Session: 09-07-01 Tidal & Current Energy II

Submission Number: 180643

Hydrodynamic and Structural Response of a Flow-Exposed Hydro-Turbine Sensor Router in Heavily Cavitating Conditions: Experiments and CFD-FE Analysis
 

This study presents an integrated experimental and numerical investigation of a novel underwater sensor routing system developed to enable strain gauge measurements on the blades of a prototype 50 MW Kaplan hydro-turbine. The articulated mechanism routes the strain gauge wires from the blade to the hub, providing cable protection while enabling continuous blade pitch adjustment.

A full-scale prototype was tested in a cavitation tunnel to evaluate its hydrodynamic performance and structural robustness under flow conditions representative of turbine operation. Tests were conducted at flow velocities up to 9 m/s, pressures from 4.0 to 14.7 psi, and orientations of 20°, 40°, and 60° relative to the incoming flow, under both cavitating and non-cavitating conditions. A tri-axial accelerometer installed inside the mechanism recorded vibrations, while a downstream pressure sensor provided synchronized pressure data for flow characterization and validation of the numerical models.

High-fidelity computational fluid dynamics (CFD) simulations using a multiphase RANS solver were conducted to predict pressure and cavitation dynamics at inflow speeds up to 20 m/s and orientations from 20° to 90°. The models captured sheet and bubble cavitation around the sensor body and showed strong agreement with measured pressure and cavitation characteristics following iterative refinements. CFD pressure fields were subsequently used as inputs for finite element (FE) analyses to predict structural responses, which closely matched experimental acceleration data.

Results demonstrated that sensor orientation strongly influences hydrodynamic loading, vortex shedding, and cavitation. Alignment with the inflow minimized unsteady loads, while larger angles increased vibration amplitudes, especially under cavitating conditions. The EFD-CFD-FE framework offers a robust approach to predicting flow-induced forces and vibrations up to 20 m/s, providing critical insights for designing reliable underwater sensory mechanisms in high-speed hydro-turbine and marine applications.

Presenting Author: Shameem (Mohammed) Islam National Research Council

Presenting Author Biography: To be added later.

Authors:

Shameem (Mohammed) Islam National Research Council
Arthur Favrel Research Institute of Hydro-Quebec (IREQ)
Patrick Perrier National Research Council of Canada
Mathieu Soares Research Institute of Hydro-Quebec (IREQ)
Jody Murphy National Research Council of Canada
Jason Murphy National Research Council of Canada