Stress & Experimental Analysis of Simple and Advanced Pelton Wheel

 

THE PROJECT P ENTITLED E

ST TRESS & EXPERIMEN NTAL AN NALYSIIS OF SIM MPLE AND A ADVANCE ED PELT TON WH HEEL SU UBMITTED D IN PART TIAL FULL LFILLMENT T OF THE REQUIREM MENT FOR R THE DEGRE EE OF BAC CHELOR OF O ENGINE EERING IN N

M MECHAN ICAL EN NGINEER RING SU UBMITTE ED BY 1. Mr. M MITHA AIWALA CHIRAG C

64913

2. Mr. M PATEL L DHAVAL L

64916

3. Mr. M GAJER RA CHINT TAN

64920

4. Mr. M VALA KULDIP

5481

GU UIDED BY

Mr. SAMIP P. P SHAH

CO-GUID DED BY

Mr. M GAUR RANG C. CHAUDH HARY

LEC CTURER, (M.E.D.) (

LEC CTURER, (M M.E.D.)

CKP PCET – SU URAT

C CKPCET - SURAT S

 

C C. K. PITH HAWALLA A COLLEG GE OF EN NGINEER RING & TEECHNOLOGY  SURATT 

THE PROJECT ENTITLED 

STRESS & EXP PERIMENTTAL ANALLYSIS OF   SIMP PLE AND A ADVANCED PELTON N WHEEL  SUBMITTED IN PARTIALL FULLFILLM MENT OF TH HE REQUIREEMENT FOR THE DEGREEE OF  BACHELO OR OF ENGINEERING IN 

MECHANICAL ENGINEERIN NG  SUBMITTED D BY  1. M Mr. MITHAIW WALA CHIR RAG  

 

649 913 

2. M Mr. PATEL D DHAVAL  

 

 

649 916 

Mr. GAJERA CHINTAN  3. M

 

 

649 920 

4. M Mr. VALA KU ULDIP   

 

 

548 81 

GUIDED BY

CO-GUID DED BY

Mr.. SAMIP P. P SHAH

Mr. GAU URANG C. CHAUD DHARY

LEC CTURER, (M.E.D.)

LECT TURER, (M M.E.D.)

CKPCET – SU URAT

CKPCET - SURAT

C C. K. PITH HAWALLA A COLLEG GE OF EN NGINEER RING & TEECHNOLOGY  SURATT 

CERTIFICATE

This is to certify that the seminar entitled “STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL” submitted by Mr. Mithaiwala Chirag (64913), Mr. Patel Dhaval (64916), Mr. Gajera Chintan (64920), Mr. Vala Kuldip (5481) in partial fulfillment for the award of the degree in “BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING” of the C.K.Pithawalla college of Engineering & Technology, Surat is a record of their own work carried out under my supervision and guidance. The matter embodied in the report has not been submitted elsewhere for the award of any degree or diploma.

GUIDED BY:

Mr. SAMIP P. SHAH

CO-GUIDED BY:

Mr.GAURANG C. CHAUDHARI

Lecturer,

Lecturer,

(M.E.D.)

(M.E.D.)

C.K.P.C.E.T.

C.K.P.C.E.T.

Mr.ANISH H. GANDHI Asst.Professor, Head of Mechanical Engineering Department C.K.P.C.E.T.

EXAMINER’S CERTIFICATE OF APPROVAL

This is to certify that the project entitled “STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE & ADVANCED PELTON WHEEL” submitted by Mr. Mithaiwala Chirag (64913), Mr Patel Dhaval (64916), Mr. Gajera Chintan (64920), Mr. Vala Kuldip (5481), in partial fulfillment of the requirement for award of the degree in “BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING” of the C.K.Pithawalla college of Engineering & Technology, Surat is hereby approved for the award of the degree.

EXAMINERS: 1. 2. 3. 4.

ACKNOWLEDGEMENT

It has been great privilege for me to work under estimated personality respected Mr. Samip P. Shah Sir highly intelligent, experienced and qualified lecturer in Mechanical Engg. Dept. C.K.P.C.E.T. Surat. It is my achievement to be guided under him. He is a constant source of encouragement and momentum that any intricacy becomes simple. I gained a lot of in valuable guidance and prompt suggestions from him during entire project work. I will be indebted of him for ever and I take pride to work under him. We are thankful to Mr. Gaurang C. Chaudhary Sir who has guided us and helped us during project work. W are also thankful to Mr.Anish H. Gandhi (H.O.D.) to provide us facility like laboratory & workshop and being kindly helpful in this project.

Mr. Mithaiwala Chirag Mr. Patel Dhaval Mr. Chintan Gajera Mr. Vala Kuldip

CONTENTS

-ABSTRACT -NOMENCLATURES

I II

-LIST OF FIGURE

IV

-LIST OF PLATES

VI

-LIST OF GRAPHS

VII

1. INTRODUCTION

1-13

1.1 INTRODUCTION TO HYDRO POWER PLANT

1

1.2 GENERAL LAYOUT OF A HYDRO POWER PLANT

2

1.2.1 GROSS HEAD

3

1.2.2 NET HEAD

3

1.3 CLASSIFICATION OF HYDRAULIC TURBINES

4

1.4 PELTON WHEEL TURBINE

5

1.4.1 HISTORY OF PELTON WHEEL

5

1.4.2 THE PELTON TURBINE OPERATING PRINCIPLE

7

1.5 LAYOUT OF PELTON WHEEL

8

1.5.1 NOZZLE AND FLOW REGULATING ARRANGEMENT

9

1.5.2 RUNNER WITH BUCKETS

9

1.5.3. CASING

10

1.5.4. BREAKING JET

11

1.6 EFFICIENCIES OF TURBINE

11

1.6.1 HYDRAULIC EFFICIENCY (ɳh)

11

1.6.2 MECHANICAL EFFICIENCY (ɳm)

12

1.6.3 VOLUMETRIC EFFICIENCY (ɳV)

12

1.6.4 OVERALL EFFICIENCY (ɳO)

12

1.7 COMPARISION BETWEEN SIMPLE & ADVANCE PELTON WHEEL

13

1.7.1 SIMPLE PELTON WHEEL

13

1.7.2 ADVANCE PELTON WHEEL

13

2. LITRATURE REVIEW 2.1 LITRATURE REVIEW RELATED TO THEORETICAL APPROACH 2.2 LITERATURE REVIEW RELATED TO ADVANCE PELTON WHEEL 2.3 OBJECTIVE OF PRESENT WORK 3. DIMENSIONAL DETAIL OF PELTON WHEEL 3.1 FORCE CALCULATION 4. MODELING OF PELTON WHEEL

14-27 14 18 27 28-30 30 31-37

4.1 INTRODUCTION TO PRO/ENGINEER

31

4.2 MODULES IN PRO/ENGINEER

32

4.3 FEATURES OF PRO/ENGINEER

33

4.3.1 PARAMETRIC DESIGN

33

4.3.2 FEATURE-BASED APPROACH

33

4.3.3 PARENTS CHILLED RELATIONSHIP

34

4.3.4 ASSOCIATIVE AND MODEL CENTRIC

34

4.4 GRAPHIC USER INTERFACE OF PRO/ENGINEER

34

4.4.1 MENU BAR

34

4.4.2 TOOLCHESTS

35

4.4.3 NAVIGATION AREA

35

4.4.4 GRAPHIC WINDOWS

35

4.4.5 DASHBOARD

36

4.4.6 INFORMATION AREA

36

4.5 MODELING OF BUCKET 5. STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

36 38-43

5.1 INTRODUCTION

38

5.2 MODELING

38

5.3 TRADITONAL RUNNER

38

5.4 ADVANCED OR HOOPED RUNNER

41

5.5 MECHANICAL CALCULATIONS

41

5.5.1 STRUCTURAL BEHAVIOR

42

5.5.2 STATIC STRESSES RESULTS

43

6. MANUFACTURING OF HOOP PELTON WHEEL 6.1 BUCKET CASTING PROCESS

44-48 44

6.1.1 BENCH MOULDING

44

6.1.2 CASTING PROCESS

44

6.1.3 BUCKET CASTING SPECIFICATION

46

6.1.4 MACHING PROCESS

46

6.2 MANFACTURING OF RUNNER

47

6.3 MANUFACTURING OF HOOP

47

7. PERFORMANCE EVALUATION

49-52

7.1 DATA OF PRACTICAL SET UP

50

7.2 SAMPLE CALCULATION

50

8. RESULT AND DISCUSSION

53-74

9. CONCLUSION

75

10. FUTURE SCOPE

76

APPENDIX - A

77

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

APPENDIX – B

EXPERIMENTAL

DATA

&

RESULTS

OF

SIMPLE

PELTON WHEEL APPENDIX – C

EXPERIMENTAL DATA & RESULTS OF ADVANCED PELTON WHEEL

APPENDIX – D

EXPERIMENTAL ANALYSIS OF SIMPLE & ADVANCED PELTON WHEEL

REFERANCES

ABSTRACT

In this project we have checked newly develop design known as hooped runner or advanced pelton wheel in which there are two hoops which supports the bucket from back side and giving it to rest on it. The new design is based on redistribution of the function of different parts of pelton wheel. In conventional runner the jet of water is directly strike to splitter of the bucket and transfers the force to it than buckets convert it into momentum by which the shaft is rotate and giving us power. Whereas in advanced pelton wheel bucket does not directly transport the force to the runner but transfer the force via these hoops and these hoops is connected to shaft and by that producing the power so due to hooped runner bucket act as simply supported beam comparing to simple pelton wheel so stress developed in hooped pelton is less due to this construction. In this project we want to achieve some critical data like stress developed and efficiency by which we can choose that which have batter overall performance. For stress analysis we use ANSYS workbench v11.0 and for finding the efficiency we made the advanced pelton wheel from this data and carried out detailed experiment. The project entitled “STRESS AND EXPERIMENTAL ANALYSIS OF SIMPLE & ADVANCED PELTON WHEEL” is broadly divided in to ten chapters. The chapter one discuss about the general layout of hydro electrical power plant and the classification of hydraulic turbines. The objective of work and necessary literature are reviewed pertaining to present topic are discussed in chapter two. The dimensional detail of pelton wheel use in this project is given in chapter three. Use of Pro/Engineer software & its modules are discussed in chapter four. Chapter five is discussed about stress analysis which we have done. The manufacturing of bucket is discussed in chapter six. The performance evolution carried out on pelton wheel is given in chapter seven. In the chapter eight the results achieved from stress analysis and by the practical are discussed. The conclusion of whole project is mentioned in chapter nine and the Future scope of present work is given chapter ten.

I   

NOMENCLATURES d = Inlet pipe diameter (m) dj = Jet diameter (m) D = Mean diameter of runner (m) Fu = Force on runner (N) g = Gravitational force (m/sec2) H = Net Head (m) Hg = Gross Head (m) Hf = Friction Head (m) Kv1 = Velocity of co-efficient m = Jet Ratio N = Speed (rpm) Ns = Specific Speed (rpm) P = Produced Power (kW) Q = Flow rate of water (m3/sec) Re = Extreme dia of runner (m) Ri = Mean radius of runner (m) v1 = Velocity of flow at inlet v2 = Velocity of flow at outlet u = Runner speed (m/sec) Z = No. of buckets

II   

Greek Symbols β1 = Inlet angle of bucket β2 = Outlet angle of bucket δ = Half length of bucket ɳh = Hydraulic Efficiency ɳm = Mechanical Efficiency ɳv = Volumetric Efficiency ɳo = Overall Efficiency ρ = Density of water (1000 kg/m3) Ψ = Angle (in general)

III   

LIST OF FIGURE

FIGURE NO.

NAME

PAGE NO.

1.1

Hydraulic turbine and electrical generator

2

1.2

General layout of hydraulic power plant

3

1.3.1

Classification according to action of fluid on moving fluid

4

1.3.2

Classification according to direction of flow of fluid in runner

4

1.4.1

Pelton turbine original patent document

7

1.4.2

Bucket geometric definitions

8

1.5.1

Straight flow nozzle

9

1.5.2

Runner of pelton wheel

10

2.1.1

Turbine housing modification in and pelton runner dimensions

14

2.1.2

Coanda effect

15

2.1.3

Casing with cylindrical dome

16

2.1.4

Casing with rectangular dome

16

2.1.5

Effect of the casing on unit discharge, efficiency and

17

efficiency behavior factor 2.1.6

Jet needle tip and nozzle seat ring modifications for jet

17

quality improvement 2.1.7

Jet diameters in the observation area of nozzle 1 measured

18

from the images at three observation angles 2.2.1

Hooped Pelton runner for Beaufort power plant

19

2.2.2

Tangential displacement from FEA on 3D model

20

2.2.3

Buckets fixed on the hoops

21

IV   

2.2.4

Arrangements of the hoops

21

2.2.5

Hydraulic efficiency of traditional runner and hooped

22

runner with no adaptation of the hoops. 2.2.6

Comparison of efficiency between a traditional runner and

22

a modified hooped runner 2.2.7

Tangential displacement of the hoops at synchronous speed

23

2.2.8

Equivalent stress at synchronous speed

24

2.2.9

Displacement of Traditional Runner of Pelton Wheel

25

2.2.10

Tangential Displacement of the Hoop (Double hoop)

26

2.2.11

Equivalent Stress (Double Hoop)

26

3.1

Construction of pelton runner blade

28

3.2

Bucket used in this project

29

4.1.1

Pro/Engineer in the industry

31

4.2.1

Modules in Pro/ENGINEER foundation

32

4.4.1

Menu bar of pro-engineering

35

4.5.1

Model of bucket created in Pro/Engineer

37

5.3.1

Model of pelton wheel

39

5.3.2

Constrains given to pelton wheel

39

5.3.3

Displacement of Traditional pelton wheel

40

5.3.4

Stress developed in the Traditional pelton wheel

40

5.5.1

Tangential Displacement of the advanced pelton wheel

42

5.5.2

Equivalent Stresses developed in the advanced pelton

43

wheel 6.1

Classification of sand moulding process

44

6.1.2

A metal casting poured in a sand mould

45

V   

LIST OF PLATES

PLATE NO.

NAME

1

Front and back view of Bucket used in this model

46

2

Hooped pelton wheel

47

3

Hooped pelton wheel after balancing

48

4

Test rig used for experiment

49

5

Hooped runner mounted on shaft.

50

 

VI   

PAGE NO.

LIST OF GRAPHS

GRAPH

NAME

PAGE

NO. 8.1

NO. 3

Max eq. Stress v/s Speed at Q = 0.01 m /sec (simple pelton

53

wheel) 8.2

Min eq. stress v/s Speed at Q = 0.01 m3/sec (simple pelton

54

wheel) 8.3

Max displacement v/s Speed at Q = 0.01 m3/sec (simple

54

pelton wheel) 8.4

Max eq. stress v/s Speed at Q = 0.00666 m3/sec (simple

55

pelton wheel) 8.5

Min eq. stress v/s Speed at Q = 0.00666 m3/sec (simple pelton

55

wheel) 8.6

Max displacement v/s Speed at Q = 0.00666 m3/sec (simple

56

pelton wheel) 8.7

Max eq. stress v/s Speed at Q = 0.005 m3/sec (simple pelton

56

wheel) 8.8

Min eq. stress v/s Speed at Q = 0.005 m3/sec (simple pelton

57

wheel) 8.9

Max displacement v/s Speed at Q = 0.005 m3/sec (simple

57

pelton wheel) 8.10

Max eq. stress v/s Speed at Q = 0.0033 m3/sec (simple pelton

58

wheel) 8.11

Min eq. stress v/s Speed at Q = 0.0033 m3/sec (simple pelton

58

wheel) 8.12

Max displacement v/s Speed at Q = 0.0033m3/sec (simple

59

pelton wheel) 8.13

Max Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton

59

wheel) 8.14

Min Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)

VII   

60

8.15

Max displacement v/s Speed at Q = 0.01 m3/sec (Advance

60

pelton wheel) 8.16

Max Stress v/s Speed at Q = 0.00666 m3/sec (Advance pelton

61

wheel) 8.17

Min Stress v/s Speed at Q = 0.00666 m3/sec (Advance pelton

61

wheel) 8.18

Max displacement v/s Speed at Q = 0.00666 m3/sec (Advance

62

pelton wheel) 8.19

Max Stress v/s Speed at Q = 0.005 m3/sec (Advance pelton

62

wheel) 8.20

Min Stress v/s Speed at Q = 0.005 m3/sec (Advance pelton

63

wheel) 8.21

Max displacement v/s Speed at Q = 0.005 m3/sec (Advance

63

pelton wheel) 8.22

Max Stress v/s Speed at Q = 0.0033 m3/sec (Advance pelton

64

wheel) 8.23

Min Stress v/s Speed at Q = 0.0033 m3/sec (Advance pelton

64

wheel) 8.24

Max displacement v/s Speed at Q = 0.0033 m3/sec (Advance

65

pelton wheel) 8.25

Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.01 m3/sec

66

(Advance pelton wheel) 8.26

Unit power (Pu) v/s Unit speed (Nu) at Q = 0.01 m3/sec

67

(Advance pelton wheel) 8.27

Efficiency (η) v/s Unit speed (Nu) at Q = 0.01 m3/sec

67

(Advance pelton wheel) 8.28

Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.006 m3/sec

68

(Advance pelton wheel) 8.29

Unit power (Pu) v/s Unit speed (Nu) at Q = 0.006 m3/sec

68

(Advance pelton wheel) 8.30

Efficiency (η) v/s Unit speed (Nu) at Q = 0.006 m3/sec

69

(Advance pelton wheel) 8.31

Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.005 m3/sec

VIII   

69

(Advance pelton wheel) 8.32

Unit power (Pu) v/s Unit speed (Nu) at Q = 0.005 m3/sec

70

(Advance pelton wheel) 8.33

Efficiency (η) v/s Unit speed (Nu) at Q = 0.005

70

3

m /sec(Advance pelton wheel) 8.34

Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.0033

71

m3/sec(Advance pelton wheel) 8.35

Unit power (Pu) v/s Unit speed (Nu) at Q = 0.005 m3/sec

71

(Advance pelton wheel) 8.36

Efficiency (η) v/s Unit speed (Nu) at Q = 0.0033 m3/sec

72

(Advance pelton wheel) 8.37

Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and

72

20 % opening 8.38

Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and

73

40 % opening 8.39

Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and

73

60 % opening 8.40

Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and

74

80 % opening 8.41

Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 100 % opening

IX   

74

INTRODUCTION

 

CHAPTER 1 INTRODUCTION 1.1 INTRODUCTION TO HYDRO ELECTRIC POWER PLANT [1] The purpose of a Hydro-electric plant is to produce power from water flowing under pressure. As such it incorporates a number of water driven prime-movers known as Water turbines.

