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by
V. vassi
of (lie
111livel-shy of Glasgow
for file degree of
OO/
/
DEDICATION
Since this program has been carried out as a joint project between Iranian Research
Organization for Science and Technology (I.R.O.S.T.) and the Glasgow University, I
would like to thank both institutes for their support.
Y. Yassi
CONTENTS PAGE
Synopsis vii
Original work viii
Nomenclature ix
CHAPTER I
MICRO HYDROS
Preface 1.1
Micro hydros and their importance 1.2
Micro hydros and the world 1.3
Micro hydro in China 1.4
Japanand micro hydros 1.4
Micro hydro in New Guinea 1.8
Micro hydros in the U.K. 1.9
Iran, hydro power and micro hydros 1.11
Resourcesand potentials 1.14
Needs & problems 1.16
Selectionof head& flow rate range 1.18
CHAPTER 11
i
The draft tube 2.18
Hydraulic characteristics 2.19
Power generatingcharacteristics 2.21
Efficiency 2.23
Types of draft tube 2.25
Blades 2.30
Theoretical introduction of propeller 2.30
Circulation and the lift force 2.31
Circulation and the blade design 2.33
Blade design procedure 2.41
CHAPTER III
APPARATUS
ii
Design details of the circuit
1.Pipings 3.16
11.Other requirementsof the circuit 3.16
1. Collector 3.17
2. Reducer 3.17
3. Straight run 3.17
4.0rifice plate 3.17
4.1. Installation requirements 3.18
4.2. Orifice design 3.21
5. Bends 3.24
6. Main gate valve 3.24
7. Return straight run 3.24
CHAPTER TV
AGNEW TURBINE
History 4.1
Selectionof turbine size 4.1
Details of the turbine 4.4
i. Main turbine casing 4.4
ii. Draft tube assembly 4.5
iii. Main turbine shaft 4.5
iv. Housing 4.6
iii
Selectionof prior improvementarea 4.12
5. Blades 4.16
8. Pointers 4.19
CHAPTER
TESTING THE TURBINE
Introduction 5.1
Procedureof testing the turbine 5.1
Data to be measured 5.2
Data required for calculations 5.3
Calculateddata at constanthead 5.3
c. Torque 5.10
d. Brake power 5.11
iv
CHAPTER VI
RESULTS
Introduction 6.1
Results 6.4
1. Open blades 6.4
2. Semi open blades 6.5
3. Open blades+ 0" guide vanes 6.5
4. Open blades+ 10' guide vanes 6.6
S. Semi open blades+ 01 guide vanes 6.7
6. Semi open blades+101 guide vanes 6.7
7. Comparisoncurves 6.8
8. The draft tube 6.9
Discussions 6.10
Quick guide to the plots 6.18
Plots 6.20
CHAPTER VIT
CONCLUSIONS
Conclusions 7.1
APPENDIX I
Propertiesof airfoil I. 1
APPENDIX 11
Geometric characteristicsof airfoils 11.1
APPENDIX III
Turbo institut (A visit report 111.1
V
APPENDIX IV
APPENDIX V
Turbine drawings V. 1
APPENDIX VI
Calibrations V1.1
References R. 1
vi
ABSTRACT
The next chapter gives the details of the test circuit that was
constructed. This could provide water volume flow rates of up to 0.15 W/s
at heads of up 25m. The two dynamometers that were used could absorb
powers of up to 25 kw and 50 kw respectively.
It was observedthat instability (with fall in power output) could occur after a
period of running. This seemed to be associatedwith an accumulation of air
bubbles at the highest point in the casing of the machine. Introduction of a
vent from this point was found to relieve this problem and ensure stable
operation.
vii.
ORIGINAL WORK
viii
NOMENCLATURE
Cc coefficientof contraction
CD
Coefficient of drag.
CL
Coefficient of lift.
Cv
Velocity coefficient.
D Pipe internal diameter,Blade dianietev.
Di Waterjet diameterat the orifice exit.
d' flub diameter
ex Distance between the center line of the orifice and center line
of the orifice
L Distance of the maximum deflection of the central curve
from the leading edge,Length of the airfoil
Depth of the airfoil, Length of the arm of the dynamometer
airfoil
N Speed
Ni Unit speed( Constanthead
Ns Specificspeed
P Power,Pressure
Pa Absolutepressure
Patm Atmophericpressure
Ph Horizontalcomponentof force
Pi Inputpower
Pil Unit input power(Constanthead
Po Outputpower
Pol Unit outputpower( Constanthead
Pv Vertical componentof force
,
Q Flow rate
Qi Unit flow rate( Constanthead
Re Reynoldsnumber
r Radius
S Supportingsurfaceof theairfoil
T Spacingof blades,Torque
TZ Resultantexternaltorqueaboutan arbitraryfixed axis
t Maximumthicknessof theairfoil
U Linearvelocity
Ub Bladevelocity
Ub-2 and Ub-3 Velocitiesrelativeto blade
x
Uf Flow velocity
U Specific indicated velocity, Inlet velocity of the turbine
U0 Outlet velocity
Ur Radial velocity
Uw Tangential (Whirl ) velocity
V Velocity of flow
WU Relative velocity
Z Height from datum, Number of blades
Angle of attack
a
Angle of attack for zero lift coefficient
ao
CC00 Angle of attack for infinit span of the airfoil
Lattice angle, Ratio of the oril'ice diameter to the
pipe diametty
P Density
0) Angular velocity
11 Efficiency
1113 Draft tube efficiency
11h Hydraulic efficiency
11M Meclinical efficiency
11max Maximum eff iciency
110, Ili Over all efficiency
xi
CHAPTER
(1)
MICRO HYDROS
PREFACE
1.2
6. Application of these turbines to agricultural activities
,
especially their installation on irrigation canals It is
important to notice that the utilization of hydropowerhas
strongly been in in
advocated, recentyears Iran.
It has not been more than two decades that attention - has ,
been drawn towards small hydro potentials (I to 100 MGW) It was only
.
after successful application of small hydro, turbines, that thoughts were
diverted towards minihydros (200 KWto I MGW)and micro hydros (up to
200 KW) potentials
.
Republic of China is the leading country in applying
microhydro turbines at her rural areas (2,4 ). Other countries such as
U.K Russia Japan and France have also worked in this context.
., ,
Never. the. less the main usersof micro hydro turbines who have also
performed some work on them , are mostly the third world countries.
Peru New Guinea, Philippines, and Nepal are amongstthose countries
which are benefiting frorn:micro hydros -
For the purpose of introduction to the work performed
by different countries on micro hydros Republic of China, Japan New
,
Guinea and U.K. were selected. The following provides a summaryof
the work on micro hydros in thesecountries .
1.3
Micro hydros in China,
1.4
Turbine Generator
r- Model Head Flow Generator Spec
Speed Voltage
Capacity (rev/miii (v)
(m) (MI/s) (kw) 50 Ilz 60 liz 5011 60 Ilz
ZD760 - LM - 60 2-6 10.3-1.64 18.30.40.55.75 1000 1200 400 460
ZD760 - LM - 80 2-6 1.4-3.54 30.40.55.75.100.125 1000 '1200 400 460
160 500 514 400 460
ZD760 - LM 100 5.5 4.174 160 428.6 450 400 460
ZD760 - LM -120 6-6.6 4.17-6.59 75 100.125 750 900 400 460
.
ZD760 -LMY-120 160200 300 300 400 460
(360) (6300) (6300)
250320 375 360 6300 6300
ZD760-LH - 200 4.2-5.7 16.4-187 500600 137.5 189.5 3150 3150
800 214.3 211.7 6300 6300
ZD560-LMY- 60 9.3 -12.7 1.21-1.35 75 1000 900 400 460
ZD560 -LH 100 12-15 5.53-5.5 500.630 500 514 6300 6300
_ 6300 6300
ZD560- L11- 120 8-14 5.1-8.5 500.630 375 360
f450)
ZD560 - L11-180 10 16.5 1250 250 257 6300 6300
IILIIO-WJ-33 18.5-50 027-0.33 75.100.125 1000 1200 400 460
JILI 10 WJ-42 49 044 160 1000 1200 400 460
-
IILI 10 - WJ-50 33.3-92 0.51-091 125.160.200.250 750 720 400 460
(900)
320.500.630 1000 900 400 460
(1200) (6300) (6300)
IILIIO-Wi-60 55.5-80 0.97-110 400.500 750 720 6300 6300
(900)
630 1000 900 6300 6300
Table 1.1. A
1.5
VO (b = :;, -4
>< =- =r <
1 CD CD
:3 CL --" '. I a 0 0
u
CD F07
'o
(D -:3 CL C: Ei - N iz
t")
(T) (D :3 CD
-3 :3
E- - cl) CD x (D
X
El r- Cl). -1 0 -A x
CL cl -6 lj
(D .. (1). (D
<
< CD -0--o tr
I :I ! (D
0 -0
Cl)33o 3 :3
4k- ol ol
: r_l
(D.1-
(f)
x--
(D
-. &
(b
Lo ca. 0 0 (D (1)
CL
C= C) CD CY)
C) 0
I
FT 0c0
=r
C)
ca. 3
,0
o F4 =r
(D (D
-0
(D ) (D 0
:)4 -:
CO
:: -,
(1)
:3' (D
0) -, j (D -I,- *'--n
C:
C)
(A. )
4- (D ci
3
-: (D
CL D
-CD (D
; -- CT)
< C)
CD 3-0CD
=
CD
0
03
NJ C) C) C)
cl,
0 -ij
C) a P 0
Ul 0 N.) t, ) cn 0 Q)
Ln 0
cr m3 -03
cn
(D
0 jn
0 c)pa
C)
CY) cn
0 C) C)
, 10 c ::;
4
F) (D UT K 0
(n (D 0
C: CD
-1 (D
LO 9
CL
(),I (7)
C)
Cl) -o (D
=) -- -.. L -. A -. 1 --&
C, (b .
cn cn o 0 -Ij .0 -1
I U)
!n :r 0 00 0 cyl 0 tn L CID
0 0 CD 0 0 0 0 (D
n Ct)
(D
a
Cl) 3-
CD (D K) cc) C)
-1 -. 41, Ul " N) M -_j (D 0 -j
CD 3 0 0 00 C) 1
0 20 11) 00
2020 N)
-0 C) 0 0
c
&T
0 CD 3
(D Cl)
(D (A) D. 4111 b. Z. C)
C Ct)
-- -PL -PL
:t
CD 0 00 0 0 0 0
(n -- a) 0 00 0 0 0 0 Nj <
0 o
Cl.
a) (D
(a
... 0 0) (D
0 (1) N -1 m
w
zy
(n Q)
1 0
03 w
0 mm -t- t..
m 1,
.C)
m X- 0-P,
(D 0 0 C) 0 0
1.6
7.5 (m), and flowrates as small as 150 (11s) cross- flow turbines
In their work they have madean attempt to standardizetheir turbines so
,
thet , for various conditions of water systerns, different designs and
different sizes of turbines would be available. Chart (L 1) shows Fuji 's
chart for their standardhydraulic turbines.
500 A VVYA: nf
VOW nf
VVYA:
01
111onion_
WE hon
R! on lufbinel
turbine 4 01VOW
1
200
Kr-fcal =ranc:
frjnctu he
100
50 -(b/;
V- Fortl.
al
#X,
A; Dhn IU(bX7C
AaDl3n
t;;
I-E 'rb
Ti
-otvturb
10oss-Ao-ii,
lo oss- lu lne
e
CIO20 u b1he
C/Sturb1he
X
X _s
&b
&b wile
wile
Opnduil-
lrpe
Condud-1pe
Pachage
Pachate
bob
bobILffblne
AffbIne N.
10
Ileaca)
IleacaUbub, ItAne
ItAne
t4u-13, i
NA,
5
U13r IUI
' le IU UF13 C
[S, \\.
I L- L--L-
.-. IIIIIIII-I-It 2.0 5.0 10 __j
0.2 0.5 1.0 20 50
Discharge Q(rn3/S)
1.7
Below, a list of turbines, designedand manufacturedby Fuji
is presented:
1.8
Table (1.2) from this article, provides a comparison between
,
impulse and reaction turbines for microhydro schemes. Also figure (1.1)
represents a selection chart for water turbines under 100(KV), according
to the criteria establishedin abovementionedarticle .
AG*
0.1
a-ai
p.,
Figure ( 1.1 ) -Selection chart for water turbines under 100 Kw.
