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Banki-Michell micro-turbines for energy production in water distribution

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Chapter · July 2016

DOI: 10.1201/b21902-159

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 Banki-Michell micro-turbines for energy production in water distribution
networks
V. Sammartano & P. Filianoti
Dept. of Civil, Energy, Environmental and Materials Engineering, Università Mediterranea di Reggio
Calabria, Loc. Feo di Vito, 89122 Reggio Calabria, Italy;
G. Morreale
WECONS, Via Agrigento, 67, 90141 Palermo, Italy.
M. Sinagra & T. Tucciarelli
Dept. of Civil, Environmental, Aerospace, Material Engineering, Università degli Studi di Palermo, Viale
delle Scienze, 90128 Palermo, Italy Viale delle Scienze, 90128 Palermo, Italy;

ABSTRACT: The design of a new Banki-Michell type turbine is proposed for electricity production from
pressurized pipes. The advantage of the new turbine is its simplicity, as well as the direction of the outlet flux,
which remains in the same plane of the impeller and of the original pipe axis. The turbine has a total length of
10-12 times the diameter of the hosting pipe. The design procedure is validated with a given set of input data
using ANSYS CFX numerical solver: the specific energy difference between the inlet and outlet section, the
expected discharge, the impeller rotational velocity. Solution is found for a given set of discharges after
changing the impeller rotational velocity in order to keep the relative velocity always equal to 2. Efficiencies
remain above 84.3% for all the tested discharges, with a maximum/minimum discharge ratio equal to 4.5 and
a peak value of 86.8%.

1 INTRODUCTION 2 TURBINE DESCRIPTION

Banki-Michell turbines combine simplicity with ef-
ficiency and represent a possible alternative to the
use of PATs (Pump As Turbines) for hydropower
energy production at the end of aqueducts delivering
water to urban tanks (Chattha et al. 2010; De
Andrade et al. 2011; Khurana & Kumar 2011; Sina-
gra et al. 2014). The traditional outlet of this type of
turbine is at atmospheric pressure and this precludes
its allocation along aqueducts or inside Water Dis-
tribution Networks (WDNs).
The use of in-line turbines could allow the selec-
tion of these sites, where a pressure reduction would
not affect discharge regulation, but rather limit the
pressure downstream of the turbine and reduce water
losses. In the following, starting from the design cri-
teria previously developed for Banki-Michell tur-
bines (Sammartano et al. 2013, 2015), a new Banki-
Michell turbine aimed to overcome this limitation is
proposed. Moreover, a detailed analysis is carried
out to investigate the variation of both the efficiency
and the total head dissipation along with the change
of the impeller rotational velocity, assuming the
electric regulation of the turbine to be available.
The Banki-Michell turbine has a constant section
along any plane normal to the impeller axis. It is
composed by four main parts (Fig. 1): the conver-
gent pipe, the nozzle, the rotating impeller and the
diffuser. The convergent pipe is aimed to accelerate
the particles, transforming most of the potential
pressure energy in kinetic energy and the nozzle
works as distributor of the discharge entering the
impeller through the inlet surface. The impeller inlet
and outlet surfaces are part of a cylinder, with gen-
erator lines parallel to the axis and are laterally
bounded by the two impeller disks. The two impeller
disks form a single solid with the blades that have
semi-circular shape and constant inner radius. The
water flow crosses twice the blade channels, before
leaving the impeller to enter the diffuser. This part,
which is missing in the original Banki-Michell tur-
bine for zero-pressure outlet flow, is designed in or-
der to minimize the dissipation of the particle spe-
cific energy along the path between the impeller and
the outlet section of the turbine case. The turbine is
assumed to replace the aqueduct pipe for a short
length, of the order of 10-12 diameters and to have
the inlet and the outlet sections equal to the section
of the aqueduct pipe, aligned on the same axis.

