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Special Issue Article

Advances in Mechanical Engineering


2017, Vol. 9(2) 1–8
Ó The Author(s) 2017
Characteristic analysis of the efficiency DOI: 10.1177/1687814017690071
journals.sagepub.com/home/ade
hill chart of Francis turbine for
different water heads

Pengcheng Guo, Zhaoning Wang, Longgang Sun and Xingqi Luo

Abstract
According to several model test results of Francis turbines, complete model efficiency hill charts were constructed. The
formation and inevitability of diversified hydraulic phenomena on model efficiency hill chart for typical head range were
analyzed and the difference is compared, as well as characteristics and commonness toward the curves are discussed
and summarized. Furthermore, hydraulic performance and geometric features are presented by particularly analyzing the
efficiency hill charts. The inherent characteristics of Francis turbine is expressed by all kinds of curves on the model effi-
ciency hill charts, and these curves can be adjusted and moved in a small range but cannot be removed out. Due to wide
range of unit speed in terms of medium-low-head hydraulic turbines, incipient cavitation curve on suction side can be
observed and it is positioned close to the operation zone; however, it fails to be visualized for the high-head turbine.
The blade channel vortex curves are in the vicinity of optimum region for low-head hydraulic turbines, while high-head
shows reverse trend. The interaction between zero incidence angle and zero circulation curve has a significant influence
on isoefficiency circles. All comparisons and analyses could provide hydraulic design basis and retrofit references.

Keywords
Francis turbine, model efficiency hill chart, hydraulic performance, geometric features, hydraulic design

Date received: 30 December 2015; accepted: 14 December 2016

Academic Editor: Peng Guoyi

Introduction of parameters fixed, which is represented by a charac-


teristic curve of hydraulic turbine. It is regarded as the
Hydraulic turbine model test is considered still the final hydraulic turbine efficiency hill chart if all kinds of per-
and indispensable verification means in hydraulic formance curves are plotted in a same graph.2–4
design of turbine, although the development of compu- The main hydraulic characteristics of the hydraulic
tational fluid dynamics (CFD) technology has provided turbine can express concentratively on the performance
a new approach for the design of turbine. Hydraulic characteristic curves or model efficiency hill chart (also
turbine characteristic curves constructed by model test known as model combined characteristic curve) based
is widely used to describe energy conversion, cavitation,
and other aspects of the hydraulic performance, as well
as force properties and other properties at different State Key Laboratory Base of Eco-hydraulic Engineering in Arid Area,
operating conditions.1 All the properties are the external Xi’an University of Technology, Xi’an, China
characteristics of the internal flow of turbine, known as
the external characteristics of hydraulic turbine. The Corresponding author:
Pengcheng Guo, State Key Laboratory Base of Eco-hydraulic Engineering
relationship among the parameters of turbine is compli- in Arid Area, Xi’an University of Technology, Xi’an 710048, Shaanxi,
cated, in order to clarify the parameters’ relationship, China.
taking two parameters as a simple function with the rest Email: guoyicheng@126.com

Creative Commons CC-BY: This article is distributed under the terms of the Creative Commons Attribution 3.0 License
(http://www.creativecommons.org/licenses/by/3.0/) which permits any use, reproduction and distribution of the work without
further permission provided the original work is attributed as specified on the SAGE and Open Access pages (https://us.sagepub.com/en-us/nam/
open-access-at-sage).
2 Advances in Mechanical Engineering

