ISLAMIC UNIVERSITY OF TECHNOLOGY

ORGANIZATION OF ISLAMIC COOPERATION (OIC)

MECHANICAL AND CHEMICAL ENGINEERING DEPARTMENT (MCE)
MCE 4362, MECHANICAL TECHNOLOGY LAB, Credit: 0.75, Credit hour: 0-0-1.5

Experiment No: 01
Name of the Experiment: Study and Performance test of a Hydraulic Reaction Turbine.

1. OBJECTIVES

i) To draw overall efficiency (  0 ) vs Flowrate (Q) curve as well as overall

efficiency ( 0 ) vs Head (H) curve.
ii) To draw mechanical efficiency ( m ) vs Flowrate (Q) curve as well as
mechanical efficiency ( 0 ) vs Head (H) curve.

2. APPARATUS
Compact Kaplan Turbine Unit.

3. THEORY
3.1 HYDRAULIC TURBINE

In a hydraulic turbine, water is used as the source of energy. Water or hydraulic turbines
convert kinetic and potential energies of the water into mechanical power. The main types of
hydraulic turbines are:
 Impulse Turbine
 Reaction turbine
The predominant type of impulse machine is the Pelton wheel, which is suitable for a range
of heads of about 150–2,000 m. The reaction turbine is further subdivided into the Francis
type, which is characterized by a radial flow impeller, and the Kaplan or propeller type,
which is an axial-flow machine. Kaplan turbines are suitable for power extraction when
water energy is available at Low Head (2-25m) and High Flowrate (70-800 m3 / s ). Francis
Turbines are the most preferred hydraulic turbines for commercial production of electricity
mainly because they work efficiently under a wide range of operation conditions (Head: 45-
400m, Flowrate: 10-700 m3 / s ).
3.2 “IMPULSE” VS “REACTION TURBINE”

The basic and main difference between impulse and reaction turbine is that there is pressure
change in the fluid as it passes through runner of reaction turbine while in impulse turbine
there is no pressure change in the runner. In the impulse turbine first, all pressure energy of
water is converted into the kinetic energy through a nozzle and a high-speed jet of water is
generated. This water jet strikes the blade of turbine and rotates it. In the reaction turbine
there is pressure change of water when it passes through the rotor of turbine. So, it uses
kinetic energy as well as pressure energy to rotate the turbine. Due to this it is known as
reaction turbine.

Figure 1: Difference between impulse and reaction turbine

3.3 KAPLAN TURBINE

The Kaplan Turbine is an inward flow reaction turbine which means that the working fluid
changes pressure as it moves through the turbine and gives up its energy. Water enters into
and leaves the turbine runner in axial direction (that‟s why it is called axial flow turbine).
Water enters into the turbine through a scroll-shaped casing that wraps around the turbine‟s
inlet guide vanes. Water is directed tangentially through the guide vanes and spirals on to a
propeller shaped runner, causing it to rotate.
The outlet is a specially shaped Draft Tube that helps to decelerate the water and recover
most of the kinetic energy of exiting water. Draft tube also minimizes the possibility of
Cavitation.
Kaplan Turbines are widely used throughout the world for electrical power production. They
cover the lowest head hydro sites and are specially suited for high flow conditions. Large
Kaplan Turbines are individually designed for each site to operate at the highest possible
efficiency, typically over 90%. They are very expensive to design, manufacture and install
but operate efficiently for decades.

Scroll-shaped
Adjustable Casing
angle Inlet
Guide Vanes

Water entering Turbine Runner

the turbine

(a)

Water exiting
the turbine
Draft Tube

(b)
 (c)

Airfoil shaped
runner
balde/vane

(d)
Figure 2: (a) Top view of a Kaplan Turbine
(b) Front view of a Kaplan Turbine
(c) Section view of a Kaplan Turbine
(d) Kaplan Turbine runner

The basic working method of all kinds of turbines (impulse/reaction) are same. Hydraulic
turbines are used to generate electricity with the help of mechanical energy. When a Kaplan
Turbine is used to generate electricity, at first the hydraulic power/water power ( Ph ) is
converted into mechanical power/shaft power ( Pm ). The shaft of the Kaplan Turbine is
coupled to the rotor of the generator hence the mechanical power is transferred to the
generator. The generator then converts this mechanical power into electrical power ( Pe ).

Mechanical/shaft Electrical Power

Hydraulic
power
power/water power
KAPLAN ELECTRICITY
TURBINE GENERATOR

Figure 3: Layout of electricity generation by a Kaplan Turbine

3.3.1 HYDRAULIC POWER/WATER POWER ( Ph )

This is the power of water which is developed due to height (head) of water. But here in the
experiment the water head (H) required for a typical Kaplan Turbine which is within the
range 2-25m, is not possible to achieve due to limitation of height in the laboratory. So, a
pump is used to create this head artificially.

