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Conceptual design optimization of Francis Turbine

Technical Report · October 2014

DOI: 10.13140/2.1.3792.2086

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 Analyzing Some Papers in Order to
Demonstrate and Illustrate Optimum
Design Methods’ Application

Presenter: Van Thanh Tien Nguyen

2014.10.18
 CONTENTS

Part I: Part II: Part III: Part IV:

Paper 1 Paper 2 Paper 3 Conclusions

2
 Part I: Paper 1
Conceptual Design Optimization of
Francis Turbine

Rodrigo Barbosa da Fonseca e Albuquerque

and Waldir de Oliveira (Brazil)

3
Outline
1. Introduction
2. Industrial Importance of the Francis Turbine
3. Design Optimization Problem
4. Flow Solver
5. Example of Calculation with the Flow Solver
6. Optimization Methods
7. Results
8. Concluding Remarks

4
 1. Introduction (1)
Objectives of the paper:

a) Presenting a conceptual design methodology for Francis turbines

b) Searching some basic geometric parameters of the machine the design

variables-in order to maximize its efficiency– the objective function –, given the
turbine rotational speed and the discharge.

c) Giving lateral constraints for the design variables.

d) Defining the problem design space for optimum design.

5
 1. Introduction (2)
Hydraulic turbines are long history turbo machines studied, designed, built and put into operation
for nearly 250 years

The traditional design of hydraulic turbines

 Carried out on a "trial-and-error" basis, were the main available design tools(Raabe, 1985;
Ueda, 1982)
 Provide good guidelines for pre-dimensioning of turbines (Schweiger and Gregori, 1989;
Lugaresi and Massa, 1987).
 Another part of this knowledge has been kept closed with the manufacturers, being passed
from "hand-by-hand", as an inheritance, to the engineering teams of the companies
The modern design of hydraulic turbines

These CFD-based tools are able to simulate accurately many important physical phenomena that
occur in the flow inside the turbine, assisting the engineers in detailing the hydraulic profiles
(Drtina and Sallaberger, 1999; Casey, 2003).
This issue is even more important in the case of design optimization: when a geometric change is
made during the optimization process, complex meshes must be rebuilt and the flow solver must
be run again. One example of a very simple methodology is the mean streamline analysis for
conceptual design optimization of pumps (Oh and Kim, 2001).

6
 1. Introduction (3)
In this study, a low-cost flow solver is coupled with two different numerical
optimization techniques.
In that work, the Euler equation for the turbomachines and various empirical
losses correlations for each turbine component – taking in account only the
main geometric parameters of the machine – are applied in order to evaluate
the turbine efficiency hill-charts.

 The design optimization problem is stated in Section 3. The proposed flow

solver is discussed in Section 4. Section 5 shows the performance prediction
of a given micro Francis turbine, by using the flow solver. A brief explanation
about the chosen optimization methods is given in Section 6. In Section 7, the
conceptual design optimization tool is applied and the results are compared
with the Francis turbine design of Section 5. Concluding remarks are given
in Section 8.

(1) Low Cycle Fatigue

(2) High 7
Cycle Fatigue
 2. Industrial Importance of the Francis Turbine

Being the type of water turbine most found today, the Francis turbines will continue, even
for a long time, being used in new hydropower plant projects, despite the strong growth of
low and very low head power plants in the last decades – these ones using Kaplan and
propeller turbines, many of them in bulb arrangements.

8
 3. Design Optimization Problem

The design variables – in order to maximize its efficiency – the

objective function.
The turbine net head should lie within upper and lower limits, these being
the nonlinear constraints of the problem. There are also lateral
constraints for the design variables, defining the problem design space
dealing with a single point optimization only, this can be useful for
achieving also a good operating range (Ueda, 1982; Souza Júnior et al.,
2005).
Formally, the design problem can be stated as a constrained nonlinear
minimization problem as follows:

