Design of the cross flow runner

The equations in this section are taken from:

Arter, A., Meier, U., Harnessing Water Power on a Small Scale Hydraulics Engineering Manual
(SKAT)
Mockmore, C. A. Prof CEng, Merryfield, F. Prof CEng, The Banki Water Turbine, 1949
Harvey, A, Micro Hydro Design Manual, (1993), ISBN 1-85339-103-4
Constants
p 1000
kg
m
3
:=
Density of water
c1 0.95 :=
Velocity coefficient for nozzle. Defined as the ratio of the actual average velocity
achieved to that predicted from Bernoulli's equation.Cannot be known accurately
before experiment. Typically ranges from 0.95 to 0.99 according to Applied
Mechanics by Hannah and Hillier and other internet sources. Therefore lower
value is chosen as nozzle is not expected to be smooth.
k1 0.087 :=
k is an experimental coefficient which relates the jet thickness to the diamerter of
the runner. According to the "Banki Water Turbine" paper this value lies between
0.075 and 0.10 so the mean was taken for calculations. The value of k ultimately
determines the number of blades required. Inputing k=0.075 gives 21 blades,
and for k=0.1 gives 16 blades. For the chosen value of k=0.087 the number of
blades is 18.
Design data
Variable parameters are: head, flow rate, efficiency and length of runner.
The head and flow rate are chosen to match the implementation section:
Net_head 15m :=
This is a measure of the energy in the water jet. Note not at the top of the
penstock.
Q 0.046
m
3
s
:= Originally a flow rate of 0.05 m^3/s was chosen. The pump sourced by the
Group could produce 16.9m of haed at a flow rate of 0.046 m^3/s and so
design calculations were tweaked slightly to match.
Assume turbine efficiency and choose optimum running speed of turbine
eo 0.55 :=
Estimated efficiency based on test results from Banki paper, estimations from MH
design manual and internet resources. Conservative
Speed 625 := rpm
Turbine running speed based on research conducted in electrical section.
Typical IMAG running speed is 1500 rpm. MH Design manual
recommends to design for a gear up ratio of 2 if using a belt drive, try to
aviod ratios over 3.
Power from turbine shaft
Calculate the estimated shaft power
Power Net_head Q p g eo := Power 3.722 10
3
W =
Velocity of jet from nozzle
V
jet
c1 2 g Net_head := V
jet
16.295
m
s
=
Diameter of runner
D1
Net_head 3.2808 ( )
0.5

862m
0.5
( )

39.37 Speed
:= D1 0.246 m =
Runner length
Length
144 Q 3.2808
3
0.0254
2

D1 c1 k1 2 g Net_head 3.2808 3.2808 ( )

0.5

:= Length 0.132 m =
Thickness of jet
Jet_area
Q 3.2808
3
0.3048
2

c1 2 g Net_head 3.2808 3.2808 ( )

0.5
:= Jet_area 2.823 10
3
m
2
=
Jet_thickness
Jet_area
Length
:= Jet_thickness 0.021 m =
percentage_of_D1
100 Jet_thickness
D1
:= percentage_of_D1 8.7 = %
Spacing of blades in wheel
Assuming no blade thickness Blade thickness correction accounting for blade
thickness.
s1 k1 D1 :=
blade_t 0.003 m :=
s1 0.021 m =
Jet_t s1 blade_t :=
t
s1
0.5
:= Denominator is sin(|1) = 0.5 runner_length_req
Jet_area
Jet_t
:=
t 0.043 m = runner_length_req 0.154 m =
no_blades t
D1
t
:=
no_blades 18.055 =
Radial rim width
a 0.17 D1 := a 0.042 m =
Radius of blade curvatures
r_b 0.326
D1
2
:= r_b 0.04 m =
Penstock pressure and friction calculations
Penstock variables
diam 0.2m :=
Chosen so that velocity in penstock is low. This is the most influential factor on
losses.
length_penstock 200m :=
Representative of a reasonably steep slope. 8.6%
frict_k 100 :=
Stickler friction coefficient as opposed to Moody
Penstock area area t
diam
2
4
:= area 0.031 m
2
=
Assuming circular pipe
Average velocity in penstock v_pen
Q
area
:= v_pen 1.464
m
s
=
Pressure in penstock based on Bernoulli's equation
Pressure g Net_head
v_pen
2
2
|

\
|
|
.

p := Pressure 1.46 10
5
Pa =
Pressure_bar
Pressure
100000 Pa
:= Pressure_bar 1.46 = bar guage
Head_loss
4
10
3
t
2
|

