Ravindra R. Navthar et al.

/ International Journal of Engineering Science and Technology (IJEST)

CFD ANALYSIS OF FRANCIS TURBINE

Ravindra R. Navthar1 Joshi Tejas2 ,Dhaneshwar Saurabh2 ,Domale Nitish2, Abhyankar Anand2
1. Asst. Prof. Dept. of Mechanical Engineering, P.D.V.V.P. College of Engineering, Vilad Ghat, P.O.
MIDC, Ahmednagar-414111, Maharashtra India. ravi_navthar@rediffmail.com

2. Dept. of Mechanical Engineering, P.D.V.V.P. College of Engineering, Vilad Ghat, P.O. MIDC,
Ahmednagar-414111, Maharashtra India,joshi.tejas21@gmail.com

Abstract

Hydroelectric power has become the most promising source in power sector to sustain the growth of any
nation. In any hydroelectric power plant, hydraulic turbine plays a vital role which affects the overall performance of
the plant and if utilized at suboptimal level, may lead to the loss of useful head. So, it becomes vital to predict the
behavior of hydro-turbine under actual working conditions. Experimental approach of predicting the performance of
hydro turbine is costly and time consuming compared to CFD approach. CFD has emerged out as a powerful tool for
predicting the performance of mechanical bodies subjected to dynamic flow conditions. There are ample of
evidences where analysts at various levels have taken the advantage of this tool to solve so many problems related to
performance analysis. Along with it, simulation technique is key feature. The aim of this paper is to analyze the
turbine for mechanical failure along with predicting its performance under actual operating condition by using CFD
which is generally constrained by using a prototype. With the technique of simulation we can not only get the values
of performance parameters but also the visualization of concentration and distribution of various parameters like
pressure, velocity, stress at various locations where we may get versed with critical zones where the failure is
supposed to occur.
Keywords: Francis Turbine, CFD Analysis of turbine runner.

1. INTRODUCTION
The energy resources hold key to the steady and ever rising growth of our country as far as economy is
concerned. Dependency on affordable, environmental friendly, easily accessible and long lasting energy sources is
the need of the era .India ranks 6th in total energy consumption. The rising exploitation of natural resources like high
grade coal and oil has put huge pressure on scarce foreign exchange. One of the hampering causes on economic
growth is the suboptimal utilization of commercial energy in productive sector. [6]

Hydro electric power available to us has got the capacity to produce 1,50,000 MW out of which currently
32,000 MW which is only about 20% of the hydroelectric potential has been exploited so far. [4] As far as current
power generation of 1,76,990 MW is concerned, hydro electric power shares around 21% of it.[7]

When we go for determining the design parameters of Francis turbine we rely on some assumptions for the
sake of simplicity. But the ideal situation never exists which departs the predetermined theoretical performance from
actual one. More of it, most of the critical distributions of vital parameters remain unexplained due the limitations of
the visualization of the working model which when encounters with actual flow conditions. This may lead to the
sub-optimized use of the turbine. To cope with this inability, CFD facilitates as a most promising tool to establish
various relationship among different parameters like pressure, velocity, and stress distribution at various loading
levels which is not possible while analyzing the performance by prototyping. Thus prototyping limits the
convenience of modification which CFD offers with the great flexibility. Along with this, CFD helps in predicting
the performance of turbine and also assists in optimizing it.

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2. LITERATURE REVIEW
CFD has emerged out as a powerful tool for predicting the performance of mechanical bodies subjected to
dynamic flow conditions. There are ample of evidences where analysts at various levels have taken the advantage of
this tool to solve so many problems related to performance analysis. Along with it, simulation technique is key
feature of it. Kiran Patel, Jaymin Desai, et al have attempted to optimize the design of all components using CFD
and prediction of the performance was done at various load situation to carry out the improvements over old designs
.[1]Manoj Kumar Shukla et al have used CFD for comparing the results with the experiment performed on prototype
with the 3-D flow analysis of Francis turbine by using CFD by using the flow conditions in accordance with the
flow conditions where actual prototype was installed.[2]Ruchi Khare, et al has worked in 3D turbulent real flow
analyses in hydraulic Francis turbine have been carried out at three guide vane opening, different rotation speed,
flow parameters like velocities and flow angles using CFX software.[3] J. Huang, J. Swiderski et al have upgraded
Francis turbine unit by implementing Canadian technologies. They have used CFD approach and methodology to
optimize Francis runner design.[4] Sanjay Jain, Arun Kumar have predicted the performance and efficiency of
Francis turbine using CFD approach and validated the same with the model testing results.[5]

