and
therefore without· doing any useful work or being pumped)
e.lectrical system physically integrated facilities for generating,
transmitting, and distributing electric power; with all facilities
operated under unitied control, management, or operating supervi~:;iuu
element (see finite-element method)
energy the capacity for doing work
erosion sur face des true tion of a mater lal by the abrasive or the
corrosive- and abrasive-action of a moving fluid; often accelerated by.
solid particles in suspension in the fluid
escalation provision in actual or estimated costs for inflation increases
in the costs of equipment, materials, labor, etc., over those specified
in an original contract
97
finite-element method method for determining the behavior of a structure

from a knowledge of the behavior under load of its components; in this
method, a structural system is considered an assembly of a finite number
of finite-size components, or elements; these elements are assumed to be
connected to each other only at discrete points called nodes; from the
characteristics of the elements, such as their. stiffness or flexibility,
the characteristics of the whole system can be derived; with whole-
system characteristics known, internal stresses and strains throughout
can be computed -- and both static and dynamic behavior can be predicted
flexibility the quality or state of being able to be flexed or bent
repeatedly
forced outage the unanticipated shutdown of a generating unit for
emergency r·easons
forced vortex rotation of a fluid, moving as a solid, about an axis where
every particle of the fluid has the same angular velocity
forebay a reservoir feeding the penstocks of a hydropower plant
form drag the drag from all causes resulting from the particular shape of
a body relative to its direction of motion
Francis turbine a reaction hydraulic turbine, of relatively medium speed,
in which water enters the runner radially and exits axially
free· vortex two-dimensional fluid flow in which the fluid moves in
concentric circles at speeds inversely proportioned to the radii of th~
circles
frequency the number of recurrences of a periodic phenomenon in a unit o~
time
gate a closure device in which a leaf, or other closure member, is moved:
across a fluid passageway to control the fluid flow (see also wicket
gates)
·gate leaf elliptical section of a wicket ·gate that functions as the
gate's fluid-control element
gate squeeze operating condition of a pump/turbine with the wicket
gates closed and maximum design pressure maintained in the spiral case
gate stem cylindrical section of ~ wicket gate that functions as the
gate's control shaft
generator a machine that converts mechanical energy into electric energy
ryuard ryate R gate that operates fully open or closed and ·functions as a
secondary device ·for shutting off the flow of water in case the primary
closure device becomes inoperable; usually operated under balanced
pressure and no-flow conditions, except for closure in emergencies
head the height of a column of fluid above a datum which would give the
fluid's unit mass, in a .conduit, a total energy equal to the sum of its
potential energy, its kinetic energy, and its pressure energy
headcover stationary top part of an hydraulic turbine
head, gross the total difference in elevation between the surface of
the water being diverted to a turbine and the water surface at the
point where it is returned after having been used for power generation
98
. head, net or effective head available for energy production after

deducting losses for friction, entrance, unrecovered velocity head in
the draft tube, etc.
head, operating difference in elevation between the water surfaces of the
forebay and tailrace, with allowances for velocity heads
head race a channel conveying wate·r to an hydraulically operated machine
head, suction the head that a pump must provide on the inlet side, to
ra1se the liquid from the supply well to the level of the pump
Hertz (Hz) SI unit of frequency which, in combination with an ordinal
number, identifies the number of cycles occurring in one second
homologous having the same relative position, proportion, value, or
structure
hot reserve reserve generating capacity, based on generating equipment
in operation but not in service
house turbine a turbine that serves a source of auxiliary power
hydraulic 1 os s loss in fluid power due to flow friction within the system
hydraulic turbine a machine which converts the energy of an elevated water
supply into the mechanical energy of a rotating shaft
hydroelectric generator an electric rotating machine that transforms
mechanical power from an hydraulic turbine or water wheel into electric
power
hydraulic unbalance condition caused by unsymmetrical distribution of
water in a rurbomachine
hydroelectricity electric power _produced by hydroelectric generation
impeller' the rotating member of a turbine, blower, fan, axial or
I '
centr1fugal pump, or mixing apparatus
.impulse turbine an hydraulic turbine that· uses a nozzfe to convert all the
flow energy into kinetic energy, at atmospheric pressure, before fluid
enters the runner (see also Pelton turbine)
intake a structure located in the forebay that directs water to the pen-
stock
interconnection a transmission line joining two or more power systems,
enabling power produced by one system to be used by the other
interstage distributor that component of a multistage (two or more stages)
turbomachine that directs fluid from one stage to the next
intertie interconnection
jet a fluid stream issuing from an orifice or nozzle
journal that part of a shaft which is in contact with, and supported by,
a bearing
Kaplan turbine a propeller-type hydraulic turbine in which the positions
of the runner blades and the wicket g.ates are adjustable for maintaining
efficiency during load changes
99
labyrinth seal a minimum-leakage seal that offers resistance to fluid ,flow

