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Journal of Hydraulic Research

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Analysis of scale effects on performance characteristics of hydraulic turbines

Tomio Idaa a Dept. of Mechanical Engineering, Kanagawa University, Yokohama, Japan Online publication date: 19 January 2010

To cite this Article Ida, Tomio(1990) 'Analysis of scale effects on performance characteristics of hydraulic turbines',

Journal of Hydraulic Research, 28: 1, 93 104 To link to this Article: DOI: 10.1080/00221689009499149 URL: http://dx.doi.org/10.1080/00221689009499149

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Analysis of scale effects on performance characteristics of hydraulic turbines

Part 2: Effects of surface roughness, runner seal clearance and Reynolds number on performance and loss distribution coefficients

Analyse d'effets d'chelle sur les caractristiques de performances de turbines hydrauliques

2me partie: L'effet de rugosit de surface, des jeux aux labyrinthes et de nombre de Reynolds sur les coefficients de repartition de pertes
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TOMIO IDA Prof., Dept. of Mechanical Engineering, Kanagawa University, 3-27-1, Rokkaku-Bashi, Kanagawa-ku, Yokohama, 221, Japan

SUMMARY Using the method described in Part 1. the effect of surface roughness of flow passages, runner seal clearance and the Reynolds number on the hydraulic performance and loss distribution coefficient V is quantitatively made clear. Vopt which is the value of V at the optimum efficiency point varies within the range of approx. 0.96-1.05 times the original value when the surface roughness of all of flow passages in a model turbine becomes 0.5-2 times the original roughness, however, does not vary with the runner seal clearance. When the Reynolds number varies with the change of head or water temperature, the admissible surface roughness of each How passage decreases as the Reynolds number increases, thus each friction coefficient becomes the value corresponding to the rough surface region. As a result, the change of performance and Kopl due to the change of the Reynolds number becomes smaller in comparison to that in the case with smooth surfaces. On the contrary, when the head, water temperature and surface roughness are unchanged and the Reynolds number varies only with the size of turbine, the relative roughness decreases as the Reynolds number increases and becomes the value in the smooth surface region. As a result, the change of performance and Vofl is larger than the former case mentioned above. In other words, the effect of roughness cannot be neglected for examining the effect of the Reynolds number on Kopl. RESUME En employant la methode dcrit dans la lre partie, on explique quantitativement Pellet de rugosit de surface dans les passages d'coulement, des jeux aux labyrinthes et de nombre de Reynolds sur les perfor mances hydraulique et sur Ie coefficient de repartition des pertes V. La valeur de V au point du meilleur rendement, Vapt change dans la fourchette d'approx. 0,96-1,05 fois plus grande que celle initiale quand la rugosit de surface de tous les passages d'coulement devient 0,5-2 fois plus grande que celle initiale, alors que Vofl ne varie pas avec les jeux aux labyrinthes. Quand Ie nombre de Reynolds varie selon la variation de chute ou de temperature d'eau, la rugosit de surface admissible de chaque passage d'coulement diminue avec l'augmentation de nombre de Reynolds, aussi chaque coefficient de friction devient la valeur qui correspond a la region de surface rugueuse. Ainsi, la variation de performance et de V,wx d au changement de nombre de Reynolds devient plus petite par rapport au cas de la surface lisse. Par contre quand la chute, la temperature d'eau et la rugosit de surface sont inchanges et que Ie nombre de Reynolds varie avec la taille de turbine, la rugosit relative diminue avec l'augmentation de nombre de Reynolds et elle devient la valeur dans la region de surface lisse. II en rsulte que Ie changement de performance et de Vof{ est plus grand que Ie cas mentionn ci-dessus. En d'autres mots, on ne peut pas ngliger l'effet de rugosit pour examiner celui de nombre de Reynolds sur Vafl. Open for discussion till August 31, 1990.

