Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be
Ghent University UGent Design of a small hydro Kaplan turbine with a self-sealing rotor S. Annerel, J. Vierendeels, E. Dick Ghent University Belgium Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Overview Motivation and initial design Sealing rotor Rotor flow analysis Diffuser flow analysis Off-design performance Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Motivation Turbine that can cope with flow rate variation from design flow rate to zero flow rate Needs movable rotor that allows complete sealing Like variable opening valve with extraction of power Complete flexibility in flow rate 6 locations on river Sambre in Belgium Flow rate: 5.5 m 3 /s to 20 m 3 /s Head: 4.40 m to 1.70 m Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Initial design Head (m) 3.60 Flow Rate (m/s) 16.0 Outer diameter (m) 2.00 Inner diameter (m) 0.80 Rotational speed (rpm) 130 Number of blades 12 Lenght diffuser (m) 4.00 Outlet diameter diffuser (m) 2.75 Shaft power (kW) 395 Total efficiency (-) 0.70 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Initial design Multiple stream tube analysis Simple radial equilibrium inlet and outlet No work exchange between streamtubes Expressed for nine blade sections Resulting design: Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Overview Initial design Sealing rotor Rotor flow analysis Diffuser flow analysis Off-design performance Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Obtaining rotor sealingness Initial design Rated flow: Closed: Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Means to reach sealingness Stacking (lean and sweep) is not efficient Solidity distribution: large chord at hub Thickness distribution: large thickness at hub Camber distribution: zero camber at hub, large camber at tip Untwist rotor: large incidence at hub (10.8) and negative incidence at tip (-2) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Obtaining rotor sealingness Closed at tip and hub Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Obtaining rotor sealingness Adjustment of stagger angles: max 1.7 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Blade form Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Final design Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Overview Initial design Obtaining rotor sealingness Rotor flow analysis Diffuser flow analysis Off-design performance Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rotor flow analysis: CFD package FLUENT Flow domain Inlet Blade Outlet1 Outlet2 1050mm 550mm 300mm 300mm 1050mm 287mm 400mm 600mm 600mm Interior Plane (InletBlade) Periodic Plane Interior Plane (BladeOutlet) Inlet Plane Outlet Plane Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Blade surface grid Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rotor flow analysis CFD Analysis (SRF, k- SST, EWT) Radius 475mm Big incidence, but lower than expected No separation Relative Velocity Magnitude Vector (m/s) Static Pressure Contour (Pa) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rotor flow analysis Radius 700mm Relative Velocity Magnitude Vector (m/s) Static Pressure Contour (Pa) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rotor flow analysis Radius 925m Almost zero incidence (small negative incidence) Relative Velocity Magnitude Vector (m/s) Static Pressure Contour (Pa) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rotor flow analysis Suction side Static Pressure Contour (Pa) Relative Velocity Magnitude Vector (m/s) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Flow distribution stream tube analysis Stream tube hub tip Radius ( m) 0.4 0.475 0.55 0.625 0.7 0.775 0.85 0.925 1 u ( m/s) 5.445 6.466 7.487 8.508 9.529 10.551 11.572 12.593 13.614 c 1a ( m/s) 6.813 6.583 6.394 6.233 6.094 5.971 5.862 5.764 5.675 w 1u ( m/s) 2.046 3.182 4.297 5.399 6.489 7.571 8.647 9.717 10.782 c 2a ( m/s) 6.021 6.074 6.094 6.095 6.087 6.072 6.054 6.033 6.011 w 2u ( m/s) 6.619 7.15 7.80 8,.514 9.282 10.094 10.938 11.801 12.676 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Flow distribution CFD analysis CFD hub tip Radius ( m) 0.4 0.475 0.55 0.625 0.7 0.775 0.85 0.925 1 c 1a ( m/s) 4.981 6.011 5.944 5.961 6.022 6.098 6.165 6.200 5.106 w 1u ( m/s) 2.305 3.249 4.384 5.472 6.563 7.626 8.692 9.737 10.586 c 2a ( m/s) 5.360 6.430 6.238 6.087 5.920 5.880 6.128 5.994 4.930 w 2u ( m/s) 7.002 7.645 8.395 9.250 10.104 11.035 11.842 12.697 12.931 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rotor flow analysis Work extracted by turbine is bigger than intended Flow is aligned to tip section: more flow rate, more work Unloading of the hub (fortunate) CFD hub tip radius ( m) 0.4 0.475 0.55 0.625 0.7 0.775 0.85 0.925 1 W ( m/s) 25.577 28.423 30.028 32.144 33.743 35.966 36.456 37.267 31.924 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Performance Diffuser recovery factor 0.70 Stream tube analysis: Q= 16 m 3 /s, H= 3.60 m P shaft = 387 kW, glob = 0.69 CFD-analysis P shaft = 540 kW, Q= 16 m 3 /s, H= 4.40 m , glob = 0.74 (with mechanical losses: glob = 0.72) rematching necessary Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Rematching Work extracted by turbine is too big allow bigger flow rate Open stator and open rotor = 26.5 23 , tip = 63.5 60 Some loss of efficiency glob 0.70 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Overview Initial design Obtaining rotor sealingness Rotor flow analysis Diffuser flow analysis Off-design performance Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser design Geometry 4000mm 400mm 600mm 370mm Mixing Plane Inlet Blade Cone Diffuser Velocity Inlet Pressure Outlet Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser analysis CFD Analysis (Mixing plane, k- SST) Static Pressure Contour(Pa) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser design CFD Analysis (Mixing plane, k- SST) Radial Velocity Magnitude Contour (m/s) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser design CFD Analysis (Mixing plane, k- SST) Axial Velocity Magnitude Contour (m/s) Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser performance verification Analysis planes Outlet rotor Inlet rotor Outlet diffuser Inlet diffuser Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser performance: pressure recovery factor Diffuser maps: 0,700 p C 2 2 2 2 2 4 4.364 1 1 2 0.8 2 2 tip hub L L LR R D D 2 2 4 4 2 2 2 2 1.37 2.235 0.9165 A R AR A R 4 2 2 2 1 2 p p p C v 2 4 2 11468.77 1608.21 6.112 p Pa p Pa v m s 0.700 p C 0.700 p C CFD analysis: Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser performance: = 26.5 20: post-swirl Inlet diffuser Outlet diffuser Inlet diffuser Outlet diffuser Outlet diffuser Inlet diffuser = mixing plane Axial Velocity (m/s) Tangential Velocity (m/s) Velocity variation Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Overview Initial design Obtaining rotor sealingness Rotor flow analysis Diffuser flow analysis Off-design performance Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Off-design performance: = 26.5 20 ; = 63.5 78; Q=8 m 3 /s (H=3.20 m) Rotor Velocity Vector Fields: No separated flow! Relative Velocity Magnitude Vector (m/s) at radius 475mm Relative Velocity Magnitude Vector (m/s) at radius 925mm Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Diffuser Static Pressure Contour (Pa) Off-design performance: glob = 0.60 Department of Flow, Heat and Combustion Mechanics www.FloHeaCom.UGent.be Ghent University UGent Conclusion Design of an axial hydro turbine with a movable rotor and blade shape such that the rotor can be completely closed was successful Rated conditions: Q= 16 m 3 /s, H= 3.60 m P shaft = 390 kW, glob = 0.70 Half flow rate: glob = 0.60
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Gas-Engines and Producer-Gas Plants
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