Experimental Flow Performance Investigation of Francis Turbines from Model to Prototype

Investigating the flow performance of Francis turbines from model to prototype is a complex but essential process for ensuring reliable and efficient turbine operation in hydropower plants. It ensures that Francis turbine designs operate efficiently under various operating conditions, extending from laboratory reduced-scale models to full-scale prototype installations. In this investigation, a Francis turbine model was tested under different operating conditions, and its properties were measured, including torque, hydraulic efficiency, power output, cavitation coefficient, rotational speed, flow rate, and pressure pulsations. The results of the Francis turbine model test indicate that it achieved the maximum torque with the designed discharge and designed head. The cavitation coefficient consistently remained higher than the critical cavitation coefficient. The initial cavitation bubbles were observed at 50% partial load but disappeared at full load. Pressure pulsations under different operating conditions showed the maximum peak-to-peak amplitude appearing at the turbine inlet domain and the minimum amplitude occurring at the draft tube elbow. A hill chart shows that the model’s best efficiency was 93.66%, and the estimated best efficiency of the prototype was 95.03% at the design head. The conclusions and methodology of this study can be generalized to other similar hydraulic turbines, especially prototype Francis turbines that lack experimental results.