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Prof. Dr. Xavier Escaler

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Department of Fluid Mechanics, Universitat Politècnica de Catalunya, 08034 Barcelona, Spain

Dr. Xingxing Huang

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S.C.I.Energy, Future Energy Research Institute, Seidengasse 17, 8706 Zurich, Switzerland

Dr. Cristian Rodriguez

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Mechanical Civil Engineering, University of Concepción, Office 322 Central Building Faculty of Engineering, Concepción, Chile

Dr. Quanwei Liang

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Dongfang Electric Machinery Co., Ltd., Deyang, China

Prof. Dr. Zhengwei Wang

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State Key Laboratory of Hydro Science and Engineering & Department of Thermal Engineering, Tsinghua University, Beijing 100084, China

Advanced Technology of Full Lifecycle Service for Hydraulic Machinery

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closed (31 October 2023)

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closed (31 December 2023)

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Dear Colleagues,

In the context of the global energy crisis and climate change, the role of hydraulic machinery, widely used for renewable energy generation and sustainable energy storage, has become more important than ever. Full lifecycle services, from design to simulation, from model test to prototype measurement, from manufacturing to installation, from monitoring to diagnostics, and from overhaul to rehab, are critical to achieving the efficient and safe operation of hydraulic machinery. Research on and the application of full lifecycle services of various types of hydraulic machinery are attracting the attention of many researchers and experts in academia and industry. Therefore, we are pleased to invite you to submit your cutting-edge achievements, including, but not limited to, the following topics:

Optimization design of hydraulic machinery;
Smart operation, industrial processes, and applied sciences;
Renewable energy, energy generation, and energy storage;
Experimental measurements and numerical simulations;
Smart sensing technology;
Online monitoring, prediagnostics, fault diagnosis, and accident retrospectives;
Model tests and field tests;
Remote communication, remote measurement, remote control, and remote regulation;
Novel approaches to flow control, noise control, and vibration control;
Smart grids, smart power plants, digital twins, neural networks, and expert systems;
Applications of machine learning, AI, intelligent manufacturing, the IIoT, and cloud computing;
Full lifecycle services for hydraulic machinery.

Dr. Xavier Escaler
Dr. Xingxing Huang
Dr. Cristian Rodriguez
Dr. Quanwei Liang
Prof. Dr. Zhengwei Wang
Topic Editors

Participating Journals

Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Applied Sciences applsci	2.5	5.3	2011	18.4 Days	CHF 2400
Energies energies	3.0	6.2	2008	16.8 Days	CHF 2600
Machines machines	2.1	3.0	2013	15.5 Days	CHF 2400
Processes processes	2.8	5.1	2013	14.9 Days	CHF 2400
Sensors sensors	3.4	7.3	2001	18.6 Days	CHF 2600
Water water	3.0	5.8	2009	17.5 Days	CHF 2600
Journal of Marine Science and Engineering jmse	2.7	4.4	2013	16.4 Days	CHF 2600

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Published Papers (11 papers)

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16 pages, 7940 KiB

Open AccessArticle

Design and Characteristic Research on Variable Displacement Mechanism of Two-Dimensional (2D) Bivariable Pump

by Tong Xing, Xu Ji, Zeri Yang and Jian Ruan

Energies 2024, 17(7), 1725; https://doi.org/10.3390/en17071725 - 3 Apr 2024

Cited by 1 | Viewed by 1115

Abstract

In a hydraulic system, a micro variable pump is required to be high pressure and high speed, and this work presents a new type of 2D bivariable pump structure in which the worm gear and worm mechanism are used to rotate the cylinder block to change the flow distribution state of the cylinder window and the piston groove to change the displacement of the 2D pump. The flow–pressure mathematical model of the 2D variable pump is established to analyze the relationship between pump displacement and the pump cylinder rotation angle and the effects of variable displacement on pump pressure characteristics, flow characteristics, and volume efficiency in Matlab. During the experiment, we tested the change in the corresponding pump output flow when the cylinder rotation angle is 0~12°, which verifies the correctness of the variable calculation model. The experimental results indicate that the volume efficiency and mechanical efficiency of the single-piston 2D pump are reduced to different degrees after variable displacement, the volume efficiency is reduced by approximately 3% at most, and the mechanical efficiency is reduced by approximately 5% at most. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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22 pages, 4771 KiB