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1 Introduction In Part 1 reported in [1], the author has analytically derived scale-effect formulae of hydraulic performances of a turbine, described a method to determine the loss distribution coefficient V in scale-effect formula of hydraulic efficiency and established Kopl - the value of V at the optimum efficiency point - as a function of specific speed /Vsq. In Part 2, the effect of surface roughness of flow passages, runner seal clearance, head and water temperature as well as the size of turbine on the hydraulic performance and V0(tt of model turbines is discussed. Model turbines used for the analysis are total of 15 units with different specific speed /Vsq including pump turbines and they are identical to those listed in Part 1. Symbols T, PT and HL represent Francis turbines, pumpturbines and Chinese models, respectively, and the value of specific speed based on optimum discharge /Vsq is added to each symbol. Then they'are expressed as T-62, PT-33, HL-74 and so on. These units are all manufactured and tested in accordance with JIS [2], [3], IEC [4] among other standards and the value of each surface roughness of flow passages is within a stipulated range. Also, all runner seal clearances are within the range of 0.20-0.25 mm. 3 Effect of surface roughness in flow passage on hydraulic performance and loss distribution coefficient Among the parameters which affect the loss distribution coefficient, the one that attracts the most attention is the surface roughness in the flow passage [5-7]. So the changes in the hydraulic performance and V of model turbines are investigated when all the surface roughness of runner, wicket gates and others become 0.5-8 times the original roughness. When the friction loss is calculated using the friction resistance coefficient of a flat plate or pipe, how to select the value of roughness will be an important matter. Fukuda [8] allocated the equivalent sand roughness of a ground surface (the roughness ratio of pitch with height 8-16) as 1/5 of the actual ground height Rmm. In this paper, the value often point height roughness Rz was used as the equivalent sand roughness referring to the latest study on disc friction by Kurokawa et al. [9]: the value of 4 times the center line average roughness Rs can be allocated as the equivalent sand roughness. Fig. 1 shows an example (Francis turbine T-38) of the total efficiency rfm, loss distribution co efficient Vm, peripheral speed coefficient K^ and discharge coefficient A^1m at the maximum efficiency point (subscript m) of respective gate opening ratio a with the roughness as parameter. In the figure, the parameter e'je{) is the ratio of respective surface roughness in total flow passage to the original roughness. The roughness on the outer surface of the runner crown/band is unchanged in order to examine the effect of the roughness in the principal flow passages. It is seen from the figure that rj'm decreases and Vm increases as the roughness increases, but the varied increments are approx. constant irrespective of a. Also it can be seen that K'um and K'mm gradually decrease due to the decrease of //'h in accordance with equation (3.35) in Part 1 [1], with roughness increase. The gate opening shown as B.E.P. where the efficiency becomes maximum does not change much even with the considerable change of roughness. Therefore, from the result, it is clear that the effect of roughness can be compared under the constant gate opening. Fig. 2 shows the effect of roughness on ATm, Vm and each efficiency of T-38 under the constant gate opening with e'/^'oon t n e abscissa. The result in the pump-turbine PT-47 at the optimum gate opening is also shown in broken line in the figure. The effect of roughness on the rfm and Vm is similar either with different gate opening or in both Francis and pump-turbines. The rj'm decreases and Vm increases as the roughness increases. The t]'v and //'mech are not affected by the roughness in the principal flow passages.
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0.96

0.92 \-

VS
0.88 h ^0.7

0.84

0.6
E

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>
0.24 h-0.78 0.5

-e

0.20 h 0 . 7 4

0.4

0.16 h 0 . 7 0 [T-38] 0.12 0.4 0.6 0.8 1.0 1.2

H 0.3

0.2 1.4

OL
Fig. 1. Effect of surface roughness on performances and V at the maximum efficiency points at each opening. Effet de rugosit de surface sur Ie rendement et sur V aux points d'efficacit maximale a chaque ouverture.

Fig. 3 shows changes of/;'01 and Vop{ with the roughness ratio for the various units. In the figure, the subscript 0 indicates values in a model Turbine which has the original surface roughness selected as the reference. Both the decreasing rate of rj'opihomo a n d t h e increasing rate of KptlKpio by the roughness can be considered similar irrespective of specific speed. Since the normal range of roughness in a model is within 0.5-2 times the roughness e'0 of the analyzed unit, it can be estimated that Kopl of a model turbine is confined within the range of 0.96-1.05 times the Kopl.0. Roughness effect is added to the diagram of Vopi versus /Vsq which has already been shown in Part 1 and illustreated in Fig. 4. When the roughness varies 0.5 to 2 times the reference value, Popl.Q varies as shown with the dash-dot lines in Fig. 4. The values of K0| which are calculated analytically from the model test results lies within the area bounded by two dash-dot lines. 3 Effect of runner seal clearance on performance and loss distribution coefficient Fig. 5 shows an example of the performance change when only the runner seal clearance (6 = 0.2 mm) of a model turbine (T-38) is varied to 0.5-8 times. The leakage flow through the crown
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seal clearance is assumed equal to that on band side. The leakage flow increases as the clearance increases thus K'm increases, rj'v decreases, and therefore, r\' also decreases. But the change of clearance has produced very little effect on n'h and V. Since it is practically improbable to make the clearance as large as shown in the figure, V can be considered, from this figure, constant irrespective of the clearance.

