Article

Francis Type Turbine Runner Design and Comparison with Model Test Results

Downloads

Yılmaz, B., SÖZEN, A., & Bendeş, O. (2024). Francis Type Turbine Runner Design and Comparison with Model Test Results. New Energy Exploitation and Application, 3(1), 27–42. https://doi.org/10.54963/neea.v3i1.202

Authors

  • Buğra Yılmaz 1 Energy Systems Engineering, Faculty of Technology, Gazi University, Ankara 06560, Turkey; 2 TEMSAN, Türkiye Electromechanic Industry Corporation, Ankara 06200, Turkey
  • Adnan SÖZEN
    Energy Systems Engineering, Faculty of Technology, Gazi University, Ankara 06560, Turkey https://orcid.org/0000-0002-8373-2674
  • Oğuzhan Bendeş TEMSAN, Türkiye Electromechanic Industry Corporation, Ankara 06200, Turkey https://orcid.org/0000-0002-2722-1212

Cavitation wear and hydraulic efficiency decrease in hydroelectric power plants have frequently been the subject of various research and studies. A hydroelectric power plant built on the Kızılırmak River in Türkiye started operating in 1960 and has not been subjected to any large-scale rehabilitation work other than general maintenance until today. The power plant has 4 Francis-type turbines, each with a power of 32 MW. Due to cavitation wear of turbine runners over the years, performance loss, vibration, and noise problems have arisen. Moreover, the maximum turbine hydraulic efficiency, which was 92% in 1960, the year the power plant was commissioned, decreased to 87.9% according to the efficiency measurements carried out at the power plant in 2020. In this study, Computational Fluid Dynamics (CFD) analyses were accomplished with Reynolds averaged Navier Stokes (RANS) calculations for the redesign of the Francis-type turbine runner and finally checked by a model test according to IEC 60193. It was observed that the model test and CFD results were close to each other, especially at the best efficiency point. The maximum turbine hydraulic efficiency, which was calculated as 94.95% as a result of CFD analysis at the nominal head, was calculated as 95.19% by the model test. The x-blade shape created in the redesigned turbine runner blades ensured homogeneous pressure distribution and increased the hydraulic efficiency significantly.

Keywords:

computational fluid dynamics Francis turbine runner design hydroelectric power plant rehabilitation

Author Biography

References

  1. Öymen, G. The role of renewable energy on sustainability (in Turkish) . Istanbul Commerce University Journal of Social Sciences , 2020, 19, 1069–1087.
  2. Ürün, E.; Soyu, E. An evaluation on renewable energy sources in Türkiye’s energy production (in Turkish). Available online: https://dergipark.org.tr/tr/pub/dpusbe/issue/31354/345354.
  3. Gökdemir, M., Kömürcü, M.İ.; Evcimen, T.U. Overview of hydroelectric energy and HEPP applications in Türkiye (in Turkish). Available online: https://www.imo.org.tr/Eklenti/568,turkiyede-hidroelektrik-enerji-ve-hes-uygulamalarina-genel-bakispdf.pdf?0.
  4. Benigni, H.; Schiffer, J.; Jaberg, H.; Özcan, A.Ö.; Duva, B.C.; Mosshammer, M. Rehabilitation of a Francis turbine using CFD and optimization techniques: A case study in Turkey. In Proceedings of the Hydro-International Conference and Exhibition, Bordeaux, France, 26–28 October 2015.
  5. HATCH. (2019). Energy efficiency in power generation, condition assessment report for Hirfanlı HPP (unpublished report) (H358793).
  6. International Electrotechnical Commission. IEC 60193-Hydraulic turbines, storage pumps, and pump-turbines—Model acceptance tests; International Electrotechnical Commission: Geneva, Switzerland, 2019.
  7. Özcan, A.Ö. Evaluation of the efficiency increment potential for francis turbines using CFD analysis. Master’s thesis, Middle East Technical University, Ankara, 2016.
  8. Benigni, H.; Schiffer, J.; Jaberg, H. Refurbishment of twin Francis turbines–maximizing the annual production. IOP Conf. Ser.: Earth Environ. Sci. 2019, 240, 022036.
  9. Celebioglu, K.; Aradag, S.; Ece, A.; Altintas, B. Rehabilitation of Francis turbines of power plants with computational methods. Hittite J. Sci. Eng. 2018, 5(1), 37–48.
  10. Dahal, D.; Chitrakar, S.; Kapali, A.; Thapa, B.; Neopane, H. Design of spiral casing of Francis turbine for micro hydro applications. J. Phys.: Conf. Ser. 2019, 1266, 012013.
  11. Kecel, S.; Yavuzcan, H.G.; Sözen, A. Examination of flow effects in Francis turbine models with different numbers of rotor blades. Politeknik Dergisi. 2017, 20(1), 241–249.
  12. Aylı İnce, Ü. E. Design of Francis type turbine using numerical methods, parameter optimization and development of the numerical infrastructure of model tests (in Turkish). Doctoral thesis. TOBB University of Economics and Technology, Ankara, Turkey, 2016. https://gcris.etu.edu.tr/handle/20.500.11851/2158.
  13. Brekke, H. Design, performance and maintenance of Francis turbines. Glob. J. Res. in Eng. Mech. and Mechanics Eng. 2013, 13(5), 28–40.
  14. TEMSAN, Türkiye Electromechanic Industry Corporation. (2022). Computational fluid dynamics report (unpublished report).
  15. Menter, F.R. Two-equation eddy-viscosity turbulence models for engineering applications. AIAA J. 1994, 32(8), 1598–1605.
  16. Benigni, H.; Schiffer-Rosenberger, J.; Penninger, G.; Weichselbraun, C.; Artmann, M.; Juhrig, L.; Becker, M.; Krappel, T.; Jaberg, H. Cavitation as a limiting factor for the empowering of a Kaplan turbine–CFD calculations, test rig results and operational experience. 2020, 1–10.
  17. International Electrotechnical Commission. IEC 62256-Hydraulic turbines, storage pumps and pump-turbines – Rehabilitation and performance improvement. International Electrotechnical Commission: Geneva, Switzerland, 2017.
  18. Demers, A. (2009). Francis turbine “x-blade” technology. Hydro News, Magazine of Andritz Hydro. https://www.scribd.com/doc/226004893/hy-hn15-en.
  19. TEMSAN, Türkiye Electromechanic Industry Corporation. (2023). Model test report (unpublished report).
  20. Jošt, D.; Škerlavaj, A.; Morgut, M.; Mežnar, P.; Nobile, E. Numerical simulation of flow in a high head Francis turbine with prediction of efficiency, rotor stator interaction and vortex structures in the draft tube. J. Phys.: Conf. Ser. 2015, 579, 012006.
  21. International Electrotechnical Commission. IEC 60041-Field acceptance tests to determine the hydraulic performance of hydraulic turbines, storage pumps and pump-turbines. International Electrotechnical Commission: Geneva, Switzerland, 1991.
  22. Jain, S.; Saini, R.; Kumar, A. CFD approach for prediction of efficiency of Francis turbine. In Proceedings of the 8th International Conference on Hydraulic Efficiency Measurement, IIT Roorkee, India, 21–23 October 2010.