Fluid–structure interaction mechanisms leading to dangerous power swings in Francis turbines at full load

Hydropower plants play an important regulatory role in the large scale integration of volatile renewable energy sources into the existing power grid. This duty however requires a continuous extension of their operating range, provoking the emergence of complex flow patterns featuring cavitation inside the turbine runner and the draft tube. When the power output is maximized at full load, self-excited pressure oscillations in the hydraulic system may occur, which translate into significant electrical power swings and thus pose a serious threat to the grid stability as well as to the operational safety of the machine. Today's understanding of the underlying fluid–structure interaction mechanisms is incomplete, yet crucial to the development of reliable numerical flow models for stability analysis, and for the design of potential countermeasures. This study therefore reveals how the unsteady flow inside the machine forces periodic mechanical loads onto the runner shaft. For this purpose, the two-phase flow field at the runner exit is investigated by Laser Doppler Velocimetry and high-speed visualizations, which are then compared to the simultaneously measured wall pressure oscillations in the draft tube cone and the mechanical torque on the runner shaft. The results are presented in the form of a comprehensive, mean phase averaged evolution of the relevant hydro-mechanical data over one period of the instability. They show that the flow in the runner, and thus the resulting torque applied to the shaft, is critically altered by a cyclic growth, shedding and complete collapse of cavitation on the suction side of the runner blades. This is accompanied by a significant flow swirl variation in the draft tube cone, governing the characteristic breathing motion of the cavitation vortex rope.

Physical Mechanisms governing Self-Excited Pressure Oscillations in Francis Turbines

Andres Müller

The importance of renewable energy sources for the electrical power supply has grown rapidly in the past decades. Their often unpredictable nature however poses a threat to the stability of the existing electric grid. Hydroelectric powerplants play an important role in regulating the integration of renewable energy sources into the network by supplying on-demand load balancing as well as primary and secondary power network control. Therefore, the operating ranges of hydraulic machines has to be continuously extended, which potentially produces undesirable flow phenomena involving cavitation. An example is the formation of a gaseous volume in the swirling flow leaving a Francis turbine runner at off-design operating conditions. At high load, this so called vortex rope is shaped axisymmetrically and may enter a self-excited oscillation, measurable through significant fluctuations of the pressure throughout the system and the mechanical torque transferred to the generator. The main objective of the present work is the identification of the physical mechanisms governing this self-sustained, unstable behavior by measurement. Furthermore, the key parameters of numerical approaches using one-dimensional hydroacoustic flowmodels or CFD require experimental validation. For this purpose, the measurements provide a comprehensive data base of various flow and system parameters at varying operating conditions. Two test cases are studied, a small scale hydraulic circuit with a micro-turbine as well as a reduced scale physical model of an existing Francis turbine. On the first test case, the study of the flow rate fluctuations up- and downstream of the oscillating vortex rope in the draft tube, together with the volume of the cavity, revealed the destabilizing effect of the flow swirl in the draft tube inlet. The second test case accurately simulates the behavior of an actual hydraulic power plant. Investigations range from a local study of the flow field in the draft tube cone bymeans of LDV, PIV, high speed visualization and wall pressure measurements to a global analysis, considering the response of the hydraulic and mechanical system to the excitation by the vortex rope oscillation. Among the main observations is a periodical variation of the flow swirl in the draft tube, synchronized with the pressure oscillations. This is likely to be caused by a cyclically appearing volume of cavitation on the runner blades, modifying the relative flow angle at the outlet. The interaction of the blade cavitation and the vortex rope oscillation via the flow swirl is found to play a crucial role in the occurrence of self-excited pressure oscillations in Francis turbines.

EPFL2014

Fluid-structure interaction mechanisms leading to dangerous power swings in Francis turbines at full load

François Avellan, Arthur Tristan Favrel, Christian Landry

Hydropower plants play an important regulatory role in the large scale integration of volatile renewable energy sources into the existing power grid. This duty however requires a continuous extension of their operating range, provoking the emergence of complex flow patterns featuring cavitation inside the turbine runner and the draft tube. When the power output is maximized at full load, self-excited pressure oscillations in the hydraulic system may occur, which translate into significant electrical power swings and thus pose a serious threat to the grid stability as well as to the operational safety of the machine. Today's understanding of the underlying fluid structure interaction mechanisms is incomplete, yet crucial to the development of reliable numerical flow models for stability analysis, and for the design of potential countermeasures. This study therefore reveals how the unsteady flow inside the machine forces periodic mechanical loads onto the runner shaft. For this purpose, the two-phase flow field at the runner exit is investigated by Laser Doppler Velocimetry and high-speed visualizations, which are then compared to the simultaneously measured wall pressure oscillations in the draft tube cone and the mechanical torque on the runner shaft. The results are presented in the form of a comprehensive, mean phase averaged evolution of the relevant hydro-mechanical data over one period of the instability. They show that the flow in the runner, and thus the resulting torque applied to the shaft, is critically altered by a cyclic growth, shedding and complete collapse of cavitation on the suction side of the runner blades. This is accompanied by a significant flow swirl variation in the draft tube cone, governing the characteristic breathing motion of the cavitation vortex rope.

Elsevier2017

On the physical mechanisms governing self-excited pressure surge in Francis turbines

François Avellan, Arthur Tristan Favrel, Christian Landry, Andres Müller, Keita Yamamoto

The required operating range for hydraulic machines is continually extended in an effort to integrate renewable energy sources with unsteady power outputs into the existing electrical grid. The off-design operation however brings forth unfavorable flow patterns in the machine, causing dynamic problems involving cavitation, which may represent a limiting factor to the energy production. In Francis turbines it is observed that the self-excited oscillation of a vortex rope in the draft tube cone prevents the delivery of maximum power when required. This phenomenon is referred to as full load pressure surge and has been the object of extensive research during the past decades. Several contributions deepened its understanding through measurement and simulation of the local flow properties and the global stability parameters. The draft tube pressure level and the runner outlet swirl are identified as key variables in the modelling of the vortex rope dynamics. Recently, a cyclic appearance of blade cavitation has been observed at overload conditions in a multiphase numerical simulation coupling the runner and the draft tube. From the analysis of the simulation it becomes obvious that the cyclic appearance of blade cavitation has a direct effect on the runner outlet swirl, thus introducing an additional interaction mechanism that is not accounted for in formerly published models. For the presented work, the results of this numerical study are confirmed experimentally on a reduced scale model of a Francis turbine. Several wall pressure measurements in the draft tube cone are performed, together with high speed visualizations of the vortex rope and the blade cavitation. The flow swirl is calculated based on Laser Doppler Velocimetry measurements. A possible mechanism explaining the coupling between the self-excited pressure and vortex rope oscillation and the cyclic appearance of the blade cavitation is proposed. Furthermore, the streamwise propagation speed of the flow swirl in the draft tube is calculated. The results offer important insights in the physics of high load pressure surge and contribute to the further development of numerical draft tube flow and stability models.