PROJECT

REPORT
ON
“Water Turbine”

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Hydro Power Plant:

In this type of power plant energy (electricity) is produced by conversion of

potential head of water stored at some height called DAM to the mechanical
energy by running of turbine shaft which is connected to the runner blade on which
water strikes.

This turbine shaft is then coupled to the generator shaft through which electricity
is produced.

Hydro power plants can be classified on different basis like:

1. Availability of Head:
 High head : >100m
 Medium head: 30 – 100m
 Low head: <30m

2. Type of load:
 Base
 Peak

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The general outline of the power plant is shown below:

The figure shows the basic parts of the hydro power plant required. The
elements of the hydroelectric power plant are – Catchment area, Reservoir,
Dam, Sluice gate, Penstock, Spillway, Surge tank, Trash rock, Fore way, Power
house, Draft tube, Switch yard for transmission lines.

Hydraulic Turbines and Their Classification:

Hydraulic turbines are the prime movers which convert the head energy of
water into shaft work.

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Hydraulic turbine can be differentiated as:

Type of Turbine Maximum Head (m) Specific Speed

Pelton 300-2000 4-70
Francis 30-500 60-400
Kaplan 2-70 300-1100

1. PELTON TURBINE

The Pelton wheel is an impulse turbine which is among the most efficient types
of water turbines. It was invented by Lester Allan Pelton in the 1870s. The
Pelton wheel extracts energy from the impulse (momentum) of moving water,
as opposed to its weight like
traditional overshot water wheel

A Pelton turbine consists of one

nozzle or set of nozzles and a pelton
wheel. The runner consists of a large
circular disc on the on the periphery
of which a number of two-lobe
ellipsoidal buckets are evenly
mounted. Each bucket has a ridge or
splitter in the middle which divides
the jet into two equal stream. The
symmetry of the bucket ensures zero
momentum in the axial thrust on the shaft bearing. It works on the principle of
Newton’s 2nd Law.
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Main parts of the Pelton turbine are:

1. Nozzle
2. Jet
3. Runner and Bucket
4. Needle Head
5. Tail water level
6. Runner disc
7. Deflector
8. Steering wheel for needle movement
9. Turbine housing
10.Turbine shaft and Coupling

Theory of Operation:

The water leaves the penstock and strike the bucket which is connected to the
runner. The water flows along the tangent to the path of the runner. Nozzles
direct forceful streams of water against a series of spoon-shaped buckets
mounted around the edge of a wheel. As water flows into the bucket, the
direction of the water velocity changes to follow the contour of the bucket.
When the water-jet contacts the bucket, the water exerts pressure on the bucket
and the water is decelerated as it does a "u-turn" and flows out the other side of
the bucket at low velocity. In the process, the water's momentum is transferred
to the turbine. This "impulse" does work on the turbine. For maximum power
and efficiency, the turbine system is designed such that the water-jet velocity is
twice the velocity of the bucket. A very small percentage of the water's original
kinetic energy will still remain in the water; however, this allows the bucket to

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be emptied at the same rate it is filled, thus allowing the water flow to continue
uninterrupted.

Because water and most liquids are nearly incompressible, almost all of the
available energy is extracted in the first stage of the hydraulic turbine.
Therefore, Pelton wheels have only one turbine stage, unlike gas turbines that
operate with compressible fluid.

2. FRANCIS TURBINE

The Francis turbine is a type of water turbine that was developed by James B.
Francis in Lowell, Massachusetts. It is an inward-flow reaction turbine that
combines radial and axial flow concepts. Medium size and larger Francis
turbines are most often
arranged with a vertical shaft.
Francis turbines are the most
common water turbine in use
today.

Main Components:

1. Runner and runner cone

2. Servomotor
3. Turbine shaft
4. Bearing pad and cover
5. Turbine cover
6. Stay vane and Scroll case
7. Guide vane
8. Link

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9. Regulating ring
10. Draft tube

Design of Francis Turbine:

Francis Turbine has a circular plate fixed to the rotating shaft perpendicular to
its surface and passing through its center. This circular plate has curved
channels on it; the plate with channels is collectively called as runner. The
runner is encircled by a ring of stationary channels called as guide vanes. Guide
vanes are housed in a spiral casing called as volute. The exit of the Francis
turbine is at the center of the runner plate. There is a draft tube attached to the
central exit of the runner. The design parameters such as, radius of the runner,
curvature of channel, angle of vanes and the size of the turbine as whole depend
on the available head and type of application altogether.