1

Figure 1. Scheme of the Banki-Michell turbine.
The main hypothesis adopted for the diffuser de-
sign are: 1) the impeller outlet tangential velocity is
zero; 2) the impeller outlet radial velocity is constant
along all the impeller outlet surface; 3) given a
straight line passing through the trace of the axis, the
mean velocity component of the particles inside the
diffuser, on the direction normal to the straight line,
is constant (Fig. 2). Conditions 1) and 2) are per-
ceived through the optimal design outlined in Sam-
martano et al. (2015). Condition 3) can be obtained
from the mass conservation and the application of
hypothesis 2), if a proper profile AB is given to the
external diffuser surface (Fig. 2).
After point B, a small restriction of the section
normal to the mean velocity (see line CD in Figure
2) is applied in order to avoid the generation of vor-
tices occurring because of the change of the path
curvature. After section BD there is first a curve
with constant rectangular section and then a diver-
gent pipe which allows the transition from the up-
stream rectangular cross-section to the downstream
circular one.
Figure 2. Scheme of the turbine nozzle, impeller and diffuser.
The main advantage of the proposed turbine is the
low construction cost for given nominal power. An-
other important advantage is that the direction of the
outlet flow is on the plane of the rotating impeller
and this strongly simplifies the return of the flow to
the original pipe direction. For this reason the tur-
bine is particularly suitable for in-line installation in
existing pipelines. If properly coupled with electric
and/or hydraulic regulation systems, the device
could also be an alternative to the classical PRV en-
ergy dissipation devices in pipe networks, with the
extra benefit of producing even a limited amount of
electric energy.
The design of the water turbine is supported by
CFD simulations that allow to optimize the geome-
try of the turbine and also to evaluate the perform-
ance of the machine according to different hydraulic
conditions, such as a large range of specific energy
drops and water discharges (Aziz and Desai 1993,
De Andrade et al. 2011; Haurissa et al. 2012; Sam-
martano et al. 2013; Sinagra et al. 2014).
3 DESIGN PROCEDURE
Numerical and Experimental investigations (Sam-
martano et al. 2015; Sinagra et al. 2015) showed that
in a Banki-Michell turbine the maximum efficiency
is obtained when the absolute tangential velocity (Vt
= V·cosα) is about twice the velocity of the reference
system (U = ω·R1), such that:
V cos α
Vr = =2 (1)
ωR1
where Vr is the velocity ratio, V is the impeller inlet
velocity, α is the attack angle, ω is the rotational ve-
locity of the impeller and R1 is the outer radius of the
impeller (Fig. 2). Assuming that the velocity V is
proportional to the root of the specific energy at the
impeller inlet, E, by means of a velocity coefficient
CV that accounts for the particle energy losses, we
get:
V = CV 2 gE (2)
Unlike the traditional Banki-Michell turbine, in
this device the water gauge pressure along the im-
peller inlet and inside the impeller is greater than
zero, and the optimal geometry strongly depends on
the occurring velocity field. Starting from previous
studies of Sammartano et al. (2013, 2015) the au-
thors obtained an empirical expression for the spe-
cific energy E using a series of CFD simulations,
taking into account different hydraulic conditions
(specific energy drop and water discharge). The nu-
merical study led to the following approximating
formula:
ω2 R12
E = ∆H − ξ (3)
2g
where ∆H is the specific energy drop between the
inlet (Hm) and the outlet sections of the turbine (Hv)
and the second term is the water gauge pressure
around the outer boundary of the impeller, which
mainly depends on the rotational velocity and on the
outer radius of the same impeller. The coefficient ξ
was estimated on the basis of a series of CFD analy- the turbine axis and the generating line to be normal
sis solving several tests with different total energy to the same plane and with a norm almost equal to
drops ∆H and a wide range of water discharges Q. In the radial component of the particle velocity at the
Table 1 the input data of the numerical simulations impeller outlet.
and the values of the coefficient ξ computed from The width B of the impeller was estimated ac-
Eq. (3) and the solved energy drop ∆H are shown. cording to the continuity equation applied at the inlet
of the impeller:
Table 1. Coefficient ξ
___________________________________________________ Q
D1 D2 Np Hm HV Q ∆H ξ
___________________________________________________ B= (4)
3 π D1λ
mm mm - m m m m -
___________________________________________________ ⋅ CV 2 gE ⋅ sin α
154 92 43 50 30.3 0.120 19.70 2.746 360
163 114 40 60 30.1 0.200 29.90 2.876 where Q = design flow rate; and λ = impeller inlet
202 141 43 60 30.1 0.200 29.93 2.690
189 132 39 70 30.3 0.150 39.71 2.900
angle (Fig. 2).
233 163 48 40 20.3 0.150 19.70 2.671
233 163 50 40 20.1 0.150 19.90 2.729
233 163 52 40 20.0 0.150 19.97 2.673 4 FLUID DYNAMIC INVESTIGATION
233 163 45 40 20.2 0.150 19.76 2.652
234 164 46 40 20.3 0.150 19.73 3.010 In order to verify the design procedure and to opti-
134 101 40 35 25.7 0.030 9.35 2.656
123 98 35 35 19.0 0.040 16.00 2.555 mize the turbine geometry a series of numerical
125 88 45 35 34.0 0.010 1.03 2.636 simulations were carried out using the Ansys CFX
127 114 30 35 14.3 0.045 20.70 2.934 commercial code. The CFD simulations were per-
138 90 50 35 30.9 0.015 4.13 2.258
___________________________________________________ formed solving the Reynolds-averaged Navier
Stokes (RANS) equations, coupled to the SST turbu-
The tests showed that the coefficient falls in the lence model. This model applies the k-ε model in the
range between 2.258 and 3.010. Because the kinetic free shear flow and the k-ω model (Wilcox 1993) in
energy associated to the second term of the r.h.s. of the inner region of the boundary layer (Vieser et al.
Eq. (3) is usually small with respect to the first one, 2003; Menter et al. 2003a). The SST model has
the average value of the computed ξ can be used in been used in most of the turbomachinery applica-
practice for the turbine design. The outer radius of tions found in the literature. Menter et al. (2004) ap-
the turbine impeller can be obtained from Equations plied the SST model to turbo-machinery simulations
1-3, given the upstream (Hm) and downstream (Hv) and found good agreement between the computa-
specific energy, as well as the discharge. The blades tions and the experimental data for all the considered
geometry is defined investigating by means of CFD cases. This model uses an “Automatic near-wall
analysis different numbers of blades Nb and diame- treatment” (Vieser et al. 2002, Esch et al. 2003,
ters ratio D2/D1. Menter et al. 2003a, b) that shifts gradually between
The shape of the diffuser is aimed to keep almost the "Low-Reynolds-Number formulation” and the
constant the velocity norm, in order to avoid energy “Wall-Function Method”, based on the grid density.
losses due to particle decelerations. The section of This wall modelling allows to reduce the computa-
the diffuser, along any plane embedding the turbine tional effort as reported in studies of Menter et al.
axis, has a rectangular shape. The diffuser is (2003a, b). Moreover, to reduce the excessive turbu-
bounded by two lateral planar walls and two curved lence levels in regions with large normal strain
walls, a bottom (AB) and a top (CD) one (Fig. 2). (stagnation regions and regions with strong accelera-
This particular shape is aimed to convey the ra- tion) the Kato-Launder production limiter (Kato &
dial trajectory of the particles leaving the impeller Launder, 1993) was selected in each simulation.
into a common direction. This is accomplished by All the CFD simulations were performed in a
keeping constant the mean velocity computed transient regime (Croquer et al. 2012) in order to
through any planar section embedding the turbine take into account the fluctuations of different vari-
axis. Due to an optimal impeller design, the tangent ables and the unsteadiness due to the rotation motion
component of the particle velocity at the impeller of the impeller. The frame change at the interface
outlet is almost zero and the outlet velocity norm is between the impeller and the steady domain was
almost equal to the radial component of the inlet ve- modelled using the unsteady sliding grid approach,
locity (Fig. 2). also called Transient Rotor-Stator approach in CFX
The bottom wall (AB in Figure 2) has a cylindri- (Ansys Inc. 2011). This model is robust and yields
cal shape, and the generating straight line has a dis- high accuracy predictions of the transient flow char-
tance from the runner’s axis increasing with its an- acteristics. Each of the RANS simulation was car-
gular coordinate (measured with respect to the ried out for a total time of 1 sec with a time step of
nozzle tip). The distance is set by assuming the ve- 2·10-4 sec, which allowed to reach the convergence
locity of the particles located on the plane shared by

