Vishwakarma Institute of Technology, Pune

Department of Mechanical Engineering

Hydraulic Machines And Fluid Power

(ME 3253)
Course Project on

Design and Analysis of Turgo Turbine

Sr.No. Group Members Roll No.

1 Piyush Kawade 32
2 Akshaan Kaware 33

3 Harshada Kulkarni 47

4 Kshitija Kulkarni 49

5 Aarya Kurlekar 52

Guided by: Prof. (Dr.) Laxmikant D. Mangate

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 Sr.No Index Page No.

1 Introduction 2

2 Literature Review 3

3 Methodology 4

4 Solidworks Model of turgo turbine 8

5 Boundary conditions for structural analysis 10

6 Results and Discussion 13

7 Conclusion 16

8 References 16

ABSTRACT:
The present research work describes the development of Turgo turbine blades on the
Solidworks software. Finite element simulation (Ansys 2021R1) has been used for
analysis of stress and total deformation produced inside the Turgo impulse turbine.
Finite element simulation is effective when it is used to analyse the strain and stress
distribution. It has been observed during analysis that the maximum stress occurs at the
root of the blade suction side.

KEYWORDS:
Hydropower, Turgo turbine, Electricity, pico hydro, Turgo, Ansys, Solidworks.

INTRODUCTION:
Energy is required in each field of commercial and human activities. Energy generation
is one of the key factors for economic and social development in both the developed
and

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developing nations of the world. Presently in India the total installed capacity including
all the resources is 182344.62 MW, of which the share for hydro energy is 21.22 % . And
the turgo turbine is one of the hydro energy sources. The Turgo turbine is a medium-
head water turbine with an impulse design. Turgo turbines in operation have an
efficiency of around 87 percent. Turgo turbines achieve efficiency of up to 90% in
industrial and lab tests. It operates with net heads ranging from 15 to 300 metres. For
specific uses, the Turgo wheel, designed by Gilkes in 1919 as a variation of the Pelton
wheel, offers certain benefits over Francis and Pelton designs. The runner, for starters,
is less expensive to produce than a Pelton wheel. Second, unlike Francis, it does not
require airtight housing. Third, it has a higher specific speed and can handle more flow
than a Pelton wheel of the same diameter, resulting in lower generator and installation
costs. Turgos function in a head range that is shared by Francis and Pelton. While there
are many huge Turgo installations, they are also popular for small hydro where cost is a
major consideration. So, we are designing turgo turbine design and analysis in ansys for
different materials like stainless steel, structural steel etc.

LITERATURE REVIEW:

1. A 2013 study on pico-hydro Turgo turbines by Williamson revealed that the

optimum inlet angle depends on the nozzle diameter. For example, for a 20 mm
nozzle, αopt ¼ 10 but 30 mm nozzle, αopt ¼ 20, which suggests that a larger nozzle
diameter requires a larger jet angle. In 2012, Cobb reported αopt to be 18-20 for a
Turgo of 28 blades and comparable PCD to Williamson's, which used only 9 blades.
Furthermore, in 2011, Koukouvinis et al. reported an optimum jet inlet angle of 30,
with a 7–10- point drop in efficiency at angles ± 10. Other published sources have
assumed αopt
¼ 25, 20, and 30 but without an explanation as to what factors lead to such different
values.
2. According to Equation, the relative exit angle, β2, should be as small as possible;
however, if the angle is too small the effluent water will interfere with the oncoming
blade. Experiments indicate that a discharge angle of 15-20 performs the best.
3. In his review of the Turgo turbine's history, Wilson stated that another
dimensionless ratio, D/d, decides all the main characteristics of an impulse turbine.
While a smaller D/d is desirable for faster speeds, if it becomes too small it could
result in flow limitations. Several sources report that the ratio of D/d for a Pelton
wheel should be no less than 10:1. The Turgo turbine can cut this ratio in half, at
least. In a recent Turgo turbine study, Williamson tested five nozzle diameters: 10,
15, 20, 25, and 30 mm. The best performing design was d = 20 mm, which
corresponds to 1.75 w/d and 7.5 D/d.
4. While these design equations exist for the Pelton, no empirical formula or suggested
an optimum number of blades exists for the Turgo turbine. The number of blades
reported in the literature varies drastically without explanation. Williamson's
turbine used 9 blades, while Cobb's used 28 blades for similar PCDs. Furthermore, a
sketch in Harvey's Micro Hydro Design Manual depicts that the jet should be split
between three blades simultaneously, suggesting that the ratio of nozzle diameter to
blade spacing ratio (d/s) is important. Gulliver and Singh recognize that additional
blades could be beneficial because they would allow the turbine to handle higher
flows, which is akin to adding multiple nozzles. Nevertheless, the optimum number
of blades and the interactions amongst blade number, jet angle, and nozzle diameter

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has not been thoroughly investigated for the Turgo turbine.

