A clearance gap (CG) between guide vanes (GVs) and facing plates exists at both ends of a Francis turbine and allows the opening angle to be adjusted for varying operating conditions. Leakage flow is induced through this gap due to the pressure difference between the two sides of the guide vanes. While some research works have used qualitative approaches to visualize and predict the strength of a leakage vortex (LV), this paper presents a method for quantifying vortices along a trajectory. In this paper, a prototype high-head Francis runner with specific speed of 85.4 is considered as a reference case. A systematic investigation across both space and time is carried out, i.e., analysis of the spatial temporal progression of LV for three operating conditions. While travelling from the CG to runner leading edge, LV evolution and trajectory data are observed and the values of vorticity and turbulent kinetic energy are calculated for the LV trajectory. Frequency spectrum analyses of pressure oscillations in the vaneless space, runner blade, and draft tube are also performed to observe the peak pressure pulsation and its harmonics. Unsteady fluctuations of the runner output torque are finally studied to identify the patterns and magnitudes of torque oscillations.

Secondary flows in Francis turbines are induced by the presence of a gap between guide vanes and top–bottom covers and rotating–stationary geometries. The secondary flow developed in the clearance gap of guide vanes induces a leakage vortex that travels toward the turbine downstream, affecting the runner. Likewise, secondary flows from the gap between rotor–stator components enter the upper and lower labyrinth regions. When Francis turbines are operated with sediment-laden water, sediment-containing flows affect these gaps, increasing the size of the gap and increasing the leakage flow. This work examines the secondary flows developing at these locations in a Francis turbine and the consequent sediment erosion effects. A reference Francis turbine at Bhilangana III Hydropower Plant (HPP), India, with a specific speed (Ns = 85.4) severely affected by a sediment erosion problem, was selected for this study. All the components of the turbine were modeled, and a reference numerical model was developed. This numerical model was validated with numerical uncertainty measurement and experimental results. Different locations in the turbine with complex secondary flows and the consequent sediment erosion effects were examined separately. The erosion effects at the guide vanes were due to the development of leakage flow inside the guide vane clearance gaps. At the runner inlet, erosion was mainly due to a leakage vortex from the clearance gap and leakage flow from rotor–stator gaps. Toward the upper and bottom labyrinth regions, erosion was mainly due to the formation of secondary vortical rolls. The simultaneous effects of secondary flows and sediment erosion at all these locations were found to affect the overall performance of the turbine.

Wear and tear of hydraulic turbine due to sediment erosion is one of the major problems in hydropower plants located in the Himalayan and Andes regions. High sediment concentration in water of such areas wears down the mechanical components rapidly which causes significant operational challenges. In the present work, a prototype high head Francis runner with speed number 0.32 has been considered as reference case and other designs have been obtained modifying the blade angle distribution with same hydraulic parameters. Full turbine steady state numerical calculations were carried out at the best efficiency point and corresponding performance and erosion pattern are observed. Hydraulic efficiency and sediment erosion rate density are compared for the different cases taken into consideration. Sediment erosion analysis gives an indication of relative erosion intensity and critical zones of erosion damage in runner. Erosion was observed at the inlet near hub and shroud region and was mostly concentrated at the outlet of runner blades for all cases, where relative velocity is higher. Numerical results from CFD are also compared with the actual eroded turbine from the powerplant.