Francis Turbine Draft Tube Research Articles

Reduced Numerical Modeling of a High Head Francis Turbine Draft Tube at Part Load

In the present study, a reduced model of the Francis-99 model turbine was investigated numerically at part load operating condition. The reduced model consists of a standalone draft tube domain of the Francis-99 model turbine. Numerical studies performed in the past on nearly complete hydro-turbine models (inclusive of the spiral casing, distributor domains, runner, and draft tube) reportedly consist of a large number of computational grids. This may increase the computational costs and data storage required to perform numerical analysis, which could be a setback for future research on new design concepts and optimization study of the draft tube domain. The reduced model was developed by mapping the phase averaged axial, radial, and tangential velocity profiles from the runner exit to the inlet of the standalone draft tube domain. Additionally, turbulent kinetic energy (k) and turbulent eddy dissipation (ε) variables were also considered for better flow prediction inside the draft tube domain. Two methods for mapping inlet boundary conditions were considered in the present study. In the first method, the entire planar profile of the runner-draft tube interface was considered. In the second method, the variables along a radial profile at the runner exit were considered with an axis-symmetric flow assumption over the entire draft tube inlet plane. The numerical results obtained from the Francis-99 reduced model turbine were validated against the numerical model of the NVKS Francis-99 model turbine (with available structured mesh) that was also analysed using the passage flow numerical technique and available experimental results. The results were found to be in reasonable agreement, with each other. The present study could be useful for the future mitigation study of rotating vortex rope by modifying the draft tube domain.

Visualization of the elliptical form of a cavitation vortex rope and its collapse by two cameras

This article presents preliminary results of an experimental study of the upper-part load instability and the associated elliptical form of the cavitation vortex rope in a Francis turbine draft tube. The influence of the operating parameters on the onset and the development of the instability is first briefly studied by pressure measurements in the draft tube. Visualizations of the cavitation vortex rope and its associated elliptical form are performed by using two synchronized high-speed cameras spaced by an angle of 90°. This allows to reconstruct the instantaneous position of the vortex center along the draft tube. It is confirmed that using a single camera leads to biased estimations of the cavitation volume fluctuations. The breathing behaviour of the vortex rope, responsible for the pressure pulsations according to several authors, cannot be definitely demonstrated without a proper reconstruction of the vortex shape based on high-speed videos from several positions. Finally, unique intermittent collapses of cavitation in the vortex center, giving rise to two distinct cavities connecting on both sides the vortex rope, are highlighted.

Experimental investigation of vortex ring formation as a consequence of spiral vortex re-connection

The unsteady shape variation of a cavitating spiral vortex is experimentally studied pointing out the repetitive creation of vortex ring (or vortex loop). To generate the spiral vortex structure, a newly designed vortex generator is employed. This generator is used to study the decelerated swirling flow leading to the spiral vortex formation as a consequence of spiral vortex breakdown, which is considered to be the main triggering mechanism for the occurrence of the coherent vortex rope structure in the Francis turbine draft tube operated at part load conditions. Thanks to its design, the vortex generator enables to change the ratio between fluxes of axial momentum and tangential moment of momentum of generated swirl. Using this set-up, the behavior of the vortex structure changes in a similar way as the flow rate variation in the draft tube of Francis turbine. At certain flow conditions, the spiral vortex movement is characterized by sudden spiral entanglement leading to disconnection of a vortex ring and followed by spiral reconnection. Thanks to the transparent diffuser of the swirl generator apparatus, both high-speed camera recording of the cavitating vortex and PIV measurements of velocity fields at cavitationfree conditions are employed. The main aim of this paper is to link the visual observation of the above described vortex dynamics with the velocity fields measured in one longitudinal and one cross-sectional planes.