while providing radial or axial clearance; a labyrinth of circumferential
touch points that provide for successive expansion of the fluid
laminar flow str'eamline flow of an incompressible, viscous Newtonian
fluid; all particles of the fluid move in distinct and separate lines,
without turbulence
leaf (see gate leaf)
leakage loss energy loss resulting from liquid leaking from a high-pressure
zone of a machine to a low-pressure zone
line compensation the balancing out of line impedance
line impedance apparent opposition to the flow of alternating current;
analogous to the actual ele~trical resistance to a direct current
load (electrical) the amount of electric power that is drawn from a
power line, generator, or other power source
·(mechanical) 1 - the weight supported by a structure
2 - the mechanical force applied to a body·
load, average (electrical) the hypothetical constant load, over a given
time period, that would produce the same energy output as the actual
loading produced
load centei the point at which the loads of a given area are assumed to be
concentrated for the purpose of analysis
load, connected the sum of the continuous ratings of the load-consuming
apparatus connected to the system, or part of the system
load curve a curve of power versus time showing the value of a specific
load for each unit of the period covered
load diversity the difference between the sum of two or more individual
peak loads and the coincident or combined maximum load
load duration curve a curve showing the total time, within a specified
period, during which the load equalled or exceeded the power values shown
load factor ratio of the average load, over a designated period, to the
peak load occurring 1n that period
load, peak (electrical) maximum load consumed or produced by a unit, or
group of units, in a stated period of time
load rejection sudden removal of the load from a turbine
margin the difference between the net system-generating capability and
system's maximum. load requirements (including net schedule transfers with
other systems)
mechanical loss energy loss due to mechanical friction between fixed and
moving parts; e.g., rubbing or sliding friction between a rotating
shaft and its bearing
meridional marked with lines in the plane of the axis
meridional plane a plane containing the runner a~is
100
momentum the quantity of motion possessed by a body; measured by the

product of the mass of .the body and its velocity
natural frequency the frequency at which a body will oscillate if disturbed
from its equilibrium position
net positive suction head (NPSH) the m1n1mum suction head required for a
pump to operate; dependent on the liquid characteristics, total liquid
head, pump speed and capacity, and impeller design
newton (N) SI unit of force required to impart to a mass of i kilogram an
acceleration of 1 meter per second per second .
node (see finite-element analysis)
nozzle a convergent or convergent-divergent tube for accelerating and
directing a fluid --.and changing its pressure energy into velocity
energy
operation factor ratio of the duration of actual service of a machine
to the total duration of the per .i.ou of time considered
outage the period in which a generating un.i.t, transmission line, or other
facility is out of service
output factor ratio of the actual energy output,. in the period of time
considered, to the energy output which would have occurred had the
machine been operating at its full rating throughout the period
(in) parallel several generating units whose alterpating current
frequencies are_exactly equal, operating in synchronism as part of the
same electrical system
pascal (Pa) SI unit of pressure equal to the pressqre resulting from a
force of 1 newton acting uniformly over an area of 1 square meter
peak load in an electrical system, the maximum instantaneous load or the
max1mum average load over a designated interval of tinle
peaking capacity that part of an electrical system's equipment operated
during the hours of highest power demand
peaking units usually old low-efficiency units (e.g., gas turbines, diesel
engines) or pumped hydroelectric storage units used primarily during
the peak-load periods
Pelton turbine an impulse hydraulic turbine in which the· pressure energy
of the water supply is converted into kinetic energy by a few stationary ·
nozzles; the resulting water jets then impinge on the buckets mounted on
the rim of a wheel (see also impulse turbine)
penstock a closed water conduit that connects the intake and the turbine,
1n a hydroelectric plant
pitting selected localized formation of cavities 1n metal surfaces due to
corrosion
pondage water held behind a hydroelectric dam of relatively small storage
capacity; used to regulate natural flow
power the time rate of doing work
101
power, dump hydroelectric power in excess of load requirements that is made

