International Journal of Trend in Scientific Research and Development (IJTSRD)

Volume 3 Issue 5, August 2019 Available Online: www.ijtsrd.com e-ISSN: 2456 – 6470

Design Calculation of 40 MW Francis Turbine (Runner)

Kyi Pyar Oo, Khaing Zar Nyunt, Ei Cho Cho Theik
Department of Mechanical Engineering, Technological University, Toungoo, Myanmar

How to cite this paper: Kyi Pyar Oo |

ABSTRACT
Khaing Zar Nyunt | Ei Cho Cho Theik
A water turbine is one of the most important parts to generate electricity in
"Design Calculation
hydroelectric power plants. The generation of hydroelectric power is relatively
of 40 MW Francis
cheaper than the power generated by other sources. There are various types of
Turbine (Runner)"
turbines such as Pelton Turbine, Cross-flow Turbine, and Francis Turbine
Published in
which are being used in Myanmar.
International
Journal of Trend in
In this paper, one of the hydroelectric power plant which is used Vertical
Scientific Research
IJTSRD26412 Francis Turbine type. The Francis turbine is one of the powerful turbine types.
and Development
Francis Turbine is a type of water turbine that was developed by James
(ijtsrd), ISSN: 2456-6470, Volume-3 |
Bicheno Francis. Hydroelectric Power Plant, Thaukyegat No.2, is selected to
Issue-5, August 2019, pp.635-639,
design the runner. This Vertical Francis Turbine is designed to produce 40 MW
https://doi.org/10.31142/ijtsrd26412
electric powers from the head of 65 m and flow rate of 70.10m3/s. The design
parameters of 40 MW Vertical Francis Turbine runner’s diameter, height,
Copyright © 2019 by author(s) and
elevation, shaft, numbers of blades and blade angles are calculated. The initial
International Journal of Trend in Scientific
value of turbine output is assumed as 94%. The number of guide blades and
Research and Development Journal. This
runner blades are also assumed. The detailed design calculations of the runner
is an Open Access
are carried out. Moreover, the selection of the turbine type according to the
article distributed
head, the flow rate and the power are also performed.
under the terms of
the Creative Commons Attribution License
(CC BY 4.0) KEYWORDS: Hydropower plant, Francis turbine, Head, Blade
(http://creativecommons.org/licenses/by
/4.0)
I. INTRODUCTION
Francis Turbines are almost mounted water from the shaft turbine. It must be assumed that friction is neglected and
vertical to isolate water from the generator. Hydropower, fluid has the guidance through the turbine. That is, the
also known as hydroelectric power, is a reliable, domestic, infinite number of vanes and relative velocity of the fluid is
emission-free resource that is renewable through the always tangent to the vane.
hydrologic cycle and hardness the nature energy of flowing
water to provide clean, fast and flexible electricity. It is a A. Hydropower Plants
clean form of power generation. Water is a natural source of A Hydropower Plant requires no fuel and it is much simpler
energy to produce electricity. Water flowing under pressure to operate and maintain. Therefore the operating costs of the
has to forms of energy: kinetic energy and potential energy. Hydropower Plant are much less than a thermal power plant.
The water or hydraulic turbines convert this kinetic and Hydropower plants can be classified by many different
potential energy into mechanical power. Hydraulic turbine aspects. This classification is according to the working of
runners can only be performed by numerical methods due to hydropower plants, for example, they can by classified be the
the complexity of these structures. The flow in hydraulic source of the water itself and by their construction or their
turbines of the Francis type is quite complicated due to its turbine. Water power is one of the major sources of energy.
three-dimensional nature and the curvature of the passages The other sources of energy being developed by water
between runner blades. power are one of the major sources of energy. The other
sources of energy being developed by fuels such as coal, oil,
II. Design Consideration of Francis Turbine etc., and nuclear power are used for energy. These are some
The expression for the power delivered to the shaft by of the conventional sources of energy.
passing water is the same for all type of reaction turbines. In
this case, it is necessary to use velocity diameter and B. Classification of Hydropower Plants
moment of momentum equation (Euler’s Equation) to There are several classifications of related to the dimension
calculate the power and efficiency of the inward flow of Hydropower Plants. Hydropower Plants can be classified
turbine. It must be assumed that friction is neglected and into the following
fluid has the guidance through the turbine. That is the 1. Large Hydro: 100MW to 1000MW
infinite number of vanes and relative velocity of the fluid. 2. Medium Hydro: 15MW to 100MW
The expression for the power delivered to the shaft by
3. Small Hydro: 1MW to 15MW
passing water is the same for all type of reaction turbines. In
this case, it is necessary to use velocity diameter and 4. Mini Hydro: 100kW to 1MW
moment of momentum equation (Euler’s Equation) to 5. Micro Hydro: 5kW to 100kW
calculate the power and efficiency of the inward flow 6. Pico Hydro: Fewer Watt to 5kW

