International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol: 11 No: 01 9

Design, Simulation and Experimental of the Very

Low Head Turbine with Minimum Pressure and Free
Vortex Criterions
Priyono Sutikno1 and Ibrahim Khalil Adam2
Fluid Machinery Laboratory, Faculty of Mechanical and Aerospace Engineering, Indonesia, Institute Technology Bandung
priyonosutikno@yahoo.com1, Ibrar222@yahoo.com2

Abstract This research was carried out in order to develop a

hydro turbine to be used for specific site of lower Head as run of flows found in turbo machinery (De Palma, 2006; Nilsson and
river, which has head less than 1.2 meters. The new development Davidson, 2003). The ability to predict three-dimensional
of Very Low Head Turbine has been done in this research based viscous flow within the passages of rotating machinery devices
on [2], use the simple civil construction and resulting the
is of considerable interest to the industry. A CFD analysis
economically viable. The recent development of computer-based
tools with more efficient algorithms has allowed a substantial provides a complementary effective cost, but still can serve to
improvement in hydraulic turbine design. The definition of an
initial geometry capable to assist certain characteristics of turbine Nomenclature
performance is a first step for useful numerical turbine analysis. mean angle of the blade
This paper presents an application of the minimum pressure
1 inlet flow angle
coefficient and free vortex criterions for axial-flow hydraulic
turbines cascade geometry design. The criterion was tested for 2 outlet flow angle
VLH turbine and it was showed that it is suitable to define the C L lift coefficient
initial geometry for machine design. The grid of the simulation
domain was generated with GAMBIT grid software package and C D drag coefficient
the results were obtained using the commercial package Navier density of fluid
Stokes 3-D FLUENT flow to analyze the fluid flow through blade W mean velocity
runner. Using this procedure, a study was carried out on a small
axial-flow turbine, specifically designed to operate in a Very Low l chord length
Head. Finally, the results are evaluated to hydraulic efficiency t blade pitch
prediction of blade runner turbines. The result of simulation has p1 pressure at section 1
efficiency of 90% and produced the power of 2071 Watt at
p 2 pressure at section 2
rotational speed 180 rpm and torque is 219.79 N-m, at the flow
rate of 293.15 l/s. p o stagnation pressure
The prototype of turbine system was tested in Laboratory by W1 ,W2 or W y1 ,W y 2 inlet and outlet velocity
using small channel system that we made it inside the laboratory.
The tested result was obtained maximum efficiency of 90% and po1, po 2 stagnation at section 1 and 2
the power output simulation and experimental has the
differential less than 5% at 200 rpm. p o stagnation pressure drop
L or X lift force
Index Term-- Very Low Head Turbine, Minimum Pressure D or Y drag force
Coefficient Criterion, Free Vortex Design, Numerical Simulation, cascade loss coefficient
and Experimental.
VLH Very Low Head
I. INTRODUCTION reduce the amount of component testing required.
The small or micro hydropowers such as lower head However, at the initial stage of the turbo machinery design,
turbines are the most prospective renewable energy sources there is a lack of information on the necessary geometrical
that have received considerable attention because of its definition for advanced CFD code application. At this stage of
potential to generate green energy 1 kW to 500 kW but the the design, it is necessary to employ some design criteria
development of this kind of energy is very low due to the civil aiming at assuring certain performance requirements, such as
work cost. There for new approach and technology of turbine optimal operational parameters, aerodynamic loading,
design that applied on this research is to reduce the cost. cavitations, shock effects, stall limits, etc.
The increasing development of numeric tools with more This work confirms the use of the criterion of the minimum
efficient algorithms, evidenced by the recent development of suction pressure coefficient in the evaluation of the optimum
computational fluid dynamics (CFD) and the advent of faster conditions of operation axial cascades with minimum
numeric processors, has allowed the treatment of complex aerodynamic loss. It was also used for definition of the initial
geometry of turbo machines. Nevertheless, more studies are

