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Development of sand erosion resistant 20 kW micro- hydro class cross- flow turbine and its site demonstration in Nepal View project
Development of sand erosion proof 20 kW micro- hydro class cross- flow turbine and its site demonstration in Nepal View project
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Original Paper
Ravi Koirala, Sailesh Chitrakar, Hari Prasad Neopane, Balendra Chhetri, Bhola Thapa
Abstract
Bifurcation refers to wye division of penstock to divide the flow symmetrically or unsymmetrically into two units of turbine
for maintaining economical, technical and geological substrates.
Particularly, water shows irrelevant behavior when there is a sudden change in flow direction, which results into the transition
of the static and dynamic behavior of the flow. Hence, special care and design considerations are required both hydraulically and
structurally. The transition induced losses and extra stresses are major features to be examined.
The research on design and analysis of bifurcation is one of the oldest topics related to R&D of hydro-mechanical components
for hydropower plants. As far as the earlier approaches are concerned, the hydraulic designs were performed based on graphical
data sheet, head loss considerations and the mechanical analysis through simplified beam approach.
In this paper, the multi prospect approach for design of Bifurcation, incorporating the modern day’s tools and technology is
identified. The hydraulic design of bifurcation is a major function of dynamic characteristics of the flow, which is performed with
CFD analysis for minimum losses and better hydraulic performances. Additionally, for the mechanical design, a simplified
conventional design method as pre-estimation and Finite Element Method for a relevant result projections were used.
Keywords: Hydraulic Design, Mechanical Design, CFD
1. Introduction
Bifurcation of Penstock in the Hydropower plant is used to divide the flow into the two units for power generation. This
division can be either symmetric or unsymmetric. The symmetric refers to the equal division of flow and unsymmetric refers to
the unequal division of flow. The angle of bifurcation, losses due to it and structural support in the intense diverted velocity
directions are some of the critical approach in its design. They are usually installed near the powerhouse where the maximum
possible pressure prevails i.e. the static pressure and the surge pressure, which have an extra ordinary hydraulic and mechanical
behavior related to vibration, power swings, propagation of pressure hence both the considerations are important. [1]
In this study, an under construction site, Daraudi Khola Hydropower Project in Gorkha district of Nepal has been taken as the
design case. The detail specification regarding the site is mentioned in the table
Received June 9 2015; revised July 2 2015; accepted for publication October 17 2016: Review conducted by Yoshinobu Tsujimoto.
(Paper number O15026J)
Corresponding author: Ravi Koirala, ravikoirala@ku.edu.np
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Designs of the water convey system usually comprises of the hydraulic and mechanical geometries. Most the small
hydropower plants during their design phase prioritized the mechanical strength design in the case of branching. However, both
mechanical and hydraulic issues are equally important in ensuring the hydraulic function and mechanical rigidity of the system. A
series of design process for a hydraulically efficient and mechanically rigid bifurcation system was designed in this study.
Penstock bifurcation requires special design that is unique from project to project. [2]
The nature of flow and the changes after the division is one of the major hydraulic behaviors in the conduit. The vibration
problems caused due to unnecessary eddies developed can cause huge head losses. These losses will decrease the potentiality of
the plant. Malik et. al. in 2009 explained the importance with Computational analysis of hydraulic behavior in Trifurcation for
Madi Khola Hydropower Project, Kaski Nepal probably for the first time in Nepal. [4]
The stress magnitude in a pipeline is usually 3–9 times greater than in regular pipeline shells. For this reason special
reinforcements are provided in order to decrease the stress concentration in crucial spots. The penstocks of hydropower plants
built in the first half of the twentieth century are rarely equipped in such kind of reinforcement. The lack of reinforcement can
result penstock failure, especially under sudden pressure rise conditions. The rupture of the penstock at Lapino Power Plant,
Poland is an example of the stress induced failure caused by improper design. [5]
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power generation system and may result in lost generating revenue or in the case of pumped storage projects, additional pumping
costs.
Angle of bifurcation, ratio of cross sectional area, type and shape of bifurcation, flow, velocity and Reynolds’s number are some
of the major factors governing head losses. Approximation of these parameters using set of equations at two dimensions may not
be relevant to determine the effectiveness.
So far the practices are concerned, often hydraulic design (angle) of bifurcation are prepared based on the flow ratio referencing
the graphs resulted from various researches. In some cases the graph may give a valid bifurcation angle (but it’s rare the cases
match) but many others were designed on larger hydraulic losses. Based upon the series of experiments, graphical representation
of the losses has been prepared.
Graphical representation from the Miller experiments and Munich test are some of the major representations. Fig 2 shows the
representation from Miller’s experiment.
