1.3.

The Cross Flow runner and inlet theory

DETACH PAGE

1.3. The Cross Flow runner and inlet theory

1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 Summary of the runner theory Development of the absolute now path Blade geometry The inlet curve Runner diameter and inlet width

1. Summary of the runner theory

Fig. 1.6: Velocity triangles and related formulae for a Cross Flow turbine
c1 = g h H = 2u1 w1 cos b1

= 1; a = 16 u3 = u2; u4 = u1; c3 = c2 gH=

a3 = a2; b4 = 180 - b1

h=

(cos a1 -

) b3 = b2 = 90

w2 = w3; w4 = w1 c1 cos a1 = u1 + w1 cos b1 c4 cos a4 = u4 + w4 cos (180 - b4) c4 cos a4 = u1 + w1 cos b1 w12 - u12 = w22 - u22; w2 = tan b1 = 2 tan a1 hmax = cos2a1 } with b1 = 30 R2/R1 = 0,666

w2 = w1 R1/R2 sin b1 tan a2 = w2/u2; u2 = R1/R2 u1;

with b1 = 30 tan a2 = 1,148 w1/u1

w1 = 0,555 c1; u1 = 0,481 c1; tan a2 = 1,3

a2 = 53; c2 = u2 / cosa2 = 0,528 c1

c4 =

a4 = 89; c4 = 0,276 c1

; with u1 =

1.3.2. Development of the absolute flow path Based on the velocity triangles and the related formulae as described in the foregoing sections, the flow path through the runner can be traced However, in this section, the absolute flow path through the first stage of the runner shall be discussed in detail in an explanatory manner, as a basis for further studies During the time needed by a fluid element to travel along the turbine blade from the entrance edge to the exit edge, the runner itself rotates. To locate the exact exit point of an absolute stream line, it is therefore of interest to calculate the angle of rotation of the runner during the passing time of a fluid element through the first stage of the runner. The task at hand is to determine intermediate velocity triangles between the entrance and the exit point of the runner blade The entrance velocity is defined as follows:
c1 a1 u1opt =1 = 16 =

= 0.48063

b1 w1opt

= 30 =

= 0.55498

The outer runner radius shall be denoted as R1, the inner runner radius as R2 and any radius in between as Ri; therefore, the peripheral velocity at the outer runner radius is u1, the peripheral velocity at the inner runner radius is u2 and any peripheral velocity in between is ui. The relative velocity component at any point between the outer and the inner radius can be expressed as: {1.16}

and with the substitution: {1.17}

with: u1 = 0.48063 w1 = 0.55498

} } k = 0.0770

The relative velocity angle b at any point between the outer and the inner runner radius can be expressed as: {1.18}

and with the substitution: {1.19}

with b1 u1

= 30 = 0.48063

} } l = 0.1155

The absolute velocity component in meridional direction at any point between the outer and the inner runner radius is the product of the relative velocity component and the sinus of the relative velocity angle at that point: {1.20}

The mean absolute velocity component in meridional direction between the outer runner radius and the inner runner radius and any other radius in between the two, corresponds to the integral of the absolute velocity component in meridional direction along the two radii: {1.21}

The angle of rotation of the runner during the travel of a fluid element from the outer runner radius to the inner runner radius, or to any radius in between the two, is: {1.22}

where: g [] = the angle of rotation of the runner in degrees. The calculation of the mean absolute velocity component in meridional direction

requires the application of a numerical integration method It is recommended to use the SIMPSON formula below {1.23}. Example: The mean absolute velocity component in meridional direction

is to be calculated along R1 to Ri1, as well as the angle of rotation of the runner gi1, The following values are given:
R1 Ri1 b k l n = 100 [mm] = 88.88 [mm] = u1 = 0.48063 = 0.0770 = 0.1155 =4

Step 1: calculation of a = ui;

Step 2: dividing the interval of u1 to ui into n = 4 sections:

ui1 uy1 uy2 uy3 u1 = uyb = uya = 0.42723 = 0.44058 = 0.45393 = 0.46728 = 0.48063

Step 3: calculating the value y for each value of uy:

y1 with uy1 = 0.44058 y2 y3 yb = cm1

0.30982 = 0.29822 = 0.28747 = 0.27748

Step 4: numerical integration with the SIMPSON rule:

Step 5: calculation of

Step 6: calculation of the angle of rotation gRi1 of the runner:

The SIMPSON formula: {1.23}

where:

a = ui b = u1 n = number of values

ya = cmi yb = cm1

Fig 1.7 shows the absolute now path of a single stream line through the first stage of a Cross Flow runner. The values given, and the velocity triangles shown, correspond to the calculations described in the foregoing section.

