TRUBINE AND DRIVE SYSTEM

Krishna B. Nakarmi

21st April 2010

Krishna B. Nakarmi /UTSS

Development steps on the

Turbine Manufacturing of Micro

Hydro Plants of NEPAL .

21st April 2010

Krishna B. Nakarmi /UTSS

Krishna Bahadur Nakarmi

Micro Hydro Consultant

IOE, CES
Project Coordinator

Technical Associates
Addresses Tel: Email : Residence : Post Box No.:
21st April 2010

00 977 1 4244313 kbnakarmi @ ntc.net.np 00 977 1 4276686, 10996

Krishna B. Nakarmi /UTSS 3

Professional Experience
30 Years of experience in the Mechanical Field as a Technical In-charge of Engineering Department at Balaju Yantra Shala (P) Ltd.

Hydropower Technology Feasibility Study Designing of MHP equipment Supervision on production in the work shop Installation and Commissioning of equipment at site. Machine constructions, R & D of Mech. Devices, Repair and Maintenance, Any kinds of general services
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General Layout of MHP

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Traditional Ghatta (Nepalise Indegenous Technology)

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Krishna B. Nakarmi /UTSS

Water Mill (Ghatta)

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Improved Water Mill

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Water mill with flour fortification device

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T1- CF Turbine

This model is a hand regulated straight forward design to mechanically drive a flat belt transmission for the operation of agro-processing machineries such as flour-mill, rice huskers and oil expellers etc.

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T1- turbine design

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T2- Turbine

This model is an attempt to come up with a low cost design. The expensive turbine housing is omitted to a large extent. It result in having water splashing all round the equipment, increasing the humidity in the mill house and spoiling the flour. This design is obsolete.
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T3 - Turbine

This model is a compact design, and the first machine with butterfly valve for flow regulation. The bearing concept is under design and not suitable for outputs higher than 20kW. This design is modified to avoid the bearing problem that rotor can be removed from the side flange.
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T3-turbine design

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Split flow Turbine

This turbine is designed for high head low flow site and expecting it will have high efficiency. But result show opposite way. So, stop production and obsolete.

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Split flow turbine design

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T4 - Turbine

T4 model has a circular wing foe flow regulation. It was the first turbine with automatic governor control used in village electrification projects.

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T5 - Turbine

T5 model is basically the concept of an enlarged T3 model. However the machine size was not adequate for the production facility in Nepal. This design was phased out.

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T6- Turbine

T6 model suitable for governor control, having a butterfly valve as the flow regulating device. This machine is much stiffer than previous design, therefore has low vibration and noise level during operations. It is a good design for high specific discharge.
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T6-turbine design

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T7- Turbine

T7 is first model with fully machine turbine blades in order to increase its efficiency. This advanced technology led to a runner failure due to fatigue stress problem, so blade design was changed and used for agro processing only. This model also recommended for 20 kW plant only.
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T7- turbine design

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T8- Turbine

T8 model is the replacement of T7 turbine in case of electrification projects. It is fully tested machine with known characteristics. This allowed to define the application ranges and to standardize the design.

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T8- turbine design

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T9 T11 Turbine

T9 T11 models are test model for the following T12 Models. All performance tests were conducted at the University of Hong Kong. The efficiency hill diagram is the result of these tests. The design adheres to the concept of the T8 series with the modified hydraulic profile and secured quality Control to guarantee the exchangeability of the spare parts.
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T12- Turbine

T12 model is the collection of past experiences, emphasizing longevity, rugged design etc. It used a new concept to ventilate the jet (Free jet approach) and is specially suited for jet flow control. The main advantage of this machine is good part load efficiency as in full load.
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T12-turbine design

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T13- Turbine

T13 is the test model turbine. It is made for testing purpose with few modifications on some parts. The performance result shows that the efficiency is increased by some percent.

