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Journal of Hydraulic Research

ISSN: 0022-1686 (Print) 1814-2079 (Online) Journal homepage: http://www.tandfonline.com/loi/tjhr20

New insight in Francis turbine cavitation vortex


rope: role of the runner outlet flow swirl number

Arthur Favrel, Joao Gomes Pereira Junior, Christian Landry, Andres Müller,
Christophe Nicolet & François Avellan

To cite this article: Arthur Favrel, Joao Gomes Pereira Junior, Christian Landry, Andres
Müller, Christophe Nicolet & François Avellan (2017): New insight in Francis turbine cavitation
vortex rope: role of the runner outlet flow swirl number, Journal of Hydraulic Research, DOI:
10.1080/00221686.2017.1356758

To link to this article: http://dx.doi.org/10.1080/00221686.2017.1356758

Published online: 15 Sep 2017.

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Download by: [University of Sussex Library] Date: 21 September 2017, At: 06:04
Journal of Hydraulic Research, 2017
https://doi.org/10.1080/00221686.2017.1356758
© 2017 International Association for Hydro-Environment Engineering and Research

Research paper

New insight in Francis turbine cavitation vortex rope: role of the runner outlet flow
swirl number
ARTHUR FAVREL, Research associate, Laboratory for Hydraulic Machines, École Polytechnique Fédérale de Lausanne,
Lausanne, Switzerland
Email: arthur.favrel@epfl.ch (author for correspondence)
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JOAO GOMES PEREIRA JUNIOR, Doctoral student, Laboratory for Hydraulic Machines, École Polytechnique Fédérale de
Lausanne, Lausanne, Switzerland
Email: joao.gomes@epfl.ch

CHRISTIAN LANDRY, Project Engineer, Power Vision Engineering Sàrl, Ecublens, Switzerland
Email: christian.landry@powervision-eng.ch

ANDRES MÜLLER, Research associate, Laboratory for Hydraulic Machines, École Polytechnique Fédérale de Lausanne,
Lausanne, Switzerland
Email: andres.mueller@epfl.ch

CHRISTOPHE NICOLET (IAHR Member), Managing Director, Power Vision Engineering Sàrl, Ecublens, Switzerland
Email: christophe.nicolet@powervision-eng.ch

FRANÇOIS AVELLAN (IAHR Member), Professor, Laboratory for Hydraulic Machines, École Polytechnique Fédérale de
Lausanne, Lausanne, Switzerland
Email: francois.avellan@epfl.ch

ABSTRACT
At part load operation, Francis turbines experience the development of a cavitation vortex rope in the draft tube, whose precession acts as a pressure
excitation source. In case of resonance, the resulting pressure pulsations lead to unacceptable torque and power fluctuations on the prototype machine,
putting at risk the system stability. However, the accurate prediction of resonance conditions at the prototype scale remains challenging since it
requires a proper hydro-acoustic modelling of the draft tube cavitation flow. Furthermore, both the head and discharge values have an impact on the
precession frequency of the vortex and the natural frequency of the system. The present paper demonstrates for the first time that the influence of
both parameters on the frequencies of interest can be represented by a single parameter, the swirl number. Its analytical expression is derived as a
function of the operating parameters of the machine. It is used to establish empirical laws enabling the determination of both frequencies and finally
the operating parameters in resonance conditions on the complete part load operating range at the model scale. The methodology presented in this
paper represents a decisive step towards the prediction of resonances on the complete part load operating range of the prototype.

Keywords: Cavitation; Francis turbine; hydro-acoustic resonance; part load; swirl number; vortex rope

1 Introduction hydropower plants plays a crucial role in this context by ensur-


ing primary and secondary grid control and the balance between
The massive penetration of the electrical power network by electrical energy production and consumption. This however
new and renewable energy sources (NRE), such as wind and requires operation of the generating units in off-design con-
solar, compromises the grid stability because of their intermit- ditions, from low load to full load conditions, to adjust their
tent and stochastic nature. The flexible operation capability of output power. Such operating conditions are characterized by

Received 20 December 2016; accepted 6 July 2017/Currently open for discussion.

ISSN 0022-1686 print/ISSN 1814-2079 online


http://www.tandfonline.com
1
2 A. Favrel et al. Journal of Hydraulic Research (2017)

