MICROFICHE REFERENCE LIBRARY

A project of Volunteers in Asia

Desiun Of . . Su -4 Communitie,
by:

Water

TUK-

for

Farms

and

Small

MohammadDt,-ali

Published by: Technology Adaptation Program Massachusetts Institute of Technology Cambridge, MA 02139 USA Paper copies are $ 7.00.

Available from: Technology Adaptation Program Massachusetts Institute of Technology Cambridge, MA 02139 USA Reproduced by permission of the Technology Adaptation Program, Massachusetts Institute Technology. of

Reproduction of this microfiche document in z : form is subject to the same restrictions as ti:;se of the original document.

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DESIGN OF SMALL WATER TURBINES FOR FARMS AND SMALL COMMUNITIES

Mohammad Durali Project David supervisor: Gordon Wilson

Spring

1976

TECHNOLOGY ADAPTATION PROGRAM Massachusetts Cambridge, Institute of Technology Massachusetts 02139

L>, ;

,,

CONTENTS

CONTENTS.,

*.....................

5 7 9

LISTOFFIGURES..................... PREFACE......................... ABSTBACT........................13 CHAPTER 1 1.1 1.2 1.3 CHAPTER 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 CHAPTER 3 3.1 3.2 3.3 3.4 3.5 CHAPTER 4 4.1 4.2 APPENDIX I APPENDIX II INTRODUCTION.

ACXNOWLEDGEMENT. . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . , . . . . . . . 15

Background, 10 Problem Statement, 10 Principles of Our Approach, DESIGN OF A CROSS-FLOW (BANKI)

11 TURBINE. . . . 19

Description, 19 Advantages of Bank Turbine, 19 Analysis of the Machine, 21 Design of the Rotor, 24 Losses and Efficiencies, 32 Blade Design, 37 Sizing of a Cross Flow Turbine,, 46 Mechanical Design, 51 Evaluation of Efficiencies, 57 Radial-Inflow Partial-Admission Water Turbine, 58 DESIGN OF AXIAL-FLOW TURBINES . . . . . . . . 61 Description, 61 Advantages, 61 Analysis, 63 Design of Blades, 65 Sizing of the Machines,

68

DISCUSSION ON ADVANTAGES OF DIFFERENT TYPES . 89 Improvements on Reaction Off-Design Performance, Machine, 92 91

TABLE OF PARTS AND WORKING DRAWINGS. . . . . 97 FRICTION LOSS IN NONCIRCULAR CONDUITS . . ..147

APPENDIX III APPENDIX IV

EFFICIENCIES.

. . . . . . . . . . . . m 149 153

PERFORMANCE ESTIMATION OF AXIAL-h?LOW TURBINES c . . . . . . . . . . . * .*

LIST OF FIGURES

NUMBER 2-l 2-2 2-3 2-4 2-5 Cross-Flow (Banki)

TITLE Water Turbine Locations on Stalling in

PAGE 20 22 26 28 Inlet Flow 31

Velocity Diagrams of Different Cross-Flow Turbine Effect Velocity of Blade Diagram Outlet Angle

Terminology Iy vsO Relative

Work Coefficient Angle 6, Converging Cross-Flow

2-6 2-7 2-8

Flow Inside Turbine-Blade

the Rotor Terminology

35 38 44

Ratio of Blade Radius of Curvature R and Rotor Length L over Rotor Outer Diameter vs. Rotor Inner-to-Outer Dia. Ratio m. Ratio of Radius to Hydraulic Diameter R/Dh, and Deflection Angle of the Blade Passage Bc vs. Rotor Inner-to-Outer Dia. Ratio m. Number of Blades Ratio m. Radial-Inflow Z vs. Inner-to-Outer Water Dia. Turbine

2-9

44

2-10 2-11 3-1 3-2 3-3 3-4 3-5

45 59 62 66

Partial-Admission

Inlet and &t' -et Velocity Flow Turbine Stage Blade Impulse Terminology Velocity Diagram

Diagrams

of Axial-

69 Impulse 75

B?ade Sections Turbine Reaction Velocity

of the Axial-Flow Diagram

83

LIST OF FIGURES (Continued) NUMBER 3-6 4-1 4-2 APPENDIX II 1 2 Loss Factor Nov. 65) for Bends (ASCE, J. Hydraulic Div., 148 148 Blade Sections TITLE of the Axial-Flow of Reaction of Reaction Reaction Machine Machine Turbine for in PAGE 85 93 94

Characteristic Curves Constant Flow Rate Characteristic Curves Constant Speed

Friction Factor f vs Re. for Different e/D. (Rohsenow, W.M., and Choi , H.Y., Heat, Ma%, and Momentum Transfer, p. 58)

APPENDIX III 1 APPENDIX IV 1 2 3 4 5 6 7 8 Turbine Lift Basic Trailing Profile Secondary Secondary contraction Profile Loss Blade and Velocity FL for Traction Losses Reynolds Factor Factor Number Effect Ratio Loss Profiles Loss Ratio Against Ratio Triangle Notation 156 156 157 157 157 158 158 158 Parameter, Scheme of Losses in Water Turbo-Generators 151

Edge Thickness Loss-Aspect Loss-Basic

PREFACE

This report is one of a series of publications which describe various studies undertaken under the sponsorship of the Technology Adaptation Program at the Massachusetts Institute of Technology. In 1971, the United States Department of State, through the Agency for International Development, awarded the Massachusetts Institute of Technology a grant. The purpose of this grant was to provide support at M.I.T. for the development, in conjunction with institutions in selected developing countries, of capabilities useful in the adaptation of technologies and problem-solving techniques to the needs of those countries. the Technology Adaptation Program provides the At M.I.T., means by which the long-term objective for which the A.I.D. grant was made, can be achieved. The purpose of this project was to study alternative water turbines producing 5-kw electric power from an available hydraulic head of 10 m and sufficient amount of flow, and to recommend one for manufacture. The work consisted of the preliminary turbine which could be used for this and designed completely. A complete for the selected type. design of different types of water application. Then one was selected set of working drawings was produced

Four different types of water turbine were studies: a cross-flow (Banki); two types of axial-flow turbine; and a radial-flow turbine. Each one has some disadvantages. One of the axial-flow turbine (one with rotor blades having 50% degree of reaction) was chosen for detailed design as presenting the optimum combination of simplicity and efficiency. In the process of making this T.A.P.-supported study, some insight has been gained into how appropriate technologies can be identified and adapted to the needs of developing countries per se, and it is expected that the recommendations developed will serve as a guide to other developing countries for the solution of similar problems which may be encountered there.

Fred Moavenzadeh Program Director

ACKNOWLEDGMENT

This Program tional

study is

was sponsored funded through

by the M.I.T. a grant from

Technology the Agency of State. are the

Adaptation for Interna-

which

Development,

United

States

Department

The views of the

and opinions author

expressed

in this

report, reflect

however, those of

those sponsors.

and do not

necessarily financial

Mohammad Durali's research Technology, This

support

during

the period

of of

the

work has been provided Tehran, project Iran. was initiated in his

by the Aria

Mehr University

by the T.A.P. with

program

director,

Fred Moavenzadeh, de Los Andes led

discussions

a group and Jorge

at the Universidad Zapp.

by Francisco for this

Rodriguez support

We are grateful

and help.

David Gordon Wilson, project supervisor department of mechanical

engineering

11

DESIGN OF SMALL WATER TURBINES FOR FARMS AND SMALL COMMUNITIES

Mohammad Durali ABSTRACT The purpose of this project was to study alternative water turbines producing 5-kw electric power from an available hydraulic head of I.0 m and sufficient amount of flow, and to recommend one for manufacture. The work consisted of the preliminary design of different types of water turbine which could be used for this application. A complete set Then one was selected and designed completely. of working drawings was produced for the selected type. Four different types of water turbine were studied: a crosstwo types of axial-flow turbines; and a radial-flow flow (Banki); Each one has some advantages and some disadvantages. turbine. One of the axial-flow turbines (one with rotor blades having 50% degree of reaction) was chosen for detailed design as presenting the optimum combination of simplicity and efficiency.

13

Chapter

INTRODUCTION

Not all produced small costs Until

consumers

have easy access plants. to afford Sometimes the

to electrical it is not

power worthwhile for

by main power customers if they 1970's

isolated needed

transmission

and maintenance main power. amounts of

are to connect an ideal

to the nearest small

the early

way to produce

electrical But with zun, wind,

power was to use dieselhigh energy prices, small provided naturally water falls

or gas-engine-driven available and so forth and cheap device power

generators. sources be as

streams,

can often for

more economical, can te made. 1.1 BACKGROUND

a simple

each case

In the country are situated on streams is sufficient

of Colombia where flow

in South America

most coffee

farms

a head of 10 m can easily available especially the price during of mains

be trapped the electric from the of many times

and there when power power

is most needed. high, to the

Although

is not very plant

the cost farms

of transmission

of power high. is

main power this

may be extremely electricity

Because seasonal,

and also prefer

because

the demand for their

farmers 1.2

to produce

own electricity.

PROBLEM STATEMENT The effort here is to design a machine which can produce

16

5 kw electric machine technical complicated maintenance. machine power should produced would

power

for

the cases

mentioned

before.

As this

be used by farmers

who on average objects is

have little to avoid very

knowledge, structures. Finally be less

one of the major Moreover the amortized than the

total

the machine capital

cost

must not need skilled cost for using this

of using

the transmitted

by mains

power plants. of engineering on this problem. of the Universidad They have to modify our work that to this

Some members of the faculty de Los Andes in Bogota developed model group for a half-kw hight;r have worked

cross-flow power levels.

turbine.

They plan

We have reported

regularly. The design of small water-turbine units has not This previously might like be the

been carried because

to a high limited

degree

of sophistication.

of their (i.e.

applications. needed

For applications in a period

one we have is plenty

electricity the design problems.

of year when there may be a good

of water) to energy

of a cheap machine

solution 1.3

PRINCIPLES OF OUR APPROACH The effort was put into two different approaches to the

problem. 3) any simple cut steel Designing workshop parts. a machine having which can easily be manufactured to weld, can be built drill and locally in by

enough

facilities the machine

Consequently,

17

each

farming etc.,

area.

The parts

such as bearings, to each area. bars, sheet

gears, In this metal,

chain, approach round bars we and

generator tried

can be shipped like

to use materials do not

angle

so on which

need much machinery were excluded.

to be used.

