Scientific Bulletin of the The 6th International Conference on

Politehnica University of Timisoara Hydraulic Machinery and Hydrodynamics

Transactions on Mechanics Special issue Timisoara, Romania, October 21 - 22, 2004

NUMERICAL SIMULATION OF A FREE JET IN PELTON TURBINE

Adriana CATANASE, Lecturer Engineer* Mircea BĂRGLĂZAN, Prof., Ph.D.

Department of Power Engineering Department of Hydraulic Machinery
University of Oradea “Politehnica” University of Timisoara
Cristina HORA, Lecturer Engineer
Department of Power Engineering
University of Oradea
*Corresponding author: Armata Romana Street 5, Oradea, România
Tel.: (+40) 259 408197, Fax: (+40) 259 432876, Email: adr_cat@yahoo.com

Last years literature shows an increasing interest

ABSTRACT
Due to periodic change of the relative position
between the waterjet and the bucket in Pelton turbines
the flow is unsteady and has a free surface. The
efficiency of the energy exchange depends on the
flow structure of the water on the bucket and,
therefore, the bucket design. Lately, more and more
technical papers related to the numerical simulation
of the flow in Pelton turbines have been published in
the literature. And this may be a preliminary step in
the design activity. The paper takes into consideration
the jet from a Pelton turbine nozzle. The equations
governing this type of flow are the continuity equation
and Navier-Stokes equation. Also, the velocity
distribution inside the jet is investigated for different
positions of needle tip.
KEYWORDS
Pelton turbine, free jet, numerical simulation
1. INTRODUCTION
Inspite the fact that Pelton turbines have known a
significantly improvement regarding the efficiency
and reliability, the flow analysis through injectors
and rotor buckets is still in research stage and the
physical phenomena are far to be completely under-
stood and described. The precise theoretical analysis
of Pelton turbines becomes more difficult due to a
few peculiarities of the flow, such as: free jet flow
and unsteady flow with free surface on the bucket.
A specific aspect of Pelton turbines simulation is
the fact that due to periodic change of the relative
position between the waterjet and the bucket the
flow is unsteady and has a free surface.
for the numerical analysis of the jet from a Pelton
turbine nozzle as well as for the unsteady flow with
free surface on the bucket shaped blade. For instance,
if we look in the Proceedings of IAHR Symposium
on Hydraulic Machinery and Cavitation we see that
there are many intense and quite recent works on the
numerical simulation of flow in Pelton turbines. Most
often, this numerical simulation is combined with
the experimental analysis. Papers presenting these
works are published in last IAHR Symposiums which
is an extremely prestigious forum of the top research
in Hydraulic Machinery.
This paper focuses on the jet from the nozzle of the
Pelton turbine that belongs to the testing rig for the
hydropower-plant “Gemenele” placed in the Labora-
tory of Hydraulic Machinery from the “Politehnica” Uni-
versity of Timisoara. The unsteady jet issuing from the
turbine nozzle was calculated numerically and the veloc-
ity distribution in different sections and for different
positions of the needle tip was determined. Moreover,
analysing the photos of many jets the enlargement of
the free jet diameter is determined. This enlargement
is affected by the head and the nozzle opening.
2. EXPERIMENTAL FACILITY AND THE
INJECTOR GEOMETRY
The testing rig consists of the hydraulic circuit,
control elements, measurement equipment and power
consumers, as shown in figure 1.
Pelton turbine belonging to the testing rig has a
rotor with 20 bucket shaped blades. The guide vane is
axial – injector type. By opening or closing the needle
tip from the regulating nozzle different operating
points are achieved.
The main sizes of the injector belonging to the
Pelton turbine testing rig are shown in figure 2.

79
 V
W F
CE
Q
T

T.P.

RAT G

ME
Legend:
– electromotor
C – coupling
M ME - electromotor
P -–coupling
C centrifugal pumps
B- –centrifugal
P reservoir pumps
B
CS- reservoir
– by-pass pipe
CS - shorting pipe
M – manometer
M - manometer
Q -–flowmeter
Q flowmeter
C.S. Rat –- governor
RAT governor
G GE - asincronous electric
G – asynchronous
generator
ME. C electric generator
V - voltmeter
P V- –frequency
voltmeter
F meter
F – frequency
T - speed indicatormeter
TP
T –- Pelton
speedturbine
indicator
W - wattmeter
TP – Pelton turbine
W – wattmeter

