High Head Model Francis Turbine Research Articles

Simulations of design and high load operation of a model Francis turbine using bridged approach to turbulence modelling

Abstract Off-design operation of hydraulic turbines is contemporarily frequented for balance of variable energy intermittence in the electric grid. Being operationally highly flexible, these turbines allow a quick transition to off-design operation from the design point. However, such operational flexibility, and therefore the grid balancing capability is impeded by generation of flow instabilities like vortex breakdown during off-design operation. Vortex breakdown causes losses in efficiency and pressure recovery, pressure fluctuations and possibly mechanical vibrations in event of resonance between system natural and flow field fluctuation frequencies. While substantial experimental and numerical effort has already been made to study draft tube vortex breakdown, an accurate numerical flow characterization of the phenomenon is still a challenge. To this end, operation of a high head model Francis turbine under design and high load regimes using a bridged turbulence modelling approach is simulated. The approach allows a seamless transition between direct numerical simulation and Reynolds averaged Navier-Stokes equations. The highest attainable accuracy is limited by the mesh size. As such a satisfactory compromise between desired accuracy and invested computational effort is attained. The flow in the draft tube is free of anomalies under design specified operation. However, at high load an axial flow stagnation occurs centrally, and the flow is separated about the stagnated zone. The core of the vortex is enlarged with flow recirculation within it. Shear layers between the central stagnant zone and surrounding outflow kink and roll up transforming it into a spiral structure. In this work, a basic yet accurate numerical flow characterization of the aforementioned flow situations is achieved.

Flow-induced pulsations in Francis turbines during startup - A consequence of an intermittent energy system

Hydraulic turbines are increasingly responsible for regulating the electric grid, due to the rapid growth of the intermittent renewable energy resources. This involves a large increase in the number of starts and stops, which cause severe flow-induced pulsations and fluctuating forces that deteriorate the machines. Better knowledge of the evolution of the flow in the machines during transients makes it possible to avoid hazardous conditions, plan maintenance intervals, and estimate the costs of this new kind of operation. The present work provides an in-depth and comprehensive numerical study on the flow-induced pulsations and evolution of the flow field in a high-head model Francis turbine during a startup sequence. The flow simulation is carried out using the OpenFOAM open-source CFD code. A thorough frequency analysis is conducted on the fluctuating part of different pressure probes and force components, utilizing Short-Time Fourier Transform (STFT) to extract the evolution of the frequency and amplitude of pulsations. Low-frequency oscillations are detected during the startup, which are induced by the complex flow structure in the draft tube. A decomposition is performed on the draft tube pressure signals, and the variations of the synchronous (plunging) and asynchronous (rotating) modes are studied. The plunging mode is stronger at minimum and deep part load conditions, whereas the rotating mode is dominant during the presence of the Rotating Vortex Rope (RVR) at part load. The velocity field in the draft tube is validated against experimental data, and the complex flow structures formed during the startup procedure are explained using the λ2 vortex identification method.

Proper orthogonal decomposition of turbulent swirling flow of a draft tube at part load

A large scale vortical structure, i.e., rotating vortex rope (RVR), generally forms at part load (PL) operation of a reaction turbine due to the combined effect of swirling flow at the runner outlet and the adverse pressure gradient in the draft tube. Even with the data analysis through advanced measurement techniques like Laser Doppler velocimetry (LDV) and Particle Image Velocimetry (PIV), the information available about the flow instabilities developed due to RVR is still incomplete. This paper presents an application of the proper orthogonal decomposition (POD) method to analyze the flow field inside the draft tube cone at PL operation of a high-head model Francis turbine. The POD analysis is performed on 250 PIV snapshots containing the axial and radial velocities. The results show that the first eight modes contain more than 95% of the total kinetic energy (KE) of the flow field and are associated with the organized motion of the flow. The first mode contains more than 50% of the total energy, and the axial velocity profile reconstructed with the first mode is identical to the mean axial velocity flow field. The maximum dissipation of the turbulent kinetic energy (TKE) occurs through unorganized motion.