Casting

and other

more complicated b) shipped layout Designing to farming is going

processes

a machine locations.

which This for

could

be manufactured a kind

and

approach manufacturing

of process The parts

to be arranged
like casting

the machine. and using plastic

production

methods

and molding,

seems to be more economical. In both of the next the rapid the industrial cases a) and b), capabilities the design the of design has to be within of the user. turbine the The based on area

the country of a cross-flow

chapter "a"

contains

assumptions. inflow turbine

In the end of Chapter is discussed axial-flow types is very briefly,

2 design

of a simple 3 is blades. about The

Chapter with short

desig?

of 2 modified two latter of approach.

turbines

design the "b"

of the type

based on the

assumptions

made on

Chapter

2 TURBINE

DESIGN OF A CROSS-FLOW (BANKI)

2.1

DESCRIPTION This machine then was .'irst designed models by Dr. of this Banki kind over 60 years

ago.

Since

some low-power

have been

developed This which water. curved plates gets

in Europe machine its energy is

and have given is an atmospheric

good performances. radial-flow energy impulse of an inward wheel jet of of

from the kinetic simply

The wheel horizontal to which

a squirrel-cage-shaped 2-l) attached. the rotor fixed between The jet blades to direct

assemblage circular of water twice. the flow inward it end

blades the passes shaft

(Fig. is

coming

out

of the nozzle

through

Tine biades the tail the 2.2 open internal water inner outward

have to be designed space inside the

to

cage and then set of blades

to drain in another

to the part of

through

another

circumference.

ADVANTAGES OF BANK1 TURBINE The cross-flow turbine has significant Its advantages simple rotor which make makes it for

it

a suitable

solution

to our problem. The atmospheric housing.

structure

easy

to be manufactured. and well-sealed as they

avoids

the need

a complicated with the flow,

The bearings they

have no contact can simply when, be

are out

of the housing;

lubricated

and they

don't

need to be sealed.

And finally,

20

TAIL-WATER ----P-P------I_-------m--e--

--

---

-v-----

---

--

-me

--

FIG.2-1.

CROSS-FLOW (BANKI)

WATER TURBINE.

21

for cross

a constant section

head and a given is obtained, rotor. then

power for

level

a simple power levels

fixed

rotor

higher

one can

simply 2.3

use a longer

ANALYSIS OF THE MACHINE The most useful re7 tion in design of a turbomachine is the

Euler

equation,

where

stands

for

rotor

peripheral of the i and 2-l). designed is 0 in o

speed, fluid stand

CC and for

is h, inlet

the is

tangential the stagnaof

component tion the

of absolute

velocity

enthalpy. rotor,

Subscripts (Fig. is

and outlet

respectively normally

The rotor of the fluid

so that the radial

the absolute direction,

velocity so

leaving

the rotor e. =

and therefore icei and then be the parameter = gc A i-o b for the rotor will simply

"work

coefficient"

22

FIG.2-2.

VELOCITY DIAGRAMS OF DIFFERENT LOCATIONS IN CROSS-FLOW TURBINE.

23

From the

first

law of thermodynamics,

= lil but static are for water enthaipy to study turbines are very the drop

A i-o

h,

A i-0

(h +"

+ zg)

the rate small

of heat and for from

transfer small units to outlet

and change like

in

the one we

in height

inlet

is negligible,

so that,
l3 T

Ah, =

using

the equations uicei

we had before, = 3 (Cf - Ci) ,

Yu2 = i
or finally

$ cc; - 2)

u: = k (CI - cf,
For an impulse equal AHo to 2.0. and nN If the machine total the value hydraulic of 'Y is normally the nozzle covers (a) the can be taken is loss head before (which equation

be taken

as nozzle

efficiency then

cf kinetic written

energy as follows,

through

the nozzle)

u2= & (2g AHorlN - cz,,

i

24

or

ui

C2 = f (AH, I~ - $ 1

(LJ)

From Eq. choice speed 2.4

(2.1)

we find diagrams

that

for

a given

hydraulic

head, the rotor

of the velocity and hence rotor

enables

us to determine

dimensions.

DESIGR OF THE ROTOR The choice of the the blade design. useful inlet and outlet angles is the the

important jet

part

of

They have to be chosen work to the rotor in both

so that passes

of water

transfers

through

the blades. Throughout this and are at design is very analysis positive point small angles in the the are measured direction angle will from tangents Also and the

to the

circles

of rotation. is zero

we assume that deviation if angle

incidence

so that to be zero.

the design From Fig.

not be affected (2-2) by simple

we assume the derivation we have for all

cases

geometry

This

is

true

for

all

shaft

speeds inter

and flow angle

inlet of

velocities. the blades "stage" is

But taken

one may question equal to 90" inlet is (i.e.

why the the of

stage angle

outlet

of the first stage).

or pass, behind this

and the choice

angle

the second

The reasoning

as follows.

25

Assume zero in the first pass;

deviation therefore, outlet

angle the angle.

for flow

the flow relative Now suppose is bigger at In this

leaving velocity that than the

the blades angle the 90' angle (Fig. pass. will of 2-3a).

be equal the blade

to the blade at the outlet will

of first be negative (Fig.

pass

As you see there This time assume will is

incidence 2-3b).

second

8, < 90" place.

case positive in Fig. (2-3~) the

incidence situation

take

Now as a comparison

shown with the 6

B = 90". blade outlet angle is kept so that if angle at outlet equal has a value of the first there of is will around pass

Therefore 9o". (Fig. will the Now assume 2-3d). If

optimum

as deviation angle "i"

the blade of incidence

to 90" then

be an angle second pass).

i = 6 (in outlet the

the inlet angle incidence

Consequently 90' (equal

the blade's then

slightly be near

more than to zero. Normally

to 90 + 6/2)

the values the

of deviation value taking for

angle

are

of the order outlet angle equal

of Z" is

to 8O. between would

Therefore

optimum Obviously

the tlade the blade

91" to 94O. not

angle

to 90

cause much effect the is cross-flow

on the performance. turbine rotor works totally from inlet at atmospheric to outlet passage fill does with

Because pressure of a blade not water there

no static-pressure Therefore the In fact,

difference flow through

passage.

a blade

accelerate and flow

or diffuse. passes through

blade

passages

do not

the blade

passage

as a jet

deflecting

26

\ 2
\
(4

(b)

FIG-z-3,

EFFECT OF BLADE OUTLET ANGLE ON STALLING.

along

the pressure

side

of the blade. velocity

Consequently the passage

the (in

flow the

will absence

,have a constant of area friction)

relative

through will the are (first

and the maximum flow which is at

be determined inner then diameter as follows B, = 90"

by the side (Fig.

smaller rotor.

of the passage The rotor

of the 2-4):

specifications velocity angle

outlet Fig. the

relative (2-4a) rotor Let C,

pass)

so from leaving

= U2

and the absolute direction (Fig.

velocity 2-4b)

of water 01~ = 90".

2 is in radial us define

(Notice coefficient.) and

that

in

this

particular

case

is

equal

to the work

m3-

r2 rl

r2

and

are

inner

and outer

radii

of the blading

respectively,

therefore m= u2 'il The above relations. From Fig. x f (Z-4a) -51 ul = we have Cl cos a1 ul = cos a - cl 1 -cl cos a1 + w1 cos (3, definitions will = u3
UC
l

help

us to write

simpler

geometric

(2.2)

28

(4

FIG.2-4.

VELOCITY DIAGRAM TERMINOLOGY.

29

Also, C rl from (2.2) = Cl sin(IT - al> = Wl sin(?I - 8,) (2,3)

and (2.3) tan B, x = (tan B, - tan al)

Therefore B, = tan-'(( 2 1 tan al) (2.4)

From the

outlet

velocity

triangle

(Fig.

2-4a)

c2=J wf +u;
If we assume no loss the relative of kinetic energy through the blade passage, then along velocity passage, of the water so using Eqs. has to remain (2.2) and (2.3) unchanged we have the blade

c2 But

= ulpyi$7

0.5)

c2 Combining (2.6)

-5z

u2 cos a

= 2

m 3 cos c%

(2.6)

and (2.5)

we have, (2.7)

u2 = cos-lJ$$-j-

30

From Fig.

(2-4b)

we have;

cos(lT-f3)

u3 .rn W 3

1 m tan cx 3 ~1~ = a2 then and if

(2.8)

but

as illustrated angles

before

at any condition

incidence so from

and deviation (2.8) we have:

are assumed to be zero

B, = B,

tan a2

1 - m cos B 1

u2

tan

-1

1 m cos B,

(2.9)

Therefore "stage"

we found geometry

two values (Eq. (2.7))

for

c12 '

one by using was found

the

first the a

and the other these the

by using equal

second-stage nondimensional 5 tan -1 ' (-

conditions. relation

Putting between

two values parameters

we get m , x

design

and

as follows: 1 m cosB l)=cos-lJg-Tp

(2.10)

FIG.2-5.

WORK COEFFICIENT$fVS.

RELATIVE 1iYLiT FLOW ANGLED,.

32

Notice

that

a1 , x curves the of x of

and

6,

are

related Eqs.

together (2.4)

by Eq. and (2.10)

(2.4). which may

Now design help

can be drawn using right vs. x vs. value B, of the for %

to choose

parameters. values

Two useful of nozzle of m . (2.4).

curves angle

may be,values b,)>

different for different curves of X

and values Figure

values on Eq.

2-5 shows (2.10) for

the design the value

based we get

Solving

Eq.

m cosf3 cos tan

1 -1 (

I2 -1+1 1 1 m cos B 1

(2.11)

For any value vice 2.5 versa.

of

m and

B,

the value

of

can be found,

or

LOSSES AND EFFICIENCIES In cross-flow machines, sheet metal. blades are normally variations Summarily made of curved in inlet the other flow losses

bent angle

strips could

of thin

So small losses.

cause high as:

incidence

can be listed of flow converging losses. a> Nozzle direction flow

hydraulic in in

losses

due to skin

friction losses

and change due to

the nozzle

and blade inside

passages;

open space

the rotor;

and mechanical

losses a factor cv the which losses acts as a velocity friction correction and

For nozzle factor

can be used to define flow, so

due to skin

converging

33

or

For the Appendix defined

loss I, as

due to the curved will be used,

nozzle

passage

the

curve

given is

in

provided

a hydraulic

diameter

Dh

4 x flow area wetted perimeter

(2.12)

If

the

radius

of curvature of loss of

is

then k

the curve versus

in Appendix angle

provides for

the values values

factor

deflection

different

R/Dh , where W2 1

% oss

and

W 1

is

the mean water of R and

velocity Dh

through

the nozzle.

Obviously '

the mean values result. b) Blade I> for the flow losses

should

be used

to get a better

Hydraulic-friction through blade the

losses. passages given

The coefficient can be found in Appendix based I. So

of

friction

on hydraulic

diameter,

and using

curve

34

% oss

L fhTxz'

w2

subscript diameter. relative II)

h "L" flow

stands is the

for

values

evaluated

on basis passage

of hydraulic and W is the

length

of the blade

velocity. Losses due to flow given the direction I, change, as for In this case we

can use the curve

in Appendix rotor 2-6,

the nozzle.

