a ee eo oe oo oe oe | Developments in Francis turbines By F. Schweiger and J. Professor" and Ressorch Siete” Extensive research work on Francis turbines has been carried out covering the data collected from itferent manufacturers and other resources to provide engineers with the reliable and up-to-date statistical information with the present trend in radial turbines. Ne SELECTION of basic Francis turbine parameters is very important from. both the technological and cconomic points of view. The right choice of turbine Specific speed is directly related to the available head, Equally important is the appropriate positioning of the turbine runner with regard to the talwater level, and this has a bearing on the safe running of the powerplant. Both conditions are reflected in the total cost of the plant. The Technological development and ability of the manufac- turer has resulted in building larger turbine units and using the energy parameters more effectively. In the case of en bing, te nerene unl ie rele in covering the marginal specific speeds which used to be in the domain of the other turbine types. To assist the project engineer with the necessary information to select turbine parameters, the data «covering Francis turbines have been gathered from manu- facturers throughout the world. The data have been classified and analysed, and the results show the development trend in Francis turbines in recent years, Francis turbine parameters Francis turbines cover a broad field of the specific speed within the range of m= 25+ 120. Each type of water {urbine is defined by the specific speed n, and expressed by the well known equation: nQuH-o o (On the basis of statistical analyses it has been estimated that the available head H is closely linked to the specific speed mg, therefore this relationship can be expressed as Hat (ny @) ‘The analytical relationship has been established on the basis of the available information obiained {rom the turbine manufacturers. These data are of considerable importance to the project engineer if’ a proposed powerplant is being assessed, For more general applications, all the geometrical and energy parameters are presented in dimensionless form, ‘The turbine is, in principle, defined by dimensionless coefficients, that is: wlenerey coefficient) = gHKy!n-"Dg? o #(flow coetficieny = OK §'n De? 4 Of exceptional importance isthe cavitation coefficient 05 expressed in simplified form: (Hy HH 6) which involves the parameter Hs defining the installation position of the turbine runner with regard othe tailwater Water Power Dam Consirscton August 985, _ eight of vane) B = Giamecer B= scelerstion de tog iy fesdim) K 5 comune 2 speed tey/min) | 5 town’s! b oa yee? Sovltion coeticen(per cent P= Subserpt for the draft tube = bsp tor the rome be ‘aperiotfr the pac ed Sp = sib oe he prafcsng Tr © Subscript fr tbe reine > substi forthe peer velsiy Y= bse forthe pudevane pet damier 2 Specie dame oman $= wcoctiint constant 4 = cnerycoecen conten 2. = SpetieSpeed constant All three dimensionless coefficients can be expressed by specific speed, thus: watind © eta) 0 ne=flod @ A. similar approach is used for the geometrical Parameters in dimensionless form. On the basis of available data the following relationships are derived: D/Da=t(n) O} Br/Du=F(ng) (10) D/Da=f(n) ay BUDx=F(nd) (1) To facilitate the turbine design, the coefficient of peripheral velocity is introduced: Ku=(aDan)(QgH)-*60- 03) {ogether withthe inlet spiral casing velocity vpand the inlet draft tube velocity vor. All parameters are expressed by specifie speed, that is Keating «sy cs) as, i) 16) The last two parameters are presented to estimate the spiral casing and draft tube inlet diameter. SEP | | | | |aaa Optimisation of Francis turbine parameters The parameters collated by the authors are used as a basis for the statistical evaluation and presentation of graphs. ‘The data cover the period from 1970, with the exception of H=f (n), (Fig I). The graphs present two. main groups characterising the hydraulic’ and geometrical Parameters, The method of statistics has been used t0 classify and analyse the data, The data