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol: 11 No: 01 10

necessary in order to evaluate the real applicability of this Where is the stagnation pressure drop across
criterion in axial-flow hydraulic turbine design. Simplified the cascade and the expression of Y is obtained by Newton
methodologies that provide a complete axial hydraulic turbine second law to the control volume.
design are scarce and hardly available in the literature. Thus,
this paper presents an application of the minimum pressure
coefficient criterion for axial-flow hydraulic turbines design.
The criterion is used in the selection of good aerodynamic
performance cascade for the initial geometry definition of the Y mWy 2 Wy 1
runner blades. The cascade panel method is used to compute
Wx t tan 2 tan 1
2 (3)
pressure distribution around the runner. In this in-viscid
method, a correction is applied for accounting the boundary The drag force on blade can be expressed as
layer effect on the cascade deflection angle, following the
D Y sin X cos pot cos
Gostelow [16] procedure.
D t
CD cos (4)
0.5 W l l
2
II. TURBINE CASCADE AND DESIGN CONCEPT
The design theory of very low head turbine is rather Where po
difference from the classical turbine design theory because of 2 = The cascade loss coefficient
its large runner diameter. The cascade theory is used in this The life force can be
0.5 Wexpressed us and the life coefficient is
paper to design the blade of turbine. The analysis of flow
t
tan 1 tan 2 cos po 2
through two-dimensional turbine cascade considers the radial t
CL 2 sin
velocity component as being null; with the current surfaces l
l 0.5 W
remaining cylindrical and parallel to the rotation axis. This (5)
2 tan 1 tan 2 cos C D tan
t
condition is possible if the meridian velocity remains constant.
l
2.1 Turbine Cascade Geometry
2.2 The Minimum Suction Pressure Coefficient Criterion
The pressure coefficient is an important parameter and gives
information on the aerodynamic loading of de cascade blades. It
is defined as
p po
CP (6)
0.5 W2
Where p is the static pressure on the blade profile and po is a
Fig. 1. Cascade, Velocity triangle, blade force and its forces reference pressure.
The minimum suction pressure coefficient Cpsmin is defined
The vector mean angle of the blade ( ) is expressed items of as the minimum value of the pressure coefficient on the airfoil
inlet and outlet flow angle 1 and 2 suction side. Normally, po is the upstream static pressure, and
this gives a negative value for Cpsmin. This coefficient can be
tan 0.5tan 1 tan 2 (1) used as an aerodynamic loading criterion, allowing the
selection of cascade with relatively low profile losses. Fig. 2
In the design of airfoil the lift (CL or X) and drag (CD or Y) are illustrates distribution of pressure coefficient. There is a Cpsmin
most important component to demonstrate the force on airfoil interval limited by a lower value, Cpsi, and a higher value, Cpss,
as shown by fig. 1. which corresponds to a cascade with a low coefficient of loss. It
is important to note that both Cpsi and Cpss, have negative values.
L D
CL CD For Cpsmin > Cpss, a slightly load is obtained, and the danger of the
0.5 W l 0.5 W l
2 2
boundary layer separation is reduced, but a comparatively
The X force balance in x direction from the control volume is large area is exposed to the flow, i.e., the friction losses are
expressed as augmented. In contrast, for a cascade with Cpsmin < Cpsi, the
From fig.1.the the above equation is transform to frictional area is relatively small but a comparatively high
pressure loading is observed, increasing the danger of

X 0.5 W12 W22 t po1 po 2 t separation.
.W2 t tan (tan 1 tan 2 ) p0 t
(2)

po po1 po 2

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol: 11 No: 01 11

W U 3C 3 U 4C 4
H
gH E gH E

The maximum efficiency

W U 3C 3
H (9)
gH E gH E

The values of angel absolute velocity and angle of relative

speed enter and leave the blade are
C 2
3 tan 1
Cx2
Fig. 2. The Pressure Coefficient of the blades at section 1 at hub r
3 tan 1 tan 3 (10)
So, in order to apply this criterion it is essential to determine the x3
C
Cpsi < Cpsmin < Cpss interval. A suitable way to accomplish this r
task is to test a series of turbo machines especially designed for 4 tan 1
Cx3
this purpose.
The shock free inflow is the fluid dynamics ideal to achieve 2.4 Radial equilibrium for axial turbo machines
minimum profile losses. Flow pas a cascade depend also to the Fig. 4 illustrates the manner in which the meridional
pitch to airfoil length ratio, for the illustration can be shown at streamlines shift in radial inward progressively under the
fig. 3, the predicted outlet angle 2 for the selected inlet angle influence of the radial pressure gradient generated by the
1 , in addition, the inlet angle is associated outlet angle to swirling flow downstream of the blade row. In consequence of
provide an estimated the optimum inflow angle for the chosen this there will be a steady growth in the slope of axial velocity
cascade geometry. profile Cx.. Some distance downstream of the blade at station 3
the radial velocity component Cr will approach zero, resulting
the radial equilibrium flow.
1 dpo dC x C d ( rC )
Cx
dr dr r dr
(11)

Solution of the inverse radial equilibrium problem

r
C
Cx ( r ) K1 2 d ( r ) (12)
rh
r
r
C
For the free vortex flow 2 d ( r ) 0 , this is the criterion
r
r
Fig. 3. Predicted outlet angle 2 for selected inlet angle 1
of the free vortex, the axial velocity must be uniform and
h

equal to the mean velocity Cx.