Losses

within

As seen in Fig. different change in blades flow

the direction to one point.

of actual This second effect set

velocity will

leaving cause a

converges direction

entering 2-6

the

of blades. the maximum of the admission line is, remains the closer of the Therefore A 20* to effect rotor

As seen in Fig. incidence angle "0". angle It "y" is Also side cause

from simple by this that the the get work effect

geometry, is half stream angle inner

caused assumed

central admission to the

undeflected. the right-hand and that the angle reasonable 40". is very d) will

the bigger jets will

surface pass.

negative

on the second as small

of admission range

has to be kept for

as possible. is between due to this

of magnitude values

admission angle

angle the loss

For these small.

of admission

Efficiencies Normally the overall efficiency for a water turbine is

defined

as;

35

F&2-6.

CONVERGING FLOW INSIDE THE ROTOR.

36

where all 11).

nh

is

the hydraulic losses

efficiency across

of the

turbine, {See also

and covers Appendix

the hydraulic

the blading.

'h

AH - Hloss
AH difference between hydraulic head of the

where turbine

AH inlet

stands

for

and outlet. rim or mechanical and bearings efficiency covers all defined the losses

The term due to disk friction

and so on and is

as;

rl,

T - Tloss T the is shaft torque. efficiency the turbine which without covers giving the any

where

represents T-I Q flow

Finally leakages power and the

the volumetric which passes

where

is

the volume part

flow

rate. evaluation efficiency. of the This efficiency term of is very

The important a turbine is to find

of the

the hydraulic

37

sensitive In order using last 2.6 Eq. section

to the blade to get (2.15),

profile

and flow effic'

angles

(see Appendix crossflow mentioned

III).

the hydraulic

&ency of the all head. the losses

turbine in the

one has to write of hydraulic

in terms

BLADE DESIGN As mentioned before the rotor in a crossflow are the turbine any is transexperience con-

sists designs mitted all

of two end plates

to which

the blades so that

joined. torque

do not have a through to the output shaft

shaft,

by the blades,

i.e.

the blades all

the bending

moment due to torque higb periodic

transmission, stress,

the blades

come under only

a relatively carry

as at each moment one would radial chord. between for if a the like

a few blades long Stiffer rotor

the whole

flow. with

Therefore small

to avoid

blades

and blades

plates

may be used to support longer rotors. volume plates rotors

the blades Therefore flow rate,

the given rotor

two end plates power level

and so allow and hence with

a specified stiffer

can be reinforced rotor diameter for

one r-an go for higher that shaft

smaller speed. higher

and longer these apparent

and hence is

The cost complexity.

advantages

of the

For the type concerned profiles with will rotors

of design having

we have chosen, no stiffer plates.

we will Also

only

be

the blade can

be segments

of a circle. tubes,

Therefore

the blades of thin sheet

be cut out

of thin-wall

or made of strips

38

Zr number of blades di: inner dia. dia. of rotor

doz outer L =, length

FIG.&7.

CROSS-FLOW TURBINE-BLADE TERMINOLOGY.

39

metal

rolled is

around

a pipe.

The most

important diameter

parameter of

to be

specified "ml' which length, design which

the ratio most

of inner

to outer rotor of Eqs.

the rotor such as blade (2.13f)

affects

of the other etc., effect using

parameters, m on other to

number of blades, parameters relate these

can be found parameters.

(2.13a) 2-7 for

(See Fig.,

blade

notation.) 0 5

y-

(2.13a)

2y - 4 = B -

(2J3b)

c sin

y = 2

dO

sin

QI

(2.13~)

R =

2 sinTBc/2)

(2.13d)

do - di
c cos

y + dO sin

Q/2

(2.13e)

C CT =

dl

sin

n/Z

'

(2.13f)

The solidity to the spacing It Eqs. will to of

(5 is defined the blades on the

as the ratio inner-diameter

of

the blade side

chord rotor. of

of the forms

be easier (2.13f).

to work with Let's define

the nondimensional

(2.13a)

40

and

then, Y = EIc/2 (2.14a)

27-e=

B-s

(2.14b)

2A sin

sin

(2.14~)

5 =

x
2 sin y

(2.14d)

X cosy 4- sin

($/2

3 (l-m)

(2.14e)

x
m sin n/Z '

(2.14f)

As discussed the blade curvature diameter Figure passage is

in

the last

section

the hydraulic of the over angle of outer ratio, from

loss radius

through of

a function camberline and the

of the ratio (centerline) deflection of the ratio rotor

of the blade of the 2-8 shows curvature passage

the hydraulic

of the blade. the rotor length versus show and

the variation ratios over

the blade values that values

the

diameter

of rctor shorter of m.

inner-to-outer

diameter blades result

These curves using bigger

and more curved

41

As mentioned passage is a function hydraulic values Both parameters

in

Section

2.5

the

loss

through and

the blade Dh is

of the ratio diameter of these R/Dh and

R/Dh 8
C

ec , where

the passage angle. us less geometrical follows:

is

the blade values of in

deflection 8c terms give of as

Bigger loss.

and smaller

parameters

can be found in Eqs. (2.13)

introduced

and (2.14),

as defined

Dh

= -

4 x flow -. wetted perimeter

but

as pointed

out before, of water is

flow

through

the blade side

passage

is

the and

deflection so the jet diameter diameter

of a jet thickness of the blade side of the

along

pressure

of the blade

fairly

constant.

Consequently

the hydraulic

passage rotor.

can be determined By the aid of Fig0

by the inner2-7 we then have

Dh

4 x (LXS) L + 2s defining fill the wetted the passage guide through the flow. perimeter fully. If and as (L +2s) Only Wl a is is the blade's the the rotor we

The reason is that the flow side

for

does not

pressure relative admission have:

and side

walls

velocity angle

of water then

the passage side

at the inner-diameter

of the rotor

WIA

'lL

a. --d 360

42

but

as

m -5 di/do

, then

Q ci IT .Wl m d 0 360
h = c/d o (Eq. (2.14) therefore,

Defining

CI E c/s

and

C CT

= k

dO 0

Substituting

these

into 44

the

relation

for

Dh

we have:

Dh

a -7TmW 360 Q 3% 7rmW

x- do x 0 1 do + 1 do 2>A

Dividing and naming

both

the denominator

and the numerator

by

do

Q a IT d2 W 360 01

then

we have

c 4--XDh = m

x
ad
0

43

Also

from

Eqs.

(2.14)

we have the

definition

of

+0

or R=tdo ,

Therefore

or R iq = <(C'cl + 2Xm) 4C' x

The parameter units velocity Ill of this kind

c'

will

be a constant having similarity

value in

for

homologous and versus of

(t ur b ines Figure of

geometry of ec

diagrams).

2-9 shows the variation versus that m for different

and the variation From Fig. at values of

R/Dh

values of

solidity. happens With factor 58")

2-9 we find m I-l closer

the maximum value as solidity we find we have of Bc that

R/Dh

to unity I) angle variations for for lower

increases. the loss 41" to

reference for the

to Fig. range change

(Appendix

of deflection much with

(between but of is

does not of

strongly

a function from

R/Dh , especially 5), of Consequently R/Dh

values

R/Dh (values of solidity CT,

1 to about

a chosen

value

the maximum value

seems to lead

to the

efficient

passage.

44

FIG.2-8.

RATIO OF BLADE RADIUS OF%R"ATURERAND

ROTOR LENGTH fa RATIO m .

OVER ROTOR OUTER DIAMETER VS. ROTOR INNER-TO-OUTER DIA.

80

60

0 0 5 ,6 .7 .0 .9 II

FltG.2- -9. RATIO OF RADIUS TO HYORAULTC DIAMETER R/Dh g AND DEFLECT ION ANGLE OF THE BLADE PASSAGE& VS. ROTOR INNER-TO-OUTER DIA. RATIO ml.

ROTOR ANGLE OF

-1

I .5
FIG.2-10.

I .6
NUMBER OF BLADES

I -7

I .8

I .9
RATIO m.

VS. INNER-TO-OUTER DIA.

46

The design mechanical mum loss. 2-10

of the design Using

rotors of

with

no stiffer than

plates

is more dominated to get

by

the blades to

by optimization the curves

the mini-

Eqs.(2.14a)

(2-14f),

shown in Fig.

can be drawn. These curves show the number inner to outer of blades for each choice of

solidity of blades width is

and rotor is reduced

diameter

ratio.

As the number the throat chord

the rotor 2-8).

becomes Therefore

longer

because

lessened

(Fig.

although

the blade

increases

as the number in bending. assuming plate

of blades

decreases

the blades

become

more flexible conclusion, (e.g.

On the basis material the blades),

of stress properties we have let

and stiffness and thickness 18 as the

typical for

2mm steel

minimum number of blades. When the number shorter, but of blades is increased, for the rotor can be

the manufacturing

difficulties

small

workshops

become progressively maximum desirable drawn stiffness 2.7 in Fig. 2-10,

more severenumber give of blades. better

We have chosen Points inside

60 as the the closed curve

designs

as far

as losses

and structural

are concerned.

SIZING OF A CROSS FLOW TURBINE For a machlne of this type working the nozzle flow nozzle under is constant fixed head, the 2.4).

velocity Therefore affects

of jet

of water

leaving

(Section

the choice the size of

of inlet the rotor,

absolute a small

angle angle

from the nozzle being desirable.

47

As discussed be kept losses angle absolute that line line). turbine. small

in Section in order

2.5,

the angle the

of admission losses within

should the rotor

also and The The inlet In

to reduce

due to flow of admission flow angle the flow the water

entering is taken

the blades equal

in the second

pass.

to 30 in our machine. designed by Banki

in a prototype crosses entrance casing

was 16O.

design (i.e.

the rotor

on an approximately points are

horizontal

and draining incorporating

on a horizontal for his

He used a cast

the nozzle

As we have tried processes, design metal confines to the in the had. covers; our design Rather there

to

avoid

complex

structures casing framework around the

and manufacturing like with rotor Banki's sheet which part resulted rotor fixed

does not have a cast we used a steel will be a main The nozzle angle of angle cover will 30'.

the water frame least giving

spray, a nozzle

be a separate That design. value

complexity drawing inlet downward. that in

of the structural Section flow 2.8.)

