Simulated Calculation of Interblade Vortex in Francis
Turbine's Whole Flow Passage
Wenwu Song
School of Energy and Environment
Xihua University
Chengdu, China
wenwus@163.com
Huiyan Wang
School of Energy and Environment
AbstractA three-dimensional model for Francis turbine's whole
flow passage is established in this paper. Simulated calculations
of fixed guide vanes, guide vanes, runner and internal flow field
of a draft tube are conducted. Velocity vector distribution and
static pressure distribution of volute, guide vanes, runner and in
the draft tube of the Francis turbine under three operating
conditions (design operating conditions, maximum flow
conditions, minimum flow conditions) are obtained. Meanwhile,
the interblade vortexes in fixed guide vanes, guide vanes and
between runner blades of the turbine are compared and analyzed
in detail on different operating conditions and at different
moments of the same cycle. Therefore, the interblade vortexes in
the guide vanes and runner, and the pressure pulsation in the
draft tube, as well as its law, especially the inter-relationship
between flow separation vortex and its pulsation frequency at the
outlet side of the blade under different operating conditions are
found out. This is of great guiding significance in improving the
operational stability of the turbine.
Keywords-interblade vortex; Francis turbine; operational
stability
I. INTRODUCTION
In recent years, most domestic and foreign large- and
medium-sized turbine sets are found out to have the problems
of vibration and blade cracking, and the problems of blade
cracking and stability even occur during the test run period or
the early running period. For example, in Dachaoshan
Hydropower Station [1], its runner was cracked during the 72h
test run period; in Xiaolangdi Hydropower Station, its spindle
was vibrating severely with abnormal noise during the early
running period of the first production unit, and after running for
1330h, it was found out that all 13 blades had cracks, and other
problems, so it was forced to shut down for repair or
improvement. In particular, if the Francis turbine is running
away from the design condition, serious flow separation
cavitation and vortex strip will be generated, which will lead to
vibration and possible fatigue damage [2]. Most domestic and
foreign large-sized Francis turbines have different degrees of
vibrations or the problems of runner blade cracking, draft tube
wall tearing, hydraulic self-excited vibration, etc. Some even
cause the resonance of the powerhouse and adjacent hydraulic
This project was funded by Major Training Project of Sichuan Provincial Department of Education (No.09ZZ031) and the Research Fund of Key
Laboratory of Fluid Machinery of Xihua University
978-1-61284-459-6/11/$26.00 2011 IEEE
4392
Xihua University
Chengdu, China
191758344@qq.com
Jinjun Li
School of Energy and Environment
Xihua University
Chengdu, China
structures and endanger the safety running of the hydropower
station.
If the Francis turbine is running under high head and large
load or large variation amplitude of running head [3], resonance
will be generated. Domestic and foreign experts thought that
this vibration is caused by a medium frequency excitation
source behind the guide vane and before the runner. However,
it is still difficult to explain with full theory.
The problems of cavitation, vibration, cracking, etc. will be
inevitable if the variation amplitude of head is too large, the
design head and rated head are low, the adjustment scope of
running load is not restricted by safety, and the manufacturing
quality of the turbine is poor. Among many factors which
cause the hydraulic vibration of the hydroelectric generating set,
the vortex motion in the guide vane and runner flow passage,
and the pressure pulsation caused by the cyclical movement of
cavitation vortex strip in the draft tube are the main sources.
With a Francis turbine as the example, three-dimensional
turbulent flow simulation of the flow fields of volute, guide
vanes, interior of the runner and draft tube are calculated and
studied. Therefore, the interblade vortexes in the guide vanes
and runner, and the pressure pulsation in the draft tube, as well
as its law, especially the inter-relationship between flow
separation vortex and its pulsation frequency at the outlet side
of the blade under different operating conditions are found out.
