SECTION 3 HYDRAULIC TURBINE SELECTION AND COST GUIDELINES (lasiicaton of Ts General. The net ead avaiable tothe turbine di lates the selection of type of turbine suitable for ue sts Particular ste, The rate of low datrmines the capac ofthe turbine Hydraulic turbines have two general lassifcations, Impulse and reaction. Reaction terbins are by far the ‘ost widely Used withia the head range eddresie by this volume Reaction tries are clasied as Francis (mixed ftow) or Propeller (ail Now). Propeller turbines ae svallable with both fked blades and varie pitch Biades (Kaplan). Both Propeler and Francis turbines ‘may be mounted ether horizontally overall Add Sonal, Propel turbines may be sunt mounted ‘Trade names have been applied to cera Propel r= bine desis such as Tube, Bulb spd Strafo, Te unaer design principals, however, are he same Temuls turbines may have some appition for small hydropower insalaions. However thee are ver few manufacturers intrested in developing» standardized ‘roduc lin. Ip general the cost to manicure «rac ‘on turbine of comparable head and capaci ese. Proprietary turbines ie rim and crossiow) are avaiable and discus Turner inthis section, These ines have unique chuaceritic whi may be Denes lor some project ‘Crowsctlons of me various ypes of turbines com meri availabe ae shown in Fire 3-1 Francs Tutbines. A Francis urine fone having 8 runner with fixed buckets (anes) usually tine oF mote to which the water eaters the trbine nad ‘Sreton, wih respect the shal. ands discharged a fn ail diecton. Princial components consist of the nner, water supply ease to convey the water t the nner, wicket gates to contol he quantity of water and fdsribate it equally tothe runner and dah tube to convey the water avay fom the turbine, A Francis turbine may be operated over a range of Nows from approsimatay 0 105 percent of ted die charge. Below 40 percent ated disharge, there can be fn ares of operation whore widraton and/or power Surpesoctur The upper limi generally corespnde to the generator rating The approximate hesé range fot ‘opertion is fom 80 1 125 percent of design hea. la fener peak effienies of Francis turbines within the ‘pacity range of 15 MW. wil be approximately #81090, erent. The peak efeiencypoit os Francis tbe ‘Stablsned a 0 percent ofthe rated capacity of he bine. In tur, the elfcleney at the rated cpus i spproximately 2 percent below peak effiinty The lecromechania Features a ak ficiency at 60 percent of rated hes wil opto ear 75 percent ‘The conventional Francis turbine i provided with « wicket gate assembly to permit plsing the unt Le ‘synchronous speed fo replat loud and sped. indo Shutdown the uni The mechani of large units ae ‘ctuated by hydra sevomotors, Sal units my be actuated by eleciie motor ete operations. It permis ‘operation ofthe turbine over the ful eng of lows a speci cases, where the Dow fle is constant. Francis {urbins without wiket gate mechanisms maybe tse ‘These unis wl operate a» xed lod dependent spon the net hed. Startup and shut down of turbines witout ices ete normaly accomplished using the shutoff Sale atthe turbine inlet Francis turbines may be mounted wth vertical ‘horaontalshalls. Vertical mounting allows s smaller lan area and permis 2 deeper setung of the turbine ith respect to alvater elevation without locating the {eneraior blow tavater.Genertor costs for vera ‘nis ar higher than for hoszontal unite because of the need for ager trust bearing. However he savings ‘on constuction costs for medium and args unis sencraloffeet this equipment costinresse, Horizontal Units ar often more economic for sal ithe? sped plications where sendard orion generar ae salable stel pate However open fume and Concrete cases ae ste use for heads below 50 fest. Conciete and open fume’ cases are dscussed in a subeequent section, ‘Closed concrete and ste iss are nso own Sp Francis turbines are generally provided with 2 90 degree elbow draft ube whieh has a venus design to ‘minimize head loss. Conia draft tubes are azo aaa: le. however the head oe wil be bigher and enevation may be more cost Propeller Turbines.