(See nozzle

combination 2.4 the

So with

reference be 150".

to Section Draining will

absolute

angle

"~11" will

be vertically

From the fact have

the work

coefficient

is

equal

to 2.0 we

%1
= Assuming (nozzle a total-to-total from Eq. and rotor),

2Ul ,

efficiency (2.1) we get,

of 75% for

the turbine

48

0 (UC*) =
then
u1 =

69,20

m2/s2

5.88 13088 9.00

m/s m/s m/s .

cl -wl

= =

The choice outer diameter

of shaft

speed

depends the

on how large speed limitations the sliding

the rotor for the

can be and what

are

bearings. :.ztween 300 rpm. gear

As we were shaft This

to use wooden bore lower limited than

bearings

velocity

and bearing speed is

us to a shaft because speed it

speed of a high

desirable, the shaft studies speeds.

up ratio

is needed

to reach

to 1800 rpm would be justifiable

(generator to specify

speed). bearings

In future

design

to run at high
specifying =

Therefore

N = 300 rpm 0.3743m. the blades

we get

dO

We would (see general

like

to join

to the

side

plates combiExtj.on

by rivets

arrangement 2.81,

drawing Therefore in order

and nozzle-rotor we would to get like

drawing possible riveting Fig.

in Section

to have the space plates. for Using

least

number of blades the bent

sufficient

ends of the blades last section we get

to the side m = 0.6

2-10

in the

and 24 blades.

49

Now using results (zero and blade incidence)

Eqs.

(2-13a)

to

(2-13f) from

we get

the

following diagram

parameters. we get B = 130"

First

the velocity

53'

and then
8 C

= = = =

52" 58' 26" 29' 0.0956 0.0293 m m m

Y R s

C = 0.0843 we have previously chosen, Z = 24 0.6 rotor 0.2246 is

m = The inner diameter of the di If losses 20% extra losses =

then will m .

be

power in

specified

to cover then rate

the mechanical shaft will be

and the

the generator flow

the output required

power has to be 6 Kw.

The volume

Q = The length

W A(U Ce)

= 0.0857

m3/s

of the rotor

then

will

be

50

L=

I-&-L-= ~adiW

O.l64 m 1

being

the admission Once more recalling

angle, the velocity relation triangles shown in Fig. 2-4,

we can write

the

folPowing

WJ C(j)
or A@ Ce)

= total

A(u Ce) 1st pass

+ A&J ce) 2nd pass

(UICe 1

- u2ce 2

>

(U3Ce 3

- u4y3 4

but

as we specified, u 2 = u3 , u1 =
u4

, CO2 = c03 = u2

$3,

= 2u

'

s4

and

AN

ce> total

= 2Uf

Therefore

AW Ce)
1st pass

2$

- Ui =
2

2Ui

- m21J: =

2u$ and A@ Cal 2nd pass

- 5

>

= u;

= m2U2
.1

51

The above transferred and only This

relations to the 18% of the

show that rotor total

for

a value pass is is

of

m = 0.6 the

, the total

energy energy pass.

in first energy

82% of

received within do not

by the the affect rotor the

second

means that losses very

as hydraulic in the second

losses pass

and the performance of

entrance the 2.8 turbine

much.

MECHANICAL DESIGN The manufacturing processes dominant under parameters drawing, view parts which in the turbine is to be

made have been the most design. rotor in the The general combination following

the mechanical the nozzle are submitted are briefly

arrangement

scheme of

and an isometric pages. Different

of the machine of the machine

described Rotor

as follows:

The turbine and 165 mm long. is 300 rev/min. It Blades on the side

has a squirrel-cage-shaped The optimum speed under

rotor, the design

380 mm 0-D. head of 10 m

has 24 blades, out

each blade

being

simply steel

a circular sheet

segment. (see Part 11

can be rolled general with

of 2 mm galvanized drawing). (Part 12). shaft. with

arrangement rivets

They are joined

to the rotor

plates

The rotor the bearing which (Part

has no drive which the

Power is the rotor, supports

transmitted

through

housing

rotates

and the shaft the rotor

goes through 14).

rotor

bearing

only

52

t-1 _----I

11

I! IiY

-+ F

E-R0 TOR COMBINA TION OF CROSS- FL0 R/RBINE

54

ISOMETRIC VIEW OF CROSS-FLOW

MACHINE

55

Bearings The bearfng steel rotor pipe, side housing, which is a short plate 13). oil-impregnated wood. speed Although for piece is of circular fixed to the

is weided plates with

to a circular rivets (Part

which

Bearings there this for It

are made of a special for its

are some limitations kind of bearing,

the maximum permissible and simplicity it

low cost

makes it

suitable

low-speed works 15).

applications. 'j

Furthermore as in dry

does not It

need lubrication. no seal

in wet as well

conditions.

requires

(Part

wear Chain

In our design the bearing rotates .a on the wooden bearing and increasing transmission Power is transmitted and gears. from the rotor

with

the

rotor, life.

so equalizing

the bearing

to the is

generator to the

by means circular

of bicycle plate which

chain

A 52-tooth

gear housing

fixed 21).

i s welded

to tihe bearing has a constant is used which

(Part

The generator and gear from combination

speed of 1800 rev/min. gives s speed ratio

A chain six

of about

turbine

to generator. hub and set is used for gears gear plate of five the in second the chain speed set cogs step are for a bicycle 22). by spacers on the

A complete derailleur gear

up (Part replaced gear

The unnecessary and only rotor) the an 18-tooth and a circular gears, is fixed

gear

(being with

driven a central set,

by a 52-tooth bore,

the same as one of circular plate is

to the gear

The latter

56

be fixed step the (Part

with 23).

a 36-tooth The last shaft.

gear being

used for

the

second

speed-up to

gear has 17-teeth level

and must be fixed we have for in this the

generator

For the power condition transmission bath would around not should in

machine chain. difficult see in choice, system. we recommend should

a good lubrication The two-step to incorporate Chapter 4 this not

be provided this turbine

makes it As you will

an oil machine do further

the

chain.

be selected on its chain

as the

final

so we did In order that

improvements life of the be used. on each shaft,

transmission and sprockets,

to increase

the

two chains side

in parallel by side

Therefore

two sprockets

be installed Housing

The housing It has a fixed

is

completely which 32),

made of thin

galvanized rotor of the

sheet (Part turbine, fixed 31),

steel. and for

section (Part

covers placed handle

most of the in the back

a removable servicing. section Frame with

door It

has a lifting two simple

and is

fastened

to the

latches

(Parts

34 and 35).

The frame generator size Nozzle The nozzle (Part different 41). mounting

is

totally is a steel

made of angles, plate welded generators

welded to short (Part

together. legs 38).

The

and its

may vary

when using

different

is

completely

made of steel and set possible

plates, on different

welded

together for of

The flow output

can be changed This is

valves the angle

powers.

by chaning

57

flap to the

(Part flap

42).

The semi-circular for different

channel settings. flow while

(Part

43) which

is welded

has holes never

Warning:

change ---the

the

turbine

&

-in operation As the system of flow while works under a relatively can cause damage. valve before the nozzle. position must high head, a change in

the turbine can result this there

is working in serious

"water-hammer"

the piping

which

To avoid The flow before

has. to be a gate almost

must be slowly changing gently. the flap

reduced position,,

to the shut-off setting,

After

the valve

be opened

The possibility absorber and the 2.9

of installing because

a surge-tank it would

as a shock increase the size

has not been studied, cost of the turbine,

EVALUATION OF EFFICIENCIES Knowing the size of different turbine parts of the turbine Following the the

hydraulic method

efficiency given in the

of the last

can be found. we get:

sections = 76%

'h This efficiency prediction, energy loss is the

total-to-total is into

efficiency acceptable, account

and is very Taking we get,

close

to our of the

so the design by drain = flow

the effect

rl t-s

60%

58

If of 90% is

a mechanical assumed then

efficiency

of 94% and a generator

efficiency

rl t-sm and rl t-su (See Appendix 2010 II.)

56.5%

51%

RADIAL-INFLOW

PARTIAL-ADMISSION

WATER TURBINE

Description This flow type of types. simply cross of its consists which of a spiral-shaped distributes the distributor flow in two an arc turbine is a potential alternative to the cross-

and axial

The turbine with rectangular portions The rotor

section inner

opposite of 80". fastened disk

circumference, out

each one being metal of with

blades

are rolled the enters through is

of sheet

and are

at one end only,around The flow passes

circumference the rotor the blades deflected

the turbine a swirling still the in rotor

as cantilevers. inward plane, motion,

radially the in radial

while to leave

and subsequently

the axial

direction.

Flow Control This type as described to the would turbine range rotor gives under the possibility constant design-point at its head. of controlling Therefore geometry and efficiency the

the volsume flow velocity consequently through diagrams the

keep their would work

design-point

the whole

of power.

ROTATABLE SLEEVE BLADES

SPIRAL

NOZZLE BLADES

FIG.&-11.

RADIAL-INFLOW PARTIAL-ADMISSION

WATER TURBINE.

60

The control the angle sleeve which fixed

of

the

flow This

could could

be easily

achieved

by reducing a rotatable have ports ports on a

of admission. rotor

be done by installing The sleeve into area. alignment would with

between could sleeve

and distributor. more or less the admission

be brought to vary

Dimensions For specified of this 450 rpm. ing type would head (10 m) and power of about output (5.5 kw) a turbine at

have a diameter with inner this side size

220 mm when turning there would

However, on the

of the rotor rotor. rotor geometry

be drain-

problems

of the the

Unfortunately, another
2).

increasing is the spiral problem axial

diameter and size the

brings

out

problem

which

(see Fig. diameter to

To solve

the draining reduce the

by increasing of the rotor

340 mm would speed

width

to 55 mm and the

to 300 rev/min. This would require fluid a spiral velocity distributor in of the same width the radial

(55 mm). dimension Conclusions

To keep the of the spiral

the spiral

small,

would

have to be increased.

A rectangular result (in entry port).

cross

section For the

of the order range of specific

of 60 x 200 mm would speed radial further. in which inflow

we are working, turbine

dimensions

as large

as this taken

make the

unattractive.

We have not

the design

Chapter

3 *

DESIGN OF AXIAL-FLOW TURBINES

3.1

DESCRIPTION In this chapter the task is to design some simple We have ratio axialto

flow design

turbines machines

as a solution with high blades water around then

to the problem. hub-to-tip-diameter for flows the blading. through a set

chosen which

enables

us to use untwisted Principally, (installed rotor to the reaction 3.2 blades, tailwater. machine. all

of nozzle

blades into the

the circumference the rotor

of the hub disk), blades and through

passes

the diffuser or a

The turbine

can be designed

as an impulse

ADVANTAGES These designs should have comparable provides (i.e. advantages with the Banki

type. processes plastic

The design if they

of these are

machines

easy manufacturing sand casting and

to be mass produced

molding). The blades are made of molded, accurate performance. than that profiles extruded or cast plastic design

which

will

give

and consequently the shaft Banki type ratio

a better speed

and off-design machines simpler machines besides

Moreover of the

in these a These

is higher transmission can also the

and therefore will be needed. other

and a lower

gear-up motor

be used as a drive

to drive

machines

generator.

FIG.S-1.