The world’s First Hydroelectric Power Plant Began Operation September 30, 1882.When you look at rushing waterfalls and rivers, you may not immediately think of electricity. But hydroelectric (water-powered) power plants are responsible for lighting many of our homes and neighborhoods. On September 30, 1882, the world's first hydroelectric power plant began operation on the Fox River in Appleton, Wisconsin. The plant, later named the Appleton Edison Light Company, was initiated by Appleton paper manufacturer H.F. Rogers, who had been inspired by Thomas Edison's plans for an electricity-producing station in New York.

In 1933, the U.S. government established the Tennessee valley Authority (TVA), which introduced hydroelectric power plants to the south’s troubled Tennessee River Valley. The TVA built dams, managed flood control and soil conservation programs and more. It greatly boosted the region’s economy. And this development happened in other place as well. Soon, people across the country were enjoying electricity in homes, schools, and offices, reading by electric lamp instead of candlelight or kerosene. New electricitypowered technologies entered American homes, Including electric refrigerators and stoves, radios, televisions, and can openers. Today, people take electricity for granted, not able to imagine life without it.

Hydraulic machines are defined as those machines which convert either hydraulic energy [energy possessed by water] into mechanical energy [which is further converted into electrical energy] or mechanical energy into hydraulic energy. The hydraulic machines, which convert the hydraulic energy into mechanical energy, are called turbines.

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

1

INTRODUCTION

 

This mechanical energy is used in running an electric generator which is directly coupled to the shaft of the turbine. Thus the mechanical energy is converted into the electrical energy. The electric power which is obtained from the hydraulic energy [energy of water] is known as Hydro-electric power. At present the generation of hydro-electric power is the cheapest as compared by the power generated by other sources such oil, coal etc.

Fig 1.1 Hydraulic turbine and electrical generator [1]

1.2 GENERAL LAYOUT OF A HYDRO-ELEC. POWER PLANT [2] Fig.1.2 shows a general lay-out of a hydro-electric power plant which consists of (1) A dam constructed across a river to store water. (2) Pipes of large diameters called penstocks, which carry water under pressure from the storage reservoir to the turbines. These pipes are made of steel or reinforced concrete. (3) Turbines having different types of vanes fitted to the wheels. (4) Tail race, which is a channel which carries water away from the turbines after the water has worked on the turbines. The surface of water in the tail race is also known as tail race. STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

2

INTRO ODUCTION

 

Fig 1.2 1 Generall layout of hydraulic h poower plant [2] 1.2.1 GR ROSS HEAD D [2] Thee different between b thee head race level and taail race leveel when no water is flo owing is knoown as grosss head. It is denoted byy ‘Hg’. 1.2.2 NET T HEAD [22] It iss also calleed effective head and is defined as the headd available at the inleet of the turbbine. When water is flowing f from m head racce to the tuurbine, a looss of head d due to fricttion betweeen the waterr and penstoocks occurss. Though thhere are othher losses also such as looss due to bend, b pipe fittings, f losss at the entrrance of pennstock etc., yet they aree having smaall magnitudde as compaared to headd loss due to t friction. If I ‘hf’ is thhe head losss due to fricttion betweeen penstockss and water than net heeat on turbinne is given bby

H= =Hg - Hf

Hf =

Wheree, Hg = gross head,

Where, V= = velocity oof flow in penstock, L= = length of the pen, D=diameeter of the penstock.

STRE ESS & EXPERIIMENTL ANALYSIS OF SIMPL PLE AND ADVA ANCED PELTO ON WHEEL

3

INTRO ODUCTION

 

1.3 CLASSIIFICATIO ON OF HYDRAUL LIC TUR RBINES [22] Thee hydraulic turbines t aree classified according to t the type of o energy aavailable at the inlet of the t turbine, direction of o flow throough the vaanes, head at the inlet of the turb bine and speccific speed of the turbines. Thus the followiing are the important cclassificatio on of the turbbine:

Turb bine Impulse 

Reaction 

Turb bine

Turrbine

F 1.3.1 Claassification according to action off fluid on m Fig moving blad des

Hydrau ulic  Turbin ne Tangential

Radial

Axial

Mixed

Flow Turrbine

bine Flow Turb

ne Flow Turbin

Flow Turbine

Outwarrd

Inward

Radial

Radial

bine Flow Turb

Flow Turbiine

Fig 1.3.22 Classificaation accordding to direection of floow of fluid iin the runneer If at a the inlet of the turbiine, the eneergy availab ble is only kinetic eneergy, the tu urbine is knoown as impuulse turbine. As the waater flows ov ver the vanees, the pressure is atmo ospheric from m inlet to ouutlet of the turbine. If at a the inlet of o the turbinne, the wateer processess kinetic enerrgy as well as pressuree energy, thhe turbine iss known as reaction tuurbine. As th he water flow ws through the runner,, the water is under pressure andd the pressuure energy goes on

STRE ESS & EXPERIIMENTL ANALYSIS OF SIMPL PLE AND ADVA ANCED PELTO ON WHEEL

4

INTRODUCTION

 

changing in to kinetic energy. The runner is completely enclosed in and air tight casing and the runner and casing is completely full of water. If the water flows along the tangent of the runner, the turbine is known at tangential flow turbine. If the water flows in the radial direction through runner, the turbine is called radial flow turbine. If the water flows from outwards to in wards, radially the turbine is known as inward radial flow turbine, on the other hand, if water flows radially from inwards to out wards, the turbine is known as outward radial flow turbine if the water flow through the runner along the direction parallel to axis of the rotation of the runner, the turbine is called axial flow turbine. If the water flows through the runner in the radial direction but leaves in the direction parallel to axis of rotation of the runner, the turbine is called mixed flow turbine.

1.4 PELTON WHEEL TURBINE [1] The pelton wheel is a tangential flow impulse turbine. The water strikes the bucket along the tangent of the runner. The energy available at the inlet of the turbine is only kinetic energy. The pressure at the inlet and outlet of the turbine is atmosphere. This turbine is used for high head and is named after L.A.PELTON, an American engineer. 1.4.1 HISTORY OF PELTON WHEEL [1] Lester A. Pelton was an American inventor who successfully developed a highly efficient water turbine, for a high head, but low flow of water operating in many situations. Most notable today the hydro-electric power stations. Little is known of his early life. Pelton embarked on an adventure in search of gold. He came to California from Ohio in 1850, he was 21 years old. In 1864 after a failed quest for gold he was working in the gold mines as a millwright, and carpenter at Camptonville, Yuba County, California. It was here that he made a discovery which won for him a permanent place in the history of water power engineering. In the mines, Pelton saw water wheels were being used to provide mechanical power for all things mining, air compressors, pumps, stamp mills and operating other machines. The energy to drive these wheels was supplied by powerful jets of water which struck the base of the wheel with flat-faced vanes. These vanes eventually evolved into hemispherical cups, with the jet striking at the center of the cup on the wheel. Pelton further observed that one of the water wheels appeared to be rotating faster than other similar machines. It turned out initially that this was due to the

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

5

INTRODUCTION

 

wheel had come loose, and moved a little on its axle. He noticed the jet was striking the inside edge of the cups, and exiting the other side of the cup. His quest for improvement resulted in an innovation. So Pelton reconstructed the wheel, with the cups off center only to find again that it rotated more rapidly. Pelton also found that using split cups enhanced the effect. By 1879 he had tested a prototype at the University of California, which was successful. He was granted his First patent in 1880. By 1890, Pelton turbines were in operation, developing thousands of horsepower, powering all kinds of equipment. In 1889 Pelton was granted a patent with the following text. Pelton water turbine or wheel is a rotor driven by the impulse of a jet of water upon curved buckets fixed to its periphery; each bucket is divided in half by a splitter edge that divides the water into two streams. The buckets have a two-curved section which completely reverses the direction of the water jet striking them. The first wheel that Pelton put to practical use was to power the sewing machine of his landlady, Mrs. W. G. Groves in Camptonville. This prototype wheel is on display at a lodge in Camptonville. He then took his patterns to the Allan Machine Shop and Foundry in Nevada City (now known as the Miners Foundry). Wheels of various types and sizes were made and tested. Hydro-electric plants of thousands of horsepower running at efficiencies of more than 90 per cent were generating electric power by the time of his death in 1910. The Pelton wheel is acclaimed as the only hydraulic turbine of the impulse type to use a large head and low flow of water in hydro-electric power stations. Pelton wheels are still in use today all over the world in hydroelectric power plants. The Pelton Wheel Company was so successful that it moved to larger facilities in San Francisco, in 1887. Pelton went to San Francisco and worked out an arrangement with A. P. Brayton, Sr. of Rankin, Brayton and Company, and together they organized the Pelton Water Wheel Company. Later Pelton sold out, but stayed on as a consulting engineer and later retired Oakland.

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

6

INTRO ODUCTION

 

Fig 1.4.11 Pelton turrbine origin nal patent document d [33] 1.4..2 THE PEL LTON TUR RBINE OP PERATING G PRINCIP PLE [3] Thee Pelton turbbine is an im mpulse turbbine that onlly converts kinetic enerrgy of the flow fl into mecchanical ennergy. The transfer of o the totaal energy from f the nnozzle exitt to the dow wnstream Reeservoir occcurs at atmoospheric preessure. The jet j stemminng from the injector imppinges on buckets, locaated at the periphery of a wheel. Figure 1.44.2 shows a Pelton buckket and its main m definittions.

STRE ESS & EXPERIIMENTL ANALYSIS OF SIMPL PLE AND ADVA ANCED PELTO ON WHEEL

7

INTRODUCTION

 

Fig 1.4.2 Buckets Geometric Definitions [3]

1.5 LAYOUT OF PELTON WHEEL [2] The Pelton wheel or Pelton turbine is a tangential flow impulse turbine. The water strikes the bucket along the tangent of the runner. The energy available at the inlet of the turbine is only kinetic energy. The pressure at the inlet and outlet of the turbine is atmosphere. This turbine is used for high heads and is named after L.A. Pelton, an American Engineer. Figure1.2.1 shows the lay-out of a hydro-electric power plant in which the turbine is Pelton Wheel. The water from the reservoir flows through the penstocks at the outlet of which a nozzle is fitted. The nozzle increases the kinetic energy of the water flowing through the penstock. At the outlet of the nozzle, the water comes out in the form of a jet and strikes the buckets (vanes) of the runner. The main parts of the Pelton turbine are 1. Nozzle and flow regulating arrangement (spear), STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

8

INTRODUCTION

 

2. Runner and buckets, 3. Casing, and 4. Breaking jet. 1.5.1 NOZZLE AND FLOW REGULATING ARRANGEMENT [2, 4] The amount of water striking the buckets (vanes) of the runner is controlled by providing a spear in the nozzle as shown in figure1.5.1 the spear is a conical needle which is operated either by a hand wheel or automatically in an axial direction depending upon the size of unit. When the spear is pushed forward into the nozzle the amount of water striking the runner is reduced. On the other hand, if the spear is pushed back, the amount of water striking the runner increases.

Fig 1.5.1 Straight flow nozzle [4]

1.5.2 RUNNER WITH BUCKETS [2] Figure 1.5.2 shows the runner of a Pelton wheel. It consists of a circular disc on the periphery of which a number of bucket evenly spaced are fixed. The shape of a cup is like STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

9

INTRODUCTION

 

a double hemispherical cup or bowl. Each bucket is divided into two symmetrical parts by a dividing wall which is known as splitter.

Fig 1.5.2 Runner of pelton wheel The jet of water strikes on the splitter. The splitter divides the jet into two equal parts and the jet comes out at the outer edge of the bucket. The buckets are shaped in such a way that the jet gets deflected through 160 or 170. The buckets are made of cast iron, cast steel bronze or stainless steel depending upon the head at the inlet of the turbine. 1.5.3 CASING [2] The function of the casing is to prevent the splashing of the water and to discharge water to tail race. It also acts as a safeguard against accidents. It is made of cast iron or fabricated steel plates. The casing of the Pelton wheel does not perform any hydraulic function.

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

10

INTRODUCTION

 

1.5.4. BREAKING JET [2] When the nozzle is completely closed by moving the spear in the forward direction, the amount of water striking the runner reduces to zero. But the runner due to inertia goes on revolving for long time. To stop the runner in a short time, a small nozzle is provided which directs the jet of water on the back of the vanes. This jet of water is called breaking jet.

1.6 EFFICIENCIES OF TURBINE [2] The following are the important Efficiencies of a turbine. (A) Hydraulic efficiency (ɳh) (B) Mechanical efficiency(ɳm) (C) Volumetric efficiency(ɳv) (D) Overall efficiency (ɳo) 1.6.1 HYDRAULIC EFFICIENCY (ɳH) It is defined as the ratio of the power given by water to the runner of a turbine (runner is a rotating part of a turbine and on the runner vanes are fixed) to the power supplied by the water at the inlet of the turbine. The power at the inlet of the turbine is more and this power goes decreasing as the water flow over the vanes of the turbine due to hydraulic losses as the vanes are not smooth. Hence the power delivered to the runner of the turbine will be less than the power available at the inlet of the turbine. Thus mathematically, the hydraulic efficiency of the turbine is written as

ɳh =

Power delivered to the runner = Power supplied at the inlet

=

. . . .

kW

Power supplied at inlet of turbine and also called water power W.P. =

kW

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

11

INTRODUCTION

 

1.6.2 MECHANICAL EFFICIENCY (ɳM) The power delivered by water to the runner of turbine is transmitted to the shaft of the turbine. Due to mechanical losses, the power available at the shaft of the turbine is less than the power delivered to the runner of a turbine. The ratio of the power available at the shaft of the turbine (known as S.P. or B.P.) the power delivered to the runner is define as mechanical efficiency. Hence, mathematically, it is written as ɳm =

=

. . . .

1.6.3 VOLUMETRIC EFFICIENCY (ɳV) The volume of the water striking the runner of a turbine is slightly less than the volume of the water supply to the turbine. Some of the volume of the water is discharged to the tailrace without striking the runner of the turbine. Thus the ratio of the volume of the water actually striking the runner to the volume of water supplied to the turbine is defined as volumetric efficiency. It is written as

ɳv =

1.6.4 OVERALL EFFICIENCY (ɳO) It is define as the ratio of power available at the shaft of the turbine to the power supplied by the water at the inlet of the turbine. It is written as ɳo =

=

. . . .

=

. . .

. . .

= ɳm x ɳh

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

12

INTRODUCTION

 

1.7 COMPARISON OF SIMPLE AND AVANCED PELTON WHEEL 1.7.1 SIMPLE PELTON WHEEL (1) It is the conventional pelton wheel with the runner having bucket on periphery. (2) In this bucket act as cantilever beam. (3) In the flow analysis resist by bucket’s inner surface. (4) The stresses produce in bucket is high due to the cantilever structure. (5) Assembly is light due to having single plate as a runner. 1.7.2 ADVANCED PELTON WHEEL (1) It has a hoop runner made of two plates as a hoop which cover the bucket an also act as a runner. (2) In this runner bucket act as a simply supported beam which have its one end hinged. (3) Flow is resists by bucket surface and also by the slot which consist the bucket. (4) In bucket stress is lesser than the simple pelton wheel due to simply supported structure. (5) Assembly is heavier due to having two plates as runner.

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

13

LITERATURE REVIEW

 

CHAPTER 2 LITERATURE REVIEW The subject of stress analysis contains a wide variety of process and phenomena. Even a brief summary of the vast amount of material that has been published on stress analysis would be well beyond the scope and intention of this chapter. Our attention is focused on few key aspect of stress analysis that is considered important and relevant to the pelton turbine along with advanced Pelton runners.

2.1 LITERATURE REVIEWS RELATED TO THEORETICAL APPROACH J. Vesely, M. Varner [4] has conducted the upgrading of 62.5 MW pelton turbine. During that they have investigate that With refurbished runner and nozzles the rated capacity will be increased up to 68.2 MW from 62.5 MW at net head of 624.8 m The power of the new runner increases by 9 % and efficiency increases by 1.4%. The power and efficiency improvement of the mentioned turbine were reached with application of runner, new design of straight flow nozzle tips, straight nozzles strike enlargement and modification of turbine housing. The commercial CFD software Fluent was used for the flow simulations through the other parts of rehabilitated turbine. Finite element stresses analysis of the runner and some components of straight flow nozzle were used as well.

Fig 2.1.1 Turbine housing modifications and Pelton runner dimensions

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  14 

LITERATURE REVIEW

 

They have modified the casing of turbine and also adopt the new design of pelton wheel which made by some modification in old one. So by this they showed that the casing of has great affect on the operation of a Pelton turbine and so it is very important to include the casing as an important factor in all investigations.

Alexandre Perrig [3] says that the Pelton turbines combine 4 types of flows: (I) confined, steady-state flow in the piping systems and injector, (ii) free water jets, (iii) 3D unsteady free surface flows in the buckets, and (IV) dispersed 2-phase flows in the casing. They have conducted the series of practical and derive some important conclusion like the impact pressure strongly depends on the energy coefficient, i.e. the angle of impact. The high-pressure pulse is strongly affected by the initial jet/bucket interaction. Its influence on the bucket torque and power signal should be kept in mind at the stage of performing mechanical dimensioning of the bucket. The initial jet/bucket interaction evidences the probable occurrence of compressible effects, generating an outburst of the jet and leading to erosion damages. When the jet impacts the bucket inner surface, a high-pressure pulse, which amplitude is larger than the equivalent stagnation pressure, is generated, and caused by compressible effects. The bucket backside acts as the suction side of a hydrofoil undergoing the Coanda effect, generating a depression, and in turn a lift force contributing positively to the bucket and runner torques. The Coanda effect may be described as the phenomenon by which the proximity of a surface to a jet stream will cause the jet to attach itself to and follow the surface contour. When such a surface is placed at an angle to the original jet or nozzle exit, the jet stream will be deflected. Figure 2.1.2 illustrates the Coanda effect between a cylinder and a vertical jet.

Fig 2.1.2 Coanda effect  STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  15 

LITERATURE REVIEW

 

Heinz-Bernd Matthias, Josef Prost and Christian Rossegger [5] have done experiment to estimate the influence of the splashed water distribution and Catch of the splash water in the casing on the turbine efficiency. Further they showed that the casing has great influence to the operation of a Pelton turbine and so it is very important to include the casing as an important factor in all investigations. The tests were made on 9 different casings. Figure 2.1.3 shows one of the casings with cylindrical dome. The radius and the width of the dome have been varied. Figure 2.1.4 shows an example of a tested casing with a rectangular dome. Modifications were made on the width of the dome.

Fig 2.1.3 Casing with cylindrical dome

Fig 2.1.4 Casing with rectangular dome

For each casing they determined the characteristic of the turbine. For a constant position of the needle of the nozzle and a constant head (constant unit discharge Qu) the best efficiency point and the corresponding unit speed Nu can be located. The best efficiency

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  16 

LITERATURE REVIEW

 

and the corresponding unit discharge now can be estimated. The results for all casings are presented in Fig. 2.1.5. In order to rate the performance of the turbine in partial load and overload conditions (variation of discharge Q res. unit discharge Q11) we defined an efficiency behavior factor. This factor is the radius of curvature at the vertex of the efficiency characteristic. High values of this factor mean high efficiency out of the optimum.