Theory of operation:

The Francis turbine is a reaction turbine, which means that the working fluid
changes pressure as it moves through the turbine, giving up its energy. A
casement is needed to contain the water flow. The turbine is located between
the high-pressure water source and the low-pressure water exit, usually at the
base of a dam.

The inlet is spiral shaped. Guide vanes direct the water tangentially to the
turbine wheel, known as a runner. This radial flow acts on the runner's vanes,
causing the runner to spin. The guide vanes (or wicket gate) may be adjustable
to allow efficient turbine operation for a range of water flow conditions.

As the water moves through the runner, its spinning radius decreases, further
acting on the runner. For an analogy, imagine swinging a ball on a string around

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in a circle; if the string is pulled short, the ball spins faster due to the
conservation of angular momentum. This property, in addition to the water's
pressure, helps Francis and other inward-flow turbines harness water energy
efficiently. At the exit, water acts on cup-shaped runner features, leaving with
no swirl and very little kinetic or potential energy. The turbine's exit tube is
shaped to help decelerate the water flow and recover the pressure.

3. KAPLAN TURBINE

The Kaplan turbine is a propeller-type water turbine which has adjustable

blades. It was developed in 1913 by the Austrian professor Viktor Kaplan, who
combined automatically adjusted propeller blades with automatically adjusted
wicket gates to achieve efficiency over a wide range of flow and water level.

The Kaplan turbine was an evolution of the Francis turbine. Its invention
allowed efficient power production in low-head applications that was not
possible with Francis turbines. Kaplan turbines are now widely used throughout
the world in high-flow, low-head power production.

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 Main components:

The Kaplan turbines have the following main components:-

1. Scroll casing and stay ring

2. guide apparatus
3. Covers
4. Runner
5. runner blade servomotor
6. regulating mechanism of the runner blades
7. co-operation of regulating the runner blades and guide vanes
8. turbine shaft
9. turbine bearing
10. shaft sleeve and seal box
11. runner chamber
12. draft tube

Design of Kaplan Turbine:

To generate substantial amount of power from small heads of water using

Kaplan Turbine it is necessary to have large flow rates through the turbine.
Kaplan Turbine is designed to accommodate the required large flow rates.
Except the alignment of the blades the construction of the Kaplan Turbine is
very much similar to that of the Francis Turbine. The overall path of flow of
water through the Kaplan Turbine is from radial at the entrance to axial at the
exit. Similar to the Francis Turbine, Kaplan Turbine also has a ring of fixed
guide vanes at the inlet to the turbine.

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Unlike the Francis Turbine which has guide vanes at the periphery of the
turbine rotor (called as runner in the case of Francis Turbine), there is a passage
between the guide vanes and the rotor of the Kaplan Turbine. The shape of the
passage is such that the flow which enters the passage in the radial direction is
forced to flow in axial direction. The rotor of the Kaplan Turbine is similar to
the propeller of a ship. The rotor blades are attached to the central shaft of the
turbine. The blades are connected to the shaft with moveable joints such that the
blades can be swiveled according to the flow rate and water head available.

Theory of operation:

The Kaplan turbine is an inward flow reaction turbine, which means that the
working fluid changes pressure as it moves through the turbine and gives up its
energy. Power is recovered from both the hydrostatic head and from the kinetic
energy of the flowing water. The design combines features of radial and axial
turbines.

The inlet is a scroll-shaped tube that wraps around the turbine's wicket gate.
Water is directed tangentially through the wicket gate and spirals on to a
propeller shaped runner, causing it to spin.

The outlet is a specially shaped draft tube that helps decelerate the water and
recover kinetic energy.

The turbine does not need to be at the lowest point of water flow as long as the
draft tube remains full of water. A higher turbine location, however, increases
the suction that is imparted on the turbine blades by the draft tube. The resulting
pressure drop may lead to cavitation.

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 Variable geometry of the wicket gate and turbine blades allow efficient
operation for a range of flow conditions. Kaplan turbine efficiencies are
typically over 90%, but may be lower in very low head applications.

Because the propeller blades are rotated by high-pressure hydraulic oil, a

critical element of Kaplan design is to maintain a positive seal to prevent
emission of oil into the waterway. Discharge of oil into rivers is not permitted.