available by surplus water
power factor ratio of the actual, average, or act.ive output (kW) of a
. generator to the apparent output (kVA)
pdwer,'firm (or primary) the power which a plant can be expected to deliver
100% of the time
power, generating station auxiliary power required for.operation of the
generating station auxiliaries
power pool two or more electric systems interconnected to supply, in the
most economical m~nner, electric power for their combined loads
. power, prime maximum power constantly available for transformation into
electric power
power~ surplus (or secondary) all power in excess of firm power
pressure rise operating condition of a pump/turbine corresponding to a
full-load rejection and a rapid wicket-gate closure
prime mover the engine, turbine, water wheel, or similar machine which
converts thermal or pr.ess;Jre energy into mechanical energy
propeller a bladed device that rotates.on a shaft to produce a useful
thrust 1n the direction of the shaft ax1s
propeller blade one of two or more plates radiating out from the hub of a
propeller and normally twisted to form part of a helical surface
propeller turbine a high-specific-speed, low-head, axial-flow hydraulic
turbine whose runner 1s a propeller
pump a machine, driven by a prime mover, that draws low-pressure fluid into
itself through an entrance port and forces it out through an exhaust port
a·s high-pressure fluid·
pumped hydroelectric storage a method of.energy storage in which excess
electrical energy pr.oduced at times of low demand is used to pump water
into an elevated reservoir; this water is released at times of high
demand; to operate hydroelectric generators
pumping operation of a pump/turbine in the pump mode
pump prime conditions associated with starting (priming) the pump against
closed wicket gates
pump shutoff the operating condition of a pump/turbine corresponding to
the release of pressurized air after a pump start
pump/turbine a reversible turbomachine that operates 1n one direction as a
turbine and in the other as a pump
race a channel transporting water to or away from hydraulic machinery, as
1n a power house
rake a toothed device for removing debris from trashracks
reaction the equal and opposite force that results when a force is exerted
on a body
102
reaction turbine an hydraulic turbine in which a por~ion of the energy of

the fluid is converted into kinetic energy when the fluid passes through
the wicket gates and the remainder of the energy conversion occurs in the
runner
reserve equipment installed equipment in excess of that required to carry
peak load
reservoir large natural or man-made basin used for water storage
resonance a phenomenon exhibited by a physical system acted upon by an
external periodic driving force, in which the resulting amplitude of
oscillation of the system becomes large when the frequency of the driving
force approaches a natural free oscillation frequency of the system
rotor the rotating member of an electrical machine
runaway -speed the speed of a reaction turbine obtained when the runner
is allowed to revolve freely without load and with the wicket gates wide
open
runner that part of an hydraulic turbine that transforms the pressure and
kinetic energy of the water into. useful w~rk; as water flows through the
turbine, it changes direction, creating a force o~ and causing the
runner t6 rotate
·run-of-river station a hydroelectric generating station which utilizes the
stream flow without storage
scroll case spiral case
seasonal diversity · diversity between two or more power systems whose
annual peak loads occur during different seasons of the year
series capacitors a bank of capacitors connected in series with an electric
power-transmission line; capacitors used to control the magnetic
component of line impedance
service outage the anticipated shutdown of a generating unit, transmission
line, or other facility for inspection, maintenance, or repair
servomechanism (servo system) an automatic feedback-control system for
mechanical motion; applies only to those systems in which the controlled
quantity or output is mechanical position or one of its derivatives
(velocity, acceleration, etc.)
servomotor (servo) the· electric, hydraulic, or other type of motor that
serves as the final control element in a servomechanism; receives power
from the :unpl ificr cleincnt and drives the· load with a li.u~ar ur rotary
motion.
shear-pin-failure condition operating condition of a pump/turbine with the
wicket gates in a nearly closed position with only two gates interacting
due to an obstruction being wedged between them
shunt capacitors capacitors connecting from a power line to a grounded
connection, usually designed to reduce that part of the electric current
causing a poor ·power factor
spare equipment equipment, complete or in parts,. on hand for repair or
replacement
103
spear needle inside the nozzle of a Pelton turbine

