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Original Paper
1. Introduction
Renewable energy sources are the key area, which brings green revolution in India. It helps India to fulfill its power demand and maintain its economic growth for next decade. Small hydropower is one of the main renewable energy resources and India has good potential in it. There are four basic type of turbine (Francis, Kaplan, Pelton and Turgo) is used for hydropower generation. Computational Fluid Dynamics (CFD) is latest state of art technological tool, which is used by designer for hydraulic design of Turbine. This paper describes how high head Francis turbine is designed using CFD. It starts with basic design of each component (Spiral Casing, Guide vane, Runner, Draft tube) and optimization & performance evolution using CFD. Basic turbine design optimization loop is as shown in Fig. 1.
2.1 Runner
Runner is most important component of Francis turbine. High-pressure water is entered at runner inlet with partial kinetic energy and flow through area between two blades of runner. Hence, by reaction principle water pressure energy is converted into kinetic energy, which produces pressure difference between two sides of blade. This pressure difference between two sides of blade produces torque and finally mechanical energy in the form of rotation of runner. Basic dimension of runner is calculated from our experience database and using literature [1.]. After freezing basic dimension i.e. diameter, width at inlet and outlet of runner, blade angle is calculated.
Accepted for publication. Corresponding author: Kiran Patel, kiran2810@gmail.com
3D Model Generation
Grid Generation
Mechanical Design
Prototype Design
Fig. 1 Turbine design optimization loop
Runner
Guide vane
Spiral casing
Draft tube
Figure 2: Design sequence of Francis Turbine components
Velocity triangles at inlet and outlet are as shown in Fig. 3(a). These basic dimensions are used for making 3D model of runner as shown in Fig. 3(b). This 3D model of runner is used for CFD calculation for optimization and performance evolution purpose.
b. Runner 3D model
3.2 Meshing
Numerical discretisation or meshing is most important step to carry out CFD analysis. Meshing is nothing but dividing fluid flow volume in small elements. Quality of CFD result depends on meshing of various components. We have used tetra elements along with prism elements at solid boundary for mesh generation. Prism elements are useful to capture boundary layer separation. Fig. 5 shows meshing of various components. Details of no. of nodes in each component are given in Table 1. Quality of mesh generated is as per the standard industrial practice, result is also checked, and they are independent from mesh effect.
Prism Layer
Figure 5: Meshing of Turbine components Table 1: Element generated in each component Components Spiral Casing Guide vane Runner Draft tube
Sr. No. 1 2 3 4
Efficiency (Nondimensional)
0.5
1.5
10
8 6 4 2
0
0 50 100 150
25%
55%
90%
100%
Figure 8: Velocity plots at various loading condition for guide vane and runner
Flow separation is also taking place in draft tube because of diffusing section and change in direction of flow. Fig. 9 Shows flow separation region in draft tube at 25% and 100% loading condition. In both the condition flow separation is observed but at 100% flow separation region is less. At 25%, loading condition high head loss is observed in draft tube, which is because of mixing of high & low momentums and flow separation, hence pressure recovery in draft tube is less. At overload condition, circumferential component of velocity is higher which is not converted in to pressure recovery and hence higher head loss is observed. Flow separation in case of draft tube cannot be eliminated, we have to design draft tube such a way that flow separation is at minimum level and pressure recovery is maximum. Runner is receiving water at required velocity and swirl from guide vane. This high-pressure water enters into the runner and because of incidence; flow is being separated at inlet. Optimization of runner design is based on pressure distribution on runner blade. As shown in Fig. 10, two sides of blade have different pressure, which produce tangential force and torque. Pressure difference on runner blade is also known as blade loading.
25% Mixing Region of high and low momentums Flow separation region
Figure 9: Velocity vector plots at various loading condition for draft tube As shown in Fig. 10 pressure difference on two sides of blade increases with loading, hence as the load increases, pressure difference increases. Because of high-pressure difference on both side of blade, high torque is also developing and hence power output increases. Pressure difference on two side of blade is governed by blade angle distribution. Pressure and velocity distribution inside passage of two blades depends on blade angle. Runner is optimized based on pressure and velocity distribution on blade and passage. Pressure distribution should be gradually reduced from inlet of runner to exit of runner as shown in Fig. 10 & 11.
Figure 11: Pressure distribution on runner blade, hub, and guide vane
At the exit of runner, pressure is below the atmosphere and at part load; it is below the vapor pressure of water. When pressure is below the vapor pressure of water, vaporous bubbles are produced. This phenomenon is called as cavitation. To determine cavitation level, separate cavitation analysis has been carried out using Rayleigh Plesset cavitation model. These bubbles are developing a vapor
core in to draft tube as shown in Figure 12. When this bubbles collapse, high-energy pressure waves are generated which produce lots of noise and vibration. Cavitation produces pitting on runner and draft tube. Cavitation analysis also shows that flow inside runner is cavitation free.
4. Conclusion
Francis turbine design is accomplished considering CFD analysis as a tool for designer. It helps us to determine trend of hydraulic losses in various components. It helps us to determine various causes of hydraulic losses i.e. flow separation, friction losses but at this stage, it is difficult for us to separate them and find individual contribution. We have also predicted performance of new design in complete operating range. CFD helps to do better and efficient design of Francis Turbine. At present model is under manufacturing and will be tested soon.
Acknowledgement
We are grateful to Jyoti ltd. as well as all the persons involved directly or indirectly without the help of which this task of design optimization of geometry of Francis turbine might not be possible.
References
[1]. Nechleba, Miroslav, 1957: "Hydraulic Turbine their design and equipment", ARTIA Prague, Czechoslovakia. [2]. Kovalev, N.N, 1965, The National Science Foundation, Washington "Hydro turbine design and constructions".
[3]. Barlit, V.V., 2007,"Hydro turbine volume 1 & 2", Department of civil engineering, MANIT, Bhopal.