II. THEORETICAL ANALYSIS
At present, the study of pressure pulsation and hydraulic
vibration caused by unstable flow in guide vanes and runner is
mainly aimed at the vibration excited by Karman Vortex Street
behind the guide vane. The frequency of Karman Vortex Street
is only calculated by the empirical formula to see if it is close
to the inherent frequency of the unit components. In addition,
flow separation vortex can also excite hydraulic vibration, and
this kind of vibration has appeared in China for many times,
and similar situations have also appeared in foreign countries.
The main source of vibration of four Francis turbines and two
Kaplan turbines listed by Karman from Sweden is the vortex
street vibration excited by flow separation vortex at the outlet
side of the guide vane and runner blade [4]. However, some
experiments show that there is no flow separation in the guide
vane and runner area during vibration and the frequency is very
different from the frequency of Karman vortex. At this time,
the vibration source is neither the Karman Vortex Street nor the
flow separation vortex. Some people think that this is related to
the inter-relationship between the guide vane outlet trail with
uneven distribution of flow velocity and runners.
The research of Karman vortex was mainly focused on
improving the accuracy of Karman vortexs frequency. The
frequency of Karman vortex was calculated by the basic
formula of f = S t W / D (where, S t is the Strouhal number,
W is the relative flow velocity, and D is the flow around
diameter). However, this formula was obtained in general
water tunnel or water trough with stable velocity field and
pressure field, that is, under stable adverse pressure gradient. In
water turbine, the pressure behind fixed guide vanes or before
guide vanes is changing with the head and the opening, and the
adverse pressure gradient at the tail of the fixed guide vanes is
also changing correspondingly. As a result, the position of the
flow separation point and the corresponding flow velocity are
changing. That is to say, the W and D in the calculation
formula of Karman vortexs frequency should not and will not
be constant.
At present, the development of numerical simulation
technology of flow field [5] provides the possibility for the study
of pulsation mechanism of vortex strip in the draft tube. The
numerical simulation technology allows us to fully understand
the configuration of vortex strip in the draft tube, the flow field
in the flow passage, and its relationship with the running
conditions and geometric parameters. We can more accurately
calculate and predict the frequency and amplitude of the
pressure pulsation caused by vortex strip in the draft tube [6].
This is very significant in predicating the hydraulic design and
overall performance of the water turbine.
While designing the Francis turbine, it should be
guaranteed that the water flow does not impact on the blade
head at the entrance of the runner, and it should be positive
incidence, while the direction of water flow at the outlet of the
runner should be normal with positive circulation. If the water
flow incidence at the inlet of the runner is too large, the head of
blade will fall off and cavitate, form interblade vortex, and
further lead to high frequency or medium frequency water
pressure pulsation. During flow separation and cavitation,
negative pressure will form on the blade, and a vacuum cavity
will form between the water flow and the surface of the blade.
If the flow separation is serious, this vacuum negative pressure
effect will tear and strip the metal surface crystal of the blade,
and even cause cavitation damage. Meanwhile, if the water
circulation at the outlet of the blade is too large, strong vortex
strip will be formed in the draft tube, which will lead to low
frequency pressure pulsation.
The interblade vortex is formed due to flow separation
caused by the impact of blade by water flow at the inlet of
Francis turbine, and the secondary flow in the runner. While
the Francis turbine is running from optimum head to high head,
the increasing of head will inevitably cause the increasing of
flow velocity at the outlet of the blade if the guide vane
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opening is not changing, and thus the incidence of the flow at
the inlet of the runner will be increased, and flow separation
will be generated at the suction side of the blade and thus form
vortex. In theory, the intensity of the interblade vortex is
proportional to the incidence of the flow at the inlet of the
runner, the size and stability of secondary flow, and the path of
vortex in the runner. Therefore, the larger the dimension of the
runner is, the greater of pressure pulsation caused by interblade
vortex in the runner will be [7].
