Professional Documents
Culture Documents
Turbomachinery
These presentations are prepared by Dr. Cneyt Sert Department of Mechanical Engineering Middle East Technical University
Ankara, Turkey
csert@metu.edu.tr
Please ask for permission before using them. You are NOT allowed to modify them. 3-1
Fluid Machinery
Fluid machinery is used to convert hydraulic energy to mechanical energy or vice versa.
Power absorbing Work is done on the fluid Mechanical Energy Hydraulic Energy
Power producing Work is done by the fluid Hydraulic Energy Mechanical Energy
Pump
Turbine
3-2
Closed volume expands and contract, sucking the fluid in or pushing it out.
http://speakeasies.biz
http://www.bicycleaccessories.us
http://en.wikipedia.org
Human heart
Tire pump
Gear pump
3-3
Turbomachines use rotating shafts with attached blades, vanes, buckets, etc.
In ME 306 well study turbomachines (mostly pumps) as black boxes, i.e. without analyzing the details of flow fields inside them.
http://en.wikipedia.org
http://www.britannica.com
Axial fan
Centrifugal pump
Pelton wheel
Classification of Turbomachines
Turbomachines
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Pumps increase the pressure of a liquid without changing its velocity considerably. Shown centrifugal (radial) pump is the most common type. Visit www.standartpompa.com to get more information on sizes and capacities.
3-5
Power absorbing
Incompressible Pump Propeller Compressible
Power producing
Incompressible Compressible
Propellers are very similar to fans, but they are used to generate thrust. Marine propellers work with incompressible water water and aircraft propellers work with compressible air. Pressure difference between the front and back surfaces of the blades create the thrust.
3-6
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Propeller Fan
The main difference between fans, blowers and compressors is the pressure difference they create.
Fans create small pressure difference. Their main purpose is to put high amount of fluid into motion. Shown is axial fan of a wind tunnel.
3-7
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Compared to compressors, blowers work with higher amouts of fluid at lower pressure ratios. They are mostly centrifugal type. Shown is an industrial type blower.
3-8
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Compressors work with smaller flow rates, but create very high pressure ratios. Shown is a multi-stage axial compressor. Compressors are used in gas and steam turbines, natural gas pumping stations, turbochargers, etc.
3-9
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Propeller Fan Blower Compressor Pelton wheel Pelton wheels are impulse type turbines commonly used to generate electricity. They convert kinetic energy of a high speed liquid into mechanical energy. Largest ones used at hydraulic power plants have capacities up to 200 MW.
3-10
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Propeller Fan Blower Compressor Pelton Hydraulic wheel turbine Hydraulic turbines are used at dams to generate electricity using high pressure water. Common types are Francis and Kaplan. Shown are the runner blades of the Francis turbines used at Three Gorges Dam / China. Atatrk Dam has a capacity of 8 x 300 MW.
3-11
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Propeller Fan Blower Compressor Pelton Hydraulic Steam wheel turbine turbine
Steam turbines are used at power plants to generate electricity using high temperature and high pressure steam.
80 % of worlds electricity is produced by steam turbines. Afin-Elbistan thermal power plant has a capacity of 4 x 344 MW.
3-12
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Propeller Fan Blower Compressor Pelton Hydraulic Steam Gas wheel turbine turbine turbine Gas turbines are similar to steam turbines, but they use high temperature and high pressure combustion gases.
A Boeing 777 is powered by 2 turbofan engines, each generting a thrust of ~500 kN.
To learn how a turbofan engine operates visit http://www.youtube.com/watch?v=GpklBS3s7iU
3-13
Power absorbing
Incompressible Pump Compressible
Power producing
Incompressible Compressible
Propeller Fan Blower Compressor Pelton Hydraulic Steam Wind Gas wheel turbine turbine turbine turbine
Power absorbing
Uncased Axial Flow Propeller Cased Impulse
Power producing
Reaction
3-15
Power absorbing
Uncased Axial Flow Propeller Axial Cased Impulse
Power producing
Reaction
Out Fluid enters an axial flow turbomachine parallel to the axis of rotation. Fluid leaves the machine also in axial direction. In
3-16
Power absorbing
Uncased Axial Flow Propeller Axial Cased Radial Impulse
Power producing
Reaction
In Out
Power absorbing
Uncased Axial Flow Propeller Axial Cased Radial Mixed Impulse Pelton wheel
Power producing
Reaction Axial (Kaplan)
Wind turbine
Kaplan turbines are axial flow machines. They are preferred for low head and high flow rate configurations. Their capacities are less than Francis type, less than 200 MW. They can provide efficiencies higher than 95 %.
3-18
Power absorbing
Uncased Axial Flow Propeller Axial Cased Radial Mixed Impulse Pelton wheel
Power producing
Reaction Axial (Kaplan) Radial Mixed (Banki) (Francis)
Wind turbine
Francis turbines are the most widely used turbomachines for hydropower. They are of mixed flow type. They can provide more than 800 MW power. For more information http://www.voithhydro.com
3-19
http://pdf.directindustry.com
3-20
Most important part is the impeller. It may have different designs such as Backward-curved, radial or forward-curved Closed (shrouded) or open
Open, radial Open Closed (Shrouded)
3-21
Pump Head ()
Datum
Consider the BE between the inlet (suction) and outlet (discharge) of a pump.