where x is the n-dimensional vector of the design variables, x = (x1 , x2 , … , xn). These
design variables are some key geometric parameters of the turbine, defined in Section 7. 9
 3. Design Optimization Problem
The search region S is defined by upper and lower bounds, 𝑥𝑗𝑈 and 𝑥𝑗𝐿 respectively, for each
coordinate of x: S = {x  𝑅 𝑛 : 𝑥𝑗𝐿 ≤ 𝑥𝑗 ≤ 𝑥𝑗𝑈 , j = 1, …, n}. The objective function is f(x) = − (x),
where  is the turbine efficiency (with the geometry according to x). gi(x), i = 1, …, m, are the m =
2 nonlinear constraint functions, namely, g1(x) = HL – H(x) and g2(x) = H(x) – HU, where H is the
turbine net head and HL and HU are respectively lower and upper limits, such that HL ≤ H ≤ HU. The
performance of the turbine ( and H) is evaluated by the flow solver, as described in Section 4.
The problem stated above can be solved by optimization algorithms that treat directly nonlinear
constraints. Otherwise, the constraints for the net head can be imposed by means of a penalization
scheme on the objective function:

− + 𝑀(𝐻𝐿 −𝐻)2 , 𝐻 < 𝐻𝐿

f= −, 𝐻𝐿 ≤ 𝐻 ≤ 𝐻𝑈
− + 𝑀(𝐻 − 𝐻𝑈 )2 , 𝐻 > 𝐻𝐿

where M is a sufficiently large positive number. Again, the objective is to maximize  (minimize
−  ) with HL ≤ H ≤ HU. The choice of the penalty factor M must not drive the optimization
process towards a penalty minimization only, missing the objective function main information, i.e.,
the turbine efficiency, . Also, the constraints must not be violated at the end of the process. Some
tests have to be performed in order to settle suitable values for M in each particular problem.
10
 4. Flow Solver
The following assumptions are made for the flow calculation:
1) incompressible fluid flow;
2) stationary absolute flow in the spiral case, stay vanes, wicket gates and draft tube;

3) stationary relative flow in the runner;

4) stationary flow in the space between the stay vanes and the wicket gates and between
the wicket gates and the runner;

5) the absolute flow (in the stationary components) or the relative flow (in the runner)
occur in revolution surfaces, concentric with the turbine shaft;
6) the absolute flow (in the stationary components) or the relative flow (in the runner)
are uniform in the sections upstream and downstream of each component;

7) the flow quantities of interest are evaluated in the mean streamsurfaces (absolute
flow for the stationary components, and relative flow for the runner), in the
meridional plane, for each component;
8) the inlet and outlet points in the mean streamlines (inlet and outlet diameters) of each
component in the meridional plane are defined by the continuity equation.
11
4. Flow Solver

12
4. Flow Solver

13
4. Flow Solver

14
 4. Flow Solver

The hydraulic losses (due to friction) are also evaluated in the vaneless spaces
between the stay vanes and the wicket gates and between the wicket gates and the
runner.
In addition to the hydraulic losses, it is also computed: 1) the leakage loss, due to the
leakage flow through the labyrinths between the runner wearing plates and the
covers; 2) the disk friction loss between the runner crown and the head cover and
between the runner band and the bottom ring; 3) the mechanical (or external) losses,
due to mechanical friction in the turbine bearing(s) and seals.
We denote as Zh the total hydraulic loss through the turbine; the total disk friction
loss is denoted by Zdf and the total leakage loss is denoted by Zleak. These losses are
given in terms of energy per unit weight. The mechanical loss, Pmech, is treated
directly as a loss of power in the turbine shaft.
15
 4. Flow Solver
The main hydraulic losses in each turbine component are evaluated by using various
empirical correlations given in the technical literature (Granja Jiménez, 2004). Table 1
summarizes the loss mechanisms elected in this analysis. The hydraulic losses (due to
friction) are also evaluated in the vaneless spaces between the stay vanes and the wicket
gates and between the wicket gates and the runner.

16
 4. Flow Solver
The theoretical specific work absorbed by the runner blades, Hblade_th (in terms of energy
per unit weight), is given by the Euler classic equation for the turbines (Quantz, 1976), that
represents the integral angular momentum equation:
Hblade_th = (u4cu4 −u5cu5 )/g (1)
where u is the runner peripheral velocity; cu is the circumferential component of the
absolute flow velocity; the index 4 denotes the runner inlet section; the index 5 denotes the
runner outlet section; g is the acceleration due to gravity. The quantities are all considered
on the mean streamline, as previously mentioned.

