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H Y D R A U L I C T U R B I N E SP E L T O N

F R A N C I S

K A P L A N

FRANCO TOSI MECCANICA - A COMPANY THAT HAS

ALWAYS BEEN A REFERENCE STANDARD IN THE POW-

ER GENERATION INDUSTRY - IS DEDICATED TO SERVE

YOUR THERMAL AND HYDRO POWER GENERATION

NEEDS WITH THE QUALITY AND ATTENTION YOU EXPECT

AND DESERVE. SINCE THE BEGINNING OF THE INDUS-

TRIAL AGE THE NAME FRANCO TOSI WAS CONSIDERED

A LEADER FOR RELIABLE TECHNOLOGY AND LEADING

EDGE DEVELOPMENT.

After a period of significant work abroad, particularly in

Germany, in 1876 the young engineer Franco Tosi was

called to Legnano to manage “Cantoni Krumm & C.”,

a steam engine and boiler manufacturer, which

thanks to Tosi’s work remarkably expanded its opera-

tions. Franco Tosi, an industrial pioneer, devoted him-

self to study and build reciprocating steam engines

that in a few years gained a reputation both in Italy

and internationally.

THE FIRST “TOSI ENGINE”, WITH A POWER OF 3 HP,

DATES BACK TO 1877 AND IN 1881 THE FIRST 40

TO 50 HP RYDER STEAM ENGINE WAS PRODUCED.

Tosi’s entrepreneurial vision and undisputed design

skills found their accomplishment with the advent of

the first power plants. His steam engines definitely

conquered both the domestic and the international

markets. In a few years Franco Tosi became a share-

holder and then, in 1884, the sole owner of a pio-

neer company in the energy sector that has borne his

name since 1881.

A name that still today is renowned all over the world.

Besides having excellent technical skills and being an

eminent industrialist, Franco Tosi was also a model

citizen who carried out outstanding philanthropic

work through his health insurance, social security and

professional training initiatives. An entrepreneurial

style whose signs are still visible and present today

in Legnano.

The industrial development of the Company “Franco

Tosi” followed the ups and downs of the European his-

tory in the early twentieth century, through two world

wars, the post-war recovery and the 1960s economic

boom including a strong internationalisation of the

Company’s markets.

T H E C O M P A N YC E N T U R I E S O F E X P E R I E N C E

3

FOSSIL

COMBINED CYCLES

HYDRO

SOLAR-THERMAL

GEOTHERMAL

BIOMASS

WASTE TO ENERGY

NUCLEAR

CHEMICAL

FOOD PROCESSING

PAPER MILLS

PETROLCHEMICAL

COGENERATION CHP

OIL & GAS

DISTRICT HEATING

SINCE IT WAS ESTABLISHED IN 1881, THE NAME OF

FRANCO TOSI IS RECOGNIZED AND APPRECIATED IN THE

WORLD OF POWER GENERATION AND IS SYNONYMOUS

WITH HIGH QUALITY AND RELIABILITY.

The results achieved by Franco Tosi and his technical

excellence are well known to all of its customers.

Franco Tosi Meccanica, through its experience and ex-

pertise, is willing to serve the needs of Power Genera-

tion with all the care its customers need and deserve.

Our product portfolio includes steam turbines up to

850 MW, hydraulic turbines up to 500 MW and heat

exchange apparatuses.

FTM has been focused on a long lasting policy of in-

vestment in R&D, with important results in terms of

products efficiency and reliability. In addition, Franco

Tosi Meccanica has been very active in the field of Re-

newable Energy such as Hydraulic, Geothermal, Solar

Thermal and Waste-To-Energy.

As a dedicated and competent Company, our primary

goal is Customers’ satisfaction. We want to achieve

this objective through an entrepreneurial approach fo-

cused on international markets. We will be delighted

to make our know-how and experience available to

our clients.

Franco Tosi Reference List has been realized through

130 years of experience on a global scale. The compa-

ny accounts for 75,000 MW of installed capacity, 1,000

turbines in more than 40 countries.

G L O B A L P O W E RS A L E S A N D M A R K E T A P P L I C A T I O N

“ W E S I N C E R E L Y P L A N O N D E V E L O P I N G F U T U R E P R O J E C T S T O G E T H E R ” .