Effects of Reynolds number on performance and loss distribution coefficients

4.1 Effects of head and water temperature The model turbines examined here are tested under different Reynolds numbers. It is expected that the value of Kopl will change with the tested Reynolds number, and 1EC Draft Code specifies the method to convert the Vopl under the tested Reynolds number to that under the reference
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1.00

0.4

0.3 2 3 e'/ei Fig. 2. Variation of performance and V at the maximum efficiency points with surface roughness. Variation du rendement et de V aux points d'elicacit maximale en fonction de la rugosit de surface.
0.3 0.5 0.7

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1.2

HL-59.
02 -

<\Z^y^ " A^<^<T-82,49

HL

74

1.1

c>~
KN.

00

~""^*fc^

PT-76

1.0

98
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- 0.9

'H-;

HL-74-7 /fr^ HL-59-V / -T-49,82 z HL-33

i i

0.4

0.6

8 10

20

e'/ej
Fig. 3. Effects of surface roughness on Voin and rj'm. Influence de la rugosit de surface sur f',,,,, et '?!.,

0.8

0.7 h

0.6

0.5 h

0.4

0.3 100 Nsq [rpm,m3/s,m]

Fig. 4. Variation of loss distribution coefficients at the optimum with specific speeds. Variation des coefficients de perte a 1'optimum en fonction des vitesses spcifiques.

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Fig. 5. Effects of runner seal clearance on performance and V. Influence du jeu a la roue sur Ie rendement et sur V.

Reynolds number [10]. So the effect of test Reynolds number will be investigated by executing similar calculations to those in previous chapters for the various heads and water temperatures. Fig. 6 shows performances and the value of V at the optimum efficiency point of model turbine T-38 referring to the Reynolds number R'm on the abscissa where only the head and the kinematic viscosity of water vary independently: water temperature is indicated instead of the kinematic viscosity in the figure. The operating condition of model (head of 35 m, water temperature of 25 C and a0 of 25 mm) is selected as the reference point as shown with in the figure and its test head and water temperature are varied over a considerably wide range of 0.1 -50 times the normal values and 0-40 C, respectively. The opt and K'm opt slightly increase with increasing Ru but the ratio (^m/ATuJopt shows hardly any change as expected from equations (2.1) in Part 1 [1]. Both /7hoPt and ^ e c h increase with increasing R^u due to the decrease of frictional loss. Mean while, because the friction coefficient of the runner seal clearance decreases with increasing R^u, the leakage flow increases and r\'s opt slightly decreases. The reason for the discontinuous increase 98
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of ^vopi i t n e region where the /?e'u is smaller is because the flow in the seal clearance changes from the turbulent flow regime to the laminar flow regime. Due to the changes of these three efficiencies, the rjpl increases slowly along with the increase of R^u. On the other hand, the Kopt decreases due to the decrease of friction loss coefficients as R^.u increases. However, the /?e'u range of the model is generally no more than (0.4-1.5) x 107 and the change of Vop{ within that range is quite small. Therefore, the change of tested Reynolds number can be ignored in determining Vopt. This tendency is exactly the same for other turbines. The above results are obtained for a model whose surface roughness of runner vanes, wicket gates and stay vanes (e R = 1.6Ra, eG = 3.2Ra, e s = 4.5Ra) is approximately equal to the admissible roughness of a flat plate under the respective Reynolds number. The value of Kopt in the case where the surfaces of all flow passages are finished perfectly smooth is shown in the figure with a dashed line as a reference. The effect of Reu on Vopt is larger in this case compared with the case shown in solid lines but even so, when the tested Reynolds number changes to 0.5-2 times, Vopl is

0 . 1 0.2 0.98

& 0.96

^- o 0.

94

0.92

0.68

0.64

-Hfc
' smooth - slightly ' rough j Pi J i i i 11 I i i
i i

-Ku-opt

0.60

0.76

0.56

i i

10'

10-

10 1

0.74

Re Fig. 6. Effects of head and water temperature on optimum performance and Vopl. Influence de la charge et de la temperature d'eau sur Ie rendement optimum et sur K0| 99