specific·speed (pump) the speed of a hologous pump of such size that it
produces 1 unit of flow·under 1 unit of head
speci fie speed (turbine) the speed of an homologous turbine of such size
that it develops 1 unit of power under 1 unit of head
speed ring stay ring
spinning reserve reserve generating equipment connected to t~e bus and
ready to take load
spiral case a portion of an hydraulic turbine that transfers water from
the penstock to the wicket gates and runner, distributing the water
so that all points on the perimeter of the runner receive the same
quantity of water
stage a pump-turbine section that contains a runner
standby equipment generating equipment that is not normally used but is
available, through a permanent connection, to replace or supplement
the usual source of supply
stator the portion of a rotating electricai machine that contains the
stationary parts of the magnetic circuit.and their associated windings
stator armature a stator which includes the main current-carrying winding
in which electromotive force produced by magnetic flux rotation 1s
induced; it is found in most alternating current machines
stay ring a structural part of an hydraulic turbine that contains the stay
vanes and ·to which the spiral case and headcover are attached
stay vane curved, airfoil-shaped, stationary, fluid-guiding surfaces
located between the spiral case and wicket gates in an hyd·raulic
turbine -- whose purpose is to give a prerotation, or prewhirl, to the·
fluid in order to reduce the relative velocity to the runner; stay vanes
also serve as columns that aid in suppQrting the generator weight and
the loads associated with the internally pressurized machine
steam electric plant. a plant in which the prime movers (turbines) connected
to the generators are driven by steam
stiffness the ratio of a steady force acting on a deformable elastic medium.
to the resulting displacement
stop logs bulkhead gates
streamline a line which is everywhere parallel to the direction of fluid
flow at a given instant
stress the force acting across a unit area in a solid material in resisting
the separating, compacting, or sliding that tends to be induced by
external forces
stress concentration factor a theoretical factor expressing the ratio of
the greatest stress in the region of stress concentration to the
corresponding nominal stress
stress raiser a'notch; hole, or other discontinuity in contour or structure
that causes localized stress concentration
104
submergence the vertical distance from the tailwater elevation to the

throat of the first-stage runner
surface pumped hydroelectric storage (SPHS) that form of pumped hydro-
electric storage in which both upper and lower reservoirs are located
above ground
surge tank a vertical tank, connected to the penstock upstream of a
turbine, that is used to limit the pressure rise in the penstock due to
rapid closing of the wicket gates following a load rejection
synchronous capacitor (condenser) a synchronous motor running without
mechanical load and drawing a large leading current, lik~ a capacitor;
used to improve the power factor and voltage regulation of an
alternating-current power system
synchronous generator a machine that generates an alternating voltag.e when
its armature or field is rotated by a motor, an engine, or other means;
the output freque'ncy is exactly proportional to the speed at which the
gener.alor is driven
synchronous machine an alternating-current machine whose average speed is
proportional to the frequency of the applied or generated vpltage
synchronous motor a synchronous machine that transforms alternating-current
electric power into mechanical power, using field magnets excited with
direct current
_synchronous speed the speed of rotation of a magnetic field in a
synchronous machine; in revolutions per second, it is equal to twice the
frequency of the alternating current in hertz, divided by the number of
poles in the machine
system reserve the capacity, in equipment and conductors, installed on the
system in excess of that required to carry the peak load
tailrace a channel into which the water is discharged after passing through
a turbine
tail water water in a tailrace, below a dam or water-power development
tap a connection from one transmission 1 ine to another or to a substation
therma,l plant . a generating plant which uses heat to produce electricity
thrust. the reaction to a compressive force on a rod
thrust bearing a bearing which sustains axial loads and prevents axial
movement of a loaded shaft
tie line transmission line connecting two systems
time-zone diversity diversity between power systems in different time
zones, resulting in periods of heavy power demand that differ in terms
of absolutP. t i.mP.
torque the turning moment exerted by a tangential force acting at a
distance from the axis of rotation or twist
torque converter a device for changing the torque speed or mechanical
advantage between an input shaft and an output shaft
105
torsion a twisting deformation of a solid body about an axis in which lines