the development of unfavourable flow patterns involving cavi- and of the electrical transmission system in the worst case. As
tation and pressure fluctuations, which can lead to output power the extension of hydropower plants operating range is increas-
swings (Rheingans, 1940). The resulting mechanical vibrations ingly required in the current energetic context, the accurate
can also reduce the life expectancy of the machine (Lowys, assessment of their stability and the prediction of resonance
Andre, Ferreira da Silva, Duarte, & Payre, 2014). conditions at the prototype scale is crucial. Experimental tests
In the case of Francis turbines operating at part load condi- are commonly performed on reduced scale physical models,
tions, i.e. with a discharge lower than the value corresponding to enabling the prediction of the hydraulic behaviour of the pro-
the best efficiency point (BEP), a cavitation vortex rope devel- totype machine in terms of efficiency and cavitation with a good
ops at the runner outlet in the draft tube. It rotates around the confidence level. However, although both geometric homology
cone centreline with a precession frequency of between 0.2 and and kinematic similarity between model and prototype scales
0.4 times the runner frequency (Arpe, Nicolet, & Avellan, 2009; are fulfilled according to IEC Standards (1999), the amplitude
Nishi, Matsunaga, & Kubota, 1984; Fig. 1). The periodical pre- of pressure fluctuations cannot be directly transposed from the
cession of this vortex in the elbow of the draft tube acts as a model to the prototype as the eigenfrequencies of the system
pressure excitation source for the hydraulic circuit, leading to depend on both the cavitation volume and the characteristics
the propagation of pressure pulsations at the same frequency. In of the hydraulic circuit. To predict and simulate resonance
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the draft tube, the pressure fluctuations induced by the vortex conditions, one-dimensional (1-D) hydro-acoustic models have
precession can be decomposed into two different contributions therefore been developed by Dörfler (1982), Couston and Philib-
(Duparchy, Guillozet, De Colombel, & Bornard, 2014; Nishi ert (1998) and more recently Alligné, Nicolet, Tsujimoto, and
et al., 1984). The convective component, i.e. asynchronous, is Avellan (2014). In these models, which also include the tur-
a local pressure fluctuation observed only in the draft tube and bine characteristic and the inertia and elasticity of the whole
corresponds to the rotation of the pressure field with the vortex piping system filled with water, the draft tube cavitation flow
core precession. A second one, called synchronous component, is often modelled by a set of parameters representing the local
has equal phase and amplitude in a given horizontal cross- momentum excitation source and the additional compressibility
section of the cone and propagates through the entire hydraulic introduced by the presence of a cavitation volume, as the cav-
circuit, including the upstream pipes of the machine. It is iden- itation compliance (Brennen & Acosta, 1976). The equivalent
tified as the response of the hydraulic circuit to the pressure compliance of the draft tube, including the effect of the wall
excitation source (Dörfler, 1982). elasticity and the compressibility of both the water and cavi-
The presence of cavitation within the vortex core strongly tation volumes, is often reduced to the cavitation compliance,
decreases the wave speed in the draft tube and therefore the since its order of magnitude is much higher than that of the
eigenfrequencies of the hydraulic system (Jacob, 1993; Landry, compliance of both the water volume and the wall in case of
Favrel, Müller, Nicolet, & Avellan, 2016). In case of reso- development of a cavitation vortex rope (Landry et al., 2016).
nance, pressure fluctuations are dramatically amplified, leading These parameters have been recently identified by Yamamoto
to pressure and output power surges (Favrel, Landry, Müller, et al. (2015) on a simplified test configuration by using the
Yamamoto, & Avellan, 2014; Fritsch & Maria, 1988) which transfer matrix method and by Landry et al. (2016) for the
can put at risk the stability of the hydro-mechanical system same test case as presented in this paper. An external exci-
tation system was used to identify the first eigenfrequency
(a) (b) (c) of the test rig. Other analytical and theoretical investigations
focused on the modelling of the swirling flow and the pre-
cessing vortex core in the draft tube (Kuibin, Susan-Resiga,
& Muntean, 2013; Susan-Resiga, Dan Ciocan, Anton, & Avel-
lan, 2006). In particular, Fanelli (1989) developed a theoret-
ical model of the pressure excitation source induced by the
vortex rope and highlighted excitation mechanisms involving
(d) (e) (f) the presence of an elbow, which confirmed the experimental
observations made by Nishi, Matsunaga, Kubota, and Senoo
(1982).
Despite the numerous contributions dealing with the part
load issues (the reader can refer to Nishi & Liu, 2013 for a
partial review), the accurate prediction of hydro-acoustic res-
onances at the model and prototype scales remains challenging
(Alligné, Landry, Favrel, Nicolet, & Avellan, 2015). The draft
Figure 1 Visualizations of the vortex rope in the draft tube cone over
one precession cycle from t = 0 (a) to t = TPVC (f) for a speed factor tube hydro-acoustic parameters and the vortex precession fre-
equal to the value at the BEP and a discharge factor equal to 64% of quency must be determined at the model scale and transposed
the value at the BEP to the prototype scale for a large number of operating points
Journal of Hydraulic Research (2017) Swirl number for Francis turbine cavitation vortex rope 3

to take into account the influence of both the head and dis- 2 Case study
charge values. The present paper aims at demonstrating that
the influence of these two parameters on the precession fre- 2.1 Reduced scale physical model
quency and the natural frequency of the hydraulic circuit can
The test case is a 1:16 reduced scale physical model of a Francis
be represented by a single parameter, the swirl number, whose
turbine featuring 16 blades and a specific speed of ν = 0.27.
analytical expression as a function of the operating parameters
The prototype generating unit is located in Canada and fea-
of the machine is developed. For this purpose, both frequen-
tures a rated output power of 444 MW. It experiences serious
cies are determined by pressure fluctuations measurements on
pressure surges at full load conditions and extensive experi-
a reduced scale physical model of a Francis turbine at sev-
mental investigations have been performed on the same test
eral operating points. Specifically, the discharge factor is varied
case at both part load and full load conditions (Favrel, Müller,
for different values of the speed factor and three values of the
Landry, Yamamoto, & Avellan, 2015; Müller, Dreyer, Andreini,
Thoma number corresponding to the range observed on the pro-
& Avellan, 2013; Müller, Favrel, Landry, & Avellan, 2017). The
totype. For each value of the speed factor, the influence of
reduced scale physical model is installed on the closed-loop test
the discharge factor on both the vortex precession frequency
rig of the EPFL Laboratory for Hydraulic Machines. The upper
and the system natural frequency is determined and the reso-
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part of the hydraulic circuit is shown in Fig. 2, including the