1.9
01
. be
*cu 0 >%
0 1.
LIJ
(L)E- 0 EP r:
*Z
tu ':t)
2 _b4
:
0 t)'= -- EP
4; . C)
9-
4)
4) >
s
m
gi 4j
Li CA
= l!Co -0A
r_
CL Z
CL) c)
cu >
r_L
t2 : F- C)
CA CU =00. r- 41
CD 0 'CJ 0
C) -E
r-D:)0r:ti 0 t- c--
cu c21 C.
r_) li :2 F=-= cu
0 , 0,
&- - r!
.L tu 0 4) u .Z_ 0
43 tu 0- : r- c. cu
>
. ld
' cu
43 ti
CL &) U0.
4A di Ci.
t: 0 CA cu
C)
LA
-C2
U &) -
cu
:j JD E
0
ot-0 Co a 4)
r_
>.
ci c) cr
-- bi)
0
:
C) C) 10
a E.
41
21 -
> ei 0
v U > et otz
r:
tu cu tu. - t
r, -0 0
=- tA tu 4) .liIA
4) C:r_
) --- -Z- 1-2--8:
lu r- o > 4)
ci 4.) >..
-n
M
=2
-0 .2a E
%- 0ZE
C.,
-U
4.)
r-- CL ,- Cl-
4) -2 0>22 00
u >Z --ZoP.
cu 0 r: c2. r- M" 0
V, L= Co cr .5 c) 0
0
<Z 00 <0
W
(D
c IM
LO,
L- g
cu
c
Ici
rU
Co
L) cc X) 0)
m cu
M *0 v; Cl. cu Z
"D
c Ex0a. (L) (U
E
' -Ue:
a.) tn --
4- 2M
co >0 CD l' Cl U-0
74 c2, .
0) 20 cin ri
E0T:Et-
In r_
0 > (n
:3
C- Cia *IJc
e0
E C-)
E
E 4,) zz ZE
E0
z > EA- L- oi
0 tn (f: 6- c:
r
c) 43--J:4.)) t2 0 *, = CA
r:
cu9Aci
C)
4 . -
M- 0 &4 .-Z
tn cu E
0E.
C) L) -0 CZ -i
4)
9/1 0
0 9.- m &j .-u
UE 43 2 tu
-0 0
;t p
&). r: m0
ui
Ei
>% CL:3j- 0 0 ("f .10E, Z ,
U) CL
.- 10 gn CA
-0 - cu
-0 E
M
E t -; y
LJ
-t5
!i r- r: 0 r- t.)
0
00
.2
in
0
t.. --
ce
tifi
c2-
;;
c2.
U)
><
CL
E
r-
c42),
'M
-
r-
0
en
r- -cu
Co
:1:1'.' D t-/j) Z C)
_am
.
f2
EE
-0
C) 0 -zi t 4.)
J:
3- ) r- Z
CL
. -zi CU >
2 : bb D.
C)
. CL)
u) vli
r_
= C) r', 4A r_ CM
cu o 10 b-
tj
Z: r,
t) ruuZ
tu rm -- C)
r-
. L)
tG
cu
manufacturers were still interested and were actually interviewed for
possible future work.
One of these companies was " water power engineering
turbine " owned by Mr. Osman Goring a mechanicalengineer
.M.
who had beenworking on micro hydros for many years. There, they had
developed a modular unit comprising a turbine tank and an inlet tank.
The prime objective of this designwas to meet the requirementsof sites
with low heads (less than 10 meters) andlowflowrates ( less than
2 (m3/s).The turbine itself was a continuous back to back-
reaction
1 Ministry of Power
I.Water resourcessection
II Rivers and damssection.
.
III Vater potentials of western states Department.
Ministry ofTahad.
I. Water resourcessection.
11 Construction deputy, power and energy department.
.
1.12
L" 0 C) o000
ta
0i.
-
1 -7Z 1y
tyl
- __7z -I
&
..
0, OOOl/
J.
Ad --
P0
06--z
IA 0
Aol
lb-L
1
I
VIP
ro
9
Opo 7
8 41, 007
t"
1007
8 7f0
7f 00
q)
T Vol
i
OF/
- - - -- N Itc
q?
z 00, 0,
z
to
A esol
WO,
;to
1&4
:w
CP
_4
VI
vi IA
A ix
IX jvi. I11.I
1l
.
I. Resources and Potentials
1.15
Studies led by the ministry of power, show that, the hydro
power potential in Iran is around 17000 (MGW), Of which only about
2000 (MGw)are being benefited and the rest remain to be used in future.
This figure does not include micro hydro, potentials. Early studies by the
same ministry show that, over 3000 micro hydro potentials exist in rural
areas (2).
Also there have been some studiesled by the ministry of
,
Jahad as an attempt to pinpoint hydro potential sites in the range of,
less than 200 K\,.?
up to 20000 Kv, across the country. They have divided
this range into three sections as shown in table (1.4) according to the
site's nominal power generatingpotential . (3 )
Table ( 1.4 )
1.16
Table (1.5)
Z
Ici
rt 0
C:)
cn 1
cn
w OD
0
rt
L') L') b- 03 r-i Co D)
1 OD OD 1 1 w CD 1 -i h-4 10 H
-4
w 00 C) e 1 w 1 u 0 w -N 0
ic
Z- Z- CD 0 CD
CD (D CD CD 0
00
0
Co rt
Im
ta La
CD Ln O\ %0 f-i LA 00
CD CD r-i %0 %D w r-i CD %D %D -1 0
%0 1-1 k Ln w LA CD %D OD IK
-p- (D
00
1 0
Co w k 0% Z- w u --4 >i
00
.(n -
el 0
0
0
LAJ 9-1
CD b.- 1- w La rt
Ln w Z-
10 P)
CD ON 00 b." CD CD k- (A -1 00 -1 1- % 0
ON
b- 0IN 00 Li CD 00 CD %0 CD 112 OD : (0
%-,
CD CD CD CD
>
N > N (D
-_r C) 0 In NW 1 (D (n Z
10 ( 0 J. 0 ri
Ei N i--i Z), ::3 P 71- r_ (D (n , 11 M tu
::r li, (n bl rt cz, i3
m :21 cr ) n (D
rr k- Z] (n cu p). H: 0
p p Li
C0
zi
Z) (D rr
1
k Z],
(D
>-
1 1
qD OD
o
1.17
valuable , basic commodity . Along with electricity lack of clinical
,
services,telecommunications,etc.. , have causeda massexodus, towards
cities. In one hand , cities do not have enough facilities to cope with this
rapid population growth . On the other hand , agricultural activities
would suffer heavy damagesdue to lack of manpower. This is due to the
fact that in Iran agricultural activities are mainly concentrated at
, ,
villages , with people leaving villages there will be no one to work on the
farms
.
The prime objective of the above short discussionis not, to
hold "lack of electricity" responsible for all the hardship and
shortcomings but its important role in man's welfare and culturecannot
by any meansbe denied.
1.18
Therefore by consulting data collected and a number of those
, ,
in charge in ministry of Jahad and ministry of power and also by
consulting both supervisors at I. R.O.S.
T. and Glasgow university it was
decided that work should concentrateon micro turbines, operatingunder
headsbelow 10 metersand flow rates lessthan 500 ( 11s).
1.19
oooo
CHAPTER
(11)
H TH ORY
Turbomach
2.1
producing an increase in the in
relative velocity also results a pressure
drop within the blades.
Turboniachinery development may be approachedthrough fluids
dynamics, experiments dimensional analysis and in practice a
,
combination oraii three is used .
,Me fundamental design relationship for all turbomachinery is
derived using the angular momentumlaw,which states:
The resultant external torque on the matter momentarily
occupying a fixed volume equals the rate of change of angular
momentum of the matter inside the volume plus the net rate of outflow of
angular momentum through the control volume . For steady flow ( or
cyclic flow ) such as considered to exist in the rotor of a turbine or
compressor the rate of change of the angular momentum of the matter
inside the volume is zero thus ;
,
i. e. TZ m Z (rxU )z
2.2
In general the absolute fluid velocity may be resolved into
three mutually perpendicular componentsat radius r: ( Figure 2.1 )
Figure (2.1. )
Ub ---:(0
2.3
Since only the tangential component of the absolute flUid velocity
called the whirl component , Uw affectg (lie aIIgLIIar momentum
,
change about the axis of rotation , then
Tz = ni Z (rx Uw )
Tz (
in r2 " Uv2 - 1*31 Uw3 ) on rotor,
2.4
Typical inlet and outlet diagrams for a turbine are shown in figure ( 2.2
Ub
Ub2 Ub3
-
UW2
-Uw3om'
(12 P2 03
Ul UO
U2-U6t U3 UAJ63
U2
INLET OUTLET
rigure (2.2)
Ihidro Turbines
1- I111PUlse
turbines.
2- Reaction turbines.
2.5
V)
T3
rn q
r
rri
(n
0
-4
Ov
rIrl
r '0 0 CD
-4 m
-"1 Ir
rn
z
-0 0
rn
cz
m1
0 r)
c2
z
oc rn
Mn 0
CD:U mZ
C. r-1 >
n
w r7l 0-
ii
fr
F-
hill!
rn
z
--4
rzi
C
I
cr
A
oil
I-L
2.6
Here, a jet of water through a nozzle is directed toward turbine
buckets ( blades) thus transferring energy from water into the wheel . An
important point here is the fact that water flows into open ( atmospheric
,
conditions ) immediately after leaving the nozzle so that the waterjet
, ,
be impinging
the blade under atmospheric conditions where it freely
would ,
splashesaround
There are also different types of reaction turbines . Thesetypes-
are mainly as follows :
2.7
SCROLL)
CASING
GUIDE VANE IRUNNIEN TO
OR REGULATING
I ROD
WICKETGATE
DRAF, TTUBE
TAIL RACE
41
I ----E
WATERINLET
FROM PENSTOCK
I
yF
S'.,ROLL
CASING
LINK
E
4E
vulut vyHLLL
2.9
As mentionedearlier , water turbines maybe classified as, impulse
and reaction turbines Each of these categories contain a number of
.
different type of turbines Naturally , these differpt designshave been
.
developed for a certain range of headand flow conditions . So far as ,
this work is concerned ; turbines suitable for relatively low heads and
be importance Figure ( 2.6 )
moderate flow rates would of more .
represents classification of different types of turbines According to this
.
figure propeller and Kaplan turbines seem more appropriate and
applicable for our purpose . Therefore in next section some details about
these turbines is presentedto justify why such design has beenselected
for a micro hydro
.
Propeller Turbines
This type of reaction turbine has a rotating element very similar
to that of the axial flow pump . The propeller shaped runner is a
development of the Francis mixed flow design and deals with large
quantities of water. Figure ( 2.7 ) represent a Kaplan turbine
.
ADJUSTABLE GUIDE
VANES
JUSTABLE RUNNER
BLADES
II
2.10,
Head (in)
2000
1000 -
800--
600 -
400 -
300 -
200 -
100
80
60
40
30
20
10
a
6
4
3
2
1-,-
1
2.11
The units operate under relatively low heads ranging from 4
meters to 40 meters, with a maximum of 70 for
meters small machines.
Separation and cavitation are often unavoidable in.the flow passagesof
propeller turbines operating with high velocities and it is the onset of
cavitation that the specific speeds, Ns of these units range from 400 to
,
840 approx.
_p
(N4
where Ns 5/4
( H) max
2.12
rF
100
."'STABLE
so- OL41)eS
..........
60- %%
%
40-
20-
0- --T -I I II
-II 80 100
0 20 40 60
Figure 2.8
U.
U. FRANCIS 4XIALFLOW
8o-
........... ................................. ..............
............
60 -
J2
40 -.
Ns
Figure,(2.9)
2.13
Theorp of axial flojp turbines
is
which constantat all radii
2.14
& for Uw3 ==0 WD / unit time = PQ Ub2 UNV2
i C. bladepower = PQUb2Uw2
Ub2 UW2_
(const at all radial
g1-1
brake power Z,
mechanical efficiency, 11,, - blade power
il
Micro o Turbines
2.15
Historical background of hydro turbines show that old Persians
were the very first people who madeuse of hydro power as water mills
(I). In present days as far as the micro hydros are concerned a
,
number of countries have enteredthis field. Amongst them China is the
country which has mostly benefited micro hydros . About 60000 of micro
turbines in four types have beendesigned, manufacturedand installed
across China (4 Japanis anothercountry which has worked on small
and micro hydros Fuj.i electric Co. is one of the Japan'scompanies
which has tried to standardize these turbines Their work involves 7
.
different types of turbines covering a power rangeof 20 Mwto 50 KV(5 ).