on the water head and flow rate coordinate or unit on the turbine constant efficiency curves, blade channel
parameter coordinate. However, in order to intelligibly vortex curves, cavitation inception curves of blade lead-
represent the relationship between hydraulic character- ing edge, cavitation erosion vortex curves, and the out-
istics and operation conditions, it is common to apply put limiting curve is conducted, and the characteristics
the basic characteristic curve (constant efficiency and differences of hydraulic characteristic curves under
curves, curves of channel vortex, or incipient cavitation varied water heads were analyzed and summarized. All
curves on runner blades) and typical hydraulic phe- the above provide a powerful theoretical basis and defi-
nomenon to describe the hydraulic characteristics of nite direction of retrofit for the hydraulic design of the
the turbine, such as the critical cavitation, incipient turbine.
cavitation, cavitation erosion vortex, and pressure fluc-
tuation of typical position.5
According to the external characteristic expression Model test
forms, characteristic curve of turbine can be classified
All model Francis turbines investigated in this article are
into linear characteristic curve and combined perfor-
installed at DF-100 universal test rig for hydraulic machin-
mance curve. Among which, the linear characteristic
ery in Dongfang Electric Machinery Co., Ltd, Deyang,
curve can be represented by operating characteristic
China. The test rig is enabled to perform model test for
curve, rotational speed characteristic curve, and water-
Kaplan turbine and Francis turbine, as well as pump tur-
head characteristic curves: (a) operating characteristic
bine in a closed-loop or semi-open loop with the maximum
curve is characterized by fixed n and H, (b) rotation
head of 100 m, see Figure 1. During experimental measure-
speed characteristic curve shows the relationship among
ments, a uniform head is maintained to keep realistic con-
Q, P, h, and n by identifying a and H, and (c) head
curve indicates the relationship about P, Q, h, and H ditions without obvious variation.
with fixed a and n. The combined characteristic curve The PCI extensions for instrumentation bus system
can be classified as the performance curves and model connected to an industrial computer was applied to
efficiency hill chart according to the prototype opera- record the data with the help of different kinds of sen-
tion and model tests: (a) performance curves apply the sor. This system is the extensions of peripheral compo-
operation parameters H and P or Q as ordinate and nent interconnect (PCI) at the filed of instrumentation
abscissa, respectively, and explain the linear external and is extensively used in experiment, measurement and
characteristic curve of the prototype turbine; (b) model data acquisition. The IEC60193 was used to estimate
efficiency hill chart uses n11 and Q11 as ordinate and the random errors, systematic errors, and other uncer-
abscissa to represent the linear external characteristic tainties.12 As for the DF-100 test rig, the systematic
curve of model turbine.6 Pan et al.7 summarize the uncertainties in the discharge, rotational speed, torque,
existing study results toward pump turbine characteris- and water head are 6 0.188%, 6 0.025%, 6 0.075%,
tic curves and divide the research results into two- and 6 0.065%, respectively, which corresponds to a
dimensional mathematical transformation and three- 6 0.214% system uncertainties in hydraulic efficiency
dimensional curved side fitting. Furthermore, a fitting calculated using formula (1). According to formula (2),
method for pump characteristic curves of various geo- the random uncertainty toward the hydraulic efficiency
metries based on cubic uniform B spline is presented by was estimated to a band of 6 0.10% by several mea-
Zhang et al.8 and proves the method works well by surements of mean value and standard deviation
building various pump test data. Magnoli et al.9 pre-
sented serious investigations into improvement of
hydraulic stability under changeling conditions; the
model measurements showed that distinct runner
design enable influence the pressure pulsation.
Hydraulic design of Three Gorges right bank hydraulic
turbine is presented by Shi;10 the method for better
hydraulic stability, excellent cavitation behavior, and
good performance characteristics at off-design operat-
ing conditions is clarified. Lewis et al.11 put forward a
method to improve hydraulic performance at off-design
operating conditions by injecting water through slots at
the trailing edges of the wicket gates.
In this article, typical model efficiency hill charts
were selected at the different water-head ranges of 100,
200, 300, and 500 m based on the model test results and
hydraulic design experience; meanwhile, a comparison Figure 1. Model Francis turbine test rig of DF-100.
Guo et al. 3

Table 1. Geometry and operating parameters of the investigated turbines.