nance conditions are investigated. An analytical expression of
reservoir, the draft tube, the spiral casing and the upstream pipe.
the swirl number characterizing the intensity of the swirling flow
The test rig features two axial double-volute pumps of 400 kW
at the runner outlet, which is the main parameter driving the
to generate the specified head by adjusting the pumps speed
precessing vortex rope dynamics (Cassidy & Falvey, 1970), is
while the discharge is adjusted by changing the opening angle
derived. It is finally used to establish empirical laws enabling
of the guide vanes. The turbine shaft is connected to a gener-
the determination of the precession frequency and the natu-
ator, which enables the control of the runner speed. The test
ral frequency on the complete part load operating range of the
rig allows for accurate performance tests of the reduced scale
model.
model of hydraulic machines within an accuracy better than
The test case is first presented in Section 2, as well as the dis-
0.3% according to IEC Standards (1999). The calibration of the
tinction between different draft tube flow regimes observed at
test rig instrumentation is performed according to IEC Standards
part load depending on the discharge value. The methodology,
(1999). The measurements of the flow discharge Q, the torque T
including the investigated operating points, the determination
applied to the shaft, the runner speed n and the specific hydraulic
of both precession and natural frequencies and the identifi-
energy at the turbine inlet gHI and at the draft tube outlet gHI
cation of resonance conditions, is described in Section 3. It
enable the determination of the turbine efficiency and the com-
also includes the derivation of an analytical expression of the
putation of the speed factor nED and the discharge factor QED
swirl number as a function of the discharge and speed fac-
corresponding to the tested operating points. These dimension-
tors. The results of the influence of the speed factor on the
less factors are defined according to IEC Standards (1999) as
flow transitions and the resonance conditions are presented in
follows:
Section 4. The empirical laws for the determination of both
the precession frequency and the system natural frequency are nD Q
nED = √ , QED = √ (1)
finally presented in Section 5, enabling the prediction of reso- E D2 E
nance conditions on the complete operating range at the model where D is the runner diameter and E = gHI − gHI is the spe-
scale. cific hydraulic energy of the turbine. The pressure level in the

Figure 2 Reduced scale physical model of a Francis turbine installed on EPFL test rig and cut-view of the cross-section of the draft tube cone
located 0.39 × D downstream the runner (section A-A), together with the location of the pressure sensors p 1 , p 2 , p 3 , p 4 (cone), p 5 and p 6 (upstream
pipe)
4 A. Favrel et al. Journal of Hydraulic Research (2017)

draft tube can be modified by changing the pressure over the 2.2 Flow regimes in cavitation conditions
free surface in the downstream reservoir with a vacuum pump.
For a given value of the speed factor nED , decreasing the dis-
The pressure level in the draft tube is defined by the Thoma
charge factor QED affects the precession frequency of the vortex
number σ = NPSH / H, where H is the net head of the turbine
rope, as well as the amplitude of the pressure fluctuations. For
and NPSH is the Net Positive Suction Head defined as follows:
the same test case, Favrel et al. (2015) highlighted flow regimes
pB̄ − pv C2 in cavitation-free conditions depending on the value of the dis-
NPSH = − hs + Ī (2) charge factor, as well as a transition in the flow structure beyond
gρ 2g
a certain value of QED , which is characterized by a loss of
where pB is the pressure in the downstream reservoir above coherence and periodicity in the vortex dynamics. In cavita-
the free surface level, pv is the vaporization pressure, hs is the tion conditions, similar flow regimes are highlighted as shown
setting level of the machine with respect to the downstream in Fig. 3, which includes the influence of the discharge factor on
reservoir level and CI is the flow velocity at the draft tube outlet. the precession frequency and the value of the coherence func-
The draft tube cone is made of Plexiglass to visualize the tion at this frequency between pressure signals measured at the
cavitation vortex rope. Wall flush-mounted piezo-resistive pres- locations p 1 and p 3 . The coherence function Cxy is computed by
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sure transducers are placed in the model to measure the absolute using the auto-spectral and cross-spectral density functions of
wall pressure. The location of the pressure sensors is given in the corresponding pressure signals estimated with the Welch’s
Fig. 2. A set of four pressure sensors regularly spaced by 90° procedure (Bendat & Piersol, 2011). For this example, the speed
is placed in a horizontal cross-section of the draft tube cone factor is set at the value at the BEP, i.e. nED = 0.288, and the
located 0.39 × D downstream of the runner outlet to enable Thoma number is equal to the prototype value σ rated = 0.11.
the decomposition of the pressure fluctuations into convec- The discharge factor is normalized by the value at the BEP, i.e.
tive and synchronous components (Dörfler & Ruchonnet, 2012; Q∗ED = 0.20. Visualizations of the cavitation vortex rope are also
Duparchy et al., 2014). Two other pressure sensors, p 5 and p 6 , given in Fig. 4 for three different values of the discharge factor
are installed in the upstream pipe of the machine to directly mea- corresponding to the different flow regimes.
sure the synchronous pressure component and to evaluate the Within the first regime, for high values of the discharge
hydro-acoustic response of the system to the pressure excitation factor, the cavitation vortex rope is not yet completely devel-
source. oped and its precession motion is quasi-axial in the upper part

(a) (b)
Regime 3 Regime 2 Regime 1 Regime 3 Regime 2 Regime 1
0.4 1

0.9
0.35
Cxy( fPVC ) (-)
fPVC / n (-)

0.8
0.3
0.7
0.25
0.6

0.2 0.5
0.5 0.6 0.7 0.8 0.9 0.5 0.6 0.7 0.8 0.9
* *
QED / QED (-) QED / QED (-)

Figure 3 Influence of the discharge factor on the precession frequency fPVC (a) and on the coherence of pressure fluctuations measured in the cone
at the locations p 1 and p 3 (b) – nED = 0.288, σ = σ rated = 0.11

(a) (b) (c)