INLET AND OUTLET VELOCITY DIAGRAMS 0FAX.IAL-FLOW TURBINE STAGE.

63

3.3

ANALYSIS Similar to the analysis equation together h01 h02 shown for the cross-flow turbine, we

can write specifications

Euler's

to relate (Fig. = ulcel 3-l).

different

velocity-triangle

- u2ce2

(3.1)

But if rotor

AH then

is

the

total

hydraulic

head difference

ac'ross

the

h01 - h02

%t

AHog

(3.2)

where Appendix

tt II).

is

the

total-'

co-total

efficiency

of the

turbine

(see

The three and reaction blading which

parameters: specify

flow the type

coefficient,

work

coefficient diagram and

of the velocity

are defined

respectively

as follows:

cX @ -T-

(3.3a)

UICel qJ z

- u2ce2 (3.3b) u2 m

%l l--=r--

+ 532

(3*3c)

64

The analysis case where outlet C

X

is

done for constant Now for of

the mean diameter,for from inlet

the usual to can

remains

to the nozzles a velocity triangle

of the rotor. hence values

each design I/J, $ and R

be chosen,

can be specified. machines the

inlet

A good approach type angle (i.e. with different

to the design of reaction

of different is to keep the

of this flow parameters

degrees "ol"

to the rotor R and 9). From (3.2)

constant

and to vary

two rtfher

and (3.3b)

we have

g AHo u = %t YJ

(3.4)

Now, choice

of shaft

speed gives

us the mean diameter

dm and d and mass flow rate

60 U IT @J-)

(3.5a)

= m will

dt+dh 2 be

(3.5b)

&

W A(U Ce) power of the turbine.

(3.6)

where

W is

the output

65

The annulus

area

then will

be

Aa

(3.7)

where diameters

is

the density. area

Also will

we know that be

in

terms

of hub and tip

the annulus

Aa

= $ (d:

- d;

(3.8)

As mentioned high value enough, for this

before

we try

to keep the

ratio

of hub to tip

diameter

to be able ratio is

to use untwisted around 0.8. triangle (3.6) speed

blades.

A reasonable

Now, a choice AU ce) are (3.5ai and hence found. gives

of velocity from Eq. (3.4), shaft

gives

us the value the . values

of of

and (3.7)

u9L9a Zq. (3,5bj

Then the

can be determined

and using Eqs.

us the value we can find

Of

of mean diameter. dh and d, .

Then using

and (3.8) If the

ratio

dh/d,

is not the dh/dt

acceptable ratio.

a new shaft

speed

has to be chosen

to optimize

3.4

DESIGN OF BLADES
Figure 3-2 shows To find blade the terminology from used in this flow angles (2). in Ref. design

procedure. information I relations

angles

we may use the The following two

and curves approximate

given the

in Reference given

curves

(2) with

a good

66

BLADE WIDTH

r
0

bt

LEADING EDGE /' \

FLOW INLET

\\\
\

FLOW OUTLET ANGLE /3r

MADE OUTLET AXLE & STAGGER A!JGLE DEVIAT ION ANGLE6

'NG EDGE

FiG.3-2.

RLADE TER!lIrJOLOGY.

67

accuracy,

for

incidence

and deviation

angles.

(3.9)
60-X 2 0.08 + ( 300.1 6 8_ = c/s c

(3.10)

Please formulae. In Eq.

see Fig.

3-2

for

information are turning

on parameters useful angle

used in above design. to

These two formulae

(3.101,

in preliminary is equal

ec

or blade

eC

6, + Mind

6,

so the blade

angles

will

be

B2

B,i-6

Suggested

values

for

leading

and trailing

edge radii

are

re

(0.03

to o.os>c

It

(0.02

to O.Ol)C

68

The design angle solidity "A"

procedure

for value

the blades for solidity

is

to choose

a stagger

and an optimum can be estmated ratio;

o . criterion

The optimum for the value of

by the Zweiffel

width-to-chord

b s

2.5

cos2c12(tgal

+ tgcx2)

(3.11)

also

from Fig.

3-2,

t C

cos

(3.12)

from Eqs.

(3.12)

and (3.11)

we find

o ,

cl=;.
In steam and gas turbines the number reasonable concerned. number of of the blades value for chord case, which the dimensions determined of the blades a are for the seems and

are normally as far as blades gives

by choosing and stresses a good choice blade

as vibration are short,

In our the blades

us a reasonable

passage

to be a good approach. Then finding blade 3.5 shapes by trying the dimensions different of the blades curves for we can find profile. the

the blade

SIZING OF THE MACHINES Single-stage axial-flow turbines are normally named on the

69

basis types

of

their

velocity triangle

triangles. are:

Two possible impulse

and most common

of velocity The design

and 50%-reaction. to guess a value of will for the

procedure for

in each case is the turbine.

total-to-total be designed the designed given with

efficiency respect

Then the machine efficiency. be calculated can then from Finally using

to the estimated will

machine

the efficiency III.

method

in Appendix to get will

The design

be optimized. the generator So the and 10 m.

In order the turbine itself

5Kw. electrical be designed turbine are for

power

10% extra

power. power

specifications hydraulic a) Design head,

of the

5,5 Kw. output

of an impulse

machine efficiency work and flow Also is coefficient coefficient specify the axial we have, of 0.80 of 20 of 0.8 that (which the and

Assumptions velocity-diagram (implicit gives absolute direction,

are a total-to-total specifications machine), angle). the rotor leaving losses of:

in an impulse an acceptable velocity

nozzle leaving

we will to be in

to minimize

therefore

AH0

Ho1 - Ho2

10 - $

from Fig.

3-3 we have,

Fig.

3.3.

IMI'CLSE VELOCITY DIAGRAM

Substituting for

the last

two relations

into

Eqr.

(3.4)

and rearranging

U we have:

rl g Hcl ++$ n

applying

numerical

values

we have

(at

mean diameter);

5.90

m/S

so A(UCe) = $U2 = 69.75 m2/s2

Then from Eq.

(3.6)

the volume-flow Q =

rate .

is

0.0791. m3/s diagram

lpnn A Ibaa from

the velocity OL1 = 68.2O

i and

a2

O"

B,

51.34O

\ B2

51.34O

71

and c1 = 13.26 m/s

w1

w2

7.38 m/s

c2

3.54

m/s

The choice following should sprockets shaft. spinning by almost gotten

of the shaft considerations:

speed has to be done with a) the value and b) a combination which gives of teeth of hub-to-tip

regard

to the ratio

diameter

be around

0.8;

,of two standard

available

can be found

us 1800 rev/min for a l/2"-pitch This value

on the generator sprocket is recommended speed lead to

The minimum number at 1800 rev/min all manufacturers.

is 24 teeth. Therefore

the value ratio

of shaft should

by specifying number regard

the hub-to-tip for sprocket

diameter teeth.

an available With rev/min rotor gives

to the above discussion for the big sprocket,

a shaft

speed of 540 of the

80 teeth be d = m

The dimensions

then wili

0.2087

72

and
dt

= =

0.2347 0.1827 height

m m = 0,026O m

dh blade

The ratio acceptable

of hub-to-tip range. design. for this

diameter

ratio

is

then

0.78

which

is

in

an

Blade separately outlet

Nozzle machine

and rotor as they

blades

should

be designed flow inlet and

have different

angles. First for given nozzle in Ref. blades: (2) by looking for different and inlet angle other through blade angle, curves profiles, an optimum (We gave the and for

information cases solidity tried having

the same deflection

of 1,5 and a stagger several profiles profile,) (3.9) with

of 45" are suggested. staggers but this value

best-looking

From Eqs.

and (3.10)

we have:

A9

ind 6

19.25"

= then

5*09O

The blade

angles

are

i
I

B1 =
B2 =

19.25O 72.29O .

73

To choose spacing.

the number of the blades above specifications

we have we have

to specify

the

From the -b
C

cos 45

0,71

-C S

1.5

(See Fig.

3-21,)

In this 15 blades sectional prefer

case a different

number

of blades gives

were

tried,

Finally crosswe

seemed to be a good number area for the blades with

as it

a reasonable blades,

(as we want chordal

to use plastic length

to have blades area). the above

bigger

and hence more

cross-sectional With follows:

specification

nozzle

blade

sizes

are as

= = = = =

0.0434 0.0651 0.0462 0.0025 0.0005

m m m m m for in Table the rotor

3-1,

C b rt 9

In the same way calculations done. for The results blade sections. are tabulated

blades Also

were 3-4

see Fig.

B; NOZZLE BLADES ROTOR BLADES o oo 51.3

6; 68.2 51.3

Z 15 16

CT 1.5 1.5

AC 45 30

AOind 19.25 5.13

8O 5.09 6.27

B; 19.25 56.34

B; 73.29 57.57

S 43.4 40.7

C 65.1 61.6

b 46.2 53.35

rR 2.5 2.5

rt 0.5 0.5

0 12.4 21.8 2

TABLE 3-l:

IMPULSE TURBINE BRING

DIMENSIONS (DIMENSIONS IN mi)

75

NOZZLE BLADES

ROTOR BLADES

. ----

FIG.304.

BLADE SECTIONS OF THE AXIAL-FLOW IMPULSE TURBINE.

76

Evaluation in Appendix each loss III

of efficiencies, and information can be found.

With we got

respect

to the method

given of

about

the blades

the value

parameter

X Nozzles Rotor blades

Pb

N pr 0.97 0080

N Pt 1.13 1.12

X Pt 0.10 0.10

X ar 4.2 1.2

X 7.20 20.20

2.48 9.04

TABLE 3-2:

BLADES LOSS FACTORS

Substituting equation we have, r) t-t for rl

the numerical and assuming

values

for

the parameters clearance for

in

the

1 mm. radial

the rotor

80.6%

The assumed value to the optimum

for

rltt

was 80%; therefore,

we are

close

enough

design. II we can find after value the other rotor will leaves efficiencies. reduce We the velocity so,

Then from Appendix specify of the that flow diffuser down to

blades .75 of its

when it

the rotor

n t-s if mechanical efficiency

75%

is 95% and generator and the unit efficiencies

efficiency will be;

equal

to

90% then

the machine

77

11 t-sm

71.0%

rl t-su

64.1%

Mechanical of

design.

It design

is not in

necessary this report. will

to describe Therefore be given. section

all only

the

details

the mechanical about

a short pages can be

description the seen. chain

different

parts drawing

In the next drawing

general-arrangement The machine and sprocket given is

and turbine

to run a 5Kw.,

1800 RPM generator descriptions

by means of are

transmission. as follows: This

Further

individualiy Rotor-nozzle components

combination. --

combination The rotor nozzle blades (Part

has high-accuracy (see (Part drawing 12) with into 1, Part li)

to he made of plastic. The up-stream diffuser for

has 16 blades.