U T I L I T I E S A N D I N D U S T R I A LP O W E R G E N E R A T I O N

6

P R O D U C T S A N D S E R V I C E S O F F E R E D B Y F T M

H Y D R A U L I C T U R B I N E S

PELTON

Head from 200 to 1300 m

up to 300 MW

FRANCIS


up to 500 MW

KAPLAN

Head from 5 to 70 m

up to 150 MW

BULB up to 20 MW

PUMPS AND PUMP TURBINES up to 250 MW

AGGREGATE PLANT SUPPLY

Hydro Turbine and Generator

Electrical and Mechanical BOP

Instrumentation and Control

Hydro Mechanical

Complete Hydro Electrical

Mechanical Package

Field Erection and Commissioning

S E R V I C E A C T I V I T I E S

Repowering

Electro Mechanical for Hydro and Steam Turbines

Revamping & Retrofitting

Conventional Maintenance

Long Term Service Agreements

24/7 Support Hotline

Monitoring

Diagnostic & Spare parts

Plant Simulators

Plant Management

Training

Rehabilitation Feasibility & Plant study

Remote Equipment Operation

Buy-Back of Old Machineries

S T E A M T U R B I N E S

Power generation

Cogeneration

Condensing

Back-Pressure

Single or Double Reheat

Single or Double Flow

Single or Double Extraction

Steam Induction

Upward, Downward, Lateral and Axial Exhaust

AGGREGATE PLANT SUPPLY

Steam Turbine Generator and Condenser

Thermal Cycle

Turbine Island

Electrical and Mechanical BOP

Instrumentation and Control

Field Erection and Commissioning

D E S I G N F E A T U R E S

FTM philosophy is to organize its product line in dif-

ferent standard turbine modules arranged alone or

together to tailor our solutions to customer specific

needs. Dedicated design solutions are thought to give

FTM steam turbines the best fitting to every market

range, from industrial to pure power generation.

SOME OF THEM:

• Back Pressure or Condensing Configuration

• Integral steam chest / Separated valve assemblies

(directly connected to cylinders or with pipe

connections)

• High back pressure LSB families

up to 5 m2 annular exhaust area

• LSB up to 9 m2 annular exhaust area (50 Hz).

• Fully 3D stator and rotor reaction blading for the

highest level blade path efficiency

• Any kind of controlled extraction

or induction / bleeding

• Skid supplied solutions (industrial), any

direction exhaust casings and high recovery and

efficiency axial ones

• Rotor Welding technology for optimized shaft

material combination

8 9

H Y D R A U L I C T U R B I N E S

T U R B I N E S A N D R A N G E O F A P P L I C A T I O N

H Y D R O M A C H I N E R Y

PELTON:


up to 300 MW

nq from 5 to 20

FRANCIS:


up to 500 MW

nq from 20 to 110

KAPLAN:

Head from 5 to 70 m

up to 150 MW

nq from 100 to 250

VALVES:

BUTTERFLY

up to DN 3000 and PN 30

SPHERICAL

up to DN 2500 and PN 160

Thanks to its long and diversified experience in hy-

dro power machinery, today Franco Tosi Meccanica is

able to cover a full range of market applications for

the power generation industry. Advanced engineering

and standardization methods are the strengths of our

approach. Nature is the most important interface for

hydroelectric power plants configuration and raises al-

ways new challenges for the engineering.

1 1

APPLICATION RANGE

Our Company has delivered important projects to the

market through decades of international experience.

We acquired specific experience in Pelton configuration

and design with heads above 1000 meters.

NET HEAD FROM 300 m TO 1300 m

OUTPUT POWER UP TO 300 MW

nq FROM 5 TO 20

EXAMPLE OF PELTON APPLICATION RANGE

The above chart of a 2 jets Pelton shows the rela-

tion between head, speed, diameter and maximum

reachable power for a typical 2 jets Pelton turbine.

Moving along one of the red continuous lines, a rota-

tional speed value is chosen and kept fixed, therefore

the curve reflects the optimal ratio between head and

Pelton runner impulse diameter. All the area below the

chosen curve is the possible operational field, where

the given power is proportional to the extracted flow.

Therefore, the curve represents the maximum power

extractable for the given conditions of rotational speed

and head. Moving along the dashed lines, which are in

an infinite number, the runner impulse diameter is kept

fixed, therefore they show the variation in maximum

attainable power with the different combinations of

rotational speed and head values.

For higher or lower number of jets configurations, the

above graph can be simply scaled up or down in max-

imum power according to the ratio between the actual

number of jets and two.

For example, at the same head and rotational speed,

when a 2 jet Pelton produces a maximum power of

10000 kW, a 4 jet Pelton produces a maximum power

of 20000 kW.

10000

20000

30000

40000

50000

60000

70000

Constant D, speed increase

Constant speed, D increase

MAX

IMUM

POW

ER [k

W]

120010008006004002000

0

1400

HEAD [m]

P E L T O NH Y D R A U L I C T U R B I N E S

1 4 1 5

DESIGN

Our engineering department can ensure the best

practices and solutions to our customers since we have

developed a large range of projects and delivered

Pelton Turbines up to six jets. 3D standardization of

main turbine components is used for quick modular

and parametric design.