Open AccessArticle

A Performance Prediction Method Utilizing Time-Dependent Subsystem Transfers between Family Systems

by Wei Cai, Zhuofang Li, Ming Zhu, Rui Guo, Jianwei Wang and Jingyi Zhao

Appl. Sci. 2024, 14(6), 2448; https://doi.org/10.3390/app14062448 - 14 Mar 2024

Viewed by 869

Abstract

Based on cluster system theory and the Markov process, a performance prediction method utilizing time-dependent subsystem transfers between family systems is proposed in this paper. The family system is divided via the mean clustering method, with the key performance parameters of subsystems utilized as identification parameters. According to the transition quantity of subsystems in the family systems, the transition probability of subsystems between family systems is described via the Markov process. The transition matrix between subsystems is established by dividing multiple intervals of key performance states. The inter-family transfer matrix and the current family system label of the subsystem are updated in real time. Thus, the transition probability of any subsystem and the total number of subsystems to be transferred to the failure-state family system can be judged, and the remaining life can be further determined. Using the real-world monitoring dataset from the FAST Telescope, the effectiveness and accuracy of the method are verified. Due to the representativeness of family systems to subsystems and the powerful transfer-describing ability of Markov processes, the proposed method shows superiority in online prediction and performance evaluation compared to the fault data-based method, such as improvements in rapidity and accuracy. In addition, the proposed method can be used to evaluate overall reliability without reference samples, thus making the prediction method more practical in complex, large systems with small or even zero sample conditions. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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21 pages, 12332 KiB

Open AccessArticle

A Simulation Study of an Electro-Hydraulic Load-Sensitive Variable Pressure Margin Diverter Synchronous Drive System with Time-Varying Load Resistance

by Wei Du, Yu Luo, Yanlei Luo and Hongyun Mu

Processes 2024, 12(1), 170; https://doi.org/10.3390/pr12010170 - 11 Jan 2024

Cited by 1 | Viewed by 1221

Abstract

This study aims to address the problem of poor synchronous accuracy when facing a time-varying load in conventional load-sensitive synchronous drive systems. The new electro-hydraulic load-sensitive (EHLS) diverter synchronous drive system was proposed by combining the diverter valve and the EHLS synchronous drive system. The variable pressure margin compensation control was proposed to further improve the system’s synchronous control performance. Based on the system control strategy and component mathematical model, the simulation models of the EHLS, EHLS synchronous, and EHLS diverter synchronous drive systems were established using AMESim, respectively, and the synchronous control performance of the systems was obtained. The simulation results show that the EHLS drive system realized the primary functions of the load-sensitive system and could realize the variable load-sensitive pressure margin control. The EHLS synchronous drive system had poor synchronous control accuracy, but variable pressure compensation valve pressure margin control could be realized. The EHLS diverter synchronous drive system effectively improved the system’s synchronous control performance and diverter synchronous accuracy by variable pressure margin compensation control. The diverter system diverter error was reduced by 40.8%, and the diverter system after the compensation diverter error was reduced by 52.6% when the multi-way valves were fully opening. The system provides the solution for high-performance hydraulic synchronous drives under severe operating conditions. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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18 pages, 6907 KiB

Open AccessArticle

Simulation and Experimental Study on Sealing Characteristics of Hydro-Pneumatic Spring GS Seal Rings

by Shuai Wang, Pengyuan Liu, Donglin Li, Zhenle Dong and Geqiang Li

Appl. Sci. 2023, 13(21), 11703; https://doi.org/10.3390/app132111703 - 26 Oct 2023

