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Design Analysis of Parts of Francis

Turbine

P M V Subbarao
Professor
Mechanical Engineering Department

Provision of Features to Blend some


Reaction into Impulse

Spiral Casing

Spiral Casing : The fluid enters from the penstock to a spiral


casing which completely surrounds the runner.
This casing is known as scroll casing or volute.
The cross-sectional area of this casing decreases uniformly along
the circumference to keep the fluid velocity constant in
magnitude along its path towards the stay vane/guide vane.

Design of Spiral Casing


dpenstock

Rcasing

Risv

How to select Q ?

Spiral Casing for 35 MW Vertical Francis Turbine

Design of Spiral Casing


dpenstock

Rcasing

Select a suitable value of


discharge per unit: Q

Risv

2
Q V penstock d penstock
4

But maximum allowable value is 10 m/s


Maximum allowable head loss in Penstock =2 to 4% of
available head

At any angle , the radius of casing is:

Rcasing

Risv
d penstock
2

Q Q
2

A full spiral is generally recommended for high head 300m, semi-spiral


is recommended for low head < 50m.

In general =1.0,
however corrected
using CFD.

Flow Distribution Analysis of Casing

Stay vanes or Guide vanes

Static Pressure Distribution in Casing.

Mega Civil Works for Mechanical Power Generation

Parts of A Francis Turbine

Geometrical Description of A Francis Turbine Parts

Stay Vanes & Guide Vanes


The basic Purpose of the stay vanes & guide vanes is to convert
a part of pressure energy of the fluid at its entrance to the kinetic
energy and then to direct the fluid on to the runner blades at the
angle appropriate to the design.
Moreover, the guide vanes are pivoted and can be turned by a
suitable governing mechanism to regulate the flow while the
load changes.
The guide vanes are also known as wicket gates.
The guide vanes impart a tangential velocity and hence an
angular momentum to the water before its entry to the runner.
The guide vanes are constructed using an optimal aerofoil shape,
in order to optimize off-design performance.

Design of Guide Wheel (Stator): Low Specific Speed

Design of Guide Wheel (Stator): High Specific Speed

/ 2 gH

Q Q / 2 gH

Design of the Guide Vanes


Diameter of guide vane shaft
1,7

Diameter Ratio D0/D1

D1

D0
0.29 1,07
D1

1,6
1,5
1,4

D2

1,3
1,2
1,1
1,0
0,0

0,2

0,4

0,6

0,8

Speed number

1,0

1,2

/ 2 gH

1,4

1,6

Design of the Details of Stay & Guide Vane Wheels


Theory of Relatively free Whirling flow:

Vw inlet GuideVane rinlet GuideVane Vw inlet StayVane rinlet StayVane


Vw exit guideVane k wgo 2 gH

k wgo 0.7 to 1.34


Bgi

The inlet angle can be calculated by


assuming a free vortex from the
flow coming from the spiral casing
V f inlet GuideVane

Dinlet GuideVane Bgi

rinlet Guide Vane


rinlet Stay Vane

Bsi

Pressure drop versus Flow Rate


Pressure drop versus discharge

Global Symmetric Flow Domain through Statinary


Vanes

Operational Configurations of Guide Vanes

The correlation between the turbine


discharge and the guide vane opening angle.

Pressure drop versus guide vane angle

Design of the Guide Vanes


How to choose the guide vane maximum angle 0 at full
load ?

go 4 4 13 1
2

/ 2 gH

Q Q / 2 gH

Design of the Guide Vanes


Level of Overlapping of the guide vanes

Design of Guide Vanes

Guide vane at Design


Position = 12.21

Guide vane at Max. open


Position = 18

Guide vane at closed position

g
n
e
l
:
L

=15

e
n
a
v
f
th o

0%
3
to

Dg
f
o

Runner inlet
( 0.870m)
Guide vane outlet for design)
( 0.913m)

Closed
Max.
Opening
Position

Guide vanes

Design of the Guide Vane Outlet Angle


The outlet angle can be calculated by assuming a free vortex from
the flow in the gap between the runner and the guide vanes

Vwgo r Vwgi r
n
go

V fo

n
ri

Dg 0 B g 0
Bg0

V fo k fo 2 gH
k fo 0.3 to 0.6
rri
Dg0

Design of the Guide Vanes


How to choose the number of vanes
The number of guide vanes has to be different
from the number of runner vanes.

zGuide Vanes
z Runner Vanes

Integer

Water
particle
Water from
spiral casing

R a d i a l
R guide
a d ivanes
a l
runner
runner guide vanes

v i e w
v i stay
e wvanes
and
and stay vanes

Number of guide vanes

Number of Guide Vanes

30

28

26

24

22

20

18

16
0,0

0,2

0,4

0,6

0,8

1,0

Speed Number

1,2

1,4

/ 2 gH

1,6

Number of Guide Vanes


Ns

Z=8

10

12

14

16

18

20

24

Dge,mm

<200

<250 250 400

400 600

600 800

800 1000

1000
1250

1250 >1700
1700

>200

<300 300 450

450 750

750 1050

1050
1350

1350
1700

1700 >2100
2100

Ns

N Pin hp
H

5/ 4
in m

The Runner

Mean Velocity triangles Across Runner

U re U ri
U r r

Velocity triangles
rri
Vwi

Uri

i
Vfi

Vai

rre
Vwe

e
Vae

U re U ri

Ure

Vfe

e
Vre

U r r

Vri

The transposition of the profiles for all the 11 streamlines

Ub

Vwi
Vri
Vai

Ub

Vwi
Vri
Vai

Ub

Vwi

Vfi
Vai

Vfi

Vri

Vfi

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