The top boundary of the interblade vortex is over flow
surface at the crown, and the bottom is the draft tube. Although
there is secondary flow in the interblade vortex, the secondary
flow shows different characteristics in different hydraulic
designs. If the secondary flow in the blade channel is stable, the
interblade vortex will be in steady state, the pressure pulsation
is relatively small, and it will not lead to harmful vibration. On
the contrary, if the secondary flow is disordered, the interblade
vortex will be turbulent and unstable [8]. The cavitation of
vortex core becomes intense due to the disturbance of the
secondary flow. The appearing and disappearing of interblade
vortex will lead to serious pressure pulsation and irregular
hydraulic impact. The secondary flow vortexes in the blade
channel caused by various reasons are shown in Fig.1.
Rear end plate
Turning direction
Blade
Front end plate Tip clearance flow
Secondary flow induced
by Coriolis force
Secondary flow induced by the
bending of axial-surface streamline
Secondary flow induced by
centrifugal force
Axis of rotation
Figure 1. Secondary flow vortex in blade channel
Figure 2. Relative velocity of fluid particles in the blade channel and
derivation of Euler equation
If assuming that the blade is infinitely thin, the direction of
relative velocity of fluid particles will be tangent to the blade,
and the angle between the relative velocity and the
peripheral speed will be equal to the blade angle e , and the
relative moving track of fluid particles will be the same as the
shape of the blade. For actual runner with limited number of
blades, the relative motion of fluid can be decomposed into two
motions: one is the motion of fluid flowing through non-
rotating runner, and the other is the motion of fluid flowing
through rotating runner. Due to the rotation of the runner, Gk = i S 2 (6)
under the effect of inertia, relative to the runner, the fluid has a
vortex in the opposite rotating direction with the same angular
velocity. This kind of vortex is axial vortex. The vector sum of 1 u u
Where, S = 2 Sij Sij and Sij = i + j
both motion velocities is the relative velocity of fluid particles
in runner with limited number of blades. Regardless of the
2 x j xi
mass effect, the Euler equation for ideal fluid at a point at the
The HLA696-LJ-108 water turbine of a Francis
outlet side of the runner blade, as shown in Fig.2, is
hydropower station was taken as the example, its basic
dv 1 p parameters are:
=
dt n (1) Design head: Hp = 220m; Height of guide vane: b0 =
285mm; Rotation speed: n = 1000rpm; Design flow rate: Qp =
The direction of vector n is along the direction of 13.15m3/s; Diameter of guide vane circle: D0 = 1390mm;
equipotential line, that is, the direction of the outlet side of the Nominal diameter of runner: D1 = 1080mm; Number of fixed
blade. Its acceleration dv / dt is the sum of axial surface guide vanes: Z2 = 9; Number of runner blades: Z=13; and
acceleration v m2 / R ( R is the curvature radius of streamline Number of guide vanes: Z1 = 16.
2
on the axial surface) and radial acceleration v n / r ( r is the A. Establishment of Flow Passage Components and
distance from the point to the axial line). Through Geometric Model of Whole Flow Passage and Mesh
decomposing the acceleration into the direction of n , the Euler Division
equation will be: The geometric models of volute, fixed guide vanes, guide
vanes, runner blades, runner, draft tube, and other flow
vm2 vn2 sin 1 p passage components are established, and the meshes are
=
R r n (2)
divided. The meshes and geometric models of volute, runner,
and whole flow passage are shown in Fig.3.
Where, is the angle between the equipotential line
(outlet side) and the radius.
By using fluid analysis software, the vortexes in the internal
flow field, between fixed guide vanes and guide vanes,
between guide vanes and runner blades, and in draft tube of the
whole flow field of a Francis turbine at the same moment of a
same cycle under different operating conditions are solved and
calculated.
