In the process of turbine modernizations, the investigation of the influences of water passage roughness on radial flow machine performance is crucial and validates the efficiency step up between reduced scale model and prototype. This study presents the specific losses per component of a Francis turbine, which are estimated by CFD simulation. Simulations are performed for different water passage surface roughness heights, which represents the equivalent sand grain roughness height.As a result, the boundary layer logarithmic velocity profile still exists for rough walls, but moves closer to the wall. Consequently, the wall friction depends not only on roughness height but also on its shape and distribution. The specific losses are determined by CFD numerical simulations for each component of the prototype, taking into account its own specific sand grain roughness height. The model efficiency step up between reduced scale model and prototype value is finally computed by the assessment of specific losses on prototype and by evaluating specific losses for a reduced scale model with smooth walls. Furthermore, surveys of rough walls of each component were performed during the geometry recovery on the prototype and comparisons are made with experimental data from the EPFL Laboratory for Hydraulic Machines reduced scale model measurements.This study underlines that if rough walls are considered, the CFD approach estimates well the local friction loss coefficient. It is clear that by considering sand grain roughness heights in CFD simulations, its forms a significant part of the global performance estimation. The availability of the efficiency field measurements provides an unique opportunity to assess the CFD method in view of a systematic approach for turbine modernization step up evaluation. Moreover, this paper states that CFD is a very promising tool for future evaluation of turbine performance transposition from the scale model to the prototype.
The applications of Computational Fluid Dynamics, CFD, to hydraulic machines life require the ability to handle turbulent flows and to take into account the effects of turbulence on the mean flow. Nowadays, Direct Numerical Simulation, DNS, is still not a good candidate for hydraulic machines simulations due to an expensive computational time consuming. Large Eddy Simulation, LES, even, is of the same category of DNS, could be an alternative whereby only the small scale turbulent fluctuations are modeled and the larger scale fluctuations are computed directly. Nevertheless, the Reynolds-Averaged Navier-Stokes, RANS, model have become the widespread standard base for numerous hydraulic machine design procedures. However, for many applications involving wall-bounded flows and attached boundary layers, various hybrid combinations of LES and RANS are being considered, such as Detached Eddy Simulation, DES, whereby the RANS approximation is kept in the regions where the boundary layers are attached to the solid walls. Furthermore, the accuracy of CFD simulations is highly dependent on the grid quality, in terms of grid uniformity in complex configurations. Moreover any successful structured and unstructured CFD codes have to offer a wide range to the variety of classic RANS model to hybrid complex model. The aim of this study is to compare the behavior of turbulent simulations for both structured and unstructured grids topology with two different CFD codes which used the same Francis turbine. Hence, the study is intended to outline the encountered discrepancy for predicting the wake of turbine blades by using either the standard k-ε model, or the standard k-ε model or the SST shear stress model in a steady CFD simulation. Finally, comparisons are made with experimental data from the EPFL Laboratory for Hydraulic Machines reduced scale model measurements.
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