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Research Article
Low-Head Energy Conversion: A Conceptual Design and
Laboratory Investigation of a Microtubular Hydro Propeller
Copyright 2012 Helena M. Ramos et al. This is an open access article distributed under the Creative Commons Attribution
License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly
cited.
Low-head microhydro systems for energy production are becoming accepted because of oil crises and new advances in their
design and eciencies. As this is still a new area for development and experimentation, it is important to test and validate
the optimal conditions and the hydrodynamic behaviour of such systems under dierent conditions. The aim of this paper is
to present a turbine design validation practise, which researchers and equipment manufactures can use for the hydrodynamic
behaviour analysis of new low-head turbines prior to production and application. Laboratory experimental tests and advanced
CFD numerical analysis are described for the flow behaviour analysis of a new prototype microtubular propeller. Laboratory
experimental results are presented and used for the evaluation of the turbine performance curves. Comparisons between
experimental and CFD results are also presented. Finally, an assessment of the hydrodynamic behaviour is made for a scaled
model application, using the theory of turbomachine similarity.
V1 u1
1
c1
u2
V2s V2
2
V2t c2
with water pipe systems, are still underrepresented in lit- vectors. A blade model configuration (BMC) was developed
erature and in particular in practise. to estimate the best blade orientation, which to lead to best
According to Ramos et al. [18], the behaviour of such eciency operating conditions, as reported by Ramos et al.
microhydro converters can dier depending on the flow [20]. The proper blades orientation is a computationally
conditions and on the runner configuration, particularly, on and experimentally demanding process, which requires at-
the inlet and outlet flow and on the shape of the blades. The tention and performance of sensitivity analysis for dierent
design of new low-head devices cannot be solely based on a characteristic parameters associated with the inlet and outlet
large turbine scaling-down methodology. To overcome this velocity triangles. Figure 1 also identifies the vectors of
limitation, CFD analysis can be used to provide design and absolute (v), periphery (c), and relative runner blade velocity
hydrodynamic behaviour information, which can strongly (u). Essential relationships are established among them to
support the experimental tools. CFD analysis is important calculate the turbine discharge for a given configuration. The
to help in the design of the best configuration for dierent periphery velocity (c) at the inlet and outlet of a blade, which
systems characteristics and flow scenarios, according to depends on the impeller rotational speed () and on the
Rawal and Kshirsagar [19]. blade radius (r), can be obtained by (1)
This paper aims to close the existing gap found in litera-
ture on how to obtain the optimal design of low-power tur- c1 = c2 = r, (1)
bines. Focus is put on a methodology and on a new de-
sign, which couples together mathematical modelling, CFD and the absolute velocity (v) depends on the discharge (Q)
numerical analysis, and laboratory testing in order to validate which passes through the impeller, given by (2)
the optimal performance of a new microtubular low-head Q Q
converter. This is an important topic because water supply v1 = v2s = = 2 , (2)
S re ri2
and distribution management systems are interested in this
solution, and as this new class of low-head converters can where S is the tubular cross-section area, and re and ri are
be implemented as decentralized solutions in pressurized the tip and hub blade radius between the runner periphery
water pipe infrastructures (e.g., in water supply, irrigation and internal bulb, respectively.
and waste water, or drainage systems) in rural and remote The blade angles (1 and 2 ) on the periphery of the inlet
areas for alternative and low-cost energy production. and outlet (subscript 1 and 2, resp.) yield the following (3):
v1 Q 1
2. Turbine Design tg1 = = ,
c1 S r
(3)
To determine optimal design results, which to lead to the v2s v1 Q 1
tg2 = = tg2 = .