Fig 2 Miller's Plot for Head Loss Coefficient in Symmetric Bifurcation [7]
After the predetermination of the size of computational model, mesh on the geometry of each angle from 45o to 70o was
performed to determine the point of minimum head loss. Definition of the domain, boundary conditions and solver parameters are
defined in Table 2.
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Table 2 Boundary conditions and fluid features for CFD analysis
Domain Definition
Fluid Water
Density 1000 kg/m3
Morphology Continuous fluid
Domain motion Stationary
Turbulence Model Shear Stress Transport [8]
Boundary Conditions
Inlet
Pressure 624000.366 Pa
Outlet 1
Mass flow rate 5682.9 kg/sec
Outlet 2
Mass flow rate 5682.9 kg/sec
Wall Features
Mass & Momentum No Slip wall
Wall roughness Smooth wall
Analysis type Steady State Analysis
Convergence Control
Min Iteration 1
Max Iteration 200
Convergence Criteria
Residual type RMS
Residual target 10 e-5
The head loss was determined by the Equation 1 for different angles. [9]
P V Pouti V
hli = in + in − + outi (1)
ρ × g 2× g ρ × g 2× g
From the analysis at varying angle of bifurcation, it has been found that the minimum head loss is at 51o and other head losses
were in irregular pattern. Angle of bifurcation is dependent on site and has no empirical relationship for least loss. The hydraulic
behavior of water in a flow conduit system is dependent on static and dynamic conditions of flow along with the geometry, the
deviation may result into the formation of vortices and turbulence in the wye. Hence, at the particular condition of 63.8 m head
and 11.32 m3/s flow, water exhibits best possible behavior at 51o. The selection process also largely depends on the geometry and
the allowable length from turbine unit to the point of manifold based on civil constraints. Fig 4 is the pressure and velocity plot in
the bifurcation with angle 51o. The velocity at the inlet to the turbine is around 2.5 m/s, which eventually reaches to 6 m/s at the
inlet of the spiral casing. The pressure generated from Fig 4 can be used in the structural analysis, but the actual design is
performed on maximum head considering surge.
Fig 5 represents the flow in the mid plane of the bifurcation. It depicts the operational scenario and location for the need of
special considerations during structural design. The point of division has wall and hence, faces the higher pressure of 6.24×105
Pascal in the region. Similarly, all points where the cross section gradually changes has variations in the flow property. The free
stream of flow can also be seen in the contour plot.
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Fig 5 Pressure distribution in the central plane and the point of maximum pressure
Fig 7 Pressure distribution at the plane before and after closure of Outlet 2
This analysis was performed noting the velocity and pressure conditions at outlet 1, outlet 2 and plane at the region of division.
During the analysis, outlet 2 was closed and the observations were made. It was found that there has been significant change at the
point of division, which was slowly balanced by the length of the flow as it reached to a distance of 5000 mm from point of
division. Fig 6 shows the flow property distribution and Fig 7 shows the pressure variation before and after closure of single unit.
The head loss in case of single unit operation is 9.21 mm which is comparatively higher due to the effect of the accumulated water
at the point of division.
The backgrounds like material properties and fluid properties were identified prior to the analysis. The Indian Standard
guidelines for the selection of the material, its allowable stress and corrosion allowance have been allocated. Table 3 shows the
background for the analysis.
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Table 3 Structural Properties for analysis
A penstock wye or branch connection usually has several stiffening beams to resist the loads applied by the shell of the pipe.
The method incorporated rib shortening, shear deformation of the stiffener beams, and variable flange width. Although valid, this
systematic design process is not efficient considering available modern computing methods. However, a spreadsheet can be used
to drastically cut down the time involved with this design method.
To analyze the wye and branch connections using beams, many simplifications and approximations are used [6]. The localized
effect of structural discontinuities, restraints of the stiffening beams, foundation support, and dead load of the water filled pipe are
neglected. End load effects and conicity of the outlet pipes are also neglected and considered to be small in comparison to the
vertical load on the beams. Here a finite certain sections are considered and computation is prepared based on this approach. This
analysis also includes this approach of approximation.
The prime design processes include the deflection of the members AO and BO at point O is equal from Fig 8. This computation
was performed considering the uniformly varying load on symmetric section as shown in Fig 9.
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Fig 9 Simplified beam method for computation of the stiffener
The finite element analysis design method provides a more complete representation of the penstock shell – stiffener system. It
is becoming the standard design tool for penstock wye design in the hydropower industry [2,4].
The minimum shell thickness was determined using the analytical methodology for pre-setting the computational limit. Based
upon which 3D CAD was developed to perform the unstiffened structural analysis for locating the critical locations with
maximum stress and deflection. The analysis was performed locating the maximum internal and external pressure at the inlet and
outlet. Although it is Fluid Structural system, the resultant force caused by surge exceeds the designed phenomenon hence design
for maximum is important but the results and analysis in terms of stress and deformation are the similar phenomena. The
computational models were applied with the load at different stiffened conditions and resultant Von misses stress and deformation
were observed. [13]
The primary dimensions were then modified to counter act on the resultant deflections and stresses. The result was obtained
with iterative computation of the stiffer and girdle rings. The main constraint for the selection of the size of the support was the
site consideration.
