Extending the operational range of Francis turbines: A case study of a 200 MW prototype

Francis turbines are now widely used to support the integration of renewable and intermittent energy sources such as solar and wind power. Consequently, these turbines often operate away from their best efficiency point (BEP). Such operations cause detrimental pressure fluctuations in the runner and draft tube, leading to early fatigue failures. To address these harmful flow conditions and extend the operating range of Francis turbines, a mitigation system was developed and tested on a large-scale, high-head 200 MW Francis turbine. The system consists of four circular rods placed in the draft tube with variable radial protrusion lengths, adjustable using linear actuators. Pressure, accelerometer, and vibration sensors installed on the turbine allowed quantification of the rod system performance. The results demonstrate the system’s capability to reduce pressure pulsations by up to 80 % in terms of maximum pressure amplitude and 100 % in terms of fatigue cycle in both low and high-frequency ranges, up to ten times the runner frequency, based on pressure analysis. The optimal rod protrusion ranges from 5 to 20 % of the runner outlet diameter function of the operating load. The impact of the rods’ protrusion on the turbine structure appears negligible from the accelerometer measurements performed on the draft tube and spiral casing. The hydraulic efficiency is reduced by up to 1 %. These findings are significant across a wide range of part-load operations, from 40 % to 60 % load, indicating the potential to extend the operational range of existing Francis turbines. The research presented here is a novel attempt to enhance the existing Francis turbines with a new degree of freedom using protruding rods.