FABRICATION OF PELTON WHEEL TEST RIG

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 1

 FABRICATION OF PELTON WHEEL TEST RIG

ABSTRACT

A pelton wheel is considered as an impulse turbine, a turbine that converts pressure head
into velocity head. This lab will use this mechanism along with a prony brake to calculate the
input power, Output power, and efficiency of the turbine. The team will be provided with
measuring devices such as a stroboscope to measure the turbine speed as well as a hydraulic
bench to control the flow rate of the liquid flowing through the turbine [1]. The experiment
will consist of two separate trials with two different water heads. This
experiment will neglect all frictional forces for the theoretical calculations. The team will record
the needed data for the experiment: turbine flow rate, turbine speed, and the net spring forces.
A performance test was conducted for a pelton wheel turbine with the objective of establishing
the relationship between the mechanical efficiency and the velocity ratio. A literature review
found a number of useful mathematical models and some key physical phenomena. The
performance test was conducted for a constant hydraulic head and flow rate while varying the
braking force. The raking force was gradually increased until the pelton wheel stopped. Readings
of the angular velocity and pressures were taken an processed using the equations found in the
literature review. A parabolic relationship between the the efficiency and the velocity ratio was
established and the peak efficiency was found. Some physical phenomena relating to the flow
field in the bucket were identified and analyzed.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 2

 FABRICATION OF PELTON WHEEL TEST RIG

ACKNOWLEDGEMENT

At this pleasing moment of having successfully completed our project, we wish to

convey our sincere thanks and gratitude to the management of our college.

We would like to express our sincere thanks to our Principal Mr. Vasudev S Appaji for
forwarding us to dour project and offering adequate duration in completing our project

We are also grateful to the Head of Department Mr. Satish Kumar R A for Their
constructive suggestion & encouragement during our project.

We deep sense of gratitude, extended our earnest & sincere thanks to our Guide Mr.
Sudhir S Department of Mechanical Engineering for their kind guidance & Encouragement
during this project.

We also express our indebt thanks to our teaching and nonteaching staffs of Mechanical
Engineering Department, Government Polytechnic Siddapura.

Sincerely,

Student name
177ME160

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 3

 FABRICATION OF PELTON WHEEL TEST RIG

CHAPTER 1

INTRODUCTION
A pelton wheel turbine is a tangential flow impulse hydraulic machine that is actively used for
the production of power from kinetic energy of flowing water. It is the only form of impulse
turbine in common industrial use. It is a robust and simple machine that is ideal for the
production of power from low volume water flows at a high head with reasonable efficiency.

The pelton wheel used in this experiment, although a model, reproduces all the characteristics of
full size machines and allows an experimental program to determine the performance of a turbine
and also to verify the theory of design.

Pelton Wheel Turbine is an impulse or a constant pressure water turbine. In this case water head
is very high. Pelton wheel consists of a wheel called rotor. The rotor of the turbine consists of a
circular disc with a number of double spoon shaped buckets evenly distributed over
the periphery. The water is the supplied from the reservoir. In such type of Turbine available
hydraulic energy of the water is converted into the kinetic energy at atmospheric pressure by
means of the nozzle. Each nozzle directs the jet along a tangent to the circle through the centers
of the buckets. Each bucket consists of a splitter which divides the incoming jet in to two
equal portions and after flowing round the smooth inner surface of the bucket the water leaves
with is elative velocity almost opposite in direction to the original jet. The change in momentum
of the water jet in passing over the buckets exerts tangential force on the wheel causing it to
rotate. Thus converts the hydraulic energy into the mechanical energy by means of the shaft
rotation
Impulse turbines operate through a mechanism that first converts head through a nozzle into high
velocity, which strikes the buckets at single position as they pass by.jet flows past the buckets is
quite essential at constant pressure thus runner passages are never fully filled. These turbines are
suited for relatively low power and high head derivations. The pelton wheel turbine is comprised
of three basic components that include the stationary inlet nozzle, the runner and the casing. The
multiple buckets form the runner. They are mounted on a rotating wheel. They are shaped in a
manner that divides the flow in half and turn in a velocity vector that is nearly 180degrees.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 4

 FABRICATION OF PELTON WHEEL TEST RIG

The nozzle is positioned in a similar plane as the wheel and is arranged so that the jet of water
impinges tangentially on to the buckets. The nozzle is controlled by movement of the spear
regulator along the axis of the nozzle which alters the annular space between the spear and the
housing. A static pressure tapping is provided to enable the measurement of the water pressure in
the inlet.