Figure 10 shows the result of the finite element analysis. After an iterative computation for the sizes, 20 mm thickness at the
point of division, 26 mm girdle thickness and 16 mm pipe thickness in the branched segments were identified. Both the
manufacturability and the performance were considered during the analysis. Finally maximum stress of 100.97 MPa was noted
which is below the allowable stress derived in Tables 3.
During the analysis, simplified beam approach and analytical design methodology were used for assumption of the external
reinforcement geometry and determining the minimum thickness. Numerical simulation aided the reliability of the design by
visually expressing the critical locations and ascertaining the strength of the multiple reinforcements in the system, which is not
possible with single method of design. No comparative study has been performed; rather an integrated approach selecting the
reliable processes excluding major approximations was implemented.
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4.3 Manufacturing and Installation
The design was manufactured by Machhapuchhre Metal & Machinery Works, Pokhara. Fig 10 are some of the photos taken
during manufacturing and installation.
5 Conclusion
Improvising the design practices for realistic results and overcoming the possible circumstances is the present day need.
Hydropower has been a reliable green energy source, in which, a large sum of investment, lots of time and intellectual minds are
invested. Hence, an optimum economical design for the reliability of plants is important.
Practices changes with time, but past references are always required. Present day computational facility eases the design
process excluding the tedious iterations involved in it. Selection of angle of bifurcation has always been a major issue which is
solved by this computational facility additionally the conventional calculation of the support in two dimension increases the risk.
Hence the major conventional design procedure with the modern day’s tools and technology will surely aid in strengthening the
reliability of design.
Acknowledgments
The authors acknowledge Nirvana Tech Engineering Solution Pvt. Ltd., Kathmandu and Turbine Design Services Pvt. Ltd.,
Lalitpur. We also extend our gratefulness to all the members of Turbine Testing Lab and Darundi Khola Hydropower Project for
the help, suggestion and guidance during the activities.
Nomenclature
hli Head loss at branch i Pouti Average pressure at outlet in branch i
Vin Average velocity at inlet g Acceleration due to gravity
Vouti Average Velocity at outlet in branch i ρ Fluid Density
Pin Average pressure at inlet σall Allowable stress
References
[1] F. Flemming, J. Foust, J. Koutnik, R.K. Fisher, 2009, “Overload Surge Investigation using CFD Data ,” International Journal
of Fluid Machinery and Systems, Vol. 2, No. 4, pp 315-323.
[2] J. H. Bambei, 2012, “Steel Penstock,” Ed. 1 ASCE Publications.
[3] K.S. Ltd.,2012, “Technical Highlights Vol. 5” Retrived 2014, from KOBE:
http://www.kobelco-welding.jp/education-center/technical-highlight/vol05.html
[4] R.K. Malik, P. Paudel, 2009, “Flow Modeling of the first trifurcation made in Nepal, Hydro Nepal: Journal of Water, Energy
and Environment, Kathmandu, Nepal,” Vol. 5, pp.
[5] A. Adamkowski, 2001, “Case Study: Lapino Power Plant Penstock Failure,” Journal of Hydraulic Engineering, Vol. 7, pp. 547-
555.
[6] A.W.W.A. Staff, “Steel Pipe: A Guide for Design and Installation” Ed: 4, American Water Works Association.
[7] D.S. Miller, 1990, “Internal Flow Systems 2,” Cranfield: BHRA.
[8] S. Chitrakar, M. Cervantes, B.S. Thapa, 2014, “Fully coupled FSI analysis of Francis turbines exposed to sediment erosion,”
International Journal of Fluid Machinery and Systems, Vol. 7, No. 3. pp. 101-109.
[9] C.A. Aguirre, R. G. R. Camacho, “Head losses analysis in symmetrical trifurcations of Penstocks – High Pressure Pipeline
Systems CFD,” AGHEM.
[10] Bureau of Indian Standards, 1995, “Pressure Vessels”. IS 11639-2.
[11] Bureau of Indian Standards, 1969, “Code for unfired pressure vessels,” IS 2825.
[12] American Iron and Steel Institute, 1998, “Buried Steel Penstock”.
[13] X. Huan, L. Houlin, T. Minggao, C. Jianbao, 2013, “Fluid-Structure Interaction Study on Diffuser Pump With a Two-Way
Coupling Method” International Journal of Fluid Machinery and Systems, Vol. 6, No. 2, pp. 87-93.
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