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TYPES OF TURBINES:

The word “Turbine” comes from Latin words “turbo”, means “vortex”, and invented by
French engineer Claude Burdin in 1822. The first turbine is used for industrial purposes
and later it was used for generating electricity, and irrigation. The two main types of
turbines are impulse and reaction turbines. Impulse turbines are Pelton, Turgo and
Crossflow turbines. Reaction turbines are Kaplan, Francis, Darrius, Propeller and
Archimedes Screw turbines. Impulse turbines are used in high head and low flow rates
where else reaction turbines are used for low head and high flow rates. Pelton turbines
are used in high heads, low flow rates. Turgo turbines are used mainly for medium
heads. Turgo turbines are same geometry like Pelton turbines and shape is one half of
Pelton turbine bucket. It has higher specific speed for the same generated power with
Pelton turbine even though it has complex design to manufacture and the specific speed
is twice the Pelton runner. The specific speed is increased when the number of jets is
increased. Normally, the water jet angle is 20 degree for the highest impulse of the
runner. The water impinges from one side and exits from other side of the Turgo
turbine. Therefore, there is no disturbance of incoming water flow to effect turgo
turbine efficiency and the pressure is not change when water goes through the blade.
The turgo turbine is widely used in micro hydro power plant because the manufacturing
cost is lower than other water turbines. Figure (a) shows the velocity flow diagram of
Turgo turbine blade.

THEORY:

Figure 1 Difference in direction of water flow between the Pelton (left) and Turgo
(right) Turbines

The Turgo turbine is an impulsive turbine. It is same as the Pelton turbine but the
runner is split in half. Turgo turbines are used for medium and high head .The Turgo
turbine works between thehead 15 m to 300 m. The Turgo turbine is an impulse
turbine; water not change the pressure as it moves through the turbine blades. The
water energy is converted into kinetic energy with helpof a nozzle. The high speed of
water jet then directed on to the turbine blades and after strikingthe water to the
turbine blades the turbine is rotated at high speed. Then the shaft is rotated andthe
electricity is generated in generator. Water exits with a small energy. Turgo Turbine
runner same as Pelton runner but it is split in half. For the same power output the Turgo
turbine runneris one half the diameters of the Pelton runner, and the specific speed is
twice the Pelton runner. The Turgo turbine can handle a greater water flow than the
Pelton turbine because the exiting water doesn't interfere with buckets. The specific
speed of Turgo turbine is

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between the Francisand Pelton.in this single and multiple nozzle can used. If the number
of jets are increased the specific speed of the turbine is increased.

Figure 2 Velocity diagram of turgo turbine

Jet Ratio, Jr = 𝐷 /dj

Jet Velocity Vj= Cv√2𝑔𝐻,

Absolute Velocity, U = KuxVj,

𝜋𝐷𝑁
Turbine Speed, U1 =
60
√𝑃
Specific Speed, Ns= 5
𝐻4
𝐷
Number of buckets, Z = 15 +
2𝑑𝑗

Flow Velocity at inlet, Vf1 = sinα1 xVj

Vf1
Whirl Velocity at inlet, Vw1 =
tanα1

Absolute Velocity at outlet,

V2 2 = Vr2 2 +U2 2 - 2Vr 2U2cosβ2

Whirl Velocity at outlet, Vw2 = √ 𝑉22 − 𝑉f22

Jet force, F = 𝜌 Q (Vw1+Vw2) z

The overall efficiency of the turbine is, Overall efficiency, ηo = ηhηoηm

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 DESIGN CALCULATIONS FOR TURGO TURBINE:
1. Calculation of the Net Head-
For the pico-hydro scheme, hydraulic head H can be calculated at any location
where elevation z, pressure p, and velocity v are known using
Hg = p/ρg+ v2/2g+z
The net Head Hn = Hg - Hf

Hg = The gross head which is the vertical distance between water surface level at
the intake to the turbine
Hf = Total Head losses due to open channel. These losses approximately equal to
6% of gross head.
We are going to design the turgo turbine for the head of 60m. For the sample
purpose we decided to go for 60m, 70m, 80m, 90m and 100m as the Turgo turbines
are operated for more than 50mhead.