The nozzle is controlled by movement of the spear regulator along the axis of the nozzle which
alters the annular space between the spear and the housing, the spear being shaped so as to
induce the fluid to coalesce into a circular jet of varying diameter according to the position of the
spear.

A friction dynamometer consists of a 60mm diameter brake wheel fitted with a fabric brake band
which is tensioned by a weight hanger and masses with the fixed end being secures via a spring
balance to the support frame. A tachometer may be used to measure the speed of the turbine.Less
efficiency, which means that they generate less power and can only be used where the flow rate
is sufficient to provide torque.

Fig. 1.1: Schematic view of pelton turbine

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 5

 FABRICATION OF PELTON WHEEL TEST RIG

CHAPTER 03

PERFORMANCE TEST OF PELTON WHEEL TURBINE

Impulse turbine changes the velocity of a water jet. The jet impinges on the turbine’s curved
blades which change the direction of the flow. The resulting changes in momentum (impulse)
causes a force on the turbine blades. Since the turbine is spinning, the force acts through a
distance (work) and the diverted water flow is left with diminished energy. Prior to hitting the
turbine blades, the water’s pressure (potential energy) is converted to kinetic energy by a nozzle
and focused on the turbine. No pressure change occurs at the turbine blades, and the turbine
doesn’t require hosing for operation.

The Pelton-wheel is an impulsive turbine used for high heads of water. This turbine was
discovered by the American engineer L.A. Pelton. The energy available at the inlet of the Pelton
turbine is only kinetic energy. The pressure at the inlet and outlet of the turbine is atmospheric
pressure. It has the following main components.

The water flows along the tangent to the path of the runner. Nozzle direct forceful streams of
water against a series of buckets mounted around the edge of a wheel. As water flows into the
bucket, the direction of the water velocity changes to follow the contour of the bucket.

Application Of Impulse Turbine

Pelton wheels are the preferred turbine for hydro-power when the available water
source has a relatively high hydraulic head at low flow rates
Advantages

1. Simple in construction and easy to maintain.

2. This turbine has high efficiency.
3. They work at atmospheric pressure so no problem of leakage.
4. It is easy to assemble.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 6

 FABRICATION OF PELTON WHEEL TEST RIG

STRIKING OF WATER THROUGH THE BLADES OF THE RUNNER

The nozzle is positioned in the same plane as the wheel and arranged so that the jet of water
impinges tangentially on to the buckets. The nozzle and a single bucket are illustrated in Figure 1
below. Each "bucket" is divided by a "splitter" ridge which divides the jet into two equal parts.
The buckets are shaped so as to prevent the jet to the preceding bucket being intercepted too
soon. After flowing round the inner surface of the bucket, the fluid leaves with a relative velocity
almost opposite in direction to the original jet. The desired maximum deflection of the jet (180°)
cannot be achieved without the fluid leaving one bucket striking the following one, and so in
practice the deflection is limited to approximately 155° (i.e. see Figure 1 below 180-25). The
bottom of the casing is open to allow the water leaving the buckets to drain away. The front face
of the casing is transparent Perspex allowing easy observation of the behavior of the water jet
and assessment of exit angles.

Fig: 1.2 STRIKING OF WATER

With this relative velocity, the jet flow spreads in the bucket, forming a water sheet. The change
in the direction of the flow along the bucket surface is coupled with a pressure increase below
the water sheet as related to the impulsive force and determined by the law of momentum. On the
surface of the water sheet where the atmospheric pressure is constant, the flow velocity is equal
to W1 provided that frictionless flow is assumed. The pressure as well as the velocity distribution
across the thickness of the water sheet will be considered in more details in Sects. 6.1.2 and 7.3
by considering the relative flow in a rotating Pelton bucket.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 7

