The clearance flow around the pump-turbine runner has significant influences on unit vibrations, which may cause accidents in transient processes. The dynamic hydraulic forces and flow patterns in the clearance flow channel (CFC) of a low specific-speed pump-turbine were analyzed based on 3D CFD simulations during the runaway oscillating process. It is shown that the axial force of the runner periodically fluctuates with large amplitudes, and its components in CFC and the main flow channel (MFC) demonstrate a similar significance level. The CFC component was formulated as a function of the clearance inlet pressure and rotational speed, while the MFC component as a function of the momentum changing rate and the runner outlet pressure force. The fluctuation of runner radial force is mainly caused by the flow evolution in MFC, however, the flow in CFC aggravates it. The pressure in CFC shows a few pulsating signals from MFC, and the radial pressure drop in CFC is proportional to the square of both radius and rotational speed. In CFC, strong rotating shear flow containing a velocity core region in the circumferential direction is formed, and rotational speed is the dominant factor.

The pumped-storage power station is an efficient stability regulator of the power grid. However, due to the instability of the pump-turbine in the S-shaped characteristic region, rotational speed fluctuation is easy to occur in the speed no-load condition, making synchronization with and connection to the grid difficult. To investigate the key factors of these difficult grid connections, the start-up processes of a practical pump-turbine under the lowest head condition were simulated by using the three-dimensional CFD method, in which the governor regulating equations with different regulating parameters were integrated successfully. The results show that the working points oscillate with the fluctuations of rotational speed, discharge, and torque, and different regulating parameters have a significant influence on the dynamic histories. In addition, the internal flow patterns, especially the backflows at the runner inlet, keep apparent values at the middle span (0.5 span) but have regular transitions near the shroud side (0.7–0.8 span). The faster the guide vanes adjust, the faster the backflows change, and the larger the macro parameters fluctuate. Overall, the instability of the start-up is the result of the periodical evolutions of backflows at the runner inlet, because the trend and period of the radial velocities at different inlet span locations are consistent with those of the discharge.

The variable speed pump-turbine is usually used to adjust the rotational speed to improve the efficiency in turbine mode and change the input power in pump mode because its rotational speed can vary within a certain range. In order to explore the evolutions of pressure pulsation and flow patterns caused by changes in the rotational speeds, the steady operating conditions under different rotational speeds in turbine and pump modes were investigated by using three-dimensional numerical simulations. The results show that as the pump-turbine operates with the highest efficiency at the rated rotational speed, the change in the rotational speed leads to the variation in macro-parameters, deterioration of the flow patterns, and increase in pressure pulsations. In addition, under a certain guide vane opening, with the increase in the rotational speed, the torque, power, and discharge increase in the turbine mode, while these parameters decrease in the pump mode. And when the rotational speed is too high or too low, it causes an obvious increase in pressure pulsations.

The clearance flow channel (CFC) of pump-turbine is a thin cavity composed of a runner and head cover or bottom ring, but excessive pressure pulsation in a flat CFC is easy to cause the head cover excitation. At present, there are insufficient studies on the flow patterns, and pressure pulsations in CFC. In this paper, the 3D CFD numerical simulation method was used to reveal the flow patterns, and pressure pulsations in the CFC of a low specific speed pump-turbine under rotational stall condition. The results showed that the stall vortexes rotated in the vaneless region of the main flow channel (MFC) when the rotating stall occurred in the pump mode; while that rotated in the runner flow channels, causing circumferentially imbalanced pressure at the runner inlet, as well as a low-frequency and high-amplitude pulsation in MFC. In CFC, uneven pressure distribution in the external cavity was formed when the clearance inlet pressure was unbalanced in the circumferential direction in turbine braking mode. The pulsation generated by the rotating stall in the MFC could be transmitted to the CFC, but the pulsation amplitude dropped sharply at the clearance inlet position, then increased first and ultimately decreased inward along the clearance flow channel. This study provides a reference for the study of hydraulic excitation of the head cover.