Design of Hydraulic Turbines: PFQHN L PFQHN L Prof. Q. H. Nagpurwala Prof. Q. H. Nagpurwala

PEMP
RMD510
Design of Hydraulic
Turbines
Session delivered by:
P f Q.
Prof.
Q H.
H Nagpurwala
N
l
Dept. of Automotive and Aeronautical Engineering
Session-15
@ M.S. Ramaiah School of Advanced Studies, Bengaluru
Session Objectives
PEMP
RMD510
To understand the importance of various parameters involved in

the design
g of Pelton,, Francis and Kaplan
p turbines
To discuss the design guidelines and various empirical design
relations
To carry out design of a typical low power Pelton turbine, a
Francis turbine and a Kaplan turbine
Session-15
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RMD510
Design of Pelton Turbine
Session-15
Schematic of Pelton Turbines
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RMD510
Pelton turbine with single

g jjet
Pelton turbine with two jets

Session-15
Pelton Turbine Installation
Session-15
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RMD510
Net Head for Power Generation
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RMD510
In practice the penstock is

sized so that at rated power the
net head is usually 85-95% of
the total head
Session-15
Jet Velocity and Energy Transfer
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RMD510
(Value of is 165-170
to avoid interference)
Jet impingement
Double hemispherical shape of bucket

and from Euler turbine equation,
equation the
energy transferred to the wheel is
Session-15
Working Design Proportions
Session-15
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RMD510
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M = 1.1 to 1.5d
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11
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12
Vertical Pelton Wheel with Six Jets
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RMD510
Fig 5.11 Vertical Pelton Turbine with 6 jets

Session-15
13
Jet Runner Interaction
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RMD510
Time dependent flow visualization

visualization, taken by a high speed camera in
a typical model Pelton turbine
Session-15
14
Design of a 1.5MW Pelton Turbine
PEMP
RMD510
Given:
Water head = 500 m
Generator power
po er output,
o tp t Pg = 1500 kW
Generator speed, Ng = 750 rpm
Generator efficiency, g = 0.8
Mechanical efficiency, m = 0.85
of turbine:
1. Brake power
p
Session-15
2. Absolute velocityy of jet:

j
15
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RMD510
3. Velocity of bucket:
4. From Euler equation
Assume: K = 0.85, reduction of relative velocity due to friction

= 165,
165 vane angle
l
Session-15
16

5. Required flow rate, Q from
power equation:
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RMD510
6. Nozzle dimensions:
17

7. Diameter of Pelton wheel:
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RMD510
8. Dimensions of bucket
B = 4 Dn = 4 x 0.08367 = 0.3347m
D = 0.9 Dn = 0.9 x 0.08367 = 0.0753m
M = 1.1Dn = 1.1 x 0.08367 = 0.092m
L = 2.4Dn = 2.4 x 0.08367 = 0.2008m
Number of buckets
Session-15
18
Choice of Materials
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19
1. Manifold
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20
2. Nozzle
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21
3. Deflector
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22
4. Runner
Session-15
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23
5. Turbine Shaft
Session-15
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24
6. Housing
Session-15
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RMD510
25
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Design of Francis Turbine
Session-15
26
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RMD510
Francis Turbine
Guide vanes
Runner blades
Rotation
Session-15
27
Work Done and Efficiency
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RMD510
Euler Turbine Equation
If the flow at runner exit is without swirl then the equation reduces to
Hydraulic
y
Efficiencyy
If c3 = 0, then
Session-15
28
Important Design Relations
PEMP
RMD510
Ratio of width to diameter of the runner,

runner n = b2/D2 = 0.1
0 1 0.4
04
Flow ratio, ca2 /sqrt (2gH) = 0.15 0.3
Speed ratio, U2 /sqrt (2gH) = 0.6 0.9
Session-15
29
Francis Turbine Design
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RMD510
The following data is given for a Francis turbine.

