ASSIGNMENT – TURBO MACHINES

A. i)  The Reynolds number is the ratio of inertial forces to viscous forces within a

fluid which is subjected to relative internal movement due to different fluid
velocities.
An increasing Reynolds number indicates an increasing turbulence of flow.

Where
Re = Reynolds Number | ρ = density (kg/m3) | V = velocity (m/s) | μ = dynamic viscosity
(Ns/m2) | L = characteristic length (m)

ii) The Euler Number is a dimensionless value used for analyzing fluid flow
dynamics problems where the pressure difference between two points is
important. The Euler Number can be interpreted as a measure of the ratio of the
pressure forces to the inertial forces.
P
Eu =
σ v2
Where
Eu = Euler number | p = pressure (Pa) | ρ = density (kg/m 3) | v = fluid velocity
(m/s)

iii) The Weber Number is a dimensionless value useful for analyzing fluid flows
where there is an interface between two different fluids.
The Weber Number is the ratio between the inertial force and the surface tension
force and the Weber number indicates whether the kinetic or the surface tension
energy is dominant.
ρ v2 l
We =
σ
Where
We = Weber number | ρ = density of fluid (kg/m3) | v = velocity of fluid (m/s) |
l = characteristic length (m) | σ = surface tension (N/m)

iv) The Mach Number is a dimensionless value useful for analyzing fluid flow
dynamics problems where compressibility is a significant factor.
 V
M=
C
Where
M = Mach number | v = fluid flow speed (m/s) | c = speed of sound (m/s)

B. i) Similitude:

To find solutions to numerous complicated problems in engineering, model studies

are conducted. To ensure that results obtained represent the prototype the following
three similarities are ensured: i) Geometric Similarity ii) Kinematic similarity & iii)
Dynamic Similarity.

ii) Flow coefficient:

The flow coefficient signifies that the volume flow rate of fluid through
turbomachines of unit runner diameter and running at unit speed is same for both
model and prototype. The flow coefficient is constant for similar rotors.
Q
π 1=
N d3

iii) Energy Coefficient:

The ratio between the energy transmitted forward in a wave per unit crest length ata
point in shallow water and the energy transmitted forward in a wave per unit crest
length in deep water.

iv) Power Coefficient:

The power coefficient can be obtained as a product of flow coefficient and head
coefficient.
P
π 3=
ρ N 3 d5

In water turbine ρ can be omitted.

The specific power of both model and prototype will remain same if their efficiencies
are the same.

v) Specific Speed:
 It is expressed in terms of discharge Q for power absorbing machines and as power
P in power generating machines.

It is the dimensionless number which plays the role of key parameter in

incompressible flow machines.

F. CASE STUDIES:
1. PELTON WHEEL

ABSTRACT: Effects governing the quality of jets in Pelton plants are

discussed, such as: the jet dispersion, which is defined by the widening of
the jet with distance from the nozzle and includes the air water mixture on
the jet’s surface etc. A clear relationship of increased jet dispersion and
decreased efficiency could be found. Furthermore, a direct correlation of
upstream bends and jet dispersion was found. This effect is induced by
secondary flows.

INTRODUCTION: Pelton turbines belong to the class of action turbines. The

kinetic energy of the jet is reduced to a minimum when passing through the
buckets of the runner. This deceleration occurs within a short distance
within the buckets. The pressures needed for the deceleration drive the
runner and effect the shaft torque for turbine operation. About 70 percent
of hydro electricity generated in plants with storage capacity is produced
with Pelton turbines, machines which are also especially suited for peak
power generation (network regulation). With respect to the total
hydroelectric generation in Switzerland Pelton turbines have a share of
about 40 percent.

THEORY: Not only Froude, Weber and Reynolds numbers have influence on
the jet properties, but also the entire upstream flow history. In the
upstream flow, secondary flow due to bends, bifurcations and elements
within the flow (e.g. internal or external servomotors for the needle
operation within the injector) hardly decay due to the usually high Reynolds
number occurring in hydro power plants. These secondary flows influence
the topology of the jet and lead to deformation (surface), deviation (jet
axis) and rotation of the jet's deformations. Secondary flow also causes
increased dispersion of the jet diameter. The closer the elements are to the
nozzle exit, e.g. needle and mouth piece, the more important their
influence on the jet development becomes. Old designs of injectors often
show smaller needle and mouth piece angles compared to more recent
designs, an indicator that the jet quality might not be optimum.

RESULTS: In the Swiss power plants listed in table 1, thermodynamic

efficiency measurements and jet visualizations were performed during the

project. The jet dispersion and deviation could be quantitatively
determined from the visualization in most of the cases. Clear correlation
between turbine efficiency and jet quality was observed.
By comparing with the efficiency measurements, we see that the larger
diameter corresponds to the lower efficiency. This result gives a clear
indication that the jet dispersion correlates with the efficiency.