15 blades, hubs

and the downstream which nozzle act as bearings (Part all

blades the rotor, the

13) are molded

The nose up-stream flow to the nozzles. bush (Part 15).

of the

blades These are

14) euides ins ,c+Lled inner

in a plastic

This the rotor,

bush

gives

a smooth which this will

surface the

to the duct efficiency.

surrounding

a feature Also (even

increase

plastic for

bush allows

us to use low-c<.st housing tribe

materials (Part 22). force

rustable) The diffuser

the center-section blades transmit

the rotor-thrust-bearing

to the

center

section.

73

79

80

The bushing molded between fixed

is

fixed

to the housing nozzle

be means of a flange size), which is clamped is in the After adhesive. to end

to the upstream the flanges to the bushing

end (i.e.

of Parts

21 and 22.

The nozzle

blading

by square-cross-section slots in

projections the bushing. with -Is also resin

of each blade. assembly

These match up with are front fastened

the blades

to the bushing blading adhesive.

The nose in

of the nozzle by structural

fastened

the hub of the nozzles blading the is similarly of Parts

The diffuser clamped between

fastened

to a flanged

bushing,

flanges

22 and 23. are lubricated the front of flows with water. Water flows the through

The rotor in through

bearings in

the hole

the nose and lubricates to the back bearing

front small *' Housing

bearing. holes

Then some water in the rotor hub.

and frame. -together. It pipe enables and flange.

The housing The upstream us to connect The center downstream

has three section, the

individual Part 21,

sections is actually

which an

are bolted adaptor. water turbine collector.

turbine (Part (Part

to a standard 22) encloses 23) is

10" the

section section

itself

and the

the outlet

Different sheets facilities from cast welded for iron.

parts to steel

of the housing flanges. Parts

can be made of rolled if there are local

steel

However,

sand casting,

21 and 22 would

be better

made

81

The frame The turbine through of the

(Part

25) is made of steel to the back the plate frame (Part using 24).

angles

welded

together. bolts (Part 26) 2,

is bolted

some of the The upper

flange plate

the housing frame supports system.

generator.

These are from disk

shown in Figure the rotor 31). to the This small

Transmission output has four in shaft slots

Power is

transmitted

by the meansof on its the is

a coupling which

(Part

disk teeth

circumference rotor loosely stub in shaft.

match

up with

the bore

of

As the disk transmit output only shaft. The output (Part flange water 33) which bearing leaking The ball tapered the right

contact

with

the

rotor

it force,

can to the

tovque,

and no bending

moment or thrust

shaft i- b fixed

(Part

32) is

supported

by a flange by bolts. which

bearing The prevents

to the housing seal in the

back plate drain side,

has a rubber into

the bearing. in with the flange bearing, washer, together keeps the with shaft a in

bearing

bush and a nut position. to raise

locking

In order combination (Parts chain rotor

the rotor is

speed used with

to the generator a tooth system ratio is

speed of four

of two sprockets The chain

34 and 35). (bicycle chain).

used in

this

standard

l/2" on the

The sprockets shafts, respectzvely.

have 80 and 24 teeth

and generator

52

We do not in this case.

recommend

the use of standard five

bicycle

sprockets kPM would leave be

To transmit

kw at a speed of 1800 and would

loading margin.

them up to their

maximum strength

no safety

To fix bushing hammering Using (Part

the
36)

larger is used.

sprocket This

to the is

rotor

shaft

a split

taper

done to avoid

any need for

or pressing

on the shaft. lower than five level kw less than five kw, the

the unit

in powers turbine

To run the flow to the turbine

at a power

has to be reduced a meter work at its before best the

by the means of a value turbine inlet. when it Obviously is run fully

installed the turbine

at least will

efficiency

loaded. Different by installing result that b) possibilities some kind for controlling were size the output but all power cases I feel

of mechanism increase in

studied,

in a significant users Design This would not find

and complexity. attractive.

these machine

possibilities

of a reaction section is

concerned

with

design

of a 50% reaction are exactly the assumptions the structure

axial

turbine. as for tabulated turbines drawing the

The principles impulse results are also of this

of the calculations Therefore only In fact

the same and of both

machine. will the

be presented. same, so to avoid it is not

repeating as it

the mechanical is quite similar

machine

submitted

83

to impulse given in

machine. the following

But a short paragraphs. of the will

description

of the

differences

is

The significance rotor specify rotor impulse and nozzle a work blades coefficient

50% reaction the

machine

is

that

its We to the

have

same cross absolute

section. flow angle

of one,and both

to be the same for and reaction flow

turbines. leaving the the

The absolute rotor axial guess velocity will

then be in

direction. for

The first efficiency is: = 68.2 is 85%. The result of the

the total-to-total diagram calculation B2 % U = 8.84

O*O" m/s

A(UC6) Q

= =

78 . 08 m2/s2 0.0704 m3/s 9,52

or

J/Kg

3 =w2 1
= C2 = Cx = A suitable accpetable dh/dt shaft is

m/s

Wl

3.54

m/s

speed for

above

results

which

can give

an

720 RPM,. Therefore;

84

= = = =

0.2345 0.2615 0.2075 0.027 0.79

dt
dh blade height

5-l fdt =
Blade be used for between design. both nozzle

For simplicity and rotor for

the blading.

rotor-blade

section

will

But because and the rotor,

of differences the solidity select

number of will of 45", Zweiffel b S

the blades be different. I.5 blades criterion

the nozzle For preliminary

of bladings a stagger From the

design for

let's

for (Eq.

nozzle (3.11))

and 16 blades for rotor

the rotor. we have

blades

O.&l,

also b c Then blade Z NOZZLE BLADES ROTOR BLADES 15 16 S 48.76 45.76 = cosx= 0.71 will . (Table 0 3-3):

dimensions b 39.3 39.3

be as follows AR0 in 20.0 20.0 6 6.4 604

B1 20 20

B2 74.6 74.6

re 2.5 2.5

rt 0.5 0.5

55,3 55.3

94.6 94.6

TABLE 3-3:

REACTION-TURBINE BLADE DIMEKSIONS.

85

NOZZLE BLADES

ROTOR BLADES

-.

-.

FIG.3-6.

BLADE SECTIONS OF THE AXIAL-FLOW REACTION TURBINE.

86

The blade

cross-sections

are shown in Fig. 'Using loss

3-5. the method coefficients given in

Evaluation Appendix given III,

of efficiencies. of different

the values 3-4:

are as

in Table

sb NOZZLES ROTOK 4.15 4048

Npr 1.0 1.03

Npt 1.12 0012

Upt 0.1 0.1

'ar 4.0 4.0

' 8.75 9.27

TABLE 3-4:

LOSS FACTORS OF REACTION-MACHINE BLADING

Specifying blade on the tip

1. to 1,5 mm radial then is, r7t-t = 85.6% the value

clearance

for

the

rotor can

of total-to-total

efficiency

be found,

which

For preliminary that the

if

design is

this

is close

enough

to the

first

guess,

so

design

acceptable. that diffuser blades will diffuse the flow then the to total-

we specify absolute efficiency

half

of its

velocity will rl t-s be,

when leaving

the rotor,

to-static

83.6%

If

95% mechanical as before

efficiency then

and 90% generator and the unit

efficiency efficiencies are,

are assumed

the machine

87

rl t-sm

79.4%.

T-$ su

71.5%

Mechanical impulse details mentlon of this turbine difference generator,

design.

The general are machine the

mechanical same.

design

on both no further than to speed

and reaction about this

machines reaction

Therefore other

will

be given,

the differences machine itself in

in size that

and performance. of the in size, impulse but

The output turbine, there

is more than is the slightly total

and the

bigger sizes

is not much frame and

of the units

(turbine,

altogether). blades better and axial diffuser which results in this machine are

The diffuser longer increase and give

diffusion,

in a few points

in efficiency. The transmission ratio is having 2.5 and the same size chain (l/2")

is used with and rotor

two sprockets respectively.

24 and 60 teeth

on the

generator

shafts,

Ghapter

DISCUSSION ON ADVANTAGES OF DIFFERENT TYPES

As seen in had individually at the problem the going turbine,

the

last

chapters,

each of the

studied

prototypes Looking the price of is are

some advantages from

and some disadvantages. country, which

the vieC: of a developing processes under

the manufacturing type

the turbine needed

to be made and the parameters All machines cost in are

of maintenance of the best not

and service machine.

important

the choice designed

to need skilled have

maintenance. to be discussed. manufactured

Therefore

and manufacturing turbine gives areas both

requirements possibilities being

The crossflow locally areas

of being

in farming and shipped

and/or

manufactured turbines

in industrial should be under

to farms.

But axial-flow to farms. could

made centrally which the

and shipped turbine

The type

of processes

cross-flow

be made are mostly but the

intermediate axial-flow (i.e. of the

processes turbines plastic Technology processes countries. molders

such as sheet-metals have parts molding, which

fabrications,

need more sophisticated etc.), it might To satisfy be preferred in industry industries

processes the goals

and casting, Program

Adaptation which provide

to choose in the developing

improvements

In that

case encouraging importance. which

such as plastic

may be of great

The amount of labor cross-flow turbine is

has to be put than

into

making

each the

much higher

what has to be done for

90

axial-flow because numbers.

type.

The axial-flow and their

machines smaller

would size

probably

be cheaper in large

of automation

when produced

Comparison high speed of the flow

of

the structures machine as it so that

of the turbines is an advantage a lower

shows that, over the

the

reaction

impulse to the forces

and cross electrical in chain

machines,

provides a simple.-

gear

up ratio and lower

generator, and sprockets For the kind

transmission

are entailed. of generator bath speed we have chosen lubricated, reaction and its the chain it will

must work not the last

in an oil long

and be well the axial turbine a far flow

otherwise machine.

even for

Therefore

low speed of cross-flow unattractive, necessary. A big portion because

two-step

transmission transmission

mkes it becoms

more expensive

of the price of the for small flow

of each of the units construction scale cost

is

the to

generator be similar scale axial

cost. for all

The rest units the This cross

seems likely For large than

production.

production types.

will

be much more costly cost for for molds

the flow

is because but initial

the material investments

the axial

machines required.

is small

and dyes are

Finally there requiring channels, is often

the

efficiencies water flow flow will

of the machines available therefore

differ.

While machine pipes,

surplus water

a high require

efficiency less costly

a lower values

and so forth.