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T14- Turbine

T14 model is made with specific design for particular site as a working model with reference to the T13 model hydraulic profile. It replaced the old model turbine, and thus produces more power than previous ones and runs very smoothly.
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T14- turbine design

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T15- Turbine

T15 model is the advance model turbine with T 12 turbine characteristic and efficiency wise T14 turbine. It is now being familiar through GTZ as T15 turbine in Nepal.

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T16- Turbine

T16 model is developed with new concept. It is basically upgraded version model or combination of T7 and T12 Turbine and few design parameters changed. This is not tested at any laboratory. But it is installed at existing plant where only turbine has to be replaced.
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T16

The client informed that they found the electric power output is increased significantly. It means the turbine efficiency is increased. So the turbine efficiency can be guessed that it reached up to 78% to 80%

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T16

On the basis of this experience if the turbine components are made precisely the turbine efficiency can be considered as 80%

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A Typical Cross Flow Turbine Design

Design by: Model:
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Krishna B. Nakarmi UTSS-08KBN/CF-03

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A typical Pelton Turbine Design

Design by: Model:
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Krishna B. Nakarmi UTSS-08KBN/PT-03

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Uses of turbine
1.

Micro Hydro Electricity Generating Saw Milling Heat Generating Agro-Processing Stone Crushing

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1.

Selection of turbine

Plant Size Locally / Imported Skill Man power for O & M Efficiency of Turbine Cost of Equipment

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Working principle of different turbines

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EXAMPLE (IMAGINARY SITE)

SITE DATA Gross Head Discharge

Hg Ql/s

36 600

m l/s (AT Rriver)

Designed net head Hn = 32.4 m (Gross Head minus Pipe Lie Losses = 5 to 10 % Hg) Designed discharge Q Available flow at river * 0.8 = 480 l/s (80% of flow of the river)

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Turbine speed
Desired turbine speed is 1500 rpm. (Because normal gen. operating speed is 1500rpm) Turbine speed depends upon the working pressure and selected turbine rotor diameter.

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Desired speed of the turbine nturb is 1500 rpm.

( because operating speed of the commercial standard alternator is 1500 rpm)

Turbine Speed to be calculated

But the speed of turbine varies according to the available net head and selected turbine rotor diameter

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Turbine Specification(T12 / T15 CF Turbine)

Unit speed Unit discharge Efficiency of turbine Turbine Rotor Diameter Rotor shaft Diameter n11 Q11 D d 40 80 0.75 0.3 80 m mm normally

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(H m)

0.5

nturb =

40*

---------Dm
0.5

(32.4 m)

nturb =

40*

------------(0.3)

nturb =

758.9 rpm

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Specific speed
(Q m3/s.)^0.5

ns = 3.65 * nturb rpm *

---------------(Hm)^0.75

(0.480)^ 0.5

ns = 3.65 * 758.9 *

------------------(32.4 0)^.75

141.3

CAN

(REFERING THIS ns CROSSFLOW OR FRANCIS TURBINE BE SELLECTED)

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Hydraulic Power
Hnet * Q l/s

Phy

-------------- (kW) 102 32.4 m * 480 l/s

Phy Phy

-----------------(kW) 102 152.4 kW (available power at the site)

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Plant efficiency ( plant )

is determined as follows: Electrical Power Output

Pel = Phy * turb*trans*gen

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Turbine Efficiency
0.70 to 0.80 in case of Cross Flow 0.75 to 0.90 in case of Pelton/ Francis

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Efficiency of transmission system (belt , coupling system) =

0.9 to 0.95 to 0.98 to 0.99 in case of normal belts in case of Habasit flat belt in case of Flexible Coupling

= 0.95 = 0.98

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Efficiency of generator = 0.76

to 0.92 in case of Synchronous Generator ( gen = 0.85 can be confirmed )

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Electrical power output

Pturb = = = Phy * turb*Trans*gen 152.4 * 0.75*0.95*0.85 92.3 kWel

So, plant equipment efficiency can be determined to be 0.6.

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Thank You
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