‘ proper urine sone having ‘runner with four. veo x las mbih he water ses though the nner inn sual dvecton with ‘espe to the shaft The ch ofthe blades maybe fied oF movable, Principal components consist af water Supply case. wieket gates. runner and v draft wube Figure 32 iusrates stay rng and wieket ae aso Iyand Figure 3:3 osrte aed bade propeller tn ‘The effiiency curve of typical fixed blade Propler turbine forms a sharp pea, more sbrop than «Francs turbine curve, For varable ich blade nite the peak ciency occurs teen outputs depending on the ‘ade sting. An envelope ofthe eseny curves over val. vVERTICAL FRANCIS HORIZONTAL FRANCIS 4H “Py vem mare Ta igor 31. Turbine cross sections lecromechanicl Features n RIGHT ANGLE TUBE lap HORIZONTAL PELTON co “ta ‘CROSSFLOW (OSSBERGER) vol Vthe ang of bade itch etn forms the variable pitch eMficieney curve. This effceney curve ls oud und at Fixed blade units are less costly than varie ich ade urbines: however, the power operating ranges more limited Turbine manufacturers have developed runner designs for head range of 15 to 110 feet. Four blade designs may te used up to 35 fect of Read, ve blade designs to 65 fet and six blade designs to 10 feet. general, peak elfcicncies re approximately the same as foe Francis torbines, Propeller turbines maybe operated at power outputs sith Nows fom 4010108 percent ofthe ried flow. Dee Sharge rates above 10S" percent may be obwined, however the higher rates ae generally above thet Dine and genersior manufactures" guarantees, Many tunis are satisictonily operated Beyond these Unis, however, for purposes of feasibitystodies, Il ‘ested that these limits be unite. Head range Tor Satisfactory operation is Hom 60 to 140 percent of Gesgn head iene loess higher het rope 210°3 percentage points below perk efceney atthe design head and as much as 15 percentage points lower head The conventional propeler o Kaplan (vail pitch bade) turbines are) mounted wth a vereal shah Horizon nd sant setngs wil be discussed separate "y. The vertical units are eauipped with wicket ete assembly to permit placing the unit on inet ye ‘hronous speed, regulate spond and oud nt shut down the unt The wicket gre mechanism units ae ‘sctusted by hydraulic servomotors Smal unite may be ‘Sua by electric moor gate operators. Variable ph Unis are equiped wth a cm mechanism to coornate the pitch ofthe Bade with gate posion snd head. The Special condion of constant om, ax previously Gite Used for Francis turbines, can be applied to propeller Turbines. For this cse,cimiation of the wicket gate assembly may be sezepabe. Vriabie pitch propeller Turbines without wicket gts are dscusted ins swbee- ‘The advantages and disadvantages dscused above with regard to "vertical versus horizontal settings for Francs turbines apply also to propel turbines. Tne water supply cases generally concrete. Either an open fume or 2 sed conduit ype of conrcton may be used. Open fume construction may be economic when heads are Below 35 fst At higher heads the fut bine shaft lengn becomes excessive. Ako open fme ‘constuction is disadvantageous with epard fo mainte: ‘nce cos. The wicket ate sssembly and uid Baring fare water fobristed causing sonal maintenance Darclarty when sit or debris isin the water. At Figure 3.2. Wickes gate and stay rng assembly for an open fame turbine (Courtesy of James Laff! snd Company) lecvomechanicl Festurescapeces hove 150 kW, wicket gate and guide bering Toading re such thal a8 open fume may not be 8 fstisfetory choice. For closed conduits, spiral cases of Seo! or concrete may be used. The eonctte case Is {onenly les cost. The croton of concrete ‘ase, ken in ection radia othe shaft is usally rectangular “Te df tbe design discussed for Francis turbines sppy alo to propeller turbines. ‘Tubular Torbines, Tubular or tube wrbines are Dorion! o¢ sunt muni unis wth propeller run- ters. The generators are leat outside ofthe water bsageway. Tube turbines are svalale equipped with fixed or variable pitch runners and with or without wicket gate assemblies. Performance characteristics of «tube turbine are similar to the performance chaacierisis cused for [ropller turbines, The efisiency ofa tube turbine wll teone to wo percent higher than fra vertical propeler rine ofthe sre sae ence the water passageway has Tess ange in econ. “The performance rang ofthe tube turbine wit varias epic lads and without wise ats is geater than for fined ble propel surbine But les than for 8 Kepan