2.3 Turbine parameters
A hydraulic turbine is characterized by the specific speed, n
usually expressed by the equation

nQ0.5
NS
g .H 0.75
(7)

For Very Low Head Turbine

Q m3 Fig. 4. Radial equilibrium of small fluid element: (a) meridional streamline
Q11 range 0.2 to 1.2 (b) pressure force on a small element at station 3
D2 H s
nD
N11 range 65 to 280 rpm The VLH turbine parameter calculated with the nominal
H (8)
values for the head (H=60 cm) and flow rate 290 l/s with tip
Eulers turbine equation is written as diameter of turbine D=400 mm. The cascade design for the
runner blades are made by assuming the free vortex radial
The Hydraulicefficiency
W U 3C 3 is
Ugiven
4C 4 by

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 International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol: 11 No: 01 12

equilibrium condition and minimum pressure criterions. This

flow distribution result by Eq. 12 is in constant axial velocity
From the table II, the value of radius, blade angle and guide
components and also in uniform radial distribution of the
vanes angle are use to draw the turbine part as illustrated
specific energy and consequently in high twisted blades.
below.
T ABLE I
i. Final profile for each suctions of blade can be shown
TURBINE DESIGN NOMINAL CONDITION at fig. 5, assembly of eight blades, and eleven profiles
with the differences stagger angles and camber
angles as written at table I. Normally, in runner
design of axial hydraulic turbines the blade chord
length assumes the smallest value in the inner radial
station due to the limit the stall effects. Since the
cavitation appear when the minimum pressure is
equaled with the vapor pressure, meaning the
cavitation index is equaled to the Cp minimum value,
in this design case is fixed at Cpss = 2.50. Fig. 5
shown the distribution of Cp from hub to tip at the
shock free condition and at deviation of angle
inflow. The nominal condition the design of VLH
turbine with specific speed 2.06 rad/s, the value of
Table II shows the main cascade design data for radial station pitch to chord length ratio 0.99 to 0.93 or length of
(Fig. 5); the absolute velocity and the relative flow angle blade at the hub is 63.16 mm to 169.78 mm at the tip.
obtained through the velocity triangle at inlet and outlet blade The intermediate radial station profiles were obtained
section. The values of the power produced and angle were between two sections haves an approximately linear
evaluated by Eq. (10) or by Eq. (13). form.
In the application of the minimum suction pressure coefficient
criterion for flow design through turbo-machinery cascade, it
is possible to find a set of cascades that can satisfy the
minimum suction pressure coefficient criterion. With specific
air foil profile, the defined geometrical parameters of cascade
are the stagger angle , the camber angle and the angle of
attack at t/l determined. As mention on the sock free inflow,
should be determined with regard of the parameters of
cascade, and any deviation of the inflow angle, the outflow
angle should relatively constant. (Fig. 3)

T ABLE II
C ASCADES D ESIGN ON RADIAL STATION

Fig. 5. Minimum Cp distribution on the section of the runner blade

The angle turbine parameter becomes

C 3 C r
3 tan 1 tan 1 3t t
x3
C Cx3 r
r U r
3 tan 1 tan 3 tan 1 3t tan 3 (13)
x3
C x3 t
C r
r U r Fig. 6. Assembly runner blades with airfoil profiles
4 tan 1 tan 1 3t
Cx3 C x 3 rt
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ii. Final runner blade, casing and guide vanes of turbine

system. Similar as runner blades guide vane
determined by the minimum pressure coefficient to
avoid the cavitation and determined with regard of
the free vortex criterion, and have the uniform axial
flow.

Fig. 9. Power versus rpm at difference heads

The runner turbine analyzed consists of eight blades. For the

Fig. 7. Turbine guide vanes and runner behind
rotating frame of reference the boundary condition are set as
rotating wall condition and the value of rotating velocity is
equal to 160 rpm, a stationary wall condition was forced by
default for absolute frame of reference (shroud). For inlet
region of guide blades, the boundary condition was specified
with the velocity axial direction, V=2.4 m/s. Outlet condition
is characterized for region small pressure, after turbine runner.
The flow considered as being incompressible and turbulent.
The turbulent model - has been useful for validation process
with value of and =10-4.
This convergence criterion is also utilized for validation the
pressure and velocity fields.

