Modelling of a Francis Turbine Runner Fatigue Failure Process Caused by Fluid-Structure Interaction

In the present paper considered is the problem of the numerical simulation of Francis turbine runner fatigue failure caused by fluid-structure interaction. The unsteady 3D flow is modeled simultaneously in the spiral chamber, each wicket gate and runner channels and in the draft tube using the Euler equations. Based on the unsteady runner loadings at each time step stresses in the whole runner are calculated using the elastic equilibrium equations solved with boundary element method. Set of static stress-strain states provides quasi-dynamics of runner cyclic loading. It is assumed that equivalent stresses in the runner are below the critical value after which irreversible plastic processes happen in the runner material. Therefore runner is subjected to the fatigue damage caused by high-cycle fatigue, in which the loads are generally low compared with the limit stress of the material. As a consequence, the stress state around the crack front can be fully characterized by linear elastic fracture mechanics. The place of runner cracking is determined as a point with maximal amplitude of stress oscillations. Stress pulsations amplitude is used to estimate the number of cycles until the moment of fatigue failure, number of loading cycles and oscillation frequency are used to calculate runner service time. Example of the real Francis runner which has encountered premature fatigue failure as a result of incorrect durability estimation is used to verify the developed numerical model.