2. Calculation of water flow rate

The water flow rate can be calculated by the measuring the river or stream flow
velocity and its cross-sectional area, then
Q=A×V
Where,
A= Area of channel V=Velocity of stream
As we can’t find the actual parameters, we considered the flow rate for 60m head as
10lps i.e.
0.01 m3/s.And for further calculations, we found out the flow rate for respective heads.

3. Calculation of Power-
The available hydraulic power, PH, of a hydraulic turbine is a function of the head

and flow: PH = ρ*g*H*Q

4. Calculation of the Turbine Speed (N)

The Correlation between the specific speed (Ns) and the Net Head is given
Ns= 85.49×√Nj/Hn0.243
Where,
Nj =No. of jet N= Ns*H 1.25/√P

5. Runner Design
The mean velocity of the free jet emerging from the nozzle of the turbine is determined
from the net head, by the equation
Vj = Cv√2gHn
At the best efficiency point the circumferential speed of the runner is connected with the
jet velocity via the relation.
u = (0.46)*Vj
Hence the Diameter or runner is

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 D = 60*u/πN
Where N is the speed of runner in rpm
6. Diameter of Nozzle or Jet
d = √4Q/πVj
7. Number of Buckets

Z = 15 + D/2d
8. Efficiency of turbine

Torque T= Q*D*(Vj - U)
Power transferred by the turbine shaft
Ps = 2π NT/60
Efficiency ɳt = Ps /Pj
We know,
For the turgo turbine design for head 60 m:

Power (W) 5000

Gross head 60
Net head 56.4
Speed Ratio (ku) 0.46
No. of Jet 1
Cv 0.98
Jet angle 200
Table 1 specification for designing

1. P =ρgHnQ
5000 = 1000×9.81×56.4×Q
Q =0.090 m3/s

2. Vj=Cv√2𝑔Hn
Vj =0.98√2 × 9.81 × 56.4 =32.6 m/s
3. U = 0.46 Vj =14.996 m/s
4. Ns =85.49 /56.40.243 =32.08 Rpm
5. N = (32.08×56.45/4)/√5 =2217.42 Rpm
6. D= (60×U)/𝜋𝑁 = (60×14.996)/𝜋𝑁 =0.128 m

7. d =√4𝑄/√𝜋𝑉𝑗 =0.0189 m
8. Z =15 +D/2d =15 + 0.128/2*0.0195 ≈ 18
9. T = 𝑄 ∗ 𝐷 ∗(Vj-U) =0.0215

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10. Ps =2𝜋𝑁𝑇/60
Ps = 4.82 kW
11. Efficiency =𝜂 =Ps/P =0.964 =96.4%

DESIGNING IN SOLIDWORKS:

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 55

MATERIAL SELECTION:

1 Material Stainless Steel Titanium alloy Structural steel

2 Nodes 2804 2804 2804

3 Elements 11726 11726 11726

4 Density 7750 kg/m3 4620 kg/m3 7850 kg/m3

5 Compressive yield strength 2.07 ×108 Pa 9.3×108 Pa 2.5×108 Pa

6 Tensile yield strength 2.07 ×108 Pa 9.3×108 Pa 2.5×108 Pa

7 Reference temperature 22 0 C 22 0 C 22 0 C

8 Poisson’s ratio 0.31 0.36 0.3

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 Table 2 Physical parameters and mechanical properties of metals used in the Turgo
impulse turbine.

Boundary conditions :

1. Fixed support:

2. Force:

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 3. Rotational velocity:

Meshing:

The meshing of a Turgo blade.

1. Material-Stainless Steel

Equivalent stress on the Turgo blade (Stainless Steel)

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 Total deformation on the Turgo blade (stainless Steel)

2. Material: Titanium Alloy

Equivalent stress on the Turgo blade (Titanium Alloy)

Total deformation on the Turgo blade (Titanium Alloy)

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3. Material-Structural Steel :

Equivalent stress on the Turgo blade (Structural Steel)

Total deformation on the Turgo blade (Structural Steel)

CFD:
We performed CFD on the turbine wheel to visualize the flow of water around it. It
also helps us in finding the velocity of water and the pressure exerted on the
buckets at a certain velocity of water (5 m/s). The Spalart Allmaras turbulence
model was used in the analysis as it gives decent results for such cases.