Fig 2.1.5 Effect of the casing on unit discharge, efficiency and efficiency behavior factor

T. Staubli and H.P. Hauser [6] have concluded that the quality of a jet of a Pelton turbine has major impact on the overall efficiency of the turbine.

Fig 2.1.6 Jet needle tip and nozzle seat ring modifications for jet quality improvement  STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  17 

LITERATURE REVIEW

 

They modify jet needle tip angle and nozzle seat ring to achieve higher efficiency that modification we can see in fig 2.1.6 above. And also they observed that the jet on the video sequences showed unsteadiness of the jet’s surface structures, which appear to develop directly at the nozzle exit. These structures entrain air, whereby precise jet observation becomes impossible further downstream. However, the jet’s contours can still be determined and measured on the images. The resulting data clearly show a jet diameter considerably larger than the theoretical values which we can see in fig 2.1.7 a second means of determining the jet’s diameter is by measuring the position of the first appearance of the bucket splitter tip when cutting through the jet. This procedure also demonstrated that the jet diverges. With nozzle modifications the quality of the jet could be improved, which showed increased turbine efficiency. At full load a 1.2 percent higher efficiency was measured after the modifications.

Fig 2.1.7 Jet diameters in the observation area of nozzle 1 measured from the images at three observation angles

2.2 LITERATURE REVIEW RELATED TO ADVANCE PELTON WHEEL Maryse Francois, Pierre and Yves Lowys [7] of ALSTOM power hydro has developed new design of pelton wheel called hooped pelton turbine which is based on redistribution of function. Classically, in Pelton runners, the buckets are encased onto a central rim,

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  18 

LITERATURE REVIEW

 

either in case of a one piece runner or of mechanically fixed separated buckets. The attachment zone is then subjected to cycled high bending stresses as the bucket repeatedly passes into the jets. Furthermore, once the pressure on the bucket has been released, its cantilever structure gets vibrating according to its natural modes and, if not properly designed and/or manufactured, a resonance may occur and severely increase the dynamic stress amplitude. In the new design, the separated buckets keep their main hydraulic function which is the transformation of the jet’s kinetic energy into a tangential force, but their structures are not solicited to also transform this force into torque by involving shear and bending at their connections with the rim. This latter function is accomplished by two hoops on which the buckets are mounted, allowing stresses to be more efficiently distributed all around the runner.

Fig 2.2.1 Hooped Pelton runner for Beaufort power plant

Calculations (Fig 2.2.2) show that the tangential displacement of the hoops is global: its value on the outer diameter in the non-loaded area is still more than half the maximum value on the opposite side within the jets influence. Therefore the whole structure participates in supporting the jets loads. So far as stresses are concerned, the results must be analyzed in term of maximum stress range over time at any point of the structure of the hoops, to be then compared to fatigue limits. The full modeling allows obtaining the evolution of stress vs. time by its spatial counterpart considering the evolution of the stresses at homologous locations near successive buckets.

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  19 

LITERATURE REVIEW

 

Fig 2.2.2 Tangential displacement from FEA on 3D model

Bernard Michel, Georges Rossi, Pierre Leroy, Pierre and Yves Lowys [8] a new development in Pelton runner design, the hooped runner, is based on a redistribution of functions between the buckets and the hoops, and thus allows stresses to be minimized and distributed more efficiently. This design which combines advantages from the mechanical point of view as well as from the manufacturing aspect without any special drawback from the hydraulic point of view confirms the interest of this new solution. This paper presents in detail the mechanical aspects as well as the results of the hydraulic comparison between traditional runners and hooped runners. This new design has been patented by Alstom Power Hydro. In the old design, the bucket had two functions: • transformation of the jet’s kinetic energy into a tangential force, • transmission to the runner rim of the torque generated by this force. The new design separates the functions: • the bucket still transforms the kinetic energy into a tangential force, • the transformation of this force into torque is carried out by hoops on which the buckets rest. This uncoupling allows the forces to be borne up by specific components in an improved way.

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  20 

LITERATURE REVIEW

 

Fig 2.2.3 Buckets fixed on the hoops

Due to the geometry of the bucket, the seat of these stresses is in the connection radius between the rim and the centre edge in the upper part of the bucket thereby generating traction stresses. As shown on fig 2.2.4, the two hoops are located on both sides of the jet, close to the natural position of the reinforcing ribs on traditional pelton runners.

Fig 2.2.4 Arrangements of the hoops

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  21 

LITERATURE REVIEW

 

Fig 2.2.5 Hydraulic efficiency of traditional runner and hooped runner with no adaptation of the hoops.

After the modification at internal and external fillets of slot we have better optimization which we can see in fig 2.2.6

Fig 2.2.6 Comparison of efficiency between a traditional runner and a modified hooped runner

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  22 

LITERATURE REVIEW

 

Also in the structural behavior Displacements results prove the validity of the concept. Calculation at synchronous speed shows the participation of the entire hoops to support the water jet forces. The tangential displacement of the hoops is global and higher in the area where the jet pressure is applied. Fig 2.2.7 shows this tangential displacement of the hoops at synchronous speed.

Fig 2.2.7 Tangential displacement of the hoops at synchronous speed

This distribution of the water jets forces on the entire hoops involves a decrease of the stress level in the runner. The following fig shows the equivalent stress distribution (VON MISES) at synchronous speed in the structural parts of the runner, it means the hoops. Maximal stresses are localized in the internal and external radius of the buckets’ openings. The maximal VON MISES stress is equal to 144 MPa.

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  23 

LITERATURE REVIEW

 

Fig 2.2.8 Equivalent stress at synchronous speed

The main part of this stress is a static traction stress created by the centrifugal forces (rotational synchronous speed). It is localized in the internal radius of buckets’ opening, at the intersection with the buckets’ internal attaches.

Dr.S.A.Channiwala & Mr.Gaurang C. Chaudhari [9] have done the experimental as well flow analysis on advanced pelton wheel and shows that The stress analysis carried out on the traditional runner and designed hooped runner shows the stress distribution. At internal and external radius of buckets, the percentage reduction of VON MISES stresses is of the order of 1.98 %, using Single hoop while the percentage reduction of VON MISES stresses is of the order of 14.22 % using Double hoop. Similarly, at the buckets, the percentage reduction of VON MISES stresses is of the order of 67.19 %, using Single hoop while the percentage reduction of VON MISES stresses is of the order of 73.57 % using Double hoop. This means that the use of hoop, allows stresses to be minimized and distributed more effectively. The CFD simulation carried out on pelton wheel shows that the velocity of flow is very high at nozzle outlet and there after decrease. Further, the highest pressure encountered is 3.9E005 Pascal in the middle of the bucket where the impact is the most direct. First there is a rise in pressure level in the middle of the bucket. Then the pressure level decreases.

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  24 

LITERATURE REVIEW

 

The experimental results prove that the power developed and efficiency in traditional runner as well as hooped runner is nearly same which shows good hydraulic behavior of the hooped pelton runner. In nutshell, the achievement of new hooped runner design is based on the redistribution of functions between the buckets and the hoops. This allows stresses to be minimized and distributed more efficiently. The design is created using simple interchangeable components, making maintenances easier without affecting hydraulic performance. They have done modeling & stress analysis with the help of Ideas-11 and for flow analysis they have use CFD code CFX-10.0

Fig 2.2.9 Displacement of Traditional Runner of Pelton Wheel

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  25 

LITERATURE REVIEW

 

Fig 2.2.10 Tangential Displacement of the Hoop (Double hoop)

Fig 2.2.11 Equivalent Stress (Double Hoop) Maximum stresses are localized in the internal and external radius of the buckets’ openings. The maximum VON MISES stress is equal to 1.15 N/mm2.Below; Fig.2.2.11 shows the isometric view of equivalent stress of double hoop. In the single hoop the VON  STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  26 

LITERATURE REVIEW

 

MISES stresses is 37.6 N/mm2.While, VON MISES stresses in double hoop is 1.15 N/ mm2 which are very low as compared to single hoop.

2.3 OBJECTIVE OF PRESENT WORK Based on literature review following objective is derived 1. To design a pelton wheel from obtained data. 2. Carry out the stress analysis of simple and advanced pelton wheel using ANSYS workbench v11. 3. To perform the practical on designed pelton wheel and obtain results like efficiency and characteristic curves. 4. To make the comparative assessment the simple and advanced pelton wheel with respect of stresses developed and overall efficiency.

 STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                  27 

DIMENSIONAL DETAIL OF PELTON WHEEL

 

CHAPTER 3 DIMENSIONAL DETAIL OF PELTON WHEEL  

 

Fig 3.1 Construction of pelton runner blade [10] STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                                 28 

DIMENSIONAL DETAIL OF PELTON WHEEL

 

The dimension of bucket is decided by these empirical relations Length L = 2.3 to 2.8 times d1, where d1 = diameter of jet Width B = 2.8 to 3.2 times d1 Depth T = 0.6 to 0.9 times d1 Inlet Angle β1 5 to 8 Outlet Angle β2 10 to 20 at centre The dimension of our bucket which is used in stress analysis and performance evaluation is given below. The jet diameter is d1 = 23.90 mm L = 66.94 mm B =76 mm T = 20 mm S = 25.3 mm δ1 = 5.78 mm

Fig 3.2 Bucket used in this project STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                                 29 

DIMENSIONAL DETAIL OF PELTON WHEEL

 

3-D model of this bucket is given in next chapter named modeling of pelton wheel. The other dimension of pelton wheel like runner diameter is given in 3.1. 3.1 FORCE CALCULATION Here we shown sample force calculation for one flow rate only, whole data including readings and results at different flow rate & different opening is given in Appendix-A The jet of water is comes out from nozzle and strikes on splitter of the bucket. The force which transferred by jet to the bucket is calculated below Flow rate Q = 10x10-3 m3/sec Runner mean diameter D = 360 mm Head H = 40 m Speed N = 680 rpm V1 = Kv1 2

 

= 0.985×√2

9.81

40

= 27.54 m/sec U1 =

=

12.817 m3/sec

Vw1 = v1-u1 = 14.773 m/sec Vw2 = 0.85 × Vw1 = 12.55705 m/sec Vu2 = u2 – Vw2 cos 15  = 0.68786 m/sec So, Force applied by jet on bucket Fu = ρ × Q × (Vu1-Vu2) = (Vu1 – Vu2) = 26.912 Fu = 269 N

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                                 30 

MODE ELING OF PELT TON WHEEL

 

CHAPT TER 4 MO ODELING OF PE ELTON N WHEEL 4.1 INTR RODUCTIION TO PRO/ENG P GINEER R [11] Pro/ENGIN NEER is leeading prodduct develo opment sollution for aany manuffacturing industry. The T softwarre is develooped and supported s b the paraametric technology by corporationn (PTC), based b in United U Statees. Pro/ENGINEER iis unique software s developed for the manufacturin m ng Industry y to meet the comppeting demands of engineeringg productiviity, faster time to mark ket, and impprove producctivity. Pro/ENGIN NEER is coomprehensiive productt developm ment solutioon for conccept and industrial design, d detaail design, simulation s and analysiis, mould/toool/die desiign, and NC tool paath creation. With the powerful p too ol of Pro/EN NGINEER, you will bee able to capture thee design intend for anyy complex model, m by incorporatin i ng intelligence into design.

Dessign CAD  Exchange

Mfg

Pro o/E Drawings

Analysis

Simulation

Fig 4.1 Pro/Enginee P er in the inddustry

STRESS & EXPE ERIMENTAL ANA NALYSIS OF SIMP PLE AND ADVAN NCED PELTON WHEEL

 

                                          31 

MODE ELING OF PELT TON WHEEL

 

4.2 MOD DULES IN N PRO/EN NGINEER R [11] Pro/ENGIN NEER is a complete c prroduct development sollution. Youu can get thee best in class tool for f product design, anaalysis, data managemeent, in manuufacturing in i single software. To T suite the definite neeeds of diffeerent custom mer, Pro/EN NGINEER provides p various moodules. Some of the impportant mod dules are as follows •

Pro//ENGINEE ER Foundatiion

•

Pro//ENGINEE ER Interactivve Surface Design D

•

Pro//ENGINEE ER Cabling

•

Pro//ENGINEE ER Intralink

Manufacturring Modulees: •

Pro//ENGINEE ER Machiniing

•

Pro//ENGINEE ER NC Sheeet Metal

•

Pro//ENGINEE ER Tool Dessign

•

Pro//ENGINEE ER Plastic Advisor A

This refereence guide covers the foundation of Pro/EN NGINEER, w which desccribe the creation off new part, assembly, drawing, d an nd surface design d withh the tools that t lead you throughh process, systematical s lly.

Sketcher

Partt Design

Assemb bly  Design n Wireeframe  Surface Design

Productio on  drawingss View w  Generattion

Detailing

Fiig 4.2 Modu ules in Pro//ENGINEE ER foundatiion STRESS & EXPE ERIMENTAL ANA NALYSIS OF SIMP PLE AND ADVAN NCED PELTON WHEEL

 

                                          32 

MODELING OF PELTON WHEEL

 

4.3 FEATURES OF PRO/ENGINEER [11] Pro/ENGINEER is a one-stop store for any manufacturing industry. It offers effective feature, incorporated for wild variety of purpose. Some of important feature are as follows. •

Parametric design

•

Feature. based approach

•

Parent chills relationship

•

Associative and model centric

4.3.1 PARAMETRIC DESIGN

Pro/ENGINEER designs are parametric. The term “parametric” means that design operation that are captured, can be stored as the take place. They can be used effectively in the future for modeling and editing the design. These types of modeling helping faster and easier modification of deign. For example, you can see a concentric a hole drilled for the base feature. If the model is not parametric, and if there are any design changes (say, in the diameter of the hole), you will have to edit each hole individually, in addition the based sketch will vary, there for, a definite number of stapes are required for the change. If the model is the parametric and related properly, a change in one value, automatically edits the related values, for example, if the diameter of the hole and dimensions of the arc are related, a change in the diameter of the hole will automatically edit the arc radius 4.3.2 FEATURE-BASED APPROACH

Features are the basic building blocks required to create an object. Pro/ENGINEER modules are based on a series of feature. Each feature builds upon the previous feature, to create the model (only one single feature can be modified at a time).each feature may appear simple, individually, but collectively forms a complex part and assemblies.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                           33 

 

MODELING OF PELTON WHEEL

 

The idea behind feature-based modeling is that the designer constructs an object, composed of individual feature that described the manner in which the geometry supports the object, if its dimensions change. The first feature is calls the base feature. 4.3.3 PARENTS CHILLED RELATIONSHIP

The parent chilled relationship is a power full way to capture your design intent in a model. This relationship naturally occurs among feature, during the modeling process, when you create a new feature, the existing features that are reference, become parents to the new feature. Consider the example the hole is drilled at 15mm from the two edges of the rectangular block. This hole is the chilled feature and the block is the parent. If we make any changes in block, the hole adjusts itself to maintain the specified relation with the parent. 4.3.4 ASSOCIATIVE AND MODEL CENTRIC Pro/ENGINEER drawings are model centric. This means that Pro/ENGINEER models that are represented in assembly or drawings are associative. If changes are made in one module these will automatically get updated in the referenced module.

4.4 GRAPHIC USER INTERFACE OF PRO/ENGINEER [11] The Pro/ENGINEER main window consists of a navigation area, Manu Bar, Tool chests, Browsers, and Information Areas, you can open multiple windows in Pro/ENGINEER but only one window will be active at a time. 4.4.1 MENU BAR The Menu Bare, also known as the pull-down menu, contents commands for all the actions to be performed. We can customize the menu bar according to our requirement. When a group of actions is stored inside a particular command; it is called the Stacked Menu.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                           34 

 

MODELING OF PELTON WHEEL

 

Fig 4.4.1 Menu bar of pro-engineering

4.4.2 TOOL CHESTS The Tool chests are usually located at the top, on the right side of the Main Window. It contains Toolbars and Buttons for operation. You can customized the contains and location of the Tool chests, using the customize dialog box. 4.4.3 NAVIGATION AREA The Navigation Area includes the Model Tree, Layer Tree, Folder Browser, and Connection. 4.4.4 GRAPHIC WINDOWS Graphic Windows is the work area, where the models are drawn and modified. The Graphic Window contains Datum Plane and Coordinate Systems for drawing reference. We can control the view in the Graphic Window, using the Orientation Command.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                           35 

 

MODELING OF PELTON WHEEL

 

4.4.5 DASHBOARD A Dashboard is a dialog box usually located at the bottom of the screen. It is consists selective area that guide us through the modeling process as we select the geometry and set our preferences, it also contains some option. 4.4.6 INFORMATION AREA The Information contained the message area and a States Bar. The message area displays a system message that prompts us for required information. The Status Bar displays the necessary information wherever applicable. The following information is usually displays •

Warning and errors

•

Number of items selected in the current model

•

Available selection filters

•

Model regeneration status, which indicates that the model must be regenerated

•

Indication that the current processes has been halted

•

Screen tips

4.5 MODELING OF BUCKET In pro/engineering we should start first by revolve operation. By executing revolve command we get sketches mode. In it we draw an elliptic arc of 180 deg according to dimension revolve it to 90 deg with respect to is own axis. After that we create datum plane with reference to on of flat surface 1⁄4 th of hemispherical shape at the distance according to dimension. Now, that we mirror the hemispherical feature about this plane and joint this two plane by extruding ,apportion of it plate surface up to this we get a hollow bowl which acts as a bucket inner face.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                           36 

 

MODELING OF PELTON WHEEL

 

Fig 4.5 Model of bucket created in Pro/Engineer

After this we extrude a sketch with reference of this bowl’s upper surface. Portion like as “T” this’ll make our splits for bucket then create a datum plane with Angular reference of bowl’s upper surface, and create a shape upper like “W” and extrude it and by this cut the bowl’s one end and than fillet the bucket’s inner face where splitter’s and bucket surface is matched this will make smooth curvature for following of water. Up this our bucket is ready.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                           37 

 

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 

CHAPTER 5 STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 5.1 INTRODUCTION By the use of ANSYS work bench, PRO-E and other computational techniques, we prepared the model of pelton wheel. In our present work modeling of the pelton wheel in PRO-Engineer and stress analysis carried out in ANSYS workbench. The stress analyses of the traditional and hooped runner carried out and compare stress level. Models of traditional and hooped runner have same number of buckets and tip diameter which is used in present numerical simulation, models showing in this chapter. This model is available in our institute’s laboratory.