\
|
|
|
|
.
Q
2
length_penstock s
2

m
2
3
frict_k
2
diam
16
3

:= Head_loss 2.328 m =
Gross head required, ie. distance from top of penstock to nozzle exit
Gross_head Net_head Head_loss + := Gross_head 17.328 m =
Percentage_of_Gross_head_lost
100 Head_loss
Gross_head
:=
Percentage_of_Gross_head_lost 13.434 =
%
It is recommended in MH Design Manual that penstock losses are be kept between 10 and 15% of gross
head
Minimal required wall thickness for penstock pipe
permissable_stress
27500000
3
N
m
2
:=
for PVC with safety factor of 3 built in, hydrostatic design
basis. From SKAT.
penstock_thickness
100000 Pa Pressure + ( )
diam
2
|

\
|
|
.

2 permissable_stress
:=
pen_thick_mm penstock_thickness
1000
m
:=
penstock_thickness 1.342 10
3
m = pen_thick_mm 1.342 = mm
diam
2
penstock_thickness
74.517 = Hoop stress eqaution holds for thin wall pipe as r / t is
greater than 10,
NB Water hammer caused by valve closing or water blockages means a larger safey factor may be
required
Specific Speed
n_s m
1
4
s
3
2
kg
1
2
Speed
1.36
1
eo
Power
1000
|

\
|
|
|
.
0.5
Net_head
5
4
:= n_s 64.227 = rpm
Classical based on metric HP. Does
not comply with SI units
N_s m
1
4
s
3
2
kg
1
2
Speed
1
eo
Power
1000
|

\
|
|
|
.
0.5
Net_head
5
4
:= N_s 55.075 = rpm
True metric specific speed
N_s = 0.86 * n_s According to SKAT, for a cross flow,
n_s: 42....170
N_s: 36....146
Design is within recommended specific speed.
Test results from Dr Banki for comparison
Input parameters from paper
Specific speed, Ns = 14 (not used incalcs)
Head = 16 ft=4.88m
Flow rate = 3 ft^3/s =0.085m^3/s
Efficiency = 55%
c coeff = 0.98
k coeff = 0.087
Runner length = 12 inches =305mm
Parameters calculated from theory
Estimated power output = 3HP=2.21kW
Speed of wheel = 263 rpm
Thickness of jet = 1.13 inches=28.7mm
Spacing of blades in wheel = 2.28 inches=58mm
Number of blades = 18.1 (20 used in experiment)
Radial rim width = 2.22 inches=56mm
Radius of blade curvatures = 2.14 inches=54mm
Results from experiment
Max power developed = 2.75 HP=2kW at 280 rpm full gate
(slightly less power, speed slightly in excess of optimum
Flow rate used = 2.22 ft^3/s= 0.062m^3/s compared to 3 ft^3/s (16 ft
head)
Head^(3/2)/Power generated = constant for other heads tested at
optimum running speeds.
Jet thickness measured = 1.05 inches
Running speed for max power was practically constant for all gate
openings - 270 rpm from experiment - 263 rpm predicted.
Highest efficiency was 68% for full gate at optimum speed.
Highest efficiency was 50 % for 1/8 gate at optimum speed
Specific speed varies from 2 to 16 under max head. Turbine can be
operated over a range of 6 to 16 efficiently
Stress on blades
Force calculations on blade using relative velocities, ie. when turbine is in motion
See SKAT manual for vector diagrams
w_1 0.555 V
jet
:=
w_2 w_1
D1
D1 2 a
|

\
|
|
.
sin 30
t
180

\
|
|
.
:=
w_1x w_1 cos 30
t
180

\
|
|
.
:=
w_1y w_1 sin 30
t
180

\
|
|
.
:=
w_2x w_2 cos 37
t
180

\
|
|
.
:=
w_2y w_2 sin 37
t
180

\
|
|
.
:=
F_x p Q w_2x w_1x ( ) :=
F_y p Q w_2y w_1y ( ) :=
F_r F_x
2
F_y
2
+ :=
Assume 2/3 of rim width for blade length
blade_l
2 a
3
:= o
180
t
atan
F_y
F_x
|

\
|
|
.
:= o 9.586 =
Treat induvidual blade as beam in bending beam
I
blade_l blade_t
3

12
:=
Bending moment at mid point
M
Length
2
|

\
|
|
.
F_r
2
:= stress
M
blade_t
2
|

\
|
|
.

I
:= stress 8.7 10
7
Pa =
On a single blade
Yield stress of steel according to H an H is between 220 and 250 MN/m^2
Design is well within safety limits.