In the analysis of Granja Jiménez (2004), the actual specific work absorbed by the runner
blades, Hblade, is evaluated according to the method proposed by Pfleiderer and Petermann
(1972):
Hblade = Hblade_th /(1+ p) (2)
where p is a semi-empirical factor which takes in account the number of runner blades and
also some geometric parameters of the runner.
The turbine net head, H, – i.e., the energy per unit weight provided by the water flow – is
calculated by:
H = Hblade + Zh (3)
17
 4. Flow Solver
The corresponding available power, Pavail, is given by:
Pavail = QgH (4)
where ρ is the water density.
The shaft power output, Pshaft, is calculated by:
Pshaft = Qg (Hblade − Zleak − Zdf ) − Pmech (5)
Finally, the turbine total efficiency, η, is calculated by:
𝑷𝒔𝒉𝒂𝒇𝒕
η= (6)
𝑷𝒂𝒗𝒊𝒂𝒍
The flow solver is a computer program in MatLab language for performing the calculation sequence
sketched above. Given the geometric parameters – i.e., the turbine conceptual design –, the rotational
speed, n, and the discharge, Q, the flow solver calculates the flow velocities, the flow angles, the
losses, the net head, the shaft power and the total efficiency at this operating point. So, this flow
solver is suitable for the proposed design optimization system: the optimization algorithm provides
the flow solver the turbine design variables, x, to be evaluated; the flow solver calculates the net head,
H, and the total efficiency, η, as output results (n and Q are pre-defined); the optimization algorithm
evaluates these results and then changes the design variables x (in the design space S) trying to
maximize η and to keep H within the constraints. The process runs until the convergence criteria are
reached or the maximum allowable number of iterations is exceeded. The empirical factors values in
the present flow solver – for the evaluation of the outlet flow angles deviations, the losses and the
free-vortex corrections in the vaneless spaces – are the same ones used by Granja Jiménez (2004).

18
 5. Example of Calculation with the Flow Solver
The flow solver just described was applied for the performance evaluation of a micro
Francis turbine with nqA = 266. The main geometric parameters of this turbine are
given in Tab. 2 (see also Figs. 3 to 7).

19
 5. Example of Calculation with the Flow Solver
The rated operating conditions of this turbine are given in Tab. 3. The wicket gates
opening, a, that corresponds to this operating point is a = 30.1°. By applying the flow
solver, some hydrodynamic characteristics of interest were evaluated at this operating
point, as shown in Tab. 4.

20
 5. Example of Calculation with the Flow Solver

For the η × Q performance prediction (keeping constant  and H), an iterative calculation
scheme should be performed. For each wicket gates opening a, within the opening range, it
should be calculated the discharge Q that corresponds to this opening with the given net
head and rotational speed, according to the flow solver.

So, for each wicket gates opening, an implicit nonlinear problem has to be solved for the
discharge. This is carried out by coupling (for each step of the wicket gates opening) the
flow solver with the f zero function from MatLabTM toolbox.

This M-function uses an efficient combination of bisection, secant, and inverse quadratic
interpolation methods, being suitable for the present problem. So, for 23° ≤ a ≤ 53°, the η
× Q performance prediction (keeping n = 1130 rpm and H = 12.6 mWC) is given in Fig. 8b.
Figure 8a shows the calculated Q × a.

21
5. Example of Calculation with the Flow Solver

22
 6. Optimization Methods
2 optimization methods have been alternatively tested for this aim: a Sequential
Quadratic Programming method (SQP) and a Controlled Random Search Algorithm
(CRSA).
 The SQP is a gradient-based method, being useful for local searches starting from
previous designs.
 The CRSA is a population set-based direct search algorithm that helps in exploratory
searching throughout the design space.