5.2 MODELING In a traditional runner the bucket is work as a cantilever beam subjected to the force generated by the jet. These alternated forces lead to fatigue stresses. Due to the geometry of the bucket, the seat of these stresses is in the connection radius between the rim and the centre edge in the upper part of the bucket thereby generating traction stresses. In a hooped runner the arms are worked as an embedded beam. By this type of design decrease stress at a most failure zone and the transformation of traction stresses by compression stresses, as the geometry of the discharge radius is inverted. The hoop is connected with buckets on a runner where buckets are fitted.

5.3 TRADITIONAL RUNNER Fig.5.3 shows the 3D–Model of traditional runner. The tangential displacement of the traditional runner is higher in the area where the jet pressure is applied.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 38 

 

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 

Fig.5.3.1 Model of pelton wheel

Fig.5.3.2 Constrains given to pelton wheel STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 39 

 

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 

Fig.5.3.3 Displacement of Traditional pelton wheel Fig.5.3.3 shows this tangential displacement of traditional runner at synchronous speed.

Fig.5.3.4 Stress developed in the Traditional pelton wheel STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 40 

 

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 

Fig.5.3.4 shows that the stress are localized where, the bucket are attached with the runner. The maximum VON MISES stresses are 17.66 N / mm2.The Maximum stresses are localized at the point where the jet is striking to the bucket.

5.4 ADVANCE OR HOOPED RUNNER The design of the hooped runner is intended to achieve easy maintenance, and the separation of functions facilitates optimization. This runner is composed of two half hoops and buckets. The definition of the attachment of the various elements to each other is obtained from the stresses transmitted to the various components. The attachment of the buckets is defined based on the centrifugal forces and the jet load. The bucket is modeled as an Inner beam simply supported, resting on its central section and subjected to a force generated by a pre- stressed screw on the outer side. The centrifugal forces are completely taken up by a compound pin (hinge) fixed to the hoops. For the jet force, the Screw load is multiplied by a lever arm effect so as to exert a contact load of the bucket to the rim that is much higher than that of the jet. The stresses transmitted to the hoops are tangential and symmetrical only, the attachment of the hoops to each other is therefore simply a classical assembly using studs. To sum up, buckets are enclosed between two hoops.

5.5 MECHANICAL CALCULATIONS Static analyses as carried out by solid finite element calculation have confirmed that the above hypotheses are well founded. These calculations were carried out using ANSYS workbench version 11 software. The calculations hypotheses are based on 18 buckets with a particularly high rated speed of 680 rpm and different jet. The large scale of the calculation carried out has allowed all the development constraints to be integrated in a single model and provides a mechanical model similar to the real runner. • Conical pin between bucket and hoops at the interior fixation. • supporting centre area of the bucket on the hoops under the water jet. • pre-stressing screw between bucket and hoops at the exterior fixation.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 41 

 

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 

5.5.1 STRUCTURAL BEHAVIOR Displacements and stress results prove the validity of the concept. Calculation at synchronous speed shows the participation of the entire hoops to support the water jet forces. The tangential displacement of the hoops is global and higher in the area where the jet pressure is applied. Fig. 5.1.1 shows this tangential displacement of the hoops at synchronous speed.

Fig. 5.5.1 Tangential Displacement of the advanced pelton wheel

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 42 

 

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 

5.5.2 STATIC STRESSES RESULTS This distribution of the water jets forces on the entire hoops involves a decrease of the stress level in the runner. The following figure shows the equivalent stress distribution (VON MISES) in the structural parts of the runner, it means the hoops.

Fig. 5.5.2 Equivalent Stresses developed in the advanced pelton wheel

Maximum stresses are localized in the internal and external radius of the bucket’s openings. The maximum VON MISES stress is equal to 10.88 N/mm2.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 43 

 

MAN NUFACTURING OF HOOP PELT TON WHEEL

 

C CHAPTE ER 6 MAN NUFACT TURING G OF HO OOP PEL LTON WHEEL L 6.1 BUCKET CASTIING PRO OCESS Maiin classificaation of castting in fig.66.1,

sand  moulding bench

flo oor

plate

pit 

machine 

m moulding

mou ulding

ng mouldin

mo oulding

moulding

Fig 6.1 6 Classificcation of san nd mouldin ng process 6.1..1 BENCH MOULDIN NG 1. Two T box bennch mouldinng. 2. Three T box beench mouldding. 3. Stucked S bench mouldinng. In which w we usse two box bench b moullding processs for castinng this buckkets. A saand casting or a sand molded m castting is a castt part produuced by form ming a mold d from a sandd mixture and a pouring molten liquuid metal in nto the caviity in the m mould. The mould m is thenn cooled unntil the metaal has soliddified. In th he last stagee the castingg is separatted from the mold. There are six steeps in this process, p 6.1..2 CASTIN NG PROCE ESS 1. Place P a patteern in sand to t create a mold. m 2. Inncorporate a gating sysstem. 3. Remove R the pattern. 4. Fill F the moldd cavity withh molten metal. m 5. Allow A the metal m to cooll. 6. Break B away the sand moold and rem move the cassting. STRE ESS & EXPERIM MENTAL ANALYSSIS OF SIMPLE AND A ADVANCED D PELTON WHE EEL                                                 44 

 

MANUFACTURING OF HOOP PELTON WHEEL

 

There are two main types of sand used for molding. "Green sand" is a mixture of silica sand, clay, moisture and other additives. The "air set" method uses dry sand bonded to materials other than clay, using a fast curing adhesive. When these are used, they are collectively called "air set" sand castings to distinguish these from "green sand" castings. Two types of molding sand are natural bonded (bank sand) and synthetic (lake sand), which is generally preferred due to its more consistent composition.

Fig 6.1.2 A metal casting poured in a sand mould With both methods, the sand mixture is packed around a master "pattern" forming a mold cavity. If necessary, a temporary plug is placed to form a channel for pouring the fluid to be cast. Air-set molds often form a two-part mold having a top and bottom, termed Cope and drag. The sand mixture is tamped down as it is added, and the final mold assembly is sometimes vibrated to compact the sand and fill any unwanted voids in the mold. Then the pattern is removed with the channel plug, leaving the mold cavity. The casting liquid (typically molten metal) is then poured into the mold cavity. After the metal has solidified and cooled, the casting is separated from the sand mold. There is typically no mold release agent, and the mold is generally destroyed in the removal process. The accuracy of the casting is limited by the type of sand and the molding process. Sand castings made from coarse green sand impart a rough texture on the surface of the casting, and this makes them easy to identify. Air-set molds can produce castings with much STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 45 

 

MANUFACTURING OF HOOP PELTON WHEEL

 

smoother surfaces. Surfaces can also be ground and polished, for example when making a large bell. After molding, the casting is covered in a residue of oxides, silicates and other compounds. This residue can be removed by various means, such as grinding, or shot blasting. During casting, some of the components of the sand mixture are lost in the thermal casting process. Green sand can be reused after adjusting its composition to replenish the lost moisture and additives. The pattern itself can be reused indefinitely to produce new sand molds. The sand molding process has been used for many centuries to produce castings manually. Since 1950, partially-automated casting processes have been developed for production lines. 6.1.3 BUCKET CASTING SPECIFICATION Material --- Pig iron cast iron (scrap) +silicon Furnace-----Oil fired furnace

Temp----1200 c

Capacity—100 kg/lot.

6.1.4 MACHINING PROCESS Grinding process-------------Amery wheel-Carbon drum 8 inch diameter Drilling process--------------Speed 360 rpm Electro plating process---- Chromium

Plate 1 Front and back view of Bucket used in this model

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 46 

 

MANUFACTURING OF HOOP PELTON WHEEL

 

6.2 MANUFACTURING OF RUNNER The centre part of the pelton wheel is runner which is prepared from mild steel. Runner prepared from circular plate which is turned and faced on lathe. The hole for connecting the bucket is drilled by vertical drilling machine. To fix the pelton wheel with the shaft of our setup the boss is necessary which is made by welding, drilling and boring process. The key way is made by vertical shaper machine. To give the better surface finish and appearance the runner is coated with zinc.

Plate 2 Hooped pelton wheel

6.3 MANUFACTURING OF HOOP Hoop is locating at runner and gives the back support to buckets. Hoop was manufacturing from galvanize iron. In G.I. plate we got the slot with using the chisels by creating pattern of bucket’s slot. To give the better surface finish hoop is coated with chromium.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 47 

 

MANUFACTURING OF HOOP PELTON WHEEL

 

After all this parts assemble doing the balancing cause this wheel rotating higher speed. This balancing is showing in figure. In balancing, somewhere removing the weight by drills the holes. And somewhere increase material by nut and washer at runner.

Plate 3 Hooped pelton wheel after balancing

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 48 

 

PER RFORMANCE EV VALUATION

C CHAPTE ER 7 PER RFORMA ANCE EVALUA E ATION We want to coompare the efficiency e o simple an of nd advance pelton wheeel for this we w have usedd pelton whheel with eigghteen buckkets as well as having hoop h on it. S Single jet iss used to run the peltonn wheel. We W have measured m sp peed using tachometer, flow ratte using b dynaamometer and a pressurre using prressure gau uge. The rotaameter, torqque using break capaacity of pum mp which is i used to ruun the turbine having size of 85 mm, head is i 44 m, imppeller diameeter is 208 mm, m input poower is 12.5 5kw and speed of impeeller is 2880 0 rpm.

Plate 4 Tesst rig used for f experim ment

STRE ESS & EXPERIM MENTAL ANALYSSIS OF SIMPLE AND A ADVANCED D PELTON WHE EEL

 

                                               49 

PERFORMANCE EVALUATION

Plate 5 Hooped runner mounted on shaft.

7.1 DATA OF PRACTICAL SETUP Rope diameter = 20 mm = 0.02 m Diameter of entry Pipe = 50 mm = .05 m Break drum radius r = 150 mm = 0.15 m Flow rate Q = 0.01 m3/sec Pressure in entry pipe Pi = 4 kg/cm2 The reading at a different flow rate & at a different openings have been taken and it is given in Appendix-A 7.2 SAMPLE CALCULATION The sample calculation for one reading is given below. 4 1000

9.81

40

C/S Area of pipe A A=

4 50

10

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 50 

 

PERFORMANCE EVALUATION

= 1.9634 10 Inlet velocity Vi = . .

=

= 5.0932 m/sec

.

= 0.3305

Total head available at inlet .

H=

.

.

41.3267

Net weight apply to the dynamometer W = (weight – spring balance reading) = (1 – 0.3)

9.81

9.81

= 0.7 9.81 = 6.867 N Input Power = = 1000

9.81

10

10

41.3267

= 4054.14 Torque produced T = W

= 6.867

0.16

1.09872 N m

Power output from the turbine .

Po =

.

136.1132

Overall efficiency

=

. .

= 3.36 % STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 51 

 

PERFORMANCE EVALUATION

Unit speed Nu =

/

=

/

.

= 184.021

Unit discharge Qu =

=

/

. /

.

= 0.000778 Unit power Pu =

=

/

. .

/

= 0.5123

 

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                 52 

 

RESULTS AND DISCUSSION

 

CHAPTER 8 RESULTS AND DISCUSSION

We have done stress analysis of simple and advanced pelton wheel with the help of ANSYS Workbench v11 and also done the practical for effect of hoop on efficiency. We have done analysis at different speed ranging from 100 rpm to 680 rpm and also for different flow rate ranging from 0.0033 m3/sec to 0.01 m3/sec. also by applying force from different direction like single, two, four and six nozzle we get wide range of stress development in pelton wheel and displacement at the tip of bucket. The data of applied force and used flow rates are given in Appendix-A for simple and advanced pelton wheel respectively. These results are shown by graph as following.

single

two

four

six

20 18

Eq. Stress Max (MPa)

16 14 12 10 8 6 4 2 0 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.1 Max eq. Stress v/s Speed at Q = 0.01 m3/sec (simple pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   53 

 

RESULTS AND DISCUSSION

  single

two

four

six

4.50E-04 4.00E-04

Eq. Stress Min (MPa)

3.50E-04 3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.2 Min eq. stress v/s Speed at Q = 0.01 m3/sec (simple pelton wheel)

single

two

four

six

18 16

Displacement ( mm)

14 12 10 8 6 4 2 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.3 Max displacement v/s Speed at Q = 0.01 m3/sec (simple pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   54 

 

RESULTS AND DISCUSSION

  single

two

four

six

14

Eq. Stress Max (MPa)

12 10 8 6 4 2 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.4 Max eq. stress v/s Speed at Q = 0.00666 m3/sec (simple pelton wheel)

single

two

four

six

5.00E-04 4.50E-04

Eq. Stress Min (MPa)

4.00E-04 3.50E-04 3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.5 Min eq. stress v/s Speed at Q = 0.00666 m3/sec (simple pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   55 

 

RESULTS AND DISCUSSION

  single

two

four

six

12

Displacement (mm)

10

8

6

4

2

0 100

200

300

400

500

600

680

Speed (rpm)

Graph8.6 Max displacement v/s Speed at Q = 0.00666 m3/sec (simple pelton wheel)

single

two

four

six

10 9

Eq. Stress Max (MPa)

8 7 6 5 4 3 2 1 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.7 Max eq. stress v/s Speed at Q = 0.005 m3/sec (simple pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   56 

 

RESULTS AND DISCUSSION

  single

two

four

six

5.00E-04 4.50E-04

Eq. Stress Min (MPa)

4.00E-04 3.50E-04 3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.8 Min eq. stress v/s Speed at Q = 0.005 m3/sec (simple pelton wheel)

single

two

four

six

9 8

Displacement ( mm )

7 6 5 4 3 2 1 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.9 Max displacement v/s Speed at Q = 0.005 m3/sec (simple pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   57 

 

RESULTS AND DISCUSSION

  single

two

four

six

7

Eq. Stress Max (MPa)

6 5 4 3 2 1 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.10 Max eq. stress v/s Speed at Q = 0.0033 m3/sec (simple pelton wheel)

single

two

four

six

5.00E-04 4.50E-04 Eq. Stress Min (MPa)

4.00E-04 3.50E-04 3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.11 Min eq. stress v/s Speed at Q = 0.0033 m3/sec (simple pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   58 

 

RESULTS AND DISCUSSION

  single

two

four

six

7

Displacement ( mm )

6 5 4 3 2 1 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.12 Max displacement v/s Speed at Q = 0.0033m3/sec (simple pelton wheel)

single

two

four

six

12

Eq. Stress Max (MPa)

10

8

6

4

2

0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.13 Max Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   59 

 

RESULTS AND DISCUSSION

  single

two

four

six

3.50E-04

Eq. Stress Min (MPa)

3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.14 Min Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)

single

two

four

six

1.8 1.6

Disp;acement ( mm)

1.4 1.2 1 0.8 0.6 0.4 0.2 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.15 Max displacement v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   60 

 

RESULTS AND DISCUSSION

  single

two

four

six

7

Eq. Stress Max (MPa)

6 5 4 3 2 1 0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.16 Max Stress v/s Speed at Q = 0.00666 m3/sec (Advance pelton wheel)

single

two

four

six

4.00E-04

Eq. Stress Min (MPa)

3.50E-04 3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.17 Min Stress v/s Speed at Q = 0.00666 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   61 

 

RESULTS AND DISCUSSION

  single

two

four

six

1.2

Displacement (mm)

1

0.8

0.6

0.4

0.2

0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.18 Max displacement v/s Speed at Q = 0.00666 m3/sec (Advance pelton wheel)

single

two

four

six

6

Eq. Stress Max (MPa)

5

4

3

2

1

0 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.19 Max Stress v/s Speed at Q = 0.005 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   62 

 

RESULTS AND DISCUSSION

  single

two

four

six

4.00E-04 3.50E-04

Eq. Stress Min (MPa)

3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.20 Min Stress v/s Speed at Q = 0.005 m3/sec (Advance pelton wheel)

single

two

four

six

0.9 0.8

Displacement ( mm )

0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.21 Max displacement v/s Speed at Q = 0.005 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   63 

 

RESULTS AND DISCUSSION

  single

two

four

six

3.5

Eq. Stress Max (MPa)

3 2.5 2 1.5 1 0.5 0 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.22 Max Stress v/s Speed at Q = 0.0033 m3/sec (Advance pelton wheel)

single

two

four

six

4.00E-04

Eq. Stress Min (MPa)

3.50E-04 3.00E-04 2.50E-04 2.00E-04 1.50E-04 1.00E-04 5.00E-05 0.00E+00 100

200

300

400

500

600

680

Speed (rpm)

Graph 8.23 Min Stress v/s Speed at Q = 0.0033 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   64 

 

RESULTS AND DISCUSSION

  single

two

four

six

0.6

Displacement ( mm )

0.5

0.4

0.3

0.2

0.1

0 100

200

300

400 Speed (rpm)

500

600

680

Graph 8.24 Max displacement v/s Speed at Q = 0.0033 m3/sec (Advance pelton wheel)

The graph 8.1 to graph 8.24 shown above is mainly three types (1)Max eq. stress v/s Speed at different flow rates (2)Min eq. stress v/s Speed at different flow rates (3)Max displacement v/s Speed at different flow rates In that we can see that max eq. stress developed in advanced pelton wheel is less than the simple advanced wheel and also the difference is high. Although the difference between min eq. stress are less. And the difference between max displacements is also high. Now the following graph shown is known as characteristics curves (or known as constant head curves) which are mainly three types (1) Qu (unit discharge) v/s Nu (unit speed) (2) Pu (unit power) v/s Nu (unit speed) (3) η (efficiency) v/s Nu (unit speed)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   65 

 

RESULTS AND DISCUSSION

 

We have done experimental analysis on both the type of pelton wheel first simple and then advanced pelton wheel. The data of experiment viz. readings and results for simple and advanced pelton wheel are given in Appendix-B and Appendix-C respectively. The comparison between important parameters like speed, torque, output power and efficiency of simple and advance pelton wheel is given in Appendix-D. The graphs shown below (graph 8.25 to 8.36) are for advanced pelton wheel. After that graph 8.37 to 8.41 shows comparison of efficiency of the simple and advanced pelton wheel at different opening for same flow rate. The graphs shows that the efficiency of the advanced pelton wheel is less than the simple pelton wheel because of hoop attached on it.