 FABRICATION OF PELTON WHEEL TEST RIG

TANGENTIAL FLOW IN PELTON WHEEL TURBINE

The Pelton Wheel needs a source of water in order to run. If the head of water is known, along
with the flow rate, then it is possible to find the best size of wheel to use, how fast it should
rotate to obtain the maximum efficiency, and what power it is likely to develop.
The velocity in the jet can be estimated by using the known fixed head. The diameter of the jet
can then be found from the known flow rate. A suitable wheel diameter can be chosen in relation
to the jet size; typically the wheel would have a diameter of 10 times that of the jet. The best
speed of rotation may then be selected, such that the speed of the buckets is approximately half
that of the jet speed. The power delivered in the jet can be calculated from the speed and cross-
sectional area of the jet. The power developed by the Pelton wheel will be less than this, in the
ratio of the wheel’s efficiency, which may be estimated by reference to the known performance
of existing machines of comparable size and output.
Depending on the head and flow rate available, the size and speed of the Pelton wheel obtained
in this way may prove to be impracticable or uneconomic. Fortunately, other types of water

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 8

 FABRICATION OF PELTON WHEEL TEST RIG

turbine are available to suit a wide variety of circumstances. The Pelton wheel is usually chosen
when the available head is high, but the flow rate is comparatively low.

FORCE EXERTED BY THE JET

Figure 6 shows a water jet emerging at speed v from a nozzle, and striking one of the buckets of
the wheel, which itself is moving at speed u. The mass flow rate is and it is assumed that all of
the water emerging from the nozzle strikes one or other of the set of buckets arranged around the
periphery of the wheel, although, for simplicity, just one bucket is shown in the diagram.

The relative velocity at which the jet impacts on the bucket is (𝑣 – 𝑢). The flow over the bucket
is decelerated slightly by frictional resistance at the surface. Suppose that the relative velocity, as
the water leaves the bucket, is (𝑣 – 𝑢), where k is a velocity reduction factor with a value
somewhat less than unity. The relative velocity is inclined at the bucket exit angle 𝛽 to the jet’s
direction. The absolute velocity of the water at exit is the vector sum of the relative velocity and
the bucket velocity 𝑢, as shown.
The force generated on the bucket may be found by considering the momentum change, as
shown in Figure

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 9

 FABRICATION OF PELTON WHEEL TEST RIG

HIGH HEAD LOW DISHARGE TURBINE

For all hydraulic machines, power absorbed or delivered is given by the relationship

P= W Q H (watts)

Where W is a constant, Q is the flow rate and H is the active head or the energy.

Generally, the H part is a fixed parameter for a particular location dictated by the geography.
Only Q is under the designer's control. Therefore sustained power availability over a given
period of time. Water stored at a higher elevation will have greater potential energy which is
converted into kinetic energy in the nozzles of the impulse turbine. So with higher head
available, the “H” part of the equation contributes more to the power and hence the” part is kept
to a flow rate where the annual quantum of water availability is the criterion. Again whether the
power is proposed to be used for meeting the peak load or base load is another contributing
factor.

TORQUE EXERTED ON THE WHEEL:

The force 𝐹𝑤 produced on the bucket by the difference between these rates of momentum flow

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 10

 FABRICATION OF PELTON WHEEL TEST RIG

POWER AND EFFICIENCY:

In the absence of friction, the relative speed is not reduced by passage over the
bucket surface, so the value of 𝑘 would then be unity. Moreover, the lowest conceivable value of
𝑐𝑜𝑠𝛽 is –1, corresponding to 𝛽 = 180°. So the factor (1 – 𝑘𝑐𝑜𝑠𝛽) could ideally just reach the
value 2. The maximum ideal efficiency, 𝜂𝑚𝑎𝑥, would then just reach 100%, all the kinetic
energy in the jet being transformed into useful power output, with the water falling from the
buckets with zero absolute velocity. In practice, however, surface friction over the bucket is
always present, and β cannot reasonably exceed a value of about 165°, so 100% efficiency can
never be achieved. It must be emphasized that the hydraulic efficiency used here gives the ratio
of hydraulic power generated by the wheel to the power in the jet. The overall efficiency of the
turbine will fall short of this hydraulic efficiency due to some loss of head in the nozzle, air
resistance to the rotating turbine, and losses at the bearings. As shown in Figure 8, you can
reasonably expect a maximum efficiency of around 60% for this small turbine. Your results
should show that the turbine may not be most efficient at its maximum power position and that
the spear valve position affects maximum speed, torque, power and efficiency

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 11

 FABRICATION OF PELTON WHEEL TEST RIG

In maximum efficiency according to the number of buckets Figure shows the relationship
between the speed ratio and the efficiency of the Pelton turbine under three operating conditions.
The horizontal axis shows the speed ratio, and the vertical axis represents the normalized
efficiency, which is the efficiency at each speed ratio divided by the maximum efficiency under
each operating condition.

