INSTRUCTION MANUAL

For
KAPLAN TURBINE TEST RIG


OBJECTIVE:
To study the operation of Kaplan turbine.
AIM:
To determine the output power of Kaplan turbine.
To determine the efficiency of the Kaplan turbine.
To plot the performance characteristics curve for Kaplan Turbine.
THEORY:
The Kaplan turbine is a propeller-type water turbine. It was developed in 1913 by the Austrian
professor Vitor Kaplan! who combined automatically ad"usted propeller blades with automatically
ad"usted wicet #ates to achieve efficiency over a wide ran#e of flow and water level.The Kaplan
turbine was an evolution of the $rancis turbine. Its invention allowed efficient power production in low-
head applications that was not possible with $rancis turbines. The head ran#es from 1%-&% meters and
the output from ' to 1(% )*. +unner diameters are between ( and , meters. The ran#e of the turbine is
from &9 to -(9 rpm. Kaplan turbines are now widely used throu#hout the world in hi#h-flow! low-head
power production.
The Kaplan turbine is an inward flow reaction turbine! which means that the worin# fluid chan#es
pressure as it moves throu#h the turbine and #ives up its ener#y. .ower is recovered from both the
hydrostatic head and from the inetic ener#y of the flowin# water. The desi#n combines features of
radial and a/ial turbines.Kaplan turbine efficiencies are typically over 9%0! but may be lower in very
low head applications. Kaplan turbines are widely used throu#hout the world for electrical power
production. They cover the lowest head hydro sites and are especially suited for hi#h flow
conditions.Ine/pensive micro turbines on the Kaplan turbine model are manufactured for individual
power production with as little as two feet of head.1ar#e Kaplan turbines are individually desi#ned for
each site to operate at the hi#hest possible efficiency! typically over 9%0. They are very e/pensive to
desi#n! manufacture and install! but operate for decades.The Kaplan turbine is the most widely used of
the propeller-type turbines! but several other variations e/ist2
Propeller turbines have non-ad"ustable propeller vanes. They are used in where the ran#e of head is not
lar#e. 3ommercial products e/ist for producin# several hundred watts from only a few feet of head.
1ar#er propeller turbines produce more than 1%% )*.
Bulb or Tubular turbines are desi#ned into the water delivery tube. A lar#e bulb is centered in the
water pipe which holds the #enerator! wicet #ate and runner. Tubular turbines are a fully a/ial desi#n!
whereas Kaplan turbines have a radial wicet #ate.
Pit turbines are bulb turbines with a #ear bo/. This allows for a smaller #enerator and bulb.
Straflo turbines are a/ial turbines with the #enerator outside of the water channel! connected to the
periphery of the runner.
S turbines eliminate the need for a bulb housin# by placin# the #enerator outside of the water channel.
This is accomplished with a "o# in the water channel and a shaft connectin# the runner and #enerator.
!L" turbine an open flow! very low head 4aplan4 turbine slanted at an an#le to the water flow. It has
a lar#e diameter 53.''m! is low speed usin# a directly connected shaft mounted permanent ma#net
alternator with electronic power re#ulation and is very fish friendly 67'0 mortality8.
T#son turbines are a fi/ed propeller turbine desi#ned to be immersed in a fast flowin# river! either
permanently anchored in the river bed! or attached to a boat or bar#e.
CONSTRUCTION $ETAILS O% KAPLAN TURBINE:
3omponents of the Kaplan turbine2-
.en stoe2 9 It is a lar#e si:ed shaped; where the water is provided to the turbine runner from the
dam.
<croll casin#2 9 .enstocs connected to and feeds water directly into an annular channel
surroundin# the turbine runner. The channel is spiral in its layout.
=uide vanes2 9 A series of airfoil shaped vanes called the #uide vanes are arran#ed inside the
casin# to form a number of flow passa#es between the casin# and the runner blades. =uide vanes
are fi/ed in position 6they do not rotate with rotatin# runner8.
=uide wheel and #overnin# mechanism2 9 It chan#es the position of #uide blades to affect
variation in the water flow rate in the wae of chan#in# load conditions on the turbine. *hen the
load chan#es! the #overnin# mechanism rotates all the #uide blades about their a/is throu#h the
same an#le so that the water flow rate to the runner.
+unner and runner blades2 9 +unner of the $rancis turbine is a rotor which has passa#es formed
between the drat tube and scroll casin#.
>raft tube2 9 After passin# throu#h the runner! the water is dischar#ed to the tail race throu#h a
#radually e/pandin# tube.
$ESCRIPTION
The present set-up consists of a scroll casin# housin# a runner. *ater enters the turbine throu#h the
<tationary #uide vanes and passes throu#h the runner a/ially. The runner has a hub and airfoil vanes!
which are mounted on it. The water is fed to the turbine by means of 3entrifu#al .ump. The runner is
directly mounted on one end of a central << shaft and other end is connected to a brae arran#ement. A
transparent hollow cylinder made of acrylic is fitted in between the draft tube and the 3asin# for
observation of flow. 1oad is applied to the turbine with the help of rope brae arran#ement. <o that the
efficiency of the turbine can be calculated. The set-up is supplied with control panel. A draft tube is
fitted on the outlet of the turbine. The set-up is complete with #uide mechanism. .ressure and Vacuum
#au#es are fitted at the inlet and outlet of the turbine to measure the total supply head on the turbine.
TEC"NICAL $ETAILS:
Output Power : 1kW/ 0.75 HP
Discharge : 3500 LPM!ppro"#
$upp%& hea':5(
)u**er: with a'+usta,%e -ur.e' /a*es.
D&*a(o(eter: )ope 0rake t&pe1 Dia 200((.
$u(p 3a*k: -apacit& 150 Liters.
Water -ircu%atio* : -e*tri4uga% Pu(p1 -apacit& 7.5 HP1 3hree Phase
Discharge Measure(e*t: Pitot tu,e with Ma*o(eter.
$pee' 1500 )PM !ppro".#
-o*tro% pa*e% -o(prises o4:
$ta*'ar' (ake star/'e%ta $tarter1 Mai*s 5*'icator1 M-0 4or o.er%oa' protectio*.
3a*ks wi%% ,e (a'e o4 $tai*%ess $tee%.
3he who%e set6up is we%% 'esig*e' a*' arra*ge' i* a goo' 7ua%it& pai*te'
structure.
UTILITIES RE&UIRE$:
*ater supply 2 -%% liters 6apro/.8
3 .hase supply! --% volt A3
>rain
<pace re?uired (.' m / 1.'m / 3.% m
EXPERIMENTAL PROCEDURE:
1. 3lean the apparatus and mae it free from dust
(. 3lose the drain valve provided
3. $ill sump tan @ with clean water and ensure that no forei#n particles are there
-. $ill manometer fluid i.e. A# in manometer
'. Bow switch on the power supply 6--% VA3! '% A:8
C. <witch on the pump with the help of starter
&. Dpen the air releasin# valve provided on the manometer! slowly release the air from
manometer
,. *hen there is no air in the manometer! close the air releasin# valves
9. Bow re#ulate the =uide Vanes position with the help of hand wheel provided.
1%. Bow turbine is in operation.
11. +e#ulate the dischar#e by re#ulatin# the =uide vane position
1(. 1oad the turbine by applyin# wei#ht on plat form.
13. Bote the manometer readin#
1-. Bote the pressure #au#e readin#
1'. Bote the +.) of the turbine
1C. Bote the sprin# balance readin#
1&. +epeat the same procedure for different load and different dischar#e
1,. *hen the e/periment is over! first remove load on dynamometer
19. 3lose the ball valves provided on manometer
(%. <witch off pump with the help of starter.
(1. <witch off main power supply.
((. >rain the water from turbine with the help of ball valve provided on turbine.
STANDARD DATA:
>iameter of the pipe 2 ,% mm
Acceleration due to #ravity 6#8 2 9., mEsec
(
>ensity of water 6Fw8 2 1%%% K#Em
3
>ensity of manometric li?uid 6Fm8 2 13C%% K#Em
3
>ia of Grae >rum 6>b8 2 %.(m
Thicness of belt 6>T 8 2 %.%%, m
3oefficient of >ischar#e 63d8 2 %.9,
*ei#ht of the Aan#er 6*38 2 %.(9, #
FORMULAE:
Total "ea'
water of m P H
d
4 4 3(' . 1% =
$is()ar*e
sec
1 (
3
m
w
h g C A Q
m
d