give a range of points which were evaluated and presented in the form of a statistical curve. The accuracy of the statistical results is estimated by the correlation coefficient r and standard deviation. ‘To show the advances in turbine desi ‘modern developments, the data perta (ng, hhave been split into two time-periods that is from 1960 till 1970 and after 1970. The function =f (14), one for each period is shown in Fig. 1. Two regression character- istics linking the head HT and specific speed , are thus: From 1960 until 1970 (Inclusive) H=75098.3/n4'% and to include an 93.75 per cent and the standard deviation =96.103, After 1970 H=$8369.1/n9 ‘= ~93.23 per cent and the standard deviation ‘The curve presenting a period from 1970 until 1982 shows a constant increase of specific speed iy at chosen head HZ. The tendency in future design will be towards turbines having higher specific speeds and the ability to take larger loads. To match such requirements, a good knowledge of flow and energy conditions through this turbine is necessary together with well developed technology. This is necessary to fulfill the rigorous conditions of the international market which requires excellent machine performance. ‘Since the dimensionless approach is independent of the size and the speed of the machine, it has been adopted for further analyses. Figs. 2 and 3 present the energy w and flow ¢ coefficient defined by Eqs. (3) and (4). Analytically the energy coefficient is expressed as: y=2.4724-0,01537m, a9 94.53 per cent and the standard deviation =0,4225, 8 a2 ery cote wre sacs The low coetiient is expresed $= 0.0622 +0,00535n— 88 per cent, and the standard deviation = 0.1366. 20) ‘The results presented in analytical or graphical form ‘can be used to choose the most suitable type of the turbine of up-to-date design features for a given head. Further, the knowledge ‘of cavitation coefficient os is of ‘great advantage considering the cavitation development in the flow passages. Fig. 4 presents the cavitation coefficient defined by Eq. (5), and its analytical relationship is expressed 464% 10-7" 2) =82.41 per cent and the standard deviation = 0.11690 The correlation coefficient is a little lower, but high Fg. 4. Cavitation ccetiiento, versus specs ng Witar Power Dam Construction Augie 985 SEEDS Feere ET [ — — J enough to ensure a reliable use of Eq. (21). Since the individual points ate plotted on a graph, it is up to the designer to decide on his specific requirements. Calculating the peripheral velocity coefficient Ki, Eq. (13) is the approach to use to assess the turbine runner ameter. Fig. shows the cavitation coefficient while the Analytical expression takes the form: Ky =0,75019~3.154% 10-Ing+ 6.361% 10-5, (229 038. 7.26 per cent and the standard deviatior The geometrical parameters are of equal importance to the design engineers, and therefore the data have been collected and analysed on the same principle as the energy parameters, in accordance with Eqs. (9), (10), (11) and 9.7. Meighrao Br/Dn versus spect speed ne ‘Water Power & Dam Constuction August 585 A For the inlet spi (12). The geometrical parameters are expressed in a form of geometry ratio reduced (o the inlet diameter. Figs. 6 ‘and 7 present the runner diameter and height ratio, and their analytical value is expressed by the following equations: Ds Du= 46+0.00829 n, +3) =96.21 per cent and the standard deviation =0.2163. 0.116024 +0,004906 ey Bu/De 1314. 4.81 per cent and the standard deviatio ‘The geometry of the guide apparatus is presented in Figs. 8 and 9, with the equations: ‘Dy/Da= 1.19985 ~0,0002495 n, (25) 17.64 per cent and the standard deviation =0,0381 By/Dx= ~0.00702 +0,0037987, 26) 10399, 6.06 per cent and the standard deviation: To obtain the basic information about the spiral casing and draft tube geometry, the inlet velocity was analysed for both sections statistically and presented in Figs. 10 and 11, Two equations are given, namely: For the outlet draft tube velocity Vor =2.2861 +0,002162.n4 en 10.14 per cent and the standard deviation = 0.50279. casing velocity: D 0 ig. 8 Height aio B/D versu spots ng| Fa. 1, Spr casevlocty