91

The following machines. Cross-Flow Turbine

t-t t-s 76% 60% 56.5% 51%

table

shows the

efficiencies

of the different

Axial-Flow Impulse Turbine

80% 75% 71% 64%

Axial-Flow Reaction Turbine

85% 83.5% 79.5% 71.5%

t-sm t-su Key :

t-t E

total-to-total total-to-static total-to-static total-to-static

efficiency efficiency efficiency efficiency

of turbine of turbine of machine of unit

blading blading (shaft power) power)

t-s t-sm t-su

2 Z E

(electrical

Based on all the best 4,l solution

considerations to the problem.

we chose

the

reaction

machine

as

IMPROVEMENTS ON REACTION MACHINE The preliminary design shown in the last chapter on that it has some design as

questionable

features.

Here we try are

tc improve

much as possible. to cover. By looking this nozzle chapter

Following

some items

which

seems necessary

at the general-arrangement the difference

drawing between

submitted the rotor-

in

(DRN, No, AF301), in

combinaticns

two schemes

can be seen.

92

This rotor. central pressure on the

improved

design

provides

less

hydrostatic through hence

force

on the

The atvlospheric hole to the other

pressure side

is bypassed of the rotor,

the rotor equalizing the axial the force

on the two sides rotor. covered and give surfaces The sliding with thin

of the rotor surfaces

and reducing the sheets the high rotor

between

and diffuser reduce the

hubs are friction on sliding they melt.)

stainless-steel life, (For

which

a long

pressure

and velocity last and aid

even the best of these

kinds surfaces

of plastic

can not

Lubrication in the rotor supplied from adaptor

is possible

by the

of holes water is

hub and grooves upstream through

on the plates. the holo-s machine

The lubricant in the stator hub. The piping.

The front new adapter The smaller

in the improved the reduces

is

changed.

enables tube

us to connect size

turbine

to 8" diameter

and valve in

the cost. turbine provides good

The oil lubricating increases

bath

the back of the for the chain system's are also

conditions the transmission

and sprockets, life. changed.

and hence

The blade settling best 4.2 angle performance. Off-Design The type use a gate assumption valve is that

profiles

The new blades optimized for

have a the

of 38" and their

shapes

are also

Performance of flow control we recommend for the machine is to

installed the

one m. ahead of the machine. turbine is going to be run under

The basic fairly steady

180 I60

i20 loo 80 60 40 20 0 zoo 0 400 600 SHAFT SPEE

FIG.401.

800

1000

1200

1400

R.

CHARACTERISTIC CURVES OF REACTION MACHINE FOR CONSTANT FLOW RATE.

r6

02 J 00 a

0 v 40

45

50
FLOW RATE

0 55
60 m3,lrn 65 70 75

FIG.4-2.

CE.ARACTERISTIC CURVES OF REACTION MACHINE IN CONSTANT SPEED.

95

loads. slight

Therefore changes in

the

required

power

can be set

on the machine

and

frequency

up to 5% would systems to control

be acceptable. the turbine which will cause

More sophisticated big increases in size

and price co customers. assumption 4-1

of the machine,

makes the

machine

unattractive Based on this

the

characteristic These

curves curves

of the are theoretical is predi-

turbine curves cated

are shown in Figures and based on predictions. using the method degree given

and 4-2.

The off-design in Reference (3),

performance which

has been found

to have a high

of accuracy.

APPENDIX I TABLE OF PARTS AND WORKING DRAWINGS

Following reaction numbers provided. process given machine. all

are

the

complete

working

drawings

of the modified Using these table

Each drawing about

has a reference each part on material,

number.

information Special

can be found type

from the

information the part

of manufacturing are

under under

which

should

be made, or sub-drawings,

the heading

"Remarks." complicated submitted parts, which part's turbine.") drawings are marked reference for additional "A," (AF300

For the case of sections "B, (1 I, C," stands for or sr;bparts etc., after

are

by letters

the master reaction

number.

'axial-flow

98

TABLE OF PARTS AND LIST OF DRAWINGS OF REACTION TURBINE COMPONENTS

PARTAF311 AF312 AF313 'AF313A AF313B AF313C AF313D AF313E

I KUM~ER ,
I I , (

NAME OF PART FRONT ADAPTOR MIDDLE SECTION DRAIN CHUTE BACK PLATE FRONT FLANGE

NUMBER REQ'D 1 1 1 1 1 1 2 1

MATERIAL CAST IRON CAST IRON STEEL 1 OMM PLATE 1 5MM PLATE 8MM PLATE 5MM PLATE 5MM PLATE

REMARKS

HOLES OF FLANGES SHOULD BE ALIGNED SEE SUBDRAWINGS

I /

CURVED PLATE SIDE PLATE FRONT PLATE

. . . contl'nued

TABLE OF PARTS AND LIST OF DRAWINGS OF REACTION TURBINE COMPONENTS(Continued) NUMBER ! REQ'D 1 1

NAME OF PART AF314(1 AF314(2 NOSE

MATERIAL

REMARKS
SEE ADJACENT TABLE FOR PROFILE COORDINATES SEE AF317 FOR BLADES PROFILE.

1 ;;;if

STATOR BLADING

AF316A AF316B AF316C I

1 I

ROTOR BLADING

3
11 : 1 1

GLASS-FIBER-REINFORCED POLYESTER THERMOSET POLYESTER RESINS 30% GLASS BY WT.

THE 1.5MH STAINLESS-STEEL SHEET SHOULD BE JOiNED TO SLIDING SURFACE BY METALBONDING. EPOXY. SEE ADJACENT TABLE FOR BLADE PROFILZ.

I AF317
AF3l8A AF318B

NOZZLE AND ROTOR BLADE SECTION DIFFUSER BLADING

GLASS-FIBER REINFORCED POLYESTER THERMOSET POLYESTER RESINS 30% GLASS BY WT.

THE 1.5MM STAINLESS STEEL SHEET SHOULD BE JOINED TO SLIDING SURFACE BY METALBONDING EPOXY. SEE ADJACENT TABLE FOR BLADE PROFILE.

AF319 AF320

DIFFUSER-BLADE SECTION BUSH GLASS-FIBER REINFORCED POLYESTER THERMOSET. POLYESTER RESINS 30% GLASS BY WT.

. ..continued

TABLE OF PARTS AND

LIST OF DRAWINGS OF REACTION TURBINE COMPONENTS (Continued)

PART j
NU%EER i AF321A AF321B -AF322 NAME OF PART

NUMBER

IREQ'D
1 2 1

MATERIAL ALUM1NW HARD STEEL STAINLESS STEEL

REMARKS

1 SLOTTED DISK ' KEY

1 SHAFT , 1 1 HUB ASSEMBLY HUB HOUSING FRONT CAP BALL BEARING

AF323A AF323B AF323C

1 1 1

CAST STEEL 1.5MM STEEL SHEET M.R.C. BEARING 206-SX ADAPTER AND NUT G-Y GARLOCK 78, 0542 COMP NO. 26448-35 DES. GRP. D. EQUIVALENT STANDARD PARTS WITH THE SAME SIZE CAN ALSO BE USED.

AF323D

SEAL

AF323E* i

(3/16"~32)~5/16" BOLT

ROUND HEAD

I I . ..continued *no drawing; standard component

TABLE OF PARTS kND LIST CT DRAWINGS OF REACTION TURBINE COMPONENTS(Continued) PART NUMBER AF324 NUMBER REQ'D 1

NAME OF PART BIG SPROCKET

MATERIAL

REMARKS

BROWNING 4OP60 TYPE 4 BUSHING Pl BROWNING 4024

NO. OF TEETH 60 PITCH l/2" PITCH CIRCLE DIA. 9.554 FOR TYPE 40 CHAIN NO. OF TEETH 24 PITCH l/2 PITCH DIA. CIRCLE 3.831 FOR TYPE 40 CHAIN l/2" PITCH NO. 40 A.S.R.C.

AF325

SMALL SPROCKET

AF326*

CHAIN

BROWNING NO. 40

-I--

. ..continued *no drawing; standard component

TABLE OF PARTS AND LIST OF DRAWINGS OF REACTION TURBINE COMPONENTS(Continued) ! PART -_-I 1 NAXE OF PART FRAME SIDE ANGLES TOP ANGLE 1 AF327C
#

I
I

f I NUKBER 1 I REQ'D 1 2+2 STEEL 80X80X8

MATERIAL

REMARK!!

2 OFF AS DRAWN OPPOSITE HAND I

TOP PLATE 1 1 , BAR ] 1 ri,,DATION FOUNDATION PLATE / I ' OIL BATH

1 AF327D j AF327D j 1 I AF327E j AF328 I j AF329 I

I I i ! I 1

2 1 2 ; 4

80X80X8 L 80MM PLATE 40x8 FLATBAR 1OMM PLATE 2 AND 3MF1STEEL SHEETS 2MM STEEL SHEET

I SEAMWELDED

OIL-BATH COVER

. ..continued

TABLE OF PARTS AND LIST OF DRAWINGS OF REACTION TURBINE COMPONENTS(Continued) NUMBER REQ'D ,_-1

NAIVE OF PART
8

MATERIAL
WiNCO INC. SERIES 5KS4G-3

REMARKS
4 POLE, 5KW, 115/230 21.7 AMP. 60 CYCLE 1800 R.P.M. 1 PH. HEXAGON HEADED
I

; AF330* I I I f i1 AF331A*i / AF331Cj 1 AF332A"I j AF332B*/ 1 AF332C*[

I

j
I

GENERATOR

VOLTS

j 1 i (5/8"~12)~2 5/8"x12 5/8" (l/2%12) 1/2"x12

I I

l/2"

BOLT

20 20 20

AF331B *[

NUT l-1/2" NUT BOLT

LOCK WASHER

4 4 4 4 4 4 _ -4 4 1 2 1 -HARD STEEL

HEXAGON HEADED

l/2"

LOCK WASHER BOLT

AF333A*; AF333B* AF333C *j A:Z33D*/ AF334 *I ,

(9/16"xl2)x2" (9/16"xl2)xNUT 9/16" 9/16"

PLAIN WASHER LOCK WASHER

ALIGNMENT-PIN (3/8%16) 3/8" 2" BOLT

I HEXAGON HEADED

AF335A"I AF335B*/ AF335C*! I I*no drawing;

PLAIN WASHER WING NUT

(3/8'k16)

. ..End

standard

compcnent

105 I

106

co

107

WI

108

109

=: 0

CURVED PLATE

111

112

1 113

7 -

114

0.0
2.5 5.0 7.5 10.0 15.0 20.0 25.0 30.0 35.0 40.0 50.0 60.0 70.0 80.0 90.0 ZE 120:o 130.0 140.0 150.0 160.0 2xax 25:5 31.5 36.0 45.0 51.0 56.5 62.0 66.0 70.0 77.0 82,O 87.0 91.5 95.0 98.0 100.0 101.5 102.5 103.0 103.5 104.0

