Performance Test on Pelton Turbine

Darwin Bonghanoy Lim1

Abstract: The performance of Pelton turbine is tested and evaluated in the University of San Carlos Hydraulic Laboratory. The Pelton turbine

was tested by varying the pressure inlet at 0.5, 1.0, 1.5, and 2 2. With these values, each pressure inlet correspondingly was also varied

the spear setting resulted the analysis of effects of varying the area of the water jet before it flow and impacts to the runner. The generated
power output was investigated with constant load resulted a constant torque analysis for this experiment. At lowest pressure inlet resulted
an ideal high efficiency for turbine performance but resulted a minimum power generated by the turbine. For the four pressure inlets that is

held to observe in this experiment, pressure inlet at 2 2 yielded a maximum power output of 360 Watts with an efficiency of 67.9%. The


optimum operation for the Pelton turbine to run efficiently is found to be and must be at pressure of 2 2 with a spear setting set to 1.

Author keywords: Pelton Buckets; Shaft Power; Pressure; Water Jet; Prony brake; Runner

Introduction
The experimental studies on Pelton hydro turbines that have been
In nature, hydraulic energy is a type of usable energy which can be
published in the literature are not many. The high complexity of
directly converted into mechanical energy. It has since more than
the unsteady jetbucket interaction in the rotating runner and,
one hundred years mainly been utilized for the production of
moreover, the contaminating effects of the outflow that splashes on
electricity. As a most important type of the renewable energy,
the casing walls make the measurements of the flow in the interior
hydraulic energy shows its very broad perspective in the future.
of the casing practically impossible. Hence, the existing
More and more hydropower plants will be built or refurbished
experimental works concern either flow visualization studies
worldwide (Zhang 2016).
(Perrig 2006) or flowbucket interaction in non-rotating buckets
Among various types of hydraulic turbines, the Pelton turbine
(Kvicinsky 2002; Zoppe 2006)
which is also called the constant-pressure turbine, represents an
important and probably also the most widely applied turbine type.
The first Pelton turbine was invented by Lester Allan Pelton in Perrig et al. used flow observation techniques to study the unsteady
1879 and tested successfully. The turbine is mainly used in evolution of the free-surface flow in a single-injector Pelton runner.
mountainous areas where the available water, for example, is They found that the impact of the droplets released from the
stored in a lake or reservoir which lies a few hundred to 1800 m buckets causes perturbations on the jet surface, which may result
above the turbine machines. The turbine power ranges from several in reduced bucket efficiency. Also, some more complex and not
kilowatts to 400 MW (Angehrn 2000). well understood mechanisms during the jet cut process were
Pelton turbine is an impulse turbine as there is no pressure drop identified and showed that they can influence considerably the
subsequent evolution of the flow in the bucket and the energy
across the buckets. The flow is axial, i.e., there is no change in
exchange efficiency (compressibility effects, spray and water
peripheral velocity and water enters and leaves the buckets at threads formation, Coanda effect, etc.) (Perrig 2006).
the same radius (Zoeb Hussian and et.al. 2009).The amount of
water striking the buckets is controlled by providing a spear in the
nozzle. The spear is a conical needle operated in the axial direction
depending up on the size of the unit. When the spear is pushed
forward (see Fig.1), the amount of water striking the runner is
reduced and when the spear is pushed back, the amount of water
striking the runner increasesThe space of the buckets is of a double
hemispherical cup or bowl. Each bucket is divided into two
symmetrical parts by dividing wall which is known as Splitter. The
Splitter divides the jet into two equal parts. The buckets are shaped
in such a way that the jet gets deflected through 160 or 170. The
buckets are made of cast iron, cast steel bronze or stainless steel
depending upon the head at the inlet of the turbine. The function of
water is to prevent the splashing of water and to discharge water to
tail race. The casing of Pelton Wheel does not perform any Fig.1 Diagrammatic arrangement of a Pelton wheel.
hydraulic function (theconstructor.org 2016) (Source: Zoeb Hussian, Mohammad Z. Abdullah, Zanial Alimuddin-Basic
Fluid Mechanics and Hydraulic Machines (2009))
Fifth-Year Student in Bachelor of Science in Mechanical Engineering,
Department of Mechanical Engineering, University of San Carlos,
Cebu City 6000, Philippines. Email: limdarwin17@gmail.com