best-eciency point (BEP) of a prototype turbine, it is im- c2 + v2t r + v2t S r + v2t
portant to analyse dierent blade slopes (i.e., angle variation)
Analysis of the flow at downstream of the impeller reveals
when designing the impeller blades. The thickness of the
a vortex formation (k), which depends on the radius of the
impeller blades should also be observed to avoid disturbances
blade, the flow cross-section and on the discharge value as
into the flow, which can cause additional losses, and may
presented in (4)
constrain the overall eciency. A maximum thickness of
1 mm was considered in this study, in order to avoid limi- k Qr
tations in the CFD mesh created for the model simulations. v2t = = k = r + . (4)
r Stg2
Figure 1 shows the velocity triangles associated with the
optimization of the blade configuration. It also shows the As the blade angle changes from the inlet to the outlet,
parameters related to each other from the direction of the between the upstream turbine section, where the flow im-
blade profiles, such as the angle variation, as indicated by the pulses the blade, to the downstream turbine section, where
ISRN Mechanical Engineering 3
yc
rh
ri
x2 a1
re xc x1
ap
P1
P2 y2
a2
P3
L/2 L/2
P4
L
P5
(a) (b)
Figure 2: Scheme of a propeller: (a) plan view and five profiles in a blade and (b) parameters associated to the tracing profiles in each blade.
0.02
0.03
Distance to the center of the shaft (m)
P1 P4
P2 P5
P3
the angles of the inlet and outlet from the axis to the pe-
t
50
60 riphery in each blade, can be calculated. It is also possible to
40
40 calculate the power, the specific speed, and the constant vor-
20 30 tex velocity. Having data from the input conditions, the cor-
rect blade configuration from the bulb section to the periph-
0 20
0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 ery (Figure 3) is then determined.
t Torque (M), impeller rotational speed, fluid mass density
(), discharge, and free-vortex constant are used to calculate
Exp (N = 70 rpm) Exp (N = 200 rpm)
Exp (N = 300 rpm) Poly. (Exp (N = 70 rpm)) the engine or mechanical power (Pmec ), by using (5),
(1)
(5)
(4)
(3)
(2 )
Figure 5: Experimental facility of the micro-tubular propeller: UDV (left), balance torque (center), and rotational speed measurement
(right).
and the eciency (t ) can be obtained by (7), using the me- is used for flow control. When the valve is fully open, the
chanical and the hydraulic power maximum possible turbine flow is 5.2 l/s.
In order to estimate the output power, the shaft transmits
Pmec Qk k the momentum to a torque balance through the turbine up-
t = = = . (7)
Ph QH gH stream curve. During testing, isotropic behaviour of the flow
upstream of the turbine was observed. Observed were also
Outer impeller diameter of 100 mm, with a bulb diameter few anisotropic occurrences through the impeller, influenced
of 50 mm, is considered for the design of this small-scale by the flow rotation and separation flow zone of the bound-
tubular propeller. This propeller design is adequate for lab- ary layer, which exists downstream of the internal impeller
oratory testing and for the most of real water distribution bulb (as presented in Figure 6).
system conditions with small flow discharge. According to Under laboratory conditions, the best eciency point
Table 1, the blades design is built to operate with a discharge (BEP) for the micro-tubular propeller (D = 100 mm) was
around 5 l/s and at a maximum rotational speed of 300 rpm. estimated at about 70% for a rotational speed of 200 rpm
To design the blades profile, presented in Figure 3, the var- (Nsqt (specific rotational speed) = 84 rpm (m, m3 /s) based on
iables presented in Table 1 are used in (3) to (6). (10)), as shown in Figure 4. The performance dimensionless
curves are based on eciency (from (7)), the head number,
and discharge number, defined as
3. Experimental Tests Discharge number ():
In order to maintain a continuous steady-state flow condi- Q
= (8)
tions, an experimental loop pipe system was developed for ND3
the analysis of the flow through a prototype of a micro- Head number ():
propeller turbine with the impeller diameter of D =
100 mm. This setup consists of a pressure pipe system with gH
= , (9)
an installed pump for recirculation, an air vessel for upstream N 2 D2
pressure control, an electromagnetic flow meter, and a where N is the rotational speed, and D is the pipe diameter
downstream reservoir with a triangular (90 ) weir. A valve or outside diameter of the blades.
