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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
EXPERIMENT 4
PERFORMANCE TEST ON COMPUTARIZED KAPLAN TURBINE TEST
RIG ELECTRICAL LOADINGOBJECTIVE
To study the performance characteristics of turbine under unit quantities
To obtain constant head characteristics
To obtain constant speed characteristics
THEORY
Hydraulic (or Water) turbines are the machines which use the energy of water (Hydro-Power) and convert it into mechanical energy. Thus the turbine becomes the prime mover to run the electrical generators to produce the electricity, Viz., Hydro-electric power.The turbines are classified as Impulse & Reaction types. In impulse turbine, the head of water is completely converted into a jet, which impulses the forces on the turbine. In reaction turbine, it is the pressure of the following water, which rotates the runner of the turbine. Of many types of turbine, the Pelton wheel, most commonly used, falls into the category of impulse turbines. While Francis & Kaplan falls in category of impulse reaction turbines.
Normally, Pelton wheel (impulse turbine) requires high heads & low discharge, while the Francis & Kaplan (reaction turbines) require relatively low heads and high discharge. These corresponding heads and discharges are difficult to create in laboratory size turbine from the limitation of the pumps availability in the market. Nevertheless, at least the performance characteristics could be obtained within the limited facility available in the laboratories. Further, understanding various elements associated with any particular turbine are possible with this kind of facility.
ii Specifications
Diameter of Impeller : 153mm Impeller Material : Gun Metal Diameter of venturimeter inlet, D : 100mm Diameter of venturimeter throat, d : 50mm Run-away speed : 2000 RPM (approx.) Maximum head : 12 m (approx.)
iii Test Setup Description
While the impulse turbine is discussed elsewhere in standard textbooks, Kaplan turbine, the reaction type which is of present concern consists of main components such as propeller (runner) scroll casing and draft tube. Between the scroll casing and the runner, the water turns through right angle into axial direction and passes through the runner and thus rotating the runner shaft. The runner has four blades which can be turned about their own axis so that the DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
angle inclination may be adjusted while the turbine in motion. When runner blade angles are varied, high efficiency can be maintained over wide range of operating conditions. In the other words even at parts loads, when a low discharge is following through the runner, a high efficiency can be attained in case of Kaplan turbine, whereas this provision does not exist in Francis and propeller turbines where, the runner blade angles are fixed and integral with hub.
The actual experimental facility supplied consists of a centrifugal pump set, turbine unit, sump tank, Venturimeter arranged in such a way that the whole unit works on re circulating water system. The centrifugal pump set supplies the water from the sump tank to the turbine through butterfly valve which has the marking to the meter the known quantity of water. The water after passing through the turbine units enters the same tank through the draft tube. The water then flows back to the turbine unit through the venturimeter for the measurement of flow rate.
The loading of the turbine is achieved by electrical AC generator connected to blub bank. The provision for measurement electrical energy by energy meter, turbine speed (digital RPM indicator), Head on the turbine (pressure gauge), are built-in on to the control panel.
EXPERIMENTAL SETUP
Supply Pump / Motor Capacity : 10HP, 3Ph, 440V, 50Hz, AC
Electrical Supply : 3 Ph, 440V, AC, 32A, with Neutral & Earth
Alternator make : Kirloskar
Alternator capacity : 3KVA
Loading : AC Alternator connected with electrical switches
Speed Measurement : Digital speed indicator with proximity sensor
Pressure Measurement : Digital dual pressure indicator connected to sensor
Outlet Pressure Measurement : Digital pressure indicator connected to sensor
Power Output Measurement : Digital AC wattmeter
Discharge Measurement : Venturimeter [Cd=0.98 ] Computer Interface : RS 485 converter
Lab view application software
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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
PROCEDURE
When all the instrumentation along with its accessories is readily connected it is just enough to
follow the instructions framed below:
1. Before switching on the MCB ensure that all the loading switches and the solenoid valve
switches are maintained at OFF position
2. Now switch ON the M.C.B. All the indicators mounted on the control panel board starts
displaying some random values.
3. Now open the butterfly valve of the turbine setup say Francis or Kaplan on which the
performance test is to be carried out initially and shut the valve completely on which the
test is not conducted.
4. Engage the belt of one particular turbine with the alternator and adjust the guide vane to
required opening position say full, half, One-fourth or One-third if you are operating for
Francis turbine or adjust the gate opening to required position say full, half, One-fourth
or One-third if you are operating for Kaplan turbine.
5. Meanwhile switch on the computer and the control panel & keep it ready with the
observation menu
6. For the application software Computerized Francis & Kaplan turbine, in the computer
follow the route, Start > Programs > Computerized Francis & Kaplan Turbine >
Application or directly select the short cut icon on the desktop.