Differently of the SQP, the CRSA does not require a careful starting design. CRSA
employs an initial population randomly chosen on the design space S. Besides to
alleviate the designer’s effort, the CRSA increases the hope of finding a global
optimum. A relatively small number of function evaluations for convergence is also an
important feature of CRSA (Ali and Törn, 2004; Albuquerque et al., 2007b).

When using the CRSA, the net head constraints are imposed by means of the penalty
scheme on the objective function as described in Section 3.

23
 7. Results
The micro Francis turbine studied in Section 5 has been used for an application
example of the proposed conceptual design methodology. Five geometric parameters
have been chosen as the design variables:

 the stay vanes inlet and outlet angles (a1P and a2P),
 the wicket gates opening angle (a) and the runner blades inlet and outlet angles (β4
and β5).

 These quantities have been chosen in order to easily identify performance

improvements at this intermediate design stage.
 The optimization is related only to the rated operating point (Tab. 3).

 The other geometric data of the turbine (Tab. 2) were keep unmodified.
 The optimization runs were performed according to Table 5 for the design variables
constraints.

 The best results are compared with the basic design in Table 6.

24
7. Results

25
 7. Results
The best SQP solution found was achieved when starting from the basic design. The
SQP convergence processes required an average number of function evaluations (solver
calls) of near 300.

The CRSA contraction processes required an average number of function evaluations

(solver calls) of near 1500.

The results of SQP and CRSA optimization methods have shown good agreement in this
problem. Apparently, the “global optimum” conceptual design – according to the turbine
flow modeling – was found. Furthermore, the solution space in this problem seems to be
very concave, i.e., with only one local minimum; thus, a (fast) gradient-based search
method is as effective as a global one.

26
 7. Results

However, the performance prediction makes sense only in the validity range of the
used empirical correlations and simplifying assumptions. The results in very off-
design conditions must be analyzed carefully. Again, it must be stressed that the key
point in this conceptual design methodology is the capability of the flow modeling
in indicating the correct trends of performance variations due to changes in the
design variables, so that different designs can be judged in a comparative sense.

27
 8. Concluding Remarks
A conceptual design optimization system has been proposed for Francis turbines. The
flow solver is a low-cost computer code based on a mean streamline analysis. The losses
are evaluated by using various empirical correlations given in the literature.

Two different optimization techniques have been alternatively coupled with the flow
solver for the automatic searching for optimum turbine designs. One method is the
sequential quadratic programming (SQP) – a gradient-based local search algorithm –
and the other one is the controlled random search algorithm (CRSA) – a population set-
based global search algorithm.

First, the performance of a micro Francis turbine was evaluated by using the flow solver.
Then, the optimization system carried out searches for the optimum conceptual design,
given the set of design variables and the operating point. The results were compared
with the basic Francis turbine design showing potential performance improvements.

28
Ending of the 1st paper
(Discuss and Question)

29
 Part II: Paper 2

Multiobjective Optimization Design

of a Pump–Turbine Impeller Based on an
Inverse Design Using a Combination
Optimization Strategy

Wei Yang and Ruofu Xiao (China)

30
Outline

1. Introduction
2 Pump–Turbine Design Strategy
3. Design Optimization Problem
4 Model Test Results
5 Conclusions

31
 1. Introduction (1)
Objectives of the paper:

 Presenting an automatic multiobjective hydrodynamic optimization strategy for

pump–turbine impellers.

 The blade shape is parameterized based on the blade loading distribution

using an inverse design method

 Applying a multiobjective evolutionary algorithm to the response surface

functions to find a Pareto front for the final trade-off selection.

 Redesigning a scaled pump–turbine optimization strategy.

 Conducting model tests to validate the final design and confirm the validity of
the design strategy

32
 1. Introduction (2)
Fig. 2 Diagrammatic drawing of pumped storage plant unit development
(Figure from Wikipedia)
Fig. 1-1 Example of daily electricity generation and
consumption
(Figure from Wikipedia)
High load  the plant can generate power as a Turbine
Low load  the plant can use the redundant grid power to
pump water up to a reservoir.
Then, the stored water can be used to generate power
when needed. Such systems need pump–turbines to work
reliably in a range of operating conditions.
33
 1. Introduction(3)

The pump efficiency and the turbine efficiency both have to be improved.