Fig. 8. Turbine system with meshing

The final physical geometry of turbine system (assembly) is
shown on fig.7 here gambit software is used final modeling of
system; the objective of this process is to find the domain
(volume domain) for simulation process of turbine system. Fig. 10. Efficiency versus rpm at difference heads

III. SIMULATION ANALYSIS OF RESULT

The simulation result of fluid flow in turbine model
system has been done by using fluent and model of rotating
reference frame theory, and the characteristic such as power,
efficiency and torque of turbine system are calculated through
the equations blow in difference head (0.4; 0.6 and 0.8 m) and
constant rotational speed from (20 and 260 rpm) as shown in
fig. 8 to fig. 10.

Power water = g Q H

Power turbine = T (14)

Fig. 11. Torque versus rpm at difference head
T
Turbine efficiency =
Q Ptotal

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From the numerical simulation has result analysis, at

efficiency 90%, the power produced are 2038 Watt on 180
rpm, 1343 Watt on 160 rpm and 730 Watt on 120 rpm at the
heads of 80 cm, 60 cm and 40 cm respectively.

Fig. 13. Efficiency versus head at difference rpm

The efficiency curves in the fig. 13 presented the comparison

between turbine running at 140, 160 and 200 rpm on the head
is between 20 cm to 120 cm. The maximum efficiency is 90%,
but at the 200 rpm, efficiency nearly 90% on the wide region
Fig. 12. Contour static pressure of guide vane blade between 80 cm to 120 cm.

It is observed that blades presenting profile with thickness and IV. EXPERIMENTAL ANALYSIS
pitch to chord ratio varied as shown at table II, has a good The experimental analysis of very low head turbine is
result and no demonstrated negative pressure indicated the validated to conduct the results of the theoretical with
cavitation occur. numerical analysis. The process and assembly of experimental
The static pressure on the guide vane and the path line contour system with its all component is illustrated by the fig.s below.
in entire flow path inflow into guide vane and out flow from The of experimental result analysis is calculated by using
the runner blades are shown in Fig. 12 and Fig. 13 dimensionless characteristics equation, and fig.s blow
respectively. The consistency of the numerical simulation can illustrated the comparison between simulation and
be verified regarding the geometric and hydraulic parameters experimental
of the design carried out. The flow direction observed on the P
blades surface and the static pressures show region subject to a P Power coefficient
larger Loading coefficient. N 3 D 5
Q
Flow coefficient (14)
ND 3
gH
Head coefficient
N 2D2

Fig. 13. Path lines contoured by static pressure on entire turbine

By analyzing the minimum pressure coefficient obtained

values, the optimum value was concluded that design value of
the Cpmin lies with in range of -2.25 < Cpmin < -1.27, where
greater hydrodynamic loading is closed to the hub and the
smaller loading in the tip of the blade see also table II.

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Fig. 14. Experiment System Components
Fig. 15. Comparison of the Flow Coefficient between Simulation and
experimental
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15
Fig. 16. Power Coefficient between simulation and experimental
Fig. 14 showed the Flow coefficient varied with the Head
coefficient, the error maximum between the simulation and
the experimental is 5% and numerical simulation is higher
than the experimental and the maximum efficiency is 90%.
Fig. 15 illustrated the comparison of the Power coefficient
varied with the Head Coefficient, the error maximum between
the Numerical Simulation and the Experimental is 3.5%. In
the experimental the pressure minimum on the section near the
hub at the maximum efficiency demonstrated the flow with
minimum losses or free shock inflow with Loading force not
appear the bubble of cavitation, but the cavitation occurs when
the flow is not shock free when turbine in run away condition.
V. CONCLUSION
The application of the minimum pressure coefficient and the
radial equilibrium free vortex as a simplified methodology for
VLH turbine design was presented. The Cascade geometry
parameter stagger angle , camber angle , pitch and chord
ratio t/l play a roll determined of the inflow angle, out flow
angle and shock free flow and related to the minimum
pressure coefficient. The optimum value was concluded that
design value of the Cpmin lies with in range of -2.25 < Cpmin <
-1.27 have loading coefficient with the minimum losses in
the shock free flow. The maximum efficiencies 90% lies to the
head varied between 40 cm to 120 cm depend on the rotation
as shown in Fig. 13.
The visualization of scalar field flow, static pressure at the
guide vane and the runner blades provides a qualitative
validation on the runner blade and guide vanes of the best
efficiency can be accomplished. The comparative studies are
presented between simulation and experimental give the
maximum differential less than 5%.
The new approach of design VLH Turbine provides the simple
methodology and simple construction make the cost of
construction is viable and possible to generate moderate power
for micro hydro used.
ACKNOWLEGMENT
This work was supported in part by Research Fund from
LPPM ITB (Institute Technology Bandung) Indonesia.
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