Fig. 1.7: Design of the absolute now path in the first stage of a Cross Flow runner
ci wi ui bi cmi gRi

R1 =

1.00000

0.55498

0.48063

30

0.27748

100 [mm] Ri1 = 88.88 [mm] Ri2 = 77.77 [mm] R2 = 66.66 [mm] 0.88269 0.50944 0.42723 39.25 0.32237 0.01596 0.29888 10.24

0.74325

0.46555

0.37382

55.74

0.38479

0.03474

0.32523

18.82

0.53423

0.42400

0.32500

90

0.42400

0.05758

0.35937

25.54

Table of values calculated for the absolute flow path.

1.3.3 Blade geometry In order to be able to design a correct Cross Flow runner, it is indispensable to determine the blade geometry, and in doing this, it is assumed that the following parameters have been chosen based on hydraulic considerations and the desired velocity triangles:
R1 R2 b1 b2 the outer radius of the runner the inner radius of the runner, locus of the end of the skeleton lines of the blades the outer blade angle the inner blade angle

It is further assumed, that the skeleton line of the blade is the segment of a circle, as is normally the case in Cross Flow turbines. Other geometrical parameters of interest are:
rb rp the curvature radius of the blade the pitch circle radius

the segment angle of the blade

To express the geometrical relationship among the parameters R1, R2, b1, b2, and rb, rp and d, a number of additional parameters need to be introduced as shown in fig. 1.9: e, x, f, c, d.

Fig. 1.9: Construction of blade geometry Fig.1.9 also represents the graphical solution to the problem: the angle (b1 + b2), is drawn from the center of the runner, so that one vector intersects the radius R1 and the other vector intersects the radius R2. The connecting line from the intersection point on R1 to the intersection point on R2, represents c. The line c intersects the circle of radius R2 at a distance of 2d from the intersection point on the circle with radius R1. Erecting the mean perpendicular on 2d, we find the line on which the center of the radius of curvature rb of the blade is situated. Drawing a line at an angle of b1 from the intersection point of the circle with radius R1, we find an intersection with the previously erected mean perpendicular which is the center of the radius of curvature rb of the runner blade, at a distance of the pitch circle radius rp from the center of the runner. Tracing the radius of curvature rb up to the intersection with the inner circle of the radius R2, and connecting the found intersection point with the center of radius rb, we establish the angle d. Connecting the intersection point of the circle with rb and the circle with R2 with the center of the runner, we determine the angle f, thereby also establishing other remaining angles as shown. The following formulae are listed in the required order for calculating the parameters d, rb and rp based on the known parameters R1, R2, p1and p2. The graphical construction of the blade geometry may be used to verify the calculated values. {1.24}

{1.25}

{1.26} x = 180 - (b1 + b2 + e) {1.27} f = b1 + b2 - (180 - 2x) {1.28}

{1.29} d = 180 - 2 (b1 + e) {1.30}

{1.31}

Example: Given: R1 = 200 [mm], R2 = 136 [mm], b1 = 30, b2 = 90 to be solved for: d, rb, rp Step 1: calculation of c:

Step 2: calculation of e:

Step 3: calculation of x:

x = 180 - (30 + 90 + 23.72) = 36.28 Step 4: calculation of f: f = 30 + 90 - (180 - 2 36.28) = 12.55 Step 5: calculation of d:

Step 6: calculation of the segment angle d of the blade: d = 180 - 2 (30+23.72) = 72.55 Step 7: calculation of the curvature radius rb of the blade:

Step 8: calculation of the pitch circle radius rp:

1.3.4 The inlet curve The water conveyed to the turbine passes through the penstock with a circular crosssection and then enters the adapter, where the cross section is transformed from circular to the rectangular cross-section of the turbine inlet housing. Before reaching the runner, now has to be transformed once more, in order that ideally each stream line should fulfill the specific entrance conditions to the runner, such as: the correct absolute velocity c0 the correct absolute entrance angle a0

Fig.1.10 shows the different cross-sections of the water flow on its path from the penstock to the runner of the turbine. The turbine inlet serves the purpose of transforming the flow at the end of the rectangular adapter to the optimal now pattern in the admission area of the runner.