In addition, stability limits in both operating modes have to be shifted so that the
overall operating range can be extended with reasonable cavitation performance.

This is a real challenge for designers because the design targets for the two
operations influence each other and are sometimes contradictory.

Most pump–turbine designs deal with the impeller geometric parameters

Design experience plays an important role in current pump–turbine designs an time
for whole optimization process.

34
 Methodology
Methodology:

1. CFD analyses

2. Design-of-experiment (DOE)

35
 2. Pump–Turbine Design Strategy
CFD analysis
1. Optimum process:

Use 3D- model

Design of Experiment(DOE)

Respond surface
methodology(RSM)

The orthogonal DOE technique was used to determine a table of design

configurations for the RSM model. The MGA algorithm was applied to the
approximated response functions to determine the optimal set of design
configurations (Pareto front). Then, the design solution was found as a trade-
off between the various hydrodynamic performance parameters
36
 2. Pump–Turbine Design Strategy
2.2 Optimum process:

37
 2. Pump–Turbine Design Strategy
2. Multiobjective Genetic Algorithm

For pump–turbine optimization finding a set of optimal trade-offs called Pareto

front between various hydraulic performances is concerning. So a multiobjective
genetic algorithm was used here. A general multiobjective optimization problem can
be described as a vector function f that maps a tuple of parameters (decision
variables) to a tuple of n objectives.

Here X is blade loading parameter space and Y represents the hydraulic

efficiencies of the pump–turbine impeller.

38
 2. Pump–Turbine Design Strategy
2.3. Blade Parameterization

The RSM model reliability depends on the number of parameters and the physical
relationships between the objective functions and the design parameters.

The RSM model is less reliable when dealing with too many design parameters such
as geometric parameters which may have no direct influence on the performance.
The input design parameters required by the method are as follows:

• Fluid properties and design specifications.

• Fluid density, revolution speed, number of blades, and discharge rate.
• Meridional channel shape.
• The hub, shroud, trailing edge, and leading edge contours of the impeller.
• Normal blade thickness distribution.
• Spanwise distribution of the circulation at the inlet and outlet. The circulation
difference between the inlet and the outlet determine the Euler work of the impeller.
• Blade loading distributions at the hub and the shroud.
• Stacking condition imposed on the high pressure side of the impeller. This was at
the leading edge for turbine operation and the trailing edge for pump operation

39
 2 Pump–Turbine Design Strategy
2.3. CFD analysis

A three-dimensional, turbulent, and steady flow simulation was used for CFD
analyses. In the pump turbine optimization process, as shown in Fig. 1, CFD plays
two roles(calculate the objective functions and validate the optimized results and
add points to the database for updating the RSM model

• They used ANSYS BladeGen for design the 3D flow passage

• Mesh: ANSYS ICEM CFD

• The shear stress transport (SST) k-x model  widely validated for numerical
analysis of pump–turbines

• A frozen rotor model was used  domains (stationary + rotation parts).

40
 3. Design Optimization Problem
A 1:9 scaled pump–turbine was redesigned as a test case

The pump and turbine design specifications are shown in Table 1.

The final design configurations, which remained unchanged during the optimization
loop, were an impeller high pressure side diameter D1 = 515.4 mm, impeller high
pressure side exit width b = 57.2 mm, impeller low pressure side shroud diameter
D2 = 300 mm, and impeller low pressure side hub diameter
Dh = 156.8mm as given in Fig. 2.
3.1 Design Parameters
The meridional channel was not changed during the optimization process

41
3. Design Optimization Problem

42
 3. Design Optimization Problem

−10𝑜 < = (2b×tan)/D1< +10𝑜

All design variables are subject to being exchanged
independently at a probability of 50%.

The mutation operator produces random disturbances to the design variable in

the amount of ±0.05 for parameter 𝑚1 and 𝑚2, ± 0.5 for parameter k, ± 0.1 for
parameter , and ± 1 for parameter . The probability of mutation is initially
15% and it decreases linearly to 1% over 150 generations

43
 3. Design Optimization Problem

3.2 Objective Functions

A pump–turbine has to work as

both a pump and a turbine,
which makes the design job a
multiobjective and multipoint
task.