Figure 4 Visualization of the cavitation vortex rope at QED /Q∗ED = 0.80 (a), QED /Q∗ED = 0.64 (b) and QED /Q∗ED = 0.55 (c) with nED = 0.288
and σ = σ rated = 0.11
Journal of Hydraulic Research (2017) Swirl number for Francis turbine cavitation vortex rope 5

of the draft tube cone. The precession frequency is almost Moreover, the measurements are repeated for three values of
constant when the discharge is decreased (Fig. 3a), while the the Thoma number σ corresponding to the minimum, aver-
coherence between the pressure fluctuations increases (Fig. 3b). age and maximum NPSH values on the prototype, respectively.
Within flow regime 2, for values of discharge factor between The parameters of the investigated operating conditions are
QED /Q∗ED = 0.78 and QED /Q∗ED = 0.58, the precession fre- summarized in Table 1 and a total of 200 configurations are
quency increases linearly when the discharge is decreased and tested.
the cavitation vortex is well developed, as illustrated in Fig. 4b. The discharge factor is modified by steps of QED = 0.005,
Below the value QED /Q∗ED = 0.58, the vortex rope precession which corresponds to a guide vanes opening angle step of
loses its periodicity and coherence, which is illustrated in Fig. 3b γ = 0.5°, approximately. The measurements are refined with
by the sudden drop in the value of the coherence function. It steps of QED = 0.0025, i.e. γ = 0.25°, around the reso-
is also confirmed by the visualization of the cavitation vortex nance conditions and the transitions between the flow regimes
given in Fig. 4c: the cavitation volume within the vortex core is to capture them accurately.
not well defined and fluctuates in an incoherent manner. Favrel
et al. (2015) showed that this flow regime is also character-
ized by a sudden drop in the intensity of the pressure excitation 3.2 Experimental investigation of resonance conditions
Downloaded by [University of Sussex Library] at 06:04 21 September 2017

source induced by the vortex precession.


An example of cross-spectral analysis between two pressure
signals measured in the same cross-section of the cone is pre-
sented in Fig. 5. It includes the coherence function (Fig. 5a), the
3 Methodology
amplitude of the cross-spectrum (Fig. 5b) and the corresponding
phase (Fig. 5c) plotted as a function of the frequency.
3.1 Operating conditions
As shown in Fig. 5a, two frequencies with a coherence
To cover the head variations on the prototype over one year, level above 0.95 are noticed. The frequency fPVC corresponds
pressure measurements are performed for four different val- to the precession frequency of the vortex. A frequency f0 with
ues of the speed factor, from nED = 0.268 to nED = 0.300. The a high level of coherence is also noticed. In Fig. 5b, a sharp
speed factor is modified by changing the runner speed whereas peak is observed at the frequency fPVC , which results from the
the turbine head value is kept constant to minimize the influ- high-periodicity of the pressure fluctuations at this frequency.
ence of the Froude number, as a change in its value can affect Conversely, a wide-band peak is observed at the frequency f0 ,
the pressure gradient along the draft tube and therefore the which unveils a stochastic component in the pressure fluctua-
shape of the cavitation vortex rope (Franc et al., 1995). For tions at this frequency. As illustrated in Fig. 5c, the phase shift
each value of the speed factor nED , a wide range of discharge at f0 equal to 0 reveals the synchronous nature of the pressure
values is surveyed, from the first value for which pressure fluc- fluctuations at this frequency, which is identified as the first nat-
tuations are observed to a value corresponding to flow regime 3. ural frequency of the hydraulic system (Favrel, Müller, Landry,

Table 1 Investigated operating points

nED (–) n (Hz) H (m) QED (–) QED /Q∗ED (–) σ rated (–) σ min (–) σ max (–)

0.268 12.40 26.7 0.16 → 0.08 0.80 → 0.40 0.095 0.083 0.111
0.277 12.82 0.16 → 0.08 0.80 → 0.40 0.102 0.088 0.119
0.288 13.33 0.18 → 0.10 0.90 → 0.50 0.110 0.095 0.128
0.300 13.88 0.18 → 0.10 0.90 → 0.50 0.119 0.103 0.139

(a) f0 fPVC (b) × 10−4 (c)


1 4

3 fPVC f0
|Gxy | (Hz -1)

0.9
(rad)
Cxy (-)

2 0
xy

0.8 f0
1 fPVC

0.7 0
0 0.2 0.4 0.6 0.8 0 0.2 0.4 0.6 0.8 0 0.2 0.4 0.6 0.8
f / n (-) f / n (-) f / n (-)
Figure 5 Coherence (a), amplitude (b) and phase (c) of the cross-spectrum between pressure signals measured in the cross-section of the cone
(positions p 2 and p 3 ) for the operating point nED = 0.288, QED = 0.13 and σ = σ rated = 0.11
6 A. Favrel et al. Journal of Hydraulic Research (2017)