turbine, The water flow throvsh the turbine s ontalie by changing the pitch of the runner Wades. When it snot reauired to regulate urine discharge and power output. a fixed lace runner may be used. This resus in slower cost ofboth the turbine and fovernor sytem. To estimate the performance ofthe fixed bade runner, se the maximum raed power and tdecharge forthe spprornte et he on he vara pitch blade performance curves Several items of auallary equipment are often necess- ry forthe operon of tube turbines. Al ube tortie ‘wtnou wicket gates shoud be equipped witha shut off Valve avtomately operated to provide shut-off and ‘artup functions. Tube turbines may als be equines ‘vith an sr eatch between the turbine and generator when the generator sno designed fr turbine runaway ‘speed. The clutch Is normally set to disengage at 125 Decent of desig spd and tied to prevent damage 1D the ceuipment irs renavay condition occurs. This ‘spect ie further discussed Sean S. Tote turbines canbe conned ether tothe peertor to spend increase The spot inceaser woud alow ‘he use of higher sped pnerator type 990 o 1200 ‘min instead of + peerator operas at urine seed. “The chor to ule » spe increase’ is wp exonomie ‘exson, Spd incressrs over the overall pat efen- Sty abou one percent fort singe ge fnreser and out two percent for double pear increase. (The manufacturer san supply exact dt eardig he ein (of spent incrensers) This aso enc and the cost (ofthe speed imceaser must be compared 1 the reduction fn ow forthe sales generator. “The required cil features are diferent fr horzontal nls tan for eral unite Horizontally mounted tobe turbines require more foor area than vertically ‘mounted units The af reaured may be lessened by ant outing, Bowever, adiinal tortie costs are Figure 3.3, Fined blade propeller runner, (Courtesy of Jemes Leeland Compasy) ecromeshanicl Festres aM Vol. vIncurred as a larger axial thrust bearing i required Exciation and powerhouse height fre horzontal nit ‘es than that required fr 3 vert! un Sundardzed tube turbines are available fom 4 domestic bine manufacturer. Ten sizes are current, ‘viable with up fo 7000 KW of capacity ad for heads Up to 60 ect. Standsraton should provige lower st ad sorter delivery prods, Fre 3-4 shows the shop assembly of x standardized tube turbine Bulb Turbines. Bulb Turbines are horizontal units whch have propeler runners directly connected tthe senertor. The generator is enclosed in a watrstght Enclosure (bulb) feats in the turbine water passage ‘ray. The bulb turbine is avalable wit xed or viable Pith blades and wih or without a wicket gate nechan ism, Pecformance characters ate sma othe ver Gal and tube type turbines previously discussed. The bub turbine wll have an improved efiene of approx ‘mately we percent overs vertical uni and one perce lover tube unit becouse of he sight water bessnge= wy Due to the compact design, powerhouse Noor space and height for Bulb turbine installations ae minimaed Maintenance time due 1 scesaby, however, may ‘be greater than for ether the vertical or the tbe pe carbines Standardized bulb turbines are offered by some foreign manufacturers Rim Type Turbines. Asim type turbine is one ia which the generator rotor is mounted onthe periphery of the turbine runner lade, Ths turbine has been ‘developed by Escher Wy Li. of Zurich, Swizerand snd: given the name Siro". The concep was ‘developed 40 years apo and approximately 7S uns are ‘ow inservice. Capacities range rom 1000 to 1900 kW ‘heads of 261030 feet. All unis but to date have fe bade proper runner. The existing sea design o leakage of water into the generator anal is eal pe. This design snot sation for variable pitch runer nor for apace ove 2000 KW. A ‘ew sel design hus been developed whch wil permit Escher Wyss to offer units mith runner ameter up to Figure 34. Shop assembly of «standardize tube turbine, (Courtesy of Allis Chalmers Corporation). leevomechanca Features 3s232 fet and ead up 10130 fot. The od ip eal ese tril be used on units with runner diameters of 18 feet (or eat heads of ess than 80 fet, Performance characerisis ofthe Stal turine are simi to those of the bulb unit Rim turbines are ‘offered wth or without wicket gates, and are also aval: ‘ble with partial closure wicket gates, which equ shut ‘of ales as discussed previous. The compact design the Srl turbine provides the smallest power house fdmensions ofall the turbine types considered i this ‘Volume. The Strfo™ design i tractive because of impisiy and compacness, however. the design for large units has ited wplcaon experience ‘Creasflow Turbines, A erosiow turbine may best be leseribod ae an pole (pe turbine with paral ar ‘mission, This ype of turbine offered by Ossberger ‘Turbine Fark Co. of Weirenburg, Germany and has the name “Ossberger Turbine.” Performance characteris ofthis turbine are sir to an impulse turbine, and consist of fat eficeney fare over wide range of flow and head condions. ‘The wide rang ssccomplshed by use of» guide vane {the entrance which dre the flow 10 mites po tion othe unnr depending on the ow. This opertion {ssl to operation of mole impulse turbine Peak efficiency ofthe Crossflow turbine is es than that of other turbine types previously dacusred Guaranteed maximum elfisency 1s 83 percent and expected peak effiency BS percent "At the present time, the largest size runner produced ty Crosow ls 4 fet in diameter. Tis nut he ait fpaciy but mult-onk instalaions are olen used. ‘Allowable heads range frm 20 to 60 feet. bine chamber, Therefore the diflerence between the turbine centerin elevation and the tailvater snot lost {oan Crosfiow turbine asthe case fran impulse tr bine. Air is admited into the chamber through an stable ar flet vale edo contol he pressure CCrosiiow turbines ae fre fom exvitaton, but are suscptble to wear when excessive sito and partes Sein the wnter, Runners wre slfceaning snd. in (ener, maintenance sess complex than fr the other topes of turbines dscussed in this volume. Floor space regurement are more tha for the other turbine sper, bt les complex structure is required fd a svings in cost might be realize, Impulse Terbines. Aa impulse turbine sone having ‘one or more fe as dscharging into an arated space tnd impinging on the buckets of «runner. EMisencies tre often 90 percent and above. Application of the femuls turbine within the eapacty and head range of this volume i ited. In general, an impulse turbine ‘il not be compete in cost wih a reaction turbine Tlow 1000 fest of head, However, cerain hydraulic ‘ondons or surge protection requirements may wa fant investigation into the suitably of nimple tr bine ia the 100 foot range lectromechanial Features M6 Single nozzle impulse turbine nave very fat ef be opersted down 1 leads of 20 cy wth good eine: For mle potzie ans, the range Is even browder Because the ‘numberof operating Jos canbe varied. Contr of the turbine i maintained by hydraulically operated needle norzies in each jt In eatin, a jet elector it provided Tor emerzency shut down. The elector divert the water e fom the bucket to the Sl of the patna This feature provides surge prtee- to forthe pensack without the eed fora pressure oleae valve Beene la ean Be api removed from ‘the senertor without chaning the Now rt Contr ofthe trbine may alto be accomplished by te deflector sone. On these vats the needle nozze is Imanvally operated nd the deflcor divers = porton of {he et for lower loads, This method ess eMient end ‘ormally wed for speed regulon of he arbne under ‘constant os Runners on the modem impulse tubing are « one. pce casting. Runners with individually attached bucketshave proved tobe ess dependable and, on oe fon, have broken sway fom the whee causing severe mage to powerhouse. Inepal cast runners ae ‘ica east, costly and require long delivery times. However muntenance cot ors impulse turbine are Tes than fora reaction turbine a they ate ree of ave tion problems Excessive sll or sand inthe water however, wil use more wear onthe runner of a8 Impule trbin thin onthe runner of most rection turbines raft tubes ae not recur for impulse urine. The runner mst be lested above maximum tallvater to Permit operiton a tmospre pressure. This require tient ceacs an addtional hea low for pulse (ur bine no equted by «reaction turbine. Impulse turbines may be mounted horizontally or vertaly. The edna! Noor space reaie for the horiaontl sting can be compeasated for by lower fenertor conte on ingle nozsle units is the lower ‘apy ies. Veruca units equ less oor space and fe often used for lage eapciy mulenorzle