20%

40%

60%

80%

100%

1.90E-03 1.85E-03 1.80E-03 1.75E-03 Qu

1.70E-03 1.65E-03 1.60E-03 1.55E-03 1.50E-03 150

160

170

180 Nu

190

200

210

Graph 8.25 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.01 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   66 

 

RESULTS AND DISCUSSION

  20%

40%

60%

80%

100%

6 5

Pu

4 3 2 1 0 150

160

170

180

190

200

210

Nu

Graph 8.26 Unit power (Pu) v/s Unit speed (Nu) at Q = 0.01 m3/sec (Advance pelton wheel) 20%

40%

60%

80%

100%

35 30 25

η (%)

20 15 10 5 0 150

160

170

180

190

200

210

Nu

Graph 8.27 Efficiency (η) v/s Unit speed (Nu) at Q = 0.01 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   67 

 

RESULTS AND DISCUSSION

  20%

40%

60%

80%

100%

1.60E-03 1.55E-03 1.50E-03 1.45E-03 1.40E-03 Qu

1.35E-03 1.30E-03 1.25E-03 1.20E-03 1.15E-03 1.10E-03 110

120

130

140

150

160

170

180

190

200

210

220

Nu

Graph 8.28 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.006 m3/sec (Advance pelton wheel) 20%

40%

60%

80%

100%

9 8 7 6 5 Pu

4 3 2 1 0 100

120

140

160 Nu

180

200

220

Graph 8.29 Unit power (Pu) v/s Unit speed (Nu) at Q = 0.006 m3/sec (Advance pelton wheel) STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   68 

 

RESULTS AND DISCUSSION

  20%

40%

60%

80%

100%

50 45 40 35 30 25 η

20 15 10 5 0 100

120

140

160

180

200

220

Nu

Graph 8.30 Efficiency (η) v/s Unit speed (Nu) at Q = 0.006 m3/sec (Advance pelton wheel) 20%

40%

60%

80%

100%

1.20E-03 1.15E-03 1.10E-03 1.05E-03 Qu 1.00E-03 9.50E-04 9.00E-04 8.50E-04 8.00E-04 110

130

150

170

190

210

Nu

Graph 8.31 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.005 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   69 

 

RESULTS AND DISCUSSION

  20%

40%

60%

80%

100%

8 7 6

Pu

5 4 3 2 1 0 110

120

130

140

150

160 Nu

170

180

190

200

210

Graph 8.32 Unit power (Pu) v/s Unit speed (Nu) at Q = 0.005 m3/sec (Advance pelton wheel) 20%

40%

60%

80%

100%

70 60 50

η

40 30 20 10 0 110

120

130

140

150

160

170

180

190

200

210

Nu

Graph 8.33 Efficiency (η) v/s Unit speed (Nu) at Q = 0.005 m3/sec (Advance pelton wheel)

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   70 

 

RESULTS AND DISCUSSION

  20%

40%

60%

80%

100%

6.10E-04 6.00E-04 5.90E-04 5.80E-04 Qu 5.70E-04 5.60E-04 5.50E-04 5.40E-04 5.30E-04 165

170

175

180

185 Nu

190

195

200

205

Graph 8.34 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.0033 m3/sec (Advance pelton wheel) 20%

40%

60%

80%

100%

6 5

Pu

4 3 2 1 0 165

170

175

180

185

190

195

200

205

Nu

Graph 8.35 Unit power (Pu) v/s Unit speed (Nu) at Q = 0.0033 m3/sec (Advance pelton wheel) STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   71 

 

RESULTS AND DISCUSSION

  20%

40%

60%

80%

100%

100 90 80 70

η

60 50 40 30 20 10 0 165

170

175

180

185 Nu

190

195

200

205

Graph 8.36 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0033 m3/sec (Advance pelton wheel) 20 simple

20 advanced

45 40 35 30

η

25 20 15 10 5 0 110

120

130

140

150

160

170

180

190

200

210

220

230

240

Nu

Graph 8.37 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 20 % opening

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   72 

 

RESULTS AND DISCUSSION

  40 simple

40 advance

60 50

η

40 30 20 10 0 120

130

140

150

160

170

180

190

200

210

220

230

240

250

Nu

Graph 8.38 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 40 % opening

60 simple

60 advance

50 45 40 35

η

30 25 20 15 10 5 0 120

130

140

150

160

170

180

190

200

210

220

230

240

Nu

Graph 8.39 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 60 % opening

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   73 

 

RESULTS AND DISCUSSION

  80 simple

80 advance

45 40 35 30

η

25 20 15 10 5 0 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260 Nu

Graph 8.40 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 80 % opening

100 simple

100 advance

60

50

η

40

30

20

10

0 130

140

150

160

170

180

190

200

210

220

230

240

250

260

270

Nu

Graph 8.41 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 100 % opening

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   74 

 

CONCLUSIONS

 

CHAPTER 9 CONCLUSIONS The development of hooped runner and subsequent numerical and experimental investigation carried out on Pelton wheel during the course of this work leads to the following conclusions. 1. The stress analysis is carried out on simple and advanced pelton wheel which shows significant results clearly mentioned that stress developed in hooped runner is less than simple pelton wheel. At the flow rate of 0.01 m3/sec the VON MISES stresses developed in simple pelton wheel is 16.92 MPa whereas at same flow rate VON MISES stress developed in hooped runner is 9.55 MPa which shows that reduction in stress development is 43.35%.This means that the use of hoop, allows stresses to be minimized and distributed more effectively. 2. The experiment carried out on advanced pelton wheel which gives characteristic curves which shows that the influence of hoop on overall efficiency of pelton turbine is very less.

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   75 

 

FUTURE SCOPE

 

CHAPTER 10 FUTURE SCOPE The analysis carried out in this project is just one step towards optimization. There is large scope of work in this subject. •

Hoop optimization can be done by parametric study of hoop in which by varying the thickness of hoop it can be achieved.

•

The fatigue analysis of pelton wheel can be done.

•

By conducting experiment Life cycle prediction of pelton wheel is also possible.

 

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL                                                   76 

 

REFERENCES [1] http://en.wikipedia.org/wiki/Pelton_wheel. [2] Dr. R.K.Bansal, “Fluid Mechanics and Hydraulic Machine”, Published By Laxmi Publication(p) Ltd.Eighth edition 2002. [3] Alexandre Perrig, “Hydrodynamics of the free surface flow in pelton turbine buckets”, Lausanne, Epfl,2007. [4] J. Vesely and M. Varner,

“A

Case Study of Upgrading of 62.5MW Pelton

Turbine”, CKD Blansko Strojírny a.s., Czech Republic. [5] Heinz-Bernd Matthias, Josef Prost and Christian Rossegger, “Investigation of the Flow in Pelton Turbines and the Influence of the Casing”, Austria, 11 April 1997. [6] T. Staubli and H.P. Hauser, “Flow visualization - a diagnosis tool for pelton turbines”, Switzerland , 2004. [7] Mayse Francois, Pierre Yves Lowys and Gerard Vuillerod, “Developments and Recent Projects for Hooped Pelton Turbine”. ALSTOM Power, Turkey, 4-7 November 2002. [8] Bernard Michel, Georges Rossi, Pierre Leroy and Pierre Yves Lowys, “Hooped Pelton Runner”, ALSTOM Power. [9] Dr.S.A.Channiwala and Mr.Gaurang C. Chaudhari, “Analysis, design and flow simulation of advanced pelton wheel”, SVNIT, Surat, June 2008 [10] Dr. Jagdish Lal, “Hydraulic Machines”, published by Metropolitan Book Co. Privet Ltd. Sixth Edition 1975. Chapter-4, 5, 9. [11] CADD Center, “Introduction to Pro/Engineer” [12] Etienne Parkinson, “Developments in numerical flow simulation applied to Pelton turbines”, VA Tech Hydro Ltd., Switzerland, Summer 2003. [13] Hydroplan UK and Gilbert Gilkes & Gordon Ltd., “Low Cost Pelton Turbine Design and Testing”, 2003. [14] John S. Anagnostopoulos and Dimitrios E. Papantonis, “Flow Modeling and Runner Design Optimization in Turgo Water Turbines”, Proceedings of World Academy of Science, Engineering and Technology, volume 22, July 2007. [15] Yodchai Tiaple and Udomkiat Nontakaew, “The Development of Bulb Turbine for Low Head Storage Using CFD Simulation”, Thailand

   

[16] Reiner Mack, “Comet supports the design of Pelton turbines”, Voith Siemens Hydro Power Generation GmbH & Co., KG, Heidenheim Germany

   

APPENDIX – A Stress Analysis of Simple and Advanced Pelton Wheel

Q = 0.01 m3/sec Stress (Simple) SR NO.

Speed (rpm)

Max

Force (N)

(MPa)

Deformation (Advanced)

Min

Max -06

(MPa)10

(MPa)

Min -06

(MPa)10

(Simple)

(Advanced)

% reduction in stress

Max

Max

(mm)

(mm)

% reduction in deformation

Single nozzle 1

100

269

16.92

6.38

9.5538

6.29

43.53

15.36

1.5132

90.14

2

200

269

16.97

3.05

9.556

2.57

43.68

15.42

1.5164

90.16

3

300

269

17.05

8.08

9.56

2.79

43.92

15.51

1.5216

90.18

4

400

269

17.17

1.53

9.566

5.30

44.28

15.65

1.529

90.23

5

500

269

17.31

2.33

9.574

8.81

44.69

15.82

1.5385

90.27

6

600

269

17.5

3.32

9.583

1.60

45.24

16.03

1.5503

90.32

7

680

269

17.66

4.25

9.59

2.33

45.69

16.23

1.5614

90.37

Two nozzle 8

100

134.56

8.66

6.36

4.779

5.05

44.81

7.75

0.757

90.23

9

200

134.56

8.71

3.05

4.782

1.15

45.09

7.91

0.76

90.39

10

300

134.56

8.8

8.08

4.786

2.62

45.61

7.91

0.765

90.32

11

400

134.56

8.91

1.53

4.792

6.85

46.21

8.04

0.773

90.38

12

500

134.56

9.06

2.33

4.799

1.33

47.03

8.22

0.782

90.48

13

600

134.56

9.24

3.32

4.809

2.13

47.95

8.43

0.795

90.56

14

680

134.56

9.4

4.25

4.818

2.88

48.74

8.63

0.806

90.66

Four nozzle 15

100

67.28

4.37

6.34

2.389

7.17

45.33

3.98

0.378

90.50

16

200

67.28

4.428

3.05

2.392

1.22

45.98

4.04

0.382

90.54

17

300

67.28

4.51

8.08

2.397

4.47

46.85

4.13

0.387

90.62

18

400

67.28

4.62

1.53

2.403

9.55

47.98

4.27

0.395

90.74

19

500

67.28

4.77

2.33

2.411

1.61

49.45

4.44

0.405

90.87

20

600

67.28

4.95

3.32

2.421

2.42

51.09

4.67

0.418

91.04

21

680

67.28

5.12

4.25

2.431

3.17

52.51

4.87

0.442

90.92

Six nozzle

 

22

100

44.86

2.91

6.33

1.593

6.30

45.25

2.71

0.252

90.70

23

200

44.86

2.96

3.05

1.596

1.90

46.08

2.77

0.255

90.79

24

300

44.86

3.046

8.08

1.6

5.43

47.47

2.87

0.261

90.90

25

400

44.86

3.16

1.53

1.606

1.05

49.17

3

0.269

91.03

26

500

44.86

3.41

2.33

1.615

1.71

52.63

3.18

0.279

91.22

27

600

44.86

3.75

3.32

1.626

2.52

56.64

3.41

0.341

90

28

680

44.86

4.07

4.25

1.636

3.27

59.80

3.62

0.44

87.84

Q = 0.0066 m3/sec Stress (Simple) SR NO.

Speed (rpm)

Force

Max

(N)

(MPa)

Deformation (Advanced)

Min

Max -06

(MPa)10

(MPa)

Min -06

(MPa) 10

(Simple)

(Advanced)

% reduction

Max

Max

in stress

(mm)

(mm)

% reduction in deformation

Single nozzle 1

100

179.23

10.729

6.52

6.188

5.86

42.32

10.222

0.98

90.41

2

200

179.23

10.78

3.14

6.191

8.85

42.56

10.279

0.983

90.43

3

300

179.23

10.863

8.25

6.195

3.16

42.97

10.374

0.988

90.47

4

400

179.23

10.981

1.40

6.2

5.64

43.53

10.508

0.996

90.52

5

500

179.23

11.13

1.76

6.209

1.17

44.21

10.681

1.005

90.59

6

600

179.23

11.32

2.46

6.218

1.96

45.07

10.894

1.017

90.66

7

680

179.23

11.48

3.21

6.22

2.71

45.81

11.093

1.029

90.72

8

100

89.61

5.499

6.50

3.182

7.89

42.13

5.178

0.504

90.26

9

200

89.61

5.549

3.14

3.185

1.39

42.60

5.235

0.508

90.29

10

300

89.61

5.633

8.25

3.19

3.62

43.36

5.331

0.513

90.37

Two nozzle

11

400

89.61

5.75

1.40

3.196

8.60

44.41

5.466

0.52

90.48

12

500

89.61

5.902

1.76

3.204

1.52

45.71

5.642

0.53

90.60

13

600

89.61

6.087

2.46

3.214

2.32

47.19

5.858

0.542

90.74

14

680

89.61

6.26

3.21

3.223

3.07

48.51

6.06

0.554

90.85

Four nozzle 15

100

44.86

2.772

6.49

1.594

6.30

42.49

2.699

0.2526

90.64

16

200

44.86

2.822

3.14

1.596

1.90

43.44

2.757

0.256

90.71

17

300

44.86

2.907

8.25

1.6

5.43

44.96

2.853

0.261

90.85

18

400

44.86

3.024

1.40

1.607

1.05

46.85

2.989

0.269

91.00

19

500

44.86

3.215

1.76

1.615

1.71

49.76

3.168

0.279

91.19

20

600

44.86

3.535

2.46

1.625

2.52

54.03

3.388

0.342

89.90

21

680

44.86

3.838

3.21

1.636

3.27

57.37

3.597

0.44

87.76

22

100

29.87

2.018

6.49

1.0612

4.47

47.41

1.853

0.168

90.93

23

200

29.87

2.116

3.14

1.063

2.54

49.76

1.91

0.172

90.94

24

300

29.87

2.28

8.25

1.068

6.11

53.15

2.007

0.177

91.18

Six nozzle

25

400

29.87

2.509

1.56

1.075

1.12

57.15

2.145

0.185

91.37

26

500

29.87

2.805

2.50

1.0833

1.78

61.37

2.325

0.236

89.84

27

600

29.87

3.167

3.66

1.095

2.59

65.42

2.549

0.342

86.58

28

680

29.87

3.505

4.73

1.106

3.34

68.44

2.761

0.442

83.99

Q = 0.005 m3/sec Stress (Simple) SR NO.

Speed (rpm)

Force

Max

(N)

(MPa)

Deformation (Advanced)

Min

Max -06

(MPa)10

(MPa)

Min

(Simple)

(Advanced)

% reduction

Max

Max

% reduction

in stress

(mm)

(mm)

in deformation

-06

(MPa)10

Single nozzle 1

100

134.56

8.054

6.51

4.779

5.05

40.66

7.668

0.757

90.12

2

200

134.56

8.104

3.14

4.782

1.15

40.99

7.726

0.76

90.16

3

300

134.56

8.187

8.25

4.786

2.62

41.54

7.821

0.766

90.20

4

400

134.56

8.305

1.40

4.792

6.85

42.29

7.956

0.773

90.28

5

500

134.56

8.457

1.76

4.799

1.33

43.25

8.13

0.782

90.38

6

600

134.56

8.641

2.46

4.809

2.13

44.34

8.343

0.795

90.47

7

680

134.56

8.813

3.21

4.818

2.88

45.33

8.544

0.806

90.56

8

100

67.28

4.139

6.49

2.425

7.25

41.41

3.903

0.384

90.16

9

200

67.28

4.188

3.14

2.427

1.21

42.04

3.959

0.387

90.22

10

300

67.28

4.273

8.25

2.432

4.43

43.08

4.056

0.393

90.31

Two nozzle

11

400

67.28

4.389

1.40

2.438

9.50

44.45

4.191

0.4

90.45

12

500

67.28

4.541

1.76

2.446

1.61

46.13

4.368

0.423

90.31

13

600

67.28

4.739

2.46

2.457

2.42

48.15

4.586

0.441

90.38

14

680

67.28

5.044

3.21

2.466

3.17

51.11

4.791

0.441

90.79

Four nozzle 15

100

33.64

2.088

6.49

1.195

6.04

42.76

2.057

0.19

90.76

16

200

33.64

2.139

3.14

1.198

2.37

43.99

2.114

0.193

90.87

17

300

33.64

2.223

8.25

1.202

5.94

45.92

2.211

0.198

91.04

18

400

33.64

2.355

1.40

1.208

1.10

48.70

2.349

0.206

91.23

19

500

33.64

2.617

1.76

1.217

1.76

53.49

2.529

0.236

90.66

20

600

33.64

2.937

2.46

1.228

2.57

58.18

2.753

0.341

87.61

21

680

33.64

3.236

3.21

1.239

3.32

61.71

2.964

0.441

85.12

22

100

22.41

1.556

6.48

0.7963

7.18

48.82

1.426

0.126

91.16

23

200

22.41

1.654

3.14

0.7988

2.70

51.70

1.484

0.13

91.23

24

300

22.41

1.817

8.25

0.8033

6.45

55.78

1.581

0.135

91.46

Six nozzle

25

400

22.41

2.047

1.56

0.8099

1.16

60.43

1.72

0.149

91.33

26

500

22.41

2.343

2.50

0.819

1.82

65.04

1.902

0.236

87.59

27

600

22.41

2.706

3.66

0.831

2.62

69.29

2.129

0.343

83.88

28

680

22.41

3.044

4.73

0.843

3.37

72.30

2.344

0.443

81.10

Q = 0.0033 m3/sec Stress (Simple) SR NO.

Speed (rpm)

Max

Force (N)

(MPa)

Deformation (Advanced)

Min

Max -06

(MPa) 10

(MPa)

(Simple)

(Advanced)

Max

Max

% reduction

in stress

(mm)

(mm)

in deformation

% reduction

Min -06

(MPa) 10

Single nozzle 1

100

89.61

5.362

6.50

3.183

7.89

40.63

5.1

0.504

90.11

2

200

89.61

5.412

3.14

3.185

1.39

41.14

5.157

0.508

90.14

3

300

89.61

5.495

8.25

3.19

3.62

41.94

5.253

0.513

90.23

4

400

89.61

5.613

1.40

3.196

8.50

43.06

5.387

0.52

90.34

5

500

89.61

5.764

1.76

3.204

1.52

44.41

5.563

0.53

90.47

6

600

89.61

5.949

2.46

3.214

2.32

45.97

5.778

0.543

90.60

7

680

89.61

6.122

3.21

3.223

3.07

47.35

5.981

0.554

90.73

8

100

44.86

2.772

6.49

1.394

6.30

49.71

2.623

0.253

90.35

9

200

44.86

2.822

3.14

1.596

1.90

43.44

2.679

0.256

90.44

10

300

44.86

2.906

8.25

1.6

5.43

44.94

2.776

0.261

90.59

Two nozzle

11

400

44.86

3.024

1.40

1.607

1.05

46.85

2.912

0.269

90.76

12

500

44.86

3.206

1.76

1.615

1.52

49.62

3.091

0.279

90.97

13

600

44.86

3.533

2.46

1.626

1.71

53.97

3.313

0.341

89.70

14

680

44.86

3.838

3.21

1.636

3.27

57.37

3.521

0.44

87.50

Four nozzle 15

100

22.41

1.405

6.48

0.7962

7.18

43.33

1.413

0.126

91.08

16

200

22.41

1.455

3.14

0.7988

2.70

45.09

1.472

0.13

91.16

17

300

22.41

1.554

8.25

0.8033

6.43

48.30

1.57

0.135

91.40

18

400

22.41

1.756

1.40

0.8099

1.16

53.87

1.709

0.15

91.22

19

500

22.41

2.018

1.76

0.819

1.82

59.41

1.892

0.236

87.52

20

600

22.41

2.339

2.46

0.831

2.62

64.47

2.12

0.343

83.82

21

680

22.41

2.639

3.21

0.843

3.37

68.05

2.336

0.443

81.03

22

100

14.93

1.093

6.48

0.5306

1.21

51.45

0.998

0.08437

91.54

23

200

14.93

1.19

3.14

0.5332

2.73

55.19

1.056

0.08758

91.70

24

300

14.93

1.355

8.25

0.5378

6.61

60.30

1.155

0.0933

91.92

Six nozzle

25

400

14.93

1.584

1.56

0.5447

1.19

65.61

1.296

0.149

88.50

26

500

14.93

1.881

2.50

0.5546

1.85

70.51

1.482

0.2368

84.02

27

600

14.93

2.244

3.66

0.5679

2.66

74.69

1.713

0.344

79.91

28

680

14.93

2.583

4.73

0.624

3.41

75.84

1.93

0.445

76.94

APPENDIX - B Experimental Data & Results of Simple Pelton Wheel

Q = 0.01 m3/sec Unit Pr. Sr. No.