ISRN Mechanical Engineering 5
Inflection
X2 point
X1
v1 v1 v1
x2 >0 x2 = 0 x 2
<0
0 0 0
(a) (b)
100
100
80
80
60
H (mm)
60
H (mm)
40
40
20
20
0
0 1 0.8 0.6 0.4 0.2 0 0.2 0.4 0.6 0.8 1
0 0.2 0.4 0.6 0.8
v (m/s) v (m/s)
(a) (b)
100 100
80 80
60
H (mm)
60
H (mm)
40 40
20 20
0 0
0.15 0.3 0.45 0.6 0.75 0 0.5 1 1.5
v (m/s) v (m/s)
(c) (d)
Figure 7: Flow velocity profiles obtained by UDV along the turbine: (a) at upstream in the nonpropeller disturbed zone, (b) at the upstream
shaft, (c) in the middle of the impeller, (d) at downstream of the impeller.
Under laboratory conditions, experimental results are this device was used for the evaluation of the flow hydrody-
obtained by regulating the discharge control valve, measur- namic behaviour in real-time situation. Figures 6 and 7 show
ing the runner speed, with a tachometer Hibok-24 for dif- dierent velocity profiles along the runner boundary layer,
ferent flow values, the discharge and head, in an electromag- where the behaviour of the flow separation zone is repre-
netic flow meter and in pressure transducers at upstream and sented, and in which the velocity profile inversion tendency
downstream of the turbine, in undisturbed flow zones. Using is visible. The most important features during the identifica-
an ultrasonic Doppler velocimetry (UDV) in the turbine tion of instantaneous flow velocity values and mean profiles
system (Figure 5), the velocity profiles were analysed. With (Figure 7) are due to: (a) flow irregularity which is in-
the UDV sample placed in a vertical-sloped position of 25 , dicated by the occurrence of three-dimensional vorticity
6 ISRN Mechanical Engineering
25 100
30 30000
20 80 25 25000
20 20000
Pmec (W)
15 60
H (m)
(%)
H (m)
15 15000
10 40
10 10000
5 20 5 5000
0 0
0 0 0.055 0.08 0.105 0.13 0.155
80 100 120 140
w (rad/s) Q (m3 /s)
H variation Q versus H
variation Q versus Pmec
(a) (b)
Figure 8: Performance curves for a runner diameter of 200 mm: (a) eciency and head versus rotational speed and (b) head and mechanical
power versus discharge.
100
Propeller (4 blades)-CFD
100 From Table 2 it is possible to confirm the good match
90 between the BMC (maximum theoretical eciency of 100%)
80 80 and the 3D-CFD simulations, even with existing losses, tur-
70 bulence eects, anisotropy in the zones of high flow circula-
60 60 tion, and scale eects, which are not considered neither in the
(%)
50
40 40 simulation use, in the first stage, angles obtained by BMC,
30 but a further investigation of the best-eciency operating
20 20 conditions require small corrections to these angles, as
10 shown in Table 2.
0 0 It is also worth mentioning the dierence in power values
0.5 1 1.5 2 2.5 between impellers with diameters of 100 and 200 mm due to
t essentially dierences in the flow values. Two geometrically
N = 70 rpm N = 200 rpm similar turbines operating at rotational speeds, which satisfy
N = 300 rpm Poly. ( N = 70 rpm) the condition presented in (11), usually have dierent e-
Linear (N = 200 rpm) Poly. (t versus t) ciency values, in particular when the relationship between
Poly. ( N = 200 rpm)
the homologous lengths is high.
Figure 9: Comparison of power and head numbers and eciency 1/2
versus discharge number for dierent rotational speeds with D = N H D
= . (11)
100 mm. N H D
4. Numerical Modelling 4.2. Hydrodynamic Behaviour. Once the BEP was established
4.1. Performance Curves. Comparisons between BMC and for the micro-tubular propeller based on mathematical
3D-CFD simulations were developed for an impeller design modelling through the BMC model and CFD simulations, a
with four blades, characterised by the specific speed, as stated detailed analysis was developed in order to better understand
in(10) the 3D hydrodynamic behaviour of the flow throughout the
impeller, as documented by Scott-Pomerantz [21]. Corre-
Q sponding flow velocities, total pressure, and wall shear stress
Nsqt = N . (10) are presented in Figure 10, for the micro-tubular propeller
H 0.75
ISRN Mechanical Engineering 7
1.83 1829 23
1.64 1602 20
1.46 1376 18
1.28 1149 16
1.1 922 14
0.92 696 11
0.74 469 9
0.55 242 7
16 5
0.37
Z Z
212 Z
0.19 Y X 2
Y X 438 Y X
0.01 0
(a) (b) (c)
Table 2: Comparisons between BMC and CFD for the tip and hub angles.
