UNIVERSITY OF ENGINEERING

AND TECHNOLOGY, TAXILA.

Lab Manual (07)

Power Generation

Submitted to: Sir Faisal Masood

Submitted by: Zahir Khan

Reg number: 20-EE-100

Section: ‘D’

Electrical Engineering Department

 Performance Analysis of Multi Turbine Test Set (Model
FM 46) and Study Of Kaplon Turbine

OBJECTIVES:
The objective of this laboratory experiment is:
 To comprehensively investigate and analyze the operation and performance characteristics of the
SOLTEQ Multi Turbine Test Set (Model FM 46).
 It includes an examination of its construction, the working principles of three types of turbines (Francis,
Kaplan, and Pelton).
 The generation of power through a 3kW pump and dynamometer.
  The experiment aims to provide a practical understanding of the functioning and efficiency of different
turbine types in the context of power generation from water flow.
Equipment Required:
The equipment used in this experiment are as follows:
 SOLTEQ Multi Turbine Test Set (Model FM 46) that includes:
 Control Panel, DC Generator, Turbine Set, Load Cell, Pressure Transmitter, Water Reservoir Tank, Flow
Meter, Centrifugal Pump, Dynamometer
Theory:
1. Introduction to Turbines:
Turbines are mechanical devices designed to convert the energy of a fluid (usually a liquid or gas) into
mechanical work. They are commonly used in power generation to harness the kinetic energy of flowing fluids
and convert it into rotational motion, which can then be used to generate electricity.
Types of Turbines:
In this experiment, we will study three different types of turbines:
Francis Turbine:
A radial flow turbine designed for moderate head and flow conditions.

Picture Credit: https://dizz.com/francis-turbine/

Kaplan Turbine:
An axial flow turbine suitable for low head and high flow conditions.

Picture Credit: https://www.echoscaninc.com/Secured/shop/product/mini-kaplan-turbine/

Pelton Turbine:
An impulse turbine designed for high head and low flow conditions.
Picture Credit: https://extrudesign.com/pelton-turbine-parts-construction-working-work-done-efficiency/
#google_vignette
2. SOLTEQ Multi Turbine Test Set (Model FM 46):
The SOLTEQ Multi Turbine Test Set, Model FM 46, is an educational apparatus designed to provide a hands-on
demonstration of the operation and performance characteristics of the mentioned turbines. This self-contained
unit includes various components for a comprehensive study.
Components of Model FM 46:
Control Panel:
The control panel serves as the central interface for monitoring and controlling the experiment. It displays
parameters such as voltage and current and allows for adjustments as needed.

DC Generator:
The DC generator is a crucial component used to convert the mechanical energy generated by the turbines into
electrical energy, which can be measured and analyzed.

Picture Credit: https://www.electricaleasy.com/2022/09/construction-and-working-of-dc-generator.html

Turbine Set:
This set includes three distinct turbines: the Francis turbine, Kaplan turbine, and Pelton turbine. Each turbine is
designed for specific flow conditions and has unique operational characteristics.

Picture Credit: Scribd

Load Cell:
A load cell is employed to measure and record the load or torque applied to the turbines. This data is essential for
assessing turbine performance.

Picture Credit: https://www.flintec.com/weight-sensors/load-cells/what-is-a-load-cell

Pressure Transmitter:
The pressure transmitter is responsible for measuring the pressure conditions within the turbine system. It
provides valuable information about the operational state of the turbines.

Picture Credit: https://industryparts.pk/products/wika-pressure-transmitter-s-10-in-pakistan

Water Reservoir Tank:
The water reservoir tank serves as the source of water for the experiment. It stores the fluid that will be used to
drive the turbines.

Picture Credit: https://www.pinterest.com/pin/plastic-vertical-water-tanks-for-sale--374924737704132148/

Flow Meter:
The flow meter accurately measures and records the rate of water flow into the turbine system. This data is
crucial for analyzing turbine efficiency.
Picture Credit: https://apureinstrument.com/flow-meter/magnetic-flow-meter/ayt-digital-liquid-magnetic-
flow-meter/

Centrifugal Pump:
The centrifugal pump is responsible for transferring water from the reservoir tank into the turbine casings. It
ensures a continuous flow of fluid to drive the turbines.

Picture Credit: https://www.serfilco.com/products/pumps/magnetic-coupled-pumps/uc-centrifugal-pump/

Dynamometer:
A dynamometer is used to measure the mechanical power output of the turbines. It quantifies the work done by
the turbines during the experiment.

Picture Credit: https://www.fab-ent.com/evaluation/strength/baseline-bims-digital-dynamometers/

Kaplan Turbine Set:

The Kaplan turbine, named after Austrian engineer Viktor Kaplan, is a type of water turbine used for converting
the energy of water into mechanical power. It is commonly employed in hydroelectric power plants, particularly
in locations with low to medium head and high flow rates. The Kaplan turbine is known for its high efficiency
and adaptability to variable operating conditions, making it a versatile choice for harnessing hydraulic energy.
Components of the Kaplan Turbine Set
Kaplan Turbine:
 The core component of the set, the Kaplan turbine, is a propeller-like device with adjustable blades. The
adjustability of the blades allows for precise control of the turbine's performance, making it well-suited for
varying flow rates and load demands.
Runner:
The runner is the rotating part of the Kaplan turbine where water flows over and causes it to spin. It is directly
connected to a generator or other mechanical equipment for power generation.
Adjustment Mechanism:
Kaplan turbines feature an adjustment mechanism that allows operators to change the angle of the turbine blades.
This adjustment regulates the flow of water and, consequently, the turbine's output power.
Draft Tube:
A draft tube is often integrated into the Kaplan turbine setup to efficiently redirect water flow from the turbine
outlet, minimizing energy losses and improving overall efficiency.
Load Cell:
A load cell is employed to measure the mechanical load or torque applied to the turbine runner. This data is
crucial for calculating power output and efficiency.
Pressure Transmitter:
A pressure transmitter is used to monitor the pressure at various points within the turbine setup, providing
insights into system performance.
Flow Meter:
The flow meter measures the rate of water flow into the turbine, allowing for accurate determination of the flow
rate during experiments.
Operating Principles of the Kaplan Turbine
 The Kaplan turbine operates on the principle of hydrodynamic energy conversion. Here's a simplified
overview of its operation:
 Water enters the turbine through a penstock, which is a pipeline that directs water from a reservoir or
source.
 The adjustable blades of the Kaplan turbine guide the water flow and regulate the angle of attack. By
changing the blade angle, the operator can optimize the turbine's performance for varying water flow
conditions.
 As water strikes the blades, it imparts kinetic energy to the runner, causing it to rotate.
 The rotating runner is connected to a generator or other machinery, and the mechanical energy is
converted into electrical power or performs other useful work.
 After passing through the turbine, water is directed through a draft tube to a lower elevation, reducing its
kinetic energy and minimizing energy losses.
Importance of Kaplan Turbine Studies
Studying the Kaplan turbine in a laboratory setting offers several educational and practical benefits:
Hydroelectric Power Generation:
Understanding the Kaplan turbine is crucial for designing and operating hydroelectric power plants efficiently, as
Kaplan turbines are widely used in such facilities.
Variable Load Applications:
Kaplan turbines are known for their adaptability to variable load conditions, making them valuable in scenarios
where power output needs to be adjusted frequently.
Renewable Energy:
As interest in renewable energy sources grows, knowledge of Kaplan turbines becomes increasingly relevant, as
they contribute to the sustainable generation of electricity from water resources.
 Mechanical Engineering:
The Kaplan turbine provides an excellent case study for mechanical engineering students, offering insights into
fluid dynamics, energy conversion, and control systems.

Procedure:
1. Preparation
 Ensure that the SOLTEQ Multi Turbine Test Set (Model FM 46) and all associated equipment are in good
working condition and properly connected.
 Fill the water reservoir tank with approximately 100 liters of water to ensure a sufficient water supply for
the experiment.
 Verify that the control panel is powered and properly calibrated.
2. Initial Setup
 Set up the experiment area with proper ventilation and lighting. Ensure safety measures are in place,
including access to emergency shutdown procedures.
 Review safety guidelines and precautions with all participants, emphasizing the importance of following
safety protocols.
3. Turbine Selection
 Choose the kaplan turbine for the initial part of the experiment.
 Align the equipment setup for the kaplan turbine installation. Ensure that the turbine is securely mounted
in the test bench.
4. Turbine Operation
 Start the centrifugal pump and gradually increase the pump motor speed to achieve a flow rate of
approximately 5 liters per second.
 Observe the kaplan turbine's operation and record the following values:
Calculations:
1. Turbine rotation speed (RPM) = 400 RPM
2. Turbine output power (measured by the dynamometer) = 2 kW
3. Pressure reading at turbine inlet (from the pressure transmitter) = 3 bar
4. Flow rate (measured by the flow meter) = 5 L/s
5. Monitor and record electrical parameters displayed on the control panel:
Voltage = 129 V
Current = 0.33A
5. Data Collection
 Collect data at 1-minute intervals for a duration of 10 minutes.
 Ensure that data is recorded accurately and consistently.

6. Turbine Shutdown
 Gradually reduce the pump motor speed to lower the flow rate.
 Safely shut down the kaplan turbine following the manufacturer's recommendations.
 Record final data for this turbine configuration.

7. Turbine Switch and Repeat

 Switch the equipment setup for the Kaplan turbine.
 Adjust the pump motor speed to achieve a flow rate of approximately 8 liters per second.
 Collect data for the Kaplan turbine following the same procedure as outlined above.
 8. Data Analysis
 Calculate the efficiency of kaplan turbine type using the formula:

Efficiency (%) = (Electrical Output Power / Hydraulic Input Power) x 100

Given values:

 Voltage = 127.9 V
 Current = 0.33 A
 Flow Rate = 5 L/s
 Pressure = 3 bar (equivalent to 300,000 pascals)
 Density of Water = 1,000 kg/m³
 Gravitational Acceleration = 9.81 m/s²
 Corrected Turbine Input Power = 447.3 watts
Power Generated:
1. Power Generated (in watts) = Voltage × Current
2. Power Generated = 127.9 V × 0.33 A
3. Power Generated ≈ 42.207 W

Efficiency:
 Efficiency (%) = (Power Generated / Turbine Input Power) × 100
 Efficiency = (42.207 W / 447.3 W) × 100
 Efficiency ≈ 9.44%
9. Cleanup
 Shutdown all equipment and power sources in an orderly manner.
 Disconnect and properly store equipment components.
 Drain the water from the system and return it to the reservoir tank.
Graphs:
In this graph, we'll take values for power generated (in watts) and efficiency (in percentage) for different turbine
setup.
Assumed Values:
 Power Generated (Watts): [30, 45, 60, 75]
 Efficiency (%): [6%, 9%, 12%, 15%]
 Torque vs power graph :
 We changed the values of load and speed rpm, this is general graph and it will look like this:

Lab Appratus Setup:

Lesson Learned:
Overall, the experiment with the SOLTEQ Multi Turbine Test Set provided a rich learning experience, offering
practical insights into the world of turbine-based power generation and fostering a deeper appreciation for the
complexities of energy conversion systems.