Enhancing Efficiency of an Old Hydropower Plant Turbine Through a Mutual Runner Design and Component Optimization

Abstract

This paper presents a systematic approach to the rehabilitation process of Sarıyar HEPP, a hydroelectric power plant that has been operational for more than 50 years. Units 1 and 2 (U1-U2) were originally designed with a head of 93 m and a turbine power of 48.5 MW, while Units 3 and 4 (U3-U4) were designed with a lower head of 76.5 m but the same turbine power of 48.5 MW. A methodology combining reverse engineering and CFD analysis is developed to identify and evaluate the critical parameters that have an impact on the existing turbine performance. A hybrid design is proposed to replace the existing two different types of turbines, which reduces manufacturing costs and design time. The performance of the new hybrid design is evaluated in detail with CFD analysis. For both existing and hybrid design, steady and unsteady analyses are performed. For all of the situations hill charts are obtained and the comparison of the old and new hybrid design is discussed in detail. The results show that the new design has improved the efficiency of the turbine and the power plant, resulting in a 14.2% efficiency increase in U1-U2 and a 21% system efficiency improvement in U3-U4. This study provides a guide to designers and practitioners for the rehabilitation of hydroelectric power plants. © IMechE 2025.