Investigation of Rotating Vortex Rope formation during load variation in a Francis turbine draft tube

Rotating Vortex Rope (RVR) has been a matter of focus for years due to the major effects on hydraulic turbine’s efficiency. The exact procedure of RVR formation is still vague. The present research focuses on the dynamics of the RVR formation during the load variation employing transient numerical simulations. Two different geometries including the full geometry and the reduced one, which consists of one stay vane, two guide vanes, one runner blade, one splitter blade and full draft tube, are considered. In order to capture the transient swirling flow features inside the draft tube, the Shear Stress Transport-Scale Adaptive Simulation (SST-SAS) model is utilized to approximate the turbulent stresses. The pressure results inside the draft tube agree well with the experimental measurements. Moreover, the velocity results show the central low-axial-velocity and high-tangential-velocity region in the draft tube properly. The flow structure is visualized using λ2 criterion. The dynamic of RVR and the physics behind the RVR formation are investigated during the load variation. The results indicate four flow regimes with different characteristics during RVR formation. The first flow regime is a stable swirling structure occurring at Best Efficiency Point (BEP). The second flow regime occurs at the beginning of the load variation where signs of flow instabilities appear. These instabilities are temporary and washed down by the upstream flow. Expanding the instabilities and creating the vortical structures in the draft tube are the important flow features in the third flow regime. The fourth flow regime is the presence of a developed rotating rope occurring at the Part Load (PL) condition. The flow regimes differ according to the size and shape of the stalled region during load rejection inside the draft tube cone. They also reveal that despite some shortcomings, the reduced model is reliable to simulate the RVR transient formation. The full geometry simulations could be also applicable for practical problems provided that the modified time step is slightly greater than the main blade rotational angle is used.

Optimal design of J-groove shape on the suppression of unsteady flow in the Francis turbine draft tube

The flow in the draft tube of a Francis turbine is highly complex and unstable when the turbine operates far from its design point. To extend the Francis turbine operation range to meet the variable energy demand, a J-groove technology is introduced on the turbine draft tube wall to stabilize the unsteady flow in the draft tube. However, J-groove contributes to energy losses in the draft tube. In this study, the J-groove shape optimization process is proposed based on steady flow analysis using the response surface method. The energy loss and swirl intensity in the draft tube are selected as objectives for the optimization design. The flow characteristics in the draft tube without J-groove and with initial J-groove and optimized J-groove shape are compared. Results show that the swirl intensity in the draft tube with the optimized J-groove is suppressed effectively with the low energy loss in the draft tube. Moreover, the pressure fluctuation in the draft tube with the optimized J-groove is mitigated significantly to stabilize the Francis turbine operation under the off-design point condition.

Numerical investigation of the cavitation dynamic parameters in a Francis turbine draft tube with columnar vortex rope

The cavitation developed in the Francis turbine draft tube is known to be a source of the hydraulic instability, especially under the conditions with columnar cavitation vortex rope occurring in the draft tube. The hydraulic system will suffer from the risk of the self-excitation and the high pressure pulsations because of the dynamic features of the complex cavitation vortex rope. The links between the cavitation dynamic characteristics and the hydraulic system stability are important for an accurate system instability prediction. For this purpose, the cavitating flows in a Francis turbine operating under the overload conditions are simulated by using the Zwart-Gerber-Belamri (ZGB) cavitation model. The cavitation dynamic parameters in different cavitation development stages and the evolutions under various overload conditions are analyzed and compared in this paper. It is shown that the cavitation dynamic parameters, including the cavitation compliance, the mass flow gain factor and the wave speed, can well represent the cavitation characteristics with the vortex rope evolution. The predicted cavitation dynamic parameters are in a reasonable agreement with other available results, with an obvious dependency on the loads. The results obtained in this study are relevant to the system stability analysis.

Experimental and numerical analysis of turbulent velocity fluctuations in a Francis turbine draft tube in part load operation

The part load operation of turbines with non-regulated runner blades is often associated with the occurrence of a rotating corkscrew-shaped vortex rope in the draft tube. Due to its negative influence on power plants, this phenomenon is an important factor in the design process of a water turbine. Investigations using CFD aim to predict the draft tube flow, especially regarding the efficiency and the losses of the turbine. As there are still discrepancies between CFD simulations and experimentally gained data, a research project on this subject was initiated, including extensive measurements with 2D-Laser-Doppler-Anemometry. CFD simulations were carried out using high-resolution hybrid RANS-LES turbulence models. In this paper, the interrelation of the turbulent velocity fluctuations and the periodic vortex rope movement is being examined. Therefore, the measured data is provided time averaged and phase resolved. The specialities of the swirling flow influenced by the periodic vortex concerning the turbulence are illustrated on two planes, one downstream the runner in the cone and one at the lowest position of the draft tube. The results show good conformity with the CFD data including periodic part of the velocity fluctuations. The dependence of the velocity field on the rotating vortex rope is significantly higher in the cone than at the end of the draft tube bend.