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
C. Types of Hydropower Plants Table1.Turbine Selection (Head-Output)
There are different types of Hydro Power Plants based on Turbine Effective Power
types of facilities for the generation of hydropower. Types Head(m) Output(kW)
Construction of large Hydropower Plants is a practical and Horizontal
economically viable proposition as the capital costs of a Over 75 100 ~ 5000
Shaft Pelton
project can be reduced with such installations. Hydropower Vertical Shaft
Plants may be classified in different ways depending on the Over 200 Over 4000
Pelton
certain classification. They are Horizontal
1. Reservoir or Storage Type 17 ~ 300 400 ~ 5000
Shaft Francis
2. Run-of-River Type Vertical Shaft
3. Pumped Storage Type 40 ~ 300 2000 ~ 20000
Francis
Cross Flow 7.5 ~ 100 50 ~ 1000
D. Main Components of Francis Turbine Kaplan 10 ~ 70 Over 100
Francis Turbines are the medium head type of hydraulic Conduit Type
turbines, having stationary (Spiral casing, Stay Vanes and 5 ~ 20 Over 1000
Bulb
Guide Vanes) and rotating component. There are several Package
components of Francis Turbine. 5 ~ 18 150 ~ 4000
Type Bulb
They are
1. Spiral casing
Table2. Relation between Water Temperature and
2. Stay ring
Standard Stream Pressure
3. Guide vanes
Water Temperature Saturated Steam
4. Runner
(C) Pressure (m)
5. Draft tube
0 0.05
6. Shaft
5 0.09
10 0.13
15 0.17
20 0.24

Table3. The relation between Elevation and

Atmospheric Pressure
Elevation(m) Pressure (Atm)
0 10.33
100 10.21
200 10.09
300 9.97
400 9.35
500 9.73
600 9.52
700 9.50
Figure1. Francis Turbines
800 9.39
900 9.27
III. Design Theory of Francis Turbine
1000 9.16
Francis Turbines can be arranged in two ways; with vertical
shaft and horizontal shaft. The vertical shaft arrangement 1100 9.05
requires the minimum space for installation and therefore 1200 8.94
permits the smallest area powerhouse.
A. The efficiency of Francis Turbine
It is not only more economical in space, but in many cases, it The expression for the power delivered to the shaft by
is the only practical solution for large machines, especially passing water is the same for all type of reaction turbines. In
when the topographical nature of the site limits the size of this case, it is necessary to use velocity diameter and
the powerhouse. moment of momentum equation (Euler’s Equation) to
calculate the power and efficiency of the inward flow
By setting of the turbine is meant the location with respect to turbine. As an assumption, it must be assumed that friction is
the head and tailwater level. Referring to Figure3.4 and neglected and fluid has the guidance through the turbine.
equating the energies of flow at the exit end of the runner to That is, the infinite number of vanes and relative velocity of
the energy of flow at the exit end of the draft tube. The result the fluid is always tangent to the vane, Steady and one-
of the various condition of head, speed and capacity are that dimensional flow concept is used for calculation.
runner of low speed and capacity are generally demanded P = Elemental mass x Tangential velocity
under the high head, while runner of high speed and capacity P = d m  V1cos α1  r1
are necessary under the low head. Similarly,
T2 = d m  V2cosα1  r2
Tm = d m (V2cosα1r1 )  r2