that were initially parallel to the ax1s becomes helices
to~sional vibration a periodic motion of a shaft in which the shaft is
~wisted about its axis in one direction and then i~ the other; this
motion may be superimposed on rotational or other motion
transformer an electromagnetLc device that can 1ncrease or reduce the·
voltage of alternating-current electricity
transmission the act or process of transporting electric energy in bulk
trashrack ve.rtical or slightly inclined steel bars placed parallel t·o each
other and spaced uniformly to prevent debris from entering a penstock; a
rake at the intake of the penstock removes debris collected at the
trashrack
tube turbine an axial-flow turbine located in a water passage with a slight
bend; the generator is located outside the water passage
turbine a fluid-acceleration machine for generating rotary mechanical power
from the energy 1n a stream of fluid
turbine generator an electric generato.r driven by a steam, hydraulic, or
gas turbine
turbining operation of a turbine or pump/turbine with the wicket gates
· in a position corresponding to maximum gate torque
turbomachine a device in which energy transfer occurs between a flowing
fluid and a rotating.element due to dynamic action, resulting 1n a
chang'e in pressure and momentum of the fluid
underground pumped hydroelectric storage (UPHS) that form of hydroelectric
pumped s~orage in which the lower reservoir is located below ground
unwater i ng removal or drainage of water; dewatering
utilization factor in electric power distribution, the maximum demand of a
~ystem or part of a system divided by its rated capacity
vane a flat or curved surface exposed to a flow of fluid so as to be forced

to move or to rotate about an axis, to rechannel the flow, or to act as
the impeller
vertically integrated system a power system that combines generation,
transmission, and.distribution functions
volute a spiral casing for a centrifugal. turbomachine designed so that
speed will be converted to pressure without shock
vortex a flow with·closed streaml~nes
vortex line a line drawn through a fluid such that it 1s everywhere tangent
to the vorticity
vorticity for a fluid flow, a vector equal to the curl of the velocity of
flow
waterhammer the series of shocks, sounding like hammer blows, produced
by suddenly reducing the flow of water in a conduit
waterwheel a vertical wheel on a horizontal shaft that is made to revolve
by the action or weight of water on or in containers attached to the rim
106
watt (W) the rate of energy transfer equivalent to one ampere. under a
pressure of one volt at unity power factor
wear deterioration of a surface due to material removal caused by relative
motion between it and another part
wearing rings replaceable rings that are installed in the casing or
impeller (runner), or both, to take the wear resulting from rotation of
the impeller, and from grit and other abrasives in the liquid
wheeling transportation of electricity by a utility over its lines for
another utility
wicket gates movable guide vanes that are located just outside the runner
of an hydraulic turbine, to control the amount of water that enters
the turbine (see also gate)
107
. REFERENCES
1. Frigo, A.A., C.A. Blomquist, and J.R. Degnan, Evaluation of Advanced

Hyd~ulic TUPbomqchinePy fop Unde~Pound Pumped HydPoelectPic Stopage~
PaPt 1. Single-Stage~ Regulated Pump TuPbines foP OpePating Heads of
500-1000 m, .Argonne National Laboratory Report ANL/ES-100 (Oct. 1979).
2. Flodl, G., and F. Strohmer, Development of a Double-Stage, Double-

ContPolled ReVePsible Pump TuPbine, Pump TuPbine Schemes: Planning,
Design, and OpePation. Proc. of Joint ASME-CSME Applied Mechanics,
Fluids .Engineering and Bio-engineering Conf., Niagara Falls, N.Y.,
pp.· 11-15 (June 18-20, 1979). .
3. ·Chacour, S.A., J.R. Degnan, D.M. LoSasso, and D.R. Webb, Design
ConsidePations fop a 1000 MeteP Head, 500 Megawatt Single- and Double-
Stage, ReVePsible Pump/TUPbine, Pump TuPbine Schemes, ibid., ASME-CSME
Conf. Proc., Re.f. 2, pp. 17-28;
4. Amblard, H., Pump TuPbines OpePating UndeP High Head, Pump TuPbine
Schemes, ASME-CSME Conf. Proc., Ref. 2, pp. 39-48.
5. Meier, W., and M. Jaquet, Single- and MUlti-stage Pump-TUPbines fop
High Head StoPage Plants, Pump TuPbine Schemes, ASME-CSME Conf. Proc.,
· Re f. 2, p p • 29-3 7 ..
6. Hartmann, 0., and W.M. Meier, Developments in High-Head Pumped StoPage,