Methodology
BMC CFD
Characteristic parameters D = 100 mm D = 200 mm D = 100 mm D = 200 mm
Nsqt = 80 rpm Nsqt = 77 rpm
Inlet hub angle (1 ) ( ) 41 46 30
Outlet hub angle (2 ) ( ) 17 11 30
Inlet tip angle (1 ) ( ) 23 24 25
Outlet tip angle (2 ) ( ) 16 14 25
Power (W) 4.7 9967 4.2 9869
100 100
80 80
60 60
H (mm)
H (mm)
40 40
20 20
0 0
0.48 0.49 0.5 0.51 0.52 0.53 0.54 0.55 0.56 0.42 0.45 0.47 0.5 0.53 0.55 0.57 0.6
v (m/s) v (m/s)
(a) (b)
100 100
80 80
60 60
H (mm)
H (mm)
40 40
20 20
0 0
0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6
v (m/s) v (m/s)
(c) (d)
Figure 12: CFD simulations for the flow velocity variation across the turbine.
5 100
2.5 Propeller (4)
Propeller (4 blades) 80
2 4 80
60 3 60
1.5
h (%)
H/H0
H/H0
(%)
1 40 2 40
0.5 20 1 20
0 0 0 0
0.4 0.5 0.6 0.7 0.8 0.9 1 0.7 0.9 1.1 1.3 1.5 1.7
Q/Q0 Q/Q0
Exp (N = 70 rpm) Exp (N = 200 rpm)
CFD (N = 70 rpm) CFD (N = 200 rpm)
H/H0 variation
(a) (b)
Figure 13: Comparison between CFD and experimental performance curves for rotational speeds of 70 and 200 rpm.
closer to the curve where the turbine shaft is located, there is regions: (1) a thin layer near the solid walls, in which the
certain anisotropy with velocity retardation induced by the tangential stress play is an important role (the boundary
impeller rotation. Once the flow passes through the bulb, layer); and (2) the remaining part is fullfilled where the shear
pressure and velocity decrease, induced by the sub-pressure stress is less significant.
existing downstream of the impeller. This leads to the Dimensionless characteristic parameters of CFD simu-
formation of a turbulent wake zone, as established by Ramos lations and laboratory tests were selected and compared as
et al. [22]. Along the turbine the fluid moves into two shown in Figure 13. In this figure, H0 and Q0 are the rated
ISRN Mechanical Engineering 9
6. Concluding Remarks
Greek Symbols
An extended analysis based on laboratory testing and numer-
ical modelling in a new prototype micro-propeller design is : Blade angle on the periphery ( ). Subscripts
presented. A summary of the main characteristics of the con- 1 for inlet and subscript 2 for outlet
verter developed in this study at two scales (D = 100 mm : Specific weight of the fluid (N m3 )
limited to small dischargesand D = 200 mmadequate t : Eciency ()
for higher discharges and power) is shown in Table 3. This : Fluid mass density (kg m3 )
type of machine is usually composed by a runner installed : Discharge number ()
in a pipe curve, without volute or guide vane as simple as : Head number ()
possible to be a cost-eective solution and easy to be imple- : Impeller rotational speed (rad s1 ).
mented in a bypass into existing water infrastructures. They
are appropriate for operating under almost constant-flow Acknowledgments
conditions, such as in water supply systems equipped with
discharge control valves or tanks with capacity to regulate. The authors are grateful to the EU HYLOW project from the
The use of the blade model configuration (BMC), together EU 7th Framework Programme (Grant no. 212423) and
with experimental tests and 3D fluid computational analyses, to the Portuguese FCT-funded project (PTDC/ECM/65731/
can help researchers and equipment manufacturers to better 2006) for the contribution to the development of laboratory
10 ISRN Mechanical Engineering
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