POWER DEVELOPED BY THE TURBINE

This is the power absorbed by the turbine wheel, taken from water

𝑃𝑤 = 2𝜋𝑁𝑇 Watts
60
The power developed by the turbine at the output shaft is called break power. Indicated power
supplied to turbine blade in which break power.

Torque

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 12

 FABRICATION OF PELTON WHEEL TEST RIG

The total force is the difference between the readings. Due to the direction of rotation, the right
hand balance will give a larger reading than the left hand balance, so for simplicity

The torque is the radius of the drum multiplied by the force.

T = F * D (N-m)

DESIGNING BUCKET OF PELTON WHEEL

There is need of a common and accessible Pelton turbine geometry as a basis for
future research. The chaotic environment surrounding the turbine during operation makes
quantifiable measurements of the flow in the turbine buckets challenging. Large velocity
gradients and two phase flow dominate the environment, and the buckets of the turbine undergo
enormous changes in pressure caused by periodic contact with a high velocity water jet. Since
the flow in Pelton turbine buckets are dependent on the design of the bucket, the investigation of
the flow phenomena cannot be done without an understanding and availability of the bucket
design. Numerical simulations are subject to an increased importance for the research of
hydraulic machinery in the last decades. On-board pressure and water thickness measurements
have to date been the only available quantifiable measurements of the flow in a rotating bucket.
These measurements can be used to validate the pressure and, to some extent, water thickness
found in numerical simulations. However, the flow pattern and behavior of the flow lacks direct
validation data that are essential for trustworthy simulation results. The main objective of this
thesis is therefore twofold and interdependent.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 13

 FABRICATION OF PELTON WHEEL TEST RIG

The flow in the designed bucket is analyzed and improvements to the Design method are
presented. All experiments were carried out in the Waterpower Laboratory at the Norwegian
University of Science and Technology. The flow in the turbine has firstly been studied using
high speed filming from the stationary frame of reference. The focus of the early study was the
effects of jet alignment on the flow in the turbine. Gradient based edge tracing is utilized to
quantify the misalignment. Validation of the method based on the jet diameter compare well with
analytical models and the method is, to the author’s knowledge, the first time advanced image
processing has been used for studying hydraulic turbines. To enable an improved study of the
flow, a visualization system has been developed to enable high speed filming from within the
rotating frame of reference. A unique post processing technique for the results from the
visualization system has been developed. The technique enables a study of the water front as it
propagates through the bucket. The location of the front has been found as an absolute position
in the physical realm for multiple angular positions. These results, combined with the publicly
available turbine geometry, can be used for direct validation of water propagation through a
rotating turbine bucket found by numerical simulations.

MECHANICAL EFFICIENCY:

The efficiency of any machine is defined as the ratio between the output energy and the input
energy:

Mechanical efficiency = Output / Input

A wheel power divided by the initial jet power is the turbine efficiency, as the equations
indicate, when a real Pelton wheel is working close to maximum efficiency, the fluid flows off
the wheel with very little residual velocity. In theory, the energy efficiency varies only with the
efficiency of the nozzle and wheel, and does not vary with hydraulic head.] The term "efficiency"
can refer to: Hydraulic, Mechanical, Volumetric, Wheel, or overall efficiency.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 14

 FABRICATION OF PELTON WHEEL TEST RIG

Purpose of Pelton Wheel Turbine Performance test

A performance test was conducted for a pelton wheel turbine with the objective of establishing

the relationship between the mechanical efficiency and the velocity ratio. A literature review

found a number of useful mathematical models and some key physical phenomena. The

performance test was conducted for a constant hydraulic head and flow rate while varying the

braking force. The raking force was gradually increased until the pelton wheel stopped. Readings

of the angular velocity and pressures were taken a processed using the equations found in the

literature review. A parabolic relationship between the efficiency and the velocity ratio was

established and the peak efficiency was found. Some physical phenomena relating to the flow

field in the bucket were identified and analyzed

OBJECTIVES:

 To construct a Pelton Turbine with proper design and to analyze its performance under
different loads.
 To demonstrate about Pelton wheel for study in fluid machinery lab.
 To determine the performance characteristics values using experimental procedure.
 To find the performance characteristics curve that is to plot.

DEPT. OF MECHANICAL ENGG. GPT SIDDAPURA Page| 15