3
of the solution maintaining a Courant number lower timal geometric parameters: α = 15°; Nb = 40; D2/D1
than 1. = 0.75. In Figures 3-5 the turbine efficiency is plot-
The computational domain was discretized with ted versus the attack angle, number of blades and di-
ANSYS® ICEM CFD™ using a non-uniformly dis- ameter ratio by keeping the other two parameters
tributed unstructured mesh. The domain was divided equal to their optimum value.
into two parts: the rotating part, called rotor, and the Once the Banki-Michell prototype was designed
steady part called stator. All meshes were generated the hydraulic efficiency was numerically tested tak-
according to a dimensionless wall distance y+ in the ing into account different values of the flow rate, in
range between 50 and 100 as suggested in the analy- the range between 0.010 m3/s and 0.045 m3/s. The
sis by Menter et al. (2003b). numerical simulations were carried out considering a
The total number of discretization elements was constant rotational velocity ω = 750 rpm.
about 1,400,000: 1,000,000 in the rotor domain and
400,000 in the stator domain.
The boundary conditions selected in the simula-
tions are: a) Fixed value of the total pressure and a
normal velocity to the boundary at the inlet section;
b) Assigned constant value of the velocity at the out-
let section (Ansys Inc. 2011).
Preliminary simulation highlighted that the water
flowing inside the whole turbine always maintains
positive relative pressure and the air phase is miss-
ing. Thus, all the simulations were carried out con-
sidering a fluid made only by the water phase.
Figure 3. Optimization curve of the attack angle.