Figure 1. “Gemenele” testing rig from the Laboratory of Hydraulic Machinery, “Politehnica” University of
Timişoara

injector In this chapter we consider the jet issuing from the

nozzle closed Pelton turbine nozzle which is shown previous in fig. 2.
opened
The flow is assumed to be axisymmetric and
without swirl flow. This type of flow is governed by
the continuity equation and also the Navier-Stokes
φ40,5
φ12

φ30
φ13

equations, presented below:

φ17

30,50 45
0

∂v
φ16

1 ∂
( rvr ) + z = 0
needle tip r ∂r ∂z
stator ∂vz ∂vz2 1 ∂
+ + ( rvz vr ) =
90,5 ∂t ∂z r ∂r
1 ∂p 1 ∂ ⎡ ⎛ ∂vz ∂vr ⎞ ⎤
=− +ν − (1)
r ∂r ⎢⎣ ⎜⎝ ∂r ∂z ⎟⎠ ⎥⎦
Figure 2. The main sizes of the injector belonging to r
ρ ∂z
the Pelton turbine testing rig
∂vr 1 ∂ ∂
3. BASIC EQUATIONS NUMERICAL
+
∂t r ∂r
( )
rvr2 + ( vz vr ) =
∂z
ANALYSIS METHOD 1 ∂p ∂ ⎛ ∂vr ∂vz ⎞
=− +ν ⎜ −
3.1. Basic equations ρ ∂r ∂z ⎝ ∂z ∂r ⎟⎠
The operation of tangential hydraulic turbines of For solving these equations, the following boundary
Pelton type is based on fundamental equation of turbo- conditions are introduced:
machinery, which derive from momentum of momen- - at the inlet of the injector: vz = const., vr = 0
tum equation. The flow is complicate due to periodic ∂vz
change of the relative position between the waterjet - at the centerline of the jet: = 0, vr = 0
and the bucket and also due to the jet interference. ∂r

80
- on the solid wall of the nozzle and the needle: vz = 0, figure 5. Also, looking at figure 6, we observe that
vr there is a low velocity region in jet near the axis and
vr = 0. Also, at the exit of the nozzle, = tan β , it spreads with the decrease of needle opening.
vz
β is the incline angle of the nozzle exit. r <m>
∂v z ∂v r
- on the free surface: = 0, = 0, p = p at .
∂r ∂r
In previous relations the following notations are
used: p – pressure, ρ - water density, ν - kinetic vis-
cosity, r, z – radial and axial coordinates, vr, vz – radial
and axial velocity components.
3.2. Numerical analysis method
With the help of Femlab algorithm, working in
Matlab 6.2, is investigated the velocity distribution
inside the jet, at different positions of the needle
from regulating nozzle. z <m>
The three equations from (1) are solved by finite
difference method using triangular mesh system for Figure 4. Velocity distribution for s/smax = 0,2
a good handling of the free surface. The finite
element grid is represented in figure 3. The number r <m>
of the cells from effective grid, which varies by the
position of the free surface, is approximately 50000.
The numerical simulation results are obtained for
five different positions of the needle tip. The needle
stroke is about 15 mm. The complete opening of the
nozzle, namely the nozzle is fully open, corresponds
to the fully retracted position of the needle.
z <m>

z <m>

Figure 5. Velocity distribution for s/smax = 0,8

r <m>

Figure 3. The finite element grid for simulation

In figure 4 and figure 5 the numerical simulation
results are represented for two positions of the needle
from regulating nozzle.
In figure 6, for turbine head H =50 m and the
position of the needle indicated by its relative value
s/smax = 0,2, we determined the axial velocity
distribution in the jet, for two axial positions along Figure 6. Axial velocity distribution at D0 and 2D0
the free jet, downstream the nozzle. These two from the nozzle
positions are at 1D0 and 2D0 from the nozzle, where
D0 is the jet diameter. We also proposed an expression for velocity
Therefore, by changing the position of the needle which taking into account the velocity distribution
from regulating nozzle obtain the flow rate variation with the jet axis z and also with the radius r of the
and that caused the modification of the velocity jet. This proposed expression is a polynomial function
distribution. This fact is presented in figure 4 and of third degree, like:

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 v(z,r) = A·z + B·r + C·z·r + D·z2 + E·r2 +
+ F·r2·z + G·r·z2 + H·z3 + I·r3 (2)
Analysing the velocity distributions represented in
figure 6, for three values of z and different values of
r, we determine all the nine constants from relation
(2). These constants are: A = -6,495·10-3; B = 1,183;
C = 0,065; D = 5,462·10-3; E = -0,154;F = 5,209·10-3;
G=7,084·10-4;
H = -1,241·10-4; I = 2,495·10-3. All these values
are for z and r in millimetres. So, the velocity function
in z and r is:
v(z,r) = -6,495·10-3 z + 1,183 r -0,065 z r +
+5,462·10-3 z2 – 0,154 r2 +
+ 5,209·10-3 r2 z + 7,084·10-4 r z2 -
- 1,241·10-4 z3 + 2,495·10-3 r3 (3)
In figure 7 we represented the calculated velocity
distribution with the relation (3), at 1D0 from the
nozzle.
10
6.5
8 a short distance between the position of the contracted
Radius [mm]
6 determined using the following relation:
r
4 D2 − D1
2
0 0
0.5 0.7 0.9 1.1 1.3
0.566 v ( r , z)
Normalized velocity
Figure 7. Calculated velocity distribution at 1D0
from the nozzle exit
Comparing the results represented in figure 6 and
figure 7 we observed that the velocity function from
relation (3) approximate with good accuracy the veloc-
ity distribution near the axis and near the free surface.
To judge the quality of the computed results we
need measurements. This will be the subject of a
further work.
4. INFLUENCE OF THE INJECTOR NEEDLE
TIP ON THE ENLARGING RATE OF FREE
JET DIAMETER
Analysing some results from literature, approxi-
mately the same that we presented here for the nozzle
in figure 2, it is revealed that the profile of the ve-
locity distribution in the jet changes remarkably by
the needle opening. So, when the flow rate is large,
meaning that the opening is large, the velocity profile
is relative flat. On the other hand, when the opening
is small, the profile has a peak value. Such variation
of the velocity profile of the jet will change the flow
pattern in the Pelton bucket.
Because the jet travels downstream the nozzle,
through the turbine casing, the surface velocity of jet
is decelerated by the shear stress caused by contact
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with the air. The friction with the air produces the
velocity decay.
More, water droplets splashed by the Pelton turbine
buckets exist around the free jet. The entrance of these
water droplets inside the jet also produces a decrease
of kinetic energy of the jet. While the amount of water
droplets spinning inside the casing depends to the
nozzle flow rate, the kinetic energy loss depends on
the needle stroke.
According to the visual observation of the flow in
model Pelton turbines ([4]), the water jet that comes
out of nozzle into atmosphere has a circular cross
section, and has a minimum diameter at the contrac-
tion position where the jet velocity is almost uniform.
From the contraction position toward the bucket
inlet, the jet velocity continuously decreases, and the
diameter enlarges to conserve the mass continuity. If
the enlarging rate is constant along the centreline of
the jet, the shape of jet is conical.
Assuming a linear enlargement of jet diameter for
jet and the bucket inlet, the jet enlargement is
tgα = (4)
2( X 2 − X1 )
1.5 where D1 and D2 are the jet diameters for two
1.23
arbitrary positions X1, respectively X2, along the jet
axis and α is half of the cone angle.
The enlarged diameter DX being in an arbitrary
position X, can be calculated using the following
relation, where D0 is the diameter of the contracted
jet at contraction position X0:
⎛ ( X − X0 ) ⎞
Dx = D0 ⎜1 + 2 tgα ⎟ (5)
⎝ D0 ⎠
Counting on the previous consideration and ana-
lysing a series of photos of the jet flow between the
nozzle tip and the bucket inlet under the various
needle stroke and operating net head, we measured
the enlarging rate of the jet diameter and the kinetic
energy decay. All the results are summarised in table
1, for a position at 2D0 along the centreline of the jet.
In the table, with subscript 2 we note the diameter
and the velocity in the section mentioned above, at
2D0 from the nozzle. Also, v 22 v m2 indicate the rate
for kinetic energy in those sections, at 2D0 and the
contraction section.
Table 1: Jet diameter enlargement
sn=s/smax HT [m] tgα D2[mm] v22 vm2
0,5 30 0,00801 23,28 0,797
0,7 30 0,00831 23,33 0,7907
0,5 50 0,011 25,12 0,83
0,7 50 0,0114 25,23 0,818
 From the above table we observe that the effect From relations (7) and (8) we also can determine
of head is stronger than that of needle stroke. But the the partial derivative ∂Q ∂s , which is a term in the
kinetic energy losses it seems to be too large. To dynamic equation of the hydraulic turbines. In figure
validate this result, measurements are needed. 9 we represent the variations of ∂Q ∂s with respect
Also, knowing the geometrical sizes of the assem- to the needle tip – nozzle opening.
bly needle tip – nozzle and for a constant head of the
turbine, the flow rate, the theoretical diameter and 0.633
1
the mean velocity of the jet can be determined at
0.7
different needle stroke ([7], [10]).
Thus, if A0 is the nozzle outlet section and 0.4
knowing that this is dependable on the stroke s of f f(s )
the needle tip, the water velocity for this section is: 0.1 f (s)
v 0 = k v 0 ⋅ 2gH T (6) 0.2
−3
Then, the corresponding flow rate is: − 5.356× 10 0.5
0 3 6 9 12 15
Q T = A 0 ⋅ v 0 = A 0 ⋅ k v 0 2gH T (7) 0 s 15

