ENERGY INFRATECH PVT. LTD.

SELECTION OF HYDRO-TURBINES and Power House dimensioning

by S.Krishnamurty

Classification of Hydraulic Turbine

Hydraulic Turbine

Reaction Turbine

Impulse Turbine

Francis Turbine Kaplan Turbine Bulb Turbine

Pelton Turbine Turgo Turbine Cross flow Turbine

BASIC INPUTS FOR TURBINE SELECTION AND RATING

1.HEAD (H)
2.DISCHARGE(Q)

HEAD

as per IS 12800(Part 1):1993

Gross Head (Hg) It is the difference in elevation between the water levels of the forebay and tail race (for Reaction Turbine) or Centre Line of Runner( For Impulse Turbine). Net Head(Hn) It is the gross head less all hydraulic losses except those chargeable to the turbine. Net head is the head available for doing work on the turbine.

HEAD

as per IS 12800(Part 1):1993

Maximum Net Head (Hmax) - It is the gross head resulting from the difference in elevation between the maximum forebay level and the tail race level (Reaction Turbine) or Centre Line of Runner for Impulse Turbine without spillway discharge and with one unit operating at no load speed. Under this condition , Hydraulic losses are negligible and may be neglected. Minimum Net Head (Hmin) It is the net head resulting from the difference in elevation between the minimum forbay level and the tail race level with all turbine operating at full gate

HEAD

as per IS 12800(Part 1):1993

Rated Head (Hr) - It is the head of which the specifications require that the turbine operating at full gate shall produce sufficient power to deliver the name plate power output. It is the 2/3rd of the difference between FRL and MDDL above the MDDL. Basically it is assumed that the volume of water above this level is same as below this level as the shape of pondage goes on decreasing. So the probability of this head to available is more .

Design Head (Hd) It is the net head under which the turbine reaches its peak efficiency at synchronous speed; Usually it is specified as =Hd=Min. Net Head+(2/3)*(Max. Net Head-Min. Net Head). This is the head which determines the basic dimensions of the turbine and therefore of the power plant. For optimum operation benefits the Design Head &Rated Head are kept same.

Discharge (Q)-It is the rate of volume of water coming to turbine. It depends on catchments

As per USBR

Specific Speed
Specific Speed: Specific Speed is a typical characteristic where all runners of a given specific speed are similar in form and vary only in size. This Speed form the basis of Classification of Turbines. It can be defined as the speed of a homologous turbine of such a size that it would develop unit power at unit head. Ns =(N x (P)^0.5) / Hd^(5/4) Where Ns= Specific Speed in rpm N = Unit Speed in rpm Hd= Design Head in Meters P = Rated Power .

Factors affecting selection of hydraulic turbines

1.Head :250m and above-Pelton 150-250m-Pelton /Francis 60-150m-Francis 30-60m -Francis/Kaplan 15-30m -Kaplan 2-15m -Bulb/Tubular up to 15m-Propeller 2.Discharge:- Low Discharge-Pelton Medium Discharge-Francis High Discharge-Kaplan 3.Specific speed:-High specific speed is essential when head is low and output is large because otherwise rotational speed is low which means cost of generator and power house more. It is classified as 30-150 rpm Pelton 80-300 Rpm-Francis 30-1000Rpm-Kaplan

Figure depicting selection of turbine on the basis of head

4.Site characteristics:-Type of rock available and depth up to which the rock is available. 5.Type of Plant:-Peak Load Plant or Base Load Plant 6.Water Quality (silt):-If the turbine lies in the overlapping zone of Francis and Pelton the silt criteria needs to be seriously considered. 7.Cost:-The minimum cost is preferred taking into view above factors also. 8.Manufacturing Difficulty:-That turbine cant be taken which is very typical to make. 9. Cavitations:-The installation of reaction turbine over Impulse turbine is affected by the cavitation. 10.Maintainence:-The turbine selected should be also easy to maintain. Pelton is easy in maintenance as compared to Francis Turbine. 11.Time out of operation:- The case of repair is normally related to sand erosion.