Water Power, pp. 102-106 (Mar. 1970).
7. Ch ac our, S. , and J. E. Gr ayb i 11 , 'IRIS', A ComputePized High-Head Pump

TUPbine Design System, ASME Paper 76 - WAFE-12, presented .at the American
Society of Mechanical Engineers Winter Annual Meeting, New York, N.Y.,
(Dec. 5, 1976). J. of Fluids Engineering, pp. 99 and 567-579
, (Sept. 1977).
8. Stelzer, R.S., Estimating RevePsible Pump TUPbine ChaPactePistics, Pump

'l'uPbine Schemes, ASME-CSME Conf. Proc., Ref. 2, pp. 139-149.
9. Stepanoff, A.J., CentPifugal and Axial Flow Pumps, 2nd ed., J. Wiley,
N.Y;, p. 196 (1957).
10. Chacour, S.A., and R.E. Deitz, 'CORA' Hyd~ulic TPansients 'Plus',
presented at ASCE-IAHR/AIHR-ASME Joint Symposium on Design and Operation
of Fluid Machinery, Fort Collins, Colo. (June 12-14, 1978).
11. Chacour, s., 'DANUTA ', A ThPee-Dimensional Finite Element PPogPam Used in
the Analysis of TuPbo-Machinepy, ASME Paper No. 71-WAFE-29 (Mar. 1972).
12. Fatigue Limit and FPactUPe Mechanics Behavior' of Caat Steel fop WateP
TUPbines, G. Fisher Aktiengesselchoff, Schaffhausen, Switzerland (1914).
13. Blomquist, C.A., A.A. Frigo, and S.W. Tam, UndePgPound Pumped Hydro-
electPic Stopage (UPHS) MidyeaP FPogPam RepoPt, Argonne National
Laboratory Informal Report ANL/EES~TM-60 (Apr. 1979).
. 108
ACKNOWLEDGMENTS
The research activities in underground pumped hydroelectric storage,

which formed the basis of this report, were funded by the Office of Advanced
Conservation Technology, U.S. Department of Energy.
The initial-contract negotiations that led to the Allis_.Chalmers

studies were conducted by G.T. Kartsounes and S.W. Tam of ·Argonne N.ational
Laboratory.
The authors are grateful to S.A. Otacour and R.A. Bramhall of the
Allis-Chalmers Corporation for their cooperation and advice.
The following individuals are also acknowledged for their reviews

and suggestions with regard to this report: T. Zowski and H.H. Chen (Harza
Engineering Company); H.H~ Chiu ·(University of Illinoi~ at Chicago Circle);
and R.J. Vissia, H. Falvey, N. Jacobs, F. Ruud, and R. Stelzer. (U.S. Depart-
ment of the Interior, Water and Power Resources Service).
CREDITS
The authors wish to acknowledge with appreciation the cooperation

of the following organizations in permitting the use of certain illustrations
in this report:
• Escher Wyss Ltd.;

• Neyrpic; and
• Voest-Alpine AG.
109
Distribution for ANL/ES-101
Internal:
C.A. Blomquist (12) A.B. Krisciunas N.F. Sather

J .M. Clinch K.S. Macal ANL Contract Copy
E. J. Croke W.E. Massey ANL Libraries
J. Dzingel J.J. Roberts TIS Files (6)
A.A. Frigo (10)
External:
POE-TIC, for distribution per UC-94e (213)