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RESULTS AND DISCUSSIONS:

Hg (m) Hn (m) Q Ns U Vj D d (m) No. of T (Nm) P Ps ɳt

(m3/s) (rpm) (m/s) (m/s) (m) Bucket (kW) (kW) (%)
s

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 60 56.4 0.0096 32.08 14.84 32.26 0.128 0.0195 18 0.0215 5 4.82 96.4

70 64.8 0.0082 30.90 16.03 34.85 0.118 0.0183 18 0.0183 5 4.84 96.8
3
80 75.2 0.0072 29.92 17.13 37.25 0.111 0.0162 18 0.0162 5 4.87 97.4
4
90 84.6 0.0064 29.07 18.17 39.51 0.104 0.0143 18 0.0143 5 4.88 97.6
0
100 94 0.0057 28.39 19.16 41.65 0.098 0.0127 18 0.0127 5 4.91 98.2
6

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 Table 3 Calculation table for head 60,70,80,90,100m
PERFORMANCE CHARACTERISTICS:

DISCHARGE VS SPECIFIC SPEED)

0.012

0.01
0.0096

0.008 0.00823
0.00724
0.0064
0.006 0.00576
DISCHARGE (Q)

0.004

0.002

0
32.08 30.9 29.92 29.07 28.39
SPECIFIC SPEED (Ns)

NET HEAD VS SPECIFIC SPEED

10094

90 84.6

80 75.2

70 64.8
56.4
NET HEAD (Hn)

60

50
40
30
20
10
0

32.08 30.9 29.92 29.07 28.39

SPECIFIC SPEED (Ns)

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 POWER OUTPUT VS NET HEAD
4.924.91

4.9
4.88
4.884.87
POWER OUTPUT (Ps)

4.86
4.84
4.84
4.82
4.82

4.8

4.78

4.76
5 6 . 46 4 . 8 75.2 84.6 94
NET HEAD (Nh)

Graph 1 represent when the discharge is decreased the specific speed is also decreased.
Graph 2 shows that when the Net Head is decreased the specific speed is increased.
Graph 3 shows that when the Net Head is increased the power output is also increased.

Metals Stainless steel Structural steel Titanium alloy

Maximum stress (VON 30.38 N/mm 30.498 N/mm 29.466 N/mm

MISES)

Minimum stress (VON 0.0021459 N/mm 0.002031 0.0015457

MISES) N/mm N/mm

Maximum Deformation 0.0023633 mm. 0.0022798 mm 0.0046859 mm

Table 4 ANSYS results for different materials

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CONCLUSION:
As discharge increases the specific speed also increases hence they are directly
proportional. Also, as net head increases specific speed decreases and power output
increases.
Total deformation observed for cut out and survival speed ranges from0.0022798 mm
to 0.0046859 mm and stress values ranges from 29.466 N/mm to 30.38 N/mm for
loading conditions of force 174 N and rotating speed 116 rps at 22 0 C temperature. As
per the review, it is clear that stainless steel is most effective performance enhanced
material. This work of turgo turbine bucket analysis shows best results for material
stainless steel total deformation and titanium alloys for equivalent (Von-Mises) shear
stresses. But if we think, according to some conditions like cost, efficiency, relatively
high strength, good corrosion resistance and large internal friction or damping
capacities and according to above analysis also in terms of total deformation and
stress(Von -mises) the stainless steel is the most efficient and better material than any
other materials for the turgo turbine. At a force of 174 N, the design made on
Solidworks software is safe.
Thus, the turgo turbine is best for the pico hydro power generation for rural
electrification as it satisfies required specification for it.

REFERNCES:

1. Williams A, Simpson R. Pico hydro-reducing technical risks for rural electrification

Renew Energy 2009.
2. Sourabh KHURANA , Varun GOEL and Anoop KUMAR.FEM Analysis of Turgo Impulse
Turbine Blade,Hmirpur,India,Walailak Journal,28 march-2013.
3. Vipin Uniyal, Nikhil Kanojia, Kshitij Pandey Sivalik.Design of 5kw hydro power plant
using Turgo turbine,IJSER,Volume 7,Dec-2016

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