3. PROBLEM STATEMENT
Hydraulic turbine being the most critical component in hydropower plants, affects the overall performance
of the power plant. Therefore for the effective design of any hydropower project, it is of immense importance to
predict the hydraulic behavior and optimum efficiency of hydro turbines before they are put in actual use. The zones
which are more prone to failure in turbine assembly are the bearings that carry the load of shaft and turbine
assembly and blade surfaces due to wear and corrosion, due to vibration and the added mass effect due to
surrounding water on natural frequencies. Also the problems associated with cavitations effect are prominent. If we
go for prototype modeling the analysis won’t be cost effective and does not lead us to optimized solution. Here we
want to analyze the turbine by using CFD to predict its optimized performance and distribution of various
parameters like pressure, velocity, stress at various locations where we may get versed with critical zones where the
failure is supposed to occur.
4. FRANCIS TURBINE
Francis turbine is a reaction turbine which works on the principle of impulse and reaction. Therefore, it
follows the law of angular momentum. The working fluid converts the part of the available head (potential energy)
into the kinetic energy in the guide vanes and as it moves on the entire blade surface. Thus the energy is transferred
to the runner blades and the runner shaft from the water so as to produce mechanical energy and further in the form
of electricity in alternators. The water is guided by the guide blades to flow over the moving vanes. Flow of water
over the runner is under pressure which gradually decreases from inlet to outlet. Water is admitted all over the
circumference of the runner as runner needs to run full of water since under pressure all the time.
The turbine is located between the high pressure water source and the low pressure water exit, usually at
the base of the dam. As the water moves through the runner, it’s spinning radius decreases, further acting on the
runner. At the exit, water acts on cup shaped runner features, leaving with no swirl and very little kinetic or potential
energy. The turbine’s exit tube is shaped to help decelerate the water flow and recover the pressure.[7]

Fig. 1 : Francis Turbine 

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5. CFD ANALYSIS OF FRANCIS TURBINE

CFD can be used to determine the performance of a component at the design stage, or it can be used to
analyze difficulties with an existing component and lead to its improved design. The turbine contains 13 blades that
revolve about the X-axis. Within the blade passage, the maximum diameter of the shroud is approximately 4.23 m
and reference diameter (hub exit diameter) is 2.52 m, The process of performing a single CFD simulation is split in
to four components:

1. Blade designing
2. Creating the geometry /mesh.
3. Defining the physics of the model.
4. Solving the CFD problem.
5. Visualizing the results in the post-processor.
6. RESULT AND DISCUSSION
6.1 Performance Results
Table 1. Performance Results

Rotation Speed 20.9439 [radian s^-1]

Reference Diameter 2.5218 [m]
Volume Flow Rate 123.8700 [m^3 s^-1]
Head (LE-TE) 8.1945 [m]
Head (IN-OUT) 14.7990 [m]
Flow Coefficient 0.3688
Head Coefficient (IN-
0.0520
OUT)
Shaft Power 15024500.0000 [W]
Power Coefficient 0.0161
Total Efficiency (IN-
83.8274
OUT) %
6.2 Blade Loading Charts

Fig. 2 : Blade Loading At 20% Span Fig. 3 : Blade Loading At 50% Span

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Fig. 4 : Blade Loading At 80% Span 

Fig.2,3,4 shows pressure difference on two sides of blade increases with loading, hence as the load
increases, pressure difference increases. Because of high-pressure difference on both side of blade, high
torque is also developing and hence power output increases.

6.3 Stream wise Plots

Fig. 5 : Streamwise Plot of Pt and Ps Fig. 6 : Streamwise Plot of C 

Fig.5 shows the Total pressure Vs Streamwise location and static pressure Vs Streamwise location over the
entire span of blade. Total pressure of water in the turbine increases up to the leading edge due to volute casing
of the turbine and fixed position of the guide vanes and decreases from leading edge to the trailing edge due to
the total conversion of the partial potential energy into the kinetic energy. The static pressure of water decreases
continuously from leading edge to trailing edge .Fig. 6 shows the velocity distribution on the entire span of the
blade from leading edge to trailing edge. Comparing this graph with the pressure distribution graph, it shows
that at the leading edge when the pressure is maximum the velocity at the same point should be minimum,
further as water flows from leading edge to trailing edge velocity increases and pressure reduces gradually.