Classification of Turbine on the basis of Discharge & Head

Classification on the basis of Head & Specific speed

Turbine selection on the basis of discharge (by VA Tech Hydro)

Pelton Turbine

Francis Turbine

Kaplan Turbine

Turbine selection on the basis of discharge & head (by VA Tech Hydro)

Axial Turbine

Bulb Turbine

Efficiency Comparision-Different Turbines (as per USBR)

Efficiency of various turbine of our projects Malana-II 50X2 MW Type of turbine As per contract As per actual Field test Pelton 91.4 Not yet Sainj 2X2.5 MW Francis 91 92 Patikari 8X2 MW Pelton 93 89.04 Teesta-III 200X6 MW Pelton 92.2 Not yet

Conflicts between Pelton & Francis When the head is between 150 & 250m
1. Discharge :-If this is high Francis is preferred 2. Efficiency:-The efficiency of Francis is more at full load around 96% while Pelton around 90%. 3. Time out of operation:-Dismantling and assembly of the sand eroded parts takes shorter time for Pelton than for Francis turbines. Therefore Pelton turbines will normally be preferred where much sand erosion is expected. However, this again depends rather strongly on the plants operation schedule.

As per USBR

If one or more turbines are stopped for a long period of for example two months a year, Francis turbines may be chosen even if the water has a high sand content because there will be enough time for an annual repair. 4.Site Characteristics:-Installation cost in case of Francis Turbine also increased when the rock available is at very high depth. So we have to excavate up to that depth and even concrete up to required level. So additional excavation cost and concreting cost comes into picture

As per USBR

Pelton vs. Francis

6.Cost comparison
5.Operation under part load
The cost of machine decreases as the speed increases

As per USBR

Conflict between Francis & Kaplan

When the head is between 30 & 60m 1.In general the Kaplan turbines are chosen for heads below 30 m. But since its part load efficiency is more it is well extended up to low head Francis turbine 2. Kaplan turbine offers also an advantage with its smaller dimensions for a certain capacity than the corresponding Francis turbine. Especially for large machines where capacities of 200 500 m3/sec are wanted the Kaplan turbine is chosen

As per USBR

3. The upper economic and practical limit for the Kaplan turbine head is in the range of 60m, though extreme cases of 70 - 75 m have been planned for this turbine type as well. The head limit is caused by mechanical strength problems in hub and blades.

Conflict between Kaplan & Bulb

For low heads Bulb turbines will be an alternative to the Kaplan turbines. 1.More favorable flow conditions:-. These favourable flow conditions have the effect that the runner diameter of a Bulb turbine may be made 15 % smaller than for a Kaplan turbine under otherwise equal conditions. 2.Less Cavitation:-The flow conditions will also reduce the cavitation risk for the Bulb turbine, which means a less submergence is needed than for the Kaplan turbine.

3.Size of Power House:-The Bulb turbine is still more favourable if only one unit shall be built because the scroll casing of a Kaplan turbine makes the power station much wider. The Bulb turbine will however, reach an upper limit design head because of the concentrated hydraulic load on the concrete foundation through the ribs. Thus the pressure will be limited to 15 - 20 m head for this turbine type.

Classification of Turbines
Type of machine Head variation Percent of rated head Load variation percent of rated output Specific Speed m-mhp Peak efficiency

Pelton
Francis Deriaz Kaplan Propeller Bulb

120 to 80
125 to 65 125 to 65 125 to 65 110 to 90 125 to 65

50 to 100
50 to 100 50 to 100 40 to 100 90 to 100 40 to 100

15 to 65
60 to 400 200 to 400 300 to 800 300 to 800 600 to 1200

90
93 92 92 92 92

as per IS 12837:1989 Clause 5.1

Power House sizing

As pert IS 12800, The overall dimensions of Power house mainly depend upon the following: 1. Overall dimension of the turbine, draft tube and scroll case; 2. Overall dimensions of the generator; 3. Number of Units in the power house; and 4. Size of erection bay
Note: Provision for inlet valve, erection of rotor and un-tanking of transformers should be made in such a way that space required is minimum without impairing the operational and maintenance requirements.

A. Length of Power House

1.
2. 3.

