PROPELLER TYPE TURBINE

Introduction
If the available pressure head is given, the only way to increase the power output of a turbine is to
increase the flow rate through the turbine. This can be done by increasing the cross-sectional area
of the flow. In the case of the pelton wheel, the flow area is very small (the cross-sectional area of
the nozzle), with radial inward flow turbine, the flow area is larger. To get an even larger flow
rate, axial flow turbines are employed.
A series of guide vanes in the spiral casing is utilized to give the water a whirl motion. Beyond the
guide vanes the water is directed in a downward direction. The water now flows downwards but
simultaneously it has a whirl movement. It thus has a spiraling flow path downward, when it enters
the rotor. The whirl velocity is slower at the outside, increasing hyperbolically to the center
(according to free vortex theory). The peripheral velocity of the blades however, increases with
the radius, so to ensure a shock-free entrance into the rotor the blades of the rotor do not have a
constant angle relative to the shaft, but in fact the angle increases towards the outside, i.e. the
blades are twisted.
 Fig. 1. A Kaplan turbine P=31 MW, N=95 r/min, H=16 m
A propeller with fixed blade angles can only deliver its maximum efficiency over a very limited
region of flow rates. The reason for this is that at flow rates other than ideal, the blades are not
lined up with the entering water direction, and shock losses occur. Also, the exit velocity leaving
the rotor should be purely axial otherwise the whirl component represents additional kinetic energy
losses. A further complication could also be that the rotor, the pressure in the center of the vortex
could become so low that cavitation could occur, a situation that must be avoided at all costs.
To increase the operational range of the turbine, the propeller blades are made adjustable – it is
then called a Kaplan turbine. The adjustment of the inlet angle of the blades is obtained by means
of a hydraulic servo motor which is mounted in the hub of the rotor. The rotor blades and the guide
vanes should always be set so as to achieve the maximum efficiency (thus maximum power for a
certain flow rate). For our purpose this will mean that the outlet velocity is then purely axial (thus
𝑉𝑤2 = 0 and 𝑉𝑓2 = 𝑉2).
The forces on the blades are very large and to obtain sufficient strength yet at the same time
keeping them streamlined, they are made thick in the middle tapering off towards the upstream
and downstream edges. The material is usually cast steel, bronze or stainless steel.
Theory
Figure 2, showing an axial flow turbine and the symbols used to indicate various dimensions.

Fig. 2. An axial flow turbine

Subscript 𝜃 denotes the position where the water leaves the guide vanes, o indicates outside
diameter, i, the inside diameter, 1 upstream edge (inlet) and 2 downstream edge (exit).
Assume now the exit angles of the blades make an 𝜃 with the tangential direction and the water
has an absolute velocity 𝑉𝜃 when leaving the guide vanes, then the whirl velocity at section ‘A-
A’ where the water leaves the guide vanes is
𝑉𝑤𝜃 = 𝑉𝜃 cos 𝜃
The water now flows as a free vortex of which the outer diameter decreases from 𝐷𝜃 to 𝐷0 . For a
free vortex,
𝑉𝑤 𝑟 = 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 = 𝐶
i.e. 𝑉𝑤𝜃 𝑟𝜃 = 𝑉𝑤𝑜 𝑟𝑜 = 𝑉𝑤1 𝑟1 = 𝐶
The whirl velocity is therefore smaller at the outside than the inside. We further assume that the
axial velocity of the water 𝑉𝑓 is the same everywhere.

Consider annular flow element radius r and thickness 𝜕𝑟 just before it enters the propeller and
having a whirl velocity 𝑉𝑤1

Fig. 3
Area of the ring is 𝜕𝐴. The mass flow rate through this ring element is 𝜕𝑚̇ = 𝜌𝑉𝑓 𝜕𝐴

To obtain maximum power, the rotor must change the incoming whirl velocity such that the
water leaves the blades purely axial (i.e. 𝑉𝑤2 = 0). The torque on the ring element is thus the
difference between the incoming and outgoing moment of momentum.
i.e. 𝛿𝑇 = 𝛿𝑚̇(𝑉𝑤1 − 𝑉𝑤2 )𝑟 = 𝛿𝑚̇𝑉𝑤1 𝑟 = 𝜌𝑉𝑓 𝛿𝐴𝑉𝑤1 𝑟 = 𝜌𝑉𝑓 𝑉𝑤1 𝑟𝛿𝐴

but 𝜌𝑉𝑓 𝑉𝑤1 𝑟 is constant for the whole region (because 𝑉𝑓 is constant and 𝑉𝑤1 𝑟 is constant). Thus
the total torque for the whole area A is

𝑇 = ∫ 𝜌𝑉𝑓 𝑉𝑤1 𝑟𝑑𝐴 = 𝜌𝑉𝑓 𝑉𝑤1 𝑟 ∫ 𝑑𝐴 = 𝜌𝑉𝑓 𝑉𝑤1 𝑟𝐴 = 𝜌𝑄𝑉𝑤1 𝑟

𝐴 𝐴

Where 𝑉𝑤1 is the whirl velocity of the water at any specific radius r, upstream of the propeller.
The power (maximum) developed is thus 𝑃 = 𝑇 × 𝜔
i.e. 𝑃 = 𝜌𝑄𝑉𝑤1 𝑟 × 𝜔 but 𝑟 × 𝜔 = 𝑢
𝑃 = 𝜌𝑄𝑉𝑤1 𝑢.
Where once again 𝑉𝑤1 is the whirl velocity of the water upstream of the propeller at any specific
radius and u the peripheral velocity of the propeller at the same radius.
Efficiencies:
𝑢𝑉
The hydraulic efficiency 𝜂ℎ𝑦𝑑𝑟 = 𝑔𝐻𝑤1
𝑒𝑓𝑓

𝑃
𝑚𝑒𝑐ℎ
The overall efficiency 𝜂𝑜𝑣𝑒𝑟 = 𝜌𝑔𝑄𝐻
𝑒𝑓𝑓

𝑃
𝑚𝑒𝑐ℎ
The mechanical efficiency 𝜂𝑚𝑒𝑐ℎ = 𝜌𝑄𝑢𝑉
𝑤1

Example
The guide vanes of a Kaplan turbine cause an inward flow with an absolute velocity of 2.4 m/s
making an angle of 45° with the tangential. The diameter at the exit from the guide vanes is 2.35
m and the breadth (height) of the guide vanes is 0.6 m. the rotor rotates at 240 rev/min. Calculate
a. The whirl velocities at the tip of the rotor (diameter 1.3 m) and at the hub (diameter 0.47
m)
b. The maximum hydraulic power that could be developed,
c. The inlet and outlet angles of the rotor blades at radii 0.235 m, 0.415 m and 0.65 m.