+)ere ) , Mano-etri( $ifferen(e in .-/

Turbine Output
Kwatt
R W N
e
C%%%%
,1 . 9 (
+)ere0
Net loa' + , 1T23+45T6 K*
E7ui8alent ra'ius
( )
(
(
T b
e
D D
R
+
=
Turbine Input
1%%%
H Q g
w

K9
Turbine Effi(ien(#
1%% =
power Input
power Output
turbine

OBSERVATION TABLE:-
S:No RPM1N5 Pressure
*au*e
rea'in*
P'1K*;(-
6
5
$ifferential
pressure
)1-5
Loa' on turbine1K*5
T21Applie'
Loa'5
T61Sprin*
Balan(e
Loa'5
Calculati! Ta"l#:-
S:No RPM Total "ea'
"
1- of 9ater5
$is()ar*e
&1-
4
;se(5
Output
19att5
Input
19att5
Turbine
effi(ien(#
1<5
NOMENCLATURE:
.d H .ressure #au#e readin# 6K#fEcm
(
8
Fw H density of water
Fm H density of mercury
h H manometric difference 6m8
3d H 3oefficient of dischar#e
T1 I T( H sprin# balance readin#
B H +.) of runner shaft
# H Acceleration due to #ravity
PRECAUTIONS $ MAINTAINANCE INSTRUCTIONS:-
>o not run the pump at low volta#e i.e. less than 39% volts.
Bever fully closed the delivery line and bypass line valves simultaneously
Always eep the apparatus free from dust.
To prevent clo##in# of movin# parts! always run the pump once in a wee.
$re?uently #reaseEoil the rotatin# parts! once in three months.
Always use clean water
If the apparatus will not be in use for more than one month! drain the apparatus completely.
TROUBLE SHOOTIN%:-
If the pump is not liftin# any water! the revolution of motor may be reversed. 3han#e the electric
connection of the motor to chan#e revolution.
If the panel is not showin# input! chec the main supply.