Head range (m) 100 200 300 500

Water head of prototype (m) Hp 80 197 300 490


Output of prototype (MW) Pp 367 784 236 82.1
Rated rotational speed of prototype (r/min) np 100 125 300 600
Diameter of runner of prototype (mm) Dp 7105 7398 3696 2288
Diameter of runner of model (mm) Dm 365.5 417.7 409.2 504.8

qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
P
t0:95(N 1) (hi  h  )2 General character analyses of model efficiency hill
fr = pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 3 100% ð1Þ chart
N (N  1) 3 h 
qffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi As shown in Figure 2, the Francis turbine model effi-
fs = 6 fH2 + fT2 + fQ2 + fn2 ð2Þ ciency hill chart can be plotted when n11 and Q11 are
taken as ordinate and abscissa, respectively, and marks
where fr and fs are the random and systematic uncer- out the constant guide vane opening curves and con-
tainties, respectively; hi is the ith measurement; N is the stant efficiency curves at the entire test operating condi-
number of measurements; h  is the mean value of N tions. The turbine pressure fluctuation isolines,
measurements; t0:95(N 1) is the T distribution coefficients cavitation inception contours, and the critical cavita-
corresponding to a 95% confidence level and (N21) tion coefficient curve at different measuring points can
degree of freedom; and fH , fT , fQ , and fn are the sys- be scaled out. Within the test range, a blade vortex
tematic uncertainties of water head, torque, discharge, inception curve and the development curve appear if
and rotational speed, respectively. the optimal region is taken as central under the small
Related parameters of investigated turbines for opening and small flow; cavitation inception curve of
four different head ranges are tabulated in Table 1. blade leading edges on the pressure side can be
The scale-down models for diameters are 0.3655, observed at high unit speed and large flow region, while
0.4177, 0.4092, and 0.5048 m which correspond to it appears on suction side at low unit speed and low
7.105, 7.398, 3.696, and 2.288 m in prototype tur- flow region, respectively; 95% output limiting curve
bines, respectively, with the rated water head of 80, and cavitation erosion vortex curves are located in the
197, 300, and 490 m. region of large opening and large flow rate. The inher-
In order to get the performance and characteristics ent characteristics of Francis turbine are expressed by
of the turbines, a lot of measurements were carried all kinds of curves on the model efficiency hill charts,
out at diverse operation points, ranging from a very and these curves can be adjusted and moved in a small
small opening of guide vane to a maximum valve. The range but cannot be removed out of the hill chart by
model hill charts were constructed for the axis of Q11 means of hydraulic design strategy.
versus n11.
95% output limiting curve
Characteristics of model efficiency hill Increasing output is obtained with the increase in the
chart wicket gate opening, but the output will reach its upper
limit while the guide vane opens to the maximum posi-
Model hydraulic turbine usually operates at the head tion. The prototype turbine can normally achieve power
region and output range that the prototype turbine may adjustment in maximum output operation, so on the
run because of the time-consuming experiment period model efficiency hill chart, the points of 95% limit out-
and expensive test costs.13 Considering the optimum put conditions under the same unit speed were con-
operating points as the center, test conditions should nected to draw an output limiting curve. Generally, the
cover the entire operation range as widely as possible. early hydraulic turbine was designed based on one-
The final results of the model test of hydraulic turbine dimensional or two-dimensional flow theory with man-
are the model efficiency hill charts; the comparison ual drawing and semi-mechanization manufacture,
shows the model turbine hydraulic performances and which would lead to the model turbine subjected to
provides references for running and selecting the proto- poor output characteristics, and the turbine arrives its
type turbine. Figure 2 shows the investigated Francis limit output rapidly as a result of the guide vane passing
turbine model efficiency hill chart for four kinds of typi- beyond the best efficiency point. The selection of model
cal head range, respectively, 100, 200, 300, and 500 m, turbine was restricted vitally due to output limiting
from which the similarities and differences can be ana- curve that often drops into the test range. For modern
lyzed and summarized. hydraulic turbine design, before the model test is being
4 Advances in Mechanical Engineering

Figure 2. Francis turbine model efficiency hill chart for water head of (a) 100 m, (b) 200 m, (c) 300 m, and (d) 500 m.

