KAPLAN TURBINE

Instruction Manual

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 KAPLAN TURBINE TEST RIG

OBJECT:
To Study the characteristics of the Kaplan Turbine.

THEORY:

The Kaplan Turbine is a propeller-type water turbine that has adjustable

blades. It was developed in 1913 by the Austrian professor Viktor Kaplan.
The Kaplan turbine was an evolution of the Francis turbine. Its invention
allowed efficient power production in low head applications that was not
possible with Francis turbines. Kaplan turbines are now widely used
throughout the world in high-flow, low-head power production.

THEORY OF OPERATION

The Kaplan turbine is an inward flow reaction turbine, which means that the
working fluid changes pressure as it moves through the turbine and gives up
its energy. The design combines radial and axial features.

The inlet is a scroll-shaped tube that wraps around the turbine's wicket gate.
Water is directed tangentially, through the wicket gate, and spirals on to a
propeller shaped runner, causing it to spin. The outlet is a specially shaped
draft tube that helps decelerate the water and recover kinetic energy.

The turbine does not need to be at the lowest point of water flow, as long as
the draft tube remains full of water. A higher turbine location, however,
increases the suction that is imparted on the turbine blades by the draft tube.
The resulting pressure drop may lead to cavitations.

Variable geometry of the wicket gate and turbine blades allows efficient
operation for a range of flow conditions. Kaplan turbine efficiencies are
typically over 90%, but may be lower in very low head applications. Since
the propeller blades are rotated by high pressure hydraulic oil, a critical
element of Kaplan design is to maintain a positive seal to prevent emission
of oil into the waterway. Discharge of oil into rivers is not permitted.

EXPERIMENTAL SETUP:
The turbine is placed on substantial base. The supply pump set draws water
from the main tank and supplies it to turbine. A pitot tube is installed in the
pipe line to measures the discharge with the help of a u-tube manometer. A
set of guide vanes is provided around the periphery of the runner to control
the load. The whole guide vane mechanism is being operated through a hand
wheel by suitable link mechanism.

PROCEDURE:
1. Clean the apparatus and make Tank free from Dust.
2. Close the drain valves provided.
3. Check the level of manometric fluid in all the manometer tube. It
should be up to half. If it is less, then fill it.
4. Close all Pressure Taps of Manometer connected to manometers.
5. Ensure that On/Off Switch given on the Panel is at OFF position.
6. Now switch on the Main Power Supply (440V AC, 50 Hz).
7. Switch on the Pump.
8. Now slowly open the gate valve and check the pressure gauge.
 9. Slowly open turbine guide vane by rotating the hand wheel until the
turbine attains the maximum speed.
10.Load the flywheel by tightening the wheel up to 0.5kg.
11.Record the pressure reading, Manometer reading. Speed reading &
reading of the spring balance.
12.Repeat the experiment for different load.

STANDARD DATA:
Diameter of Flywheel (dB) : 200mm
Diameter of Rope (dR) : 12 mm
Diameter of Pipe (d) : 104 mm
Coefficient of Velocity (Cv) : 0.9
Density of water (  w ) : 1000 kg/m3
Density of manometric fluid (  m ) : 13600 kg/m3
Acceleration due to gravity : 9.81 m/sec2
Weight of rope (W3) : 0.24kg

OBSERVATION TABLE:

S.N. N W1 W2 Manometer Pressure Pressure

RPM (kg) (kg) Reading Gauge Gauge
Reading Reading
h1(cm) h2(cm)
Pd Ps
(kg/cm2) (mmHg)
FORMULAE:
For Measurement of Discharge
 h  h2 
h 1 m of water
 100 

 
H1 = h m  1 m
 w 

Q  C v * a * 2 gH 1

Where,
Q = Flow rate/Discharge.
H1 = Pressure Head.
h = Difference in Pressure.
Cv = Coefficient of discharge.
a = Cross Sectional Area of Pipe.
g = Acceleration due to Gravity.

Effective Water Head

Ps
H  10.3  ( Pd  ) (meter of water)
760

Input Power (Ei) = Power supplied at inlet of turbine also called water
power. (in KW).
Ei = ( x g x Q x H) / 1000
Where,
H = Effective Water head.
ρ = Density of Water = 1000 kg/m3.
 g = Acceleration due to gravity = 9.81 m/sec2 .
Q = Flow rate or Discharge.
d B  2d R
Re  ,m
2
T  W1  W3  W2   g  Re N-m

2  N T
Output Power Eo  (in KW)
60  1000

Where,
dB = Diameter of Flywheel, (mm)
dR = Diameter of Rope, (mm)
N = Revolution (RPM)
W1 –W2 = Load on Shaft
E
Overall Efficiency (ηo) = E  100
o

CALCULATION TABLE:
S.No. Effective Discharge Output Input Overall
Water Head Q (m3/s) Efficiency
Eo Ei
Hr(m) ηo(%)
(KW) (KW)

NOMENCLATURE:
d = Diameter of Pipe
a = Cross-section area of Pipe
w = Density of water
 g = Acceleration due to gravity
h = manometer difference in cm
Ei = Power supplied at the inlet of Turbine.
Eo = Output Power.
N = Number of Revolution, RPM
Q = Flow rate or Discharge
ηo = Overall Efficiency
dB = Diameter of Flywheel, (mm)
dR = Thickness of belt, (mm)
P = Pressure Gauge Reading.
H = Effective Water head.

PRECAUTION:
 The main valve should be closed before starting the machine.
 Do not load the turbine suddenly. Loading should be done gradually
and at the same time supply of water should be increased so that the
run at normal speed.

REFERENCE:
1. Dr. R. K. Bansal, “A TEXT BOOK OF FLUID MECHANICS AND
HYDRAULIC MACHINES (S.I. Units)”, 9th ed. LAXMI
PUBLICATIONS (P) LTD, 2005