Experiment Set-up
Fig. 2. Schematic Diagram of the Set-up in University of San
Carlos: (1)-(14) Foot valve; (2) Centrifugal pump; (3) Gate valve near the
pump; (4) Secondary bypass gate valve; (5) Prony brake water gate valve; (6) Prony
brake; (7) Pelton turbine; (8) Spear flow adjuster; (9) Gate valve near the turbine; (10)
Pressure tank; (11) Primary bypass gate valve; (12) Gate valve for priming of centrifugal;
(13) Axial pump.
Fig. 2 shows the Turbine set-up currently existing in the University
of San Carlos-Talamban Campus. The priming of the centrifugal
pump uses an axial pump where it sucks water to the reservoir and
then travels by a bypass line going into the centrifugal pump. A
two bypass line is present which is commonly used for different
operations. But the present experimentation of the Pelton turbine
uses the primary bypass line because it uses a pressure tank. In the
prony brake a water supply is needed to cure too much friction
during the operation thus allowing it to run at normal conditions.
The set up also has installed foot valve in order to avoid suction of
any materials that can harm both the axial and centrifugal pumps.
All other parts in the set-up is mainly comprised of pipe lines and
other gate valves.
Experiment Methods
Pump Priming and Start-up
Priming is the process in which the impeller of a centrifugal pump
will get fully sub merged in liquid without any air trap inside. The
process of priming the pump is first to ensure that other gate valves
connecting in the axial pump is closed. After which all the valves
are checked, the axial pump is turned on. Together the gate valve
supply is opened to let the water flow in the centrifugal pump to
begin priming. After some time, the priming cup is opened to check
if the water is nearly full. The shaft is also rotated to allow any air
trapped in the centrifugal pump to escape. After which the water
pouring out, the priming cup is then closed to allow water to be
stable inside the pump. One person must stand before the gate valve
for the supply of the water in the turbine to prepare it to open in a
counter-clockwise direction after the push button is pressed. When
the centrifugal pump starts, the primary bypass line must be fully
open. The axial pump is then safely turned off. The shaft of the
Pelton turbine connecting to the prony brake was rotated to check
if it is safe to be operated. The gate valve near the spear flow
adjuster was opened slowly in a counter-clockwise direction to
allow the water to flow into the Pelton turbine. After which the gate
valve for the supply of the prony brake is opened to allow it to
operate smoothly considering that it is exposed into so much
friction during high torques. Also that water lubrication was needed
to prevent a magnetic drag or eddy-current brake (Muller-Girard et
al. 2003). The performance test of the Pelton turbine is then applied
by loading it with weights near the arm length to evaluate its
braking power to determine its power output and efficiency. The
pressure of the water is set which comprises of four namely 1 ,
2
1.5 ,2 , and 0.5 . Each pressure was evaluated for the
2 2 2
performance test of the Pelton turbine. The yielded parameters of
the experiment namely the inlet pressure, speed, and weir height is
directly recorded. The torque is measured by using the weights.
Also the experiment enables to analyze the effects of adjusting the
spear at any pressure used. Thus the performance of the Pelton
turbine is justified according to the data gathered.
Turbine Shutdown
The water supply of the prony brake is cut out by turning the gate
valve in clockwise direction to close it. The water supply from the
centrifugal pump is then cut by the gate valve near the spear setting.
The primary bypass valve was turned fully open to normalize the
flow of water supply. One man then slowly turns the gate valve
near the centrifugal pump supply until the pressure gage touches
the red line also referred to be the critical pressure occurred in the
flow near the gate valve. After which the critical point is reached,
the centrifugal pump is turned off rotating the gate valve as fast as
possible to protect the impeller.
Data Gathering
The prony brake was used to determine the torque calculating the
power generated by the turbine. Thus,
= 2 (1)
where, T is the torque and N is the shaft speed which is directly
measured. According to the present turbine it has an arm length
equal to 72cm.
For measuring the Flow rate, the Rectangular-notch weir was used.
The length of the weir is measured using the tape measure.
2 3
= 2 2 (2)
3
where, is the flow rate, Cd is the Rectangular-notch weir
coefficient of discharge, g is the gravitational acceleration, H is
height of the opening of the weir.
The velocity at the inlet and outlet can then be calculated using the
Bernoullis equation.
2 2
+ + 1 = + + 2 (4)
2 2
where, is the pressure, is the velocity and is the elevation
head. The continuity equation is also used to determine the In Fig.4, the flow rate and the rectangular notch weir height is
velocity. graph accordingly. As the flow rate increases the weir height also
3
= 1 1 = 2 2 (5) increases to the power of as shown in Eq.2.
2

where, is the cross sectional area of the pipe, Q is the flow rate of
the water 0.009
Assuming that the momentum of the water is all transferred into 0.008
rotative energy to the buckets. Thus the total head of the turbine
0.007

Flow Rate (m^3/s)

can be calculated.
0.006 1 kg/cm2
2 = 2 (6) 0.005 1.5 kg/cm2
0.004 2 kg/cm2
where, 2 is the velocity of jet, Q is the flow rate of the water, H is 0.003 0.5 kg/cm2
flow head. 0.002
0.001
The water power is calculated using the formula,
0
1 2 3 4 5 6 7 8 9
= (8)
Weir height (cm)

where is the specific weight of the water and is the

Fig.4.Flow rate vs Efficiency Results
discharge flow.