Pressure oscillation suppression by air admission in a Francis turbine draft tube

When Francis turbine operated at part-load conditions, there is strong vortex rope in the draft tube, which may induce violent pressure oscillation, mechanical vibration and noise. This paper treats the pressure oscillations at a part-load operation by analyzing the unsteady multiphase flow in a Francis turbine. Air admission is used to alleviate pressure oscillation under different cavitation number. In order to improve the numerical accuracy, a modified method including the Level-set based method and FBDCM model is applied in the calculation. The simulation results indicate that the modified method can reasonably predict the pressure oscillations in turbine with good agreement with experimental data. The method can reflect more detailed flow characteristics and capture a clearer phase interface compared to the conventional method. It is noted that air admission with suitable ventilation rate does suppress the pressure oscillation in the turbine. The pressure oscillation in the vaneless area due to rotor-stator interaction cannot be depressed completely. Further, the mechanism on the pressure oscillation suppression in the draft tube is due to the spiral motion depression of vortex rope by air admission. As the increase of air admission, the pressure and its gradient distributions become much homogeneous. The homogeneous distribution of pressure in the draft tube would be favourable for the suppression of pressure oscillation

Numerical and experimental investigation of the effect of baffles on flow instabilities in a Francis turbine draft tube under partial load conditions

An improved method for preventing vortex rope formation and alleviating the associated pressure fluctuations in turbine draft tubes is investigated using baffles in the draft tube to hinder the swirling flow emerging from a Francis turbine runner. A strong swirl produces flow instabilities and pressure fluctuations. Partial load operating conditions at the rated water head and three flow rates are taken into consideration. It is demonstrated using a computational fluid dynamics simulation that this method effectively eliminates the vortex rope, particularly when using four baffles. The amplitude of the pressure pulsation in the draft tube modified with four baffles was 0.42 times that in a traditional draft tube. The baffles were found to reduce the tangential velocity of the flow in the draft tube and consequently hinder the development of the fierce swirling flow. This type of decrease is more significant compared to the gradual decay due to viscous effects of the solid wall in a traditional draft tube. The conclusion was verified by the results of experiments conducted using a novel device. The measured increase in turbine efficiency exceeded 3% at the evaluated partial loading point, indicating improved economic performance of the turbine.

Investigation on Combined Air and Water Injection in Francis Turbine Draft Tube to Reduce Vortex Rope Effects

In this paper, the effect of water, air, and their combined injection from two different injection points is studied in order to reduce vorticity effects in a draft tube of prototype turbine working at three operating points. The flow from spiral case to the end of draft tube is simulated using the shear stress transport k–ω turbulence and two-phase models. Using an appropriate validation method, acceptable results were obtained under the noninjection condition. To determine suitable number of points and inlet flow rate for air injection as well as the appropriate nozzle diameter for air and water injection, a new method which considers the ratio of total loss to the pressure recovery factor is used, in addition to using the traditional method which calculates the total loss in the draft tube. Comparing results of the three types of injections shows air injection in the operating range greater than 70% of turbine design flow rate, is much more effective than water injection or the combination of air and water injection. However, in the operating range below 70%, either water or air injections are not suitable, but combination of these two fluids can improve system performance.

Suppression of cavitation in the draft tube of Francis turbine model by J-Groove

Cavitation is recognized as a phenomenon that can cause serious damage to a hydro turbine and can reduce its performance when operating at off-design point. This is an undesired phenomenon, which needs to be improved. In order to suppress the cavitation in the Francis turbine draft tube, a technology with grooved draft tube named J-Groove is introduced in the Francis turbine. The Francis turbine performance and the internal flow characteristic are investigated both with and without J-Groove installation by the experimental method and numerical simulation. Visualization was used to capture the cavitation rope in the Francis turbine draft tube to compare with the computational fluid dynamics analysis result. The results show that the turbine performance both with and without J-Groove installation is quite similar. Regardless of impact on performance of Francis turbine by J-Groove, it suppresses the cavitation vortex rope and pressure fluctuation in the Francis turbine draft tube efficiently.