unis, Seleton of Turbine Efficiency Curves General, A calculation af he annual energy must be mace in order 10 determine the fesiity of Idrosacic power insaltion. The eseuation con Sis ofthe product of multlying flow, head and ef ‘Sency overt specie period of me. There ate several methods for eximating the ene. Incuding flow dur thn curves and systematic outing studies that simulate the operation of the plant The simultea operation dis can be performed ether by hand clelton oF ‘more commonly bya iil computer. There are many ‘Computer programs avalble to simulate the operation ‘fa hydfonecrse power plant (Reservoir System ‘Analy for Conserstion = HEC Program) Ifthe hed and discharge ate are elatively constant, vol. van over turbine. generator, sation ve and dtriors Yio, and transformer efficiency of 85 percent can be use for estimating the eneryy fom sow duration curve. Whenever the ow rate and/or te ead varies. ‘more precise analyse ofthe eficency ofthe hyraue turbine is required. A value of 95 percent may be sed forall ther loses including generator sation use snd etrioration and wansforme. Therefore the total + ‘feng to be used in the power operton stds isthe Product ofthe turbine eflensy and al other losses (095) 1fhe turbine and generatorarecoupied together wih e sped increser, the lowes, oer tha thet Wine, maybe estimated 399 percent, ‘Trbine EMiclency Curves. Typical effiincy curves of the various types of turbines ae shown for om ‘rion in Figure 35. These curves are shown lat $e he vraton a effiency ofthe turbine through the load range at the design head, Performance af the various types of turbines when opersted a heads above tnd below design Read ate discussed below Approx imate efficiencies at rated capac fo he reston tu bines ae howe for tarbine ith «throu diameter of ‘one foot. Rated eficeny wil increase a hese of the turbine increases. The bottom curve shows the ation: ship of efficiency to thoat ameter. The ated efien- © for turbines with throat mers targer than one foot may be clelted in accordance with this cure ‘This curve was developed fom model et comparisons with eldest procotyye unis Is common practice {0 apply the stepup value to all efiency valves throughout the operting ane, ‘The efficiency curves shown ae pia expected ef- ences. Actual effieaces ary with manvfacurer and esas Torin the approximate ficiency for resetion t= bin, determine the approximate throat ameter fom Figure 3-6 or 7. nd ad the sie sep op factor fn the otiom curve. Add this tlue tothe cated efiiency ‘aloes ven forthe appropriate turbine pe. Size sep 4p efficiency factors do not apply to impulse or cross Now type turbines The values asshown may be used "Not, that these curves can ony be wed when the head ‘on the turbine does nt vary and ess prec reste are ‘warranted. For more precise els, se the following Section on turbine performance ‘curves, USBR Enginering Monograph No. 20 or onsult with turbine smanutactures ‘Turbine Performance Curves. Figures 3-8 and 39 show performance characteris for Francs. Kaplan ‘arabe pitch blade Propler wih wicket gates) Pro- pelle ined blade with wicket gates) and Tbe (arabe Pitch blades without wicket ates) type turbines. These ‘urves were developed from typical performance curves ofthe turbines of specie spec that mas aerate for ‘he head range consideredin ths volume The dst sed wis obuined from urbane manufacturers” ita and LUSBR Engineering Monogram No. 20. Comparison of performance curves of various specie speed runners ‘ere made und the average performance valu were leeromechanicel Features ” sed. The masimum ero scursatthe lowest Wand ‘as approximately three perent, These curves may be ‘sed To determine the omer output ofthe turbine nd tenertor when the Now rates and heads ste known, ‘These curves are proposed herein because they ae so ly adapted for use in gal computer instead of the ‘ore conventional "contourype" performance cure ‘often found in Iterature on turbines The curves show erent turbine discharge, sQq, versus percent yn {or rain, kW, thouphou te range of operating heads forthe turbine Following. determination of the selected turbine capacity as discussed in Secon 2, the power ouput st heads and lows above and below rated Red (4) and Nlow (Qq) may be determined from the cures folows