Optimization of Anti-Wear Performance of Hydraulic Turbine Based on Response Surface Methodology

Francis turbines operating in sediment-laden flows experience efficiency loss and reduced service life due to abrasive wear. To enhance wear resistance, this study optimized the turbine at Mupo Hydropower Station in Sichuan Province. Using the Plackett–Burman design, three runner parameters were identified as most influential: blade number, inlet setting angle, and outlet setting angle. A central composite design based on response surface methodology was then applied to these factors. Multiple regression models linking the parameters to turbine head, efficiency, and wear rate were established, revealing a trade-off between hydraulic performance and wear resistance. Multi-objective optimization, a method that simultaneously addresses and balances multiple competing goals, was performed to minimize wear rate while maintaining the original head. The optimal parameter combination was obtained as follows: blade number Z3 = 17, inlet setting angle α1 = 65°, and outlet setting angle α2 = 22°. Numerical results demonstrate a 32.3% reduction in runner wear under these parameters, with the head requirement satisfied, confirming a significant improvement in overall turbine performance.