Transient analysis of load rejection for a high-head Francis turbine based on structured overset mesh

Tremendous development and integration of intermittent renewable energy resources have forced the hydraulic turbines to experience transient processes more frequently and thus endangered the stability of the machine. The principal objective of this paper is to present the numerical investigation into load rejection towards a high-head model Francis turbine based on the structured overset mesh, which provides greater flexibility over the standard mesh techniques and adequate mesh quality during the movement of the guide vanes. The numerical results show good agreement with experimental measurements. The formation and evolution process of the vortex rope in the draft tube are elaborated by the velocity invariant Q and the swirl number S reaching its maximum value due to the formation of precessing vortex rope. Evidence is presented which shows that significant influence of the rotor-stator interaction is captured, and the pressure fluctuation amplitudes caused by the changing of angular position of guide vane are also powerful. Furthermore, the velocity profiles in axial and radial imply that an increasing recirculating flow region is developed at the center of the draft tube during the transient process. The findings presented in this paper enhance the insight into transient features of load rejection process.

Erratum to: Experimental investigations of transient pressure variations in a high head model Francis turbine during start-up and shutdown

In the published article [1] there is an error in the listing of the last author. “Dahlhaug G. Ole” should be “Ole Gunnar Dahlhaug” as listed in this erratum.

Synchronized PIV and pressure measurements on a model Francis turbine during start-up

This paper presents the experiments performed on a high head model Francis turbine during start-up. Synchronized time dependent pressure and velocity measurements were performed to investigate the instabilities in the turbine. A total of four steady state operating points, namely synchronous load, part load, best efficiency point, and high load are considered to perform the turbine start-up. The runner angular speed was observed to increase almost exponentially during the guide vane positions from completely closed to no load condition. The frequency of wave propagation due to the interaction between runner blades and guide vanes was observed to follow the trend of increase of runner angular speed. A vortex rope frequency was captured in the draft tube during synchronous load to part load of the start-up. Two different mechanisms, namely, the development of stagnation point and the available recirculation regions were observed to cause the formation of vortex rope in the draft tube.

Experimental investigation on a high head Francis turbine model during shutdown operation

Increased penetration of intermittent energy resources disturbs the power grid network. The frequency band of the power grid is normally controlled by automatic opening and closing of the guide vanes of hydraulic turbines. This has increased the number of shutdown cycles as compared to the defined ones for the normal operation of turbines. Turbine shutdown induced a significantly higher level of pressure fluctuations and unsteadiness in the flow field, decreasing its expected life. This paper presents experiments performed on a high head model Francis turbine during shutdown. The pressure and 2D Particle Image Velocimetry (PIV) measurements were performed to investigate the pressure fluctuations and flow instabilities in the turbine. The pressure sensors were mounted in the draft tube cone and vaneless space to measure the instantaneous pressure fluctuations. In the present study, the initial high load operating condition was considered to perform the turbine shutdown. The data were logged at the sampling frequency of 40 Hz and 5 kHz for PIV and pressure measurements, respectively. Time-resolved velocity and pressure data are presented in this paper to show the pressure fluctuations and causes of generation of unsteady flow in the draft tube.

Erratum to: Experimental investigations of transient pressure variations in a high head model Francis turbine during start-up and shutdown

This corrects the article “Experimental investigations of transient pressure variations in a high head model Francis turbine during start-up and shutdown” in volume 26, issue 2 on page 277. In the published article “Vaginal adhesions in a woman with the history of dystocia. Journal of Hydrodynamics, 2014, 26(2): 277–290. 10.1016/S1001-6058(14)60031-7,” the spell of author's name is given incorrectly. The Editorial Office of Journal of Hydrodynamics would like to correct the author's name. The Editorial Office apologizes for any inconvenience that it may have caused. Chirag Trivedi, Michel J. Cervantes, B. K. Gandhi, Dahlhaug G. Ole The author list should be corrected as follows: Chirag Trivedi, Michel J. Cervantes, B. K. Gandhi, Ole Gunnar Dahlhaug

Experimental study of a Francis turbine under variable-speed and discharge conditions