Vseversus soci seed ng | ys = 13.07786— 0.085237 mg 28) = ~84.16 per cent and the standard deviation =2,3897. The cross-section inlet areas of the spiral casing and draft tube can be worked out at a given flow rate and inlet velocity accordingly. Type graph Inthe present work the hydraulic and geometric parameters have been treated separately. To obtain more nivel presentation “iis desirable to” join both rameters in dimensionless form. By introducing the Specie speed as a function of y and 4, the following relationship is obtained: Eq. (29) defines the unit in terms of the required flow and hhead. Using the dimensionless theory and linking the flow and head with the runner geometry, the specific diameter 8; of the machine is obtain Bre yO KeDulghy?Q-0 G0) Both parameters or and 8+ present the basic dimension- less coefficient which define entirely the unit from the hydraulic and geometrical points of view. The evaluation of the coefficient oy and 8, give a field of points which has to be analysed statistically. The result of this analysis ig the regression function 8r=f(o,), shown in Fig. 12. Since 8y-and oy are functions of w and $ coefficients, both coefficients are presented simultaneously in the same graph. The regression function is expressed by the equation: = 19018 0s) sos. a 99.12 per cent and the standard deviation =0.857. ‘The diagram in Fig. 12 is called a type graph and presents the optimum statistical data of the Francis turbine units made up to the present. It can be used for calculating the basic runner diameters and to follow the systematic development of Francis units. The results indicate the ‘development progres of the trbine manufacturers. ‘The information collected in this article can be used for 4uick estimation of Francis turbine basie parameters. All the available data have been used to present the optimum. conditions, and therefore the statistical curves show the average vaiue of the hydraulic and geometric parameters for the design point. ‘The results can be considered reliable after the preliminary data have been chosen for a new project. ‘The type graph is very complex. All the basic Francis turbine parameters are systematically presented and analysed on it, an state-of-the-art in the development of these machines ‘ig. 12 Spc sone cametr verse ‘specite speedo Water Power Dam Constcton August 165 = = = = | | _ a ] The gre tothe Acknow thea been ca Bons. Turboias Labor: welder cobalt such € with d MARTI Cr, 2 been u of hy genera than | stress mild s taining the At catego also. these +TET TEPPEreeeaean ‘The graph could be used asa statistical indicator to point tothefuturedesign andconstruction of Francisturbines. 2 Feetathors tes To expres thelr erate to Research Couns of ‘Seven for supporting sexes stork also, thewovkcouitnoehave ‘ten eames out without te formation provided by many ms, favtculirly KM(W, Sweden? Neyrpe, ance: Dominion Enpeerng Glory Canndas” Vou, West “zomany:_Allnchalmers, US: TAabetastut, egos: Ther lps pratt acknowledged Biohography Semen F, Gprcon ua Futistaog, PG, 'Turtne development on the Le ve", Warr ‘Power Di Contraction, March 082 Geatstn J Ey Abaaue. pout turbines Hydraulgues", Ecole Pobetaigue Fédérale se auchne, insta de Machine Hy delgues, Sensing. Monon" WawerkraRwerke”, Vols and Ml, VDI-Velag, West German: 1986. Stacia anaicn wubnshegs soja sea 82 1982 Field welding of stainless Basis, V., “Handbook of Applied Myers," MeGraw Hil, USA; 1 Se Mones J, Rooncie, J, Guanes, J. H. avo ot. BREW, F io ipa War Foner & Bam Conachon, Beebe se Tries, Tota Capon, Tokyo, Japan DDESIERVOF. ax DEL CVA. "Modern rend in selecting and designing Hac biter Per Dr Ciracon, Aut Ernie USA, ” Ritonarier ax Roc D, “PraicalExeine wih Flow Indeed Ubaion, Sper Verg, W,Ceygy. 