Caleta the rated dichary Qy using the efcien- values ascused previously Oy = (UBL RW) / UH RXERXED, (8) Compute the percent dachrgs, Oy and per ent head, “6H, for the various ow and Read ‘quirements afhe ste 8Qx = (0/0q) x10. SSH = (HUH) 100, (8) Enter the curves with the Qp and find the SGkW on the appropiate Hy. ine. Calculate the P= Wa) 0K. (kW) ‘The heavy lines at the border of he curves represent limits of satsfactory operation within normal indstty ‘maximum recommended capac at ted capac. The “urbine can be operated beyond thse pte openings however. aviation qusantes generally 200898) beyond hese points The botlom boundary Hine repre sents the limit of sable operation. The bot lis ‘ary with manufacturer Reaction utbines experience ‘ough opeation somewhere between 201040 percent of fated discharge with iteton and/or power surge It deat prec the magnitude nd rang ofthe rough ‘opertion asthe water pssagemay configuration of the Dowerous aes this conden. Where operation is Feauired at lower output. saghtening vanes canbe Placed inthe daft tbe Seow the sachare ofthe ae ero minimize the magnitude of the asturtance ‘These modifeatons reduce the effcency a higher loads. The right-hand boundary is established from Sandard generator guarintces of {1S percent of eaed Capacity, The Read operation Soundanes re pc however they do vary wth manufacturer Is deemed ‘hat thes yp performance curves are satisfactory Tor prekminary fesibityasersments, When the Q fora particule selection is beyond the curve boundaries, generation Is limited fo the m= imum S6kWs for the iy. The excess water must be bypassed. Whea the Sus Below the boundaries, no vol. ¥8 Eq288% 8 SE 9=90% Ep288% 8 40 60 80 RATED CAPACITY (%) 3 2 3 a B 20 = 2 2 2 45 6 7 8 9 10 TURBINE THROAT DIAMETER (FT) ores: 1. &q = Turbine Efficiency at rated output, Hl, and head, Hy 2. The values shown are typical for a turbine with a | foot Gianeter runner. The values shown in the size step up curve nay be added to the E_ values for larger units. Values apply for Francis, fixed and variable pitch propeller, tube, slant, bulb and rim turbines. Do not apply step up on’ Impulse or cross Flow turbines. Figure 38. Turbine efcieny curves lecomechancal Features a8 vol. v_° g : 6 GENERATOR RATING # o Z = a g g = = 2 « 5 2 1 5 60 80 100 150 200 300 TURBINE EFECTIVE HEAD (FT) ores: 1. “The approximate throat diameters are based upon typical values for the turbine set with the centerline of the runner at minimum teil water elevation. Actual diameters vary with turbine menu factuers. ‘The estimated diameters may be used for vertical or horizontal Francis turbines. Figure 3.6. Francs turbine throstcamters lecromechanicl Features a Vol. v18 20 30 40 60 80 100 TURBINE EFECTIVE HEAD (FT) notes: 1. The approximate throat diameters are based upon typical values for the turbine set with the centerline of the runner at minimum tail water elevation. Actual diameters vary with manufacturers: The estinated diameters may be used for both Fixed and variable pitch propeller turbines, vertical, tube, slant, bulb and rim types. Dinensions for standardized tube turbines are shown on 2 Separate sheet. Figure 37, Propeller rrbine trot diameters lecromesheicl Festures a0 vol. vVERTICAL OR HORZONTAL FRANCIS TURBINE & 2 8 8 RATED DISCHARGE ,Q, (%) 38 3 20 30 40 50 60 70 80 90 100 IO RATED GENERATOR CAPACITY, KWp (%) VARIABLE PITCH PROPELLER WITH WICKET GATES VERTICAL TUBE ,BULB OR RIM 3 8 3 = ¢ 4 z 2 8 8 & é 8 30 40 50 60 70 60 90 100 110 120 RATED GENERATOR CAPACITY ,KWp (%) ig = Hy Oy Eq Eg/T1-81, (KM) 8 fated capacity at Hy Selected Design Head, (ft.) ‘Turbine Discharge at Hp & hig. (cfs) Turbine effictency at Hy & Kis (8) Generator efficiency, (2) Figure 38. Francis and Kaplan performance curves lectomechanical Features su vol. ¥VARIABLE PITCH PROPELLER WITHOUT WICKET GATES VERTICAL, TUBE ,BULB OR RIM RATED DISCHARGE ,Qy (%) 3040 50 60 70 80 90 100 10 RATED GENERATOR CAPACITY, KWe (%) FIXED BLADE PROPELLER WITH WICKET GATES VERTICAL, TUBE, BULB OR RIM %e) a 8 6 8 0 30 «4080 60 70 80 90 100 0 RATED GENERATOR CAPACITY, KWa (%) Hig Hy Oy Eq g/M16 81, CK) & = a o e & g € we = Rated capacity at Hy = Selected design Head, (Ft.) = Turbine Discharge at Hy & hips (cfs) = Turbine efficiency at Hy & Hig, (8) = Generator