Research on head losses in Escher Wyss type distribution pipes @ by Dr. A. ChristDuring recent years the design of the Escher Wyss branch pieces of distribution pipes has ‘boon so far developed that head losses are smaller than for classical branch pieces with ‘external reinforcements. By using models tested with air as the tlow medium, the head losses of each stage of development could be checked and at the same time basic data for calculating head losses in actual distribution pipes evaluated. Field measurements on such pipe conlirmed the good flow qualities of the new distribution piaces. ‘About ten years ago, when the first internally reinforced distribution pieces were devel- ‘oped, subsequent model tests with air were ‘aarried out in order to determine their pres sure losses. These trials already showed that in the region of hydraulic symmetry (i.e. in “he zone where actual distribution closely proaches design distribution), the pressure losses were somewhat lower than those of a congruent distribution piece with outer rain forcement. In unsymmetric ranges, however, the pressure losses of the internally rein- forced branch pieces were clearly higher Since then new branch piece designs nave been developed with lower head losses in Fig. Diagram Jef: Hro +1 = tg (head of wate faa = 8052 Diagram right: {low MY = maximum inlet mass the main or even in all distributing ranges. Near the economically most important hy- draulic symmetrical ranges, in particular, head losses are considerably lower as against the classical design. Fig. 1a and 1b show the success of this de- velopment. Comparison with the classical design is given in the form of head loss coefficients & (1a) and in the form of a power loss coetticient vs (1b. A noteworthy feature of the latest design ‘J Reauetion of the woight ana iss of energy in bution pipes for hydraulle power plants. (A. Sis, 1M. Hassan) EW Nows 1057/8 and 1958/1, [A Frat stage of development with intemal reinforcement B Second stage of de nal reinforcement © Design of tho latest branch pieces 1D Branching with extemal reinforcement lopment with intr- v= HEN lacy cone. ponding to Fig. 1B fess ¢ and powes Fetes vy of a lopment stages. of inte i iforced branch pieces Compared oth an eteraly feinlorced branch pace Sion tribution macs Rows: 3< The “fi {oreed branch pieces wo superar to the conventional nos only nvr rest Setibung ange. With the late dosgn, the goa! of Geer all How ‘eSimen i wel tained Theva of M at Fig. 1 for the 3 fbranch found by means of the fo Towing easations: = im art fig; the z higher valuo being the actual(Fig. 2), firstly, the enlarged diameter in the Inlet region which enables strongly conical sections to be provided at the outlet. And this permits the reinforcement to be kept smaller, 50 that there is less protrusion into the actual branching zone without concessions having ity or maximum stresses. Starting from point A in Fig. 2, therefore, the water flow will only be accelerated, which helps to avoid eddies and nead losses. At first glance it may be appear (Fig. 2) that the flow cross sections at point B are larger than at point A. But an accurate calculation de- ‘monstrates that, owing to the pronounced conieity between A and 8 the cross section is in fact reduced between these two points. Secondly, sharp defections’ in the outer contour of the new design, often sources of eddies and losses, are carefully avoided ‘and, thirdly, the velocity of flow in the actual branch piece is considerably reduced (by the square of the diameter ratio). The velocity head and the losses are again reduced in proportion to the square of the velocity itself ‘As a result of these three factors the losses in the new branch pipes are very !ow, provid ‘ed that the diffuser at the entry works effi ciently. Since the latter has to be built steeper than is normally admitted, there were al first some doubts as to this new design. But air trials on the models soon proved that the advantages by far outweighed the draw- backs. ‘Common to all branch pipes are the nega~ tive head loss coefficients (Fig. 1a) of the straight sections in the region approaching hydraulic symmetry. This means that the energy of the water flowing through the straight section is higher than the m energy in the entry section. This fact, al though somewhat difficult to understand, has been known since 1928? and repeatedly con- firmed in the meantime. Fig. 3 may help to clarify the reasons for the phenomenon. ‘Sketched into Fig. 9, entry section, is a nor- mal velocity distribution conforming to the Reynolds’ Numbers in penstocks. Whereas TF, Potermann: Report trom the Hydraulic Institute ‘tthe Munich Techoleal High Sehoat, 1028. Fig, 2 Design of the latest branch plece type. Tho fol ‘owing Components contib- io "Towards Keeping the losses low: Enlargement of Cross section atthe antrance (thevelociy mead 2 bee comes very smal). 