50. Seer Se Menke Bre Beste Svante elindigns de rote i o-marin Pda”, ca Houle lhe, NO Tasst The feof hyropone ie thee onsracig mot Korey NU No Fojtirovanie gion”, Eneo Msi Soot idee A. 4 sinless oa Water Power & Dame “vivor parametiow i osnoynn.esometiseskih Tphego shine steel hydraulic turbines By A. Akhtar ‘Supanising Enginer* Laboratory tests are described, which were caried out to investigate parameters to optimize the structural integrity of \weldments made from 13/2 and 13/4 martensitic stainless steel base metals with austenitic 15/25 and a 0 per cent Cobalt containing weld metals. Ultrasonic vibratory apparatus has been used for cavitation tests. Welding vi iables such as pre-heat, post weld heat treatment and heat input have been investigated using shielded metal arc welding with d.c. reverse pola. MARTENSITIC stainless stels containing 11.5-14 per cent Cry 2-6 pet cent Ni and less than 0.06 per cent C have been used in recent years for the construction of a variety ‘of hydraulic. machines. Large turbine runners with generating capacities of SOO MW and weights of more than’ 100. are currently in operation!, The high Yield stress (typically 550 MPa compared with 225 MPa for ‘mild steel turbines) and a superior resistance to cavitation erosion are their most attractive features, Castings con- taining 13 per cent Cr and 4 per cent Ni, which fall under the ASTM specification A-743, ae the best know inthis category, although rolled plates containing 13 Cr-2Niare also in use. Corrosion fatigue and fracture toughness of these steels have been the subject of a number of recent Studies*™ Welding’ of the lower carbon containing (maximum 0.06 per cent C, 13 per cent Cr, 2-6 per cent Ni) steels is somewhat easier than that of theit higher carbon containing (0.11-0.15 per cent C) counterparts with 11.5-13 per cent Cr and 0-1 per cent Ni. Well known ‘examples of the higher carbon containing variety are the ‘AISI-410 and the cast variety CA-15, as for ASTM A-743. Welding electrodes of a composition similar to that of the base metal are used for shop welding™®. A pre-heat level of about 150°C with an interpass temper~ ture of 250°C is required {o.prevent cracking of the weldment in the ease of the higher carbon (0.1-0.15 per cent) containing variety. Although sound weids can be Produced with Tess. stringent pre-heat and. interpass temperature control in the ease of the variety containing less carbon. the weldments from both these types of base ‘metals tend to have poor corrison fatigue, fracture tough- ress! and impact energy""®"? compared with those of the corresponding base metal. Post weld heat treatment at 600-700°C remains essential to obtain weldment WaterPower Dam Construction August 1985 properties comparable with those of the base metal. Tt is generally expensive to dismantle turbines and transport them {o the workshop to be repaired. Repair ‘work is therefore preferably carried out on site. Pre-heat and post weld heat treatment are difficult to apply with the turbine in place. Therefore base metal type electrodes are considered unsuitable for field welding. Austenitic Stailess steel electrodes, such as the E-308L type, have been used for some time for field repair. The principal advantage of the E-308L type is the high solubility of hydrogen in austenite which alleviates the problem of hhydrogen-induced cracking in martensitic stainless steel weldments. The significantly lower yield stress of the E-308L. (2S MPa), however, “does not permit its application. for structural welding of the martensitic Stainless steels having yield stresses typically of the order of 580 MPa. A variety of other electrodes have been ‘examined in an earlier study". The object of this article is {o present data on the structural integrity of weldments and the cavitation behaviour of two optimum choices Experimental procedure Cast 13/4 and rolled 13/2 base materials were used, Compositions of the base materials and the weld deposits are shown in Table | and are plotted on the Schaeffler diagram shown in Fig. 1, Mechanical properties of the ‘base materials and the weldments are shown in Table IL Base materials were heat treated in accordance with ASTM A743. Welding was carried out using the shielded ‘metal are process with dc. reverse polarity (electrode positive). ‘Cavitation erosion tests were conducted in accordance with ASTM Standard G-32-77, using Branson ultrasonic vibratory apparatus with an’ oscillation frequency of 20 kit. “Micro-hardness tests were carried out using a diamond crn