2 2 + + = + + 2 2
Pump head
3-22
i.e. pump head is the pressure rise across the pump expressed as a head.
Pump head is directly related to the power delivered to the fluid, known as water horsepower
=
for fluid
Pump head can be defined as the power delivered to the fluid per weight of the fluid flowing through the pump in unit time (weight flow rate).
3-23
Efficiency of the pump is defined as (see the distributed handout for more details) = < 1
3-24
Performance of Turbomachines
Important quantities of interest for a turbomachine are Volumetric flow rate (discharge, capacity)
Head
Size of the machine Rotational speed
or
For a pump, fundamental characteristic (performance curve) is a plot of vs. at a given rotational speed . It is customary to plot and on the same figure. For a turbine, fundamental characteristic is a plot of vs. at a given head of . It is customary to plot and on the same figure.
3-25
Free delivery
Note that all these curves are for a given rotational speed .
Flow coefficient :
Head coefficient :
2 2
Power coefficient :
= 3 5
Reynolds number :
1 = = 2
3-28
where 1 and 2 refer to two different operating conditions of similar pumps. These three equalities are known as affinity laws.
Exercise : Show that when affinity laws are satisfied, efficiencies of two similar operating points (homologous points) are equal.
Exercise : How do nondimensional performance curve ( vs. ) of two geometrically similar pumps compare with each other? What about vs. and vs.
3-29
Pump sizes are the same and size parameter drops from nondimensional groups, resulting in the following simplified affinity laws 1 2 = 1 2 , 1 2 2 = 2 , 1 2 1
3 1
2
3 2
3-30
(3 /)
() ()
0
40 0 0
0.1
41 114.9 0.35
0.2
41 134.1 0.60
0.3
40 152.9 0.77
0.4
38 175.4 0.85
0.5
34 196.2 0.85
0.6
26 204.1 0.75
0.7
15 187.3 0.55
3-31
= 60 1200 2
It is desired to deliver 0.03 m3/s of water against a head of 36 m. Determine a) speed of the pump b) efficiency of the pump c) power consumption of the pump
Point 1
(a point similar to point 2) 1 = ? 1 = ? 1 = 1500 Point 2 60 50 40 [] 30 20 10 0 0 0.01 0.02 [3 /] 0.03 0.04
3-32
Rotating speeds are the same. drops from nondimensional groups, resulting in the following simplified affinity laws 1 2 3 = 3 1 2 , 1 2 2 = 2 1 2 , 1
5 1
2
5 2
3-33
It is desired to deliver 0.1 m3/s of water against a head of 70 m. For these requirements it is thought that using a similar pump with a smaller impeller would be more efficient.
a) Determine the required percent reduction in impeller diameter. b) Determine the percent decrease in power consumption.
120 Point 1 (a point similar to point 2) 1 = ? 1 = ? 1 = ? 100 80 [] 60 40 20 0 0 0.1 [3 /] 0.2 0.3 Point 2 (desired operating point) 2 = 0.1 3/ 2 = 70 2 = ?
3-34
a) Plot performance curves of pump A using both dimensional and nondimensional parameters.
b) Calculate the required diameter, rotational speed and power for pump B operating at its BEP.
System Characteristic
A pump works at an operating point on its characteristic curve. But this operating point depends on the system that the pump is installed in.
Following pump works between a suction reservoir () and a discharge reservoir ().
BE between points and
2 2 + + = + + + 2 2
Pump
2 2
Friction factor
Pipe diameter
s are average velocities in suction and discharge pipes. Using the continuity eqution = /
2 + 22
2 22
or simply
= 2
3-37
= + 2
+ 2
Minimum head the pump should provide is equal to the total geometric head.
Additional pump head is necessary to overcome frictional losses. This part increases with the square of the flow rate.
3-38
+ 2
3
+ 2
2
+ 3 2
+ 2
1
+ 2 2
+ 1 2
increases
increases
3-39
Operating Point
A pump installed on a system will not work at an arbitrary point. It will operate at the point where pump and system characteristics intersect. Operating point
Normally we want the operating point to be close to the BEP (design point). However BEP is not always the most economical operating point as far as the power consumption is concerned, i.e. BEP is not necessarily the minimum point.
3-40
[%]
0 5 10 15 20 25 30 35 40 45 50 []
3-41
Cavitation
In a liquid flow cavitation occurs when the local static pressure falls below the vapor pressure of the liquid. For a cavitating flow liquid locally vaporizes forming bubbles. bubbles collapse as they travel to higher pressure regions and cause erosion/surface pitting. flow becomes unsteady and noisy causing turbomachine to vibrate. performance of turbomachine drops. For a pump, critical low pressure region is the entrance, and for a turbine it is the exit. High speed regions like propeller blade tips are also critical. Listen to the sound of a cavitating pump : www.youtube.com/watch?v=Qw97DkOYYrg Watch propeller tip cavitation :
www.youtube.com/watch?v=GpklBS3s7iU
3-42
Cavitation Damage
Damage on Francis turbine blades Damage on centrifugal pump impeller
en.wikipedia.org
en.wikipedia.org
www.pumpfundamentals.com
3-43
Vapor pressure
Total head at the suction side of the pump (Datum can be arranged so that = 0)
Suction side of the pump is the side where fluid enters into the pump. It is used because it is the critical region due to low pressures.