Abstract This work investigates the unsteady pressure fluctuations in a hydraulic turbine that are observed during steep ramping. Although hydraulic turbines are expected to operate seamlessly during steep ramping, the resulting pressure amplitudes are so significant that they take a toll on a machine's operating life. Objective of the present study is to investigate time-dependent pressure amplitudes in the vaneless space, runner and draft tube during power ramping-up and -down under variable-speed configuration. Novelty is to vary both discharge and rotational speed of a runner. The measurements are performed on a high-head model Francis turbine. The investigations revealed that amplitudes of characteristics frequencies, especially rotor-stator interaction, are small during steep ramping however, at the end of transient cycle, the amplitudes quickly increased 30-fold. During steep ramping, blade passing frequency was appeared in the runner, which is uncommon phenomenon in high-head Francis turbines. Strong reflection of pressure waves towards runner from vaneless space (guide vane walls) may be one of the causes for the appearance of blade passing frequency in the runner.

Experimental study of mitigation of a spiral vortex breakdown at high Reynolds number under an adverse pressure gradient

The flow in the off-design operation of a Francis turbine may lead to the formation of spiral vortex breakdowns in the draft tube, a diffuser installed after the runner. The spiral vortex breakdown, also named a vortex rope, may induce several low-frequency fluctuations leading to structural vibrations and a reduction in the overall efficiency of the turbine. In the present study, synchronized particle image velocimetry, pressure, and turbine flow parameter (Q, H, α, and T) measurements have been carried out in the draft tube cone of a high head model Francis turbine. The transient operating condition from the part load to the best efficiency point was selected to investigate the mitigation of the vortex rope in the draft tube cone. The experiments were performed 20 times to assess the significance of the results. A precession frequency of 1.61 Hz [i.e., 0.29 times the runner rotational frequency (Rheingans frequency)] is observed in the draft tube cone. The frequency is captured in both pressure and velocity data with its harmonics. The accelerating flow condition at the center of the cone with a guide vane opening is observed to diminish the spiral form of the vortex breakdown in the quasi-stagnant region. This further mitigates the stagnant part of the cone with a highly dominated axial flow condition of the turbine at the best efficiency point. The disappearance of the stagnant region is the most important state in the present case, which mitigates the spiral vortex breakdown of the cone at high Reynolds numbers. In contrast to a typical transition, a new type of transition from wake to jet is observed during the mitigation of the breakdown. The obtained 2D instantaneous velocity fields demonstrate the disappearance region of shear layers and stagnation in the cone. The results also demonstrate the existence of high axial velocity gradients in an elbow draft tube cone.

Numerical Simulation and Validation of a High Head Model Francis Turbine at Part Load Operating Condition

Hydraulic turbines are operated over an extended operating range to meet the real time electricity demand. Turbines operated at part load have flow parameters not matching the designed ones. This results in unstable flow conditions in the runner and draft tube developing low frequency and high amplitude pressure pulsations. The unsteady pressure pulsations affect the dynamic stability of the turbine and cause additional fatigue. The work presented in this paper discusses the flow field investigation of a high head model Francis turbine at part load: 50% of the rated load. Numerical simulation of the complete turbine has been performed. Unsteady pressure pulsations in the vaneless space, runner, and draft tube are investigated and validated with available experimental data. Detailed analysis of the rotor stator interaction and draft tube flow field are performed and discussed. The analysis shows the presence of a rotating vortex rope in the draft tube at the frequency of 0.3 times of the runner rotational frequency. The frequency of the vortex rope precession, which causes severe fluctuations and vibrations in the draft tube, is predicted within 3.9% of the experimental measured value. The vortex rope results pressure pulsations propagating in the system whose frequency is also perceive in the runner and upstream the runner.