efficteney, (2) Figure 3.9, Propeller turbine peefrmance curves lecromechuncal Features vol. vpower can be generated. When the Sly i above or below the boundaries, no power ean be generate. Tre optimum number f turbines may be determined bye ofthese curves for an snnusl power computation ipower being Tost because the Mus comity below the lower boundais, the annual power produced Dylowering the KW rating ofeach unit and sang unit shouldbe computed Ifthe power increase is substan- tial an appronimat urine cost ofthe aerastives may be approximated rom the turbine cots coves imcremental inrease ia cost er Wh compared If he total constuction cost ofthe powerhouse asumed 0 roughly equal the cost ofthe turbine and generator. he ‘st per kWh derived sbove can be doubled and com red ith the Rasncial ale ofthe enery I the sles- Hi of more turbines sams favorable rom this cll tion, it shouldbe pursued in further det with more curate states. Conversely, the fst selection of the ‘number of turbines may be compared with lesser ‘numberof units and compared ons ost per KWh basis 1 dererbed above. Flowing the establishment ofthe number of unis, ‘the rating point ofthe turbines can be optimized. This eneraly is don aller an estimate of the total project ost have been made. Ang power production of r= ‘ines having a higher ating ands lower rating should be ‘alcalated and compared tothe annual power produc: ‘on ofthe trbine selected. With the annual cst et ‘mate, a cost per KW may be calculated forthe selected ‘uroine. Total projet costs forthe lower and hisher ‘ect ratings maybe estimated by corecting the ur ‘ine/generatr cons rom te cost char and correcting ‘he remaining costs on a bass oa constant cost per KW ect. Rats of incremental cost vide by incremen {al energy generuton inisteeconomi easily. Aa fan example fa comemplated capac increase would produce 1,000,000" kWh per year and would cost $20,000 per sear ia debt service and operation and ‘maintenance, the ierementl com of enera 20 mils) Wh. IF energy is worth more than this the capacity increases use ‘The rated head of the turbine canbe further refine by optimization ina similar manner. The annual power production s computed for higher and lower heads with ‘sume capacity rating The rated head yielding he highest snnul output shoud be used The boundaries established on these curves are tpi= cal, Should eneray ouput of particular site be cur led tis suggested that turbine manufacturers becom. sulted as these boundaries can be expanded unr cet- ta condions. Standardled Tube Turbine Performance curves for the ll-Charmer unite are shown on Figure 310, The ‘tine procedure for selection of turbines previously descrited is anpiable for tube turbines, Flowing Selection of the size, Figure 311 may be ured for fstimating power over the range of Now and head lecvomechanicl Features Dimensions of Turbines General, The size ofresstion turbines may be ete ‘mated afer the capa, KW. and effective head have oun established. Figure 3:4 shows the approximate ‘yout dameter of Francis turbines, both vers! and horizontal, Figure 3-7 shows the approximate threat diameter for Propel turbines and’ may be used for ‘both Fixed and vale pth lage unis, vertical tubo bor rim pes. Othe dimensions ofthe turbine ‘may be found ia Volume Vi Civil Festus. These fdmensions ate suitable for testy assessments, ‘Actual dimensions vary with manufoturer and should te obtained fom the manufacturers for final sng studies Dimensions of Standardized Tube Turbine. Dimen- sions of the Ali-Chalmers units re shown n Figure 3: ir Dimensions of Impulse and Crossflow Turbines, ‘These turbine dimensions ae nt provided. Manufae- turers shouldbe conaried and dimensions requested ‘when the aplication is suitable fr these types of tar- es. ‘Turbine/ Generator Cots General. Chars have been prepared forthe various \ypes of turbines and: generators considered la this ‘volume. The dts used'to prepare thse chars were Obtained from turbine, generator and governor ‘manufacturers over the past ive years and escalated 10 Sly 1978 price level. Priests ae not avaible on a ‘ines as moe turbines ave custom dein. In gener {urbe and peerator costs per installed kW decease a the capacity‘ the unit increases. However, the effer- lence on the cost The tower