Design Of The Runner Of A Kaplan Turbine For Small .
TAMPERE UNIVERSITY OF APPLIED SCIENESEnvironmental EngineeringFinal thesisTimo FlaspöhlerDesign of the runner of a Kaplan turbine for small hydroelectric power plantsSupervisorJaakko MattilaCommissioned byTampere University of Applied Sciences, Mechanical engineeringdepartmentTampere 2007
TAMPERE UNIVERSITY OF APPLIED SCIENESEnvironmental EngineeringTimo FlaspöhlerDesign of the runner of a Kaplan turbine for small hydroelectricpower plantsFinal thesis78 pages, 42 pages AppendixSupervisorJaakko MattilaNovember 2007KeywordsElectricity tariff, small hydroelectric power plant, Kaplan turbine,runner, adaptation mechanism, stress analysis, technical drawingsABSTRACTThe final thesis deals with the design of the runner of a Kaplan turbine. It might bethat due to the increasing of the electricity tariff in the last years smallhydroelectric power plants become cost effective. Since the runner of a smallhydroelectric power plant is quite small, it has to be reexamined if the hub of therunner provides enough room for a proper adaptation mechanism. For this purposethe main characteristics of the runner are determined. Then, important data such asthe suction head, the occurring forces or the critical speed are established. Afterthose data are known, a detailed stress analysis of the developed adaptationmechanism follows. The stress analysis shows that the mechanism to adjust theblades is able to withstand the occurring forces. Finally drafts of the runner and itsparts are done.
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS1 (134)Environmental EngineeringTimo �————————TABLE OF CONTENTSABSTRACT .iiTABLE OF CONTENTS .1LIST OF SYMBOLS.412INTRODUCTION .81.1Pelton turbine.91.2Francis turbine .91.3Kaplan turbine .101.4Definition of a small hydroelectric power plant.111.5Waterpower in Finland .111.6The price of electricity in Finland .12ASSIGNMENT OF TASKS.132.13Variation matrix.163.14List of requirements.14Selection .17CALCULATION OF THE MAIN CHARACTERISTICS.204.1Power .214.2Speed of the turbine.224.2.1Specific speed .224.2.2Rational speed .234.2.3Runaway speed .234.3Runner diameter section .244.4Hub diameter .244.5Blade characteristics of some different heads and discharges.255CAVITATION .266DESIGN OF THE BLADE .2876.1Distortion of the blade under ideal circumstances.286.2The “Tragflügeltheorie” .316.2.1Procedure .32CALCULATION OF THE FORCES.367.1Tangential force.367.2Axial force .377.3Resulting force.387.4Hydraulic moment .387.5Centrifugal force.41
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS2 (134)Environmental EngineeringTimo �————————7.6Weight of the blade .428CRITICAL SPEED .439STRESS ANALYSES .459.1Axle ot.509.3.1Contact pressure ending.539.4.2Shear .549.4.3Contact pressure .559.5Link.569.5.1Buckling .579.5.2Stress calculation of the links eye.589.6Crosshead .609.7Bolt .629.7.1Bending.629.7.2Shear .639.7.3Contact pressure .649.8Shaft.669.910Hub .67CALCULATION OF THE SCREWS.6810.1Screw connection of the lever and the pivot .6810.2Screw connection between the blade and the pivot.7310.3Screw connection between the upper and the middle hub.7410.4Screw connection between the middle and the lower hub.7511 EXPLANATION OF THE RUNNER DESIGN .7612 ASSEMBLING.7813 CONCLUSION .7914APPENDIX .8114.1Calculation of the mains characteristics .8114.1.114.1.214.1.314.1.414.1.5Power .81Rational speed .81Runaway speed .81Runner diameter .82Hub diameter .82
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS3 (134)Environmental EngineeringTimo �————————14.2 Cavitation .8314.3Design of the blade .8414.3.1Velocities and the angles angle of distortion (180 -β ) .8414.3.2Calculation of the blade characteristics .8514.4 Calculation of the forces.8914.4.1Tangential force.8914.4.2Axial force .8914.4.3Resulting force.9014.4.4Hydraulic moment .9014.4.5Centrifugal force.9114.5 Critical speed .9214.6Stress analysis.9214.6.1Axle 5Link.9814.6.6Crosshead .10014.6.7Bolt .10014.6.8Shaft.10214.7 Calculation of the screws.10414.7.1Screw connection of the lever and the pivot .10414.7.2Screw connection of pivot and flange .10814.7.3Screw connection between the upper and the middle hub.11214.8 Drawings.11614.915Tables .125REFERENCES .133
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS4 (134)Environmental EngineeringTimo �————————LIST OF SYMBOLSAAreaA3Core cross section of the threadAbBlade areaAersErsatz areaANNominal cross section of the screw shankAprojProjection screenBWidebWidebLengthcVelocitycAbsolute velocitycWidecqSpring constant for elastic lateral oscillationDDiameterDeRunner diameterDiHub diameterdDiameterdwOuter diameter of the annular surface of the screwdhHole diameterEElastic modulusESpecific hydraulic energy of machineeyLengthFForceFaAxial forceFBLongitudinal forceFcCentrifugal forceFKlClamping forceFlLifting forceFrResulting forceFspTension forceFtTangential forcefzSetting amount