Various Components of Hydro Power Plant and its

manufacturing by BHEL Bhopal:-

1. DAM:

A dam is a barrier that impounds water or underground streams. Dams generally

serve the primary purpose of retaining water.
Hydropower and pumped-storage
hydroelectricity are often used in conjunction
with dams to generate electricity. A dam can
also be used to collect water or for storage of
water which can be evenly distributed between
locations. Based on structure and material used,
dams are classified as timber dams, arch-
gravity dams, embankment dams or masonry
dams, with several subtypes. It is onsite
construction component of hydro plant.

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2. SLUICE GATE:

A sluice is a water channel that is controlled at its head by a gate. The terms
"sluice gate", "knife gate", and "slide gate" are used interchangeably in the
water/wastewater control industry. The term sluice gate refers to any gate that
operates by allowing water to flow under it. When a sluice gate is fully lowered,
water sometimes spills over the top, in which case the gate operates as a weir.
Usually, a mechanism drives the sluice gate up or down. This may be a simple,
hand-operated, worm drive or rack-and-pinion drive, or it may be electrically or
hydraulically powered.

3. PENSTOCK:

A penstock is a sluice or gate or intake

structure that controls water flow, or an
enclosed pipe that delivers water to hydraulic
turbines and sewerage systems. It is a term
that has been inherited from the technology
of wooden watermills. Penstocks for
hydroelectric installations are normally
equipped with a gate system and a surge tank.

Flow is regulated by turbine operation and is

nil when turbines are not in service.

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4. MAIN INLET VALVE:

The conduits in all water power plants except large low head plants, are
ordinarily provided with shut off devices. Generally these components are
valves. They exist in different types and design depending on function and
requirements.

In any power plant valves for different purposes are usually needed. Normally
it is a shut-off valve just in front of the turbine. In this way the turbine may be
emptied without emptying the shaft or penstock. In addition the guide vane
cascade is depressurized so that leakage flow is avoided.

With a long head race tunnel and surge chamber it is normal to have a shut off
valve just downstream of the surge chamber. In this way the shaft or penstock
may be emptied without emptying the tunnel.

To prevent large damage at an eventual rupture of the penstock, a pipe break

valve is normally installed in the pipe just downstream of the shut off valve.
This valve closes automatically when the water velocity exceeds a certain set
value.

The most relevant types of valves which are manufactured by BHEL are:

-- Spherical valves

-- Butterfly valves

a) SPHERICAL VALVE:

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 FIG a.1 and a.2

Spherical valves are applied mostly as shut off valves in front of high head
water turbines. They are however, used as pipe brake valves as well. Spherical
valves are presently covering a pressure range of 160 m to 1250 m water head.
The spherical valves consist of the valve housing with flanges, valve rotor,
bearings and seals. The valve housing has a spherical shape. It may either be
axially split permanently in two halves and bolted together with heavy flanges,
or these two halves may be welded together after the rotor has been installed.
Fig. a.1 shows a picture of a complete spherical valve in open position, and
Fig.a.2 shows a picture of a spherical valve rotor.

The opening and closing operation of the valve is carried out by one or two
servomotors.

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b) BUTTERFLY VALVE:

Butterfly valves are normally

applied in front of low and
medium head water turbines,
i.e. heads up to 200 m. For
high head power plants the
butterfly valve is from time to
time used as a closing device
in inlet tunnels and
alternatively as emergency
closure valves.

Valves consist of mainly of a

ring shaped housing, the valve
disc, operating mechanism and
counter weight.

The butterfly valve shall be able to open and close under equalized water
pressure on the disc sides as well as to close at full turbine discharge. In
addition emergency closure valves shall close automatically in the case of
penstock rupture.

The opening is done by means of one (or two) servomotors. This may be
mounted on the side of the valve and is acting on the counterweight arm which
is bolted to the trunnion.

valve is also manufactured. Its housing on which disc (door) is housed, valve
disc, operating mechanism i.e., servomotor etc is manufactured and assembled
and tested in BHEL Bhopal.
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5. SPIRAL CASING:

These are the connecting link

between penstock and stay rings.
Spiral casing are gradually
decreasing conduct around the
circumference of the wheel
(maximum at the entrance and
minimum at the tip). These carry
water from the penstock and supply
to the runner. These are made of
decreasing cross section because the
losses occur during the flow can be
avoided.