5 VALIDATION OF THE DESIGN

PROCEDURE

In order to validate the previous hydrodynamic pro-

cedure a Banki-Michell prototype was designed tak-
ing into account the following project input data: an
energy drop ∆H of 10 m, with Hm = 35 m and Hv =
25 m; a water discharge Q = 0.03 m3/s; a rotational
velocity of the impeller ω equal to 750 rpm. The
outer impeller diameter D1 was first computed by
solving Equations 1-3 along with the inlet velocity V
and the specific energy drop E. Coefficient ξ was set Figure 4. Optimization curve of the number of blades.
equal to the mean value, ξ = 2.656 (Table 1), and CV
was set to 0.98. The optimal value of the outer di-
ameter, D1 = 134 mm, was estimated investigating
seven values of the attack angle (α = 8° - 18°)
through CFD analyses. The turbine width B was cal-
culated equal to 77 mm according to Equation (4).
The impeller geometry was then defined by investi-
gating four numbers of blades Nb, from 30 to 60, and
four diameter ratios D2/D1 ranging from 0.65 to 0.8.
The CFD analysis was performed iteratively by test-
ing a single parameter at time up to reach the opti-
mum geometry. In each simulation the turbine per-
formance was estimated as the ratio between the
power supplied to the rotor, Pm, and the power lost Figure 5. Optimization curve of the diameter ratio.
by water passing through the turbine, Ph:
T ⋅ω P In Figure 6 a contour plot of the velocity field in
η= = m (5) the whole turbine domain and a detailed view of the
( Pinlet − Poutlet ) Ph impeller region are shown.
where T is the torque, Pinlet and Poutlet are respec-
tively the hydraulic power at the inlet and outlet sec-
tion of the turbine. The analysis led to the follow op-

Figure 6. Contour plot of the absolute velocity with a zoom of
the impeller region.
The water velocity is uniformly distributed along
the inlet surface of the impeller, maintaining an al-
most constant attack angle. At the outlet section of
the impeller the velocity norm maintains low values,
similar to the values at the outlet section of the tur-
bine. As it can be seen in the plot the divergent sec-
tion allows to properly reduce the velocity and to
minimize the formation of turbulent structures
downstream the impeller. The contour plot of the
relative pressure in the whole domain and a detailed
view of the impeller are reported in Figure 7.
Figure 7. Contour plot of the relative pressure with a zoom of
the impeller region.
The plot shows always positive relative pressure
values, supporting the hypothesis of only one liquid
water phase inside the impeller and the diffuser used
in the CFD simulations.
The efficiency of the turbine was computed for
different hydraulic conditions corresponding to dif-
ferent discharge values. The efficiency values and
the velocity ratio estimated in each simulation were
reported in Figure 8 (the efficiency is shown beside
each point).
Figure 8. Efficiency curve of the designed turbine.
The plot shows that at the BEP corresponds to the
design point of the turbine, Q = 0.030 m3/s, with a
hydraulic efficiency of 85%. The efficiency also
maintains a value greater than 80% in the range be-
tween 0.02 and 0.04 m3/s, with the relative velocity
Vr falling in the range between 1.71 and 2.7. A
strong reduction of the efficiency can be observed
for low values of the relative velocity, corresponding
to low discharge values.
The specific energy at the outlet section of the
turbine, plotted versus the water discharge, is re-
ported in Figure 9. The plot shows that at the BEP
point the total head is the same considered in the de-
sign procedure, i.e. HV = 25 m. In Figure 10 the me-
chanical power Pm is plotted versus the water dis-
charge.
Figure 9. The estimated values of the specific energy at the out-
let section of the designed turbine.
On the basis of what has been shown so far, to
improve the overall efficiency of the hydroelectric
plant it is required to act on the velocity ratio Vr in
such a way to have a value always close to that of
the BEP point, Vr = 2.
5