Fig. 7 : Streamwise Plot of Alpha and Beta 

Fig. 7 shows angle at which water enters into the guide vane. Beta is the angle at which water discharge.

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Fig.7 shows relation between inlet angle (Alpha) and outlet angle (Beta). To achieve optimum efficiency Alpha
should be minimum and beta should be maximum as possible. Graph shows, at the minimum value of angle
Alpha the outlet angle Beta is maximum. To achieve better performance inlet angle should lie in the range of
15-30 degree and outlet angle should remain in the range of 60-85degree

6.4 Blade to Blade Plots

Fig. 8 : Contour of Pt at 50% Span

Fig. 8 shows the distribution of total pressure (Pt) along the blade. Total pressure reduces as we go towards exit of
runner which is below atmospheric at exit. At 50% span there is sudden rise in pressure and it goes on reducing as
we go along the blade profile from inlet to outlet. The variation of pressure along the blade surface in indicated by
different colors.

Fig. 9 : Contour of W at 50% Span Fig. 10 : Velocity Vectors at 50% Span 

Fig. 9 shows that whirl velocity at the inlet of runner is maximum which is result of partial conversion of
pressure energy into kinetic energy.As we go towards the exit of runner it reduces which is in accordance with
the principle of impulse-reaction. At the exit of runner water possess unusable kinetic energy which makes the
use of draft tube to convert kinetic energy into pressure energy to facilitate discharge of water into tailrace. Fig.
10 shows the velocity vector at 50% span indicates little turbulence at the inlet of runner due to change in
direction along the runner blade indicating high velocity which gradually reduces and becomes steady at the exit
of runner.

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Fig. 11: Velocity Streamlines at Blade

Fig. 11 shows the streamline velocity distribution along the trailing edge of the blade. Velocity of water is
decreasing as we go towards the trailing edge and little turbulence is observed.

7. CONCLUSION

The experimental approach of evaluating the performance of Francis turbine is costly as well as time
consuming. Conversely CFD approach is faster and large amount of results can be produced at virtually no added
cost. The CFD approach for the prediction of efficiency of Francis turbine was developed with accomplishment of
analysis of Francis Turbine performance. CFD analysis shows the distribution of various parameters like Pressure,
velocity at various points along the blade profile by using boundary conditions of pressure and mass flow rate at
inlet and outlet. It can be concluded that CFD approach assists in reduction in cost of model testing and saving in
time which leads to cost-effective analysis and may enhance the viability of hydropower development.

9. REFERENCES
[1] Kiran Patel, Jaymin Desai, Vishal Chauhan and Shahil Charnia (2011) “Development of Francis Turbine using Computational Fluid
Dynamics”, The 11th Asian International Conference on Fluid Machinery and The 3rd Fluid Power Technology Exhibition, November 21-
23, 2011, IIT Madras, Chennai, India, Paper ID: AICFM_TM_015.
[2] Manoj Kumar Shukla, Rajiv Jain, Prof. Vishnu Prasad and S. N. Shukla(2011); “CFD Analysis Of 3-D Flow for Francis Turbine”, MIT
International Journal of Mechanical Engineering Vol 1 pp 93-100; 2 August 2011.
[3] Ruchi Khare, Dr. Vishnu Prasad and Dr. Shushil Kumar.(2010)“CFD Approach for Flow Characteristics Of Hydraulic Francis Turbine”,;
International Journal of Engineering Science and Technology Vol. 2(8), 2010, 3824-3831
[4] J. Huang, J. Ji, Lushui, T. Tung, M. Riley;. “Francis Turbine Upgrade for the Lushui Generating Station by Using Computational Fluid
Dynamics - A Case Study”, Hydraulic Energy Group, Sustainable Buildings and Communities, CANMET Energy Technology Centre -
Ottawa, Natural Resources Canada, Ottawa, Ontario, Canada.
[5] Sanjay Jain, R. P. Saini and Arun Kumar(2010); “CFD Approach for prediction Of Efficiency Of Francis Turbine”, IGHEM-2010,Oct 21-
23,2010, AHEC, IIT Roorkee, India.
[6] V. Raghuraman and Sajal Ghosh (2003); “Indo-U. S. Cooperation in Energy- Indian Perspective”, Confederation of Indian Industry; March-
2003.
[7] Merle C.Potter,David C. Wiggert(2009):Fluid Mechanics,Cengage Learning, 2009 Edition,pp,553-558.  

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