Cited by 2 | Viewed by 1964

Abstract

Hydro-pneumatic springs often work under high pressure and alternating load conditions, which can easily cause seal damage, leakage, and serious failure. Relevant studies have shown that the dynamic seal failure of hydro-pneumatic springs is the main cause of hydro-pneumatic spring failure, and the sealing performance of GS sealing rings directly determines the service life of hydro-pneumatic springs. The influence of different sealing structure parameters on the sealing performance of GS sealing of hydro-pneumatic springs has been studied, which can provide effective theoretical guidance for the design of sealing structures related to hydro-pneumatic springs. However, the existing research on hydro-pneumatic springs mainly focuses on the characteristics of damping and stiffness; there is a relative lack of research on sealing performance and sealing structure, and the performance change law of GS seals under different working conditions is unclear. In this paper, a GS seal ring is selected as the main seal of the hydro-pneumatic spring, the material parameters of the GS seal ring are obtained via the single-axis compression test, and the finite element simulation method is used to establish the sealing model under different compression ratios of 10–30% and different pressure impacts of 5–30 MPa. By doing so, the stress nephogram, sealing ring shape, and sealing contact pressure of the GS sealing ring under different simulation parameters are obtained. From the test results, the decrease in compression ratio after the wear of the sealing ring is the main reason for the seal leakage of the hydro-pneumatic spring. The maximum contact stress of the sealing ring occurs at the lip of the step ring, and the maximum sealing pressure of the sealing ring is determined by the contact pressure of sealing surfaces II and III. The sealing performance of the GS-type combination sealing ring is affected by the compression ratio of the sealing ring and the impact pressure; when the compression ratio of the sealing ring is 15%, the sealing ring can meet the sealing work needs below 25 MPa. The research results provide a theoretical basis for the design of GS sealing of hydro-pneumatic springs and the effective improvement of the life and reliability of related equipment. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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23 pages, 14467 KiB

Open AccessArticle

On the Added Modal Coefficients of a Rotating Submerged Cylinder Induced by a Whirling Motion—Part 2: Numerical Investigation

by Rafel Roig, Xavier Sánchez-Botello and Xavier Escaler

J. Mar. Sci. Eng. 2023, 11(9), 1828; https://doi.org/10.3390/jmse11091828 - 19 Sep 2023

Viewed by 1415

Abstract

Part 2 of this work presents a numerical methodology, validated using the experimental results presented in Part 1, to calculate the added modal coefficients of a submerged cylinder in water both when it oscillates and when it rotates with a whirling motion. The numerical methodology is based on computational fluid dynamic simulations that obtain the added modal forces on the cylinder when it is forced to vibrate with mode shapes calculated using acoustic-structural modal analysis. Then, these forces are processed with a curve-fitting algorithm to extract all the coefficients. Most numerical coefficients presented a close agreement with the corresponding experimental ones, although the added modal damping was overestimated. In general, the added modal mass was found to be independent of both the rotating speed and the whirling frequency except for low whirling frequencies when it increased. The added modal damping was found to depend on both parameters, and the rest of the coefficients were independent of the whirling frequency and only depended on the rotating speed. As a conclusion, this numerical approach has permitted the study of particular conditions that could not be experimentally tested and thus broadened the knowledge of the behavior of the added modal coefficients of rotating submerged cylinders. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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22 pages, 7671 KiB

Open AccessArticle

On the Added Modal Coefficients of a Rotating Submerged Cylinder Induced by a Whirling Motion—Part 1: Experimental Investigation

by Rafel Roig, Xavier Sánchez-Botello, Esteve Jou and Xavier Escaler

J. Mar. Sci. Eng. 2023, 11(9), 1758; https://doi.org/10.3390/jmse11091758 - 8 Sep 2023

Cited by 1 | Viewed by 1125

Abstract

The operation of submerged rotating machines, such as marine current or tidal turbines, can present deleterious fluid phenomena that may provoke extreme structural vibrations. To predict their dynamic responses, it is necessary to know the added modal coefficients of their runners under a whirling motion. For that purpose, a bespoke test rig was designed to investigate the added modal coefficients of a submerged cylinder, which could rotate at different speeds both in air and completely submerged in water inside a cylindrical tank. First, the modes of vibration were experimentally measured by exciting the cylinder with a push-release method during steady tests or with ramps in rotating speed during transient tests. The calculated natural frequencies and damping ratios were then used in a mathematical model of the dynamic system to calculate the added modal coefficients. During steady tests, the natural frequencies and damping ratios of the whirling modes changed significantly as a function of the rotating speed. Additionally, a whirling mode was observed to change its direction at a given rotating speed. During transient tests, rotating speed ramps with high accelerations were found to present lower lock-in amplitude and frequencies. Moreover, fast downward ramps presented lock-in amplitudes four times higher than fast upward ramps. Consequently, the added modal coefficients changed accordingly as a function of the rotating speed, ramp acceleration, and ramp direction. For these reasons, it was confirmed that the modal responses of submerged rotating bodies must be calculated for each operational rotating speed, even at low velocities, and for each transient event in order to precisely predict their vibration behaviors. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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26 pages, 7285 KiB