New Guinea is anothercountry which has benefited application of micro
hydros at her rural areas. In the U. K. also a number of companieshave
embarked upon design and production of micro hydros (6 ). But lack of
government back up has almost paralyzedthe work. Agnew turbine is
one of the micro hydros developed in the U. K., anumberof which
were actually manufactured and installed at different sites in Scotland.
However due to the reasonmentionedaboveno researchwas done on
,
thisturbine to improve its efficiency( 7,8 ).
Apart from that some research work has also been undertaken on
,
establishing criteria for selection of micro hydros according to the
available head and flow rate (9). As far as Iran is concerned, no work
has yet been undertaken on micro hydros. According to a report by the
ministry of power of Iran (2 ), around 3000 natural sites suitable for
micro hydros havebeen spotted around the country. However, this
figure dovs not include runs off rivers irrigation or any other man
made canals . Due to ever increasing demandfor electricity and daily
reduction of fossil fuel resources, Iranian governmenthas given priority
to renewable power generating resources such as hydro power In
.
accordance to the governmentalprogramswork on hydro power began,at
I. R. 0. S. T. by establishmentof a turbo machinery group at its
mechanical engineering research center. Design and establishmentof a
turbo machinery laboratory and improvementson Agnew micro hydro
.
turbine are the first assignments of this group Prime objective of this
.
2.16
project may be summarized as making improvements on Agnew turbine
to achieve the highest possible efficiency. However, study of the work
by different sources on micro hydros show that apart from Agnew
,
turbine , non of other turbines have beenof Kaplan design . Therefore it
was appropriateto concentrateefforts on this type of turbine .
2.17
The draft tube
In this way, the turbine would be installed above the tail race
level thus accessingto it for repair work purposesor any other reasons
would be much easierthan otherwise.
2.18
Sometimes the above is referred to as "the hydraulic
characteristics" of draft tubes,and it maybe explained in more detail as
follows :
7/D
/VZ
C\f U4
>
Tw yTW
0.50 0.50
>
Ds
(b)
P82 k2U2 2 2
+-+ Z2
Pas k5U5 ZS
-+-+
pg 2g 2g (1)
P9
2.19,
Koo"
P'5 Patm
Pa2 K2U2 2 U5
Patm Ks 2
2.20
2. If as in a pelton turbine, water from a reaction turbine is
discharged into atmosphere,then a considerableamount of kinetic energy
would be lost. This kinetic energy is as a result of a high velocity which
water possesseswhen leaving the runner. Reduction of this velocity may
be accomplished by application of a draft tube of smoothly increasing
cross-section area. The dischargevelocity reduction would then result in
a pressure head;which would in turn causean increasein the negative
pressure head at the runner outlet This would lead to an increasein the
.
working head of the turbine, causinga higher output and thus raising the
efficiency of the turbine
.
P k2U2 2
++ Z2 e2
pg 2g
P2 Pa2 Patm
Where :-=--
P9 P9 P9
2.21
As mentioned above this energy (e2)cannot be utilised by the turbine
and therefore is regardedas a loss
.
2 2 K2U2 2
K%U:
z K 5U5
e2
+-- hf - )+Hs +
-(Hs 2g 2g 2g
K5U5 2
e2
- +hf (4)
2g
2.22
'Efficiency of a draft tube
.
Let us assumethat there is no draft tube, and water is discharged
into atmosphere, straight from the runner into the tail water pool Then
.
e2will be given by:
K2U2 2
e2 -+ hf (5)
2g
U,, 2 2
SU5
AHf
= Hs +Kl. -K -hf (6)
2g 2g
KLUZ-2 K5U5 2
--hf
2g 2g
11D :--
2_U2 2
_14,:
2g
2.23
0/0 e2k. In
, . 100
H
60
40
20
10
6
N,
4N
3
10 20 30 60 100 200.360 m
2.24
DIFFERENT TYPES OF DRAFT TUBES
F5 F2
to - (7)
L58
i. Simpleelbowtube
2.27
A
D2
1)2 D=l
I-- I
-, - 2----
CO'
1 (1 I
uM
6gi
=0.3-0-35 0=4*.
13
ecti oil
(
It)
(b)
/0
/
--
insn--z
of
I
TO 3.7 D2--
7 7:
2.28
I-T
.--Z C--
Fi8tire 2.13
vJ,
.. 2
7/,
Fintire 2.14
qe
(a) ILN
0
S.
Figure 2.15 - Elbow type tube (a) Single pier type (b) Double pier type
2.29
1RY.A Y)P. Q.
2.30
that the driving force of the water is naturally divided betweena small
number of blades, therefore there would be a great difference between
the pressures on the pressure side of the blade and on its suction side
.
This would result in different fluid velocity on either side of the blade,
with higher velocity being encounteredon the suction side Needlessto
.
mention that the fluid velocity difference as a consequenceof pressure
difference is in accordanceto Bernoulli's equation Since the turbine
.
operates in an entirely closed duct from inlet to tail race However these
.
differences tend to increaseas the number of bladesdecrease Therefore,
.
velocities (relative & absolute)of water leaving the runner would not be
the sameeven within the range of two successiveblades It is, however,
.
due to these considerabledifferencesthat a three dimensional
approach
may be employed for designing the blade.
One of the major obstaclesin the way of calculations would be
the fact that most of the coefficients related to the blade profile are not
determined To circumvent this problem it be
. would advisable to select
a suitable blade profile all the coefficients of which are known.
2 7tr co (I)
2.31
Now if the same cylinder rotates with the same angular
velocity in a medium flowing at a velocity V, then the circulation would
be given by:
FL
LVp
Where :
FL pLVC
V2 V2
FL 1/2 ( CL S) 1/2 (CL L 1) (4)
Where:
CL ==Coefficient of lift
S= Airfoil supporting surface
I= Depth of the airfoil
2.32-
Circuldation and the blatle design
III .
rD
Ub-l
U2
Figure 2.16
2 7r r (Uwi UW2)
-
C= (7)
z
Where :
Z= Number of blades
2 7cr
Let T=-= Spacingof the blades
z
(UWI UW2)
C=T - (8)
On the other hand, for axial flow hydro turbines the following
equation holds :
Where:
Ub=
Peripheralvelocity (blade velocity)
11h= Hydraulic efficiency
2.34
I-u
ft
a Z.-J- -- _1b
Wut
Figure 2.17
Wtl2 )
I'm = Tp Uf ( Wui - (9)
Where:
PI- P2--Over pressureof tile runner
2.35
Since in propeller turbines Ubi Ub2 and Ufi= Uft, with hz
representing the head loss within the runner, then the Bernoulli equation
for relative motion would be:
U2 W2u,
Pl- P2 (b-2) -U2 (b-1) u2 -
where:
Ub-I = Blade velocity relative to inlet.
Ub-2=Blade velocity relative to outlet.
Also;
From expressions (9), (10) and (11) the resultant force of the
two components( i. e. Phiand Pvi), Pzi may be found:
Wu2 + Wul
4 2g hz
FLI =T (Wu2 Wul )I Uf2 +[ ( 1+ 1 (12)
W2U, -)
-
W2
2g u2 -
2.36
Bu since C=T( WU2-Wui ) and the expressionunder the
,t
radical sign dimensionally is equivalent to velocity (to be represented
by Ww )then expression(12) would become:
C W-oL
Assuming a loss free flow through the runner (i. e. hz=0 ) then a
velocity diagram for inletAndoulletotthe runner may be constructed-From
this diagram values for W-o and its inclination Ow may be obtained
(figure 2.18).
U6, Li,
-U
Uf-
U u
WL wl
Figurc 2.18
Facing the reality, liz actually exists and its existence, according
to expression (13), would cause an increase of g hZ/ (WL12 - WUI ) to the
horizontal component of W-o The verticai component of Woo
.
2.37
would, however, remain unchanged since the flow componentof the
velocity through the runner (Uf) is assumed constant. Changesin
Woo would result in W'. o and P'.o (figure 27)
. ,
Figure 2.19
FL --pLC W'-o
FL w1
00
FD W.CI
FL -
tan (P-o
2.38
Since
FL=1/2 V2 V2 L 1)
( CL S)=1/2 (CL
and
FD: (CD W2 1)
--': 1/2 -oL
Then
FD W200
1/2pCLL JV2 /2 CDL I
FL - -
P (16)
tan (P-o tan (P. )
CD
(UWI UW2) I/2 (CL
T - -` woo
tan (P. ))I
whence
CD UWI UW2
- T 2C
CL-- =2
tan (P. ) woo II woo
.2.39
Applying specific velocities in the above:-
CD UWI UW2
- T
CL-- =2 (18)
tan (P-o) woo I
Ub -- (UWI UW2 ) --
/2
- Ili,
1. Blade diameter=D
2. flub diameter=d
3. Net head=H
4. Desired hydraulic efficiency= 71h
5. Approximate output angularvelocity = co
6. Approximate flowrate Q
7. Number of blades=Z
Ur Q
=
Area of flow
2.411
1-4
U4. ul
U, Ul
cr
V.
Wf
C,
Ci
Figure 2.20
Also, having the angular velocity, 0) the blade velocity at
any radius may be calculated by, Ub = &i D co. Here, also for a
UbP-- Ub2.
propeller turbine,
Where :
U= specificindicatedvelocity
U= specific velocity of flow in turbine
2.43
Having sufficient data,then construction of velocity diagrams
be
may proceeded.(figure 2.20 )
I CDL
71h :-- U Woo -( CLL (23)
T tan
the value for CLL- CDL/tan ( P-o) is calculated. To find this value
,
the chord length for the section in questionwould be required. Usually,
a range of 0.9 to 1.05 is recommended for the ratio I/T where,
T=nD /2 known as the blade pitch, and I is the chord length ( 10 ).
,
(Care should be taken to avoid confusion betweenthe blade pitch and the
airfoil thickness).
0=900- P.
da.
Cl, =- (a -ao)
da
CD: CDV+
dcl)
-C2
d,c'L
dCD
(--
da da. 1111
1)(-) 2( (X (Xo) 2+- +.
dc2L _ (cc- cco) Jtanp. -(CVD )tanp-o
du da UW-0I,
Solving this quadratic and having the value of ao fi-om figure ( 11.2
would result in the value of the angle of attack, a.
2.45
Now, applying a to expression(19); /W-w
CL
am=a- 57.3
6n
P= 90' - P.0 + an
11000/
'.
The lattice angle, P, may be calculated.Now, having all the required
data and the technique mentioned in appendix (11)the airfoil section may
be constructed.
This procedure could be employed for all other cylindrical
sections.Figure (2 21 ) represents
an airfoil section by
constructed the
.
aboveprocedure.
Fieure 2.21
(Z
2.46
CHAPrl 'I ER
APPARATUS
Apparatus
For the purpose of testing the turbine a suitable test circuit was
required. Since such a circuit was not available in Iran therefore itwas
decided to design a circuit. On the other hand, as the work was being carried
out at I. R.O.S.T, (a referenceresearchorganization)therefore it was decided
to preparea laboratory for testing water turbines with a view of its extension
to a turbo machinery laboratory.The lab. is actually situatedat the Asr-E-
Enghclab research complex at the western suburbs of the city of
Tehran.Photos (3.1) and (3.2) show the outside and inside of the lab.
respectively at the beginning of the work.
Laboratory desian
Photo ( 3.2 )
3.2
16-
CT E
_0
00 %-
cp 0
x
C)0
>
C)
C300
C3
0 0
C3
-E
0
L-
r-, Ij L) 1-1
0
>
0
>
0 (D
4-a
E
0 0 67
ci
c0
EE
iz
3.3
1. The reservoir
This consists of a (20 ml) cubical open metal container. Photo (3.3)
shows a view of the tank-Also photo (3.4) shows a view of the tank at the
beginning of its manufacture.
Photo (3.3)
The internal volume of the tank has beendivided into three sectionsby
interconnectedmetal sheetsto reducethe effects of shock waves of incoming
water from turbine to the walls of the tank.Photo (3.5) representsa view of
the shock absorbing metal sheets.Eight holes have beenmade on one of the
side walls, close to the bottom of the tank for the purpose of installation of
pumps.
3.4
Photo (3.4)
ii.