44
3. Design Optimization Problem
1. Pump mode hydraulic efficiency p for the
pump design mass flow rate.

2. Pump mode hydraulic efficiency p80 for the

80% pump design mass flow rate to influence
the hump performance for the pump mode.

3. Turbine mode hydraulic efficiency t for the

turbine design mass flow rate.

4. Turbine mode hydraulic efficiency t80 for

80% of the turbine design mass flow rate.
The axes of Fig. 8 represent the percent variation of
the 80% mass flow rate efficiencies with respect to
a baseline configuration
Fig 9. the efficiency of pump mode at design
condition is 90.2%, which did not meet the design
efficiency 90.6%. And the efficiency of turbine
mode at the design condition is 92.5%. 45
 3. Design Optimization Problem
3.3 Optimization Procedure

The optimization procedure was carried out in

an automatic way by integrating all the codes
and software into the Isight platform together.

In the work flow:

Isight software was used for DOE database

generation, MGA searching, and platform
establishment.

MATLAB codes were used for the inverse design

method and the RSM model generation.

ANSYS products were used for geometry

generation, grid generation, and CFD analyses.

46
 3. Design Optimization Problem

Four CFD calculations were used for each design configuration. The
calculations were reduced by using an orthogonal DOE model to determine a
table of design configurations.

There was a total of nine parameters with two levels used for each parameter
which gave an orthogonal DOE table L64(29) with 64 tests in total.

If the inverse design computation did not converge, an actuator duct

(AD) design that assumes axisymmetric flow (infinite number of
blades) was used instead.

At least 256 times CFD calculations were needed for the whole
optimization process.

Pump inlet has the mass flow rate of 401 kg/s.

47
 3. Design Optimization Problem

shroud 48
4 Model Test Results

Model tests of both the baseline

configuration and the final design,
as shown in Fig. 16, were used to
verify the optimization results. The
measured pump efficiency curves
shown in Fig. 17 for various flow
rates indicate that the optimized
impeller has higher efficiencies at
all the operating points. These
results are consistent with the CFD
results. The measured head curves
in Fig. 17 show that the final design
has better performance for small
flow rates and the unstable hump
performance curve was improved
after optimization

49
 4 Model Test Results
The turbine efficiency curves at the design head Hd
= 63.9m in Fig. 18 show that the optimized design
had higher efficiencies.
This is consistent with the optimization objectives
(turbine efficiency at the design point) and
t80(turbine efficiency at 80% design mass flow
rate). For pump–turbine design the best
efficiencies for pump operation are usually at
lower heads than for turbine
Figure 19 shows the turbine efficiency curves for
the rated head for turbine operation Hr = 83.2 m,
the optimized design has a better performance at
low flow rate and an almost same performance at
high flow rate.
Thus, both the CFD and the test show that the
turbine performance at the design point and low
flow rate of the rated point is improved.

50
 5. Conclusions
A multiobjective optimization strategy based on a 3D inverse design method and
CFD, RSM, DOE, and MGA methods was developed for pump–turbine designs.
The design started from the pump operation.

 The CFD results were used to generate RSM functions relating the design
parameters and the objectives. Then, a Pareto front was achieved to choose a
configuration as the final design for the various design demands. Both CFD
simulations and the model test were conducted to confirm the final design and
validate the optimization results.

 The use of the inverse-based blade parameterization with fewer design

parameters than conventional optimization strategies reduces the complexity of
the RSM correlations

 The strengths of the 3D inverse design method coupled with CFD analyses can
be used not only with pump–turbine designs but also for optimization of all kinds
of turbomachinery.

