Addis Ababa University

Addis Ababa Institute of Technology

School of Mechanical and Industrial Engineering

Thermal Engineering
Thesis Proposal

On

Design and CFD Analysis of a Micro Kaplan Turbine Runner.

By

Getachew tikue

Advisor: Dr.-Ing. Edessa Dribssa.

Co-advisor : Ato Tilahun Nigussie

April 16, 2016

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Contents
Abstract ...................................................................................................................................................................... 1
1 Introduction ......................................................................................................................................................... 2
2. Back Ground…………………………………………………………………………………………………………………………………………………3

3. Problem Statement ............................................................................................................................................. 4

4. Literature Review ............................................................................................................................................... 4
4.1. Theoretical Evidence................................................................................................................................... 4
4.2. Empirical Evidences.................................................................................................................................... 5
5. Objectives........................................................................................................................................................... 5
5.1. Main Objective ............................................................................................................................................ 5
5.2. Specific Objectives...................................................................................................................................... 6
6.Methodology…………………………………………………………………………………………………………………………………………….…..6

7. Significance of the Research…………………………………………………………………………………………………….………………….7

8. Beneficiary of the Research ............................................................................................................................... 7

9. Expected Out Put ............................................................................................................................................... 7
10. Time Schedule……………………………………………………………………………………………………………………………………………8

11. Budget………………………………………………………………………………………………………………………………………………………..9

12. Project and Study Location (Site).. ................................................................................................................ 10

13. References ...................................................................................................................................................... 11

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Abstract

Today, the power generation industries have become one of the important industries in the world.
This may be due to the increasing demand from the increased population as well as the expansion of
industries in the world. This increasing of demand in electricity causes the depleting of energy resources
such as oil, natural gases and coal reserves. Grid extension to remote/rural areas is expensive, micro
hydro power whenever possible can be used as an off-grid, availability of enough power sources,
necessity to enhance the capacity of use of such resources and sustainable future environment are the
main motivations behind this research project. For sustainable future development, entire world has to
reduce the green house gas emissions by reducing the use of fossil fuels and relying more on renewable
energy sources to support the present and future energy demands.

Hydropower is a very good example of renewable energy and it is the most reliable base-load energy
source.Ethioopia, is rich with different kinds of renewable energy resources. One of the most effective
renewable energy, for which Ethiopia is blessed with, is hydropower which uses hydro turbines to
generate electricity. Now a days, due to the increasing of global warming, climate change and rising of
fuel prices utilization of hydro-power as renewable energy source is of great interest. Hydro-power
energy is abundantly available in different capacity’s which can be achieved from potential hydro sites
with sufficient water discharge and pressure heads. For this purpose, selected types of hydro turbines
can be designed and developed depending upon the site locations.

For run-of-rivers with many fluctuations in flow rates, Kaplan hydro turbines is one type which can be
used to generate the hydro-electric power for varying loads. Research work on low head small Kaplan
turbines can lead to achieve the maximum output and more efficiency using the latest computational
techniques. Even though use of renewable energy like hydro water is more than crucial, there is no
company or institution that manufactures this turbine yet in Ethiopia. In this thesis, research work is
presented on the design, simulate and blade profile optimization of the complex geometry to enhance the
power output of micro hydro Kaplan turbine. Before application of the computational fluid dynamics,
collecting coordinate pointes of blade profile, preparation of 3D model runner blade, assembly of the
developed blade model with the shaft and hub for the purpose of CFD simulation analysis will employed
to get an optimized runner model. After successful validation, suitable number of blade will be use for
the proposed runner.

Keywords: Micro Kaplan Turbine, Runner Blade, CFD, Optimization, Hydropower, Run-of-River

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1 Introduction

It is obvious that majority of Ethiopian population (83%) are living in country cites [1].Only 17% (2009)
of the population who are living in the town have an access to electricity [2].So, people who are living in
the rural area can use wood charcoal as the primary fuel for cooking, lighting because of it is cheap and
easily available. However, using wood charcoal has consequences on deforestation (soil) erosion which
leads to global warming and air pollution because of smoking leads to health problem. This causes a
negative impact on the environment as well as pollution due to the use of wood charcoal as primary
fuels. Even though very large hydropower plants are under construction in the country to increase the
national power grid coverage as well as to export some portion of the produced energy to neighbouring
countries, grid coverage for remote areas in country is not expected to be fulfilled in near future. Of
course all the hydro electrical dames in the world won’t help provide power to a home or village outside
the reach of electrical power source.