the hen, the higher the ost pr installed KW. This increase is due to the larger Size and lower synchronous sped turbine required for {he low head splation. The cost carves are sutble India the eat of project. However, tis recom. ‘mended that pies be fequesed from manuftrers ‘when final feasiity studs are made. Ii lo sug {sted that firm bids be received onthe turbines 0d feterators prior othe final design ofthe powerhouse ‘The ids would permit competion between the vsous ‘ypes avalible and an evaluation of the overall yer tion cost be made intuding cv costs and average annual energy generation, ‘Turbine/ Generator Cost Curves. The cont curves Inctasd in ths volume are follows: ‘Tasbine Type Figure No. Vert & Horiontl Francis T2 Vera Kaplan (Variable Pich Propet) 3-13 Standareied Tube sie Bb and Rim xis Cross Flow 316 Turbine Manufacturers. Exhibit 1 tt of ‘manufactures which design smal hydroelectie tu ines within the capacity ange of his volume, sD vol vfo Baa ee rae PE TT Setanta Stine a Moone ee Figure 310, Als Chalmers standardiaed Tube turbine performance curves lecromechanil Features a Vol. v‘= Pare Saa nin ce = 120 ‘At ctr mento ren Poporion rom ara lamear ith aa ca cin ca (ray Ga Ge cence, gio ese as ear nae Hae a 2002992608 339 950357 Ee Figure 3-11. Als Chalmers standard tube turbine dimensions lecvomechuncl Features ais vol. vMw GENERATOR RATING 3Mw g 3 3 3 2 & 3 3 = 3 g 8 a & 2 1.3MWw iw 150 OS MW 60 80 100 150 200 300 TURBINE EFFECTIVE HEAO (FT) noTes: 1, Estimated costs are based upon a typical vertical turbir direct coupled to the generator. Cost includes turbine, generator, exciter, inlet valve non speed regulating governor and Installation. Installation costs estimated at 15% of total equipment cost. ‘Add $60,000 for speed regulating governor. Horizontal Mounting Deduet 7%. Cost Index is July 1978. Figure 312, Francis turbine costs lecvomechanical Features 516 Vol. v8 GENERATOR RATING 3 8 g Z 3 8 3 i g z 5 8 5 8 8 20 30 _40_50 60 7080 100 TURBINE EFFECTIVE HEAD (FT) Notes: 1. Estimated costs are based upon a typical vertical Kaplan turbine with concrete spiral case direct coupled to the generator. Gost includes turbine with adjustable blades and wicket gates, generator exciter, speed regulating governor and instal lation. Instal lation costs estinated at 15% of the total equipnent cost. For fixed blade Propeller turbine deduct 10%. Cost Index is July 1978 Figure 3:13. Vera! Kaplan and Propeller costs lecromechanicl Features sa vol. vGENERATOR RATING @ 2 5 g ¢ : i : 2 z 5 8 i 5 < 0 15 20 30 40 50 TURBINE EFFECTIVE HEAD (FT) Estimated costs are based upon standardized tube turbines coupled to the generator through a speed increaser. Costs include turbine with variable pitch blades and fixed guide vanes, inlet Butterfly Valve, air clutch, speed increaser, gen erator with exciter, speed regulating governor, controls and Installation, Installation costs were estimated at 15% of total equipment costs. Deduct $27,000 for Fixed blade type. Cost Index’ is July 1978 Figure 314. Sandurd Tube turbine sess leczomechancl Festures 3 vot. vGENERATOR RATING 1000 900 800 | 700 = = 600 tw i820 2530 40 5060 TURBINE EFFECTIVE HEAD (FT) @ & i g 3 3 3 8 g 2 E g 3 & 5 Notes: 1. “Estimated costs are oased upon typical-horizontal bulb turbines with variable pitch blades and wicket gates direct coupled to the generator Cost includes turbine, generator, exciter, speed regulating governor and instal lation. Instal lation costs estimated at $250,000 for the large units, to $75,000 for the small units For’ fixed blade units, deduct 108. Cost of rim turbines are approximately the sane as bulb turbines and the above chart may Se used for preliminary costs of sane. Cost Index is July 1978 Figure 318, Bults and Rim trtine costs Elecomechancal Features a vol. v« s g @ & z 3 3 0.25 MW 20 30 40 5060 80 100 180 200 300 TURBINE EFFECTIVE HEAD (FT) notes: Estimated costs are based upon a typical single turbine direct coupled to the generator at high heads and coupled through a speed increaser at low heads. Costs include turbine, generator, exciter, inlet valve, fon speed regulating governor and installation. ‘Add $60,000 for speed regulating governor. Cost Index is July 1978 Figure 316. Crossfiow turbine cots lecemechanical Features 220 vol. ¥