The turbine efficiency is calculated by dividing the power
generated by the prony brake over the power available by the
water.
= 100%
Results and Discussion
As shown in Fig.3, the shaft power and spear settings graph is
shown. The Pelton turbine yields a maximum shaft power when the
spear setting is at a fully open state which is in the 8th setting. The
pressure at inlet also indicates a maximum shaft power at 2 2.
Fig.5 shows the water power vs spear setting graph. The spear
setting is designated by numbers with 1 as the lowest which means
the sphere is located almost near into the tip diameter which closes
the flow almost zero. 8 is the largest opening of the spear setting.
At higher opening of the spear, the shaft power tends to increase
(9)
this means that there is enough flow and energy that hits in the
buckets of the Pelton wheel. Fig. 6 explains why this shaft power
tend to increase. As the opening of the spear increases the discharge
flow also increases thus according to Eq. 8 where the power of
water is proportional to the flow rate.
2000
1800
Water Power (Watts)

1600

The lowest pressure inlet at 0.5 2 has a direct proportional effect 1400
1 kg/cm2
on shaft power. 1200
1000 1.5 kg/cm2
500 800 2 kg/cm2
450 600 0.5 kg/cm2
400 400
350 1 kg/cm2 200
Shaft Power (watts)

300 1.5 kg/cm2 0

1 2 3 4 5 6 7 8
250 2 kg/cm2
200 Spear Setting
0.5 kgt/cm2
150 Fig.5.Spear settings vs Water Power Results
100
50
0 Fig. 7 shows the Spear setting against the turbine efficiency. The
1 2 3 4 5 6 7 8 9 maximum power yielded in the shaft for this experiment was

Spear Setting recorded at inlet pressure of 2 of an output power at 443.8
2
Fig.3.Spear settings vs Shaft Power Results Watts. The efficiency of this point is at 25.8% only where the water
power generated is at 1722.1 Watts. The maximum efficiency

yielded was at 0.5 of 98.31% efficiency. But the generated
2
power is not that ideal where only 147.9 Watts resulted at a water the draft tube access door or liner may be measured to track relative
power of 150.48 Watts. cavitation noise. All this parameters were carefully analyzed to
maintain the efficiency of the turbine. In Fig.9 the yielded result
for flow rate vs efficiency detected that at high flow rates the
turbine decreases its efficiency. The maximum efficiency was at a
0.009
pressure inlet of 0.5 already stated above where minimum
2
0.008
shaft power was resulted.
0.007
Flow rate (m3/s)

0.006 1 kg/cm2
0.005 1.5 kg/cm2
0.004 2 kg/cm2
0.003 0.5 kg/cm2
0.002
0.001
0
1 2 3 4 5 6 7 8
Spear Settings
Fig.6 Spear setting vs Flow rate results

Fig.8 Typical Performance Chart of Pelton turbine

(Source:Hydro Life Extension Modernization Guide, Volume 2)
100
90
Turbine Efficiency (%)

80
110
70 1 kg/cm2
100
60 1.5 kg/cm2
2 kg/cm2 90
Turbine Efficiency (%)

50
0.5 kg/cm2 80 1 kg/cm2
40
1.5 kg/cm2
30 70
2 kg/cm2
20 60 0.5 kg/cm2
10
50
1 2 3 4 5 6 7 8
Spear settings 40
30
Fig.7.Spear setting vs Turbine Efficiency Results
20
0 0.005 0.01
Fig. 8 shows the typical performance of the Pelton turbine given Flow rate (m3/s)
flow rate and turbine efficiency. According to Zhang that the
Fig.9. Power specific speed Cavitation Results
performance of the turbine can degrade over time due to cavitation
and/or erosion damage resulting to weld repairs. Perdiodic
performance checks, through absolute or relative testing, are The relation of output power generated in the shaft with respect to
necessary for maintaining accuracy and must be made at a number the turbine efficiency is illustrated in Fig.10. As seen in the graph,
of operating heads in order to be comprehensive. Turbine increasing the shaft power would result an opposite decrease in
performance parameters for Pelton units are defined in ASME and turbine efficiency. As seen in the performance curves conducted by
IEC 60041 and typically include the following: Generator Output, Gass (1998) in Fig.11 where the efficiency of the turbine as it tends
Turbine Discharge, Headwater and Tailwater Elevations, Inlet to increase much further will result in to lower turbine efficiency
Head, Discharge Head, Gate Position, and Water Temperature. due to overdriving the shaft into its limits. Therefore an optimum
Typical vibration measurements may include: shaft displacement Efficiency and power output is chosen for safer and life lasting
(x and y) at turbine and generator bearings and thrust bridge applications of the turbine.
displacements (z). Acoustic emission on
 110
Notation
100
The following symbols are used in this paper:
90
Turbine Efficiency (%)

