Design & Analysis of Pelton Wheel Turbine

P M V Subbarao
Professor
Mechanical Engineering Department

Internal Details of the Machine.

Koyna Hydro Electric Project

Koyna Dam from the
catchment area of about
891.78 Sq. Km

Koyna river rises in the

Mahabaleshwar, a famous hill
station in the hill range of Sahyadri.
It flows in a north - south direction
almost parallel to the Arabian Sea
coast for a distance of 65 Kms.

Details of Koyna Hydro Electric Project

Number of units: 4
Capacity of each unit=250MW
Head
Normal Head=415m
Maximum Head=510m

Creation of Reservoir

Specific speed in rpm

Ns

N P
H

MORE ADAPTED TYPE OF TURBINA IN FUNCTION OF

THE SPECIFIC SPEED.
Specific Speed in
Turbine type
Jump height in m
r.p.m.
Until 18
Pelton of an injector
800
From 18 to 25
Pelton of an injector
800 to 400
From 26 to 35
Pelton of an injector
400 to 100
From 26 to 35
Pelton of two injectors
800 to 400
From 36 to 50
Pelton of two injectors
400 to 100
From 51 to 72
Pelton of four injectors
400 to 100

Selection of Speed of A Turbo Machine

3000
N
zp

for

f 50 Hz

Zp : Number of pairs of poles of the generator

Questions to be Answered

Is it possible to change number of units in Stage

IV?
What is the allowable speed of the generator for
each unit, if number of units is 2, 5, 6 or 7?

Design of Any Selected Pelton Wheel Unit

Different capacities for each sub-group.

Design for Normal Head.
Assume an overall efficiency: 90 94%
Calculate the required flow rate.

P pelton Q g H

General Layout of A Hydro Power Plant

THE CONDUIT SYSTEM

Water from the storage is diverted into the main conduit
system through a 3,370ft long intake channel and an intake
tower, trash racks and two intake gates each 21ftX8ft.
The head race tunnel is 12,000ft long and 21ft in diameter.
It is concrete lined for the whole of the length expect for
the last 1600ft at the surge end where 17ft diameter steel
lining is provided.
The diameter of the tunnel, in the stretch of steel lining is
reduced on ground of economy

Pipe Material

Open Channel Gravity

Channel

drawn brass
Bed drawn
Slopecopper
commercial steel
wrought iron
2
asphalted cast iron
galvanized iron
h cast iron
wood stave

4 fV
S0
2 gD

4A
Dh
P

Absolute Roughness, e
micron
Flow(unless
noted)
1.5
1.5
45
45
120
150
260
0.2 to 0.9 mm

concrete

0.3 to 3 mm

riveted steel

0.9 to 9 mm

Design of Penstock

Q V penstock

2
penstock

In general

Vpenstock 2 gH
But maximum allowable value is 10 m/s
Maximum allowable head loss in Penstock =2 to 4% of
available head

General Design of Under Ground Power Tunnels/Penstocks

h friction x H
f

2
Pipe Material
penstock

4 fLV

2 gd penstock

drawn brass
drawn copper
commercial steel
2
wrought iron
asphalted cast iron
galvanized
0.9iron
hcast iron
wood stave

0.0625

k
5.74

log
3.7 D Re

concrete2 gH
Vpenstock kv, penstock
riveted steel

Absolute Roughness, e
micron
(unless noted)
1.5
1.5
45
45
120
150
260
0.2 to 0.9 mm
0.3 to 3 mm
0.9 to 9 mm

kv , pestock : 0.2 to 0.15 (inversly proportion al to Specific Speed)

Design of Penstock
Group No.

Unit Size
MW

1.

500

2.

333.3

3.

200

4.

166.7

5.

142.85

6.

125

7.

111.1

8.

100

Qp

Dp

Head loss

Distributor : Only for multi jet Wheel

Design of Distributor

Penstock

Q V penstock

2
penstock

The Nozzle and Jet : A Key Step in Design

b

djet,VC

Free Surface Shape for Maximum Power

d0

Initial guess for Diameter of the Jet at the outlet, do

2
Q d o K vo 2 gH
4

0.81 K vO 0.83
It is important to find out the VC and outlet jet
diameters/areas

Geometrical Relations for Nozzle

1.1dO 1.3dO
2dO 2.4dO
dO

0.8dO 0.9dO
5dO 9dO

1.2dO 1.4dO

Performance Analysis of Nozzle-Spear Valve

Ideal Nozzle-spear Valve:
2
V
p
gz constant Along flow direction
2
Real Nozzle-spear Valve:

2
p V

ptotal constant- p friction

2

p friction
f

4 fLV

2
penstock

2d penstock

0.0625Pipe Material
2

k

5
.
74
drawn
brass
log
0.9
Recopper
3.7 Dhdrawn
commercial steel
wrought iron
asphalted cast iron
galvanized iron
cast iron
wood stave

Absolute Roughness, e
micron
(unless noted)
1.5
1.5
45
45
120
150
260
0.2 to 0.9 mm

concrete

0.3 to 3 mm

riveted steel

0.9 to 9 mm

Numerical Computation of Total Pressure Variation

Efficiency of Spear Nozzle Valve

ptot inlet ptot exit

spearvalve 1
100
ptot inlet

Acceptable Range: 97.5% -- 99%

Design of Penstock
Group No.

Unit Size
MW

1.

500

2.

333.3

3.

200

4.

166.7

5.

142.85

6.

125

7.

111.1

8.

100

djet

Head loss

spearvalve

Geometrical Relations for Nozzle

The values of varies between 20 to 30

whereas varies from 30 to 45.

Industrial Correlations for Jet Area variation with

stroke
Optimal value of Outlet jet area, ao

ao As Bs

s is the displacement of spear

b a
A 2ro sin a
sin b a
2
b a sin b sin a sin a
B
2
sin b a

Computation of Variation Jet Area with stroke

Mean Diameter of Pelton Runner

Mean diameter or
Pitch circle diameter:
Dwheel
Circumferential
velocity of the wheel,
Uwheel

U wheel 2gH
U wheel Kuwheel 2 gH

Experimental values of Wheel diameter to jet diameter

Dwheel /djet,VC

6.5

7.5

10

20

Ns (rpm)
turbine

35
0.82

32
0.86

24
0.89

10
0.90

Higher ratios are preferred for better efficiency.

Modern wheels for high heads use ratios as high as 30!
Ns

d jet ,VC

4Q

K v1 2 gH

N wheel P
4

H5

0.98 K v1 0.99

Optimal values of Wheel diameter to jet diameter

30

25

20

Dwheel

15

d jet
10

0
0

10

15

20

25

30

Ns

35

40

45

50

Group No.

Unit Size
MW

1.

500

2.

333.3

3.

200

4.

166.7

5.

142.85

6.

125

7.

111.1

8.

100

Geometric Details of Bucket

The hydraulic efficiency
depends more on the main
bucket dimensions (length
(A), width (B) and depth
(C)).
The shape of the outer part
of its rim or on the lateral
surface curvature also has
marginal effect on
hydraulic efficiency.

Empirical Geometry of Bucket Shape

III

II

C
IV
V

I
DW

2 bi
A

be
B

Empirical Relations for Bucket Geometry

A = 2.8 djet,VC to 3.2 djet,VC

B = 2.3 djet,VC to 2.8 djet,VC
C= 0.6 djet,VC to 0.9 djet,VC
bi = 50 to 80
be is varied from section I to section V
I: 300 to 460
II: 200 to 300
III: 100 to 200
IV: 50 to 160
V: 00 to 50

Number of Buckets

d jet ,O

Dwheel
cos
2d
1
Dwheel
ku ,wheel
d
y
21
sin
kvO Rwheel
dO,
Vj,O

d
RP

RW w
q

lj

Maximum allowable angle between two successive buckets

q 2 y
Minimum number of buckets

360

Dr Taygun has suggested an empirical relation for z

Dwheel
z 0.5
15
d jet ,VC

Group No.

Unit Size
MW

1.

500

2.

333.3

3.

200

4.

166.7

5.

142.85

6.

125

7.

111.1

8.

100

Absolute and Relative Paths of Jet : Orthogonal Interactions

Vjet
Ublade

be
ae

Vrel,jet,exit

Vjet,exit

Ublade

 cos b e
2U Vai cosa i U k
1
cos bi

d
2
Vai
2

U
cos b
d 2 cosa i k
1
Vai
Vai cos bi e

Define Blade Speed Ratio,

cos b e
d 2 cosa i k
1
cos bi

Approximate Velocity Triangles: Pelton Bucket

d ,max 2 k cosbe 1

Pb mU Vre cos b e Vri

Start of Jet Bucket Interactions

Sequence of Jet Bucket Interactions

q50

q150

q250

q350

Bucket Duty Cycle

Compute angles of onset and close of
interactions.
Select few locations during bucket jet interaction.
Compute mass of jet intercepted by the bucket and
corresponding blade exit angles.
Numerically integrate the work done by a bucket
per rotation.
Compute Average Power developed by bucket
and efficiency.