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in the range of no more than 0.64-0.60. Fig. 4 shows Vopt derived from the calculated performance under the Rcu = 7 x 106 specified in the IEC Draft Code with . It is seen from Figs. 4 and 6 that the change of Fopl with different test Reynolds number is fairly small compared with the scattering of V0jlV 4.2 Effect of size Fig. 7 shows the effect of turbine size on the hydraulic performance and the loss distribution coefficient at the optimum efficiency point: DjD' on the upper abscissa of the figure is the size ratio to the model. The runner diameter is varied 0.2-50 times the reference model which runner diameter is 466 mm. To investigate the effect of only size, wicket gate angle is kept unchanged, net head and surface roughness of flow passages are all identical to that of the model. The calcula tions were made for both cases where the runner seal clearance was proportional to the diameter (a dash-dot line in the figure) and where the seal clearance was constant ( = 0.2 mm, solid line) irrespective of diameter. It is seen from Fig. 7 that the larger the size, the smaller the friction loss due to both the increase of Reynolds number and the decrease of relative roughness, and as a result, ??hopi ar>d 7mechopt D/D'

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xx.

S5>-

0-92

0.78

H 0.76

74

Fig. 7. Effects of sizes on optimum performance and Vm, Influence de la taille sur Ie rendement optimum et sur V,vr 100
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increase and Kopl decreases. The ??hopt and Vopl are not affected by the seal clearance. When the seal clearance is constant (solid line), the larger the size, the more rapidly the ratio of leakage flow to the turbine discharge decreases thus ^ v0| becomes closer to 1.0. On the other hand, when the seal clearance varies proportionally to the runner diameter (a dash-dot line), the larger the size, the more the increase of Reynolds number in seal clearance flow resulting in the decrease of friction coefficient which causes the slight decrease of rjvopt. In both cases, however, rjvopl and 7mechopt change very little at D/D' > 1. Thus the larger the size, the more the increase of rjopl. The A T m o p [ and Kuopl change according to equation (3.35) in Part 1 [1], Prototypes smaller than models are also being manufactured for mini hydro projects and the effect of size at D/D' < 1 is also shown in Fig. 7. When turbines become smaller, r]h opl decreases due to the increase of relative roughness, and under the condition where the seal clearance is constant (0.2 mm), the decrease of rjvopl is more considerable than that of >/hopl, thus the t]opl also decreases drastically with decrease in size. Since the seal clearance is normally considered not to change much irrespective of the size due to the machining tolerance, it is apparent that the conversion of *?vop, is important in scale effects on performance of small turbines. Fig. 8 (T-38) and Fig. 9 (PT-47) show the effect of size directly plotted with D/D' on the abscissa

0. 90 fc_ I i I i i i i I 0.2 0.4 0.7 1

: 2

1I i i i I I 4 7 10

1 20

1_ 40

D/D' Fig. 8. Change in optimum performance of prototypes with various sizes (1). Variation du rendement optimal des prototypes en function de la taille (1). 101

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0.2

0.4

0.7

2 D/D'

10

20

40

Fig. 9. Change in optimum performance of prototypes with various sizes (2). Variation du rendement optimal des prototypes en fonction de la taille (2).

under the normal case where the runner seal clearance varies proportionally to the runner diam eter: the ordinates are performance for a particular size as a ratio to the model's ones (with prime) at optimum efficiency point under constant gate opening. In order to investigate the effect of surface roughness in the flow passages, two cases are displayed: the one is the case where the runner diameter varies under the same roughness as the model (solid line in the figures), and the other where the roughness is 4 times the model (a dash-dot line, approx. similar to that of proto type). When the size becomes larger, not only r\ increases but Ku, Km and Kp (subscript opt is omitted for simplification) also increase as shown in Figs. 8 and 9. It is clear as shown in the upper area of figures that KU/K and Km\K^ are approx. proportional to (rj/ri')l/2 and KjKp to (??//7')3/2 respectively according to equations (3.35) and (3.39) in Part 1. Furthermore, Ku/Km is approx. constant irrespective of size indicating that equation (2.1) in Part 1 is appropriate. From the above, it is clear that the effect of Reynolds number on turbine performances is significantly different dependent on cases where either the head and/or kinematic viscosity of water are varied or the size is varied. It should be emphasized that when the effect of size is discussed, it is necessary to consider the effects of surface roughness and runner seal clearance, and to individually convert t]h, r)v and ^mech as described in Part 1. 102

