Performance Comparison of Optimized Designs of Francis Turbines Exposed to Sediment Erosion in various Operating Conditions

Abstract

Erosion on hydro turbine mostly depends on impingement velocity, angle of impact, concentration, shape, size and distribution of erodent particle and substrate material. In the case of Francis turbines, the sediment particles tend to erode more in the off-designed conditions than at the best efficiency point. Previous studies focused on the optimized runner blade design to reduce erosion at the designed flow. However, the effect of the change in the design on other operating conditions was not studied. This paper demonstrates the performance of optimized Francis turbine exposed to sediment erosion in various operating conditions. Comparative study has been carryout among the five different shapes of runner, different set of guide vane and stay vane angles. The effect of erosion is studied in terms of average erosion density rate on optimized design Francis runner with Lagrangian particle tracking method in CFD analysis. The numerical sensitivity of the results are investigated by comparing two turbulence models. Numerical results are validated from the velocity measurements carried out in the actual turbine. Results show that runner blades are susceptible to more erosion at part load conditions compared to BEP, whereas for the case of guide vanes, more erosion occurs at full load conditions. Out of the five shapes compared, Shape 5 provides an optimum combination of efficiency and erosion on the studied operating conditions.