Steady-State and Transients Measurements on a High Head Model Francis Turbine

Steady-State and Transients Measurements on a High Head Model Francis Turbine

Steady-State and Transients Measurements on a High Head Model Francis Turbine

Steady-State and Transients Measurements on a High Head Model Francis Turbine

Vortex Rope Formation in a High Head Model Francis Turbine

Francis turbine working at off-design operating condition experiences high swirling flow at the runner outlet. In the present study, a high head model Francis turbine was experimentally investigated during load rejection, i.e., best efficiency point (BEP) to part load (PL), to detect the physical mechanism that lies in the formation of vortex rope. For that, a complete measurement system of dynamic pressure, head, flow, guide vanes (GVs) angular position, and runner shaft torque was setup with corresponding sensors at selected locations of the turbine. The measurements were synchronized with the two-dimensional (2D) particle image velocimetry (PIV) measurements of the draft tube. The study comprised an efficiency measurement and maximum hydraulic efficiency of 92.4 ± 0.15% was observed at BEP condition of turbine. The severe pressure fluctuations corresponding to rotor–stator interaction (RSI), standing waves, and rotating vortex rope (RVR) have been observed in the draft tube and vaneless space of the turbine. Moreover, RVR in the draft tube has been decomposed into two different modes; rotating and plunging modes. The time of occurrence of both modes was investigated in pressure and velocity data and results showed that the plunging mode appears 0.8 s before the rotating mode. In the vaneless space, the plunging mode was captured before it appears in the draft tube. The physical mechanism behind the vortex rope formation was analyzed from the instantaneous PIV velocity vector field. The development of stagnation region at the draft tube center and high axial velocity gradients along the draft tube centerline could possibly cause the formation of vortex rope.

Experimental investigation on a high head model Francis turbine during load rejection

Francis-99 is a set of workshop aiming to determine the state of the art of high head model Francis turbine simulations (flow and structure) under steady and transient operating conditions as well as to promote their development and knowledge dissemination openly. The first workshop (Trondheim, 2014) was concerned with steady state operation. The second workshop will focus on transient operations such as load variation and start-stop. In the present work, 2-D particle image velocimetry (PIV) with synchronized pressure measurements performed in the draft tube cone of the Francis-99 test case during load rejection is presented. Pressure sensors were mounted in the vaneless space and draft tube cone to estimate the instantaneous pressure fluctuations while operating the turbine from the best efficiency point (9.8°) to part load (6.7°) with the presence of a rotating vortex rope (RVR). The time-resolved velocity and pressure data are presented in this paper showing the transition in the turbine from one state to another.

Experimental Investigation of a High Head Model Francis Turbine During Steady-State Operation at Off-Design Conditions

Francis-99 is a set of workshops aiming to determine the state of the art of high head Francis turbine simulations (flow and structure) under steady and transient operating conditions as well as promote their development and knowledge dissemination openly. The first workshop (Trondheim, 2014) focused on steady state conditions. Some concerns were raised regarding uncertainty in the measurements, mainly that there was no clear vortex rope at the Part Load (PL) condition, and that the flow exhibited relatively large asymmetry. The present paper addresses these concerns in order to ensure the quality of the data presented in further workshops.To answer some of these questions, a new set of measurements were performed on the Francis- 99 model at Waterpower Laboratory at the Norwegian University of Science and Technology (NTNU). In addition to PL, two other operating conditions were considered, for further use in transient measurements, Best Efficiency (BEP) and High Load (HL). The experiments were carried out at a head of 12 m, with a runner rotational speed of 333 revolutions per minute (rpm). The guide vane opening angle were 6.72°, 9.84° and 12.43° for PL, BEP and HL, respectively. The part load condition has been changed from the first workshop, to ensure a fully developed Rotating Vortex Rope (RVR). The velocity and pressure measurements were carried out in the draft tube cone using 2D PIV and six pressure sensors, respectively. The new PL condition shows a fully developed rotating vortex rope (RVR) in both the frequency analysis and in the phase resolved data. In addition, the measurements confirm an asymmetric flow leaving the runner, as was a concern in the first Francis-99 workshop. This asymmetry was detected at both design and off-design conditions, with a stronger effect during off design.