Fig. 1.10: Cross-sections of now at the inlet of Cross Flow turbines Fig.1.11 illustrates the desired flow pattern, where all stream lines have the correct velocity and angle of admission at any radius R1 so that the following condition is valid: r cu = constant Assuming this condition is fulfilled, all stream lines will enter the runner at R1 having equal velocity components in peripheral direction cu0. If it is further assumed that the entire pressure energy has already been converted into kinetic energy at the end of the inlet, the absolute velocity c of each stream line approaching R1 corresponds to the free jet velocity c0 proportional to

Fig.1.11: Ideal flow conditions in the inlet If cu and c have constant values along the entrance are on R1 the absolute velocity angle a0 at the entrance to the runner is constant as well. The inlet curve therefore is ideally a line forming a constant angle between the tangent of a point on the inlet curve and its radius vector to the origin of the inlet curve, as shown in fig.1.12.

Fig.1.12: Constant angle of the ideal inlet curve The only curve in which the feature of forming a constant angle between its tangent and the line to its origin is inherent, is the logarithmical spiral. The logarithmical spiral is expressed by the formula: {1.32} rf = ekf k = cot k (k > 0) where
rf e k = the distance of a point on the angle from the origin = the natural logarithm = 2.7183 = cot k = cotangent of the angle between the tangent to the logarithmical spiral and its radius vector to the origin of the spiral = tan a0 (fig.1.13) f = the angle expressed in radians between two points on the spiral and the origin of the spiral

Fig.1.13: Design of the logarithmical inlet spiral Example: The inlet curve of a Cross Flow turbine is to be drawn with the following given parameters:
R1 a0 = 100 [mm], the outer runner radius = 16 [deg], the absolute entrance angle

= 90 [deg], the admission are for which the spiral is to be designed

The radius rf shall be calculated for every step of 5 between f = 0 and f = 90. Step 1: calculation of k: k = 90 - a0 k = tan a0 = 0.287 Step 2: converting f every 5 from 0 to 90 into radians. 360

2p Step 3: calculation of rf:

Step 4: calculation of Rf: R f = rf R 1

360 rfR1

2p f deg. 0 5 10 rad. 0 0.087 0.175 rf 1.000 1.025 1.051 Rf 100.0 102.5 105.1

15 20 25 30 35 40 45

0.262 0.349 0.436 0.524 0.611 0.698

1.078 1.105 1.133 1.162 1.191 1.222 1.253

107.8 110.5 113.3 116.2 119.1 122.2 125.3

50 55 60 65 70 75 80 85 90

0.873 0.960 1.047 1.134 1.222 1.309 1.396 1.484

1.204 1.317 1.350 1.384 1.420 1.455 1.492 1.530 1.569

128.4 131.7 135.0 138.4 142.0 145.5 149.2 153.0 156.9

1.3.5 The runner diameter and inlet width The flow admission area is the product of the inlet width b0 and the length L of the admission arc, as shown in fig. 1.14

{1.33} A = b0 L where the length of the admission arc L is determined by the admission arc L angle f[], and the runner diameter D = 2 R1 {1.34}

The required flow admission area depends on the desired flow through the turbine under specific head conditions, according to equation {1.35}: {1.35} Q = A v where:
Q A v = discharge through the turbine [m/s] = flow admission area [m] = the flow velocity in perpendicular direction to the flow admission area [m/s]

The velocity component perpendicular to the flow admission area is equivalent to the absolute velocity component in meridional direction cm, and there-fore: {1.36} Q = A cm The absolute velocity component in meridional direction cm may also be expressed by the relation: {1.37} cm = c sin a where: a = absolute velocity angle c = absolute velocity

Fig.1.14: Flow admission area of a Cross Flow turbine. If we substitute the absolute velocity component with the corresponding free jet velocity, neglecting any head losses due to friction of flow, c may be expressed as: {1.38}

where: g = gravitational constant H = net head therefore, the discharge through the turbine may be written in different ways, using the above substitutions:

{1.39}

Equation {1.39} contains all relevant parameters influencing the discharge through the turbine, namely:
- b0 - R1 - f the inlet width the radius or diameter D=2R1 of the runner the admission arc angle the square root of the net head

- sin a

the sinus of the absolute velocity angle at the entrance to the runner

Further, it becomes evident, that the inlet width b0 and the runner radius R1 have an equal and linear influence on the discharge capacity of a Cross Flow turbine. Put in other words, a turbine with an inlet width of b0= 300 [mm] and with a runner diameter of D = 400 [mm], would have the same discharge capacity as a turbine with an inlet width b0 = 400 [mm] and diameter of the runner of D = 300 [mm], provided both machines work under the same net head and have an equal absolute velocity angle a, as well as equal admission arc angles f Speed of the two machines on the other hand, would be different, due to equal peripheral velocities but different diameters of the respective runner.