51
52
Ending of the 2nd paper
(Discuss and Question)

53
 Part II: Paper 3

Design Optimization of a High Specific Speed

Francis Turbine Runner

Y Enomoto, S Kurosawa and H Kawajiri(Japan)

54
Outline

1. Introduction
2. Optimization runner shape
3. Investigation of instability vibration of Francis turbine
4. Conclusions

55
 1. Introduction (1)
Objectives of the paper:

a) Achieving the improvements of turbine efficiency throughout a wide operating

range, a new runner design method which combines the latest Computational
Fluid Dynamics (CFD) and a multi objective optimization method with an
existing design system was applied in this study.

b) Evaluating the validity of the new design system by model performance tests.

c) Besides optimization of runner, investigating instability vibration which

occurred at high part load operating condition by model test and gas-liquid two-
phase flow analysis.

56
 1. Introduction (1)
The demands for improvement of turbine performance in wider operating range
have been increasing in recent years. Main characteristic of turbine performance
are:
1) efficiency,
2) cavitation and
3) pressure fluctuation

In this study, we have two purposes. One is optimization of runner shape which has
high efficiency, and another one is investigation of this instability vibration
phenomenon. As for the optimization of the runner shape, a new runner design
method which combined the latest CFD and a multi objective optimization method
with an existing design system was introduced. In this study the optimization runner
shape was conducted for high specific speed about 0.21.

CFD analysis were conducted using compressible cavitation analysis based on LES
turbulence model. By using this model, CFD analysis can successfully catch the
oval cross section whirl and be able to help investigating the mechanism of outbreak
of oval cross section whirl.
57
 2. Optimization runner shape
2.1. Methodology:

 At first, optimize the runner shape at design

point (maximum efficiency point).
 Next, confirm this runner performance at
other operating points and tune runner shape
based on the results. (CFD is performed, but
this method depends on the skill of designer).
 Choose in order to evaluate turbine
performance with changing various runner
design parameters.
 Evaluate turbine efficiency at 12 operating
points from partial load to over load and from
high head to low head were defined as multi
objective functions and total weighted
efficiency

58
 2. Optimization runner shape
The concept of design system is
shown in figure 2

At first, whole flow passage

analysis from spiral case inlet to
draft tube outlet was conducted
for conventional turbine.

Design of Experiments (DOE)

Executing runner design

parameters by CFD.

…..

59
 2. Optimization runner shape
2.2. Parameter design points
Design parameters were defined based on considering following points.

1) As for whole runner blade shape optimization, pressure distribution on the blade
surface was gradual from inlet and outlet in order to restrict increasing hydraulic
loss.

2) In the optimization of the blade inlet shape, the occurrence of flow separation
and inlet cavitation was reduced and good turbine performance was achieved in
wider operating range.

3) In the optimization of the blade outlet shape, outlet angle and outlet width
distributions, secondary flow was decreased in wider operating range to achieve
high turbine efficiency.

4) In the optimization of outlet width distributions and runner band shape,

improvements of turbine efficiency and anti-cavitation characteristics had been
consistent.
60
 2. Optimization runner shape
2.3. Evaluated function and restricted condition
Evaluated functions were defined as hydraulic efficiency that was calculated based on
hydraulic losses at 12 operating points. Restricted condition was defined as the
pressure coefficient on the blade surface (minimum value).
2.4. CFD analysis method
The analysis domain is limited to the region from runner to draft tube
The boundary condition of the runner inlet was set applying the velocity distribution
obtained from CFD results of a whole flow passage from the spiral casing to draft
tube.
2.4.1. Whole passage flow calculation.
Turbulence flow simulation based on Reynolds–Averaged Navier-Stokes (RANS)
equation was adapted. Reynolds-Stress model (RSM) is adopted as the turbulence
model in the numerical model test. The number of grid points is about 14 million.
As for the outlet boundary condition, the average pressure was set fixed.
Furthermore, about the surface of the wall, the non-slip boundary condition was
prescribed, i.e. the velocity components were set to zero.

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 2. Optimization runner shape
2.4.2. Runner shape optimization

Figure 3(b) shows computational domain which is used in runner shape optimization
I. RNG k-ε turbulence model had been confirmed accurate in prediction of many
hydro turbine and pump turbine, was applied to calculate the Reynolds stress

II. Outlet boundary condition was defined as the fixed average pressure.

III. The number of grid points is about 5,500,000.

62
 2. Optimization runner shape
2.5. Runner shape optimization
Carry out runner shape optimization by DOE, flow-passage shape must be defined by
parameter values, so geometry definition programs were used to design the runner
shape.
In this study, 8 design parameters were used to optimizing the variables such as blade
inlet diameter, blade inlet angle, runner crown shape, runner band shape and so on.