Open AccessReview

Review of Recent Advances in the Drive Method of Hydraulic Control Valve

by Yanchao Li, Ruichuan Li, Junru Yang, Xiaodong Yu and Jikang Xu

Processes 2023, 11(9), 2537; https://doi.org/10.3390/pr11092537 - 24 Aug 2023

Cited by 15 | Viewed by 3863

Abstract

Hydraulic control valves are widely used in industrial production, agricultural equipment, construction machinery, and other large power equipment for controlling the pressure and flow of fluids in hydraulic systems. The driving method has a significant impact on the response and control accuracy of hydraulic valves. This paper reviews the driving methods of spools from five aspects: solenoid drive, material expansion drive, motor drive, hydraulic valve drive, and another drive. It summarizes the various schemes currently available for spool drive and analyzes each of them. After optimizing the driving method of the valve core, the control accuracy can reach 3%, and the minimum response time is 7 ms. According to the characteristics of the different drive methods, the differences between them are compared, the advantages and disadvantages of each drive method are analyzed, and the application scenarios for each drive method are identified. Solutions to the drawbacks of the existing drive methods are proposed, which provide directions for further optimization. We have found that solenoid drives are simple to control, low cost, and the most widely used. Material telescopic drives, motor drives, hydraulic valve drives, and other drives are costly, complex to control, and optional for use in special requirement situations. Based on the existing spool drive methods, an outlook on future drive methods is presented. This review facilitates a comprehensive understanding of the drive methods of hydraulic valve spools, points out the shortcomings of the existing drive methods, and is of great significance in improving the existing drive methods and proposing new drive methods. This paper has a positive effect on improving the control accuracy and responsiveness of hydraulic valves. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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22 pages, 18880 KiB

Open AccessArticle

Performance Study of a Supersonic Swirl Separator

by Yi Liu and Chang Ding

Processes 2023, 11(7), 2218; https://doi.org/10.3390/pr11072218 - 24 Jul 2023

Cited by 2 | Viewed by 1901

Abstract

At present, as a new separation technology, supersonic separators have great potential in the separation of natural gases. However, their system performance is still low. In this paper, a supersonic swirl separator design is proposed with an integration approach of the discrete phase model (DPM), bi-coupling, and the random walk model, and it is used to predict the flow process of liquid droplets within the device. Such a numerical method is further employed to study the influence of key parameters on system performance. The results show that with an increase in the inlet port number and the ratio of the gas-liquid area, the separation performance decreases. As a result, the expansion, condensation effect, and economy of the separation system are greatly improved. When the deflection angle exceeds 20°, the separation temperature increases greatly. Consequently, this may ruin the condensing environment. The working pressure ranges are: (1) the boost ratio (the dry outlet pressure/total inlet pressure) is less than 0.76; (2) the wet pressure ratio (the wet outlet pressure/total inlet pressure)is less than 0.46. The increase in droplet diameter can improve the separation performance, and the droplets are completely separated as the diameter reaches 1.75 μm. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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19 pages, 20823 KiB