Manager, Chicago Operations and Regional Office, DOE
Chief, Office of Patent Counsel, DOE-CORO
President, Argonne Universities Association
Energy and Environmental Systems Division Review Committee:
W.C. Ackermann, U. Illinois
E.E. Angino, U. Kansas
B.A. Egan, Environmental Research and Technology, Inc.
R.E. Gordon, U. Notre Dame
W.W. Hogan, Harvard U.
W.N. Poundstone, Consolidation Coal Company
L.H. Roddis, Jr., Charleston, S.C.
G.A. Rohlich, U. Texas, Austin
R.A. Schmidt, Booz, Allen, & Hamilton
J .J. Stukel, U. Illin.ois
R.D. Allen, Battelle Pacific Northwest Laboratories
H. Amblard, Neyrpic, Grenoble, France
I.A. Berman, Commonwealth Edison, Chicago
D.R. Bervig, Black and Veatch, Kansas City, Mo.
R.S. Burkhart, Harza Engineering Co., Chicago
C. Carter, Oglethorpe Power Corp., Atlanta
0. Ceravola, Hydroart S.P.A., Milano, Italy
G.C. Chang, Cleveland State U.
H.H. Chen, Harza Engineering Co., Chicago
D. Chisholm, Ontario Hydro, Toronto
H.H. Chiu, .U. Illinois at Chicago Circle
J. Clark, Northern Michigan Electric Cooperative, Inc., ·Boyne City, Mich.
J.W. Daily, U. Michigan
J.R. Degnan, Allis Chalmers, York, Pa. (5)
G.E. DeViney, Commonwealth Edison, Chicago
L.F. Eriksen, Bechtel, Inc., San Francisco
M.S. Erispaha, Voest-Alpine International Corp., New York City
A. Ferreira, Electric Power Research Institute, West Springfield, Mass.
S. Finkelstein, Ontario Hydro, Toronto
J.H. Gibbons, Office of Technology Assessment, U.S. Congress
A.J. Giramonti, United Technologies Research Center, East Hartford, Conn.
D.L. Glasscock, Harza Engineering Co., Chicago
A. Gokhman, E.D.S. Nuclear, Inc., San Francisco
0. Gross, U. of Wisconsin - Milwaukee
llO
D. Hariri, U. of Wisconsin -Milwaukee

D. Heinzen, Inland Power & Light Co., Spokane, Wash.
J. Hoppe:r,. U. of Wisconsin - Milwaukee
J.C. Howe, .Charles T. Main, Inc., Boston
J.H.S. Huang, Ontario Hydro, Toronto.
G. Karadi, U.S. DOE
G.T. Kartsounes, Institute for Paper Chemistry, Appleton, Wise.
D.E. Kash, USGS, Reston, Va.
G. Kojro, Ontario Hydro, Toronto .
E.S. Loane, GPU Service Corp., Reading, Pa.·
D. LoSasso, Allis-Chalmers Corp., York, .Pa.
W.V. Loscutoff, Battelle Pacific Northwest Laboratories
A.M. Manaker ,. Tennessee Valley Authority, Chattanooga
W. Meier, Escher Wyss, Ltd., Zurich, Switzerland ·
E.F. Mosonyi, Tech. U. of Karlsruhe, Federal Republic of Germany
·A. Pujol-Rius, U. of Wisconsin- Milwaukee
J.L. Ramer, U.S. Army Corps of Engineers, Milwaukee
C.W. Ridgely, Hooper Construction Corp., Madison, Wise.
F .0. Ruud, U.S. Dept. of Interior, Denver
E. Schobinger, Vevey Engineering Works, Ltd., Switzerland
F.P. Sener, Cleveland Electric Illuminating
J.S. Shaffner, Jr., Bechtel, Inc., San Francisco
A. Somer, Ateliers des ·Chamilles, S.A., Switzerland
S. Strauch, U.S. DOE ·
R. Swingen, U. of Wisconsin - Milwaukee
R. Thalmann, Vevey Engineering Works, Ltd., Switzerland
P.A. Thompson, Rensselaer Polytechnic Inst., Troy, N.Y.
J. Turcotte, General Electric, Schenectady, N.Y.
R.C. Ungenmach, Potomac Electric Power Co., Washington, D.C.
P. Vaticon, U. of Wisconsin- Milwaukee
R. Viss ia, Water and .Power Resources Service, Denver
D.C. Willett, Acres American, Inc., Buffalo, N.Y.
A. Zakrzewski, U. of Wisconsin - Milwaukee
T. Zowski, Harza Engineering Co., Chicago