FROM: Jets of Pelton turbines performed by the Hochschule Lucerne and the Ecole
Centrale de Lyon in collaboration with ANDRITZ Hydro
Peron, M., Parkinson E., Geppert L., Staubli T., “Importance of jet quality on Pelton
efficiency and cavitation“, IGHEM2008, Milan, Italy, 2008
2. FRANCIS TURBINE

ABSTRACT: This research describes a methodology for the parametric

design, computational fluid dynamics (CFD) aided analysis and
manufacturing of a Francis type hydro turbine runner. A Francis type hydro
turbine consists of five components which are volute, stay vanes, guide
vanes, runner and draft tube. The hydraulic performance of the turbine
depends on the shape of the components; especially on the shape of the
runner blades; to obtain accurate results and meet hydraulic expectations,
CFD analyses and advanced manufacturing tools are necessary for the
design and manufacturing of the hydro turbine runner.

INTRODUCTION: Turbines are used for hydropower generation. There are

basically two types of hydraulic turbines, the first one is impulse and the
second one is reaction type turbines. Impulse turbines work based on
momentum principle; while in the reaction type turbines, the flow is fully
pressurized and it works according to conservation of angular momentum.
The potential energy of fluid is converted to kinetic energy. Francis and
Kaplan type turbines are examples of reaction turbines. Francis type
turbines have a wide range of specific speed. Furthermore; these are the
most commonly used hydraulic turbines for hydropower generation.
DESIGN METHODOLOGY: In this study, a CFD-based design method is used
to obtain the runner blade shape and characteristics. The process starts
with the design of the runner blade with the supplied parameters for a
specific power plant, Q (volumetric flow rate), H (Head) and Ns (Specific
Speed). The shape and design for the runner blades alter with the changes
in each of these parameters. Before the mesh generation for the design and
CFD analyses, boundaries of the flow passage should be defined. BladeGen
module of ANSYS was selected for the design because of its merits.
BladeGen provides rapid simulations, modification and optimization when
used with ANSYS CFX.

RESULTS AND DISCUSSION: Angles and initial dimensions of the blade

profile were determined by the help of in-house MATLAB codes to create
the runner blade profile. To obtain smooth profiles, lean and wrap angles
definition were changed by checking the 3D blade profile and angles by the
help of the ANSYS BladeGen module. Two different meshes are used for the
CFD simulations Fig. shows inlet and the outlet velocity triangles. Subscript
1 corresponds to inlet and subscript 2 corresponds to outlet.

CONCLUSION A collaborative design methodology is developed for the

parametric, CFD aided design and manufacturing of hydro turbine runners.
The aim of this study is to explain the design and manufacturing
methodology for Francis type hydro turbines using a specific power plant in
Turkey as a case study. The design of runner blade of Francis turbine to get
the desired head and efficiency relied on the correction of runner shape
 with trial-error, in-house MATLAB codes and help of CFD. The efficiency for
the designed runner at the Best Efficiency Point (BEP) is 92%. This designed
runner will be the first runner manufactured and tested at TOBB ETU
Center for Hydro Energy Research. The manufacturing and test facility of
the center is still under construction and as a continuation of the work
presented herein, the facility will start its operation in a short time.

FROM International Journal of Materials, Mechanics and Manufacturing,

Vol. 1, No. 2, May 2013

3. KAPLAN TURBINE
ABSTRACT Enhancing Efficiency of Kaplan Turbine by Implementing
Advance Features. The sharp increase in the cost of energy in recent years
has led to a strong demand for more efficient electric generation and the
evaluation of 1% of efficiency has become higher than of the price of
generating equipment. Efficiency can be gained by replacing or modification
one or several turbines components as well as improvement in hydraulic
structures. In this paper Efficiency enhancement is currently in the center of
interesting of many researchers and several studies and experiment have
already been made.

INTRODUCTION Hydropower is a renewable, non-polluting and

environment friendly source of energy for conversion of mechanical energy
into electrical energy .The Kaplan's blades are adjustable for pitch and will
handle a great variation of flow very efficiently. They are 90% or better in
efficiency. Hence failure of a Kaplan turbine operation result efficiency loss
of production supply. Operating life of a Kaplan turbine can be drastically
curtailed by improper start up and shut down practices. So properly planed
executed maintenance schedule is in dispensable for very power plant
having hydraulic turbine on their main equipment in their process plant.
PROBLEM IDENTIFICATION The tendency of higher power concentration in
hydraulic turbines, bring as a consequence an increase in both the load and
hydraulic forces in the machine. These conditions produce major stresses in
bearing and possible vibration problems that could cause fatigue and
fracture the bearing. White metal is used as bearing bush material of
thickness2mm to prevent wear of bearing and shaft the filling of white
metal bush is done for a regular interval of 6 month and hence the plant
have to be closed down for at least 15-20 days on each failure. The failure
causes lose of generation of electricity .

REMEDY FOR FAILURE

I. Replace The Seals With Self Lubricating Seals
Replacing the seals using self lubricating seals the chance failure is less
,with the increase of lifetime of the bearing, cost are eliminated related to
machining of worn parts, grease and oil used in the distributor mechanism.
Self lubricating material has an advantage of longer lifetime and its higher
load capacity when compared with PTFE foils
II. Design Of Blades In order to decrease the maximal stress value it is
necessary to reduce the hydrodynamic loads on the blade which is possible
by increase in number of blades. The efficiency is obtained at different
runner blades and guide vanes opening, for the different head values
III. Fatigue Analysis Of Bearing Bush The fatigue analysis can be made which
validates the bearing bush for usage in turbine which can bear high load
capacity and can sustains high temperature so that the lifetime of bearing is
increased