Yamamoto, & Avellan, 2016). It is therefore possible for this Gxx (f0 ) has the same order of magnitude regardless of the
particular test case to identify the natural frequency without discharge conditions.
external excitation system, as it was used by Landry et al.
(2016). In the following, this feature will be exploited to deter- 3.3 Swirl number
mine the natural frequency of the system for all the investigated
operating points. The phenomenon of precessing vortex core is well known and
The influence of the discharge factor on both the preces- encountered in a wide range of engineering applications involv-
sion frequency and the system natural frequency is presented ing swirling flows (the reader can refer to Escudier, 1987 and
in Fig. 6 for a constant value of the speed factor, together with Syred, 2006 for a review). It has been identified as a mani-
the influence on the value of the auto-spectrum amplitude at festation of the vortex breakdown instability which occurs in
the frequencies fPVC and f0 measured at the location p 6 . The swirling flows beyond a certain value of swirl intensity (Lucca-
amplitude at the frequencies fPVC corresponds directly to the Negro & O’Doherty, 2001). Moreover, it has been shown that
hydro-acoustic response of the system to the pressure excitation the dynamics of the precessing vortex core mainly depend on
source, as only the synchronous pressure component is observed the swirl intensity of the incoming flow, whereas they can be
in the upstream pipe. assumed independent of viscous effects for high values of the
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As shown in Fig. 6a, the natural frequency f0 rapidly Reynolds number (Cala, Fernandes, Heitor, & Shtork, 2006;
decreases when the discharge is decreased within flow regime Cassidy & Falvey, 1970). In the case of Francis turbines oper-
1. Within regime 2, the frequency value f0 slowly decreases ating at part load, it is thus safe to assume that the vortex
and remains quasi-constant for low values of discharge. Beyond precession frequency and the natural frequency of the system,
the transition from regimes 2 to 3, the natural frequency which is influenced by the cavitation volume within the vortex
starts increasing. This is a consequence of the incoherent core, are strongly dependent on the swirl intensity of the flow
fluctuations of the cavitation volume within the vortex core exiting the runner.
arising from the loss of coherence in the vortex structure The swirl intensity is commonly characterized by the swirl
beyond the transition from regimes 2 to 3. It is more dif- number S, which is defined by the ratio between the axial flux
ficult to determine accurately the frequency f0 by a cross- of angular momentum and the axial flux of axial momentum
spectral analysis within regime 3, since the corresponding (Gupta, Lilley, & Syred, 1984) as follows:
peak is not very clear in the cross-spectrum of the pressure R
Cm · Cu · r2 · dr
fluctuations. S = 0 R (3)
When the discharge is decreased within flow regime 1, R 0 C2m · r · dr
the value of the natural frequency f0 approaches that of the where Cm and Cu are the time-averaged axial and tangential
precession frequency fPVC . As a consequence, the amplitude velocity components, respectively, and R is the radius of the
at the frequencies fPVC is amplified (Fig. 6b). The amplitude section. In the following, an analytical expression of the swirl
reaches its maximum in resonance conditions at QED /Q∗ED = number as a function of the operating parameters is derived by
0.78 when the natural frequency matches with the precession considering the velocity diagrams and a simple representation of
frequency. By decreasing again the discharge factor, the natural the flow at the runner outlet. The velocity diagrams at the run-
frequency decreases while the precession frequency increases, ner outlet are represented in Fig. 7 when the machine operates
which results in a weakening of the system’s hydro-acoustic at part load (Q < Q0 ), swirl-free (Q = Q0 ) and full load condi-
response. No notable influence of the discharge factor on the tions (Q > Q0 ) with the same runner angular speed. The angle
amplitude at the frequency f0 is observed in Fig. 6b: the value β between the runner blade trailing edge and the relative flow

(a) Regime 3 Regime 2 Regime 1 (b)


Regime 3 Regime 2 Regime 1
0.4 10-2
fPVC fPVC Resonance
f0 f0

10-3
Gxx( f ) (Hz-1)

0.3
f / n (-)

0.2 10-4

0.1 10-5
0.5 0.6 0.7 0.8 0.9 0.5 0.6 0.7 0.8 0.9
* (-) * (-)
QED / QED
QED / QED

Figure 6 Influence of the discharge factor on both the precession frequency and the natural frequency (a) and on the auto-spectrum amplitude at the
precession frequency measured in the upstream pipe (location p 6 ) (b) – nED = 0.288, σ = σ rated = 0.11
Journal of Hydraulic Research (2017) Swirl number for Francis turbine cavitation vortex rope 7

The axial flow velocity is expressed as a function of the dis-


charge Q and the speed and discharge factors are introduced in
Eq. (9). The following expression for the swirl number is finally
obtained:

 
π2 1 1
S = nED · − 0 (10)
8 QED QED
Figure 7 Velocity diagrams at the runner outlet of a Francis turbine
for Q < Q0 , Q = Q0 and Q > Q0 , i.e. part load, swirl-free and full where Q0ED is the discharge factor in swirl-free conditions for a
load conditions, respectively
given speed factor. The influence of the discharge factor on the
swirl number computed with Eq. (10) is given in Fig. 8, together
velocity W is considered as a constant, since it is imposed by the with experimental values measured by laser Doppler velocime-
runner design. try (LDV) along the diameter of one horizontal cross-section
For a given value of the runner frequency, i.e. for a given of the draft tube cone (Favrel, 2016). The experimental results
Downloaded by [University of Sussex Library] at 06:04 21 September 2017

nED -value, there is a value of discharge Q0 for which the flow at are in good agreement with the analytical law for QED > 0.12,
the runner outlet is theoretically axial. In such conditions, called although a slight offset is observed. Beyond the transition from
swirl-free conditions in the following, the relative flow angle β regime 2 to regime 3, i.e. for QED < 0.12, the experimental data
at a given radial position r can be expressed as follows: do not follow the analytical law anymore. The latter predicts a
value of swirl number tending toward +∞ when the discharge
C0m C0 factor value approaches zero, which lacks physical meaning.
tanβ = = m (4)
U ωr The discrepancy between the experimental results and the ana-
lytical law within regime 3 might be explained by the occurrence
where C0m is the axial flow velocity corresponding to the dis-
of flow separations in the runner blade channels, resulting
charge Q0 , U is the runner circumferential velocity and ω is the
in different values of the relative flow angle β at the run-
angular speed of the runner. When the discharge is decreased
ner outlet. For values QED /Q0ED > 1 (full load conditions), the
below the value Q0 , the machine operates in part load condi-
swirl number is negative since the flow rotates in the opposite
tions and a tangential flow velocity component Cu appears at
direction.
the runner outlet, as illustrated in Fig. 7. At these conditions, Cu
A theoretical value of the swirl number can be determined
can be expressed for a given radial position r as a function of
by using Eq. (10) for all the tested operating points (nED , QED ).
the axial velocity component Cm and the angular speed of the
However, this requires the value of the discharge factor Q0ED in
runner ω:
swirl-free conditions. These conditions are commonly identified
Cm Cm C0 during model tests by determining the limits of the cavitation-
tanβ = = = const. = m (5) free zone with visualizations of the flow in the draft tube cone.
U − Cu ω r − Cu ωr
Although LDV measurements might enable a more accurate
  determination of the value Q0ED , a similar procedure is used,
Cm Cm since the final objective of the present paper is to propose a sim-
Cu = ω r − = ωr 1− 0 (6)
tan β Cm ple and relevant methodology for the prediction of frequencies
The above expression is, then, introduced in the definition of of interest in an industrial context.
the swirl number. By considering that the axial flow velocity is
independent of the radial position, i.e. Cm = 4 Q / π D2 , the
swirl number can be computed and expressed as a function of 2
analytical law
the axial flow velocity Cm and the angular speed of the runner ω: 1.5 experimental values (LDV)