Figure 4 shows runner shape and surface flow near the design point of conventional and
optimized runner. Figure 4 also shows surface flow near design point of conventional
and optimized runner. 63
 2. Optimization runner shape
2.5. Runner shape optimization

Figure 5 shows velocity contour in draft tube. There was not the large
difference in both velocity contours, and the loss in draft tube was almost
same.

64
 2. Optimization runner shape
2.6. Model test

The model runner was made based on CFD analysis results and tested turbine efficiency
characteristics. Figure 6 shows model turbine view of the model test. Turbine discharge
characteristics on design speed factor are shown in Figure 7.
+ The broken line indicates conventional runner model.
+ The solid line indicates the optimized runner’s one.
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 3. Investigation of instability vibration of Francis turbine

3.1. Investigation of instability vibration by model test

The model test was conducted to investigate the area and phenomenon of the
instability vibrations. In this test measurement of pressure fluctuation with 8
locations ((1)casing inlet , (2)(3) between runner and guide vane, (4)(5)upper draft
tube, (6)draft elbow, (7)(8) draft elbow exit) and the observation of whirl by the
high-speed video camera were conducted.

Figure 8 shows schematic view of model test equipment. The test was conducted
with 3 guide vane openings (aM=100%, 88%, 78%), which are normalized by the
guide vane opening corresponding to the optimum operating point. By changing
speed factor nED and Thoma number σM (from 0.15 to 0.27) , the area that instability
vibrations occurred was pinpointed. Figure 9 shows the area that instability
vibration occurred.

66
3. Investigation of instability vibration of Francis turbine

67
3. Investigation of instability vibration of Francis turbine

Figure 11 and figure 12 show the pressure

fluctuation wave form and the FFT analysis
results at the condition of aM=88%,
nED=0.44,σM=0.24. And observation results of
runner outlet are also shown in Figure 13. From
FFT analysis results, it can be seen that, there
are about 5 Hz dominant frequency at upper
draft tube and 39.6 Hz dominant frequency at
casing inlet and between runner and guide vane.
The rotational speed of runner (nM) is 17.6 s-1.
The 5 Hz dominant frequency at upper draft
tube is about one third of rotational speed of
runner, therefore the frequency was caused by
whirl rotation. However the 39.6Hz dominant
frequency at casing inlet has no relation to these
runner rotational speed and whirl rotational
speed.

68
 3. Investigation of instability vibration of Francis turbine
3.2. CFD analysis
In order to investigate the mechanism of outbreak of oval cross section whirl, CFD was
conducted.
3.2.1. Governing equation.
Governing equation was used compressible Navier-Stokes Equations whose term was
transformed by Gausian Filter.

69
 3. Investigation of instability vibration of Francis turbine

3.2.2. Turbulence model

Subgrid-scale Reynolds stress was formulated by Smagorinsky model.

3.2.3. Cavitation modelling

It is known that when cavitation occurs, volume of the gas phase increases, and speed of
sound suddenly decrease. Figure 14 shows the relation between void of fraction and
speed of sound.

70
 3. Investigation of instability vibration of Francis turbine
2) State equation (solution of speed of sound)

71
 3. Investigation of instability vibration of Francis turbine

It can be seen from these

figures that the oval cross
section whirl occurred near
the runner cone wall
surface.

And the oval cross section

whirl is formed by the
centrifugal force by the
leaning of the runner corn
shape and the dynamic
pressure of the mainstream
direction.

72
 4. Conclusions

The results are obtained as follows:

1) This optimization system was a useful engineering tool of a Francis turbine

development and the optimized runner had high turbine efficiency in whole
operating range.

2) When the instability vibration at high partial load condition is caused, an oval
cross section whirl occurred. This whirl may be caused by the recirculation flow
near the runner cone wall.

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 Thank you for listening

Questions / Discussion

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