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5 Conclusions This report has quantitatively clarified the effect of surface roughness of flow passages, runner seal clearance and the Reynolds number on the hydraulic performance and loss distribution coefficient V using the method described in Part 1. The effect of each item on Vopl which is the most vital factor for the scale-effect is summarized as follows: 1. When the surface roughness of flow passages in the model turbine becomes 0.5-2 times, the value of Vm becomes 0.96-1.05 times the original value. 2. Vopf does not vary with the change of runner seal clearance of the model turbine. 3. When the head or the water temperature of the model turbine varies, the admissible roughness also varies due to the Reynolds number, therefore, the decreasing rate of K0| becomes small as a result of the effect of admissible roughness despite the increase of the Reynolds number. 4. When only the size of the model turbine varies, the relative roughness decreases with the increase of the Reynolds number and becomes a value in the smooth region, therefore, the decreasing rate of VopS is greater than that with increasing Reynolds number resulting from the increase of head and water temperature. Acknowledgement The author received much material concerning model turbines from Fuji Electric Co., Ltd. The author expresses his heartfelt thanks to Mr. T. Kubota of Fuji Electric for not only permitting the release of experimental data but for contributing his valuable knowledge on the author's results studied. Experimental data were also provided by Toshiba Corporation and author's appreciation is given to Mr. H. Tanaka of Toshiba for his fine contribution. The author is also grateful to Prof. 5. P. Hutton of University of Southampton for helpful suggestions and a critical reading of the manuscript in English. Finally, the author extends his appreciation to Mr. Y. Usui, an assistant, and many graduate students of Kanagawa University for their efforts in making the numerical calculations and processing the results.

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Notations AR[ a0
RI

D, D' /),,Z)2 e g II A Km
*P

A'u Ns, n

runner inlet area (= 2nrRl bRi) wicket gate opening height of runner vane inlet respective linear dimension of prototype and model runner inlet and outlet diameter surface roughness acceleration of gravity effective head type number {= 7nnQ]nj{gHY'4\ discharge coefficient {= (Q//l R i)/(2g//) l/2 | power coefficient [= />/(e,4RI(2g//)3/2/2}] peripheral speed coefficient (= rR]a}l(2gH)U2\ discharge specific speed (= Q l/2 /// 3/4 ) rotating speed 103

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p Q RcJ
^eu
''KI

V a

V, 1h ^mechi 1v Q

w
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power output discharge from turbine turbine Reynolds number {= Z)|(2,s,'//)1/2/v) reference Reynolds number (= Z)2/v) runner vane inlet radius loss distribution coefficient gate opening ratio (=a0/oopt) runner seal clearances total and hydraulic efficiency mechanical and volumetric efficiency density, or radius ratio to >'Ki (with subscript) angular velocity

Subscripts 0 original value opt optimum operating condition m maximum efficiency point at each gate opening Superscript model

References / Bibliographie 1. IDA, T., Analysis of scale effects on performance characteristics of hydraulic turbines (Part 1: Scale Formulae of Hydraulic Performance and Loss Distribution Coefficients in Model Francis Turbines and Pump-Turbines), Hydraulic Research, Vol. 27, No. 6, (1989), pp. 809-831. 2. Japanese Industrial Standard, JIS B 8103: Methods for Model Tests of Hydraulic Turbines, (1989), (in Japanese). 3. Japanese Industrial Standard, JIS B 8104: Methods for Model Tests of Reversible Pump-turbines, (1989), (in Japanese): This standard was united to JIS B 8103 in publishing. 4. IEC Pub. 193, International Code for Model Acceptance Tests of Hydraulic Turbines, (1965) and Amendment No. 1 (1977). 5. OSTERWALDER, J., Efficiency Scale-up for Hydraulic Turbomachines with due Consideration of Surface Roughness, J. Hydraulic Research, Vol. 16, No. 1, (1978), pp. 55-76. 6. HUTTON, S. P. and FAY, A., Analysis of Efficiency Scale-up for Hydraulic Machines, Water Power, (19746), pp. 205-213. 7. OSTERWALDER, J. and HIPPE, L., Guidelines for Efficiency Scaling Process of Hydraulic Turbomachines with Different Technical Roughness of Flow Passages, J. Hydraulic Research, Vol. 22, No. 4, (1984), pp. 77-102. 8. FUKUDA, H., The Effect of Runner Surface Roughness on the Performance of Francis Turbine, Bulletin of JSME, Vol. 7, No. 26, (1964), pp. 346-356. 9. KUROKAWA, J. et al., Roughness Effects on the Flow along an Enclosed Rotating Disk, Bulletin of JSME, Vol. 21, No. 162, (1978-12), pp. 1725-1732. 10. IEC Draft, Determination of the Prototype Performance from Model Acceptance Tests of Hydraulic Machines with Consideration of Scale Effects, IEC TC4, 4 Central Office 47, (1987-1).

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