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS5 (134)Environmental EngineeringTimo eration of gravityHWideHHeadHGross headHnNet headHsSuction headhWideIMoment of inertiaKprofile characteristic numberKAApplication factorkASnap factorlChordlLengthlkBuckling lengthlkClamping lengthMMomentMhHydraulic momentMspTension torquenSpeednmaxRunaway speednQESpecific speednmaxRunaway speednmaxRunaway speednQESpecific speedPPowerpContact pressurepatmAtmospheric pressurepvVapor pressurepminminimal water pressureQDischargeRRadiusReRunner radius
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS6 (134)Environmental EngineeringTimo �————————RiHub radiusRmTensile strengthRpo.2Elastic limitrRadiustGrating dispartmentuTangential velocityWbSection modulusWtPolar section moduswRelative velocityyThicknessyLengthzNumber of bladeszNumber of the screwszLengthαAngleβAngleδAngle of attackδTFlexibility of the uptight partsδSFlexibility of the screwεAngleζaLifting coefficientζALifting coefficientζWDrag coefficientηhHydraulic efficiencyηsefficiency of the energy changeλThickness ratioλAngle of slipλg0.2Marginal strengthμFriction factor at the intersticeФForce ratioФkSimplified force ratioρDensity of waterσCavitation coefficientσbBending stress
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS7 (134)Environmental EngineeringTimo �————————σkBuckling stressτsShear stressτtTensional stressωAngular velocity
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS8 (134)Environmental EngineeringTimo �————————1INTRODUCTIONThe demand for increasing the use of renewable energy has risen over the last fewyears due to environmental issues. The high emissions of greenhouse gases haveled to serious changes in the climate. Although the higher usage of renewableenergy would not solve the problems over night, it is an important move in theright direction. The field of renewable energy includes, for example wind power,solar power and waterpower. /1/The first use of waterpower as an energy source dates back centuries. The energywas utilized, for instance, to grinding grain. The applied machinery for this purposewas based on simple water wheels. Over the years the machinery has beendeveloped and become more and more advanced. Hydropower was the firstrenewable source which was used to generate electricity over 100 years ago.Today, hydropower is an important source of producing electrical energy;approximately 20% of the world electricity is supplied by hydroelectric powerplants. /1, 2, 3, 4/Depending on the head and discharge of the sites, the hydroelectric power plant hasto be equipped with a specific turbine in order to get the highest efficiency. Thereare several different kinds of water turbines and can be divided into impulse andreaction turbines. An impulse turbine is where the water pressure is transformedinto kinetic energy before the water reaches the runner of the turbine. The energyhits the runner in a form of a high-speed jet. A turbine, where the water pressureapplies a force on the face of the runner blade is called a reaction turbine. Thefollowing three following turbines are usually utilized in the modern field ofhydropower: Pelton turbine Francis turbine Kaplan turbineThese are discussed in more detail below./1/
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS9 (134)Environmental EngineeringTimo �————————1.1 Pelton turbineThe Pelton turbine belongs to the group of impulse turbines. It consists of a wheelwhich has a large number of buckets on its perimeter. One or more jets thud on thebuckets which cause the torque. The wheel and generator are generally directlyconnected by a shaft. The range of head, in which the Pelton turbine is used, isbetween 60m and more than 1,000m.The Pelton turbine has quite a highefficiency and can be in the range of 30% and 100% of the maximum designdischarge for a one-jet turbine and between 10% and 100% for a multi-jet turbine./1, 3/NozzleInlet pipeWheelFlowJetFigure 1.1: Pelton Turbine /3/1.2 Francis turbineThe Francis turbine is a reaction turbine. It has fixed runner blades and adjustableguide vanes. Francis turbines are generally arranged so that the axis is verticalalthough smaller turbines can have a horizontal axis. The admission of a Francisturbine is radial and the outlet is axial. The field of application of the turbine isfrom a head of 25m up to 350m. It has an efficiency of over 80% in a ranging fromapproximately 40% to 100% of the maximum discharge. /1, 3/Guide vanesFlowDraught tubeFigure 1.2: Francis Turbine /3/Runner bladesFlow