Photo ( 3.5 )
3.5
11. Pumps
To produce the necessaryheadsand flow ratesto the turbine, six pumps
were installed, connected to the 11(Kw) electromotors. Photos (3.6) and (3.7)
represent the installation processof the pumps Also photo (3.8) shows all
six pumps after installation. A high voltage control panel was designed and
made for operation of the pumps. Photo (3.9) shows the control panel.
However, since enough power for the operation of the electromotors was
not available at the site, therefore, 250 meters of(20OAmps)power
line was laid from the main power houseto the site.
Gate valves were installed at inlet and outlet of eachpump.Also, one
way valves were installed at the out let side of each pump to avoid returning
of water pumped by other operating pumps, back into the reservoir. Also
shock absorbers were installed at the outlet side of the pumps to reducethe
effects of vibration on the circuit.
111.Collector
Collector, is a4 meter long cylindrical volume, which actually
connects, the pumps to the circuit. Its diameter is twice larger than the
diameter of the pipings. Water is first pumped into the collector through
inlets connected to the pumps outlets; after which water runs into the
pipings. The collector maybe visualized on photo (3.8).Aby passoutlet of
125( mm) diameter along with a gate valve are installed at the other end of
the collector which can lead water back into the reservoir. This is normally
used for smaller adjustments of flow rate and head.
IVAffuser (Reducer)
This is of semi conical shapeand is connectedto the other end of the
collector to provide a smooth reduction of diameter from collector to that of
the pipings. In this way, the lossesdue to crosssectional changeswould be
mimimized. Photo (3.3) also shows the diffuser.
3.6
Photo (3.6)
Photo ( 3.7
3.7
Photo (3.8)
Photo ( 3.9)
3.8
V. Pipinas
The piping consists of 10 inches pipes all through from the diffuser
into the turbine inlet.
Photo (3.10)
3.9
Circuit's measurina devices
1. Orifice plate
For the purpose of measuring flow rate an orifice plate is used. These
plates have been designed and manufactured according to ISO standards.
These standards are provided in appendix (IV). Also, standards for proper
location of installation of orifice plates are presented in the same appendix.
11. Manometers
Altogether, there are three manometers installed at different locations
for various purposes. These manometers are as follows:
1. Differentialmanometer, for obtaining pressure difference between
two faces of the orifice plate. With the help of this reading, calculation of
flow rate would be possible (1 1).Photo(3.1 1) shows one of these
manometers.
Photo ( 3.11 )
3.10
2. Another manometer is placed at the entrance of the turbine to read
the actual head of the incoming water to the turbine.
3. The third manometer is placed at the entrance of the draft tube, in
order to show the vacuum head generated by it. This reading may also be
used to calculate the efficiency of the draft tube.
However, these manorneters were later substituted by pressure sensors,
so that, the pressure readings could be read directly on the electronic panel.
111.Dynamometei-
To measure the torque produced by the turbine shaft, a hydraulic
dynamometer was employed. Photo (3.12) represeiits a view of the hydraulic
dyminionieter.
Photo ( 3.12 )
3.11
However, for avoiding the vibrations causedby the unbalancedrotors
of the dynamometer, a Pronney dynamometer was designed and
manufactured later.
Becauseof the nature of the hydraulic dynamometer,it was impossible
to align it with the main turbine shaft. This is due to the fact that, the
turbine shaft is subtended 45' to the line of horizon, and installation
of the dynamometer at such an angle becauseof keeping the level of water
inside the dynamometerat a desiredlevel to obtain enoughbrake power, was
impossible.To connect the two, angular motion of the turbine shaft was
transferred via a pair of toothed wheels and a toothed belt to a 22.50
,
one to one gear box. In this -way the 45* motion of the turbine
shaft was reduced to 22.5'. The remaining angle ( another22.5' )
was recovered by employing a 22.50 universal joint; connected to the
horizontal dynamometerinput shaft.
Pronnev Dynamometer
3.12
unwanted braking. Figure (3.2) represents a schematic front view
of the dynamometer.
Rotating drum which is a solid cylindrical volume and is keyed to
the main output shaft of the gear box and in fact rotates with it.
Brake shoes are actually pressed against the drum and therefore the
generated torque is transferred to the outer casing .A load cell
which is connected to the wing of the dynamometer ( welded to
the casing ) would sense the torque and show its amount on the
electronic panel in terms of (N Photo (3.13) and photo (3-14)
m).
show two different views of the Pronney dynamometer.
IV. Tacho meter
An electronic tachometerwas connectedto the dynamometer'sshaft to
read the angular motion of the turbine shaft. in r.p.m.
V. Electronic reading panel
On this panel readings of the manometers, torque and the angular
velocity could be read.Figure (3.15) represents a front view of the panel.
00 #41M
Photo ( 3.15 )
3.13
-lq
=1
3 14
Photo ( 3.13 )
Photo ( 3.14 )
3.15
Desilln details of the circuit
I. Pipinjjs
3.16
tI
1. Collector
2. Reducer
3. Straight run
4. Orifice plate
5.90' bends
6. Main gate valve
7. Straight run
1;
Photo ( 3.16 )
3.18
vicinity of the orifice plate.On the upstream face of the
orifice plate the length of the pipe adjacentto the plate
should be at least equal to (2 D) and cylindrical. The pipe
is said to be cylindrical when no diameter in any plane
differs by more than 0.3%, from the value of (D)
obtained as a mean value of all measurementsof the
diameter.The value for the pipe internal diameter(D) is
the arithmetic mean of measurementsat four diametersat
least distributed in each of at least three cross-section
themselves distributed over a length of two of
.5D)
which being at distances (0D) and .5D) from the
upstreamtapping.
it should be noted that within the abovementioned (2D
Iength,there should be no fittings or any other meansof
disturbance..
On the down stream face of the orifice at least along a
length of (2D) from the upstreamface the diameter of
the pipe should not differ from the meandiameter of the
upstreamstraight length by more than 3%.
The inside surface of the measuring pipe shall be
clean,free from pitting and deposits and not encrusted for
at least a length of ( 10 D) upstream and (4D
downstreamof the orifice plate.
Also there are minimum upstream and downstream
straight length required for installation between various
fittings and the orifice plate.Although someremarkshave
been made earlier on the subject but all the details are
presented in appendix (IV). The values mentioned are only
minimum values and application of longer lengths are
recommendedespecially for researchpurposes.Table (3.1)
represents some details on required straight length for
orifice plates.
3.19
> E :2 't
-E-m
G -in Ln Ln tn
o A
v t ;; i; - rt ri ;3 i3 - i3 Fi ri H ri '. 9 9,
1..
c 0- 0-
2
= .t, -e 0 Ln (0 (D to to r- f-
. rr- Co Co
Co Co .-t:
-Z
E cr
0= m
Ln -0
0
tn rl
El =
c 0 M0 0
U) cli
CY
Ci Ci
z3 s s z3 za s ;Z iz zz In E 1
>0 = Z C,
-r4 -cli -r4 -N -r4 -11 -le - c
!! e-
75
"
-
-
r4
-- --
fli
-- -- -- -- -- --
(0
--
0q
C) q CD
0
.;
r
43
> C.
Cl
0
ci
ci
M>
.0>
0
Co Co CC) w
to C:
C)) 0 f4
r4
CN
CN
q
PA
PA
(D
CN
CN
wi
r4
r4
r4
M
cl
(0
r)
r)
q
qT
qT
4) c3
u
cn
c3
V. ;: i3 rn g; ;Z
-C 0c
-C 0c 0 -OD -Co Co
- -Co -02 (1) -
- 111 -
- Z = == t!
M -- - - - - - - - -- Q
m tz
ci tu c)
to (D (0 (0 (0 (0 r- Co C) (4 tn 0 Co (1
nn
xxL Li cu
r4 ri ri cl
- - - - - - - Ln
E w c; > 0
..Z
Z 0
'D
CL - tc) c
ll, c; m
Q
.c:
0-
0- -0
.>
.Z-
> -3 c3 0% ri
m
0 cuQc ri - - - - -Z u; 0
Ln 19
Ln 19 In
In LD
Z0
V0
IM
IM -
- m Q 0
.Z ot
.Zot 4)
,
r_
r- ci
, Ln Ln U)
Ln ul Ln ul u')
Ln Ln Co 0)
U) (0 CO --, 1; C)
1 r4 0 C) cOki
ctuCL)
m LE I c 41 *t
(P c;
.s E
tl
.LL v
cu (D
0 c -. m
-- -- -- -- -- -- -- --r-A -- -- --
-- ED
E %4C in 0
ch EE
0
CL m 10 a
Z ri ei
c2
e
l
qgt
Ict
IIgt
00
qii
q
n r4
(0
C)
r-
0
Co
mm V 'a
- -
c
-ri .C
c --0a00
0
c
0
0
u tu (D
M
00
rr 00
c
C>
E wv
,C cu- t: - - T = z = Z = t! 2 u uu
uu
0E-
0E - q?
-q xt -
(D -
(0
(D , 0 -=
Co Co 10 (D c4 (0 " 0
(4 (D Z 00
CLCL
a
r 14 ri
r14 pl q? Ln 0
(L)
E
* '0
'" . -
-a)
iu cu
4-U
E
> 49
W
E
cu 00
c- a EE
tu
tu 0 > Z %-
c) 00 Z
b 40
du CC
( E 0
00 00 CO
-( :7 2 *;
r4
Tc M-u 0 0 c2
0 C,
4 m
Ict -lit -q: to
r- 3: ca -ca (114CC. m
(0 to
to
ihcc cu 0m
- - -r4 r4 tr) e
0
0
m
0 tr)
tn 0
0 tn 0 tn 0c2 ul
ta 0CD v (2
0 Ln 0
r4 ri ti ri %r *j in La (D (0
w r- r- m . LL
c; 6
c; c; cs d cs c; (S
KS- cs d cs - %S cs
v
3.20
4*4
3.21
Thickness E of the plate
0, Q.
(01 0
Axial centre-line
Direction of flow
Upstream
edge G
JjI
..
birectionof flow
-- -w-
C)
(> __
A-rienue tappinp
3.23
The spacing 12 of the downstreampressuretapping which
is nominally equal to but it can very between0 48D
.5D .
and 0.52 D when P<0.6 and between 0.49 D and
0.51 D when P>0.6 The spacing 12was selected
.
in
and made such a way so that it would suite all values of
P.
Appendix (IV), presentsall the standarddetails of the
orifice plates their installation requirements and their
design
.
3.24
CHAPrl I ER
(IV)
AGNEW TURBINE
A2new turbine
History
Intrigued by the oil crisis during early 1970's Mr. Agnew thought
,
of benefiting other alternatives and rather unconventional sources of
energy. He selected micro hydro potentials and started his work on
designing a suitable turbine for such potentials.
At first, it was intended to make a turbine similar to that of
Kaplan; but without guide vanes.Such a choice was made due to the fact
that , kaplan turbines usually have high running speeds.This Would help
in reduction of losses due to conversion of turbine speedto a suitable
speed for the generator; since most of small standardalternators,run at
3000,1500, or 1000r.p.m.
However, with a help of a small companythe first prototype was
manufactured; which was not a successfulturbine. Figure (4.1), shows
this turbine. Later through H. I. D.B. (Highlands and Islands development
board) Mr. Agnew was joined by Mckellar Engineering Ltd. Their work
then lead to the presentturbine, which is a 45' inclined, adjustableblade
axial propeller turbine.
Figure (4.2) representsschematicview of the Agnew turbine. At
,
present, 10 Agnew turbines are installed and working at different
locations in Scotland.Also,an overall view of the turbine at the test rig is
shown by the photo (4.1).
4.1
Figurc ( 4.1 )
ol
in
(i)
I
4.3
Photo (4.1)
150 mdesign was differentiated directly from the 300mm. design. This
would serve two different purposes. First, a smaller turbine's
requirements in terms of head and flow rate, would be more limited and
to
closer conditions present in Iran. Second, this turbine may also be used
as a (1: 2) modle for 300 mm design.
4.4
These two parts are flanged together 2.Photo (4.2 ) represents a view of
the casing.
Photo (4.2)
4.5
iv. Housings (Bearings and seal assembly)
All three bearings are placed inside the bearings housing, 4. The
Photo (4.3)
4.6
Photo (4.4)
.L,-
Photo (4.5)
4.7
vi. Butterfly valve assembly
This valve has originally been designed for the sudden Closure of the
turbine inlet in emergencies. However for our purpose it was
, ,
eleminated since, shut down of the turbine could easly be achlu-, ved by
switching off the pumps.