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ANL/ES-101

C. A. Blomquist, A. A. Frigo, and J. R. Degnan

U.S. DEPARTMENT OF ENERGY

This report was prepared as an account of work sponsored by an

Portions of this document may be illegible in

MEMBERS OF ARGONNE UNIVERSITIES ASSOCIATION

This report was prepared as an account of work sponsored by

Printed in the United States of America

ARGONNE NATIONAL LABORATORY

EVALUATION OF ADVANCED HYDRAULIC TURBOMACHINERY

Carl A. Blomquist, Arthur A. Frigo, and .John R. Degnan*

U.S. DEPARTMENT OF ENERGY

*Allis-Chalmers Corp., Hydro-Turbine Div., York, Pennsylvania; services

f$TRHIUHfHIJ Of THIS OOCUMEU tg IJNlPMtT~

2 PRELIMINARY DESIGN RESULTS: TWO-STAGE, TOP-GATED PUMP/TURBINES. 18

3 DETAILED ANALYSIS OF WICKET GATE AND DISTRIBUTOR COMPONENTS. 49

ACKNOWLEDGMENTS AND CREDITS 108

·1 Sectional View of an Unregulated, Two-Stage Pump/Turbine. 5

3 Sectional View of a Double-Gated, Two-Stage Pump/Turbine, 7

24 Pump Performance Characteristics: 500 MW, 1000 m,

46 Shear-Pin-Failure Condition for the 1500-m-Head Wicket Gate 62

1 Comparison of Certain Parameters of Single- and Two-Stage

9 Basic Load Cases for the DANUTA Program . . 58

13 Res~lts of IRIS Program Spiral Case/Stay-Ring Analysis for

EVALUATION OF ADVANCED HYDRAULIC. TURBOMACHINERY

Carl A. Blomquist, Arthur A. Frigo, and John R. Degnan

This UPHS report applies, like Part· 1, to Francis-·

Six different two-stage, top-gated pump/turbines have

. The authors foresee no major turbomachinery obstacles

This report 1s the second in a series of three on turbomachinery

A pump/turbine is an axial-, radial-, or mixed-flow hydraulic machine

1.1 DESCRIPTION OF TWO-STAGE PUMP/TURBINE AND COMPONENTS

A two-stage pump/turbine can be described as two single-stage machines

The purpose of the spiral case is to p'rovide an even drstr ibution of

a number of pieces, a process dictated by shipping limitations and economy of

The prime purpose of the components described so far is to guide the

The function of the draft tube, aside from acting as a conduit to

The headcover must be rugged, resistant to vibration, and able to

Pump-turbine shafts are machined from integral steel forgings ~n all

1.2. TYPES OF TWO-STAGE PUMP/TURBINES

There are three different types of two-stage pump/turbines: 1) non-

1.3 HIGH-HEAD TURBOMACHINERY

With increasing developments ~n high-head, single- and multistage

Fig. 1. Sectional View of an Unregulated (Non-Gated),

Fig. 2. SeL:Liuual View of a 'l'op-t;ated, Two-Stage Pump/Turbine

The problems in designing high-head, single-stage machines are hydrau-

Fig. 3. Sectional View of a Double-Gated, Two-Stage Pump/Turbine

specific speed ~s increased to improve efficiency, problems may arise from

Mechanical problems are related to the static and dynamic loads

Fig. 4. Comparison of the Stay-Vane and Wicket-Gate

Construction problems arise from the increased mass of the components.

1.4 ADVANTAGES AND DISADVANTAGES OF TWO-STAGE PUMP/TURBINES

The two-stage, gated pump/turbine is the logical extension of single-

When compared with multistage pump/turbines, which are inherently

Two-stage, gated units do have certain drawbacks. They require, for

1.5 TWO-STAGE PUMP/TURBINE STATE OF THE ART

A two-stage, gated pump/turbine has not yet been installed in service.

Table 1. Comparison of Certain Parameters of Single-

Speed, rpm 600 600

Runner outside diameter, m 3.15 2.40

An earlier Escher Wyss proposal,6 called the "One + One" arrangement,

Fig. 5. Horizontal Shaft Arrangement of the Escher Wyss

A double-gated, two-stage pump/turbine (Fig. 7) with a capacity of 300

Electricit~ de France has placed an order with Neyrpic for design