An experimental investigation of the rotating stall in reduced scale model of a low specific speed radial pump-turbine at runaway and turbine brake conditions in generating mode is achieved. Measurements of wall pressure in the stator are performed along with high-speed flow visualizations in the vaneless gap with the help of air bubbles injection. When starting from the best efficiency point (BEP) and increasing the impeller speed, a significant increase of the pressure fluctuations is observed mainly in the wicket gates channels. The spectral analysis shows a rise of a low frequency component (about 70% of the impeller rotational frequency) at runaway, which further increases as the zero discharge condition is approached. Analysis of the instantaneous pressure peripheral distribution in the vaneless gap reveals one stall cell rotating with the impeller at sub-synchronous speed. High-speed movies reveal a quite uniform flow pattern in the guide vanes channels at the normal operating range, whereas at runaway the flow is highly disturbed by the rotating stall passage. The situation is even more critical at very low positive discharge, where backflow and vortices in the guide vanes channels develop during the stall cell passage. A specific image processing technique is applied to reconstruct the rotating stall evolution in the entire guide vanes circumference for a low positive discharge operating point. The findings of this study suggest that one stall cell rotates with the impeller at sub-synchronous velocity in the vaneless gap between the impeller and the guide vanes. It is the result of rotating flow separations developed in several consecutive impeller channels which lead to their blockage.

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a b s t r a c tWe introduce and validate a novel mathematical model for computing the radial profiles of both axial and circumferential velocity components, respectively, of the swirling flow exiting the runner of hydraulic turbines within the full operating range. We assume an incompressible, inviscid, axisymmetrical, and steady swirling flow, with vanishing radial velocity at runner outlet. First we find the correlation between the flux of moment of momentum downstream the turbine runner and the operating regime given by turbine's discharge and head. Second, we express the relationship between the axial and circumferential velocity components, corresponding to the fixed pitch runner blades, using the swirl-free velocity instead of the traditional relative flow angle at runner outlet. It is shown that the swirl-free velocity profile practically does not change with the operating regime. Third, we introduce a constrained variational problem corresponding to the minimization of the flow force while maintaining the prescribed discharge and flux of moment of momentum. This formulation also accounts for a possible central stagnant region to develop when operating the turbine far from the best efficiency point. Fourth, we show that by representing the unknown axial velocity profile with a suitable Fourier-Bessel series, the discharge constraint can be automatically satisfied. The resulting numerical algorithm is robust and produces results in good agreement with available data for both axial and circumferential velocity profiles measured on a model Francis turbine at several operating regimes. Our mathematical model is suitable for the early optimization stages of the runner design, as it provides the swirling flow configuration at runner outlet without actually computing the runner. By optimizing the parameterized swirl-free velocity profile one can achieve through the inverse design approaches the most suitable runner blades configuration at the trailing edge.

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Flow numerical simulations in a low specific speed radial pump-turbine scale model are performed to investigate off-design operating conditions in generating mode. The Best Efficiency Point (BEP) and the runaway operating conditions at 10° guide vanes opening are addressed. The computational domain includes the full reduced scale model water passage from the spiral casing inlet to the draft tube outlet. The numerical simulation is performed using the Ansys CFX code, solving the incompressible unsteady Reynolds-Averaged Navier-Stokes equations. Wall pressure measurements in the stator are used to validate the numerical results. Then, detailed analysis is focused on the onset of the flow instabilities when the machine is brought from BEP to runaway. In these severe operating conditions, one single stall cell is found to rotate with the impeller at subsynchronous speed in the vaneless gap between the impeller and the guide vanes. It is found to be the effect of flow separation developed at the inlet of several consecutive impeller channels which lead to their blockage.

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.