TOTAL PRESSURE(contour)

5.643e+006

5.003e+006

4.364e+006

3.724e+006

3.084e+006

2.444e+006

1.805e+006

1.165e+006

5.250e+005

- 1.148e+005

- 7.546e+005

NUMERICAL SIMULATION

Completely CFD unsteady biphase simulation is perfor-

med to study the jet impact on the bucket, in order to

maximize the turbine efficiency. Finite Element Mecha-

nical simulation and fatigue analysis are performed to

find the most critical regions and to reduce the stress.

[Pa]

1 6

EXAMPLE: LOW SPECIFIC SPEED

FRANCIS APPLICATION RANGE

One of the most important parameter to fit a turbine

model into a given plant configuration is the maximum

installation depth. An example of typical Francis con-

figuration can be defined by the charts above which

clearly express the relationship among head, diameter,

revolutions per minute and power of our turbines.

The first chart describes the application range from 40

m to 160 m. Diameters change in relationship to the

head and the desired configuration in terms of revolu-

tions per minute.

The second chart describes the power in terms of kW at

the change of diameter and revolutions per minute. In

between the two limits at lower and upper rotational

speeds all generator number of poles configuration are

feasible. For example, with a head of approximately

160 m and 250 rpm, the diameter of the turbine is

approximately 3,4 meters with a corresponding maxi-

mum power greater than 45 MW.

LOW Ns FRANCIS: HEAD VS. RUNNER DIAMETER GIVEN A

MAXIMUM INSTALLATION DEPTH

APPLICATION RANGE

Natural conditions are never the same. Thanks to our

wide experience, we have developed a set of solutions

for the configuration of the most challenging environ-

mental conditions. The application range for our Francis

Turbines could be best defined as follows:



nq FROM 20 TO 110

F R A N C I SH Y D R A U L I C T U R B I N E S

LOW Ns FRANCIS: POWER VS. RUNNER DIAMETER GIVEN A

MAXIMUM INSTALLATION DEPTH

POW

ER [k

W]

DIAMETER [m]

0

10000

20000

30000

40000

50000

0 1

600 rpm

250 rpm

2 3 4

4

DIAMETER [m]

HEAD

[m]

0

0 1

600 rpm 250 rpm

3

20

40

60

80

100

120

140

160

180

1 8 1 9

[Pa]

ABSOLUTE PRESSURE

1966909.51861709.01756508.51651308.01546107.51440907.11335706.61230506.11125305.61020105.2

914904.7809704.2704503.8599303.3494102.8388902.3283701.8178501.3

73300.9

VOLUME FRACTION

0.990.940.880.830.770.720.660.610.550.500.440.390.330.280.220.170.110.060.00

DESIGN

FTM is able to design the entire turbine and to study

new components to fit existing installed parts. In case

of lack of original drawings, FTM can perform reverse

engineering in order to get the 3D model of the turbine

components. This gives the possibility to estimate the

efficiency improvement due to the replacement of the

hydraulic active parts.

CFD ANALYSIS

Complete hydraulic channel is simulated in order to

estimate the turbine performances depending on the

wicket gates opening. Specific analysis is performed to

identify the regions which can be affected by cavitation

problems. Complete unsteady simulation is performed to

detect and reduce instability phenomena at partial load.

2 0

APPLICATION RANGE

Our Company has delivered important projects to the

market through decades of international experience.

We acquired specific experience in configuration and

design both for Vertical and Horizontal Kaplan.

K A P L A NH Y D R A U L I C T U R B I N E S

VERTICAL SHAFT



HORIZONTAL SHAFT



KAPLAN TURBINE MODELS APPLICATION RANGE

The most characteristic feature of a Kaplan turbine,

which immediately permits to identify a standard

model, is the number of runner blades. Due to the

limited load carrying capability of each runner blade,

the more the turbine head increases, the greater num-

ber of blades is needed to convert the water pressure

into mechanical energy. The close correlation between

the turbine head H and the specific speed nq permits

to reflect the just explained function into a relationship

between the specific speed and the number of turbine

blades, which is expressed in the chart above.

In the graph are reported real-case application data

of FTM turbines, which lay on the chart space with

a typical hyperbolic shape, as the specific speed nq

grows with the turbine flow and decreases with the

turbine head. Three typical zones are identifiable: the

high head zone on the left, typically corresponding to

relatively low specific speed Kaplan turbines (below

100) and great number of blades (7-8), the interme-

diate central zone with 5 blades solutions and the high

specific speed (above 200) zone on the right, with few

blades (3-4) and typically horizontal applications. It is

clear also from the number of applications that the 5

blades type is the most flexible design in terms of dif-

ferent environmental conditions coverage capacity.

