Influence of Hydraulic Design on Stability and on Pressure Pulsations in Francis Turbines at Overload, Part Load and Deep Part Load based on Numerical Simulations and Experimental Model Test Results

Abstract

Francis turbines have been running more and more frequently in part load conditions, in order to satisfy the new market requirements for more dynamic and flexible energy generation, ancillary services and grid regulation. The turbines should be able to be operated for longer durations with flows below the optimum point, going from part load to deep part load and even speed-no-load. These operating conditions are characterised by important unsteady flow phenomena taking place at the draft tube cone and in the runner channels, in the respective cases of part load and deep part load. The current expectations are that new Francis turbines present appropriate hydraulic stability and moderate pressure pulsations at overload, part load, deep part load and speed-no-load with high efficiency levels at normal operating range. This study presents series of investigations performed by Voith Hydro with the objective to improve the hydraulic stability of Francis turbines at overload, part load and deep part load, reduce pressure pulsations and enlarge the know-how about the transient fluid flow through the turbine at these challenging conditions. Model test measurements showed that distinct runner designs were able to influence the pressure pulsation level in the machine. Extensive experimental investigations focused on the runner deflector geometry, on runner features and how they could reduce the pressure oscillation level. The impact of design variants and machine configurations on the vortex rope at the draft tube cone at overload and part load and on the runner channel vortex at deep part load were experimentally observed and evaluated based on the measured pressure pulsation amplitudes. Numerical investigations were employed for improving the understanding of such dynamic fluid flow effects. As example for the design and experimental investigations, model test observations and pressure pulsation curves for Francis machines in mid specific speed range, around nqopt = 50 min−1 are reported, analysed and commented here. The analysis of experimental results allowed the identification of designs and configurations, which can improve the machine stability.