Similarity research of Francis turbine draft tube pressure fluctuation

In this paper, it presented the similarity research of Francis turbine draft tube pressure fluctuation between model turbine and the corresponding prototype. First, a qualitative analysis was made by runner outlet triangle velocity. Then a comparison was made between popular method and the method recommended by this paper which based on relative discharge taken zero swirl discharge as reference and dimensionless pressure pulsation amplitude taken runner outlet blade velocity head as reference respectively on model and prototype. Also a comparison of draft tube pressure fluctuation was made between model test data and prototype data from 12 power plants based on this method respectively. It had shown some similarity between model turbine and homologous prototype and had given the similarity range by statistic method. At last, a method was given concerning prototype draft tube pressure fluctuation amplitude prediction and a comparison was carried out between prediction results and site test results. It fitted very well which can prove the feasibility of this method.

Francis turbine draft tube parameterization and analysis of performance characteristics using CFD techniques

Abstract The present paper focuses on the parameterization of the draft tube elbow based on the initial geometry of the GAMM Francis turbine model. The goal was to obtain a draft tube geometry that improves the hydrodynamic performance. For this purpose, CFD analyzes were carried out, considering the GAMM Francis turbine pre-distributor, distributor and rotor geometry, and different parameterized draft tube geometries. Related to the draft tube parameterization methodology, it has modified the generatrix geometry of the elbow that defines its contour. Three types of curves were used to define the elbow contour geometry: logarithmic spiral format curve, circle arc format curve and denominated hyperbolic spiral curve. These curves and their combinations were used to define the elbow contour in the longitudinal plane, resulted in four draft tubes geometries. The numerical results were compared with experimental results, showing good conformity. The efficiency of the Francis turbine was higher for the four draft tubes of this work than the original draft tube GAMM Francis turbine. Therefore, it was found that the draft tube in hyperbolic-logarithmic spiral format has the highest efficiency and the draft tube in logarithmic spiral format has the lowest loss coefficient. Consequently the hydrodynamic performance have been discussed in this work.

Characteristics of Synchronous and Asynchronous modes of fluctuations in Francis turbine draft tube during load variation

Francis turbines are often operated over a wide load range due to high flexibility in electricity demand and penetration of other renewable energies. This has raised significant concerns about the ...

Space and time reconstruction of the precessing vortex core in Francis turbine draft tube by 2D-PIV

Francis turbines operating at part load conditions experience the development of a high swirling flow at the runner outlet, giving rise to the development of a cavitation precessing vortex rope in the draft tube. The latter acts as an excitation source for the hydro-mechanical system and may jeopardize the system stability if resonance conditions are met. Although many aspects of the part load issue have been widely studied in the past, the accurate stability analysis of hydro-power plants remains challenging. A better understanding of the vortex rope dynamics in a wide range of operating conditions is an important step towards the prediction and the transposition of the pressure fluctuations from reduced to prototype scale. For this purpose, an investigation of the flow velocity fields at the outlet of a Francis turbine reduced scale physical model operating at part load conditions is performed by means of 2D-PIV in three different horizontal cross-sections of the draft tube cone. The measurements are performed in cavitation-free conditions for three values of discharge factor, comprised between 60% and 81% of the value at the Best Efficiency Point. The present article describes a detailed methodology to properly recover the evolution of the velocity fields during one precession cycle by means of phase averaging. The vortex circulation is computed and the vortex trajectory over one typical precession period is finally recovered for each operating point. It is notably shown that below a given value of the discharge factor, the vortex dynamics abruptly change and loose its periodicity and coherence.