= m(V1cosα1r1  V2coscosα 2 r2 )
Tt

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Power equation is A. Low-Speed Runner
Power = Torque Angular Velocity B. Medium Speed Runner
C. High-Speed Runner
Power = m  (V1 cosα 1 r1  V 2 cosα 2 r2 )ω D. High Speed- High Capacity Runner
V1cos α1 = Vw1 & V2 cosα 2  Vw2
C. The setting of Turbine Draft Head
U1 = r1ω1 & U 2  r2ω2 By setting of the turbine is meant the location with respect to
From above the relations, the equation of power is the head and tailwater level. Referring to and equating the
energies of flow at the exit end of
Power = m(Vw1U1 ) the runner to the energy of flow at the exit end of the draft
Above equation can be changed by tube.
2
UVw1 P2 V22 Pa Vf
ηm =   Z  Hs   Z  H1
gHd W 2g W 2g
=
Where,
Where, h is hydraulic efficiency of turbine.
B.P H 1 = Energy lost in friction during the passage of water
W
 UVw1 through the draft tube
h = g
H 1 = Elevation of existing of the runner through the draft
Further the overall efficiency is, tube
η0 ηm  ηh Z = height of runner bottom above any assumed datum
= P2 =Pressure of exit section of runner
B.P UV
 1 w1 Pa = Atmospheric pressure
W gH d
η 0 g  UVw1
= Since the flow through the draft tube is turbulent, the friction
B.P
η 0 = WHd V2
in the draft tube is proportional to 2 . Also, velocities at the
various section of the draft tube are proportional to V2 since
W = γ.Q the profile of flow is fixed.
B.P
η0 γQH Thus,
= d
p2 Pa V2
 H s  2 (1  K)
Where, W = W 2g
B.P = Power of the turbine in kW Where,
η0 2
=Overall efficiency H 1  (V2 )
3 2g
Q = Flow rate through the turbine in m /sec
V22
3 ( )
λ = Specific weight of water in kN/ m K = 2g
Hd = Design head in m
ηd = efficiency of the draft tube
B. Runner Design as Affected by Speed and Capacity V22
H a  H s  ηd
Head and available rate of flow varies widely among power H2 = 2g
plant. Generally, large flow rates accompany with low head
relatively small rates of flow are available at high heads. Where,
Because of the difference in flow rates, low head usually σ = Thoma’s cavitation coefficient
requires runner of large water capacity and high head
required runner of low capacity. Accordingly, the runner
may be again classified as being of high, low and medium
capacity, and the term may refer to either the discharge rate
or the power output since the latter is a function of the
discharge.

Figure3. Static Draft Head and Various Type of

Turbines

D. Specific Speed
Limit of Specific Speed,
N sl  21000  35
H  25
Calculate Specific Speed, after decided the rated speed,
Figure2. Types of Runner Specific Speed,

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470

N s = N  Pt(i)
1
2 IV. Result Data
Table5. Result Data
H5
4 Descriptions Symbols Values Units
Inlet tangential velocity U1 27.48 m/s
E. Normal Efficiency Outlet tangential velocity U2 40.05 m/s
N N
η n =  1.172  ( s )  4.344  ( s )  82.321 Inlet absolute velocity V1 21.42 m/s
100 100 Outlet absolute velocity V2 5.61 m/s
Maximum Efficiency, max= th  2.08log Pt (i)  4.61 Inlet flow velocity Vf1 10.95 m/s
Speed factor, u= - 4.4×(Ns /100)2 + 0.039×(Ns/100)+ 0.695 Outlet flow velocity Vf2 5.61 m/s
1
Inlet whirl flow velocity Vw1 18.4 m/s
Runner inlet diameter, D 1 = 84.6 × K × H
2
Runner outlet Outlet whirl flow velocity Vw2 0 m/s
u
N Inlet relative velocity Vr1 13.3 m/s
diameter, Outlet relative velocity Vr2 40.41 m/s
D2 = D1 ×[-1.7×12-2 (Ns /100)2 + 0.44× (Ns /100)+ 0.321] Runner inlet angle α1 3075 Degree
Runner outlet angle α2 90 Degree
Runner inlet height, Guide vane inlet angle β1 130 Degree
B1 = D1 ×[8.7×10-3 (Ns /100)2 + 0.15× (Ns /100)- 0.028] Guidae vane outlet angle β2 7.97 Degree
Runner outlet height, Turbine output power Pt 42.75 MW
Generator Output power PG 42 MW
B2 = D2 ×[0.2875+ 0.0175× (Ns /100) ]
2