Gauge reading 2

(kg/cm )

spring

Flow Weight

(lpm)

(kg)

Net

Power

Speed

Pi/2g

(Vi) /2g

(kg)

(rpm)

m

m

m

watt

(N)

(N m)

(watt)

%

(Nu)

balance rate

Power

2

reading

H

(input)

Weight

Torque

(output)

η

Unit Speed

Discharge

Unit

(Qu)

Power

10

-03

(Pu)

20 % opening 1

4

600

1

0.40

1378

32

0.59

32.59

2129.01

5.90

0.94

136.13

3.36

214.36

1.56

0.51

2

4

600

2

0.90

1347

32

0.59

32.59

2129.01

10.83

1.73

244.28

6.03

209.53

1.56

0.92

3

4

600

4

1.40

1256

32

0.59

32.59

2129.01

25.55

4.09

537.36

13.25

195.38

1.56

2.02

4

4

600

5

1.59

1241

32

0.59

32.59

2129.01

33.41

5.35

694.31

17.13

193.04

1.56

2.61

5

4

600

6

1.04

1206

32

0.59

32.59

2129.01

48.61

7.78

981.79

24.22

187.60

1.56

3.70

6

4

600

7

0.61

1180

32

0.59

32.59

2129.01

62.67

10.03

1238.42

30.55

183.56

1.56

4.66

40 % opening 7

3.4

600

1

0.30

1384

24

0.59

24.59

1606.34

6.84

1.09

158.54

4.57

232.85

1.68

0.76

8

3.4

600

2

0.50

1356

24

0.59

24.59

1606.34

14.76

2.36

335.17

9.67

228.14

1.68

1.60

9

3.4

600

4

0.66

1324

24

0.59

24.59

1606.34

32.79

5.25

727.14

20.98

222.76

1.68

3.46

10

3.4

600

5

0.89

1316

24

0.59

24.59

1606.34

40.32

6.45

888.57

25.64

221.41

1.68

4.23

11

3.4

600

6

0.58

1264

24

0.59

24.59

1606.34

53.13

8.50

1124.57

32.45

212.66

1.68

5.36

12

3.4

600

7

0.63

1270

24

0.59

24.59

1606.34

62.45

9.99

1328.11

38.32

213.67

1.68

6.33

60 % opening 13

3.2

600

1

0.22

1348

22

0.59

22.59

1475.67

7.61

1.22

171.79

5.25

233.50

1.73

0.89

14

3.2

600

2

0.21

1322

22

0.59

22.59

1475.67

17.59

2.82

389.51

11.91

229.00

1.73

2.02

15

3.2

600

4

1.01

1293

22

0.59

22.59

1475.67

29.32

4.69

634.91

19.42

223.98

1.73

3.30

16

3.2

600

5

0.54

1281

22

0.59

22.59

1475.67

43.77

7.00

938.96

28.72

221.90

1.73

4.88

17

3.2

600

6

0.96

1233

22

0.59

22.59

1475.67

49.46

7.91

1021.18

31.24

213.58

1.73

5.31

18

3.2

600

7

1.26

1226

22

0.59

22.59

1475.67

56.26

9.00

1155.14

35.33

212.37

1.73

6.00

600

1

0.53

1320

20

0.59

20.59

1345.00

4.62

0.74

102.22

3.33

235.84

1.79

0.58

80 % opening 19

3

20

3

600

2

0.72

1299

20

0.59

20.59

1345.00

12.51

2.00

272.16

8.86

232.09

1.79

1.55

21

3

600

4

1.29

1265

20

0.59

20.59

1345.00

26.57

4.25

562.88

18.32

226.01

1.79

3.21

22

3

600

5

1.09

1254

20

0.59

20.59

1345.00

38.34

6.13

805.07

26.20

224.05

1.79

4.59

23

3

600

6

1.24

1211

20

0.59

20.59

1345.00

46.71

7.47

947.24

30.82

216.36

1.79

5.40

24

3

600

7

1.35

1206

20

0.59

20.59

1345.00

55.46

8.87

1120.16

36.45

215.47

1.79

6.39

100 % opening 25

2.8

600

1

0.29

1305

18

0.59

18.59

1214.33

7.01

1.12

153.11

5.32

240.98

1.85

0.96

26

2.8

600

2

0.46

1281

18

0.59

18.59

1214.33

15.07

2.41

323.27

11.24

236.55

1.85

2.04

27

2.8

600

4

0.81

1247

18

0.59

18.59

1214.33

31.27

5.00

652.92

22.69

230.27

1.85

4.11

27

2.8

600

5

1.52

1240

18

0.59

18.59

1214.33

34.16

5.47

709.43

24.66

228.98

1.85

4.47

29

2.8

600

6

1.29

1187

18

0.59

18.59

1214.33

46.25

7.40

919.36

31.96

219.19

1.85

5.79

30

2.8

600

7

1.05

1137

18

0.59

18.59

1214.33

58.36

9.34

1111.25

38.63

209.96

1.85

7.00

Q = 0.0066 m3/sec

Sr. No.

Unit

Spring

Pr. Gauge reading 2

(kg/cm )

Flow

balance

2

(Vi)

Power

NET

Power

discharge

Unit

(Qu)

Power

Unit

rate

Weight

reading

Speed

Pi/ૉg

/2g

H

(input)

Weight

Torque

(output)

η

Speed

(lpm)

(kg)

(kg)

(rpm)

(m)

(m)

(m)

(watt)

(N)

(N m)

watt

(%)

(Nu)

03

10-

(Pu)

20 % opening 1

3.2

400

1

0.07

1326

32

0.58

32.58

2129.01

9.06

1.45

201.27

9.54

232.28

1.08

1.08

2

3.2

400

2

0.65

1264

32

0.58

32.58

2129.01

13.20

2.11

279.55

13.25

221.42

1.08

1.50

3

3.2

400

4

1.09

1162

32

0.58

32.58

2129.01

28.46

4.55

553.83

26.25

203.55

1.08

2.97

4

3.2

400

5

0.91

1095

32

0.58

32.58

2129.01

40.03

6.40

734.22

34.8

191.82

1.08

3.94

5

3.2

400

6

1.21

963

32

0.58

32.58

2129.01

46.90

7.50

756.33

35.85

168.69

1.08

4.06

6

3.2

400

7

0.91

870

32

0.58

32.58

2129.01

59.73

9.55

870.30

41.25

152.40

1.08

4.67

40 % opening 7

2.4

400

1

0.30

1237

24

0.58

24.58

1606.33

6.85

1.09

141.90

8.91

249.47

1.11

1.16

8

2.4

400

2

0.64

1171

24

0.58

24.58

1606.33

13.30

2.12

260.92

16.39

236.16

1.11

2.14

9

2.4

400

4

1.23

1085

24

0.58

24.58

1606.33

27.08

4.33

492.18

30.91

218.81

1.11

4.03

10

2.4

400

5

1.12

977

24

0.58

24.58

1606.33

38.03

6.08

622.34

39.09

197.03

1.11

5.10

11

2.4

400

6

1.56

956

24

0.58

24.58

1606.33

43.49

6.95

696.37

43.74

192.80

1.11

5.71

12

2.4

400

7

1.16

828

24

0.58

24.58

1606.33

57.25

9.16

793.94

49.87

166.98

1.11

6.51

60 % opening 13

2.2

400

1

0.67

1129

22

0.58

22.58

1475.66

3.21

0.51

60.71

4.152

237.55

1.14

0.56

14

2.2

400

2

0.38

1066

22

0.58

22.58

1475.66

15.79

2.52

281.98

19.28

224.30

1.14

2.62

15

2.2

400

4

1.14

1045

22

0.58

22.58

1475.66

28.04

4.48

490.75

33.55

219.88

1.14

4.57

16

2.2

400

5

1.22

918

22

0.58

22.58

1475.66

37

5.92

568.94

38.90

193.16

1.14

5.30

17

2.2

400

6

1.72

886

22

0.58

22.58

1475.66

41.94

6.71

622.36

42.55

186.42

1.14

5.79

18

2.2

400

7

1.93

808

22

0.58

22.58

1475.66

49.67

7.94

672.10

45.95

170.01

1.14

6.26

80 & opening 19

2

400

1

0.36

1149

20

0.58

20.58

1345

6.20

0.99

119.32

8.95

253.23

1.17

1.27

20

2

400

2

0.72

1019

20

0.58

20.58

1345

12.50

2

213.45

16.01

224.58

1.17

2.28

21

2

400

4

1.52

919

20

0.58

20.58

1345

24.25

3.88

373.22

28

202.54

1.17

3.99

22

2

400

5

1.96

767

20

0.58

20.58

1345

29.73

4.75

381.98

28.65

169.04

1.17

4.08

23

2

400

6

2.03

751

20

0.58

20.58

1345

38.92

6.22

489.50

36.72

165.52

1.17

5.24

24

2

400

7

1.68

640

20

0.58

20.58

1345

52.17

8.34

559.22

41.95

141.05

1.17

5.98

100 % opening 25

1.8

400

1

0.47

1128

18

0.58

18.58

1214.32

5.19

0.83

98.07

8.15

261.64

1.21

1.22

26

1.8

400

2

0.58

1087

18

0.58

18.58

1214.32

13.92

2.22

253.41

21.05

252.13

1.21

3.16

27

1.8

400

4

1.49

1026

18

0.58

18.58

1214.32

24.53

3.92

421.49

35.02

237.98

1.21

5.26

27

1.8

400

5

1.43

925

18

0.58

18.58

1214.32

34.96

5.59

541.67

45.01

214.55

1.21

6.76

29

1.8

400

6

2

830

18

0.58

18.58

1214.32

39.18

6.26

544.63

45.25

192.52

1.21

6.79

30

1.8

400

7

1.74

793

18

0.58

18.58

1214.32

51.59

8.25

685.15

56.93

183.94

1.21

8.55

Q = 0.005 m3/sec

Gauge Sr. No.

Unit

Spring

Pr.

reading 2

(kg/cm )

Flow

balance

2

(Vi)

Power

Net

Power

Discharge

Unit

(Qu)

Power

Unit

rate

Weight

reading

Speed

Pi/2g

/2g

H

input

weight

Torque

(output)

η

Speed

(lpm)

(kg)

(kg)

(rpm)

(m)

(m)

(m)

(watt)

(N)

(N m)

(watt)

(%)

(Nu)

04

10-

(Pu)

20 % opening 1

3.1

300

1

0.02

1188

31

0.33

31.33

1536.76

9.51

1.52

189.32

12.32

212.24

8.93

1.07

2

3.1

300

2

0.22

1070

31

0.33

31.33

1536.76

17.42

2.7

312.26

20.32

191.16

8.93

1.78

3

3.1

300

4

0.96

965

31

0.33

31.33

1536.76

29.77

4.76

481.20

31.31

172.40

8.93

2.74

4

3.1

300

5

1.30

943

31

0.33

31.33

1536.76

36.21

5.79

571.87

37.21

168.47

8.93

3.26

5

3.1

300

6

1.52

889

31

0.33

31.33

1536.76

43.89

7.02

653.47

42.52

158.82

8.93

3.72

6

3.1

300

7

1.45

819

31

0.33

31.33

1536.76

54.40

8.70

746.16

48.55

146.31

8.93

4.25

40 % opening 7

3.2

300

1

0.28

1255

32

0.33

32.33

1585.81

6.98

1.11

146.76

9.25

220.71

8.79

0.79

8

3.2

300

2

0.37

1219

32

0.33

32.33

1585.81

15.95

2.55

325.76

20.54

214.38

8.79

1.77

9

3.2

300

4

1.41

1129

32

0.33

32.33

1585.81

25.37

4.06

479.77

30.25

198.55

8.79

2.60

10

3.2

300

5

1.30

1079

32

0.33

32.33

1585.81

36.20

5.79

654.21

41.25

189.76

8.79

3.55

11

3.2

300

6

1.42

1019

32

0.33

32.33

1585.81

44.83

7.17

765.15

48.25

179.21

8.79

4.16

12

3.2

300

7

1.48

972

32

0.33

32.33

1585.81

54.11

8.65

880.82

55.54

170.94

8.79

4.79

60 & opening 13

2.6

300

1

0.40

1136

26

0.33

26.33

1291.51

5.81

0.93

110.61

8.56

221.38

9.74

0.81

14

2.6

300

2

0.72

1110

26

0.33

26.33

1291.51

12.52

2

232.80

18.02

216.31

9.74

1.72

15

2.6

300

4

1.40

1087

26

0.33

26.33

1291.51

25.01

4

455.33

35.25

211.83

9.74

3.37

16

2.6

300

5

1.47

986

26

0.33

26.33

1291.51

34.65

5.53

571.57

44.25

192.15

9.74

4.23

17

2.6

300

6

1.38

941

26

0.33

26.33

1291.51

45.28

7.24

713.63

55.25

183.38

9.74

5.28

18

2.6

300

7

1.30

901

26

0.33

26.33

1291.51

55.85

8.9

842.78

65.25

175.58

9.74

6.23

80 % opening 19

2.2

300

1

0.51

1132

22

0.33

22.33

1095.31

4.78

0.76

90.74

8.28

239.55

10.6

0.85

20

2.2

300

2

0.82

1083

22

0.33

22.33

1095.31

11.49

1.83

208.39

19.02

229.18

10.6

1.97

21

2.2

300

4

1.46

953

22

0.33

22.33

1095.31

24.88

3.98

397.10

36.25

201.67

10.6

3.76

22

2.2

300

5

1.42

919

22

0.33

22.33

1095.31

35.02

5.60

539.02

49.21

194.47

10.6

5.10

23

2.2

300

6

1.45

884

22

0.33

22.33

1095.31

44.58

7.13

659.97

60.25

187.06

10.6

6.25

24

2.2

300

7

1.47

836

22

0.33

22.33

1095.31

54.18

8.66

758.55

69.25

176.91

10.6

7.18

100 % opening 25

2

300

1

0.52

1106

20

0.33

20.33

997.21

4.61

0.73

85.40

8.56

245.29

11.1

0.93

26

2

300

2

0.87

1092

20

0.33

20.33

997.21

11.04

1.76

201.98

20.25

242.18

11.1

2.20

27

2

300

4

1.49

1025

20

0.33

20.33

997.21

24.54

3.92

421.36

42.25

227.32

11.1

4.59

27

2

300

5

1.32

891

20

0.33

20.33

997.21

36

5.76

537.29

53.87

197.60

11.1

5.86

29

2

300

6

1.40

878

20

0.33

20.33

997.21

45.08

7.21

662.93

66.47

194.24

11.1

7.23

30

2

300

7

1.42

830

20

0.33

20.33

997.21

54.70

8.75

760.42

76.25

184.07

11.1

8.29

Q = 0.0033 m3/sec

Sr. No.

Unit

Spring

Pr. Gauge

Flow

reading

rate

Weight

Reading

Speed

Pi/2g

/2g

(kg/cm2)

(lpm)

(kg)

(kg)

(rpm)

(m)

balance

Power

Net

H

(input)

Weight

Torque

(output)

η

Speed

(m)

(m)

(watt)

(N)

(N m)

(watt)

(%)

(Nu)

(Vi)2

Power

Discharge

Unit

(Qu)

Power

Unit

04

10-

(Pu)

20 % opening 1

3.8

200

1

0.51

1496

38

0.14

38.14

1234.83

4.72

0.75

118.39

9.58

242.22

5.39

0.50

2

3.8

200

2

0.72

1398

38

0.14

38.14

1234.83

12.54

2

293.76

23.78

226.35

5.39

1.24

3

3.8

200

4

1.27

1338

38

0.14

38.14

1234.83

26.71

4.27

598.62

48.47

216.64

5.39

2.54

4

3.8

200

5

1.42

1185

38

0.14

38.14

1234.83

35.06

5.61

695.93

56.35

191.86

5.39

2.95

5

3.8

200

6

1.30

1162

38

0.14

38.14

1234.83

46.03

7.36

895.84

72.54

188.14

5.39

3.80

6

3.8

200

7

1.45

1128

38

0.14

38.14

1234.83

54.41

8.70

1028

83.25

182.64

5.39

4.36

40 % opening 7

3.6

200

1

0.45

1404

36

0.14

36.14

1170.08

5.38

0.86

126.72

10.83

233.53

5.54

0.58

8

3.6

200

2

0.77

1369

36

0.14

36.14

1170.08

11.97

1.91

274.46

23.45

227.71

5.54

1.26

9

3.6

200

4

1.28

1294

36

0.14

36.14

1170.08

26.65

4.26

577.60

49.36

215.23

5.54

2.65

10

3.6

200

5

1.42

1202

36

0.14

36.14

1170.08

35.09

5.62

706.44

60.37

199.93

5.54

3.25

11

3.6

200

6

1.41

1175

36

0.14

36.14

1170.08

45

7.20

885.62

75.68

195.44

5.54

4.07

12

3.6

200

7

1.49

1115

36

0.14

36.14

1170.08

54.02

8.64

1008.73

86.21

185.46

5.54

4.64

60 % opening 13

3.4

200

1

0.33

1312

34

0.14

34.14

1105.34

6.55

1.04

143.93

13.02

224.53

5.70

0.72

14

3.4

200

2

0.53

1297

34

0.14

34.14

1105.34

14.41

2.30

313.04

28.32

221.96

5.70

1.56

15

3.4

200

4

1.31

1283

34

0.14

34.14

1105.34

26.34

4.21

566.12

51.21

219.56

5.70

2.83

16

3.4

200

5

1.39

1188

34

0.14

34.14

1105.34

35.38

5.66

703.99

63.69

203.31

5.70

3.52

17

3.4

200

6

1.44

1113

34

0.14

34.14

1105.34

44.71

7.15

833.39

75.39

190.47

5.70

4.17

18

3.4

200

7

1.49

1068

34

0.14

34.14

1105.34

53.98

8.63

965.62

87.36

182.77

5.70

4.83

80 % opening 19

3.2

200

1

0.38

1323

32

0.14

32.14

1040.59

6.05

0.96

134.17

12.89

233.35

5.87

0.73

20

3.2

200

2

0.61

1276

32

0.14

32.14

1040.59

13.62

2.18

291.18

27.98

225.06

5.87

1.59

21

3.2

200

4

1.08

1168

32

0.14

32.14

1040.59

28.56

4.57

558.69

53.69

206.01

5.87

3.06

22

3.2

200

5

1.09

1142

32

0.14

32.14

1040.59

38.31

6.12

732.68

70.41

201.42

5.87

4.02

23

3.2

200

6

1.43

1109

32

0.14

32.14

1040.59

44.78

7.16

831.75

79.93

195.60

5.87

4.56

24

3.2

200

7

1.51

1032

32

0.14

32.14

1040.59

53.78

8.60

929.47

89.32

182.02

5.87

5.1

100 % opening 25

3

200

1

0.53

1307

30

0.14

30.14

975.85

4.56

0.73

99.92

10.24

238.05

6.07

0.60

26

3

200

2

0.78

1287

30

0.14

30.14

975.85

11.93

1.90

257.23

26.36

234.41

6.07

1.55

27

3

200

4

1.45

1246

30

0.14

30.14

975.85

25.01

4

521.95

53.48

226.94

6.07

3.15

27

3

200

5

1.18

1131

30

0.14

30.14

975.85

37.37

5.98

707.96

72.54

205.99

6.07

4.27

29

3

200

6

1.40

1079

30

0.14

30.14

975.85

45.06

7.21

814.34

83.45

196.52

6.07

4.92

30

3

200

7

1.56

1007

30

0.14

30.14

975.85

53.29

8.52

898.75

92.1

183.41

6.07

5.43

APPENDIX - C Experimental Data & Results of Advanced Pelton Wheel

Q = 0.01 m3/sec

Unit

Pr.