g = gravitational acceleration (9.81 m/s2);

80 = Total head(m);
1 kg/cm2 N= Speed of shaft(rev/min);
70
P= Shaft power (Watts);
1.5 kg/cm2
60 P=Inlet pressure (

);
2 kg/cm2 2
50 Q = Flow rate (m3/s);
0.5 kg/cm2 T = Torque generated by the shaft(Nm);
40
z = elevation head (m)
30
= Specific weight of the water(N/m3);
20 = Pi constant (3.14159);
70 170 270 370 470
Brake Power (Watts) References
Fig.10. Cavitation coefficient versus Power specific speed for Perrig, A., Valle, M., Farhat, M., Parkinson, E., Favre, J., and
Kaplan and Francis turbines.(source: Dixon S.L. and Hall C.A. (2010). Avellan, F. Onboard flow visualization in a Pelton
Fluid Mechanics and Thermodynamics of Turbomachinery 6th edition,The
Boulevard, Langford Lane, Kidlington, Oxford,225 Wyman Street, Waltham,USA, turbine bucket. In Proceedings of the 23rd I.A.H.R.
332.) Symposium on Hydraulic machinery and systems,
Yokohama, Japan, 1721 October 2006.
Perrig, A.,Farhat, M., and Avellan, F. High speed flow
visualization of an impinging jet on a Pelton turbine
bucket. In Proceedings of the 5th Joint ASME/JSME
Fluids Engineering Conference, San Diego, California,
30 July2 August 2007, paper no. FEDSM2007-37628
Kvicinsky, S., Kueny, J.-L., and Avellan, F. Numerical and
experimental analysis of free surface flow in a 3D non
rotating Pelton bucket. In Proceedings of the 9th
International Symposium on Transport phenomena and
dynamics of rotating machinery, Honolulu, Hawaii,
USA, 1014 February 2002, paper no. FD18/FD-125
Zhang, Zhengi (2009) Pelton Turbines: Springer International
Publishing, Zurich Switzerland. pp. 1-10.
Zoppe, B., Pellone, C., Maitre, T., and Leroy, P. Flow analysis
inside a Pelton turbine bucket. ASME Trans. J.
Fig.11. Example - Original vs. New Performance Curves Turbomach., 2006, 128, 500511.
(Source: Gass, M.E.: Modernization and performance improvements of Zoeb, Hussian, Mohammad Z. Abdullah, Zanial Alimuddin-
vertical Pelton turbines Hydropower & Dams Issue Two 1998)
Basic Fluid Mechanics and Hydraulic Machines (2009)
Gass, M.E.: Modernization and performance improvements of
Conclusions vertical Pelton turbines Hydropower & Dams Issue
The Performance of Pelton turbine in the Univesity of San Carlos- Two 1998
Hydraulics Lab. was tested and evaluated. As a result, the Pelton IEC, 60041 Field Acceptance Tests to Determine the
turbine yielded a maximum efficiency of 98.31% but only Hydraulic Performance of Hydraulic Turbines, Storage
generated a shaft power of 147.9 Watts where pressure inlet is at Pumps and Pump-Turbines, 1991
the lowest. Also at maximum pressure input, the turbine generated NERC, Appendix F, Performance Indexes and Equations,
the maximum shaft power of 443.8 Watts where only 25.8% of January, 2011

power was delivered to the runner. At 1 and 1.5 of pressure ASME PTC 18, Hydraulic Turbines and Pump-Turbines,
2
yielded some larger shaft power were generated with above 50% Performance Test codes - 2011
efficiency of power is transferred. At higher pressure inlet, the
maximum efficiency yielded is at 67.9% where it generated a larger
shaft power of 360 Watts and below this values yielded a smaller
efficiency. Therefore to use the turbine to drive a power generator,

it is optimum to use a pressure inlet of 2 2 at a spear setting of 1

to achieve a maximum power output.