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Development of Pelton turbine using numerical simulation

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2010 IOP Conf. Ser.: Earth Environ. Sci. 12 012048

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

Development of Pelton turbine using numerical simulation

K Patel1, B Patel1, M Yadav1, and T Foggia2
1
Hydraulic Engineer, ALSTOM Hydro R & D India Ltd., GIDC Maneja, Vadodara –
390 013, Gujarat, India
2
Hydraulic Engineer, Alstom Hydro France, Etablissement de Grenoble, 82, avenue
Leon Blum BP 75, 38041 Grenoble Cedex –France

E-mail: patel@power.alstom.com

Abstract. This paper describes recent research and development activities in the field of
Pelton turbine design. Flow inside Pelton turbine is most complex due to multiphase (mixture
of air and water) and free surface in nature. Numerical calculation is useful to understand flow
physics as well as effect of geometry on flow. The optimized design is obtained using in-house
special optimization loop. Either single phase or two phase unsteady numerical calculation
could be performed. Numerical results are used to visualize the flow pattern in the water
passage and to predict performance of Pelton turbine at full load as well as at part load. Model
tests are conducted to determine performance of turbine and it shows good agreement with
numerically predicted performance.

1. Introduction
Hydro power is eminent renewable energy source to suit higher energy demand of the world. Pelton turbine
is useful to develop power using hydraulic energy in the case of high heads available. This type of turbine
consists in 4 major components i.e. collector (manifold), injector, bucket and housing. Each component is
playing a significant roll for better performance of machine, hence optimization is required. Numerical
simulation is playing a very essential role for optimization of various components of Pelton turbine.
Optimization cycle as shown in Fig. 1 consists of design of each component using hydraulic calculation tools.
After completion of basic design, 3-D model of each component has to be made. At last numerical simulation is
performed which gives performances of each component. Qualitative as well as quantitative evaluations of
numerical result of components are performed based on head loss coefficient, distribution of secondary flow,
flow separation & distribution, interaction & interference of flow, torque. If the numerical results are good then
model test is performed to evaluate performances of final design of machine.

2. Numerical simulation of Pelton turbine components

2.1 Manifold
A manifold is the hydraulic conduit that carries water from inlet valve to the injectors. It should distributes
water to the injectors with the minimum losses. From hydraulic data, site characteristics and general turbine
characteristics, optimization of manifold gives improved performance. The manifold shape depends on the
number of nozzle; in general these are symmetrically distributed. The manifold consists of the various elements
as below:
-wye-pieces (bifurcations).
-connecting cylinders between the bifurcations.
The design of bifurcation is most important for better performance. Bifurcation definition is based on Ø and L,
diameter and length coefficient respectively. All these variables are included in manifold design tool, which
supplies input for parametric geometry creation. This model is used for numerical analysis.


c 2010 IOP Publishing Ltd 1
25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

parametric
Input design data
Design
To tool

Numerical simulation
(meshing, solver)

Result (Head loss, secondary flow, flow

separation & distribution, interaction &
interference, torque,)

No
satisfy

Yes

Optimised design

Fig. 1 Optimization cycle

On the basis of the manifold design, cross sections are generated and used in post processing to calculate all
parameters like total pressure secondary kinetic energy and turbulence kinetic energy as shown in Fig. 2. The
hydraulic losses and quality of jet depends on hydraulic of manifold. Too small diameters and bending radii or
steep changes of direction would produce decrease in turbine efficiency. On the contrary, too large diameter or
bending radii would result in a too heavy and costly manifold. Boundary layer separation, generation of
secondary kinetic energy and turbulence kinetic energy are parameters for optimization of manifold geometry.
Main objectives of manifold optimization are to get an optimized flow distribution, decrease in head loss,
secondary flow minimization and keep the overall dimensions as required for project. Further optimization
process focused on the optimization of the bifurcation design, which includes reduction in boundary layer
separation and secondary flow reduction before injector.
To get reliable numerical analysis results, good quality of mesh with sufficient number of nodes is required
for optimization purpose tetra elements are used with prism layer at near wall. The correct boundary conditions
are required to get good quality of numerical analysis result. At inlet of manifold mass flow rate is specified and
at outlet static pressure with respect to reference pressure. K-e turbulence model is used with high resolution as
advection scheme.

Fig. 2 Post processing cutting plane position

definition

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

2.1.1Comparison of numerical results of conventional & optimized manifold

The comparison of numerical analysis results of conventional and new optimized manifold is shown as
follows.
The new design shows reduction in head loss coefficient and secondary kinetic energy as shown in Fig. 3 and Fig.
4. The shape of manifold influences jet quality and thereby has a further effect on the efficiency through the jet-
bucket interaction. So velocity at injector inlet has to become as uniform as possible and turbulence level has to
be reduced. Figure 4 shows that in new design secondary kinetic energy is also reduced.