No.

Gauge

Flow

reading

rate

Weight

reading

Speed

(lpm)

(kg)

(kg)

(rpm)

(Vi)

spring

2

(kg/cm )

Power

2

Sr.

balance

Power

Discharge

Unit Power

Unit

Pi/ૉg

/2g

H

(input)

Weight

Torque

(output)

η

Speed

(Qu)

(m)

(m)

(m)

(Watt)

(N)

(N m)

(Watt)

(%

( Nu)

10

-03

(Pu)

20 % opening 1

4

600

1

0.3

1183

40

1.32

41.32

4054.15

6.86

1.09

136.11

3.35

184.02

1.56

0.51

2

4

600

2

0.55

1154

40

1.32

41.32

4054.15

14.22

2.27

275.03

6.78

179.51

1.56

1.03

3

4

600

4

1.1

1046

40

1.32

41.32

4054.15

28.44

4.55

498.59

12.29

162.71

1.56

1.87

4

4

600

5

1.2

1031

40

1.32

41.32

4054.15

37.27

5.96

643.96

15.88

160.37

1.56

2.42

5

4

600

6

1.45

1021

40

1.32

41.32

4054.15

44.63

7.14

763.58

18.83

158.82

1.56

2.87

6

4

600

7

1.7

980

40

1.32

41.32

4054.15

51.99

8.31

853.72

21.05

152.44

1.56

3.21

40 % opening 7

3.4

600

1

0.3

1189

34

1.32

35.32

3465.55

6.86

1.09

136.80

3.94

200.04

1.68

0.65

8

3.4

600

2

0.5

1163

34

1.32

35.32

3465.55

14.71

2.35

286.74

8.27

195.67

1.68

1.36

9

3.4

600

4

1

1114

34

1.32

35.32

3465.55

29.43

4.70

549.31

15.85

187.42

1.68

2.61

10

3.4

600

5

1.2

1106

34

1.32

35.32

3465.55

37.27

5.96

690.80

19.93

186.08

1.68

3.29

11

3.4

600

6

1.5

1079

34

1.32

35.32

3465.55

44.14

7.06

798.08

23.02

181.53

1.68

3.80

12

3.4

600

7

1.7

1060

34

1.32

35.32

3465.55

51.99

8.31

923.42

26.64

178.34

1.68

4.39

60 % opening 13

3.2

600

1

0.3

1153

32

1.32

33.32

3269.35

6.86

1.09

132.66

4.05

199.72

1.73

0.68

14

3.2

600

2

0.55

1129

32

1.32

33.32

3269.35

14.22

2.27

269.07

8.23

195.56

1.73

1.39

15

3.2

600

4

1.1

1083

32

1.32

33.32

3269.35

28.44

4.55

516.23

15.79

187.59

1.73

2.68

16

3.2

600

5

1.15

1071

32

1.32

33.32

3269.35

37.76

6.04

677.74

20.73

185.52

1.73

3.52

17

3.2

600

6

1.5

1048

32

1.32

33.32

3269.35

44.14

7.06

775.16

23.70

181.53

1.73

4.02

18

3.2

600

7

1.65

1016

32

1.32

33.32

3269.35

52.48

8.39

893.43

27.32

175.99

1.73

4.64

600

1

0.25

1125

30

1.32

31.32

3073.15

7.35

1.17

138.68

4.51

200.99

1.79

0.79

80 % opening 19

3

20

3

600

2

0.55

1106

30

1.32

31.32

3073.15

14.22

2.27

263.59

8.57

197.60

1.79

1.50

21

3

600

4

1.05

1055

30

1.32

31.32

3073.15

28.93

4.63

511.55

16.64

188.49

1.79

2.91

22

3

600

5

1.1

1044

30

1.32

31.32

3073.15

38.25

6.12

669.24

21.77

186.52

1.79

3.81

23

3

600

6

1.4

1026

30

1.32

31.32

3073.15

45.12

7.22

775.75

25.24

183.31

1.79

4.42

24

3

600

7

1.7

996

30

1.32

31.32

3073.15

51.99

8.31

867.66

28.23

177.95

1.79

4.94

100 % opening 25

2.8

600

1

0.35

1110

28

1.32

29.32

2876.95

6.37

1.02

118.59

4.12

204.97

1.85

0.74

26

2.8

600

2

0.5

1088

28

1.32

29.32

2876.95

14.71

2.35

268.24

9.32

200.90

1.85

1.68

27

2.8

600

4

1

1037

28

1.32

29.32

2876.95

29.43

4.70

511.34

17.77

191.49

1.85

3.21

27

2.8

600

5

1.1

1030

28

1.32

29.32

2876.95

38.25

6.12

660.26

22.95

190.19

1.85

4.15

29

2.8

600

6

1.35

1002

28

1.32

29.32

2876.95

45.61

7.29

765.84

26.61

185.02

1.85

4.82

30

2.8

600

7

1.6

977

28

1.32

29.32

2876.95

52.97

8.47

867.17

30.14

180.41

1.85

5.46

Q = 0.0066 m3/sec Unit

Pr.

No.

Gauge

Flow

reading

rate

Weight

reading

Speed

(lpm)

(kg)

(kg)

(rpm)

(Vi)

spring

2

(kg/cm )

Power

2

Sr.

balance

Power

Discharge

Unit

(Qu)

Power

Unit

Pi/ૉg

/2g

H

(input)

Weight

Torque

(output)

η

Speed

(m)

(m)

(m)

(Watt)

(N)

(N m)

(Watt)

(%)

(Nu)

10

-03

(Pu)

20 % opening 1

3.2

400

1

0.1

1131

32

0.58

32.58

2129.01

8.829

1.41

167.31

7.85

198.12

1.08

0.89

2

3.2

400

2

0.3

1071

32

0.58

32.58

2129.01

16.677

2.66

299.26

14.05

187.61

1.08

1.60

3

3.2

400

4

0.7

952

32

0.58

32.58

2129.01

32.373

5.17

516.37

24.25

166.77

1.08

2.77

4

3.2

400

5

0.7

885

32

0.58

32.58

2129.01

42.18

6.74

625.50

29.37

155.03

1.08

3.36

5

3.2

400

6

1.25

778

32

0.58

32.58

2129.01

46.59

7.45

607.42

28.53

136.28

1.08

3.26

6

3.2

400

7

0.9

660

32

0.58

32.58

2129.01

59.84

9.57

661.74

31.08

115.61

1.08

3.55

40 % opening 7

2.4

400

1

0.2

1038

24

0.58

24.58

1606.33

7.848

1.25

136.49

8.49

209.33

1.11

1.11

8

2.4

400

2

0.4

982

24

0.58

24.58

1606.33

15.69

2.51

258.25

16.07

198.04

1.11

2.11

9

2.4

400

4

0.75

916

24

0.58

24.58

1606.33

31.88

5.10

489.32

30.46

184.73

1.11

4.01

10

2.4

400

5

0.8

827

24

0.58

24.58

1606.33

41.20

6.59

570.91

35.54

166.78

1.11

4.68

11

2.4

400

6

1.45

783

24

0.58

24.58

1606.33

44.63

7.14

585.58

36.45

157.91

1.11

4.80

12

2.4

400

7

1

650

24

0.58

24.58

1606.33

58.86

9.41

641.03

39.90

131.08

1.11

5.25

60 % opening 13

2.2

400

1

0.7

979

22

0.58

22.58

1475.66

2.94

0.47

48.27

3.27

205.99

1.14

0.44

14

2.2

400

2

0.3

908

22

0.58

22.58

1475.66

16.67

2.66

253.71

17.19

191.05

1.14

2.36

15

2.2

400

4

0.9

856

22

0.58

22.58

1475.66

30.41

4.86

436.16

29.55

180.11

1.14

4.06

16

2.2

400

5

0.6

745

22

0.58

22.58

1475.66

43.16

6.90

538.79

36.51

156.75

1.14

5.01

17

2.2

400

6

1.5

713

22

0.58

22.58

1475.66

44.14

7.06

527.37

35.73

150.02

1.14

4.91

18

2.2

400

7

1

598

22

0.58

22.58

1475.66

58.86

9.41

589.75

39.96

125.82

1.14

5.49

80 % opening 19

2

400

1

0.25

960

20

0.58

20.58

1344.99

7.35

1.17

118.34

8.79

211.58

1.17

1.26

20

2

400

2

0.45

809

20

0.58

20.58

1344.99

15.20

2.43

206.10

15.32

178.30

1.17

2.20

21

2

400

4

0.9

726

20

0.58

20.58

1344.99

30.41

4.86

369.92

27.50

160.01

1.17

3.96

22

2

400

5

0.6

648

20

0.58

20.58

1344.99

43.16

6.90

468.64

34.84

142.81

1.17

5.01

23

2

400

6

1.5

626

20

0.58

20.58

1344.99

44.14

7.02

463.02

34.42

137.97

1.17

4.95

24

2

400

7

1.1

529

20

0.58

20.58

1344.99

57.87

9.26

513.00

38.14

116.59

1.17

5.49

100 % opening 25

1.8

400

1

0.3

939

18

0.58

18.58

1214.32

6.86

1.09

108.03

8.89

217.80

1.21

1.34

26

1.8

400

2

0.35

898

18

0.58

18.58

1214.32

16.18

2.58

243.54

20.05

208.29

1.21

3.03

27

1.8

400

4

1

837

18

0.58

18.58

1214.32

29.43

4.70

412.72

33.98

194.14

1.21

5.15

27

1.8

400

5

0.7

756

18

0.58

18.58

1214.32

42.18

6.74

534.32

44.00

175.35

1.21

6.66

29

1.8

400

6

1.6

732

18

0.58

18.58

1214.32

43.16

6.90

529.39

43.59

169.79

1.21

6.60

30

1.8

400

7

1.2

620

18

0.58

18.53

1214.32

56.89

9.10

591.06

48.67

143.81

1.21

7.37

Q = 0.005 m3/sec Unit

Pr.

No.

Gauge

Flow

reading

rate

Weight

reading

Speed

(lpm)

(kg)

(kg)

(rpm)

(Vi)

spring

2

(kg/cm )

Power

2

Sr.

balance

Power

Discharge

Unit

(Qu)

Power

Unit

Pi/ૉg

/2g

H

(input)

Weight

Torque

(output)

η

Speed

(m)

(m)

(m)

(Watt)

(N)

(N m)

(Watt)

(%)

(Nu)

10

-04

(Pu)

20 % opening 1

3.1

300

1

0.3

938

31

0.33

31.33

1536.76

6.86

1.09

107.92

7.02

167.57

8.93

0.61

2

3.1

300

2

0.45

877

31

0.33

31.33

1536.76

15.20

2.43

223.43

14.53

156.68

8.93

1.27

3

3.1

300

4

1

755

31

0.33

31.33

1536.76

29.43

4.70

372.29

24.25

134.88

8.93

2.12

4

3.1

300

5

1.1

733

31

0.33

31.33

1536.76

38.25

6.12

469.87

30.57

130.95

8.93

2.67

5

3.1

300

6

1.3

704

31

0.33

31.30

1536.76

46.10

7.37

543.86

35.39

125.77

8.93

3.10

6

3.1

300

7

1.6

634

31

0.33

31.33

1536.76

52.97

8.47

562.73

36.61

113.26

8.93

3.20

40 % opening 7

3.2

300

1

0.25

1056

32

0.33

32.33

1585.81

7.357

1.17

130.17

8.20

185.71

8.79

0.70

8

3.2

300

2

0.45

1030

32

0.33

32.33

1585.81

15.20

2.43

262.41

16.54

181.14

8.79

1.42

9

3.2

300

4

1.2

960

32

0.33

32.33

1585.81

27.46

4.32

441.82

27.86

168.83

8.79

2.40

10

3.2

300

5

1.4

929

32

0.33

32.33

1585.81

35.31

5.65

549.71

34.66

163.38

8.79

2.99

11

3.2

300

6

1.45

914

32

0.33

32.30

1585.81

44.63

7.14

683.55

43.10

160.74

8.79

3.71

12

3.2

300

7

1.6

897

32

0.33

32.30

1585.81

52.97

8.47

796.16

50.20

157.75

8.79

4.33

60 % opening 13

2.6

300

1

0.25

986

26

0.33

26.33

1291.51

7.35

1.17

121.55

9.41

192.15

9.74

0.89

14

2.6

300

2

0.45

952

26

0.33

26.33

1291.51

15.20

2.43

242.54

18.77

185.52

9.74

1.79

15

2.6

300

4

1

898

26

0.33

26.33

1291.51

29.43

4.70

442.80

34.28

175.00

9.74

3.27

16

2.6

300

5

1.25

881

26

0.33

26.33

1291.51

36.78

5.88

543.03

42.04

171.69

9.74

4.01

17

2.6

300

6

1.4

843

26

0.33

26.33

1291.51

45.12

7.22

637.38

49.35

164.28

9.74

4.71

18

2.6

300

7

1.65

816

26

0.33

26.33

1291.51

52.45

8.39

717.56

55.56

159.02

9.74

5.31

80 % opening 19

2.2

300

1

0.25

943

22

0.33

22.33

1095.31

7.35

1.17

116.24

10.61

199.55

10.6

1.10

20

2.2

300

2

0.5

917

22

0.33

22.33

1095.31

14.71

2.35

226.08

20.64

194.05

10.6

2.14

21

2.2

300

4

1.2

848

22

0.33

22.33

1095.31

27.46

4.39

390.27

35.63

179.45

10.6

3.69

22

2.2

300

5

1.25

834

22

0.33

22.33

1095.31

36.78

5.88

514.06

46.93

176.48

10.6

4.87

23

2.2

300

6

1.45

809

22

0.33

22.33

1095.31

44.63

7.14

605.03

55.23

171.19

10.6

5.73

24

2.2

300

7

1.6

771

22

0.33

22.33

1095.31

52.97

8.47

684.33

62.47

163.15

10.6

6.48

100 % opening 25

2

300

1

0.35

917

20

0.33

20.33

997.21

6.37

1.02

97.97

9.82

203.37

11.1

1.06

26

2

300

2

0.55

903

20

0.33

20.33

997.21

14.22

2.27

215.21

21.58

200.26

11.1

2.34

27

2

300

4

1.2

836

20

0.33

20.33

997.21

27.46

4.39

384.75

38.58

185.40

11.1

4.19

27

2

300

5

1.25

806

20

0.33

20.33

997.21

36.78

5.88

496.80

49.81

178.75

11.1

5.41

29

2

300

6

1.4

780

20

0.33

20.33

997.21

45.12

7.22

589.75

59.14

172.98

11.1

6.43

30

2

300

7

1.6

755

20

0.33

20.33

997.21

52.97

8.47

670.12

67.20

167.44

11.1

7.31

Q = 0.0033 m3/sec Unit

Pr.

No.