performed, several numerical optimizations and geo- angle at optimum operating condition to improve pro-
metric shape inspections, combined with advanced pro- totype turbine efficiency at low-head and rated operat-
cessing technology and numerical control machining ing condition; accordingly, the stability and the
technology, have been carried out. As a result, the out- weighted average efficiency could be improved at
put limit of the model turbine passes far away from the weighted operation condition. Cavitation curve of
optimum region and rarely falls into test range. The blade leading edge on pressure and suction side is
output limiting curves in Figure 2 are only a matter of directly related to the incidence angle of runner leading
schematic diagram, which are actually excluded from edge; the cavitation inception on suction side will
the entire test range. emerge rapidly from the optimum unit speed to the low
unit speed on model efficiency hill chart. While the tur-
bine turns from optimal unit speed to high unit speed,
Incipient cavitation curve of runner blade pressure the blade leading edge passes zero incidence angle and
and suction side then turns to negative incidence angle; when reaching a
The model efficiency hill charts of Francis turbine are certain intensity, it can induce the cavitation inception
bound to have much in common according to the anal- on pressure side of the blade leading edge, so it is far
ysis of hydraulic design. In general, the cavitation from the optimum operating region on the efficiency
inception curve of blade leading edge on suction side hill chart.
gets closer to optimum region than that of on pressure The model test institutions attend to connect cavita-
side; furthermore, the incipient cavitation curve on suc- tion inception curves of blade leading edge on pressure
tion side has an increasingly serious effect on model and suction sides and the blade channel vortex curves.
selection for low-head Francis turbine. It is beneficial Belonging to the same scope of observation experiment,
for the Francis turbine with slightly positive incidence it is difficult to substantially observe and identify the
Guo et al. 5

difference between blade channel vortex and cavitation For the isoefficiency curves of the different water
phenomenon, especially at the operating conditions’ heads, the shape and efficiency gradient in all directions
conjunction of the blade channel vortex and the cavita- shows typical common and distinct difference. It gener-
tion of the blade leading edge. ally believed that the turbine energy performance is the
For Francis turbine at different water-head ranges, best when the runner operates at zero incidence angle
cavitation inception of blade leading edge on pressure and zero outlet circulation or with slightly positive out-
is quite different from suction side. As for middle-low let circulation or alternating outlet circulation; there-
water-head Francis turbine, cavitation inception curve fore, the slope of the isoefficiency curve is significantly
of blade leading edge will fall into the model efficiency smaller at the direction of the curve Db = 0 and Vu = 0
hill chart because of its wide range of unit speed. In on the model efficiency hill chart. Operation probabil-
addition, cavitation inception curve on suction side can ity of prototype turbine at the high water-head condi-
be observed on the efficiency hill chart, and it is posi- tion is less than the one at the middle-low water head;
tioned close to the operation zone and difficult to be a positive incidence angle at the blade leading edge is
excluded from the operation range for low-head designed to improve the efficiency under large load,
Francis turbine, as shown in Figure 2(a). While operat- but the disadvantage is the negative influence on the
ing at the high or super-high water head, there is lower hydraulic efficiency under small opening and low unit
level of cavitation incipient on efficiency hill chart due speed.
to the narrow operation unit speed range and small The guide vane and the draft tube play a crucial role
speed test span. in the entire shape of the efficiency curve on efficiency
hill chart. For the runner, although relatively good
Blade channel vortex inception and development inflow conditions are obtained at zero incidence angle
curves direction, the hydraulic loss of tandem cascades will
increase sharply with the guide vane opening decreas-
According to the model test of hydraulic turbine, it is ing. This means that the efficiency of constant effi-
defined as the blade channel vortex inception if vortex ciency curve will drop sharply under small opening and
flow appears simultaneously in three blade channels of high unit speed region. The outlet circulation of the
runner; while vortex presents at every channel, it is runner has a great influence on the energy recovery of
defined as the blade channel vortex development. Blade the draft tube, and the best energy recovery perfor-
channel vortex inception curve and its developing curve mance of the draft tube will be achieved by the runner
will drop in the experimental working range, and both outlet with slightly positive circulation or alternating
are parallel from high unit speed to low unit speed circulation; thereby, the high-efficiency region of the
incurved down at part-load conditions. In comparison, turbine shows the characteristics of elliptical partial left
the blade channel vortex of the low water-head turbine distribution along zero outlet circulation curve.
is adjacent to optimum region, while the circumstance In addition, guide vane and draft tube play different
is contrary for high water head. Many experimental roles for the turbine efficiency improvement at different
curves showed that the blade channel vortex of the water-head ranges. For the high and super-high water-
low-head model runner appears in the vicinity of 60% head Francis turbine, the guide vane opening is gener-
of Pr and one of the medium-high water-head runners ally small and the flow velocity is high, so the hydraulic
is about 45% of Pr, and it is difficult to exclude it com- loss caused by tandem cascades is relatively large. This
pletely outside the stability operation region. The blade means that the optimum design of tandem cascades in
channel vortex of the high and super-high water-head the high and super-high water-head turbine should be
turbine occurs in minimum flow rate condition and is given prior consideration. With regard to middle-low
eliminates far from the 45% of Pr. water heads, significant energy recovery of draft tube is
presented. From the model efficiency hill chart perspec-
Isoefficiency curve tive, the area of high efficiency is wide along zero outlet
circulation direction. Interaction between lifting water
Theoretically, two characterization curves are used to
head and partial optimum unit discharge leads the
represent the operation state of the runner on efficiency
energy recovery of draft tube to a progressive weaken-
hill chart of the Francis turbine: zero incidence angle
ing and the impact factor of tandem cascades on
(Db = 0) curve and zero circulation (Vu = 0) curve.
The two orthogonal curves interact and restrict with hydraulic performance to increase; the high-efficiency
each other, which play a controlling role for the trend range varies from ellipse near zero circulation gradually
and gradient of the model constant efficiency curve. to a standard circular along zero incidence angle con-
The constant efficiency ring on efficiency hill chart is trol, as validated in Figure 2(a) and (d). Furthermore,
affected by the interaction between the inlet incidence success or failure on hydraulic design of draft tube
angle and the outlet circulation of the runner. tends to extremely effect the low-frequency pressure
6 Advances in Mechanical Engineering