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS10 (134)Environmental EngineeringTimo �————————1.3 Kaplan turbineThe Propeller turbine and the Kaplan turbine are reaction turbines. They haverelatively small dimensions combined with a high rational speed. Hence thegenerator dimension is rather small and inexpensive. In addition, both the Propellerand the Kaplan turbines show a large overload capacity. The intake of the flow isradial. After the inlet the flow makes a right angle turn and enters the runner in anaxial direction.The difference between the Propeller and Kaplan turbines is that the Propellerturbine has fixed runner blades while the Kaplan turbine has adjustable runnerblades. Propeller turbines can only be used on sites with a comparatively constantflow and head while Kaplan turbines are quite flexible.The Kaplan turbine can be divided in double and single regulated turbines. AKaplan turbine with adjustable runner blades and adjustable guide vanes is doubleregulated while one with only adjustable runner blades is single regulated. Theapplication of Kaplan turbines are from a head of 2m to 40m. The advantage of thedouble regulated turbines is that they can be used in a wider field. The doubleregulated Kaplan turbines can work between 15% and 100% of the maximumdesign discharge; the single regulated turbines, however, can only work between30% and 100% of the maximum design discharge. /1, 3, 5/Guide vanesFlowFlowRunner bladesDraught tubeFigure 1.3: Kaplan turbine /3/
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS11 (134)Environmental EngineeringTimo �————————1.4 Definition of a small hydroelectric power plantTo define whether a hydroelectric power plant is a small one or not depends on itscapacity. However, European countries do not agree where the capacity limit for asmall hydroelectric power plant should be. In the UK, for example, the limit isfixed at 20MW while in France the capacity limit is 12MW. In Finland, thecapacity limit is only 1MW. /1, 6/1.5 Waterpower in FinlandAlthough Finland is called the land of 1,000 lakes, hydropower does not play asignificant role in energy production.2%2.8%OilWood fuels2.8%6%24.4%Nuclear EnergyCoalNatural gas10.9%Peat14.7%Net imports of electricity20.2%Hydro and wind powerOther energy sources16.2%Figure 1.4: Total energy consumption of Finland in the year 2006 /7/As shown in figure 1.4, hydropower, together with wind power, comprises just2.8% of the total energy. The main energy sources in Finland are oil (24.4%) andwood fuels (20.2%). Nuclear energy, coal and natural gas are also important energysources.The main reason for the small share of hydropower as a source of energy lies withthe characteristics of the natural landscape. Although Finland has many watersources, it is a relatively flat country. For this reason, the heads are mostly to lowto build large or medium-size hydroelectric power plants. Furthermore, areaswhere the heads are high are normally under environmental protection. The onlyway to increase the electricity production by water power, therefore, would be tobuild small hydroelectric power plants. This option has not been cost effective due
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS12 (134)Environmental EngineeringTimo �————————to the low electricity tariff - the income would have been too little to coverinvestments. However, due to the price rise in electricity over the last few years,this option might be reconsidered.1.6 The price of electricity in FinlandFigure 1.4 shows the price development of electricity in Finland over the last 6years. Although the years 2004 and 2005 show a downturn, the electricity tariffincreased approximately by a factor of three from 2000 to 006YearFigure 1.4: Electricity tariff 2000-2006 /8/In Figure 1.5 it can be seen that the annual average of the electricity tariff in 2007will be less than in 2006. However a new increase in the price of electricity can beexpected for the few next years.4035EUR/MWh302520151050JanFebMarA prMayJunM onthFigure 1.5: Electricity tariff January- October 2007/8/JulA ugSepOct
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS13 (134)Environmental EngineeringTimo �————————2ASSIGNMENT OF TASKSThis final thesis is one part of a project carried out by Tampere Polytechnic which,at the time of writing, was in its initial staged. The aim of the project is to exploreif it is worth building small hydroelectric power plants in Finland.The aim of this final thesis is to develop a Kaplan turbine’s runner with adjustableblades - adaptive for small hydroelectric power plants. For this purpose, aprototype of the runner is to be designed with a proper mechanism for adjusting theblades. The concern is that the hub of the turbines for small heads does not providemuch space for the adaptation mechanism. The mechanism’s parts have to be bigenough to resist the occurring forces and small enough to fit in the hub. This thesisdetermines whether this is possible or not. If the stress analysis shows that themechanism is suitable, a draft of the runner will be drawn. The requirements of thedischarge and the head are set at the site where an experimental rig for theprototype can be founded.Jaakko Matila project supervisor, owns a small hydroelectric power plant equippedwith a Francis turbine. The Korpikosky power plant, built on Lake Korpijärvi,provides enough space to build an experimental rig for the runner and as it wouldallow a direct comparison between a Kaplan and a Francis turbine. The turbine isdesigned to work in a maximal head of 3.7 meters and a highest discharge of 3m3/s.To guarantee a smooth running of the project, experts from different fields areinvolved: Jaakko Matila and Simo Marjamäki are responsible for technical issues:Antti Klaavo for economical matters and Juha Paukkala for any legal questions.