HEAD LOSS COEFFICIENT

1.2
ORIGINAL OPTIMISED
1

0.8
kcoll

0.6

0.4

0.2

0
NOZZLE1 NOZZLE2 NOZZLE3 NOZZLE4 NOZZLE5 NOZZLE6 AVERAGE
Number of injector

Fig. 3 Head loss coefficient

SECONDARY KINETIC ENERGY

1.2
ORIGINAL OPTIMISED
1

0.8
SKE/TKE

0.6

0.4

0.2

0
NOZZLE1 NOZZLE2 NOZZLE3 NOZZLE4 NOZZLE5 NOZZLE6 AVERAGE

Number of injector

Fig.4 Secondary kinetic energy

To validate numerical and test result, we have measured static pressure at each bifurcation and compared
with the numerical analysis result. Model test is carried out with all injectors open. Numerical analysis is carried
out. The detail summary of comparison of model test & numerical result is shown in Fig. 5. Numerical analysis
result shows good agreement with model test result. This validates the use of numerical analysis for future
developments.

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

COMPARISON OF CFD AND TEST RESULT

1.0005
CFD
1 TEST

0.9995
Normalised Pressure

0.999

0.9985

0.998

0.9975

0.997

0.9965

0.996
1 2 3 4 5
BIFURCATION LOCATION

Fig. 5 Comparison model test & CFD result for bifurcation pressure measurement
2.2 Injector
The jet quality plays a very important role to achieve the efficiency of the machine. The jet should have
uniform velocity distribution and be free from secondary structures. Practically the jet has non-uniform velocity
distribution with secondary structures coming from the upstream of the injector. This free jet also losses its
momentum interacting with air. Here an attempt is made to understand the behavior of the jet. An experimental
set-up was made to measure the diameter and the total pressure in the free jet from the injector.

Fig. 6 Experimental set up

2.2.1 Experimental set-up

The Fig. 6 shows the experimental setup of the measurements done on the free jet. The jet was produced
using the standard injector. Total pressure measurements were done with Pitot tubes along lines shown in Fig. 7.
The measurements were done at 100mm from the nozzle diameter. The experiment was carried out in two phases.
The first phase was using the injector attached to the straight pipe (i.e. Straight jet). The second phase was using
the injector attached to the bifurcation (i.e. Deviated jet). Numerical two-phase calculation was done using
commercial CFD software.

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

Fig. 7 Measurement location

Figure 8 A and 8 B shows the plot of normalized total pressure measured with the Pitot tube compared with
CFD results. It shows the comparison of CFD results and experimental results for straight and deviated jet
respectively. The total pressure profiles are having a good match in both the cases. The width of the wake
depends on the distance from the nozzle tip. The width of the wake decreases and the velocity profile is smooth
as the distance increases. For the straight jet (Fig. 8A) the wake is in the centre while for the deviated jet (Fig.
8B) the wake is deviated from the centre (G.Berntsen & H.Brekke [1]). This is the result of the secondary
structures developed in the free jet due to the upstream bifurcation used in the experimental set-up. The Pitot
tube used for total pressure measurements was may be too big to capture the velocity gradient within the wake.

experimental result numerical result experimental result numerical result 1.1

1.1
1
1

0.9 0.9

0.8
N o rm a lis e d T o ta l P re s s u re

0.8
N o r m a li s e d T o t a l P r e s s u r e

0.7 0.7

0.6 0.6

0.5 0.5

0.4 0.4
0.3
0.3
0.2
0.2
0.1
0.1
0
0
2 1.5 1 0.5 0 -0.5 -1 -1.5 -2
-2 -1.5 -1 -0.5 0 0.5 1 1.5 2
Z
Z

Fig. 8 A. Straight Jet result B. Deviated Jet result

2.3 Bucket
Pelton turbine pressure energy of water is converted into kinetic energy at exit of injector. This high speed
water jet is striking on bucket which makes it to rotate. Design of bucket is completed by using 3D surface
design tool which is developed in house. Geometrical modeling is first step of optimization loop. This 3D-
model of bucket is used to make rotating domain which is required for numerical simulation. Grid is generated
into this rotating and stationary domain. Tetra along with prizm elements are used for generation of mesh in
rotating domain. Hexa elements are used for stationary domain, see Fig.9.
Multiphase homogeneous flow simulation is conducted as water and air particle mixing with each other.
Interaction of water jet with rotating bucket is time dependent hence unsteady analysis has been conducted.
Velocity of water jet is given as inlet boundary condition. Bucket is treated as rotating wall boundary with no slip
condition. Unsteady rotor-stator interface (GGI) model is used as interfacing side of rotating and stationary
domain. An extreme end of rotating and stationary domain is treated as periodic boundary condition and all other
parts are given as opening boundary condition. High resolution is used as advection scheme along with second
order backward euler as unsteady scheme.