Actual detailed study of the turbine and its parts and all drawings
was accomplished in Glasgow. All queries were discussed with
Mr. P.Agnew. It was then found that, for the purpose of manufacturing
the turbine some final touches had been made to the design at the
workshop to make the manufacturing process, easier and possible. Also,
a number of drawings were missing. At the time, all the missing detailed
drawings were redrawn according to their matching parts and in
accordance to the assembly drawing of the turbine.
4.8
Assemblinjj, testing and trouble shootings
All parts of the turbine except the main turbine casing and the draft
tube were manufactured at I. R.O. S.T's workshop based at Asr-E-
Enghelab complex, where actually the laboratory is situated. The casing
and the draft tube were manufactured by an outside workshop. Assembly
process took place at the laboratory, after which the turbine was craned
up to the stand and installed. The turbine was then tested with different
limited flow rates underno load conditions for many times. Since
everything seemed under control then it was connected to the measuring
devices. The turbine was then tested under different loading conditions
with higher flow rates and speeds. Under such conditions a number of
problerns started arising, which seriously effected the turbine's
performance and damaged some parts. The causes of these problems may
fall into two categories:
problems caused by vibrations and the way they were encountered may
be highlighted as follows: Collision of running blades against the casing
which caused deformation of blade edges, and in two cases, their
breakage, from the welding point of the blade and the tail. To recover
the blade every time it was neccessary to empty the tank and refill it. To
strengthen the welding point, special electrodes were used at another
outside workshop; after which no similar case was observed.
4.9
Since unbalanced rotors of the hydraulic dynamometer were a
major source of propagation of vibrations , later, another dynamometer of
Pronney type was designed, manufactured and installed; instead of the
original hydraulic type.
One of the major problems of the second category which were
chiefly caused by reduction of dimensions was rapid wear of the seal,
which resulted in, water traveling upwards into the bearings housing and
damaging bearings. This required changing of the seal after a few hours
working of the turbine under load. This problem was caused due to the
fact that, because of halving the dimensions, the bearing housing did not
penetrate deep enough into the seal housing . Therefore, the joint was not
strong enough against the pull of the toothed belt, connecting the main
shaft to the gearbox and the dynamometer. This belt pull could cause
eccentricity between the main shaft's center line and the turbine's casing
center, which in turn could, cause excessive vibrations and danger of
collision of running blades against the casing.Photo (4.6) shows the
connection of the turbine and gear box by the toothed belt.
Photo (4.6)
4.10
To strengthen the part againstthe belt pull and its effects the seal
housing was redesigned and manufacturedin order to allow the bearing
housing to penetrate well inside it. After this modification the seal
worked for a year and is still working. Photo( 4.3) also showsthis
section .
Deformation of the parts of the blade angle controlling
mechanism was another problem resulted from the reduction of
dimensions. The constituting small parts of the mechanism simply could
not take the loads exerted upon them and therefore they either were
deformed or broken at times. To Circumvent theseproblems the blade
angle controlling parts were redesigned and strengthened in a way to
tolerate the shocks and the bending momentsexertedon them by the tail
of the blade. Modifications were made to these parts according to
available space inside the runner. Drawings of these parts are also
presentedin appendix (V).
Areas of improvements
4.11
turbine. These areas are namely,guide vanes, draft tube and the runner
blades.
During early running tests and actual base modle tests the
general behavior of the turbine was closely observed.These observations
indicated reasonable performance of the running blades and the draft
tube.Therefore it was decided to begin with introduction of guide blades
to the turbine,and parallel with testing the turbine,observeand study the
perf6rmance of both the running blades and the draft tube.In this way a
better view of their weak points,design shortcomings -:,and
.-,
performancescould have beenobtained.
Guide blades
LNumber of blades
4.12
ZG==ZR- I
i. e.
ZG=
No.of guide blades
ZR=
No. of runner blades
100
- ir
owl' 71Lr
Photo ( 4.7
4.13
3. Position of the blades
Photo ( 4.8 )
4.14
00
-N
Photo 4.9
which theroots of the holding rods rest. A needle bearing and two
seals on each side of it comprise the third main part and separate the
internal shaft and the casing. The bearing makes it possible for the
internal part to rotate with the turbine's shaft inside the stationary
4.15
casing . Photo (4.10), represents the assembly of this part and the guide
blades.
maim
Photo ( 4.10 )
5.Blades
4.16
Figure ( 4.3 )
Figu re ( 4.4 )
I. The root is of cylindrical cross-section (5mm diameter and
7mm long), and rests inside the casing of the extension of the
4.17
main shaft. 2.The body is of square cross section and 5.5 cm long
which passes through the hollow shaft welded to the blade. The square
,
cross-section helps avoid rotation of the guide blade around the
operating rod due to water pressure. 3.The cylindrical section passes
through the bushingswelded on the turbine's casing.The close tolerance
betweenthis section and the bearing serves two purposes.First, is to
avoid water passing through and ejecting into atmosphere. Second, is to
secure the holding rod againstside movements. 4.The end screw holds
the rubber seal,the pointer, and a holding nut. The holding nut actually
secures the pointer so that its position would not changeonce it is set at
the beginning of the test. (Photo 4.12 )
8. Pointers
4.18
Photo ( 4.11 )
Photo ( 4.12 )
4.19
measured in terms of degrees Photo (4.13), represents a pointer on the
.
main casing of the turbine.
photo ( 4.13 )
4.20
Photo ( 4.14 )
1. The weight of the runner, which can cause some bending moment
in the shaft. This would in turn cause eccentricity between the
shaft's center line and the center line of the casing of the turbine.
4.21
2. Load exertedby the bulk of water flowing over the blades. This
would cause the same bending effects as the above.
OTHER MODIFICATIONS
4.22
Photo ( 4.15 )
Photo ( 4.16 )
4.23
observedat the exit of the turbine without the draft tube and later after
installing the draft tube. It was then noticed that air bubbles mixed
with the flow, were discharged into the reservoir.
It was then concluded that the possible cause of loss of speed
could be as the result of air packets mainly causedby cavitation
inside the turbine's casing and it's interferencewith flow. Therefore, a
vent hole of I 0(mm) diameter was made at highest point of the casing.
As a result, the air packetswere dischargedthrough this hole, and via a
flexible pipe into the reservoir, and the problem was completely
eliminated. Figure (4.17) representsa view of this modification.
Photo (4.17)
4.24
(7HAPrl I ER
TS ING
TH
TURBIN
Introduction
Real operating conditions for a water turbine is such that, the turbine
operates with natural flow (Q) under some head (H).Provision of such
conditions in a laboratory is possible by application of a suitable pumping
unit. Here, the pumps (1-6) draw water from a reservoir and deliver it under
some specified pressure to the turbine. The rate of flow and the head may be
varied by to is
starting a pump additional what operating at the time, or by
opening or shutting off a valve.
How ever, the following steps are to be taken before taking any
readings:
5.1
3. In caseof applying hydraulic dynamometer,water inlet to the
dynamometeris openedunder no load conditions ( i. e. out let fully open
Data to be measured
5.2
Data required for calculations
2. Internal diameter of the pipe (of the piping system) and the
internal diameterof the orifice plate. These two measurementsare
required for the calculation of the flow rate (11).
5.3
Thesetwo values may be calculatedby using the value of flow rate
(Q ).The following would presentthe relations usedto calculate
the velocity values.
Since Q=A. U
2)
4. Q / (7c. D
5.4
4D
D
4, = CcAo
.
Figure ( 5.1 )
the jet or, vena contracta to the area of the orifice (A o),a
is
contraction coefficient usedwhich is defined as follows:
Ai = Cc.A
Cc= Aj / Ao
5.5
Thenfor a circularorifice
(7c dj 2
4)
Cc 2/d2
= (7c
=(dj
4) d2
PI+ U12 P2 U2 2
I
-(A2/AI)2
5.6
A2
However, : -- CcAoand h=P/pg+ z; so that
equation (1) reduces to
2g(hi -h2)
U2
5.7
relate the ideal to the actualflow.This is calledthe coefficientof
velocity Cv;thus, for viscous flow in an orifice the following
dischargeequation will hold:
CvCcAo4[2g(hl -l12)]
-2
4 I_CC2
A 02 / At
Cd
K= (5)
"'Ji -C2Ao2 /Ai2
KAo'-2gAh (6)
5.8
oooo'
Rej
2 All d
K v
1-02 103 1()4 105 106
1.2
Venturi
Vent ri mete meters 1
Ian j nozzles I
han
1.1 A ,,!,' III
TI II
I .
I1
d 1
15
bD 06
0.6
d
d. 0.5
-
.5
1.0
d
D .4
I
0.9
K / Orifices
-. 1 -r-
0.8 -
1.4
-d
- i 0.8
0.1 0.8]
- H11
IN
-- / /
-
o.7 4
d 0.
0.6
DI
d 41
0.14
0.
111 --TI=0.1
d
d 0.2
Figu re ( 5.2
5.9.
Ah is then computed from equation ( 6). However the main
problem here is to determinedischargeQ when a certain value of
Ah is given.When Q is to be determinedthere is no direct way to
obtain K by entering figure (5.2) with Re , because Re is a
function of the flow rate which is still unknown Hence, another
scale which does not involve Q is constructedon the graph of
figure ( 5.2 ) The variables for this scale are obtained in the
following manner: because Red = 4Q/7rdv and
Q=k 7Cd2/ 44 2g Ah then Red may be written in terms
of Ah as
Red=KNF2gAh d/v
Thus the slanted lines and thetop scalein figure (5.2 )are used
when Ah is known and the flow rate is to be determined.
Therefore T= F. L (Nm)
5.10
To calibrate the torque meter a known weight was connectedto
the end of the arm of the dynamometer.The product of this weight
and the length of the (
arm from the centerof the dynamometerto
the end of the arm where the weight was connected ) is the
expected value to be shown on the panel.In casethe value was not
as expected then the electronic sensorhad to be set to show the
expected value. This procedure was repeated a few times with
different weights to make sure of certainty of the readings.
e. Input power ( Pi
Pi pgQH (watts)
11t = Pi / PO
5.11
Calculated values at unit head
V2 V2
U2 V2
Ph= Pi/(H) Poi=Po/(H)
5.12
Trouble shootings
5.13
began for other possible sourcesof causing such decreases.
Eventually after checking all mechanical factors and obtaining
,
no results, thoughts were diverted towards the flow.Theflowwas
closely observedat the exit of the turbinewithout draft tubeand
later after installing the draft tube.It wasthen noticedthat air
bubblesmixedwith the flow,weredischargedinto the reservoir.
It wasthenconcludedthat thepossiblecauseof lossof speed
could be as the result of air packetsmainly dueto cavitation
inside the turbine'scasingandit's interferencewith flow.
Therefore,a vent hole of 10 (mm)diameterwas madeat
highest point of the casing. As a result, the air packetswere
discharged through this hole, and via a flexible pipe into the
reservoir, and the problem was completely Photo
eliminated. (4.17)
( chapter4) represents a view of this modification.
5.14-
INTRODUCTION
plots.
The turbine is designed in such a way that its runner blades can rotate
aroundtheir axis of the blade tails betweenzero to thirty degrees. The turbine
wastestedfor different settingsof blades such as zero, ten, fifteen, twenty and
thirty degrees. For the purpose of comparison only results of two settings of
fifteen and thirty degreeswere selected.
Therefore the following conditions for the original turbine are presented
6.1
After installation of guide vanesthe sametests were performed on the turbine,
for different settingsof runner blades (i.e. open and semi-open)in conjunction
with various settingsof guide vanes. Guide vanescan rotate around their axis
by ten degrees. Zero degreeguide vane would mean that the blades are along
theline of flow and ten degreesguide vanesmean that vanesare rotated by ten
degreesclockwise in the direction as the subsequentrotation of the impeller.
In this condition the flow is diverted by ten degrees by the guide vanes.
Thereforethe ultimate settingsafter modification are as follows:
vanes
F. Runner serni-open blades with en degrees angle of the guide
vanes
For all six (two original and four modified turbine) above situations the results
for
arepresented three conditions:
Constanthead
2. Constantspeed
3. Constantefficiency (which are extractedfrom 1& 2)
The results presentedin this chapterfor the above six situations are unit flow,
torque,power and efficiency againstunit speed. The operating point for each
condition is also presented.
To clarify the best conditions, the comparisonof the results is shown.