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS14 (134)Environmental EngineeringTimo �————————2.1 List of requirementsTimo FlaspöhlerR RequirementList of requirementsW WishProject:Kaplan RDates,1.12PurposeSmall hydroelectric power plantWorking rangeR2.1Discharge3 m3/sR2.2Head3.7m3GeometryR3.1NumberR3.2Blade diameter730mmTimoR3.3Hub e bladesForcesMechanical d-resistantDate: 01.10.20071Page 1
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS15 (134)Environmental EngineeringTimo �————————Timo FlaspöhlerR RequirementList of requirementsW WishProject:Kaplan TurbineRValue,No.DescriptionWManufacturingW7.1In the Tampere PolytechnicW7.2Using purchased parts7.3Prototype8AssemblingR8.1Accessibly assemblingR8.2Simple assembling9RSimple ponsibleComments,7RDates,12.1Date: 01.10.2007TimoFlaspöhlerAccident prevention rulePowerHigh efficiencyDatesDeadline17.12.2007Page 2
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS16 (134)Environmental EngineeringTimo �————————3Variation matrixTable 3.1: Variation matrix1: Axle2: Shaft3: Upper hub4: Middle hub5: Lower hub6: Blade7: Blade number8: Pivot9: Bearing pivot10: bearingBush bearing dryBush bearingoperationwith greasingiglidur H370iglidur H i18-10material11: Lever12: Link
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS17 (134)Environmental EngineeringTimo �————————13: Bearing linkABBush bearing dryBush bearing withoperationgreasingC 14: Bearing15: Crosshead16: Bolt17: Bolt18: Fuse elementiglidur H370iglidur 16-2Bolt without headBolt with head andBolt with head andsplint pin holethreaded rNi16-2Locking ringSplintSpring cotter3.1 SelectionChosenStatement1:AThe axle is made out of stainless steel and will be welded on theupper hub. Thus the chosen material is corrosion-resistant withgood weldability.2:AThe shaft has to be corrosions resistant and will be welded to thecrosshead. The chosen material is a stainless steel with a goodweldability.
TAMPERE UNIVERSITY OF APPLIED SIENCESFINAL THESIS18 (134)Environmental EngineeringTimo �————————3:BThe upper hub is corrosion resistant. Since the upper hub and theaxel will be connected by welding, the upper hub should also befrom a weldable material. The chosen material fulfills both theserequirements and thus a good choice.4:BThe middle hub needed to be highly machinable because of theholes needed to fit the pivot. It is corrosions-resistant.5:AThe lower hub needs only to be corrosion resistant. Thus thisinexpensive material is sufficient.6:BThe blade has to be as thin as possible: thus the material shouldhave a high resistance against bending and be stainless. Thematerial chosen for the blade was stainless steel with the higheststrength against bending.7:AFour blades are usually used at heads up to approximately 25-30m./9/8:BThe p
connected by a shaft. The range of head, in which the Pelton turbine is used, is between 60m and more than 1,000m. The Pelton turbine has quite a high efficiency and can be in the range of 30% and 100% of the maximum design discharge for a one-jet turbine and between 10% and 100% for a multi-jet turbine. /1, 3/ Figure 1.1: Pelton Turbine /3/
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