By using small water turbines fed from a river or stream, individuals can gather consistent power from
the water, no matter how far from the utility power grid. Thus off grid power sources play vital role to
provide electricity for remote villages in the country. Because of the total power generated from
different projects are consumed by different industries, mega cities, towns, and export market for
economical and political leverages, a huge gap between the national power supply and demand is
created. Hence, widely used renewable energy sources including wind, solar, bayo-gass and water
energy is the only way which can solve the problem of energy crisis in the country.

Ethiopia is a country blessed with water resources, huge potential of building Micro hydro power
enriching in hydro-power potential to be capable of generating huge capacity of hydro power. But this
potential has not contributed any significant role in producing the hydro-electrical energy in the country.
Designing the low head Micro Kaplan hydro turbine is as an alternative to wood charcoal, due to the
presence of many rivers which provides much need of power, environmentally friendly and reduce
impact of deforestation. In Ethiopia there are a number of small hydro plants [3]. Most of them are cross
flow type turbines which are not suitable in location where there is high head and less flow rate [4].Now
a days, for many micro-hydro sites, a Kaplan turbine is the one way which can use for low head and
high flow rate conditions. This study aims at providing model and flow simulation of Kaplan turbine
runner of a micro hydro project using CFD tools in order to analyze its efficiency and to develop a low

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cost and high performance of micro Kaplan water turbine for producing electrical power from very low
head water resources.

2. Back Ground
Most of the non-electrified regions are found in rural part of Ethiopia. These regions can be electrified
either by extending the grids of the existing power systems or by constructing isolated (stand alone) power
systems. In general, it is preferred to go for the extension of the existing grids but they are not always
affordable. The fact that most of the non-electrified parts are located in remote and difficult areas, like
hilly regions, forests, and they are scattered, which demand enormous investment for grid. Hence Off grid
electrification for remote place is now a day’s become attractive and alternative option for remote villages,
which are detached from the central grid. The Ethiopian Government is now aware the national utility
alone through Continuous grid extension cannot accelerate rural access to electricity. To improve rural
access to electricity, the government has recently updated its strategies and improved any obstacle and
constraints to accelerate off-grid rural electrification (Scaling up renewable energy). Where rivers having
consistent flow characteristics, a hydro power system can be preferable.

3. Problem Statement

Even though there are an incredibly many micro hydro power resource sites are existed at the specified
site (Deinkaka vilage), for example Mojo river having flowing throughout the year and is suitable for
micro Kaplan turbine designing, manufacturing and testing of any Kaplan turbine runner is not yet done
because of the unavailability of the technology and limitation of capacity of the country. Still wood
charcoal is the primary fuel and difficult to extend grids with the existing power system. Therefore, the
purpose of this study is concerned, in design and CFD analysis of micro Kaplan hydro turbine runner,
evaluate/ optimize its performance using CFD in which is used to provide a contribution for the successful
design of complete micro Kaplan hydro turbine at the specified site Deinkaka vilage to satisfy the energy
demand of remote village, where central grid electricity has not reached yet due to many geographical and
economical constraints and the documentation will serve as a manual which makes difference for future
work of energy sector for the nation .

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4. Literature Review

4.1. Theoretical Evidence: Hydraulic turbines have a series of blades fitted to the hub mounted on a
rotating shaft Flowing water is directed onto the blades of a turbine runner, creating a force on the blade
since the runner is spinning in this way energy is transferred from the water flow to the turbine. The
velocity and pressure of the liquid reduce while flowing through. According to the way of energy
transfer, Hydro turbines are classified into two categories namely Impulse and Reaction Turbine. In
impulse turbines Pressurized water from the penstock is converted to high-speed water jets that transfer
the kinetic energy of the jet to the turbine blades or cups causing rotation. The pressure drop in the water
flow occurs at the nozzle and the Impulse turbine includes the Peloton wheel, Turgo wheel and Cross-
flow turbines. Impulse turbines generally operate best with medium or high head. Reaction turbines
require much larger amount of water flow but lower head than impulse styles, making them ideal for
sites where there may be relatively flat land, but a large water flow. In reaction turbine, the water
passages are completely filled and the water acting on the runner wheel is under the pressure greater
than atmospheric. To maintain the pressure it consists of spiral casing in reaction turbine. From the
spiral casing the water passes through the guides vanes that guiding the water direction at right angle to
the runner. After passing the runner blades, the water flows out to the atmosphere through the draft tube
in every reaction turbine. Major components of reaction turbine are spiral casing, guide vanes, runner,
and draft tube. Reaction turbines include Propeller, Kaplan, and Francis turbine. In reaction turbines, the
fluid fills all the runner passages completely where the impeller is located, and any head change or
pressure drop will occur in the impeller (Daugherty, 1954). The flow shows opposite characteristics to a
pump; entering into the larger end of a passage and exiting from a smaller gap after releasing all the
energy converted through the drop of pressure in the rotating wheel (White, 1986).low head small
Kaplan turbine is a reaction turbine in which its can be adjusted or fixed for appropriate loads. The
Kaplan turbine while slightly different in some aspects also has adjustable blades, which can be adjusted
even during operation of the machine through gearing (Duncan, 1970). Even though it is more complex
than the Francis Turbine, it is known to be more efficient for part loading at low power settings.