3-44
NPSH (contd)
There are two values of that we work with required ( )
available ( )
is the value that must be exceeded to prevent cavitation. It is measured by the manufacturer of the pump and provided as an extra curve on the pump characteristic plot.
3-45
NPSH (contd)
is the value that we need to calculate for the problem of interest. Consider the BE for the suction side of a pump
2 2 + + = + + + 2 2
Pump
Suction pipe
3-46
NPSH (contd)
Using the last equation in the definition of
2 = + 2
=
No cavitation Cavitation
To prevent cavitation
Exercise : What can be done to make larger for the pump shown in the previous slide?
Exercise : How does the vapor pressure of water change with temperature? What does this information tell us as far as cavitation prevention is concerned?
3-47
NPSH (contd)
Exercise : 184 mm impeller diameter centrifugal pump of Standart Pompa 32160 series running at 1450 rpm is used to pump water at 25 from a reservoir whose surface is 1.2 m above the centerline of the pump inlet. Reservoir is open to atmospheric pressure.
www.standartpompa.com
The piping system from the reservoir to the pump consists of 3.2 m of cast iron pipe with a diameter of 5 cm and an average roughness of 0.05 cm. Minor losses at the suction side of the pump are; a sharp edged inlet ( = 0.5), three flanged smooth 90o elbows ( = 0.3 each) and a fully open flanged globe valve ( = 6).
Estimate the maximum flow rate that can be pumped without cavitation.
3-48
Exercise : For the pump given in the previous slide calculate the suction specific speed at BEP and show that it is much larger than the critical value of 3. What does this calculation tell us?
3-49
Specific Speed ( )
Suction specific speed () that we use for cavitation check is actually a specific form of a more general nondimensional number called specific speed ( ). is obtained by combining and as follows =
1/2 3/4
= ()3/4
Radial
Mixed
Axial
0.1
0.2
0.4 0.6
10
100
95 90 Radial
Adapted from Aksels textbook
Mixed
Axial
[%]
85
80 75 70 0.1 0.2 0.4 0.6 1 2 4 6 10
3-51
Pump A provides
Pump B Provides
= +
Same goes through both pumps. Total head provided is the sum of individual heads.
3-53
System characteristic
Pump A
Operating point
Pump B
Above a certain pump B is forced to operate above its free delivery point. For such a case it just creates extra loss and should be shut off and bypassed.
3-54
[] 50 [%] 30
10 0 0.01 0.02 0.03 0.04 0.05
3-55
[3 /]
= +
Pump B
= = Each pump provides the same head .
Pump A+B
System characteristic
Operating point
Pump A or B
3-57
Operating point
System characteristic
Above a certain pump B is forced to operate above its shutoff head. For such a case it just creates extra loss and should be shut off and its branch should be blocked with a valve.
3-58
Pump Selection
Two main inputs for pump selection are required head
20
15 10 5 10 15 20 30 40 50 [3 /] 100 2900
www.standartpompa.com
200 300
600
3-60
50 184 50 % 60 65 70 45
175
160
73.5 70 65 60 50
40
There are three similar pumps with impeller diameters of 160 , 175 and 184 .
35
30
25
20 10 6 2 20 15 N
160
184
10
5 0
20 40
60
[3 /]
Turbines
Fundamental performance characteristic or a reaction type turbine is the power produced vs. rotational speed curve at a given head. At a given head
Affinity laws used for pumps are valid for turbines too.
Specific speed can be used for preliminary turbine selection, but it is defined in a slightly different way compared to pumps
=
1/2 5/4
()5/4
3-62
Mixed 1 2
Axial 4 6 10
Francis Kaplan
[%]
Turbines (contd)
Exercise : Calculate the specific speed of the following turbines a) Francis type radial flow turbine at the Round Butte hydroelectric power station in Madras rotating at 180 and producing 119 of power at a flow rate of 127 3 / from a head of 105 .
b) Francis type mixed flow turbine at the Smith Mountain hydroelectric power station in Roanoke, VA, rotating at 100 and producing 194 of power at a flow rate of 375 3 / from a head of 54.9 . c) Kaplan type axial flow turbine at the Warwick hydroelectric power station in Cordele, GA, rotating at 100 and producing 5.37 of power at a flow rate of 63.7 3 / from a head of 9.75 .
Exercise : Learn the meaning of the following turbine related terms Runner blade, wicket gate, stay vane, crown, penstock, draft tube, tail water Exercise : How hydraulic power works ? http://www.youtube.com/watch?v=cEL7yc8R42k Virtual turbines
http://www.youtube.com/watch?v=HzQPNpP55xQ
3-64