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

Fig. 9 A. Model of bucket B. Grid generated into bucket

2.3.1 Discussion on numerical result

Numerical result is very useful especially to understand flow behavior inside bucket. At entry of jet is
striking on sharp splitter point and its position is continuously changing along the splitter with rotation (P. Leroy,
B.Zoppe, [2]). Initially when the bucket is empty, jet is spreading on bucket and coming out from top portion of
bucket as shown in Fig. 10A. Later on with the time and as position of jet is changing, water sheet is coming out
from the central region. At the end water sheet is coming out from lower region of bucket i.e. near cutout side. In
case of multi jet vertical machines more than one jet is simultaneously striking on rotor which causes bucket to
never completely empty. Before bucket gets completely empty another jet is striking on the same bucket and
interference (Tsuneaki Fujii, Toshiaki Karaki, [3])of one jet with water sheet from previous jet is taking place as
shown in Fig. 10B.

Fig. 10 A . Jet exit from top B. Jet interference

In multi jet machine drop in efficiency is found due to interference of jet and water sheets inside the buckets
(Yuji Nakanishi, Takashi Kubota, [4]). Pelton model test in vertical configuration is shown in Fig. 11. Model test
is carried out in full operating range. Numerical and experimental results show good agreement.

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

Fig. 11 Vertical Pelton Turbine Model

3. Conclusion
The flow in manifold is numerically calculated with the objective of understanding the main flow features
and improving the geometry such that both, the losses in the manifold are reduced and the quality of the jet is
improved. Jet quality is derived from the velocity distribution at injector inlet. Given that the quality of the jet is
highest for a perfectly even velocity distribution and lowest level of turbulence kinetic energy, calculations show
that the existing geometry of the manifold improved both with respect to the losses within the manifold
(reduction in separation near to bifurcation) and with respect to jet quality (less level of secondary structure at
injector inlet).

From the experimental results we can conclude that the jet diameter is well predicted. A high reliability of
numerical result is achieved for free-surface water jet flow.

Multiphase transient numerical analysis is very much useful to understand the flow physics and predict
performance of Pelton turbine. In actual model test it is very difficult to observe flow distribution inside bucket,
interference of jet which have been easily understood, improved and optimized by numerical simulation.
Performance of machine is improved due to optimized bucket.

Nomenclature
D Diameter of turbine [m] ∆p Pressure difference [Pa]
g Gravitational constant – 9.81 [m/sec2] ρ Fluid Density [kg/m3]
H Head of turbine [m] η Efficiency ( P/ ρ . g . Q. H )
Kcoll Head loss coefficient (∆p/(1/2 . ρ . V2) V Velocity [m/sec]
L Bucket width [m] TKE Turbulence kinetic energy [m2/s2 ]
N Speed [rpm]
N11 Unit speed ( N.L / √H ) Subscripts
P Power developed [W] u,v,w velocity component in x, y, z
P11 Unit power ( P / L2 . H3/2 ) respectively
Q Discharge [m3/sec]
Q11 Unit discharge ( Q / L2 . √H )
SKE Secondary kinetic energy (1/2 . ρ . V2-1/2 .
ρ . (Vv + Vw )

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25th IAHR Symposium on Hydraulic Machinery and Systems IOP Publishing
IOP Conf. Series: Earth and Environmental Science 12 (2010) 012048 doi:10.1088/1755-1315/12/1/012048

References
[1] Berntsen G and Brekke H 2001 Analysis of the free surface non-stationary flow in a Pelton turbine
Hydropower and Dams Issue 6
[2] Leroy P, Zoppe B, Pellone C and MaitreMyers T Flow analysis inside a Pelton turbine bucket J. of Turbo
mach. Transactions of ASME 128 500-11 July 2006
[3] Fujii T, Karaki T, Tsukamoto T and Kurokawa J Research of the jet interference of pelton turbines 23rd IAHR
symp. (Yokohama, Japan) October 2006
[4] Nakanishi Y and Kubota T 1996 Scale effect of jet interference in multi nozzle Pelton turbines
Hydr .mach.and cavitation 333-41