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4.2. Empirical Evidences

Prasad Vishnu, Gahlot V.K.[5]. Studied On Simplified CFD Approach For Design Optimization Of
Axial Flow Kaplan Hydraulic Turbine Runner, CURIE Journal, Birla Institute of Technology, Pilani
,2009

Muhammad Abubakar, Saeed Badshah, Talal Ahmad, Noor Rahman (2014) [8]. Carried Research
work on Modeling and Analysis of a very Low Head Kaplan Turbine Runner Blades for Rural Area of
Punjab

Timo Flaspohler (2007),[10]. Tampere University of Applied Sciences, Mechanical engineering

department, Carried the study on Design of the runner of a Kaplan turbine for micro hydroelectric
power plants

Marzena and K.Tesch,[12]. Turbomachinery and Fluid Mechanics Department,Gdansk University of

Technology, Narutowicza 11/12, 80-233 Gdansk, Poland, Used computationl fluid dynamics for Runner
blade geometry optimization in Kaplan turbine.

Karthik,A.S.,Arjun,S.M .,Kokatnur,C.C.,Kurbet,Dr. S.N.,(2014), [13]. Carried research work on

Design And Static Analysis Of Micro Hydro Kaplan Turbine Blade e‖, IJETST Vol. 01, No.03,Pp.268
271,May,Issn:2348-9480

Hora Cristina & Hora Horea, 2010.[11]. "FEM modeling of fluid flow for Kaplan turbine runner",
Fascicle of Management and Technological Engineering, 10, 1.79-1.86.

5. Objectives

5.1. Main Objective

The main objective of this research work is concerned in design and CFD analysis of micro Kaplan
hydro turbine runner using Solid-Work and ANSYS CFX software for study it’s performance or
efficiency in which is used to provide a great contribution for the successful design of complete micro
Kaplan hydro turbine at the specified site sustainably and efficiently to satisfy the energy demand for the
population who are living at Denkaka village. And then availability of electricity to the local community
should reduce use of non renewable energy sources where central grid electricity has not reached yet due
to many geographical and economical constraints.

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5.2. Specific Objectives

The specific objectives of the research work are indicated as follows.

 Site selection and collecting basic input data’s (H,Q,V)

 Check data’s weather suitable for Kaplan or not

 Sizing the rotor of Kaplan

 Develop 3D model ( geometry) of the rotor, using solid work soft ware

 Apply CFX flow simulation

 Optimization of rotor, to maximize performance

 Check structural analysis ( stress, shear )

 Evaluation of results relative to another similar research works

 Discussion of conclusion and recommendation

6. Methodology

The methods employed to achieve the objectives of the research are:

1. Literature Survey: A review of literature is conducted on the area of hydro power energy use
and efficiency in related to Kaplan turbines. Available journals, case studies and previous
research works are surveyed in order to have a clear understanding of the subject matter.

2. Data collection: The necessary input data for the thesis, like head, discharge and specific speed
to provide the information of the expected power available are collected from different sources.

3. Design calculation of micro Kaplan turbine runner.

4. Solid model: Getting the coordinate points of the blade profile, Final data imported in solid
work for the development of 3D model, assemble components of rotor then ok.

5. Apply CFX and optimize its performance

6. Evaluate CFD results relative to another similar works.

7. Conclusion and Recommendation

8. Write the complete report of the thesis.

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To achieve the above stated objectives, CFX and SOLID-WORK software are to be used for Complex
Geometrical Structure Creation, which provides the most complete, and robust solution, tailored for
developing rapidly high-quality mechanical products with the highest productivity in design changes. In
addition, this SOLID-WORK software will be used for the preparation of manufacturing drawings in
addition to AUTO CAD software.

7. Significance of the Research

After completing of this thesis work, the expected outcome of the developed micro Kaplan hydro-
turbine runner is efficient and has an optimized runner blade profile. And the document that I use on
how to design the low head micro Kaplan turbine rotor will serve as manual or guide line for the rotor
which makes a difference for future work of energy sector of the nation.