⎡ sin 2α 2 ⎤ Figure 9. f = ∂Q ∂s variations with the needle

A 0 = π ⋅ sin α ⋅ ⎢d 0 ⋅ s − ⋅s ⎥ (8)
⎣ 2 ⎦ stroke
where: s is the stroke of the needle tip and d0 is the Table 2 shows the flow rate, the theoretical
nozzle diameter. diameter and the mean velocity of the jet when
This expression is obtained because we consider different needle strokes are considered. The head of
(for the injectors of Pelton turbines) that the water the turbine is HT = 50 m.
guiding surfaces at the exit area can be reduced to
Table 2: Different parameters of the free jet
conical surfaces, having the same axis, characterized
by the generators angles 2α - for the needle tip, sn = s/d0 Q [l/s] dtheor [mm] v [m/s]
respectively 2β - for the nozzle. 0,384 1,702 8,313 31,352
The A0 surface depends, therefore, on d0, α, and s, 0,615 2,61 10,32 31,202
and its expression is a parabola having the following 0,846 3,959 12,67 28,445
shape: By performing the measurements on the testing
A0 ≅ a⋅s - b⋅s2 [m2] rig shown in figure 1, the velocity coefficient and the
where: a = π⋅sinα⋅d0 and b = π⋅sinα⋅(sin2α)/2. corresponding diameter of the jet through a certain
Practically, for the dimensions of the injector section are determined. These parameters are varying
shown in figure 2, respectively for α = 30,50 and d0= due to supplementary losses caused by the friction
13 mm, we obtain a = 0,0207 and b = 0,6972, and with air.
the flow rate variation with respect to the needle tip
5. CONCLUSIONS
opening is presented in figure 8.
Simulation for Pelton turbines is more difficult
0.005
×
4.67210
−3 than for other hydraulic turbines because of the free
surface flow downstream the nozzle and the unsteady
0.004 flow in the bucket.
QT (s) The jet from a Pelton turbine nozzle has been
QT 0.003 numerically investigated, under the assumption of
Qs axisymmetric flow. The calculation shows that the
0.002 needle considerably influences the velocity distribution
in the jet. Also, the enlargement of the jet, the
0.001
contraction diameter and its position are determined.
We proposed an expression for velocity which
−4 taking into account the velocity distribution with the
×
6.10710 0
0 2 4 6 8 10 12 14 16 jet axis z and also with the radius r of the jet. The
1 s 15 velocity function that we determined, approximate
Figure 8. The turbine flow rate variation with respect with good accuracy the velocity distribution near the
to the needle tip- nozzle opening axis and near the free surface.

83
REFERENCES 5. Liu Jie, Fengquin, H., Masuda, J. (2002) Effect
of Free Jet Enlargement on the Bucket Flow in
1. Nonoshita, T., Matsumoto, Y. (1996) Numerical
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Simulation of Jet in a Pelton Turbine, XVIIIth
6. S. Kvicinsky, (2002) Numerical Simulation of
IAHR Symp., Valencia. Spain.
Free Jet Flow with Application on Pelton Turbines,
2. Kamiyama, T. et. al. (2002) Viscous Flow in
Doctoral thesis, IMHEF, Lausanne.
Free Jet for Pelton Turbine, XXIth IAHR Symp.,
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(2000) Experimental Investigation of Low Jet
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