6. STAY RING:

The stay ring consists of an

upper and a lower ring to which
the stay vanes are welded. The
stay vanes are given a favorable
hydraulic shape to conduct the
water towards the guide vanes
with minimal losses. The stay
vanes also carry the axial forces
inside the scroll casing. The
vanes in the stay ring conduct the

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water towards the guide vanes. In addition the hydraulic forces are transferred
through the stay ring and the stay vanes which are anchored to the concrete with
large pre stressed stay bolts.

TOP COVER AND PIVOT RING:

These are the circular ring with seat or projection provided on them to accumulate
the guide vanes. Top cover is provided on the top of the guide vanes in which the
hub of the guide vanes are connected which is connected with the lever to the arm
which is bolted on the regulating ring. As the regulating ring rotates with the help
of servomotor the arm rotates, rotating the lever to the guide vanes and hence flow
of water is regulated.

Pivot ring is provided on the base of the guide vanes which act as supporting or
pivot to the guide vanes. It is also of circular shape. For Kaplan the runner starts
from the pivot ring while in Francis it starts from the guide vanes.

7. GUIDE VANES:

The basic purpose of the guide vanes or stay

vanes is to convert a part of pressure energy
of the fluid at its entrance to the kinetic
energy and then to direct the fluid on to the
runner blades at the angle appropriate to the
design. Moreover, the guide vanes are pivoted
and can be turned by a suitable governing
mechanism to regulate the flow while the load
changes. The guide vanes are also known as
wicket gates. The guide vanes impart a

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tangential velocity and hence an angular momentum to the water before its entry to
the runner. The flow in the runner of a Francis turbine is not purely radial but a
combination of radial and tangential. The flow is inward, i.e. from the periphery
towards the centre. The height of the runner depends upon the specific speed. The
height increases with the increase in the specific speed. The main direction of flow
change as water passes through the runner and is finally turned into the axial
direction while entering the draft tube.

8. REGULATING RING:

The guide blades of a Francis turbine are pivoted and connected by levers and links
to the regulating ring. The regulating ring is attached with two regulating rods
connected to the regulating lever. Thus regulating lever in turn is connected with
regulation shift, which is operated by the piston of servomotor.

When load on the turbine increases, regulating ring is moved in reversed direction
to increase the passage between the guide blades thus allowing more water to meet
the increased load demand. Similar is the function and connection in case of
Kaplan turbine except that servomotors are connected to runner blade also to give
the required motion, hence this system is known as “Double Regulation” and gives
higher efficiency.

9. RUNNER:

It is basically a rotating part of the turbine on which blades are either casted or
bolted and then it is mounted on the shaft which transmits energy. Runners are
classified on the basis of type of working head.

Runner of a Pelton wheel consists of a circular disc mounted on a horizontal shaft.

On the periphery of the runner, a number of buckets are fitted uniformly. The

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Pelton runners may be designed either for casting of the disc and buckets in one
piece or the disc and each of the buckets are casted in separate pieces and the
bolted together. The first method mentioned is preferred and common for the
Pelton turbines in modern power plants where the turbine units are of the high
power and bigger sizes.

Runner of the francis is a circular wheel on which a series of radial curved vanes
are fixed. The runner may be either cast or fabricated. For a large unit, cast steel or
stainless steel may be used and for small unit, cast iron. The surface of runner is
made smooth to reduce losses. The runner is so shaped that water flow through the
runner in combination of radial and tangential flow and leaves runner without
shock.

Kaplan consists of an axial flow runner usually with four to six blade of aerofoil
shape. In consist of a slot in which blades can be bolted and can be rotated with the
help for servomotors according to the load.

Runners for Pelton, Francis and Kaplan for projects like Parbati III, Srinagar,
Pulichintala, Rampur had been manufactured in BHEL Bhopal. Other than this
guide vanes are finished here, drilling of blades of Kaplan are also done here.

10.DRAFT TUBE:
 It makes possible the installation of the turbine above the tail race level
without the loss of head.
 The velocity of water at the runner outlet is very high. By employing a draft
tube of increasing cross sectional area, the discharge takes place at a much
lower velocity and thus, a part of the kinetic energy that was going as a
waste is recovered as a gain in the pressure head, and this increases the
efficiency of the turbine.

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  The draft tube prevents the splashing of water coming out of the runner and
guides the water to the tail race.

Types of draft tubes are :

 Simple elbow tubes

 Conical draft tube
 Circular inlet and square outlet
 Moody’s bell- mounted tube

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