Ph  Q H (Watt) <1>

Where,
Q = Flow Rate ( m3 / s ).
 = Specific weight of water = 9810 N/m3 .
H = Water head at the turbine inlet (m).
In the experimental setup, the “Flow Rate Q” of water can be estimated from the “differential
height reading of the manometric fluid (mercury), h ” by using the following empirical
formula,

Q  2.38 h , (Litre/second) <2>

Where,
h = differential height of the manometric fluid (mercury) in (mm Hg)
The water head H, developed artificially by the pump at the turbine inlet can be calculated
with the help of a differential pressure gage. The pressure gage measures the pressure
difference which is developed across the pump. The gage reading P and water head H are
related by the following expression:
P
H (m) <3>

Where,
P = Pressure difference (Pascal).
 = Specific weight of water = 9810 N/m3 .

3.3.2 MECHANICAL POWER ( Pm )

This power is the result at the turbine shaft that means the rotational power of the shaft. This
output power of the turbine is the mechanical power. Mechanical power is measured by
measuring the torque (T) created in the shaft as well as its rotational speed ( n )
simultaneously. The torque developed (T) at the turbine shaft can be measured by applying
an external torque equivalent to this torque. To apply this external torque a weight (W) is
loaded at a perpendicular distance (r) from the shaft center.


Pm  T  

 (W  r )    <4>
2 n 
 (W  r )  (Watt) 
60 
Where,
n = Rotational speed of the shaft (rpm).
 = Angular speed of Pelton wheel (rad/s).
W = Total applied weight (N).
r = Perpendicular distance from the shaft center to the line of action of added weight.

W
While calculating W, the weight of the load hanger must be encountered along with the
added weights.
3.3.3 ELECTRICAL POWER ( Pe )

The electrical power is produced with the help of the mechanical power produced from the
Kaplan Turbine. The power is:
Pe  VI (Watt) <5>
Where,
V = Output Voltage (volts)
I = Output Current (ampere)

3.3.4 MECHANICAL/TURBINE EFFICIENCY

Power output at the turbine shaft Pm 

m    <6>
Power available to water Ph 

3.3.5 OVERALL EFFICIENCY

Electrical power generated Pe 

o    <7>
Power available to water Ph 
4. DATA TABLE
Perpendicular distance from the turbine‟s shaft center to the line of action of the applied
weight,
r = 13.6 cm = 0.136 m.
Mass of the load hanger = 200 gm = 0.2 kg.

Differential
Pressure Rotational
Total Manometer
Gage Speed of Voltage,
No. of applied Deflection, Current, I
Reading, turbine V
Observation Weight, (amp)
P shaft, n
W (N)
h (cm) (Volts)
2 (rpm)
( kg/cm )

01

02

03

04

05

06

07

08

5. RESULT TABLE

No. of  T H Ph Pm Pe m o
Q (m3 / s)
Observation (rad/sec) (Nm) (m) (W) (W) (W) (%) (%)

01

02

03

04

05

06

07

08
6. CALCULATIONS (add additional papers if needed)
 7. PLOTS
Scale:
Along Horizontal Axis:

Along Vertical Axis:

Mechanical Efficiency,  m (%)

Flowrate, Q (m3 / s) ; Head, H (m)

 Scale:
Along Horizontal Axis:

Along Vertical Axis:

Overall Efficiency,  o (%)

Flowrate, Q (m3 / s) ; Head, H (m)

8. DISCUSSIONS (add additional papers if needed)
The following points must be discussed:
 The plots and the relationship between the plot variables.
 Errors in results (if any) and their possible causes.
9. ASSIGNMENT (add additional papers if needed)
i) Draw a simple 2D figure of Kaplan Turbine Identifying its salient parts.
ii) What will happen if we use Kaplan Turbine for high water head applications?
iii) What is most likely to happen to a Kaplan Turbine without having any Draft Tube if
we use it in commercial Hydropower sites?
iv) Consider two Kaplan Turbines: one has GV (guide vanes) at its inlet and the other
hasn‟t. Do you think there will be any difference between their performances? Explain
your points.
v) How the geometrical features of the runner blade of Kaplan Turbine make it possible
to convert Hydropower/Waterpower into rotational shaft power?
vi) Why is it necessary to twist the runner blade along its length?
vii) What would be the consequences of using a scroll casing designed with a constant
cross sectional area, in the direction of the flow?
viii) Write short note on Cavitation.
ix) What is the basic difference between Kaplan Turbine and Propeller Turbine?
x) Define specific speed of a turbine. What is the significance of it? How do you
categorize Kaplan Turbine based on its specific speed?
xi) Consider 5 Hydro-electric power stations „A‟; „B‟; „C‟; „D‟ and „E‟. „A’ has
been designed to operate with a head of 390m and a discharge rate of 50 whereas
„B‟ has an operational head and discharge rate of 10m and 79 respectively. Plant
„C‟ is a Tidal power plant in a lake in South Korea. Plant „D‟ is operating at the estuary of
a river in France and plant „E‟ is located at the base of one of the tallest mountains in
Switzerland. List the plants which will be most suitable for installing a Kaplan turbine?