Figure 10. The mechanical power Pm.
6 ELECTRIC REGULATION OF THE
IMPELLER ROTATIONAL VELOCITY
In order to maintain a good velocity ratio in spite of
the water discharge variability, it is possible to elec-
trically regulate the rotational velocity of the impel-
ler, to maintain a velocity ratio VR always equal to
2. Using the same discharge values of the previous
cases, the numerical simulations were carried out us-
ing the rotational velocity ω corresponding to the
condition VR = 2 in each hydraulic condition.
In Figure 11 the efficiency curves of the turbine
in the two configurations, with and without regula-
tion system, are shown. Also, the rotational velocity
required for each value of the tested flow rate is
shown beside each point.
Figure 11. The efficiency curves of the turbine in the two con-
sidered configurations, with and without regulation system.
RANS simulations were carried out in order to
test the convenience and the feasibility of such solu-
tion. As it can be clearly observed the regulation
system does improve the efficiency of the designed
turbine, especially for low values of the water dis-
charge. The regulation system allows to reach an ef-
ficiency peak of 86.8%, in any case the regulation
system and greater than 84.3% for all the tested wa-
ter discharge values.
The values of the downstream specific energy HV
of the two configurations are compared in Figure 12.
Observe that the control of the rotational velocity
has not a significant effect on the total head at the
turbine downstream section. Only for high values of
the water discharge the downstream specific energy
HV is a bit lower in the configuration with the regu-
lation system.
Figure 12. The estimated values of the specific energy at the
outlet section of the designed turbine for the two considered
configurations.
To complete the analysis of the turbine with the
regulation system, the mechanical power of the tur-
bine in the two configurations has been compared. In
Figure 13 the plot shows that the regulation system
improves the turbine power production particularly
for high values of the water flow. For example for
the highest flow rate, Qmax = 0.045 m3/s, the me-
chanical power with the regulation system is Pm =
7.7 KW, while without regulation is Pm = 6.0 KW.
Figure 13. The mechanical power Pm of the designed turbine in
the considered configurations.
In order to achieve an electric regulation system
a back-to-back converter can be used. This system
consists of two conventional pulse width modulated
(PWM) voltage source inverters (VSIs). These in-
verters decouple the speed control of the electrical
generator from the active and reactive power control
implemented in the grid side converter. The latter
converter is controlled in order to satisfy the grid
regulations and maintain high quality electrical en-
ergy production, while the former ensures very
flexible speed control of the electrical generator,
tracking the maximum power point extracted from
the hydraulic turbine (Consoli et al. 2010). This
electrical regulation system can be coupled with a
permanent magnet synchronous generator (PMSG)
because of its high efficiency, high power density,
low inertia and high power factor (Consoli et al.
2013).
7 CONCLUSIONS
A new design procedure for a Banki-Michel turbine
with positive pressure outlet flow has been applied
to a test case and the performance of the resulting
device has been numerically tested by means of
CFD analysis. The results are quite encouraging, es-
pecially if an electric regulation system is used to
control the impeller rotational velocity. In this case
the efficiency of the turbine is always greater than
84.3% for a maximum/minimum discharge ratio
equal to 4.5 and attains the peak 86.8% value for the
minimum discharge value.
The specific energy reduction between the inlet
and the outlet section of course drops along with the
discharge, almost independently from the electric
regulation. This implies that it is not possible to
maintain the same minimum specific energy value
Hv downstream the turbine with different discharge
values, by getting at the same time a good efficiency
value of the turbine. To this end, the use of hydraulic
regulation is mandatory.
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