Figure 3. Geometric models of volute and runner, and whole flow
III. NUMERICAL SIMULATION CALCULATION OF passage mesh diagram
INTERBLADE VORTEX
Standard k two-equation model is adopted in this B. Determination of Calculation Operation Condition
paper. For HLA696-LJ-108 water turbine, the whole flow field
of volute, fixed guide vanes, guide vanes, runner and draft
D l k tube, as well as the situation of the interblade vortexes are
= + + G (3) only calculated in the minimum flow conditions, design
Dt xi k xi operating conditions and maximum flow conditions. The
parameters of the operating points are listed in Tab.1.
D l 2
= + + c1 G c 2 (4)
Dt x i x i k k TABLE I. ARAMETERS OF THE OPERATING POINTS
Operating point Minimum Design Maximum flow
flow operating
Where, l = C
k 2 is the viscosity coefficient of conditions conditions conditions

A (m3/s) B (m3/s) C (m3/s)

Model
turbulent vortex; Gk is the stress generated item (or source HLA696-LJ-108 10.553 13.15 15.224
item) caused by velocity gradient: Unit flow 0.61 0.753 0.88
u j Model efficiency 91% 93.79% 91%
Gk = ui'u 'j (5)
xi
After modeling,

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 IV. CALCUALTION RESULTS AND ANALYSIS
The calculation results of whole flow field flowing
situations of water in volute, fixed guide vanes, guide vanes,
runner and draft tube on different operating conditions and at
different moments of the same cycle are as follows.
The pressure and velocity distribution results at the
midsection of the whole flow field, and the circumfluence of
water in the volute under the design operating conditions are
shown in Fig.4. The comparative results of circumfluence
distribution in the runner blade under design operating
conditions and non-design operating conditions, as well as the
pressure distribution on all blades are shown in Fig.5. The
circumfluence of fixed guide vanes, guide vanes and runner,
and the velocity and pressure distribution of the runner at an
instantaneous are shown in Fig.6.
Pressure distribution Velocity distribution Circumfluence of volute
at the midsection at the midsection
Figure 4. Pressure and velocity distributions at the midsection of the
whole flow passage
Design operating Non-design operating Pressure distribution
conditions conditions
Figure 5. Circumfluence of runner blade and pressure distribution of
the whole blade
Figure 6. Circumfluence distribution of guide vane and runner, and
instantaneous velocity and pressure distribution in the runner blade channel
From the above Figures of static pressure distribution of
runner, flow situation among guide vanes, circumfluence
distribution of volute, pressure and velocity distributions on
runner blade, and circumfluence distribution of runner, we can
see that under the design operating conditions, the pressure
distribution on the rubber blade is uniform, the variation of
gradient is obvious, the energy conversion of water is
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abundant, the circumfluence of guide vane is good, there is no
impact at the head, no vortex at the tail, and the circumfluence
in the volute is ideal. However, in non-design operating
conditions, there are vortexes between blade channels on
different operating conditions and at different moments of the
same cycle between fixed guide vanes and guide vanes, and
between guide vanes and runner blades. At minimum flow
conditions, the water impact near the crown area at the front of
the inlet side of the runner is serious. After impact, water will
flow laterally from the crown to the band under the influence
of the blade and runner crown. Meanwhile, large flow
separation will be formed at the suction side, and then
interblade vortexes will be formed. If the opening is increased,
the situation of the vortex can be improved.
The distributions of interblade vortexes at the cross
sections near the lower end surface of the guide vanes and
fixed guide vanes at 1/4 cycle under various operating
conditions are shown in Fig.7 for comparison.
Design operating Maximum flow Minimum flow
conditions conditions conditions
Figure 7. Distribution of interblade vortexes at the cross sections near
the lower end surface of the guide vanes and fixed guide vanes at 1/4 cycle
Under different operating conditions, the pressure field
distribution at the peripheral directions of the outlet of volute,
the outlets of fixed guide vanes and guide vanes are similar.
The pressure fluctuation at the outlet of the fixed guide vanes
is smaller than that at the outlet of guide vanes. This may be
caused by the dynamic and static interferences by the runner
and guide vanes at the inlet of the runner, and the inconsistent
number of blades.