R 1
Cm · ω · r · (1 − (Cm /C0m )) · r2 · dr
S (-)

S= 0
R (7)
R 0 C2m · r · dr 0.5

0
  R 3
ω 1 1 r · dr -0.5
S= · − 0 · 0 R (8) 0.1 0.15
QED (-)
0.2 0.25 0.3

0 r · dr
R Cm Cm 0
QED = 0.245

  Figure 8 Comparison between the analytical law of the swirl number


ω·R 1 1 and values of the swirl number determined by LDV measurements in
S= · − 0 (9) cavitation-free conditions at nED = 0.288
2 Cm Cm
8 A. Favrel et al. Journal of Hydraulic Research (2017)

4 Experimental results Table 2 Value of the discharge factor corresponding to


the resonance conditions for each value of the speed factor
4.1 Swirl-free conditions and flow regime limits Qres
ED (–)
The limits of the cavitation-free zone are first determined for nED (–) σ min σ rated σ max
each investigated value of the speed factor (see horizontal
dashed lines in Fig. 9). The value Q0ED is, then, considered as 0.268 0.1471 0.1401 0.1320
0.277 0.1542 0.1502 0.1398
being the average of the values corresponding to the upper and 0.288 0.1629 0.1552 0.1452
lower limits of the cavitation-free zone. For any given nED - 0.300 0.1700 0.1624 0.1524
value, the difference between the guide vane opening angles
corresponding to the upper and lower limits of this zone does
not exceed γ = 2°.
The limits of the flow regimes are determined according to
their description given in Section 2.2. The transitions between
the flow regimes and the swirl-free conditions are reported in
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Fig. 9 for σ = σ rated . The value Q0ED corresponding to the


swirl-free conditions increases linearly when the speed factor
is increased. Moreover, the QED -values corresponding to the
transitions between flow regimes 1 and 2 increase when the
speed factor is increased, and appear to follow the shift of the
swirl-free conditions. This suggests that the transition is mainly Figure 10 Resonance and swirl-free conditions as a function of the
driven by the swirl intensity of the flow exiting the runner. Con- speed and discharge factors
versely, the QED -value corresponding to the transition between
flow regimes 2 and 3 is almost constant, suggesting that addi-
The resonance conditions experimentally identified are given
tional parameters have to be considered to explain the loss of
in Fig. 10 as a function of the speed and discharge factors for the
coherence and periodicity in the vortex dynamics beyond this
three σ -values, together with the swirl-free conditions. Similar
transition. Consequently, the operating range corresponding to
to the transition between flow regimes 1 and 2, the value Qres ED
regime 2 grows when the speed factor is increased. Since the
linearly increases in a similar way to the value Q0ED when the
vortex is highly coherent and the intensity of the pressure exci-
speed factor is increased. This suggests that the resonance con-
tation source is elevated within this regime (Favrel et al., 2015),
ditions occur for a given value of the swirl intensity of the flow.
the risk of resonances inducing synchronous pressure pulsations
From a theoretical point of view, this result can be explained
of high amplitude is potentially higher for higher values of the
as follows. The dynamics of the precessing vortex rope mainly
speed factor, i.e. for lower values of the turbine head on the
depend on the swirl intensity of the flow while the natural fre-
prototype.
quency of the system is strongly affected by the presence of
cavitation in the draft tube. The cavitation volume depends on
4.2 Resonance conditions
the pressure within the vortex core, which is directly related to
The resonance conditions are identified for all the investigated the vortex circulation and the swirl intensity of the flow. Con-
nED -values by using the methodology described in Section 3. sequently, both the precession frequency and the system natural
They correspond to the value of discharge factor Qres
ED for which frequency are directly dependent on the swirl intensity of the
the amplitude of the synchronous pressure pulsations reaches its flow and it can be expected that they match at a given value
maximum. The uncertainty on this value is equal to QED = of the swirl number. It is also observed that the corresponding
±0.0025. The results are given in Table 2. ED decreases when the Thoma number σ is increased
value of Qres
for a given value of the speed factor.
0.32
Finally, the influence of the speed factor on the pressure pul-
Transition Transition Swirl-free
regimes 2-3 regimes 1-2 conditions sations amplitude measured in resonance conditions is shown
0.3 nED = 0.300 in Fig. 11a for the three σ -values. A comparison between the
nED (-)

nED = 0.288 pressure signals measured at the location p 6 in resonance con-


0.28 ditions for two values of speed factor for the case σ = σ rated is
nED = 0.277
also given in Fig. 11b. For a given σ -value, the amplitude of the
nED = 0.268
pressure pulsations in resonance conditions is hardly affected by
0.26
0.05 0.1 0.15 0.2 0.25 0.3 a change in the value of the speed factor. This indicates that the
QED (-) excitation source intensity and the cavitation flow parameters in
Figure 9 Flow regime limits and swirl-free conditions as a function resonance conditions are not influenced by the value of the speed
of the speed and discharge factors – σ = σ rated factor. For higher values of the Thoma number, the amplitude of
Journal of Hydraulic Research (2017) Swirl number for Francis turbine cavitation vortex rope 9