Open AccessArticle

Numerical Investigation of Flow and Structural Characteristics of a Large High-Head Prototype Pump–Turbine during Turbine Start-Up

by Xilong Yin, Xingxing Huang, Shaozheng Zhang, Huili Bi and Zhengwei Wang

Energies 2023, 16(9), 3743; https://doi.org/10.3390/en16093743 - 27 Apr 2023

Cited by 10 | Viewed by 1428

Abstract

Transient processes that occur in pumped storage power plants can cause high-pressure conditions, which in turn can result in vibrations in the pump–turbine structure and even damage to structural components. It is therefore crucial to research the transient process of the large pump–turbine units and the flow-induced vibrations of the structural components. The three-dimensional flow field and structural field models of a high-head prototype pump–turbine were constructed to study its flow characteristics and structural characteristics under the turbine start-up. Calculations and analyses were performed on the pressure variation and the flow-induced stress concentrations of the pump–turbine during start-up in turbine mode. The simulated pressure distributions during the turbine start-up were mapped onto the finite element calculation model of the structures of the pump–turbine to calculate the flow-induced stress concentrations. This study provides a reference to improve the design and operation of high-head prototype pump–turbines based on the findings of the flow and structural characteristics. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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29 pages, 32199 KiB

Open AccessArticle

Influence of Radial Installation Deviation on Hydraulic Thrust Characteristics of a 1000 MW Francis Turbine

by Yifan Wang, Kun Jin, Xingxing Huang, Peng Lin, Zhengwei Wang, Wenliang Wang and Lingjiu Zhou

Water 2023, 15(8), 1606; https://doi.org/10.3390/w15081606 - 20 Apr 2023

Cited by 8 | Viewed by 2007

Abstract

In this paper, a 1000 MW Francis turbine was used to study the influences of uneven clearance distribution caused by various radial installation deviations on the hydraulic thrust of a runner under the rated operating condition with steady-state CFD analysis. Then, the influences of radial installation deviation on the pressure pulsations of the runner and the fluid domains most affected by the deviation were investigated via unsteady CFD calculation. The results show that the radial hydraulic force on the chambers increased linearly with the increase in the radial installation deviation. Additionally, the high-pressure zone was not located in the same position as the radial deviation. With increasing values of the radial installation deviation, the high-pressure zone rotated along the opposite direction of the rotating direction of the runner. This study also found that the flow in the upper crown chamber was most affected by radial installation deviation and that the percentage of high frequencies of the pressure pulsations increased with the flow in the clearances. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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19 pages, 4760 KiB

Open AccessArticle

Effect of Generator Rotor Radial Deviation on the Unbalanced Magnetic Pull of 1000 MW Hydro-Generator Unit

by Jiwen Zhang, Jianwei Zhang, Xingxing Huang, Gaoqiang Chen, Zhengwei Wang and Congdong You

Processes 2023, 11(3), 899; https://doi.org/10.3390/pr11030899 - 16 Mar 2023

Cited by 4 | Viewed by 2408

Abstract

The 1000 MW hydro-generator unit has huge geometrical dimensions and requires high installation accuracy. The control of its installation deviation will directly affect the installation quality and operational performance of the unit and the rotor eccentricity is one of the core problems faced in the installation and operation of the giant hydro-generator unit. This paper presents a method to calculate the asymmetric magnetic field by means of the transient finite element calculation to reveal the effect of the generator rotor radial deviation on the unbalanced magnetic pull of the unit. The effects of rotor dynamic eccentricity on the magnetic field are analyzed in the time and frequency domains, respectively. The results show that both the DC component and the key harmonic component of the unbalanced magnetic pull increase with the increase of the eccentricity value, and this variation relationship is nearly linear. when the eccentricity is no more than 0.15 mm, the unbalanced magnetic pull caused by the rotor eccentricity is calculated to be small, which is acceptable. The conclusions of this investigation can help to straighten out the requirements and standards for the installation deviation control of the large hydro-generator units. Full article

(This article belongs to the Topic Advanced Technology of Full Lifecycle Service for Hydraulic Machinery)

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Journal Name	Impact Factor	CiteScore	Launched Year	First Decision (median)	APC
Applied Sciences applsci	2.5	5.3	2011	18.4 Days	CHF 2400
Energies energies	3.0	6.2	2008	16.8 Days	CHF 2600
Machines machines	2.1	3.0	2013	15.5 Days	CHF 2400
Processes processes	2.8	5.1	2013	14.9 Days	CHF 2400
Sensors sensors	3.4	7.3	2001	18.6 Days	CHF 2600
Water water	3.0	5.8	2009	17.5 Days	CHF 2600
Journal of Marine Science and Engineering jmse	2.7	4.4	2013	16.4 Days	CHF 2600

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