1 6.2
Due to the important role of the draft tube in overall performance
of the turblite its behavior was under close scrutiny all throughthetesting
process . Por this purpose the turbine was tested with the draft tube
as a complete cone and without it. Later the exit cross section of the
drafl tube wits cut at an angle of 45 ' to the center line of the cone
so that its exit cross section stood horizontal and parallel to the free
surface of water.
The outcomes of testing the turbine without tile draft tube were,
splashing high speedwater,deafening noise, relatively poor performance
of the turbine and considerablevibrations,as expected.
When the draft tube was tested as a complete cone although tile
performance or the turbine was recovered and tile noise and vibrations
diminished yet high levels of turbulence were observedat the exit of the
tube just below the water free level.This turbule.tice causedconsiderable
fluctuations in all readings.The main causeof the turbulence was the fact
that , the tube was of complete cone shape and subtended 45' to the
line of liorizon. Therefore the water exiting the tube did not discharge
into a constant pressuremedium.1lere,at the upper parts of the exit cross
section of tile tubewater wasdischargedinto relatively lower depth of tile
pool and at the lower ends ofthe cross section, water -was discharged.,
into deeper levels of the pool.Ilierefore the outcomfilg, flow had the
_,
tendelicy to discharge into parts with lower pressureand this pushed the
flow into higlief parts of the exit of the draft tube,causing turbulence at
the exit.
At tile end the exit of the draft tube was cut horizontally so that
water was dischrged into the pool at a, uniform pressure level across
..
the exit cross section. Thererbre the turbulence at the exit completely
diminished.
As Indicated before have been installed at the test
, Six PLIIIII)S
stand.For obtaining variouslicad an'd.flow conditions different number of
pumps came into operation in each test.As the prime objective of these
tests was to ascertain the bchavior of the turbine for heads below ten
6.3
meters therefore higher heads had to be ignored.
Although all tests were
taken for one to six pumps but experience showed that the heads
obtained for more than four in
pumps operation, exeeded ten meters. For
this purpose only the data for upto four pumps are presentedhere and the
rest are available at the laboratory's library.
RESULTS
I., OPENBLADES
6.4
( 6.10.1 ) to ( 6.12.1 ) representthe efficiency and power plots againstthe
flow rate,indicating the operating point of the turbine, for 500,1000
and 1300 r.p.m. respectively Xigure ( 6.13.1 ) shows curves of
efficiency v percentage of full load for constantspeeds of 500,and 1000
r.p.m. On figure ( 6.14.1 ) the constantefficiency curves of power v speed
are shown.
6.5 ,
main characteristicsfor unit flow, unit torque, unit power and efficiency
for
against unit speed one to fourpumps are presentedin figures ( 6.5.3 )
to ( 6.8.3 ),respectively.Plots of the operating characteristicsare shown
by figures ( 6.9.3 ) to ( 6.13.3 ).Curves of efficiency v power for constant
speeds of 500,1000 and 1300 r.p.m. are shown by figure ( 6.9.3 ).Plots of
efficiency and power against flow rate for the sameconstantspeedsare
represented in figures ( 6.10.3 ) to ( 6.12.3 ). Figure ( 6.13.3 ) shows the
efficiency v percentage of full load curves for constant speeds of
500,1000 and 1300 r.p.m. on the sameplot.Figure ( 6.14.3 ) showsthe
constantefficiency curves on the baseof power againstspeed.
6.6
5.SEMI OPEN BLA DES WITH O'GUIDE VANES
, 6.7
represented in figures ( 6.10.6 ) to ( 6.12.6 ). Figure ( 6.13.6 ) shows the
efficiency v percentage of full load curves for constant speeds of
500,1000 and 1300 r.p.m. on the sameplot.Figure ( 6.14.6 ) shows the
constantefficiency curves on the base of power againstspeed
6.8
respectively.On each plot six curves of efficiency v power are shown for
each of the six different blades settings.Also figures ( 6.38 ) to ( 6.40 )
represent the same comparison curves for the two best performing
blades settings for the sameconstant speeds.
Curves of efficiency v percentage of full load for all six blades
setting are compared on figures ( 6.41 to 6.43 ) for 500,1000 and
1300 r.p.m respectively. Also figures ( 6.44 to ( 6.46 ) represent the
same comparison curves for the two best performing blades settings for
the sameconstant speeds.
6.9
DISCUSSIONS AND CONCLUSIONS
DISCUSSIONS
6.10
Figures (6.1.2 ) to ( 6.4.2 ) represent comparisons of main
characteristic plots for semi open blades. General behavior of these plots
are almost the sameas those of open blades.The major difference may be
noticed in figure ( 6.8.2 ), and that is the fact that the efficiency curve for
two pumps in operation coversthe widest range of unit speed amongst
all curves as well as showing the highest efficiency obtained.
Comparative plots of characteristics for open blades with zero
degree guide vanes are shown in figures ( 6.1.3 ) to ( 6.4.3 ).In
figure ( 6.5.3 ) the sametrend as before is observedfor unit flow curves.
Highest values of torque with respectto unit speedhave been obtained
when two and three pumps were operation in ( figure (6.6.3 )).Values for
unit power generated by two and three pumps are almost the sameand so
are the efficiencies gained by them, figures ( 6.7.3 ) and (6.8.3).
However,as may be visualized from figure ( 6.8.3 ),values of efficiency
for 2,3 and 4 pumps in operation are very close with three
pumps,producing highest efficiencies.
Comparative characteristicsof the turbine for open bladeswith ten
degree guide vanes are shown by figures ( 6.5.4 ) to ( 6.8.4 ).Unit flow
and unit torque curves show the same trend as for zero degree guide
vanes. Highest values of unit torque are obtained for two and three
pumps,although their values are very close. However, unit power curves
show clear difference between two and three pumps, with two pumps
generating highest amounts of unit power. This is where the unit power
curves for three and four pumps are very close with the four pumps curve
figure ( 6.7.4 ).From figure ( 6.8.4 ) it
covering a wider unit speedrange,
be observed that the highest levels of efficiency have been
may
two pumps were in operation where efficiency curves for
attained when
three and four pumps are very close to one another.
Figures ( 6.5.5 ) to ( 6.8.5 ) show comparative characteristics
of the turbine for semi open runner blades with zero degree guide vanes.
In figures ( 6.5.5 ) and (6.6.5 ) the usual trend for unit flow and
6.11,
unit torque curves is observed.From figure ( 6.7.5 ) it may be deduced
that the highest values for the unit power have beengeneratedby two
and three pumps,whereas,the levels of unit power fell rapidly as the
number of pumps increasecito four.Highest efficiencies have also been
obtained when two and three pumps were in operation,according to
figure ( 6.8.5 ).At the highest point the two curves seemto be very close
whereas,at other points efficiency levels attained by two pumps are
,
clearly higher than the rest of other pumps.As the number of pumps
increasethe efficiency of the turbine tend to fall.
Comparative characteristics curves of semi open bladeswith ten
degrees guide vanesare shown by figures ( 6.5.6 ) to ( 6.8.6 ).Here,again
the same trend as before is shown for unit flow and unit torque
graphs,figures (6.5.6 ) and (6.6.6 ).Also it
as may be observed from
figures (6.6.7 ) and (6.9.6 ),highest levels of unit power and efficiency
are obtained when two and three in
pumps were operation,and their fall
can clearly be observedas the fourth pump comes into operation,exactly
the sameas semi open bladeswith zero degreeguide vanes.
As mentioned before figures (6.15 ) to ( 6.30 ) represent
comparisons of characteristicscurves for all six different blades settings,
on one plot for 1,2 and 4 pumps in operation, separately.
,3
From figures ( 6.15 ) to ( 6.18 ) it may be observed that semi open
blades with guide vanes have always had the lowest amount of unit flow
rate in comparison with other blades settings. Figures ( 6.19 ) to ( 6.22
show that the highest amount of unit torque has always been obtained by
open blades with zero degree guide vanes. This would explain the high
amount of unit power generated by the same blade setting shown on
figures (6.23 ) to ( 6.26 ).From figures ( 6.27 ) to ( 6.30) it is clearly
observed that the turbine having the guide vanes has always reached the
highest levels of efficiency for any of four combinations of blades
settings. Figures ( 6.31 ) to (6.34 ) select the best performance conditions
6.12
before and after installation of guide vanes( i. e. semi open blades,and
semi open blades with zero degree guide vanes).
It has already been mentioned that operating characteristicsare
basically used for the purpose of appraising the power generating
capability of the turbine. The following continues the discussion and
lead it to operating characteristics( constantspeed) of the turbine.
71hefollowing figures show plots of efficiency against power for
different constant speeds.Selected constant speeds are 500,1000 and
1300 r.p.m.On figure ( 6.9.1 ) only two curves of 500 r.p.m. and 1000
r.p. m. can be observed. This is due to the fact that there were not enough
data points for 1300 r.pm. to generatethe appropriatecurve, since the
turbine with open blades for one and two in
pumps operation could not
attain the speed of 1300 r.p.m. On this plot the values of efficiency gained
by the turbine for any amount of power for higher speedof 1000r.p.m.
have always been more than those of 500 r.p.m. speed.In caseof semi
open blades figure ( 6.9.2 ), the highest speedof 13 00 r.p. m. has always
had the highest values of efficiency for all values of power.Curves of 500
1000 r-p. m are very close at lower amounts of power and for
r.p.m and
higher values of power the 1000 r.p.m. curve showshigher values of
On figure
efficiency, as well as much wider range of power generated.
),
( 6.9.3 the plot for open blades with zero degree guide vanes, both
curves of higher speeds clearly show much higher values of efficiency
than those of 500 r.p.m. curve. These two curves are also very close to
one another. For open blades with ten degree guide vanes, conditions of
almost the same and the only difference is in wider gap
curves are
between the two higher speed curves.Here the 1300 r.p.m curve shows
the highest values of efficiency against power, figure ( 6.9.4 ). Plots for
both semi open bladeswith zero and ten degreeguide vanesshow almost
the same behavior all through, for all three curves. Here again the
6.13
higher speedcurves show highest values of efficiency at all times.As
it may be observed frorri both plots, the 1000r.p.m. curve show higher
values of efficiency almost up to half way through the values of
power.There after,the values of efficiency for 1300 r.p.m. curve clearly
exceed those of 1000 r.p.m. and also cover a wider range of power
generated figures (6.9.5)and(6.9.6).
Figures ( 6.35) to ( 6.37 )show comparisonsof (efficiency v
power ) for all different blades settings on one plot, separatelyfor 500,
1000, and 1300r.p.m speeds. In all three cases curves are very close for
lower values of power but they divert as the values of power increase.
However, the curve for semi open bladeswith zero degreeguide vanes
shows higher values of efficiency againsthigher values of power for all
threecases.
Selected curves of efficiency v power for best performance
conditions before and after installation of guide blades for above
mentioned constant speeds are representedby figures ( 6.38 ) to ( 6.40).
In all three cases curves of semi open bladeswith zero degreeguide
blades clearly exceed those of semi open blades both in terms of
efficiencies gained and the power ranges.
The second set of constant speed plots show the plots of
efficiency v flow rate and power v flow rate both on one plot for
various blades settings and for different constantspeeds.Blades settings
and con:stant speeds are the same as indicated On
above. eachplot an
intersection point betweenthe graph of power and the curve of efficiency
is observed,which may be regarded as the "operating point " of the
turbine for that specific condition.
Study of these operating points show that in all cases highest
operating points belong to the turbine with the guide blades.Comparison
of operating points for best performanceblades settingsbefore and after
installation of guide blades show that for the semi open blades,the
6.14
turbine has gained an efficiency of 49% with a generated power of
3150 (w) for a flow rate of 65 (11s).These values for the semi open
blades with zero degreeguide bladesare 78%, 4600 (w), and 56.5 (11s)
Values
respectively. of the latter also represent the highest operating
point amongstall.