fluctuation because of its huge momentum in the trail- the turbine are mainly responsible for the negative cir-
ing edge for middle-low water-head Francis turbine. culation in tailing edge, which is represented by the
curve DE. At high water head with low flow rate range,
flow separation and cavitation are found on the suction
Characteristics of pressure fluctuation in side of the blade due to the existing large positive inci-
different quadrants dence angle in the runner leading edge. Meantime,
medium-high frequency pressure pulsations triggered
Unsteady flow such as pressure variation and fluctua- by blade channel vortex have an influence on turbine
tion in a large hydraulic turbine usually lead to the stability and even blade crack, which is featured by the
instability of operation. The cause and revolution of curve EA. The region surrounded by points A, B, C,
pressure fluctuation in hydraulic turbine is especially D, and E is defined as the stable operation range of
sophisticated and presents different characteristic fre- Francis turbine.
quencies.14 Furthermore, pressure fluctuation in differ-
ent components or diverse operating conditions shows
varied features. According to the principle of hydraulic Prototype turbine selection
design, hydraulic characteristics of pressure fluctuation
Type selection of prototype turbine is influenced by dif-
can be discriminated approximately in different quad-
ferent characteristics of different water-head model effi-
rants on model efficiency hill chart.
ciency hill charts, and respective selection zone also
Francis turbine is generally designed according to
shows distinguishing feature.
no impact or slight positive incidence angle in leading
First, low water-head hydraulic turbine customarily
edge, and normal outflow or a little bit positive circula-
operates in a large range of water-head variation, and
tion or alternating circulation in the outlet edge at the
its operating region on efficiency hill chart is wide, so
best efficiency point. As shown in Figure 3, the circum-
the type selection is limited by the cavitation inception
ferential velocity component increases with the decrease
curve of blade leading edge, especially the suction side
in load, and then, a strong helical off-centered vortex
cavitation inception curve. On the contrary, as for high
rope appears in the draft tube. It brings out a low-
and super-high water-head hydraulic turbine, it is rarely
frequency pressure fluctuation and induces the turbine
linked to the cavitation inception curve. Second, the
vibration.
stability operating region in efficiency hill chart of the
In Figure 3, the curve AB is the boundary of
high and super-high water-head hydraulic turbine is
unstable operation region caused by high-amplitude
much wider than that of low water head, so turbine
low-frequency pressure pulsations. At the range of low
load-adjusting range varies from 45% of Pr to 100%
water head with large flow rate, separation flow and
for the high and super-high water-head turbine, while
cavitation at leading edge on pressure side could be
the low water head would be limited within 60% of Pr.
observed under large negative incidence angle flow con-
Third, in order to keep away from low-frequency pres-
ditions. In this case, vortex ropes appear in the draft
sure fluctuation arising from vortex rope, steady output
tube, which seriously affect the dynamic stability of the
range of the prototype turbine not lower than 40% of
turbine, and the corresponding boundary curve is BC. Pr at low discharge is suggested.
Curve CD is the 95% output limiting curve. At high-
load region, concentric vortex rope and vibration of
Hydraulic characteristics of hydraulic
turbines
For low water-head Francis turbine (about 100 m
design water head), frequent pressure pulsation in
upper load operation makes it difficult to eliminate in
model test; furthermore, it presents increasing challenge
to remove it with decreasing design water head. Given
large unit discharge and cavitation coefficient, running
without cavitation requires a larger suction height. It is
a failure to exclude blade channel vortex beneath 60%
of Pr due to relatively less energy produced by unit
water head. The cavitation curve of leading edge on
suction side may drop in the turbine operation range in
case where water-head variation of prototype turbine is
large. The high-amplitude of low-frequency pressure
Figure 3. Efficiency hill chart of model turbine. fluctuation exceeds 8% of peak-to-peak value.
Guo et al. 7