It depends upon the Unit Spacing Length of erection bay Length required for the EOT Crane to handle the last unit

1.Unit Spacing(Us)

Inner diameter of the generator barrel is determined as per the norms and outer diameter of the barrel is taken as 0.5 to 1.5m more depending upon the size of machine.
As per Std. Malana II 8400mm As per Std. =10500 11500mm Teesta III 12000mm

Outer diameter of barrel

79008900mm

A clearance of 1.5 to 2m shall be added on either side of the extremities of the generator barrel. These clearance should be such that concrete thickness on either side of scroll case should be 1 to 1.5m in case of fully embedded steel scroll case. Usually spacing with scroll/spiral case clearance is more and will be basis.
As per Std. Malana II
12183mm

As per Std.
-

Teesta III
16484mm

Spiral case overall diameter

Us

1418315183

20000mm (as CW sump is between units)

18484-19484 24000mm

Malana II HEP

Teesta III HEP

A)Length of service bay Ls : 1.5times Us B)Length required for EOT crane to handle the last unit k : 3 to 5 m C)Length of Control Block Lcb C)Length of Power House:

2.Length of Power House

No. of units x Us +Ls +k + Lcb

As per Std. Malana II
20000mm 18700mm 12000mm =6x24000+480 00+5000+1895 0=198890mm

As per Std.
19484 =1.5x19484 =29226

Teesta III
24000mm 48000mm 18950mm 214300mm

Unit Spacing Length of service bay Length of control block

15183 =1.5x15183 =22774mm

Length of =2x20000+1870 67500mm Power House 0+5000+12000 =75700

Malana II HEP

Teesta III HEP

3.Width of Power House

On the upstream side provision should be made for the following: a)A clearance of about 1.5 to 2 m for concrete the upstream of scroll case b)In case the main inlet valve is also accommodated in the power house, a valve pit of approachable size should have to be provided as per IS 7326(Part 1) and IS 7332(part 1)
As per Std Malana II As per Std. Teesta III

Distance of spiral case from centerline D,E

MIV Dia/width W Width of spherical valve :Max=2.6(MIV) Width on U/s side= D+W+2000 Width on D/s side= E+2000 Total Width

4534, 5183
1200 =2.6x1200 =3120 =9654 =7183 =16837

4376, 6373
1300 5126 =9400 =8100 =17500

5828, 6477
1900 =2.6x1900 =4940 =12768 =9977 =22745

8330, 8375
1900 5890 11500 =10000 =21500

c)The spaces as indicated against item(a) are supposed to be sufficient for accommodating the auxiliary equipment also but may have to be reviewed considering the layout of essential equipment and operational requirements.

Malana II HEP

Malana II HEP

Teesta III HEP

Teesta III HEP

3.Height of Power house

Height coefficient

K3 = 0.65 or 0.75 or 0.85 Hj =K3 x sqrt of Df (for Suspension) and K3 X sqrt of (Di for umbrella)

Height of the Load Bearing Bracket

Distance between centre line of turbine and machine hall floor

H2 =Hj+Lf+6.75

Total Height from datum line to top of generator

H =H1 + H2

Height of largest package to be lifted

around 7 to 8.5

Height of slipring housing above machine hall floor

around 1 to 1.5m around 2.5 to 6.5 m

Hook allowance

Crane Height above crane rail top

around 4 to 6.5 m

Allowance below roof over EOT :0.5m Total Height of the Power House

Ht= H + ht of service bay+ ht Of unloading largest package + crane ht & hook allowance + allowance below roof over EOT + margin

As per Std. Height coefficient k Height of Load bearing bracket Hj Core Length Lc Length of stator frame Lf Distance between centre line of turbine and machine hall floor 0.75 =kxsqrt(Df) =1320 =1290 =Lc+1600 =2890 =Hj+Lf+6000 =10110

Malana II 1300 1520 3170 10170

As per Std.

Teesta III 0.75

1380 3315.28 =Lc+1600 =4915 =Hj+Lf+6000 =12295

1340 2860 3860 13900

As per Std. Pelton wheel dimensions Wheel pitch diameter D2 Jet dia Outer wheel diamter Number of Buckets (Approximate)

Malana II

As per Std.

Teesta III

2300 171 2900 20

2330 229.4

3000 252 3800

3020 318

20

21

21

Suction head Hs To avoid discharge water Hs>4*H1 splash =2145>2400 CL of Turbine wheel is set above TWL 2400

Hs = 1.87 + 2.24*Q/ns =2145

3442

3407

3442 4200

4000

Teesta III HEP

Malana II HEP