Next set of plots of ' constant speedplots represent curves of
efficiency v percentageof load for eachblades setting separately,figures
( 6.13.1 ) to (6.13.6 ). On figure (6.13.1 ) two curves for 500 and 1000
r.p.m. for open blades are observed. Here the highest values of efficiency
have been obtained for 1000 r.p.m speed.On figure ( 6.13.2 ) plots for
semi open blades are shown. Here again the values of efficiency for
speed of 1000 r.p.m are the highest,whereasthose of 1300 r.p.m. are the
lowest for up to 50% of the load and after that they exceedthe values of
efficiency for 500 r.p.m. On figure ( 6.13.3 ) it can clearly be observed
that the values of efficiency for open blades with zero degreeguide
blades'for 1300 r.p.m are the highest and then come those of 1000 r.p.m.
and the lowest ones are of 500 r.p.m. Open blades with ten degrees
guide vanes show a different behavior here, highest values of efficiency
are gained for the speed of 1000 r.p.m and then come those of 1300
r.p.m. and then 500 r.p.m as the lowest figure( 6.13.4 ).Plots for semi
open blades with zero and ten degree guide vanesshow almost the same
behaviorAn both cases loads of more than 70 % gain higher values
of efficiency for 1300 r.pm. and below that 1000r.p.m. speedobtains
higher values of efficiency.Therefore thesetwo curves cross eachother at
around 70 % of the load.Also values of efficiency for zero degree guide
vanes are clearly higher than those of ten degree guide vanes, figures
6.13.5 ) and ( 6.13.6 ).
Figures ( 6.41 ) to ( 6.43 ) provide a comparative illustration of the
above curves for different constantspeeds. From figure ( 6.41 ) it can
6.15
be observedthat for low speeds ( i. e. 500 r.p.m. ) the turbine with open
blades and zero degreeguide vanesattain the highest values of efficiency
at all times, apart from last ten percent of the full load (i. e. from 90 % to
100 %) where the efficiency values for semi open bladeswith zero
degree guide vanes exceed all others.Figures ( 6.42 ) and ( 6.43 )
show clear dominance of the curves of semi open blades with zero
and ten degrees guide blades In almost the last 10 % of the full load
they fall slightly below the values of open blades with zero degree
guide blades. Figures ( 6.44 ) to ( 6.46 ) show the efficiency v percentage
of full load curves for selected best performance blades settings before
and after modification, for different constant speeds. Figure ( 6.44 )
shows how both blades settings behave very closely for loads below
50 % and over that the values of semi open bladeswith zero degree
guide blades exceed those of semi open blades, for 500 r.p. rn speed. For
1000 r.p.m speed,a clear wide gap is visualized betweenthe two curves
with semi open blades with zero degree guide blades having higher
values. This gap reduces as the load percentage increases, figure
( 6.45 ). For 1300r.p.m speed again a gap is observedbetweenthe two
curves Mere the is
gap much wider than that of 1000 r.p.m. speed and
again it tends to become narrower towards higher load percentages, figure
( 6.46 ). Thesethree plots draw a clear picture of the performanceof the
turbine under-its best performing conditions before and after introduction
of guide blades.
Figures ( 6.14.1 ) to ( 6.14.6 ) representthe constantefficiency
curves for various blades settings. Basically these curves help detect the
highest efficiency zones.Also with the help of thesecurves it would be
possible to determine the best operating range of the turbine for
,
specified ranges of power and speed. A study of the aboveplots show
that in the best operating range with 81 % efficiency, the generated
power would vary between 1000 (w) to 4600 (w) for a speed range
6.16
of 800 r.p.m to 1700 r.p.m., respectively.Thesevalues are related to
the semi open bladeswith zero degreeguide vanesturbine,illustrated by
figure ( 6.14.5 ). The plot for best working blades setting before
modification ( i. e. semi open blades ) shows 61 % efficiency for a
power generating range of 700 (w) to 3800 (w) for a speed range
of 600 r.p.m. to 1850 r.p.m., figure ( 6.14.2 ).
6.17
QUICK GUIDE TO THE PLOTS
The first six set of plots are related to six different blades settings,
representing, the main characteristicsfor one to four pumps, camparison
curves of the main characteristics of one to four pumps on one plot,
operating characteristics including, efficiency v power, efficiency and
power against the flow rate on one plot, efficiency v percentageof ftill
load, and the constant efficiency curves.Theseplots are representedas
follows:
18
Figure (6.15 ) to (6.30 ) illustrate comparisongraphsand curves
of main characteristics for all blades settings simultanously for one to
four pumps, pages 6.104 to 6.119. Comparisonof the efficiency curves
against unit flow for one to four pumps, pages 6.120 to 6.123jigures
(6.31 ) to (6.34 ).
Figures (6.35 ) to (6.40 ) illustrate comparativeconstantspeed
plots of efficiency v power for different blades settings simultanously,
pages6.130 to 6.135.
Figures ( 6.47 ) to ( 6.52 ) representplots of efficiency v flow rate
for the draft tube, pages 6.136 to 6.141
.
6.19
Figure( 6.1.1 )
6.20
Figure ( 6.2.1 )
6.21
Figure ( 6.3.1 )
6.22
0032- OPEN BLADES 4 PUMPS OPEN BLADES 4 PUMPs
0.030- 1.4-
0.028- 1.2-
0,026- 10-
0.024- DO-
a
0 0.022- 06-
j 0
U.
z z
O020- 04-
00is- 02-
0.016 00- 0
00
60-
so-
50-
Go-
40-
40- 30-
z
R
IL
u. 20-
Uj
20-
10-
0
0
Figure ( 6.4.1
6.23
UNIT FLOW
p p p p p p p p
0 0 0 0 C)
C) 0
in 0 CA (A Ln
0
m
C) z
-Ii
1
CD cn
0)
Pl
C)
C:
)
Cl
0 0.0
CD
C:
99K ccc
10 M -0 ir_0 .1
0 (1) Q) (A .
6.24
UNIT TORQUE
C) (A 0 (n 0 En C)
Cj - 01" 0
::
0
m
z
ol
-n
C25, 0
m
Cl)
0
0 0.00
cn -D.WK)-
mo 0M CC:
CC 'o -0
999K
m T ' uT
co (ACl) (1) -U
6.25
UNIT POWER
%%
%
%%
%
%%%
%
%%
%
%%
%
%
%
z
ITJ
0 11.0 0
-0 Mm 'a
CCC
cn ch Cl)
Cf)
u Co
M 0
m
6.26
EFFICIENCY
aM
cccc
1, *0 'u 10
Q) Q)
0 % m
z
0
Im
I
CD 0- 10
cl)
D
m 0 00
m0
6.27
EFFICIENCY(%)
b. cn (3) -4
0Q
0-
0-
CD "10
m
z
lel-I
03
C3
0 c
0 C3
-0
0
m
:0
6.28
EFFICIENCY (%)
03 CA
C)
0
0
z 0
CA -0
m
z
ca
cn
m 0
m M
0
0
-n
C)
a
0, %
al
0
-4 1
0
c"
00 cn 0
0 0 0
0 0
POWER (W)
6.29
EFFICIENCY (%)
i1
Pl
CD
al
POWER (W)
6.30
EFFICIENCY (%)
cyl (3)
Ul
m
z
C,
u
m
m 0
0 m
0
n
cyl Z
0
(3
P
3
cil
(A
CD
t--
U)
0)-
C) Ul
C) 0 0
000 0
POWER (W)
6.31
EFFICIENCY
0000 On
0m
ITI
0)
0 _
01%
co
-
CJI
0- C) 0
6.32
POWER (W)
cn (n (D (A
C:) CD C:)
0 C:) 00
0
Z
Z
--i
M
CD
C:
)
M
Z
ITI M
cn
CD
10
0- M
im
r_n 15
cn C)
(D
CD M
-2-
CD
CD
CD
Mumme
6.33
Figure ( 6.1.2
6.34
Figure ( 6.2.2 )
6.35
F
0.040- 2O
SEMI OPEN BLADES 3 PUMPS SEMI OPEN BLADES 3 PUMPS
0.035
1.5
Is
0030-
lo-
0 cy
i ir
U.
0.025-
z 05-
0020-
0.0-
0015-
0 200 400 000 e0() - T-
1000 1200 0 200 400 600 Boo 1000 11200
U141TSPEED UNIT SPEED
30-
60- 0 0
25-
so-
20-
40-
0 30- 15-
20- M 10-
10- 5-
0- 0 0 0- 00
0 200 400 600 Boo 1000 '1200 0 200 400 600 Soo 1000 1200
UNIT SPEED UNIT SPEED
Figure ( 6.3.2
6.36
Figure ( 6.4.2 )
UNIT FLOW
ppppp
00 CA) C3
Cn 0
Cy)
*00.0
4p
0
0
-n
0D
1.0
c
0, o
Cl) 0 -a IV IV -0 1.
"a accc1.
mK9Kc1.
m 'D 'u -0 M
(A ch V)
6.38
UNIT TORQUE
p p
Ul 0 cyl 0
pp
CA 0 p
01
0
0-
0 * 00
CD
m
C) 0
m
z
03
m
CD
0-
%-o
co
C3
0 Poo 0
b. C.) t) -
*.
'o _0
U) (n _0
co -0
6.39
UNIT POWER
co CY) Co Z,
4%
0 0 C) 0 0 C)
C)
Cf)
m
0
0
m
z
CD
C:)
CD 0
ell%
ON
m
C/)
co
1
0
10
Cl)
-a
m
m
cc
CCC
''Ao (a
'o -0
6.40
EFFICIENCY
4. cn m -4
00 . 0 00
0 0
0 . .. 00
0
.%
%%
%
%10 cn
%% m
%% 3:
0 o
0- o 0
m
z
0 0
cy)
0- CD
0
CD
11-1
ON
bo
00
C3
40
0
0
. 0
cl) cccc
rcr9
m
m
6.41
EFFICIENCY(% )
(A) -N cn
0-
cn
m
K
0
C)
C) -u
m
z
03
C)
C)
CD
c:)
UQ
CD
C)
C)
K)
cn
C) -
CD
C)
C)
00
n
6.42
EFFICIENCY (%)
CA) CA
C) cl)
0 M
z
c/)
0
0
m
co Z
'o
m
m
03
c') 0
0
n m
CA
CD
C)
(71
C) K3
(n
POWER (W)
6.43
EFFICIENCY (% )
0 C)
0
0 cl)
zm
o
cn-0
m
0Z
m
m co
0
CD 0
-n
M
T1
1" cp
(n w
0 cyl 0 cn 0 (n
000 00
000 00
POWER (W)
mmmmmwl
6.44
EFFICIENCY (%)
w A.
00
0
0 cl)
m
F.
z0
i -u
c/)
'o rn
m z03
M
ci ! -
0 r,
n C)
8m
ITJ
CD
t-%
cy)
0
coA- -.
IIIIIAIIIaIaI
0
C) C3 ch
C) 0 En 0 cn
000 Cl
000
POWER (W)
-mmd
6.45
EFFICIENCY (%)
cn 0 cn 0 (A 0 CA -th,
(D A,
CA En
0 En
fn
0
cl)
0m
09
Zo
W
-u
m
z
cl)
a
m a)
m
0
m
co
t, )
CA -
0- 00
ON
-4
CA
CJI
0 C3
C) C3 0
co
1 -1 71
r- 7 10 "a
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6.46
POWER (W)
cn C) 01 C3 M CD CA
Cl CD C) C) C) C) C)
C) C) C) C) C) C) C
C:)
00
c.n
CA)
ch
0
CY)
CY)
C)
0
CD cyl
C)
40
c)
C)
cn
m
0
m
z
CD
0
Cl) m
"U (/) *0
m
m
13
OPEN BLADES+0 DEGREE GUIDEVANES OPEN BLADES 0 DEGREEGUIDE VANE
3.6-
IPUMP IPUMP
0.045-
3.0-
25-
0.040-
2.0-
000 111
0.035- . D
V a
,
0 w
0 11.5-
t
D z
0.030-
05-
0.026-
0.0-
0.020-
40 , 0 2DO 400 600 a
0 21;0 600 Soo
UNIT SPEED UNIT SPEED
I PUMP I PUMP
200- so-
40-
160-
30-
1100-
20-
iL
60- IL
LU
10-
0-1 0
o
0 200 4; 600 800
0 2; 0 400 600 80
UNIT SPEED
UNIT SPEED
Figure 6.1.3
6.48
OPEII BLADES* 0 DEGnEE6 GUIDE VAIIEM
80-
2 Pumps
40
Z,
0
FE
III 20
0.0 0
Figure ( 6.2.3 )
6.49
I
Figure ( 6.3.3
FigUre ( 6.4.3 )
UNIT FLOW
p p ppp
C3 b 000
ca 03
0
0 CA CA
(.n
0
0
0
m
z
0
C3
(n
0
%-. o
>
z
m
U)
00
mTm
C:C:C:c
M 'u
(1)
0 Do.0
6.52
UNIT TORQUE
Ln
m
z
m cn
cc +
1
0
11 C)
CD 0
m
G)
C)
0) m
<
If >
z
m
CD
co
010-00
0 'a 'D av
0
6.53
UNIT POWER
CA Cil C) (.n
C, C:, 0 0
%,
im. I -I II I . -i
C)
G)
m
m
G)
C:
Ni.
p- m
<
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m
Z.,)
1-1
0-
0 0.