(a) (b)
0.04 0.08
nED = 0.268 nED = 0.288

0.03 0.04
RMS (-)

Cp (-)
0.02 0

min
0.01 -0.04
rated

max

0 -0.08
0.26 0.27 0.28 0.29 0.3 0 10 20 30 40
nED (-) n × t (-)

Figure 11 Influence of the speed factor on the RMS value of the pressure signals measured at the location p 6 in resonance conditions (a) and
pressure signals measured at the same location in resonance conditions for two values of the speed factor for the case σ = σ rated (b). The pressure
signals are made dimensionless by E, the turbine hydraulic specific energy
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the pressure pulsations in resonance conditions increases, since f0 D 3


St0 = (12)
resonance occurs at lower values of the discharge factor, for Q
which the intensity of the pressure excitation source is higher
(Favrel et al., 2015).
For all the operating points within flow regimes 1 and 2, the
vortex precession frequency and the system natural frequency
5 Resonance prediction at the model scale
are determined by cross-spectral analysis and the corresponding
Strouhal numbers are computed. The theoretical swirl number
5.1 Empirical laws for frequency prediction
corresponding to the operating point is computed by using Eq.
The experimental results described in the previous section sug- (10). Both Strouhal numbers are, then, plotted as a function of
gest that, for a given σ -value, both the precession frequency the swirl number in Fig. 12 for the case σ = σ rated . For the pre-
and the natural frequency of the system mainly depend on the cession frequency, all experimental data collapse to one single
swirl intensity of the flow exiting the runner. Moreover, hydro- linear function (Fig. 12a). In case of the natural frequency, they
acoustic resonances, corresponding to a matching between these collapse to one power function, as shown in Fig. 12b. Linear
frequencies, seem to occur for a given swirl intensity of the flow. and power regression laws fitting the experimental data are also
That would imply that the influence of both the speed and dis- given in Fig. 12. Concerning the precession frequency, equiva-
charge factors on the precession and natural frequencies could lent results were highlighted by Cassidy and Falvey (1970) in
be reduced to simple dimensionless laws linking both frequen- the case of a swirling flow created by swirl vanes. The same
cies with the swirl number. The Strouhal numbers StPVC and behaviour is observed for all the σ -values, as shown in Fig. 13.
St0 corresponding to the precession frequency and the natural The standard deviations of the experimental data with respect to
frequency of the system, respectively, are therefore introduced: the regression laws are also included in Fig. 13.
In conclusion, for a given σ -value, the influence of both the
fPVC D3 speed and discharge factors on the frequencies fPVC and f0 can be
StPVC = (11)
Q represented only by the swirl number, thus drastically reducing

(a) (b)
1.5 1.5
nED = 0.268 nED = 0.288 regression law nED = 0.268 nED = 0.288 regression law
nED = 0.277 nED = 0.300 nED = 0.277 nED = 0.300
fPVC D3 / Q (-)

f0 D3 / Q (-)

1 St PVC = 0.429 S + 0.120 1 St 0 = 0.012 S -8.382 + 0.426

0.5 0.5

0 0
0.5 1 1.5 2 0.5 1 1.5 2
S (-) S (-)
Figure 12 Strouhal number for the precession frequency (a) and the natural frequency (b) as a function of the swirl number computed analytically
– σ = σ rated
10 A. Favrel et al. Journal of Hydraulic Research (2017)

(a) (b)
1.5 1.5
f0 D3 / Q (exp.) Regression
laws with
fPVC D3 / Q (exp.)
std. deviation
1 1

f D3 / Q (-)
f D3 / Q (-)

0.5 0.5

0 0
0.5 1 S (-) 1.5 2 0.5 1 S (-) 1.5 2
Sres = 0.76 ± 0.10 Sres = 0.84 ± 0.09

(c)
1.5

1
f D3 / Q (-)
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0.5

0
0.5 1 S (-) 1.5 2
Sres = 0.97 ± 0.06

Figure 13 Determination of the value of the swirl number corresponding to the occurrence of hydro-acoustic resonance at the model scale for
σ = σ min (a), σ = σ rated (b) and σ = σ max (c)

the number of operating points required for the investigation of linearly with the value of the speed factor. This can be approx-
the vortex rope dynamics during model tests. imated by the linear relation Q0ED = 0.7252 · nED + 0.0355
(Fig. 14). Finally, the following relation is obtained:
5.2 Validation by prediction of resonance conditions  
8 · Sres 1
The empirical laws presented in Fig. 13 enable the prediction of Qres = 1 − (15)
ED
π 2 nED 0.7252 · nED + 0.0355
both the vortex precession frequency and the system natural fre-
quency on the complete part load operating range of the Francis
turbine at the model scale. Moreover, the swirl number Sres for For each investigated value of the speed factor, the value Qres ED

which hydro-acoustic resonance occurs, i.e. with f0 = fPVC , can is computed with Eq. (15). The uncertainty on the value Sres
be determined for each investigated σ -value by using Fig. 13. induced by the standard deviation of the experimental data with
Based on the expression of the swirl number, a relation linking respect to the regression laws is taken into account and leads to a
the speed factor and the discharge factor in resonance conditions prediction of resonance conditions over a range of discharge fac-
is, then, derived: tors for a given nED -value. The results are reported in Fig. 14 and
compared with the values obtained experimentally. An excellent
  agreement is obtained between the analytical prediction and the
π2 1 1
nED · − 0 = Sres (13) experiments. To validate the methodology, the resonance condi-
8 QED QED
tions are experimentally identified for an additional speed factor
For a given speed factor, the value of discharge factor for which nED = 0.317 and are compared with those predicted by using
a resonance is expected to occur can be determined by the Eq. (15). The results are also given in Fig. 14 and show once
following expression: again an excellent agreement.
The most important difference is obtained for the lowest
 
