Electricity generation is becoming increasingly flexible in Europe these days. Due to the integration of new renewable energy sources like wind and photovoltaic, other conventional resources, such as hydropower, operate within a brought range around their best efficiency point, thus leading to higher dynamical loads at the water-bearing parts, especially at the runner and the guide vanes (background). By scrutinizing the literature of the past years, one could summarize the outcome in that way, that research projects focused either on model measurements with higher visual accessibility or, less often, on prototype measurements in existing power plants. Today prototype measurements are performed, if possible, to eliminate scaling effects. Moreover, increasing computing power allows prototype simulations to be carried out within a reasonable time. At the acknowledged research projects, prototype and model measurements and numerical simulations have been performed to identify the main gaps in Francis turbines’ lifetime assessment (methods). One special outcome of these investigations was the impracticality of numerical simulations and calculation time, respectively, of start and stop events. Therefore, a prototype measurement with focus at this operating point should be performed to provide more data and an insight into the unit’s behavior. The future goal is a comprehensive machine unit lifetime assessment of the water-bearing parts in a Francis turbine machine set (results). This complex task needs several steps, beginning from measurements through simulations towards data processing. A particular challenge is posed, when the assessment methods are applied to old machines.

Part I of the publication series addressed the fundamentals of lifetime assessment of prototype Francis turbines. This paper (Part II) focuses on the numerical part of the procedure. The essential steps and requirements shall be presented (background). The starting points for the numerical considerations are the pressure fields of the transient CFD simulations, which are exported per time step and applied to the existing structure via a fluid–structure interaction. That enables a transient mechanical stress calculation to be conducted, resulting in the fatigue analysis of the component to estimate the remaining lifetime. The individual model requirements should be represented accordingly and applied to the prototype facility (method). The results obtained from this application should be discussed and evaluated. It has to be mentioned that the validation of the numerical results will be performed at Part IV of this publication series (results). The present paper will end up discussing the results and conclusions about further data processing (Conclusion).