Inlet diameter of Runner D1 2.1 m

Runner shaft diameter, Outlet diameter of Runner D2 3.1 m
Pt Inlet high of Runner B1 0.97 m
Ds = 2 ×
(863 × N ) Outlet high of Runner B2 1.3 m
Runner discharge diameter D3 3.22 m
Inlet peripheral velocity, Runner shaft diameter Ds 0.8 m
U1= πD 1 N No: of Runner blades Z 16
60
No: of guide blades - 24
Inlet absolute velocity, Runner elevation Hs -6 m
V1= 0.6 2  g  H Turbine speed N 250 rpm
Specific speed Ns 280 m-kW
Inlet flow velocity, Runaway speed Nr 486 rpm
Q Critical speed Nc 972 rpm
Vf1 =
πD1 B1 Efficiency t 94 %

Outlet peripheral velocity, Table 6.Comparison of Theory and Actual Data

πD 2 N Descriptions Theory Actual Units
U 2
=
60 Runaway Speed 486.4 432.8 rpm
Runner inlet angle, Turbine of Power 42.7 41.24 MW
Vf1 Outlet Runner Diameter 3.06 2.94 m
tan α 1 =
Vw1 Generation Power 41.89 40 MW
Runner Discharge Diameter 3.22 3.04 m
Guide vane inlet angle,
Shaft Diameter 0.8 0.7 m
B 1 = 180°- β1
Runner Outlet Height 1.3 1 m
Vf1
tan β =
U1  Vw1
Theoretical Output Power,
Ptheo = ρgQH

F. Design Input Data

The required design data must be known from Thautyegat
No.2 Hydroelectric Power Plant, in Bago Division
(Myanmar).

Table4 .Input Data

Descriptions Symbols Value Unit
Effective Head H 65 m
Discharge Q 70.10 m3/s
Overall efficiency ηo 94 %
Output Power of Turbine P 44.7 kW
Figure4. Two Dimensional View of Runner

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 International Journal of Trend in Scientific Research and Development (IJTSRD) @ www.ijtsrd.com eISSN: 2456-6470
Figure5. Three Dimensional View of Runner
Discussions and Conclusions
Hydropower is contained of two main portions as the
mechanical and electrical system. Generally, Francis
Turbines are placed in Vertical Francis Turbines
configuration. Vertical Francis Turbine is very widely used in
the world for large hydroelectric Power plant.
@ IJTSRD | Unique Paper ID – IJTSRD26412 | Volume – 3 | Issue – 5
The runner design is very important for any type of turbine.
In this paper, the design calculation of the runner of 40 MW
Vertical Francis Turbine which is taken from Thaukyegat
No.2 Hydroelectric Power Plant is carried out. This runner is
designed in the maximum power output conditions. Any type
of turbine, runner blade design is very important. In this
paper, the runner blade design of 40MW Francis Turbine is
calculated.
Acknowledgment
Firstly, the author would like to thank my parents for their
best wish to join the B.E course at TU(Meiktila). The author
greatly expresses her thanks to all persons who will concern
to support in preparing this paper.
REFERENCES
[1] Salman Bahrami, Multi-Fideidy, Design Optimization of
Francis Runner Blades, (Dec 2015)
[2] Einar Agnalt, Pressure measurements inside a Francis
Turbine Runner, (Oct 2014)
[3] Kurosawa, Design Optimization Method for Francis
Turbine, (Dec 2014)
[4] Tun Oke, U, Design and Calculation of Francis Turbine
(Runner), (Sept 2009)
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