Guide vanes in Francis turbines

El Cajon, HONDURAS

Revelstoke, CANADA

P = 169 MWH = 72 mQ = 265 m3/SD0 = 6,68 mD1e = 5,71mD1i = 2,35 mB0 = 1,4 mn = 112,5 rpm

La Grande 3, Canada

La Grande 3, Canada

La Grande 3, Canada

Guide vane cascade, Francis

Guide Vane End Seals

High efficiency Less erosion Less leakage in closed pos.

Guide vanes

Main function:Adjust the turbine load

The guide vanes consist of number of blades that can be adjustedin order to increase or reduce the flow rate through the turbine. The vanes are arranged between two parallel covers normal to the turbine shaft.

Pressure distribution and torqueLL

DD

Torque

Arm

LL

DD

Guide vanes in closed position

ZDl 0= lBHgF 00 =

000 aFMTorque ==

Guide vanes in open positionTr

ailin

g ed

ge

Trai

ling

edge

Contour of the guide vane

Pressure distribution along the contour of the guide vane:

=

+

+=

g2c

g2cHh

lossesg2

chH

22

2

Pressure distribution can be found using Bernoullis equation:

Pressure distribution along the contour of the guide vane:

Stagnation-Point at Leading Edge

Small flow rateLarge flow rate

Guide vane contour

gc2

2

Variation of the torque when the guide vane opening changes:

( )02 0m fQDM2C =

=

0

3

4

1

2

Sin 0

c m1

cm145s H

Horsepowernn =

0nsPowerplant0nsPowerplant

38365Solbergfoss34198Nore II37346Gravfoss23113Grnsdal

36,5308Fiskumfoss18104Rssga40,5308Fiskumfoss1378Mesna31,5269Iverland1372Hol I38,5264Oltesvik1269Nedre Vinstra27,5208Dynjafoss1266Skjrka

38365Solbergfoss14

34198Nore II7

31,5269Iverland10

38,5264Oltesvik9

27,5208Dynjafoss8

36,5308Fiskumfoss12

40,5308Fiskumfoss11

37346Gravfoss13

0nsPowerplant

23113Grnsdal6

18104Rssga5

1378Mesna4

1372Hol I3

1269Nedre Vinstra

2

1266Skjrka1

The guide vane maximum angle 0 at full load

NB: This is for Norwegian designed GE-turbines

45s HHorsepowernn =

Specific speed, ns

Guide vane angle

The servos work

The servo has to:Take care of the torque from all guide vanesfor all guide vane angles

The torque consist of:Hydraulic torqueFriction torque

Hydraulic torque

20m

QDC2M

=

( )0m fC =The hydraulic torque can be found from a CFD-analysis

Friction torque

( )Z

DBHd,fM ff

=

d

ff (,)= empirical value = friction factor

H = Head

Stroke

Friction

Closing

Opening

Hydraulic forces

Fully

ope

n

Opening

High head Francis turbineMeasurements of the servos work

Forc

e in

100

0 kg

Horse shoe vortex damage

Cavitation damage

Sand erosion in the guide vanes

Jhimruk Hydro Power Plant

Head coverHead cover

k

Bottom cover

Guide vane shaft

Head cover

Z

Y

1 2

The deflection of the head cover

H = 435, P = 25 MW

Reduction of clearance

Efficiency of repaired turbine

[MW]

H = 430 m

Design of the Guide Vane Inlet Angle

The inlet angle can be calculated by assuming a free vortex from the flow coming from the spiral casing

StayVaneinletStayVaneinletuGuideVaneinletGuideVaneinletu rCrC =

BDQCGuideVaneinlet

GuideVaneinletm = Dinlet Guide Vane

rinlet Stay Vane

B

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

110 rCrC uou =

00 BDQCmo

=

D0

r1

B0

Design of the Guide VanesHow to choose the number of vanes

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

Integerzz

VanesRunner

VanesGuide

Design of the Guide VanesHow to choose the number of vanes

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

Integerzz

VanesRunner

VanesGuide

Design of the Guide VanesHow to choose the guide vane maximum

angle 0 at full load

( )11344 2 ++=o

Design of the Guide VanesOverlapping of the guide vanes

Design of the Guide VanesNumber of guide vanes

16

18

20

22

24

26

28

30

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6

Speed Number

Num

ber o

f Gui

de V

anes

Design of the Guide VanesDiameter of guide vane shaft

1,0

1,1

1,2

1,3

1,4

1,5

1,6

1,7

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6

Speed number

Dia

met

er R

atio

D0/D

1

D1

D2

07,129,01

0 +=DD

Statement of ProblemGivens Net head...201.5m

Flow rate...2.35m3/sTurbine speed.1000rpm

Work out Design of Runner, Guide vanes,Stay vanes, Spiral casing andDraft tube

Compare Design output with Jhimruk turbines

Calculations - based on hydraulic principles only,

Thickness of runner blades - neglected,

Designs of components - done for the best efficiency point,

Other several assumptions - mentioned locally in calculations.

Design Considerations

Design of Guide Vanes

.

1,0

1,1

1,2

1,3

1,4

1,5

1,6

1,7

0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4 1,6

Speed numberD

iam

eter

Rat

io D

0/D1

D

1

D

2

07,129,01

0 +=DD

Diameter of guide vane axisD0 = D1 (0.29 +1.07)

= Q

602 n

=

gH2/ =

66.1=

gHQQ 2/=

319.0=

Chosen:Nos. of guide vanes z =20

mD 011.10 =

037.0=

Q

= Q

Design of Guide Vanes

.

Tangential and meridional velocities

05.11

)(CuC gvou = smC gvou /64.39)( =

smC gvom /58.8)( =

Assuming gap between runner and guide vanes5% of the runner inlet diameter.

[ (( )

=

11

)( )Cosz

Qt

DBC

gvogvo

gvom

tan (gvo) = Cm(gvo)/Cu(gvo)(gvo) = 12.210

Value of gvo in full guide vane open position is selected 180

Design of Guide Vanes

.

Velocities at outlet, axis and inlet of guide vanes(depending on varing values of and t)

Outlet agvo=12.210 tgvo=5mmCm(gvo) = 8.582 m/secCu(gvo) = 39.65 m/secCgvo = 40.56 m/sec

Axis agvc=28.040 tgvc=30mmCm(gvc) = 9.521m/secCu(gvc) = 17.87 m/secCgvc = 20.25 m/sec

Inlet agci=340 tgvi=15mmCm(gvi) = 7.864 m/secCu(gvi) = 11.65 m/secCgvi = 14.06 m/sec

Cm(gvi)=7.86 m/secCgvi=14.06 m/sec

Cu(gvi)=11.65 m/secCgvc=20.25 m/secCm(gvc)=9.521 m/secCu(gvc)=17.87 m/sec

Cgvo=40.56 m/sec

Cm(gvo)=8.58 m/secCu(gvo)=39.65 m/sec

L = 204

Design of Guide Vanes

Guide vane at DesignPosition = 12.21

Guide vane at closed position

Guide vane at Max. openPosition = 18

.

Guide vanesGuide vanesGuide vanesGuide vanesGuide vanesGuide vanes

Runner inlet ( 0.870m)

Guide vane outlet for design) ( 0.913m)

ClosedPosition

Max. Opening Position

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanes

R a d i a l v i e wrunner guide vanes and stay vanesR a d i a l v i e wrunner guide vanes and stay vanes

Water from spiral casing

Water particle