Gauge

Flow

reading

rate

Weight

reading

Speed

(lpm)

(kg)

(kg)

(rpm)

(Vi)

spring

2

(kg/cm )

Power

2

Sr.

balance

Power

Discharge

Unit

(Qu)

Power

Unit

Pi/ૉg

/2g

H

(input)

Weight

Torque

(output)

η

Speed

(m)

(m)

(m)

(Watt)

(N)

(N m)

(Watt)

(%)

(Nu)

10

-04

(Pu)

20 % opening 1

3.8

200

1

0.3

1246

38

0.14

38.14

1234.83

6.86

1.09

143.36

11.60

201.74

5.39

0.60

2

3.8

200

2

0.45

1205

38

0.14

38.14

1234.83

15.20

2.43

306.99

24.86

195.10

5.39

1.30

3

3.8

200

4

0.85

1128

38

0.14

38.14

1234.83

30.90

4.94

584.03

47.29

182.64

5.39

2.47

4

3.8

200

5

1.2

1080

38

0.14

38.14

1234.83

37.27

5.96

674.56

54.62

174.86

5.39

2.86

5

3.8

200

6

1.5

1054

38

0.14

38.14

1234.83

44.14

7.06

779.59

63.13

170.65

5.39

3.30

6

3.8

200

7

1.6

1046

38

0.14

38.14

1234.83

52.97

8.47

928.41

75.18

169.36

5.39

3.94

40 % opening 7

3.6

200

1

0.2

1205

36

0.14

36.14

1170.08

7.84

1.25

158.45

13.54

200.43

5.54

0.72

8

3.6

200

2

0.5

1180

36

0.14

36.14

1170.08

14.71

2.35

290.93

24.86

196.27

5.54

1.33

9

3.6

200

4

1

1125

36

0.14

36.14

1170.08

29.43

4.70

554.74

47.41

187.12

5.54

2.55

10

3.6

200

5

1.4

1100

36

0.14

36.14

1170.08

35.31

5.65

650.89

55.62

182.96

5.54

2.99

11

3.6

200

6

1.65

1090

36

0.14

36.14

1170.08

42.67

6.82

779.35

66.60

181.30

5.54

3.58

12

3.6

200

7

1.7

1066

36

0.14

36.14

1170.08

51.99

8.31

928.64

79.36

177.31

5.54

4.27

60 % opening 13

3.4

200

1

0.2

1162

34

0.14

34.14

1105.34

7.84

1.25

152.79

13.82

198.86

5.70

0.76

14

3.4

200

2

0.55

1139

34

0.14

34.14

1105.34

14.22

2.27

271.46

24.55

194.92

5.70

1.36

15

3.4

200

4

1.1

1094

34

0.14

34.14

1105.34

28.44

4.55

521.47

47.17

187.22

5.70

2.61

16

3.4

200

5

1.4

1083

34

0.14

34.14

1105.34

35.31

5.65

640.83

57.97

185.34

5.70

3.21

17

3.4

200

6

1.65

1054

34

0.14

34.14

1105.34

42.67

6.82

753.61

68.17

180.37

5.70

3.77

18

3.4

200

7

1.7

1033

34

0.14

34.14

1105.34

51.99

8.31

899.89

81.41

176.78

5.70

4.51

80 % opening 19

3.2

200

1

0.3

1134

32

0.14

32.14

1040.59

6.86

1.09

130.47

12.53

200.01

5.87

0.71

20

3.2

200

2

0.5

1110

32

0.14

32.14

1040.59

14.71

2.35

273.67

26.29

195.78

5.87

1.50

21

3.2

200

4

1.05

1063

32

0.14

32.14

1040.59

28.93

4.63

515.43

49.53

187.49

5.87

2.82

22

3.2

200

5

1.2

1057

32

0.14

32.14

1040.59

37.23

5.96

660.20

63.44

186.43

5.87

3.62

23

3.2

200

6

1.45

1034

32

0.14

32.14

1040.59

44.65

7.14

773.30

74.31

182.37

5.87

4.24

24

3.2

200

7

1.75

1011

32

0.14

32.14

1040.59

51.52

8.24

872.42

83.83

178.32

5.87

4.78

100 % opening 25

3

200

1

0.25

1118

30

0.14

30.14

975.85

7.35

1.17

137.82

14.12

203.62

6.07

0.83

26

3

200

2

0.5

1098

30

0.14

30.14

975.85

14.71

2.35

270.71

27.74

199.98

6.07

1.63

27

3

200

4

1.1

1057

30

0.14

30.14

975.85

28.44

4.55

503.83

51.63

192.51

6.07

3.04

27

3

200

5

1.2

1046

30

0.14

30.14

975.85

37.27

5.96

653.33

66.94

190.51

6.07

3.94

29

3

200

6

1.45

1018

30

0.14

30.14

975.85

44.63

7.14

761.33

78.01

185.41

6.07

4.60

30

3

200

7

1.7

995

30

0.14

30.14

975.85

51.99

8.31

866.79

88.82

181.22

6.07

5.23

APPENDIX - D Experimental Analysis of Simple & Advanced Pelton Wheel

Q = 0.01 m3/sec Speed

Torque

( rpm )

Sr. No.

Simple

% diff

(Nm)

% diff

Power (output)

% diff

Efficiency

( watt )

Power

η

% diff

Adva.

Speed

Simple

Adva.

Torque

Simple

Adva.

(output)

Simple

Adva.

Efficiency

20 % opening 1

1378

1183

14.15

0.94

1.09

-15.49

136.13

136.11

0.01

3.36

3.35

0.01

2

1347

1154

14.33

1.73

2.27

-31.01

244.28

275.03

-12.59

6.03

6.78

-12.59

3

1256

1046

16.72

4.09

4.55

-11.31

537.36

498.59

7.21

13.25

12.29

7.21

4

1241

1031

16.92

5.35

5.96

-11.50

694.31

643.96

7.25

17.13

15.88

7.25

5

1206

1021

15.34

7.78

7.14

8.20

981.79

763.58

22.23

24.22

18.83

22.23

6

1180

980

16.95

10.03

8.31

17.13

1238.42

853.72

31.06

30.55

21.05

31.06

40 % opening 7

1384

1189

14.09

1.09

1.09

0.40

158.54

136.80

13.71

4.57

3.94

13.71

8

1356

1163

14.23

2.36

2.35

0.49

335.17

286.74

14.45

9.67

8.27

14.45

9

1324

1114

15.86

5.25

4.70

10.43

727.14

549.31

24.46

20.98

15.85

24.46

10

1316

1106

15.96

6.45

5.96

7.61

888.57

690.80

22.26

25.64

19.93

22.26

11

1264

1079

14.64

8.50

7.06

16.94

1124.57

798.08

29.03

32.45

23.02

29.03

12

1270

1060

16.54

9.99

8.31

16.83

1328.11

923.42

30.47

38.32

26.64

30.47

60 % opening 13

1348

1153

14.47

1.22

1.09

10.48

171.79

132.66

22.78

5.25

4.05

22.78

14

1322

1129

14.60

2.82

2.27

19.36

389.51

269.07

30.92

11.91

8.23

30.92

15

1293

1083

16.24

4.69

4.55

3.01

634.91

516.23

18.69

19.42

15.79

18.69

16

1281

1071

16.39

7.00

6.04

13.75

938.96

677.74

27.82

28.72

20.73

27.82

17

1233

1048

15.00

7.91

7.06

10.78

1021.18

775.16

24.09

31.24

23.70

24.09

18

1226

1016

17.13

9.00

8.39

6.80

1155.14

893.43

22.66

35.33

27.32

22.66

80 % opening 19

1320

1125

14.77

0.74

1.17

-58.14

102.22

138.68

-35.67

3.33

4.51

-35.67

20

1299

1106

14.86

2.00

2.27

-13.40

272.16

263.59

3.15

8.86

8.57

3.15

21

1265

1055

16.60

4.25

4.63

-8.91

562.88

511.55

9.12

18.32

16.64

9.12

22

1254

1044

16.75

6.13

6.12

0.22

805.07

669.24

16.87

26.20

21.77

16.87

23

1211

1026

15.28

7.47

7.22

3.39

947.24

775.75

18.10

30.82

25.24

18.10

24

1206

996

17.41

8.87

8.31

6.36

1120.16

867.66

22.54

36.45

28.23

22.54

100 % opening 25

1305

1110

14.94

1.12

1.02

9.01

153.11

118.59

22.55

5.32

4.12

22.55

26

1281

1088

15.07

2.41

2.35

2.53

323.27

268.24

17.02

11.24

9.32

17.02

27

1247

1037

16.84

5.00

4.70

6.05

652.92

511.34

21.68

22.69

17.77

21.68

27

1240

1030

16.94

5.47

6.12

-11.96

709.43

660.26

6.93

24.66

22.95

6.93

29

1187

1002

15.59

7.40

7.29

1.49

919.36

765.84

16.70

31.96

26.61

16.70

30

1137

977

14.07

9.34

8.47

9.29

1111.25

867.17

21.96

38.63

30.14

21.96

Q = 0.0066 m3/sec Speed

Torque

( rpm )

Sr. No.

Simple

% diff

(Nm)

Power (output) % diff

( watt )

% diff

Efficiency η

Power

% diff

Adva.

Speed

Simple

Adva.

Torque

Simple

Adva.

(output)

Simple

Adva.

Efficiency

20 % opening 1

1326

1131

14.71

1.45

1.41

2.78

201.28

167.31

16.88

9.54

7.86

17.62

2

1264

1071

15.27

2.11

2.67

-26.36

279.55

299.27

-7.05

13.25

14.06

-6.09

3

1162

952

18.07

4.55

5.18

-13.75

553.83

516.38

6.76

26.25

24.25

7.60

4

1095

885

19.18

6.41

6.75

-5.37

734.22

625.50

14.81

34.80

29.38

15.57

5

963

778

19.21

7.50

7.46

0.59

756.37

607.42

19.69

35.85

28.53

20.42

6

870

660

24.14

9.56

9.57

-0.13

870.31

661.75

23.96

41.25

31.08

24.65

40 % opening 7

1237

1038

16.09

1.10

1.26

-14.96

141.91

136.49

3.82

8.91

8.50

4.68

8

1171

982

16.14

2.13

2.51

-17.90

260.93

258.26

1.02

16.39

16.08

1.92

9

1085

916

15.58

4.33

5.10

-17.67

492.19

489.32

0.58

30.92

30.46

1.48

10

977

827

15.35

6.09

6.59

-8.28

622.35

570.92

8.26

39.10

35.54

9.09

11

956

783

18.10

6.96

7.14

-2.59

696.37

585.59

15.91

43.75

36.45

16.67

12

828

650

21.50

9.16

9.42

-2.83

793.94

641.04

19.26

49.88

39.91

19.99

60 % opening 13

1129

979

13.29

0.51

0.47

8.53

60.72

48.27

20.49

4.15

3.27

21.21

14

1066

908

14.82

2.53

2.67

-5.65

281.98

253.72

10.02

19.28

17.19

10.83

15

1045

856

18.09

4.49

4.87

-8.54

490.75

436.17

11.12

33.56

29.56

11.92

16

918

745

18.85

5.92

6.91

-16.70

568.95

538.80

5.30

38.91

36.51

6.15

17

886

713

19.53

6.71

7.06

-5.20

622.36

527.38

15.26

42.56

35.74

16.03

18

808

598

25.99

7.95

9.42

-18.53

672.10

589.75

12.25

45.96

39.97

13.04

80 % opening 19

1149

960

16.45

0.99

1.18

-18.92

119.33

118.35

0.82

8.95

8.80

1.72

20

1019

809

20.61

2.00

2.43

-21.42

213.45

206.11

3.44

16.01

15.32

4.31

21

919

726

21.00

3.88

4.87

-25.51

373.22

369.93

0.88

28.00

27.50

1.78

22

767

648

15.51

4.76

6.91

-45.22

381.98

468.65

-22.69

28.66

34.84

-21.58

23

751

626

16.64

6.23

7.06

-13.37

489.50

463.03

5.41

36.73

34.43

6.26

24

640

529

17.34

8.35

9.26

-10.92

559.23

513.01

8.26

41.96

38.14

9.09

100 % opening 25

1128

939

16.76

0.83

1.10

-32.41

98.08

108.04

-10.16

8.15

8.90

-9.16

26

1087

898

17.39

2.23

2.59

-16.28

253.42

243.54

3.90

21.06

20.06

4.76

27

1026

837

18.42

3.92

4.71

-20.00

421.50

412.73

2.08

35.03

33.99

2.96

27

925

756

18.27

5.59

6.75

-20.65

541.68

534.33

1.36

45.01

44.00

2.25

29

830

732

11.81

6.27

6.91

-10.22

544.64

529.40

2.80

45.26

43.60

3.67

30

793

620

21.82

8.25

9.10

-10.24

685.15

591.07

13.73

56.94

48.67

14.51

Q = 0.005 m3/sec Torque

Speed (rpm)

Sr. No.

Simple

(N m)

% diff

Power(output) % diff

(Watt)

Efficiency % diff

η

% diff

Power

Adva.

Speed

Simple

Adva.

Torque

Simple

Adva.

(output)

Simple

Adva.

Efficiency

20 % opening 1

1188

938

21.04

1.52

1.09

28.41

189.33

107.92

43.00

12.32

7.02

43.00

2

1070

877

18.04

2.79

2.43

12.85

312.27

223.43

28.45

20.32

14.53

28.45

3

965

755

21.76

4.76

4.70

1.35

481.21

372.29

22.63

31.31

24.25

22.63

4

943

733

22.27

5.79

6.12

-5.63

571.88

469.87

17.84

37.21

30.57

17.84

5

889

704

20.81

7.02

7.37

-4.94

653.48

543.86

16.77

42.52

35.39

16.77

6

819

634

22.59

8.70

8.47

2.69

746.17

562.73

24.58

48.55

36.61

24.58

40 % opening 7

1255

1056

15.86

1.12

1.17

-4.72

146.76

130.17

11.30

9.25

8.20

11.30

8

1219

1030

15.50

2.55

2.43

4.83

325.76

262.41

19.45

20.54

16.54

19.45

9

1129

960

14.97

4.06

4.32

-6.40

479.77

441.82

7.91

30.25

27.86

7.91

10

1079

929

13.90

5.79

5.65

2.47

654.22

549.71

15.97

41.25

34.66

15.97

11

1019

914

10.30

7.17

7.14

0.48

765.15

683.55

10.66

48.25

43.10

10.66

12

972

897

7.72

8.66

8.47

2.17

880.82

796.16

9.61

55.54

50.20

9.61

60 % opening 13

1136

986

13.20

0.93

1.17

-25.76

110.62

121.55

-9.88

8.57

9.41

-9.88

14

1110

952

14.23

2.00

2.43

-21.27

232.80

242.54

-4.18

18.03

18.77

-4.18

15

1087

898

17.39

4.00

4.70

-17.44

455.34

442.80

2.75

35.26

34.28

2.75

16

986

881

10.65

5.54

5.88

-6.17

571.57

543.03

4.99

44.26

42.04

4.99

17

941

843

10.41

7.25

7.22

0.35

713.64

637.38

10.68

55.26

49.35

10.68

18

901

816

9.43

8.94

8.39

6.12

842.79

717.56

14.86

65.26

55.56

14.86

80 % opening 19

1132

943

16.70

0.77

1.17

-52.76

90.75

116.24

-28.10

8.29

10.61

-28.10

20

1083

917

15.33

1.84

2.35

-27.83

208.39

226.08

-8.49

19.03

20.64

-8.49

21

953

848

11.02

3.98

4.39

-10.27

397.10

390.27

1.72

36.25

35.63

1.72

22

919

834

9.25

5.60

5.88

-4.93

539.03

514.06

4.63

49.21

46.93

4.63

23

884

809

8.48

7.13

7.14

-0.10

659.98

605.03

8.33

60.25

55.23

8.33

24

836

771

7.78

8.67

8.47

2.30

758.56

684.33

9.79

69.25

62.47

9.79

100 % opening 25

1106

917

17.09

0.74

1.02

-38.25

85.41

97.97

-14.71

8.56

9.82

-14.71

26

1092

903

17.31

1.77

2.27

-28.45

201.98

215.21

-6.55

20.25

21.58

-6.55

27

1025

836

18.44

3.93

4.39

-11.77

421.37

384.75

8.69

42.25

38.58

8.69

27

891

806

9.54

5.76

5.88

-2.06

537.29

496.80

7.54

53.88

49.81

7.54

29

878

780

11.16

7.21

7.22

-0.09

662.93

589.75

11.04

66.48

59.14

11.04

30

830

755

9.04

8.75

8.47

3.24

760.42

670.12

11.87

76.25

67.20

11.87

Q = 0.0033 m3/sec Torque

Speed

% diff

(rpm)

Sr. No.

Simple

Power (output)

(N m)

% diff

Adva.

Speed

% diff

Simple

Adva.

Torque

(Watt) Simple

Adva.

Efficiency η

Power (output)

% diff

Simple

Adva.

Efficiency

20 % opening 1

1496

1246

16.71

0.76

1.09

-44.16

118.39

143.36

-21.09

9.59

11.60

-21.09

2

1398

1205

13.81

2.01

2.43

-21.04

293.76

306.99

-4.51

23.79

24.86

-4.51

3

1338

1128

15.70

4.27

4.94

-15.57

598.63

584.03

2.44

48.48

47.29

2.44

4

1185

1080

8.86

5.61

5.96

-6.22

695.93

674.56

3.07

56.36

54.62

3.07

5

1162

1054

9.29

7.37

7.06

4.15

895.85

779.59

12.98

72.55

63.13

12.98

6

1128

1046

7.27

8.71

8.47

2.72

1028.00

928.41

9.69

83.25

75.18

9.69

40 % opening 7

1404

1205

14.17

0.86

1.25

-44.96

126.72

158.45

-25.04

10.83

13.54

-25.04

8

1369

1180

13.81

1.92

2.35

-22.68

274.47

290.93

-6.00

23.46

24.86

-6.00

9

1294

1125

13.06

4.26

4.70

-10.21

577.60

554.74

3.96

49.36

47.41

3.96

10

1202

1100

8.49

5.62

5.65

-0.62

706.45

650.89

7.86

60.38

55.62

7.86

11

1175

1090

7.23

7.20

6.82

5.29

885.63

779.35

12.00

75.69

66.60

12.00

12

1115

1066

4.39

8.64

8.31

3.86

1008.73

928.64

7.94

86.21

79.36

7.94

60 % opening 13

1312

1162

11.43

1.05

1.25

-19.26

143.93

152.79

-6.16

13.02

13.82

-6.16

14

1297

1139

12.18

2.31

2.27

1.56

313.05

271.46

13.28

28.32

24.55

13.28

15

1283

1094

14.73

4.22

4.55

-7.93

566.13

521.47

7.89

51.22

47.17

7.89

16

1188

1083

8.84

5.66

5.65

0.21

703.99

640.83

8.97

63.69

57.97

8.97

17

1113

1054

5.30

7.15

6.82

4.67

833.40

753.61

9.57

75.40

68.17

9.57

18

1068

1033

3.28

8.64

8.31

3.80

965.63

899.89

6.81

87.36

81.41

6.81

80 % opening 19

1323

1134

14.29

0.97

1.09

-12.49

134.18

130.47

2.76

12.89

12.53

2.76

20

1276

1110

13.01

2.18

2.35

-7.79

291.18

273.67

6.01

27.98

26.29

6.01

21

1168

1063

8.99

4.57

4.63

-1.31

558.70

515.43

7.74

53.69

49.53

7.74

22

1142

1057

7.44

6.13

5.96

2.77

732.68

660.20

9.89

70.41

63.44

9.89

23

1109

1034

6.76

7.17

7.14

0.36

831.76

773.30

7.03

79.93

74.31

7.03

24

1032

1011

2.03

8.60

8.24

4.24

929.47

872.42

6.14

89.32

83.83

6.14

100 % opening 25

1307

1118

14.46

0.73

1.17

-60.17

99.93

137.82

-37.92

10.24

14.12

-37.92

26

1287

1098

14.69

1.91

2.35

-23.06

257.23

270.71

-5.24

26.36

27.74

-5.24

27

1246

1057

15.17

4.00

4.55

-13.69

521.95

503.83

3.47

53.49

51.63

3.47

27

1131

1046

7.52

5.98

5.96

0.34

707.96

653.33

7.72

72.55

66.94

7.72

29

1079

1018

5.65

7.21

7.14

0.98

814.35

761.33

6.51

83.45

78.01

6.51

30

1007

995

1.19

8.53

8.31

2.55

898.76

866.79

3.56

92.10

88.82

3.56