23 The strongly conical shape of the exit regions permits the reinforcement sickle. to be kept very small, resulting im only small low isturo- ance. even at quite unsym= imotres! detebution Simooth deviation oft ‘owatds the tatral branching causing no eddies. Fig. Development of the elecly protien in 2 branch love (represented schema Neal). The pressure tosses ff the straight brane may bacome negative because i Now stom mally om the tentral zane, whieh moves Sorplus or kinetic anergy. The fateral branening isd mainly by flow panicles ‘rom the boundary layer with low velocity head. Its loss {a moreore relatively highthe main velocity is reduced in the two follow- ing diffuser sections, the shape of the velacity Profile is considerably changed, the origin- ally steep gradients of the velocity profiles in the boundary layer becoming more and more flat and the boundary layer itself be- coming thicker and thicker, At the end of the iffuser it covers a much greater percent- age of the cross section than at the be- ginning, so that the central zone is fairly Testricied. As the axes of the diffuser sec- tions are bent progressively, the remaining central zone lies somewhat excentric to the diffuser axis, approximately concentric with the original pipe axis. Owing to its relatively high kinetic energy he central zone tends to move straight for- ward, forcing the whole boundary layer with less kinetic energy into the lateral branch. In the straight section, therefore, water stem- ‘ming from the central zone will be collected, Whereas almost the whole boundary layer water will be deviated into the side branch, The central zone of the incoming flow has about 10% over-velocity compared with the mean velocity, which means about 20% kinetic over-energy. If'no losses occurred and if only water from the central zone pene- trated into the straight section, a loss coef- ficient of {y.2=—0.2 would be found. But as neither the flow is completely tree of los- ses nor the separation of the central zone and boundary layer a total one, a loss coefficient of —0.075 is found instead of —0.2. It is ob- vious that the loss coefficient of the lateral branch is so high that the sum of the dissi pated energies of both branches will always ve positive. Model tests An accurate numerical prognosis of head loss coetticient cannot, however, be drawn from these qualitative considerations. Only tests can give these data, preferably tests carried out with air on models, a method be- ing used at the Escher Wyss laboratories suc- cessfully for more than 30 years, All curves, in Fig, 1 are the results of such tests, the pri ciple of which is shown in Fig. 4 and its ex- tension in the laboratory in Fig. 5 All sections of the branch piece are pre- ceded or followed by relatively long straight tubes which ensure undisturbed flow into the model and smooth out irregularities of the velocity profiles after the model. Flow meas~ uring orifices are fitted at the end of both 7 Sorenger- Experimentoio Untersuchungen an gers Gan und geerimmtan Ditusoren. 1855 2urrem, Variag 16 branch tubes. Testing consisted in measur ing flow rates as well as the three static pre: sures at the end of each straight section. A previous pressure loss calibration of the straight tubes permits these losses to be sub- tracted from those measured, In this way the actual branch piece losses can be clearly ‘separated from the wall friction losses, This ‘simple principle, however, is in reality some~ what more complicated: the density of the working medium is not constant. Its variation with pressure and temperature calls for tem- perature measurements, And the probes must be very small in order to keep the flow entirely undisturbed, Furthermore, an energy coefficient = has to be attributed to the velocity heads tnees in the measured 3 tion oeeee of the. straight ‘model. These fretion loses Fig. 5 Ale testing Inthe laboratory. In the very long Imass, low ot te_straght means of a throtting valve mmounted at the end of this oe@ “i! to allow for the fact that a 2a for the fact that fully developed velocity distribution profile contains more kinetic energy than a rect tangular one. Then, test evaluation proceeds in accordance with Apastomptted Ah 2G — (00) +p in whien opis the pressure loss in the straight entry tube between the second pres- sure tap and the bifurcation point. AS the losses in the branch piece represent very small differences between large measured values, extreme test accuracy is required ‘The main pressure drops could indeed be measured by a Betz-type manometer with an accuracy of about 'vaees inch water head, the temperature accurately to "/10°C by thermo- ‘couples. Figs. 5 and 6 convey an impression of the elaborate nature of such tests. Complementing these rather laborious tests, on single branch pieces trials on models of entire distributing pipe arrangements have also been carried out. In these tests the i fiuence of one branch piece upon that fol- lowing it is correctly found, and as normally only the flow regimes which will also be of importance in the full-scale execution have to be tested, the time required for testing will be far shorter: in particular, when diter- | ‘ent model types have to be compared, the preliminary pressure loss calibration of the straight tubes can be omitted. Fig. 8 compares the head loss coefficients of two different models of the Olivane distri- bution pipe, These C-values comprise, in ad- dition to the branching losses, also all friction losses between entrance and exit measuring re, presnure alt= nemetor (accu ‘=m water ead), then agalvanometerformess: uring Temperatures with thermocouples (accuracy TiesCentigrsge), and. walet or mercury filed Utubes for determining resus ih Fig. 7 Modal of a compete lsribution pipe (Olvone) Such models are especialy favourable for relatively rapid ‘omparon tests of diferentrayon (ma) Fea, Fig. 8 Pressure lose coeticlents resulting from com parison txts on models like Fig. 7 The Melon losses tthe straight tubes sre inciidea, The Internally reine forced design is clearly superier to the convention ‘ep group of curves 1 to 4: part load. Curves 1 and 2 wore massured with only branches 1 and 2 apan Curves 3 and 4 with only'3 and # open, whereas tho tthor two branches were loses Lower group: ull 102d; a branches are open. ‘The cotfesponding curves printed in black repre the renpectiva losses of a dlatioutlon sige of Tunth outer