7. Now start the pump by pressing the starter button on the pump starter. Now water start
flowing to the turbine through venturimeter and the setup becomes operational.
8. Now on software screen click on the COMM SET option as shown in the figure.
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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
9. Now Computer port setting dialog box will open as shown in the figure. Now select the
required connected port and press OK.
10. Now select the turbine type from the option given in the application software say Francis
or Kaplan. Once the turbine type is selected one could hear a sound of solenoid valve
valve opening for the selected turbine type.
11. After selecting the turbine type, select the type of experiment to be conducted in the
particular turbine from the option given in the application software say Constant
Head/pressure operation or Constant Speed Operation.
12. After selecting the required type of turbine and the type of experiment to be conducted
for the performance test click on START TEST option on the application software
screen a dialog box with the file name will be displayed as shown in the figure
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Now select the required file path and press OK. In the data indicator tab of the software
all the values will start indicating as shown in the control panel.
13. Once all the values are displayed on the software as per the values indicated in the digital
indicators of the control panel click LOG DATA and all the data will be logged in the
data tabulation tab of the software along with performance graphs
14. Log different values at different loading condition by clicking the same icon.
15. As the test is running, the computer will carry out all the Calculations and
Tabulations. Repeat the same procedure for other condition say for different guide vanes
opening for Francis turbine whereas for different gate opening for Kaplan turbine.
16. After logging the data for different condition unload the turbine by putting OFF the
loading bulbs by using the software if the loads are being applied using software or put it
OFF manually if the load is being applied by using the loading switches.
17. To save the data click on the STOP TEST option on the software and then click on the
SAVE TO EXCEL option on the software
18. An Excel Sheet opens with all the logged values along with the performance graph.
19. To save the file go to FILE > SAVE AS > FILE NAME > OK
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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
20. After the completion of the expirement put OFF the supply pump and SHUT the valves.
NoteSoftware is running Software is running continuously Software is not running
8. Constants and Nomenclature
Pi Venturimeter Inlet Pressure Kg /cm2
Pt Venturimeter Throat Pressure Kg /cm2
PV Vacuum Pressure (Outlet pressure) Kg /cm2
D1 Venturimeter Inlet Diameter m
D2 Venturimeter Throat Diameter m
A1 Venturimeter Inlet Area m2
A2 Venturimeter Throat Area m2
H v Venturimeter Head m
h Venturimeter Inlet and Throat Pressure Difference m
Cd Coefficient of Discharge No unit
Q Discharge m3/sg Acceleration due to gravity m /s2
N Turbine Speed RPM
H Head on Turbine m
W Specific Weight of Water N /m3
BPElectric Brake Power Electric KW
BPShaft Brake Power Shaft KW
H Hydraulic Hydraulic Input to Turbine KW
NU Unit Speed No unit
PU Unit Power No unit
QU Unit Discharge No unit
NS Specific Speed No unit
ηTurbine Turbine Efficiency No unit
LIST OF FORMULAE
Turbine Break Power, ( BP )
BPElectric=n x1000 x60 x60
Energy Meter Constant x TimeKW
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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Where,n=No of blinks /revolution¿energy meter
BPShaft=BPElectric
Transmission EfficienyKW
Discharge, (Q )
Q=C d xA1 x A2 x√2g HV
√ A12−A2
2m3/s
Where,A1=Venturimeter Inlet Area∈m2
A2=VenturimeterT hroat Area∈m2
Cd=Coefficient of Disc h arge
g=Acceleration due¿ gravity∈m / s2
P I=Venturimeter Inlet Pressure∈Kg /cm2
PT=Venturimeter T hroat Pressure∈Kg /cm2
HV =Head on Venturimeter∈mHV =10 hHV =10 [P I−PT ]
Head on the Turbine, H
H=10 (PI+( PV
760 )) Where, H=Head onTurbine∈mP I=Venturimeter Inlet Pressure∈Kg /cm2
PV =Vacuum Pressure [Outlet Pressure ]∈Kg /cm2
Hydraulic Input to the Turbine in W
Phyd=WQH
Where,W =Specific Weig ht of Water ∈N /m3
Q=Disc h arge∈m3/sH=Head onTurbinein m
Turbine Efficiency
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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
% ηTurbine=BPPHyd
x100
Where,BP=Brake Power∈KWPHyd=Hydraulic Input ¿ turbine∈KW
Unit quantities under unit head
Unit Speed
NU= N
H12
Where,N=Turbine Speed∈RPMH=Head onTurbine∈m
Unit Power
Pu=P
H32
Where,P=Brake Power of Sh aft∈KWH=Head onTurbine∈m
Unit Discharge
Qu=Q
H12
Where,Q=Disc h arge∈m3/sH=Head onTurbine∈m
Specific speed
N S=N P
12
H54
Where,N=Turbine Speed∈RPMP=Brake Power of Sh aft∈KWH=Head onTurbine∈m
Percentage Full Load
% Full Load=Part load BPMaxload BP
x100
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
GRAPHS OF FRANCIS AND KAPLAN
For constant head characteristics Turbine efficiency Vs Unit speed Unit power Vs Unit speed Unit discharge Vs Unit speed
For constant speed characteristics Turbine efficiency Vs Percentage of full load Efficiency Vs discharge BPSHAFT Vs discharge
PRECAUTIONS
Do not start pump set if the supply voltage is less than 300v (phase to phase voltage).