Net head, H = 60 m
S d N = 700 rpm
Speed,
Shaft power = 294.3 kW
o = 84% ; h = 93%
Flow ratio = 0.20
0 20
Width ratio n = 0.1
Outer diameter of the runner = 2* inner diameter of runner. The thicknesses of
vanes occupy 5% of circumferential area of the runner,
runner velocity of flow is
constant at inlet and outlet and discharge is radial at outlet. Determine:
(i) Guide blade angle
((ii)) Runner vane angles
g at inlet and outlet
(iii) Diameters of runner at inlet and outlet, and
(iv) Width of wheel at inlet
Session-15
30
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Choice of Material
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1. Spiral Casing, Stay Ring and Stay Vanes
Session-15
40
2. Covers
Session-15
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3. Draft Tube Cone
Session-15
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4. Draft Tube
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5. Guide Vanes
Session-15
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6. Runner
Session-15
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7. Labyrinth Seals
Session-15
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8. Turbine Shaft
Session-15
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47
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Design of Kaplan Turbine
Session-15
48
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Definition of Heads of Kaplan Turbine
Session-15
49
Design Specifications
Session-15
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50
Power and Specific Speed
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RMD510
Power
= 97.806
97 806 W = 98 kW
Specific Speed
H = Gross head
Hn = Net head
H
Hence,
Session-15
Correlation by
y F. Schweiger
g
and J. Gregory
51
Rotational Speed
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RMD510
E = Specific
p
hydraulic
y
energy
Therefore
Therefore,
Session-15
This speed is optimal because it

is synchronous to the generator
speed Thus,
speed.
Thus the turbine can be
directly coupled to the
generator.
52
Runaway Speed
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RMD510
The runaway speed is the max. speed which the turbine can theoretically
attain. It is achieved during load rejection.
The following guideline can be used to determine the runaway speed.
Choosing double regulation for the turbine

turbine,
Session-15
53
Runner Diameter
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RMD510
Hub Diameter
Session-15
54
Suction Head
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The suction
Th
i head,
h d Hs, is
i the
h head
h d where
h the
h turbine
bi is
i installed;
i
ll d if the
h
suction head is positive, the turbine is located above the trail water; if it is
negative, the turbine is located under the trail water. To avoid cavitation,
the range of the suction head is limited. The maximum allowed suction
head can be calculated using the following equation:
Where:
patm
pv
g
c4
Hn
Session-15
atmospheric pressure [Pa]

water vapor pressure [Pa]
water density [kg/m3]
acceleration of gravity
outlet average velocity [m/s]
cavitation
it ti coefficient
ffi i t [-]
[]
net head [m]
55
Cavitation
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RMD510
Given:
Suction head,
Therefore,
Session-15
56
Outlet Velocity
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RMD510
The outlet velocity c4 can be established via the discharge and the
diameter at the outlet of the water ppassage.
g Since the dimensions of
the water passage are not known, the outlet velocity has to be
assumed. An outlet velocity of 2m/s is chosen. Using this velocity, a
ddiameter
a ete of
o 1.38m
.38 would
wou d aarise
se at tthee outlet
out et oof tthee wate
water passage - a
quite realistic value.
As long as the chosen suction head is below the established suction
head, no cavitation occurs.
A suction head of 0.45m is chosen.
Session-15
57
Blade Shape
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RMD510
Two different views of a blade

Session-15
58
Velocity Triangles
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u tangential velocity [m/s]

c absolute velocity [m/s]
w relative
relati e velocity
elocit [m/s]
Session-15
59
Spanwise Blade Sections
PEMP
RMD510
To define the twist of the blade, the velocity triangles at six different radii
of the blade are determined. The angle of each radius gives information
on the twist of the blade.
Session-15
60
Analysis of Velocity Triangles
Session-15
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RMD510
61
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Therefore,
Session-15
62
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RMD510
Velocity triangle information at 6 radial locations from hub to tip
Session-15
64
Procedure for Blade Characteristics
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RMD510
Step-1
Lift coefficient at each radius is determined by the following equation:
Where
w2
w
patm
Hs
pmin
relative velocity at blade exit [m/s]

medial relative velocity [m/s]
atmospheric pressure [m]
suction head [m]
minimal water pressure [m]
s
c3
c4
K
efficiency of the energy change [-]

[]
velocity after the runner [m/s]
outlet velocity [m/s]
profile characteristic number
The values of the following parameters are assumed as per the guidelines:
pmin = 2 - 2.5,
Session-15
s = 0.88 - 0.91,
K = 2.6 - 3
65
PEMP
RMD510
Step-2
The ratio l/t is determined using the following relation:
Where:
g
acceleration of gravity [m/s2]
h
hydraulic efficiency [-]
H
gross head [m]
cm
meridian velocity [m/s2]
angle of slip []
u
tangential velocity [m/s2]
(180-) inflow angle []
Session-15
The angle of slip has to be assumed;

the range for the assumption is as
follows:
= 2.5
2 5 - 3
3
Using this assumption, an approximate
value of the ratio l/t can be established.
66
PEMP
RMD510
Step-3
Session-15
The ratio of the lift coefficients

a/A can
a/
ca be read
ead off
o from
o the
t e
given chart.
Using this ratio the lift coefficient