With regard to the medium-high water-head Francis inception curves on suction side can be observed on
turbine (about 200 m design water head), the range of the hill chart, that is positioned closer to the operation
specific speed has enormous advantage in designing zone; unfortunately, it fails to be found for the high-
super-giant hydraulic turbine with small runner dia- head turbine. The curves of blade channel vortex get
meter; for instance, the runner diameter of 1000 MW close to optimum region for the low-head hydraulic
Francis turbine in Baihetan Hydropower Plant is about turbine, while reverse trend is present for high-head
8.5 m, while 750 MW turbine in Three Gorges reaches turbines. The interaction between zero incidence angle
to 10 m.15 The blade channel vortex and cavitation curve and zero circulation curve has a crucial influence
curve of leading edge on the suction side can be on isoefficiency circles. The slope of isoefficiency curve
excluded outside the turbine normal operation region, is significantly smaller at the direction of curve Db = 0
however, which sets a still higher demand on hydraulic and Vu = 0 on model efficiency hill chart. Low-head
design. A high suction height and deeper excavation turbine type selection is limited by the cavitation
depth is a requirement for turbine operating without inception curve of blade leading edge, and the load-
cavitation, which brings expensive construction and adjusting range is widely beneath 60% of Pr, while it
operating costs. And the peak-to-peak value of low- varies from 45% to 100% of Pr for the high and
frequency pressure fluctuation is below 5%. super-high water-head turbine. The hydraulic turbines
With regard to high and super-high water-head under varied water heads have the points in common
Francis turbine (above 300 m design water head), the with respective characteristics.
essential consideration of hydraulic and structural
design is silt abrasion problem due to high flow velo- Declaration of conflicting interests
city during turbine running, which are prone to wear
on the blades and greatly influence their life expec- The author(s) declared no potential conflicts of interest with
respect to the research, authorship, and/or publication of this
tancy.16,17 The blade channel vortex and cavitation
article.
curve on the pressure and suction side are far away
from turbine stability operation range. For the runner
with diameter D = 1–4 m, its manufacturing and Funding
repairing are demanding and complex as a result of The author(s) disclosed receipt of the following financial sup-
high synchronous speed, small runner size, and large port for the research, authorship, and/or publication of this
number of runner blades, especially the weld proce- article: This research was supported by the National Natural
dure at the crow and band of the blade midsection, Science Foundation of China (51479166).
where the ordinary number of blade is 17, even 32
with splitter blades. Lower suction height is required References
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a opening of guide vane (°)
h hydraulic efficiency
Db inlet incidence angle

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