Investigation of the fluid-structure interaction of a high head Francis turbine using OpenFOAM and Code_Aster

The increasing energy consumption and highly stressed power grids influence the operating conditions of turbines and pump turbines in the present situation. To provide or use energy as quick as possible, hydraulic turbines are operated more frequent and over longer periods of time in lower part load at off-design conditions. This leads to a more turbulent behavior and to higher requirements of the strength of stressed components (e.g. runner, guide or stay vanes). The modern advantages of computational capabilities regarding numerical investigations allow a precise prediction of appearing flow conditions and thereby induced strains in hydraulic machines. This paper focuses on the calculation of the unsteady pressure field of a high head Francis turbine with a specific speed of n_q ≈ 24 min^-1 and its impact on the structure at different operating conditions. In the first step, unsteady numerical flow simulations are performed with the open-source CFD software OpenFOAM. To obtain the appearing dynamic flow phenomena, the entire machine, consisting of the spiral casing, the stay vanes, the wicket gate, the runner and the draft tube, is taken into account. Additionally, a reduced model without the spiral casing and with a simplified inlet boundary is used. To evaluate the accuracy of the CFD simulations, operating parameters such as head and torque are compared with the results of site measurements carried out on the corresponding prototype machine. In the second part, the obtained pressure fields are used for a fluid-structure analysis with the open-source Finite Element software Code_Aster, to predict the static loads on the runner.