reinforcement {measuring cross section. He my 2 61 head batwoan the inlet and th section. The superiority of the internally reinforced type is clearly visible, On these models the velocity profiles in the four exit pipes were extensively measured. Here, too, an advantage of the internally reinforced aistributors was revealed: their velocity profiles are less unsymmetrical than those of conventional distributors (Fig. 9). (Owing to the strong acceleration at the exit of the branch piece the unavoidable unsym- 8 meiries in the velocities profiles caused by the deviation are to a great extent smoothed out and will be amortised completely after a short piece of straight pipe, which in each case may only be of advantage for the fol- lowing turbo-machine. ‘Measurements on a full-scale plant Rounding off all these model tests, the Olivone distributor pipe provided a welcome opportunity to measure the pressure losses also on the full-scale plant (Fig. 10). Con- ventional instruments were sufficient for this purpose: one normal weight balanced ma- ometer coupled to a pressure line switch for the static pressure in the four branch pipes, | Inet guarantee limit 880, 5120 Exit guaramee Exit messuriog Forzonia plana drawn alter a branch place of con- | Yentional and one of Ine Swing. to. he strong. ow relntoreed design ‘ances the velocity profile ter an internally reinforced Branching Bi Symmetrical than ser # con- Sontonsl ane@ Fig, 1. Sehematie arrangement ofthe Instruments for Imessuring the presaure losses of tho Olvone sistbu The accuracy of the losses Messured was about 2 om of water heas. and four meroury differential manometers for measuring the differences between inlet and outlet pressures (Fig. 11) During the previous reception tests on the Pelton-type turbines of this plant, the regulating needle positions were calibrated in order to indicate the water volume flow. The amount of water could therefore be “Pena? quickly calculated from the accurately meas ured needle positions. ‘The pressure taps were inserted following the standards as carefully as possible, four in each measuring section. As on reception tests lasting about 20 minutes at constant turbine load all instruments were read period- ically, The average of these values was iva fests can be int polsted inva My — VP dian (gram by means of a straight fines The intaraection points Of this line with the low rat ofS misoe (VP = 35 see") ropresont the losses at warranty conditions. Fig. 19. Ollvone diatsbution "rene contirmed that uring tothe srongly pra fd, internally reinforced distribution pieces, the pres ‘sure losses are very low:Used for the evaluation. Fig. 12 shows the overall nead losses as measured, plotted as ‘a function of the square of the volume flow. All points may be interpolated by straight lines. The losses at the nominal tlow rate (m/sec, \V2= 25 mi/sec-?) can be easily read from the diagram. Certain corrections at inlet and exit were fixed in advance, as the measuring sections did not coincide with the guarantee limits. ‘The mean of all quarantee head losses was 0.72 m, which may be regarded as very suc- cessful when compared to the guarantee of 09 + 0.4 m. The results, however, yielded one surprising 2henomenon: the head loss of the first dist bution was very low. Fig. 14 represents the relative distribution of the head losses of the four branches calculated firstlyfrom the single ‘model tests, secondly from the tests on the complete distributor model, and thirdly taken fromthe measurements on the full-scale plant. Indeed, the first branch is favoured at the cost of the other three. An explanation for this nonconformity between model and full- scale plant Is easy to find in Fig. 10 and in the differential flow effects (Fig. 2). Owing to the secondary flows induced by the centrifu- gal forces in the bend before the entrance to the first branch piece, ral zone of Fig. 3 no longer remains in the region of the pipe axis but is deviated more to the side branching. The latter therefore traps a greater amount of this high-energy central zone, which of course reduces its loss coetti- lent. The straight branch pipe, however, solleets more of the boundary layer, thus in- creasing its loss. This effect might be taken Fig. 14 Relative amount of the pressure losses inthe Olivone distribution pipe. 4) calculated following tests on single modes 8) following tests onthe completa model {©} following measurings on fll-zeale plant ‘as 2 reminder to redesign the entire arrange- ment in all scale madels. In the present case the necessity of rebuilding not only an adequate piece of pipe but also the bend at the entry would have resulted in a model that could not have been practically mounted in the laboratory. Furthermore, the nonconform= ity mentioned is not a total one, but only a differential in as much as the total losses did rot alter but simply their distribution on the straight and lateral branching, In conformity with the model tests, however, is the negative pressure loss in the straight branch of the second piece. It is only due to this effect that the loss of the third branch is somewhat lower at full load (Fig. 12a) in spi of the fact that it comprises about 0.2 m more of friction water head losses than the second one. Tha reason forthe relatively mall tossee ofthe fet fll fale branching has to. be Toekee tor inthe bend belor the distrbution pipe, which ‘could not be robull in the {sale moeel. The secondary Mow caused by this bend shits ha cera flow Zone inthe fet branch place in the direction of the. latoral branching. Therefore a (greater amount of this zone Is trapped By this branching, weigh results in lower loeses is.