Study of the vortex-induced pressure excitation source in a Francis turbine draft tube by particle image velocimetry

Francis turbines operating at part-load experience the development of a precessing cavitation vortex rope at the runner outlet, which acts as an excitation source for the hydraulic system. In case of resonance, the resulting pressure pulsations seriously compromise the stability of the machine and of the electrical grid to which it is connected. As such off-design conditions are increasingly required for the integration of unsteady renewable energy sources into the existing power system, an accurate assessment of the hydropower plant stability is crucial. However, the physical mechanisms driving this excitation source remain largely unclear. It is for instance essential to establish the link between the draft tube flow characteristics and the intensity of the excitation source. In this study, a two-component particle image velocimetry system is used to investigate the flow field at the runner outlet of a reduced-scale physical model of a Francis turbine. The discharge value is varied from 55 to 81 % of the value at the best efficiency point. A particular set-up is designed to guarantee a proper optical access across the complex geometry of the draft tube elbow. Based on phase-averaged velocity fields, the evolution of the vortex parameters with the discharge, such as the trajectory and the circulation, is determined for the first time. It is shown that the rise in the excitation source intensity is induced by an enlargement of the vortex trajectory and a simultaneous increase in the precession frequency, as well as the vortex circulation. Below a certain value of discharge, the structure of the vortex abruptly changes and loses its coherence, leading to a drastic reduction in the intensity of the induced excitation source.

Identification of the wave speed and the second viscosity in cavitating flow with 2D RANS computations - Part II

The 1D modelling of cavitation vortex rope dynamics in Francis turbine draft tube is decisive for prediction of pressure fluctuations in the system. However, models are defined with parameters which values must be quantified either experimentally or numerically. In this paper a methodology based on CFD simulations is setup to identify these parameters by exciting the flow through outlet boundary condition. A simplified test case is considered to assess if 1D cavitation model parameters can be identified from CFD simulations. It is shown that a low wave speed and a second viscosity due to the cavitating flow can be identified.

Francis turbine draft tube modelling for prediction of pressure fluctuations on prototype

The prediction of pressure fluctuations amplitudes on Francis turbine prototype is a challenge for hydro-equipment industry since it is subjected to guarantees to ensure smooth and reliable operation of the hydro units. The European FP7 research project Hyperbole aims to setup a methodology to transpose the pressure fluctuations measured on the reduced scale model to the prototype generating units. This paper presents this methodology which relies on an advanced modelling of the draft tube cavitation flow, and focuses on the transposition to the prototype of the draft tube model parameters identified on the reduced scale model. Different modelling assumptions of the draft tube are considered and their influence on the eigenmodes and the forced response of the system are presented.

Computational fluid dynamics simulation and geometric design of hydraulic turbine draft tube

Any hydraulic reaction turbine is installed with a draft tube that impacts widely the entire turbine performance, on which its functions are as follows: drive the flux in appropriate manner after it releases its energy to the runner; recover the suction head by a suction effect; and improve the dynamic energy in the runner outlet. All these functions are strongly linked to the geometric definition of the draft tube. This article proposes a geometric parametrization and analysis of a Francis turbine draft tube. Based on the parametric definition, geometric changes in the draft tube are proposed and the turbine performance is modeled by computational fluid dynamics; the boundary conditions are set by measurements performed in a hydroelectric power plant. This modeling allows us to see the influence of the draft tube shape on the entire turbine performance. The numerical analysis is based on the steady-state solution of the turbine component flows for different guide vanes opening and multiple modified draft tubes. The computational fluid dynamics predictions are validated using hydroelectric plant measurements. The prediction of the turbine performance is successful and it is linked to the draft tube geometric features; therefore, it is possible to obtain a draft tube parameter value that results in a desired turbine performance.

Cavitation surge modelling in Francis turbine draft tube

Francis turbines may experience cavitation surge phenomenon in the draft tube inducing large pressure fluctuations which can jeopardize the hydraulic system integrity. To predict this phenomenon, a one-dimensional draft tube model is derived from flow momentum and continuity equations including the convective terms that are not considered in the existing models. A parametric analysis of the draft tube model is carried out to investigate the influence of parameters on the cavitation surge onset identified by the hydraulic system stability. It is shown that convective terms have a stabilizing influence modifying stability limit prediction driven by the divergent geometry modelling of the draft tube.