Due to significant changes in the energy system, hydraulic turbines are required to operate over a wide power range. In particular, older turbines which are not designed for these environments will suffer under off-design conditions. In order to evaluate whether or not such a turbine could fulfill the new requirements of the energy market, a study about the behavior of a prototype plant in low-load operation is presented. Therefore, prototype site measurements are performed to determine the most damaging operating point by means of acceleration sensors and pressure transducers. Moreover, unsteady computational fluid dynamics (CFD) simulations considering two-phase flow and two hybrid turbulence models are used to analyze the flow conditions inside the turbine. The resulting pressure pulsations are mapped onto the runner blade to obtain stress and further calculate damage factors. Accordingly, the stresses are compared to those obtained by the strain gauge measurement. Moreover, the influence of active flow control by means of air injection on plant behavior and runner lifetime is discussed as well.

Part I of this series of publications addressed the background and fundamentals of the lifetime assessment of prototype Francis turbines. Part II concentrated on the developed methods of numerical calculation and assessment procedures. The present contribution (Part III) deals with the instrumentation and the metrological range of the assessment procedure. The most important sensors, measurement tools, and data acquisition units are presented (background). The instrumentation of the prototype Francis turbine is used, on the one hand, for machine unit monitoring and plant operating and, on the other hand, for generating measurement data to validate and adjust/correct the numerical simulations. Measurement data form the basis for further evaluations at various levels. A wide variety of measured variables are required to carry out the remaining lifetime of a component using fatigue analysis. Those variables include pressure and acceleration signals, vibration monitoring, and strain gauge applications for mechanical stress analysis. The available measurement signals are divided into groups based on the developed method. Thus, already-available data from the control room are compared with machine monitoring and temporarily measured data. The correlation of all available data is essential today to determine an exact idea of the occurring flow phenomena and their effects on the mechanical stresses on the component. This interaction of the different data sources and, subsequently, the use of selected quantities for the numerical calculation are part of the newly developed concept for fatigue strength analysis of mechanical components of a turbine unit (methods). The results of this journal article are divided into the discussion of the necessary instrumentation and mounting of the sensors and into the evaluation, presentation, and interpretation of the measurement data. In addition, a fatigue strength assessment is made at the position of the strain gauges. These results serve as a basis for validating the numerical stress calculation. It is worth mentioning that the validation of the numerical results and the discussion of the deviations and error consideration is carried out in Part IV of this publication series (results). This journal article of the series on condition assessment of prototype Francis turbines ends with a discussion of the results and conclusions for further data processing (conclusion).

Depending on a dynamical energy market dominated by the influence of volatile energies, the operators of hydro-power plants are forced to extend the operating range of their hydraulic machines to stay competitive. High flexibility towards low-load, a rising number of start-ups and fast response times are required for better control of the electrical grid. The major downside of these operating regions is that pressure pulsations, which are induced by the means of flow phenomena, lead to higher fatigue damage regarding the runner. Therefore, site measurements in combination with numerical methods can be used to gain a deeper understanding of the runner lifetime. This paper presents a numerical approach to understand the critical operation zones and access fatigue damage, including steady state, unsteady and transient computational fluid dynamic (CFD) one-way coupled with a transient finite element method (FEM).

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).