115

116

117

I I

118

OS

119

m 7 I

ROTOR BLADING_

121

Yc mm
0.0
1.0 2.5 3.75 5.0 6.25 10.0 12.5 15.0 17.5 20.0 22.5 25.0 30.0 32.5 35.0 37.5 38.75 40.0 41.25 42.5 43.5 44.5 45.5 46.5 47.5 48.75 50.0 E5 2:o E5 4:75 S5 10.0 11.5 12.5 13.25 13.85 14.0 13.85 13.25 12.6 12.0 11.25 10.5 9.12 8.62 7.75 6.75 x5 210 0.0

Xt mm I t mm
0.0
3.0 6.0 129:: 15.0 18.0 21.0 24.0 27.0 30.0 31.5 33.0 36.0 37.5 39.0 42,O 45.0 E 51:o 54.0 57.0 60.0 0.0 0.76 0.86 i-y8 1:43 1.76 2.02 2.52 3.28 3.78 4.13 4.34 4.34 4.43 4.59 4.54 4.28 4.13 4.03 3.53 2.83 2.17 0.0

-!l

123

cu Lc 0

124

125

I r, \

t /

R/=1.0 Rf=0.2

mm mm

mm 0.0
K5 0:75 1.5 i-i 6:0 1E 15:o 18.0

mm 0.0 0.69
0.84 1 , Of, 1.52 1.96 2.38 2.74 3.30 3.73 4.05 4.28 4.43 4.50 4.47 4.33 4.08 3.37 3.31 2.84 2.33 1.79 1.25 0.73 0.28 0.0

21.0
24.0 27.0 30.0 33.0 36.0 39.0 42.0 45.0 48.0 51.0 54.0 57.0 60.0

126

--

127

128

129

220

SHAFT

I II I

HUB HOUSING (1 of 2

132

133

134

135

136

137

- -I

138

? Tr

------m--A-----,
--v-----------i

---e--m--t
I

-a-----.

-.

--

FRAME (plan

view)

2 of 2

140

I I I I I I I I I I I I I I I I

402

-i

I Q 00

TOP ANGLE

142

I I I I

I8

144

\ Y

8G9

1 \

\ \ \

145

35

I 0I

ALIGNMENT-PIN --

APPENDIX II FRICTION LOSS IN NONCIRCULAR CONDUITS

Pressure section

drop

due to flow from;

through

a non-circular

cross-

bend can be found

where is

is

the loss

factor, K

the

average

flow

velocity diameter

and of the

the mass density. and the (Fig,

is a factor

of hydraulic as well

cross-section angle

radius I-l),

of the bend,

as the deflection

of the bend The hydraulic

diameter

is defined

as;

ADh 5

4 x flow area wetted perimeter

'

and then in terms

pressure of D h'

drop as:

due to friction

loss

can also

be expressed

where factor E/D

L is

the length

of

the conduit

and

fh

is

the

friction Re and

on the basis should

of hydraulic as,

diameter.

Obviously

be defined

Re then fh

v Dh E 7 using

and Fig.

E/D I-2.

F $-

can be found

147

148

0.20

0.15

1 VALUES OF R/a 0 FIG. 7.

20 DEFLECTION ANGLE LOSS FACTOR FOR BENDS.(ASCE,J.HYDRAULIC DIV.,NOV. 65)

e. 0.004 CI *
0.003

--- -IO3 IO4 IO5 Re = VII/v IO7

FIG, 2. FRECTlON FACTOR f VS. Re. FOR DIFFERENT e/D. H.Y.Choi, Heat,Mass and Momentum Transfer P 58 1

(W.M.Rohsenew

and

149

APPENDIX III EFFICIENCIES

The total-to-total

efficiency

of a turbine

is

defined

as

?J

tt

turbine output power enthalpy drop from inlet total and temperature to outlet total of efficiency is concerned with

pressure pressure the blading hydraulic

This losses.

definition

The total-to-static defined as,

efficiency

of a turbine

is

t-s

= pressure

Turbine output enthalpy drop and temperature the amount

power from inlet to outlet going of

total static out

pressure of the

This turbine

efficiency by drain

concerns flow plus

of energy losses

the internal

the blading.

For a turbine efficiency disk friction

as a machine

an overall which

total-to-static should is include the

of the machine and other

can be defined mechanical losses.

That

rl t-sm

-rltsxrlm

where as,

TJ m

is

the mechanical

efficiency

of the machine

and defined

150

'i,'

T -T loss T

where

stands

for

shaft

torque. unit account the efficiency which is of the generatar

For a turbo-generator should also be taken into

= -

output electrical input mechanical

energy work

Then the overall

efficiency

of

the

unit

will

be defined

as;

rl t-su

nt,sXrlmxll g

See Fig.

II-1

151

HYDRAULIC LOSSES ENERGY LEP,VI% TtfE TURBIiIE TO TAIL-MTER FIECHANICAL LOSSES

GENERATOR LOSSES

OUTPUT ELECTRICAL PONER (GENERATOR)

FIG. 1 --

SCHEME OF LOSSFS Ii! GlATER TIJRRO-GENERATORS.

APPENDIX IV PERFORMANCEESTIMATION OF AXIAL-FLOW TURBINES

There axial-flow straightforward by H.R.M.

are several turbine.

ways to evaluate given

the efficiency

of an

The method

here which given in in

seems very the paper the written

is based and H.J.A. Enginetring,

on the method

Craig

Cox and published Volume 185 32/71,

Institution

of Mechanical THE METHOD

1970-71.

For an axial-flow two groups.. of the nozzle friction, 1 losses. Group

turbine are

stage,

losses

can be divided and secondary

into losses

1 losses

due to profile and group

and rotor etc.

blading,

2 losses

are due to disk only as with group

leakages, Therefore

Here we will efficiency

be concerned

blading

can be defined

l-lt-tb 2 work It factors is convenient

work done in blading done in blading + group to evaluate blade = outlet c2 Xn $ the group velocities. w2 + Xr $

1 losses 1 losses as loss

based on relative Group 1 losses

Therefore,

where

X n

and losses

are for

the sum of loss the nozzle

factors

due to profile respectively.

and

secondary

etc.

and rotor,

153

-.

154

. .

Then to take account the area

the

losses

due to tip

leakage

and etc. efficiency

into by

we have to multiply ratio Ar defined E

the value

of blading

as follows; area

Rotor blade swept annulus area

Evaluation

of loss

factors loss factor loss is factor the sum of profile Xs , where the loss former factor one is

The blade X and secondary P defined as

xP = x pb 'pi

Npr Npt + mp,

+ (Axp)s,e

+ (ax 1 Pm

Each one of these X Pb N Pi N Pr N Pt 5 basic 5 loss = loss 5 loss z profile - profile radius E profile

are

defined loss

as:

profile correction correction correction loss loss

factor factor factor factor factor

due to incidence due to high due to trailing increment increment Reynolds edge edge Number

Wp) t
iAx > p s/e (oxp lrn

due to trailing

dtle to back surface

loss

factor

increment

due to high

Mach number

155

This turbines case for N Pi would

method

can acceptably that this

be used for report is

axial-flow with.

water In this and

of the kind design-point be zero

concerned (mpjrn

preliminary and the simple

design form for

, (fip)s,e will be

X P

pb Npr Npt

(axpIt

Each of Figs. blade

these

parameters to 111-B. as;

can be found The Reynolds

using

curves

given

in

III-2 opening

Number is

defined

on the

Re

*2O2 E 7

or

clol V

See Fig.

III-1

for

the

terminology factor

of the blades, can be found factor XS using is Figures defined III-7 as

The secondary-loss and III-8, where

the secondary-loss

xS

(Ns+qb

(Xsjb

where ('s)b
z

basic

secondary-loss ratio.

factor

(Ns$i/b-

secondary-loss

156

Fig. 1. Turbine

blade

and velocity

triangle

notation

16

__

Fluid Inlet at mln.rdcl ,cont,!!on

orgee loss

10

20

:i F:il:O !Iw

40

50 60 CiJ: - ET :N;LE -B speed ccnc bon) FL

70

cn

90

Fig.2 . Lift parameter,

157

-G-l

0 Fig.3.

01

I 0.2

I c3 RATIO-I-~

I
'24

I
05

I
06

I
07

0.8

Contraction

ratio

for average

profiles

., s %33
i p: 25 Y

.- .
,

!!

! I 5 20 I 2 C0c:~crt.o~ rc:,o

/
/ /

5 m

05

5s I

I I

ri
I

r VI

MODIFIED

LIFT

CGEFc.Z EYT -

;x:s,%:

TRAMr;

E3;E

Tr!'CKSESS

TC PITPI

R;T.G -tc/s

Fig.4.

Basic profile

loss

Fig. 5 .Traiiing

edge thickness

losses

158

REYNOLDS li.NE_~

Rz,, -based

on biade o~enq number effect

Fig.6,

Profile

loss ratio

against

Reynolds

-.._
L 7 / /
---I

25

4or------

33 -,b/h

-35

/ F c: I//
/ ,

!5 NVLQSE ASPECT RATIO -b/h

-loss-aspec:

45 bit,

50

- sj

/ I

Fig.

7. Secondary

ratio

factor

( 55 98 10 SQUARE OF 1-F. FF:A-iJE YECN VE:SC:TY RATIO ACROSS 3LA: .; -et tie x~ry~ou!~e? bcc:o;i:#

Fig.

8. Secondary

loss-bask

loss factor

159

LIST OF SYMBOLS

area blade width flow chord angle of the blades absolute

velocity, of

the blade

diameter friction
g

factor due to gravity head

acceleration hydraulic blade

h h i K L lil N
0

height

enthalpy incidence head-loss length mass flow rotational opening pressure volume radius flow rate of rate speed the blades angle factor

spacing torque

of the blades

. ..continued

'LIST OF SYMBOLS(continued) U W Z ci B A 6 blade tangential relative velocity, velocity flow

number of blades angle of absolute angle of relative deop or rise deviation efficiency turning stagger angle or setting angle velocity velocity

of a vaiable

angle

mass density
CT

solidity flow coefficient work coefficient

speed of revolution

(angular

velocity)

161

SUBSCRIPTS

annulus hub inlet leading m n

0

edge

mean value nozzle outlet profile rotor tip axial direction property and radial direction

P r t
X

stagnation inlet

to the blade

out of blade tangential direction

* * *

163

REFERENCES

(1)
(2)

Horlock, J.H. Axial Flow Turbines. Robert E. Kreiger Publishing Co., Huntington, New York, 1973. Dunavent, J. C.,and Erwin, J. R. Investigation of Related Series of Turbine Blade Profiles in Cascade. National Advisory Committee for Aeronautics, Washington, NACA. TN3802. Craig, H. R. M., and Cox, H. J. A. Performance Estimation of -Axial Flow Taurbines. The Institution of Mechanical Engineers (Thermodynamics and Fluid Mechanics Group), Volume 185 32/71, 1970-71.

i3)