For example a turbine with H = 20 m, Q = 50 m3/s

will be very likely to rotate at 187.5 rpm (if with direct

connection to the generator) and have a specific speed

nq of 140, leading to a 5 blades solution.

TYPICAL KAPLAN TURBINES APPLICATION RANGE

SPECIFIC SPEED [nq]

NET

HEA

D [m

]

0 10050 150 200 250 3503000

90

80

70

60

50

40

30

20

10

7-8 blades vertical5 blades vertical

or horizontal (S-type)

4 blades vertical or 3 blades horizontal

(bulb, open pit)

2 2 2 3

DESIGN

FTM product range covers axial turbines both in hori-

zontal and vertical layout, S-Type, steel and concrete

spiral case. The machining capability goes up to 10 m

of external runner diameter.

VELOCITY (LINE)

3.332e+001

2.499e+001

1.666e+001

8.333e-003

3.383e-003

[m s^-1]

NUMERICAL ANALYSIS

CFD analysis are performed to study the flow in the

hydraulic channel, in order to optimize the profile and

to get the best conjugation law between wicket gates

and runner blades opening.

The hydraulic pressure is imported from CFD to Mecha-

nical Finite Element simulation, to study the localized

stresses and to design the local relief grooves and the

fillet radius of the runner blades.

2 4

APPLICATION RANGE

Thanks to a well proven experience, FTM is able to de-

sign and produce customized main shut-off and pen-

stock valves as well as pressure relief valves.

The chart above can be used for a rapid evaluation of

the hydraulic torque acting on the rotor and therefore

for the design of the rotating system, starting from a

non-dimensional parameter obtained from the ratio

between the current and the reference flow. The refer-

ence valve characterization is obtained through a series

of CFD simulations.V A L V E SB U T T E R F L Y - S P H E R I C A L

P R E S S U R E R E L I E F V A L V E S

BUTTERFLY UP TO DN 3000 UP TO PN 30

SPHERICAL UP TO DN 2500 UP TO PN 160

FLUID TORQUE COEFFICIENTON THE ROTOR

80

VALVE OPENING [deg]

cC [-

]

0 20 40 60

0

1,5

3

4,5

6

cq=0.2cq=0.5cq=1cq=2

2 6 2 7

DESIGN

The selection of the valve typology is based on the

operating characteristics of the turbine. Advanced

design tool permits to find the solution to fit any ope-

rational requirement.

NUMERICAL ANALYSIS

Plant hydraulic transient analysis is performed in order

to optimize water column dynamic response in terms

of over-pressure and over speed. CFD and mechanical

finite element analysis are performed to study the flow

into the valve and to verify the structural integrity.

VELOCITY

14.6313.7212.8011.8910.9810.07

9.158.247.336.415.504.593.672.761.850.930.02

[m s^-1]

2 8

All rights reserved.

Subjects to change without prior notice.

Information in this document contains general descriptions which are not legally binding for Franco Tosi Meccanica.

Each turbine produced by Franco Tosi Meccanica is specifically tailored to the needs and requests of our client.

Each request shall be discussed with our Marketing & Sales Department.

O U R J O B F O R Y O U R P O W E RI N T H E W O R L D

ALBANIA

ARGENTINA

AUSTRIA

BAHRAIN

BELGIUM

BOPHUTHATSWANA

BRAZIL

BULGARIA

CHILE

CONGO

COSTARICA

EQUADOR

ETHIOPIA

FRANCE

GERMANY

GHANA

GREECE

GUADALUPE

GUATEMALA

INDIA

INDONESIA

IRAN

IRAQ

ITALY

JAMAICA

JORDAN

KOREA

LEBANON

LIBYA

MALTA

MEXICO

NETHERLANDS

NICARAGUA

PAKISTAN

PANAMA

PERÙ

PHILIPPINES

POLAND

PORTUGAL

QATAR

RUSSIA

SAUDI ARABIA

SOUTH AFRICA

SERBIA

SPAIN

TAIWAN

THAILAND

TURKEY

UAE - ABU DHABI

UAE - DUBAI

UNITED KINGDOM

UKRAINA

URUGUAY

U.S.A.

UZBEKISTAN

VENEZUELA

WWW.FRANCOTOSIMECCANICA.IT

FRANCO TOSI MECCANICA SPA

Piazza Monumento, 12 20025 Legnano (Mi) [email protected] [email protected]@francotosimeccanica.it

U.S.A. OfficeFranco Tosi/Energy Allied5847 San Felipe, Suite 4150Houston, TX 77057, U.S.A.Phone: +1 713 590-5370Fax: +1 713 [email protected]

hydraulic turbines - · pdf fileself to study and build reciprocating steam engines ......

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