Transient pressure measurements at part load operating condition of a high head model Francis turbine

Hydraulic turbines are operating at part load conditions depending on availability of hydraulic energy or to meet the grid requirements. The turbine experiences more fatigue during the part load operating conditions due to flow phenomena such as vortex breakdown in the draft tube and flow instability in the runner. The present paper focuses on the investigation of a high head model Francis turbine operating at 50% load. Pressure measurements have been carried out experimentally on a model Francis turbine. Total six pressure sensors were mounted inside the turbine and other two pressure sensors were mounted at the turbine inlet pipe. It is observed that the turbine experiences significant pressure fluctuations at the vaneless space and the runner. Moreover, a standing wave is observed between the pressure tank outlet and the turbine inlet. Analysis of the data acquired by the pressure sensors mounted in the draft tube showed the presence of vortex breakdown co-rotating with the runner. The detailed analysis showed the rotating and plunging components of the vortex breakdown. The influence of the rotating component was observed in the entire hydraulic circuit including distributor and turbine inlet but not the plunging one.

Transient Pressure Measurements on a High Head Model Francis Turbine During Emergency Shutdown, Total Load Rejection, and Runaway

The penetration of intermittent wind and solar power to the grid network above manageable limits disrupts electrical power grids. Consequently, hydraulic turbines synchronized to the grid experience total load rejection and are forced to shut down immediately. The turbine runner accelerates to runaway speeds in a few seconds, inducing high-amplitude, unsteady pressure loading on the blades. This sometimes results in a failure of the turbine components. Moreover, the unsteady pressure loading significantly affects the operating life of the turbine runner. Transient measurements were carried out on a scale model of a Francis turbine prototype (specific speed = 0.27) during an emergency shutdown with a transition into total load rejection. A detailed analysis of variables such as the head, discharge, pressure at different locations including the runner blades, shaft torque, and the guide vane angular movements are performed. The maximum amplitudes of the unsteady pressure fluctuations in the turbine were observed under a runaway condition. The amplitudes were 2.1 and 2.6 times that of the pressure loading at the best efficiency point in the vaneless space and runner, respectively. Such high-amplitude, unsteady pressure pulsations can affect the operating life of the turbine.

Experimental investigations of transient pressure variations in a high head model Francis turbine during start-up and shutdown

Penetration of the power generated using wind and solar energy to electrical grid network causing several incidents of the grid tripping, power outage, and frequency drooping. This has increased restart (star-stop) cycles of the hydroelectric turbines significantly since grid connected hydroelectric turbines are widely used to manage critical conditions of the grid. Each cycle induces significant stresses due to unsteady pressure loading on the runner blades. The presented work investigates the pressure loading to a high head (Hp = 377 m, Dp = 1.78 m) Francis turbine during start-stop. The measurements were carried out on a scaled model turbine (HM = 12.5 m, DM = 0.349 m). Total four operating points were considered. At each operating point, three schemes of guide vanes opening and three schemes of guide vanes closing were investigated. The results show that total head variation is up to 9% during start-stop of the turbine. On the runner blade, the maximum pressure amplitudes are about 14 kPa and 16 kPa from the instantaneous mean value of 121 kPa during rapid start-up and shutdown, respectively, which are about 1.5 times larger than that of the slow start-up and shutdown. Moreover, the maximum pressure fluctuations are given at the blade trailing edge.

Experimental and Numerical Studies for a High Head Francis Turbine at Several Operating Points

Experimental and numerical studies on a high head model Francis turbine were carried out over the entire range of turbine operation. A complete Hill diagram was constructed and pressure-time measurements were performed at several operating conditions over the entire range of power generation by installing pressure sensors in the rotating and stationary domains of the turbine. Unsteady numerical simulations were performed at five operating conditions using two turbulent models, shear stress transport (SST) k-ω and standard k-ε and two advection schemes, high resolution and second order upwind. There was a very small difference (0.85%) between the experimental and numerical hydraulic efficiencies at the best efficiency point (BEP); the maximum difference (14%) between the experimental and numerical efficiencies was found at lower discharge turbine operation. Investigation of both the numerical and experimental pressure-time signals showed that the complex interaction between the rotor and stator caused an output torque oscillation over a particular power generation range. The pressure oscillations that developed due to guide vanes and runner blades interaction propagate up to the trailing edge of the blades. Fourier analysis of the signals revealed the presence of a vortex rope in the draft tube during turbine operation away from the BEP.