Under Minimum flow conditions, due to the small
discharge angle from the guide vanes, the water impact near
the crown area at the front of the inlet side of the runner is
serious. After impact, water will flow laterally from the crown
to the band under the influence of the blade and runner crown.
Meanwhile, large flow separation will be formed at the suction
side, and then interblade vortexes will be formed. The
occurring of vortex reduces the velocity near the crown at the
outlet of the runner. If the opening and the flow rate are
increased, the head impact, flow separation at the suction side
and the lateral flow at the inlet of the blade will be gradually
improved.
Meanwhile under minimum flow conditions, the water
impact, flow separation and interblade vortexes at the head of
runner blade will reduce the relative velocity of water at the
outlet, especially near the crown. Therefore, the discharge
angle is small. Under the same peripheral velocity, the
peripheral component of absolute velocity is large, while the
radial velocity is small, and the axial velocity at the outlet is
also small. So water will flow from the crown to the band at
the outlet of the runner. Most of the water will flow to the
outer edge, the over flow area at the downstream of the runner
will be reduced, a large area of recirculation zone and a dead
water zone will be formed at the center, and large recirculation
will form at the lower part of the runner cone. This will
interfere and squeeze out the water at the outlet of the runner.
With the increasing of the opening, the peripheral velocity at
the outlet of the runner will decrease, and the radial velocity
and axial velocity will increase. The lateral flow at the outlet
of the runner will disappear, and the lower of runner cone will
be filled with down flowing water, and the flow in the draft
tube cone will be improved.
From the above calculation results of flow field, we can
see that under the same head, the frequency of Karman vortex
behind the blade is increasing with the reducing of the
opening. The frequency of Karman vortex behind the guide
vanes is much higher than that behind the fixed guide vanes.
The distribution of vortex flow in the whole cycle of draft
tube under minimum flow conditions is shown in Fig.8. The
distribution of vortex flow in the whole cycle of draft tube
under design operating conditions is shown in Fig.9. The
distribution of vortex flow in the whole cycle of draft tube
under maximum flow conditions is shown in Fig.10.
1/4 cycle 2/4 cycle 3/4 cycle 4/4 cycle
Figure 8. Vortex flow in draft tube under minimum flow conditions
1/4 cycle 2/4 cycle 3/4 cycle 4/4 cycle
Figure 9. Vortex flow in draft tube under design operating conditions
1/4 cycle 2/4 cycle 3/4 cycle 4/4 cycle
Figure 10. Vortex flow in draft tube under maximum flow conditions
From the above calculation results, we can see that different
degrees of draft tube vortexes will occur under minimum flow
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conditions and maximum flow conditions. Under minimum
flow conditions, this vortex strip is severely offset in spiral
shape, and the pressure fluctuation is large. Under maximum
flow conditions, this vortex strip is contracting next to the
runner, and the shape of vortex strip is changing greatly at
different rotation moments. Under design flow conditions, this
vortex strip is obviously improved.
V. CONCLUSIONS
The three dimensional model of an A696-LJ-108 Francis
turbine in a specific hydropower station is established in this
paper. The distribution of velocity vector and static pressure of
volute, guide vanes, runner and draft tube flow passage under
three conditions (design operating conditions, maximum flow
conditions and minimum flow conditions) are calculated. The
interblade vortexes in fixed guide vanes, guide vanes and
between runner blades of the turbine are compared and
analyzed in detail on different operating conditions and at
different moments of the same cycle. This opens up a new way
in finding out the interblade vortexes in the guide vanes and
runner, the pressure pulsation in the draft tube, as well as its
law, especially the inter-relationship between flow separation
vortex and its pulsation frequency at the outlet side of the blade
under different operating conditions. This is of great guiding
significance in analyzing and improving the operational
stability of the turbine.
ACKNOWLEDGMENT
Special thanks to the School of Energy and Environment of
Xihua University for providing the laboratory and EEAE
Committee for providing this template.
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