0
co
0
cn
a 0
m
m
0
Kr. ic
9) Q)
6.54 '
EFFICIENCY
fl) 03 Ul (3) -4 co
0 0000 -N 00
C3
Cp
LD
m
z
ca
0-
0
m
cn
0
m
G)
bo m
m
u (3)
1.-111
C)- 1. G)
n 0040
0
... .0
0
z
Pol m
cf)
0
.... '0
co
6.55
EFFICIENCY
00 0 (D Q0 CD CD
CD
cm
93
0
O_
C)
0-
CD 0
0
m
Z
(JQ
CD O_
m
cn
CD
0
m
m
m
CD
0-
Q
tn (0
1 -,
w000
C:)
O(D
CD _A
0 m
6.56
EFFICIENCY
Ca (n
00
0Z
0 U3
z
>
z
i cl)
cn +
00
m
m0
0m
0
n
c"
C> m
S,
71
m
V
CD
1-1%
(ON
Q
L3
(n 00
00 C)
000
POWER (W)
6.57
6.58
EFFICIENCY
-r 00
0
C)
0
0M 0
0Z
z
Z C:)
m
m+
m
C) 0
0 cl
nm
m
m
G)
CD
0-%
CN
LI)
0-
C3 cl)
C3 0 C)
C) C)
POWER (W)
6.59
EFFICIENCY (%)
G) (n (3) -4 Oo
000 -bk C) C)
c)-
0
0
z 0
U)
9
rj)
I
cl)
m
MM
CD cy)
lo-I
ca c CJI
0
cnl
00 0
0 8 a El 3
6.60
POWER (W)
(A
C.
0
CA
CYI C3
CD
(n
C) C) CD C) C) CD
C) C) CD C)
CD C) C) C)
co
IQ 1.
C)
-0
C)
C: )
C)
C)
00
C:)
C)
T1 C."
4
CD CD
C)
C>
0
-4
C) Lin
C) 0
0
0)_
C) "D 0
m 0
z
z
C3
00 m
C) +
-0 0
m 0
m
G-)
X
CD m
C) m
0
G)
m
<
>
z
m
(n
6.61
Figure ( 6.1.4 )
6.62
Figure ( 6.2.4 )
OPEN BLADES 0 10 DEGREES GUIDE VA14ES OPE" 9LADEG 10 DEGREE@GUIDE VAtJES
0024-
3 PUMPS 3 PUMPS
25-
0022-
20-
0020-
41
41
L
0 10- 0
OIS- 0
5-
0- 0
0014.
, , 0 40
0 200 400 Goo 80 1000 0 2; 60 000 1000
UNIT SPEED
UNIT SPEED
60-
40- 40
U5
20- 20- 0
0- 0 0 0- a
Figure ( 6.3.4
6,64
OPEH BLAVE9410DEOnEES GUIDE VAtIES
OPE" EWES 4 10DEGMES GUIDEVANES 35.
4 Pumflo
4 PUMPS
0 02Z
25-
ai; vk
20.
0018L
0.011k
OOR *
4 PUMPS
4 rumrs
60-
40-
40-
30-
20-
20-
0. o
00 0 0
Figure ( 6.4.4
6.65
UNIT FLOW
p ppppp
8 13 2 0
Q a Ul
0
-u
m
z
cu
rn
cn
C)
m
;u
m
m
cn
, Ti c
01-1%
0) m
Cf)
%.. 0
co
o 1.oN
6.60
UNIT TORQUE
a Ln 0 C" 0 CA
0- I w
:J
rn
z
03
U)
+
C)
-n rn
cca G)
(D rn
cn
G)
<
>
z
U)
co
8-
c o
z 0 o. 0m
:1
C0 .1."o "u
10
m
m (1) V) W
6.67
UNIT POWER
CY) 0D CY)
-t
000
K)
co
0
m
cn
f
CD of
a' - *0
1
G)
'100 c
C)
m
0
0.010 <
0
>
10
00 z
8- v
10
" o
z
=i
Cl)
m
m
10 10
I
6.68
EFFICIENCY
cy) -4 Oo
o. 4 0-
0
-u
rn
z
M.
T1 :J
I: m
U)
+
0
G)
m
m
/A cf)
G)
c:
0
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<
>
0
"'o CD
"" "
"0
&&
"1,
9
-
0
""'.
a
z
=i
m
m
0
6.69
EFFICIENCY(%)
C13 CA (7) -4
0 c, Q
tt
0-
0
u
m
z
C13
m
ftl
m
G)
m
m
G)
OR-
0
0
too 0 z
cl)
--4
ID m
V 10
M
O
6.70
EFFICIENCY
C)
0
U
rn
z
03
0
0
z
rn
(t) "+
m 0
m
0 m
0 G)
0- ow M
C3 m
G)
STI
,n
r-
0
m
0-
cz
C) 00
0 C3
CA
C)
POWER (W)
6.71
EFFICIENCY
to 0)
0 C)
0
U
m
0 z
Z
+
M
m
0
0
0
m
G)
C m
m
(n
-n
r-
0
m
CZ
CA
1.--0
CA)
C)
C)
C) C)
C3
POWER (W)
6.72
EFFICIENCY(%)
(A) LTI
-D,
0 C)
0z
0
0m
CD
X--
C3 C3
C3
C)
POWER (W)
6.73
EFFICIENCY
'o
m
z
0 a)
V)o
Wil
1-. w,
;a
cyl
6.74
POWER (W)
C) fLn CD CYI C3 .9h.
(n CA
C)
En C) CA Cl CD C) C)
C3 C) C C) C) (D C>
C) C) C)
CD CD CD
Ut
C
C)
C) CA(3)
Ul
C,
T1
C)
00
C)
0
m
z
03 0
0
z
m
En C,
C3 + >
C)
z
mM
C) -n
;xm
a -n
m
m0
cn (1) m
"10 QZ
m0
m C) m
<0
c
mX
CA <
m
U)
%. 10
6.75
MA OPEN BLADES*0 DEGREESGUIDEVANES
0024 SEMI OPEN BLADES# 0 DEGREES GUIDE VANE'
4-
I PUMP
I PUMP
0.022 -
3-
2-
0018
0010
0-
0014- II .I. I
111vIII 4O 600 800
0 200 400 600 800 20
UNIT SPEED U141TSPEED
GUIDEVANE$
OEMOPENBLADES0 DEGREES GEKM GUIDEVANE$
00 DEGREES
OPENBLADES
100-
1 PUMP PUMP
60- 01
so-
40-
Go- 30-
40- 20 -
20- 10-
0-
0-
Figure ( 6.1.5
6.76
IiIEMIOPENBLADES*0 DEGREESGUIDE VA14EB
14- BEANOPENBLADESf0 DEGREESGUIDE VANES
2 PUMPS
2 PUMPS
0020 -
0
12-
0.025 -
0024 -
0022
0020 -
4-
%
Colo -
2- S,
0018 -
01
0014
0 200 400 600 so() 1000 1200 0 2W 400 aw aw 1000 1200
: UMPS
00.
150- %
'100-
40-
so-
20-
0- 0 0
0- 00
F igure
igu" ( 6.2.5 )
6.77
Figure ( 6.3.5 )
SEMIOPEN BLADES40 DEGREES GUIDEVANE, SEAMOPEN BLADES40 DEGREES GUIDEVANES
0020. 35-
4PUMpa 4 PUMPS
30-
0018-
25-
20-
0.01a
-
le t'UIs - 0
0014-
t: 10 0
*4
5-
0012-
0- 0
0010
.5
0 200 400 6DO SDO 100( 0 200 400 600 600 1000
+0 DEGREES
SEMIOPENBLADES VANES
GUIDE
GUIDEVANES
f0 DEGREES
SEMIOPENBLADES
4 PUMPS
140- 4 PUMPS
80-
120-
loo- 60-
so-
40-
Go-
ts
a
40 - 20-
20-
0- *0
0- 0
6'2 60-
46o ' 660 eU--iabo
01 200 400 Goo Soo 1000
UNIT SPEED
UNIT SPEED
Figure ( 6.4.5
UNIT FLOW
p p p p
0 0 0 0
cn 0 cn 0 CA
0
..0
CA
14 -0
1 m
z
C:)
0
-n cl
(a
C:
m
U)
I
CD
0)
G)
X
m
m
C/)
G)
Co
0-
>
z
C0
13
M
m
A. WM
0 U)
co -0 Cl) -u
6.80
UNIT TORQUE
co
m
0 - .1. r 0
m
z
.1.01, uo
G)
m
m
G)
-n
>
z
CD m
Cl)
m
CD
00
10 1
I10 10.00
.96 C4 to -
a
6.81
UNIT POWER
f%) 0) 00 0 K) (3) co C)
0000 -t, 00 C) 0 0
%%
%
%
0
% U)
m
0
0\ 0
'u
z
03
CD
e-, (3)
C*%
0 M
... 0
m
m
U)
CD 0
C) C:
m
'
o.
<
0 >
z
'o
0 -
M
cc
.0
a Z'o
6.82
EFFICIENCY
-N al (7) -4 Oo co
00 00
. .. 0
%
%
C: ) -
m
z
CD
oo%
(ON m
bo
G)
m
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6.85
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6.87
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6.92
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6.93
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6.100
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6.126
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-0
6.137
DRAFT TUBE EFFICIENCY
(3) -4 OD ca
0 0
cl)
m
9
m m
z
0
03
CD
c/)
1-1
CD
al
0
m
110 0
%_w ;u
m
m
0
c:
0
m
m
c/)
w
T
c
T
ch
"n
r-
0
m
lz
cl)
6.138
DRAFT TUBE EFFICIENCY (%
(3) -4 cco (D
(11
a0
z,
OD
m
K
0
'D
m
8- z
ca
11 9
m0a 0)
CD
e-S m
0
M
m
Q m
0
c
cl
p-
tj
0
(1)
6.139
DRAFT TUBE EFFICIENCY (%)
-L 8 -N En 0) -4 00 co
Il
co
cyl
N
6.140
DRAFT TUBE EFFICIENCY(%)
ca (A 0) 00 (D
-N -4
00000
m
cn
0
En a
cn m
m
m
w
G)
c:
0
m
cn
4..
'D
c:
_0
on CA
m
co
cn
-
"n
r-
0
-4
co
*. CA _j
6.141
CONCLUSIONS
In this work more than 500 readings are taken in the laboratory of which less
than 50% of them are presentedin about 140 figures. By considering and
comparing all thesethe following can be concluded:
precise heads and flow rates within its specified range of micro hydro
turbine requirements.
2. Installation of Guide Vanes upstream of the Runner (this includes a
second support bearing) can increase the performance of the turbine
significantly. The improvement in efficiency for one typical condition is
over 20% (runner blades semi-openand guide vane angle zero, Fig. 6.4.5,
best efficiency 85%, compared with original turbine, Fig. 6.4.2, best
efficiency 63%).
3. Application of the guide vanes yields extension of the high efficiency
domain of performatices. It can be seenfrom Fig. 6.14.5 that the turbine
(with guide vanes) can operate from 1000 to 4800w with 81% efficiency
7.2
REFERENCES
RI
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14. Hydro power in Iran - Iran ministry of power - 1983
15. G.L Krivchenco - Hydraulic machines,turbines and 12ul-nps -
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16. MiroslavNechleba - Hydraulic turbines and pumps -ARITA -
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17. D. G. Shepherd - Principles of turbo machine!y - Mac Milan
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R2
27. Load control lJormicro hydros International
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cand
29. Machinery and equipment for micrj hydros International
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water powermid dam cons(ruction- No. 1 1,11.17-1986
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P-118-198
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1966
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110. AINLEY, D. G. 'Md AMMISON, G. C. R. -A method of
j*Oj-jjjajjcc
I?Lj: estimation Im axial flo%,
v turbines Ael-011LIfical
-
j-esc.,
qj-clj council, It & fvI (2974) - 1957
41. MARKOV NA calciligtion of the acrodynamic
0
cl iaracteri sties Of tL11-binc bluding -Translation by Associated
'I'echnical Serviccs - 1958
10