Turbulence Resolving Flow Simulations of a Francis Turbine in Part Load using Highly Parallel CFD Simulations

The operation of Francis turbines in part load conditions causes high fluctuations and dynamic loads in the turbine and especially in the draft tube. At the hub of the runner outlet a rotating vortex rope within a low pressure zone arises and propagates into the draft tube cone. The investigated part load operating point is at about 72% discharge of best efficiency. To reduce the possible influence of boundary conditions on the solution, a flow simulation of a complete Francis turbine is conducted consisting of spiral case, stay and guide vanes, runner and draft tube. As the flow has a strong swirling component for the chosen operating point, it is very challenging to accurately predict the flow and in particular the flow losses in the diffusor. The goal of this study is to reach significantly better numerical prediction of this flow type. This is achieved by an improved resolution of small turbulent structures. Therefore, the Scale Adaptive Simulation SAS-SST turbulence model - a scale resolving turbulence model - is applied and compared to the widely used RANS-SST turbulence model. The largest mesh contains 300 million elements, which achieves LES-like resolution throughout much of the computational domain. The simulations are evaluated in terms of the hydraulic losses in the machine, evaluation of the velocity field, pressure oscillations in the draft tube and visual comparisons of turbulent flow structures. A pre-release version of ANSYS CFX 17.0 is used in this paper, as this CFD solver has a parallel performance up to several thousands of cores for this application which includes a transient rotor-stator interface to support the relative motion between the runner and the stationary portions of the water turbine.

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