Do not forget to give electrical earth and neutral connections correctly. Otherwise, the
RPM Indicator gets burnt if connections are wrong.
Frequently, atleast once in three months, grease all visual moving parts.
Initially, fill-in the tank with clean water free from foreign material. Change the water
once in a month.
Atleast every week, operate the unit for five minutes to prevent any clogging of the
moving parts.
To start and stop the supply pump, always keep Gate valve (Butterfly valve) closed.
Gradual opening and closing of the Gate valve is recommended for smooth operation.
Handle the switches gently.
After the experiment is over, switch off all the indicators.
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Constant Head/Pressure Operation
Sl.No. Turbine Type
Type of Experiment
Blade / Guide
Opening
Inlet Pressure
(kg/cm^2)
Throat Pressure
(kg/cm^2)
Delivery Pressure
(kg/cm^2)
Outlet Pressure
(kg/cm^2)
Speed (RPM)
Discharge(Cu m/s)
1 Francis Turbine
Constant Pressure Full
2 Francis Turbine
Constant Pressure Full
3 Francis Turbine
Constant Pressure Full
4 Francis Turbine
Constant Pressure Full
5 Francis Turbine
Constant Pressure Full
6 Francis Turbine
Constant Pressure Full
Turbine Output Shaft Input Turbine Specific Unit Unit Unit % Full
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SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Head (m) Power (W) Power (W) Power (W) Efficiency (%) Speed Ns Speed Nu Discharge
Qu Power Pu Load
Constant Speed Operation
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Sl.No. Turbine Type Type of Experiment
Blade / Guide Opening
Inlet Pressure (kg/cm^2)
Throat Pressure
(kg/cm^2)
Delivery Pressure(kg/cm^2)
Outlet Pressure(kg/cm^2)
1 Francis Turbine Constant Speed Full2 Francis Turbine Constant Speed Full3 Francis Turbine Constant Speed Full4 Francis Turbine Constant Speed Full5 Francis Turbine Constant Speed Full6 Francis Turbine Constant Speed Full
Speed (RPM)
Discharge(Cu m/s)
Turbine Head (m)
Output Power (W)
Shaft Power (W)
Input Power (W)
Turbine Efficiency (%)
% Full Load
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Constant Head/ Pressure Operation
Sl.No. Turbine Type
Type of Experiment
Blade / Guide
Opening
Inlet Pressure
(kg/cm^2)
Throat Pressure
(kg/cm^2)
Delivery Pressure
(kg/cm^2)
Outlet Pressure
(kg/cm^2)
Speed (RPM)
Discharge(Cu m/s)
1 Kaplan Turbine
Constant Pressure Full
2 Kaplan Turbine
Constant Pressure Full
3 Kaplan Turbine
Constant Pressure Full
4 Kaplan Turbine
Constant Pressure Full
5 Kaplan Turbine
Constant Pressure Full
6 Kaplan Turbine
Constant Pressure Full
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Turbine Head (m)
Output Power (W)
Shaft Power (W)
Input Power (W)
Turbine Efficiency
(%)
Specific Speed Ns
Unit Speed Nu
Unit Discharge
Qu
Unit Power Pu
% Full Load
Constant Speed Operation
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
Sl.No. Turbine Type Type of Experiment
Blade / Guide Opening
Inlet Pressure (kg/cm^2)
Throat Pressure (kg/cm^2)
Delivery Pressure(kg/cm^2)
Outlet Pressure(kg/cm^2)
1 Kaplan Turbine Constant Speed Full
2 Kaplan Turbine Constant Speed Full
3 Kaplan Turbine Constant Speed Full
4 Kaplan Turbine Constant Speed Full
5 Kaplan Turbine Constant Speed Full
6 Kaplan Turbine Constant Speed Full
Speed (RPM)
Discharge(Cu m/s)
Turbine Head (m)
Output Power (W)
Shaft Power (W)
Input Power (W)
Turbine Efficiency (%)
% Full Load
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
RESULT:
1. Efficiency of the Kaplan turbine ________________
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
KAPLAN TURBINE
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB
SREE CHAITANAYA COLLEGE OF ENGINEERING , KARIMNAGAR
DEPARTMENT OF MECHANICAL ENGINEERING MFHM LAB