8 · Sres 1 value of speed factor nED = 0.268 for the case σ = σ rated
Qres =1 − 0 (14)
ED
π 2 nED QED and is equal to QED = 0.0058. This difference corresponds
approximately to a variation of guide vanes opening angle of
However, this expression requires the value of the discharge fac- γ = 0.5°, which is an acceptable error in comparison to the
tor Q0ED in swirl-free conditions. As the latter depends on the total variation necessary for completely covering the part load
value of the speed factor, it must be determined experimentally. flow regimes 1 and 2, running from about γ = 11° to 18° for
However, according to Fig. 9, the value Q0ED increases almost the present test-case.
Journal of Hydraulic Research (2017) Swirl number for Francis turbine cavitation vortex rope 11

(a) (b)
0.34 0.34

0.32 0.32
swirl-free conditions
0.3 exp. resonance 0.3

nED (-)
nED (-)

pred. resonance
0.28 0.28

0.26 0.26

0.24 0.24
0.05 0.1 0.15 0.2 0.25 0.3 0.05 0.1 0.15 0.2 0.25 0.3
QED (-) QED (-)

(c)
0.34

0.32

0.3
nED (-)
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0.28

0.26

0.24
0.05 0.1 0.15 0.2 0.25 0.3
QED (-)

Figure 14 Comparison between the predicted and experimental values of discharge factor in resonance conditions for σ = σ min (a), σ = σ rated (b)
and σ = σ max (c)

5.3 Possible applications 1-D representation of the hydropower plant unit, the prototype
natural frequency could be predicted on the complete part load
For a given σ -value, it is demonstrated that the influence of
operating range by expressing its value as a function of the swirl
both the speed and discharge factors on the vortex precession
number.
frequency fPVC and the system natural frequency f0 can be rep-
resented by a single parameter, which is the swirl number. If
the frequencies fPVC and f0 are determined for a limited number 6 Conclusions and perspectives
of part load operating points and expressed as a function of the
swirl number, the resulting empirical laws enable the prediction A new approach for predicting the vortex precession frequency
of both frequencies on the complete part load operating range and the natural frequency of the hydraulic circuit on the com-
at the model scale. As a consequence, the resonance conditions plete part load operating range of a Francis turbine is introduced.
can also be predicted at the model scale for the complete part It is based on an analytical expression of the swirl number as
load operating range. The empirical laws presented in the article a function of the operating parameters of the machine, i.e. the
are only valid for the present test case, including the hydraulic speed and discharge factors, which is derived in the present arti-
machine and the hydraulic circuit, but the same methodology cle. Pressure measurements are carried out on a reduced scale
can be applied to any test case since the dependence on the swirl physical model of a Francis turbine for several part load oper-
number is a physical characteristic of the precessing vortex rope. ating points and three different values of the Thoma number,
The prediction of resonance conditions on the corresponding covering the complete operating range observed on the proto-
real machine requires the determination of the hydro-acoustic type. It is demonstrated for the first time that the impact of both
parameters describing the draft tube cavitation flow at the model the speed and discharge factors on the precession frequency
scale. This can be realized by using a proper 1-D hydro-acoustic and the system natural frequency, which is mainly influenced
modelling of the test rig, including elasticity and inertia of the by the cavitation volume within the vortex rope, can be repre-
whole piping system filled with water, and by determining the sented only by the swirl number, the main parameter driving the
natural frequency of the system (Landry et al., 2016). At part dynamics of the precessing vortex rope.
load conditions, the system natural frequency is strongly influ- Empirical laws linking both frequencies with the swirl num-
enced by the characteristics of the draft tube cavitation flow. ber can be established for a given Thoma number by mea-
As the natural frequency shows a strong dependence on the surements at only a limited number of operating points, which
swirl number, as highlighted in Section 5.1, it is suggested that enables the prediction of their value on the complete part load
similar laws can be derived for the hydro-acoustic parameters operating range. However, the results are only valid for the
modelling the draft tube cavitation flow at part load. By trans- given test case, which includes the machine and also the test rig
posing these laws to the prototype scale and by using a proper used for model tests since the natural frequency depends on the
12 A. Favrel et al. Journal of Hydraulic Research (2017)

hydraulic circuit. Nevertheless, the methodology can be applied pv = vaporization pressure (Pa)
to different test cases, which might however require the use of Q = discharge (m3 s−1 )
an external excitation system for the determination of the natural QED = IEC discharge factor (–)
frequency. S = swirl number (–)
More generally, the results presented in this paper suggest St = Strouhal number (–)
that the hydro-acoustic parameters modelling the draft tube cav- T = period (s)
itation flow can be predicted on the complete part load operating T = torque (N m)
range if they are determined at only a limited number of operat- U = runner rotating velocity (m s−1 )
ing points and, then, expressed as a function of the swirl number. W = relative flow velocity (m s−1 )
By transposing their value to the prototype scale and by using a β = relative flow angle (rad)
proper 1-D modelling of the hydropower plant unit, the determi- γ = guide vanes opening angle (rad)
nation of the prototype natural frequency on the complete part ν = specific speed (–)
load operating range will be possible. This paves the way to ρ = water density (kg m−3 )
the prediction of the resonance conditions on the complete head σ = Thoma number (–)
range of the prototype. This procedure is however only appli- ω = angular speed (rad s−1 )
Downloaded by [University of Sussex Library] at 06:04 21 September 2017

cable for the cases of resonance at the first natural frequency of NPSH = net positive suction head (m)
the system, excited by a precessing vortex core. Further inves- BEP (suffix) = best efficiency point
tigations will focus on the determination of the hydro-acoustic LDV (suffix) = laser Doppler velocimetry
parameters and their transposition to the prototype scale to pre-
dict the occurrence of resonance conditions on the real machine References
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