8. Beneficiary of the Research

The output of thus research work will give a benefit for hydro power producers particularly for micro
Kaplan-turbine runner and its blade in the country. In addition the overall experience gained from the
conclusion of this thesis paper will aid micro, mini and small hydro Kaplan turbine runner blade
designers in decision making process promoting for further research and development. All in all the
overall benefit of thus research work will provide in technology transfer, solve the problem of designing
complex runner blade and it serves as ladder or bridge in designing of complete micro Kaplan turbine.

9. Expected Out Put

The final output that will expect from this thesis work is

 Obtaining of an efficient 3D model of Kaplan turbine rotor

 Could get an optimized rotor blade

 Performance of runner is maximum

 Great contribution in reducing use of non renewable energy resources

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 10. Time Schedule

Months
May June July August September October November
No Activity
Weeks
1&2 3&4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Literature review on Design of micro Kaplan
1
hydro turbine rotor
Site data collection and checking whether
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suitable for Kaplan or not

Sizing and Geometrical modeling of micro

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Kaplan turbine runner for varying flow rates

CFD Simulation and optimizing the

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performance of the runner

5 Verification of CFD results

6 Static structural analysis

7 Draft report writing and submission

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Write up of final report and submission

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11. Budget

The required budget for this thesis is tabulated below

S.N Item Amount Remarks

1 Stationery 1500.00

2 Soft ware & CD 1500.00

3 Transport 1300.00

4 Printing & Bindings 1500.00

Sum 5800.00

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12. Project and Study Location (Site)

Addis Ababa Institute of Technology (AAiT), Addis Ababa University, Ethiopia

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13. References

[1] http://data.worldbank.org/indicator/SP.URB.TOTL.IN.ZS

[2] http://data.worldbank.org/indicator/EG.ELC.ACCS.ZS/countries/ET?display=graph

[3] The Micro-hydro Kaplan turbine Manual: Design, Manufacture and Installation for Small
scale Hydropower, Jeremy Thake, ITDG Publishing, 2000.

[4] Micro-Hydropower Under Ethiopian Conditions,ZelalemHailu, School of Graduate Studies

Addis Ababa University, 1993

[5] Prasad Vishnu, Gahlot V.K., Studied On Simplified CFD Approach For Design
Optimisation Of Axial Flow kaplan Hydraulic Turbine Runner, CURIE Journal, Birla Institute
of Technology, Pilani ,2009

[6] Failure Analysis of A Kaplan Turbine Runner Blade” IAHR, 24th Symposium on Hydraulic
Machinery and Systems October 27-31, FOZ DO IGUASSU, 2008

[7] Ajaz Bashir Janjua *, M.S.K., and MuhammadSeed***, Blade Profile Optimization of
Kaplan Turbine Using CFD Analysis. Mehran University Research Journal of Engineering &
Technology, 2013. Volume 32, No. 4: p. 559-574
[8] Muhammad Abubakar, Saeed Badshah, Talal Ahmad, Noor Rahman (2014):- Carried
Research work on Modelling and Analysis of a very Low Head Kaplan Turbine Runner Blades
for Rural Area of Punjab

[9] Alok Mishra, R.P.S., M.K. Singhal, CFD Based Performance Analysis of Kaplan Turbine for
Micro Hydro Power, in International Conference on Mechanical and Industrial Engineering.
2011.

[10] (Timo Flaspohler)(2007), Tampere University of Applied Sciences, Mechanical engineering

department. Caried the study on Design of the runner of a Kaplan turbine for micro
hydroelectric power plants

[11] Hora Cristina & Hora Horea, 2010. "FEM modeling of fluid flow for Kaplan turbine
runner", Fascicle of Management and Technological Engineering, 10, 1.79-1.86.

11
[12] (Marzena and K.Tesch), Turbomachinery and Fluid Mechanics Department,Gdansk
University of Technology, Narutowicza 11/12, 80-233 Gdansk, Poland. Used computationl fluid
dynamics for Runner blade geometry optimization in Kaplan turbine.

[13] Karthik,A.S.,Arjun,S.M .,Kokatnur,C.C.,Kurbet,Dr. S.N.,(2014), Caried research work on

Design And Static Analysis Of Micro Hydro Kaplan Turbine Blad e‖,IJETSTVol.
01,No.03,Pp.268 271,May,Issn:2348-9480

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Submitted by:

Getachew Tikue ______________ _______________

Student Signature Date

Approved by:

Dr. Ing Edessa Dribsa ______________ _______________

Advisor Signature Date

Ato Tilahun Nigussie _______________ _______________

Co- Advisor Signature Date

Dr. Yilma Tadesse _______________ _______________

Chairman, Dept.’s Signature Date

Graduate Committee

______________________ _______________ ________________

Chairman, Faculty’s Signature Date

Graduate Committee

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