A can be
b established.
bli h d
67

Step-4
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RMD510
This figure gives

information on the drag
coefficient W of the
different profiles.
Each of the curves
represents one of the
profiles which are listed
beside the chart.
First, it has to be decided
which of the profiles
should be chosen;
following this, the drag
coefficient of this profile
can be determined by
y
using the chart.
Session-15
68
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RMD510
Step-5
The angle of slip can be calculated using the following equation:
Check whether the assumed angle of slip and the calculated angle of slip are
similar or not.
If the difference is too great, repeat the procedure using the angle of slip
calculated from the above equation.
Steps
p 2 to 5 must be repeated
p
until the angles
g of slipp do not change
g anymore;
y
however, it is necessary to always choose the same profile in Step 4.
When the angle is fixed, it can be assumed that the last calculated values of
Steps 2 to 5 are accurate enough.
Thus, the ratio l/t and the profile are determined.
Session-15
69
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RMD510
Step-6
The angle of attack of the chosen profile
can now be established using the given
figure.
The Steps 1-6 are to be followed for all the
six radial sections of the blade.
blade
Session-15
70
Calculation of Blade Characteristics
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RMD510
Lift Coefficient
and
Therefore
Therefore,
Session-15
and
= 0.08
0 08
71
Calculation of Blade Characteristics
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RMD510
Ratio 1/t
Reciprocal
ec p oca of
o l/t
Session-15
72
Lift Coefficient
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RMD510
From the graph
Therefore,
h f
the
h lif
lifting
i coefficient,
ffi i
A
Session-15
73
Drag Coefficient
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From the graph

Session-15
74
Angle of Slip,
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RMD510
A l off slip
Angle
li
It can be seen that the calculated value (= 2.7o) of angle of slip is fairly close to
the assumed value (= 3o).
Session-15
75
Angle of Attack and Angle of Twist
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RMD510
Angle of attack
A l off ttwist
Angle
it
=
Session-15
76
Radial Variation of Blade Parameters
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RMD510
The listed values in the Table are obtained using the profile 430
To get the accurate angle of distortion, the angle has to be subtracted from the
angle (180-).
Session-15
77
Choice of Materials
Session-15
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RMD510
78
1. Spiral Casing
Session-15
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RMD510
79
2. Stay Ring and Stay Vanes
Session-15
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RMD510
80
3. Guide Vanes
Session-15
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RMD510
81
4. Runner
Session-15
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RMD510
82
5. Draft Tube Cone
Session-15
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RMD510
83
6. Turbine Shaft
Session-15
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RMD510
84
Session Summary
Constructional features of hydraulic turbines are briefly

discussed.
Design guidelines and typical working design proportions of

Pelton Francis and Kaplan turbines are explained.
Pelton,
explained
Design examples of the three types of turbines are presented.
Typical materials used in different components of hydraulic

turbines are listed.
Session-15
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RMD510
85
PEMP
RMD510
Th k you
Thank
Session-15
86

Design of Hydraulic Turbines: PFQHN L PFQHN L Prof. Q. H. Nagpurwala Prof. Q. H. Nagpurwala

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Design of Hydraulic Turbines: PFQHN L PFQHN L Prof. Q. H. Nagpurwala Prof. Q. H. Nagpurwala

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PEMP

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

To understand the importance of various parameters involved in

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Design of Pelton Turbine

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Schematic of Pelton Turbines

Pelton turbine with single

Pelton turbine with two jets

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Pelton Turbine Installation

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Net Head for Power Generation

In practice the penstock is

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Jet Velocity and Energy Transfer

Double hemispherical shape of bucket

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Working Design Proportions

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Working Design Proportions

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Working Design Proportions

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Working Design Proportions

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Working Design Proportions

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Vertical Pelton Wheel with Six Jets

Fig 5.11 Vertical Pelton Turbine with 6 jets

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Jet Runner Interaction

Time dependent flow visualization

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Design of a 1.5MW Pelton Turbine

2. Absolute velocityy of jet:

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Design of a 1.5MW Pelton Turbine

4. From Euler equation

Assume: K = 0.85, reduction of relative velocity due to friction

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Design of a 1.5MW Pelton Turbine

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Design of a 1.5MW Pelton Turbine

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Design of Francis Turbine

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Work Done and Efficiency

Euler Turbine Equation

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Important Design Relations

Ratio of width to diameter of the runner,

@ M.S. Ramaiah School of Advanced Studies, Bengaluru

Francis Turbine Design