Types of Hydraulic Machines

LMH Laboratory for Hydraulic Machines

Mechanical Engineering Bachelor: 6th Semester Introduction to Hydraulic Turbomachines

-1- Hydraulic Turbomachines:Different Types and Application Areas

Prof. François [email protected]

Laboratory for Hydraulic MachinesSwiss Federal Institute of Technology Lausanne


2

Content

Pumps and TurbinesHydropower

Turbines: Pelton, Francis, Kaplan, BulbsStorage pumps and Pump-Turbines

Power GenerationPumps for Thermal Power GenerationPumps for Oil & GasDesalinationPumps for Rocket EnginesPower Hydraulic


3

Hydraulic Turbines

Driving Machines

Driving Power defined as positiveP Machine PowerPh Available Hydraulic PowerTurbine Efficiency

DischargeSpecific Energy

ω

ηρ

= ⋅ >

= ×

= × ×

0T

h

h

P TP PP Q E

T

h

PP

η =−

−

⎡ ⎤⋅⎣ ⎦⎡ ⎤⋅⎣ ⎦

…

…

3 1

1

m s

J kg

Q

E


4

Pumps

Work Absorbing Machines

Pump Power defined as negativeP Machine PowerPh Resulting Hydraulic PowerMachine Efficiency

ω

ηρ

= ⋅ <

= ×

= × ×

0P

h

h

P TP PP Q E

P hPP

η =


5

Specific Energy BalanceTurbine

BZ

BZ

II

Hydrodynamics

( )= −

= − −∑I I

TB rB

E gH gH

g Z Z gH


Machine Nomenclature

Hydrodynamics


Runner or Impeller Power Transfer

Traversing Discharge

Transferred SpecificEnergy

Power Transfer

Driving (Turbines)

Being Driven (Pumps)

tQ

⎡ ⎤⋅⎣ ⎦… 3 -1m stQ

⎡ ⎤− = ± ⋅⎣ ⎦… -11 1 J kgt rbgH gH E E

[ ]ρ= …t t tP Q E MW

1

1

> 0P

< 0P

Brillant Extension Project, British Columbia, Canada, Kaplan Turbine CAD Model, PF2 EPFL Test Righttp://www.columbiapower.org/projects/brilliantdam.asp

Energy Conversion

http://www.columbiapower.org/projects/brilliantdam.asp


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Classification of Hydraulic Runners

Specific Energy TransferSubscript 1: High Energy SideSubscript -1: Low Energy Sideρ ρ

ρ ρ

= −

⎡ ⎤⎡ ⎤= + + − + +⎢ ⎥⎢ ⎥⎣ ⎦ ⎣ ⎦

⎡ ⎤⎡ ⎤= − + − + −⎡ ⎤ ⎢ ⎥⎢ ⎥⎣ ⎦

⎣ ⎦ ⎣ ⎦

1 1

221 1 1 1

1 1

221 1 1 1

1 1

Water WheelDisplacement Machine Impulse Turbine

Reaction Machine

2 2

2 2

tE gH gH

p Cp CgZ gZ

p Cp CgZ gZ

: Elevation: Gravity

Zg ρ

: Absolute Pressure: Density

p: Flow VelocityC


ρ ρ⎡ ⎤⎡ ⎤

= − + − + − ±⎡ ⎤⎢ ⎥⎢ ⎥ ⎣ ⎦⎣ ⎦ ⎣ ⎦

Reaction

221 1 1 1

1 1

Water WheelDisplacement Impulse Turbine

2 2t rb

p Cp CE gZ gZ E

Types of Energy ConversionTransfer Modes

Energy Conversion


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3 Types of Water Wheels

Overshot

Undershot

Norse Mill

Energy Conversion


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Seqia, Al Jazzari, XIII Iraq

Water Supply

Noria

Energy Conversion


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The Water Wheel:Medieval Roots of the Industrial-Revolution

Main Medieval Prime Movers8th Century

Labor Saving Potential

Monastic Orders

> 40 Industrial Processes16th Century

Industrial Revolution Precursor

18th CenturyPrime Mover of Cotton Mills

200 kW Max. Power

Georgius Agricola, "De re metallica", 1556

Energy Conversion


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Hydroelectric Power Development

Water Turbine Development

Fourneyron (1830s)Francis Turbine (1840s)Pelton (1880s)Kaplan (1910s )

Trend to High Specific Power

Machines


Largest Hydropower Plants in the World

Hydropower Plant Country Capacity EPFL 3 Gorges China (2009) 18'200 MW

Itaipú Brazil / Paraguay 12'600 MW Guri (Raúl Leoni) Venezuela 10'000 MW

Grand Coulee USA 6'494 MW Sayano – Shushensk Russia 6'400 MW

Krasnoyarsk Russia 6'000 MW Churchill Falls Canada 5'428 MW

La Grande 2 Canada 5'328 MW Bratsk Russia 4'500 MW

Ust-llim Russia 4'320 MW Tucurui Brazil 4'245 MW

Tucurui Dam & Power Plants

http://www.eln.gov.br/

http://www.eln.gov.br/


World ClassExperimental

Infrastructure

Complying IEC 60193 StandardsEfficiency Uncertainty <2 ‰

PF 1 PF 2 PF 3Max Head: 100 mCE 120 mCE 100 mCEMax Discharge: 1.4 m3/s 1.4 m3/s 1.4 m3/sGenerating Power: < 300 kW < 300 kW < 300 kWMax Speed: 1'500 rpm 2'500 rpm 2'500 rpmPumping Power: 900 kW 1000 kW 2 x 400 kW

EPFL Testing Facilities

• Research• Education• Experimental

Validation

Machines


Scale Model

PF2 EPFL Test RigMachines


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Piccard-Pictet ~1850

Niagara Falls

Classification of Hydraulic RunnersFourneyron’s Turbine

Machines


18


Pelton Wheel

Impulse turbineTangential flowHigh head


19

Pelton’s Turbine

Machines


20

Pelton Turbine


21

Cleuson-Dixence

Pelton Turbine, 5 jets

423 MW Unit Max. Power

~28 t Runner Masshttp://www.cleuson-dixence.ch/home.htm

http://www.cleuson-dixence.ch/home.htm


22


Francis Turbine

Reaction machineRadial flowMedium Head


23

Francis Turbine

Voith - 1880

Machines


24

Pump-Turbine


25

Francis Turbine


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Itaipu (Brazil, Paraguay)

18 Francis Turbines

740 MW Unit Max. Power

~ 300 t Runner Masshttp://www.itaipu.gov.br

PF1 EPFL Test Rig

http://www.itaipu.gov.br/index.php?q=en/node/1


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Columbia Basin


28

Columbia Basin


29

Grand Coulée Dam9+9 125 MW Francis Units

3 x 690 MW + 3 x 805 MWhttp://www.usbr.gov/power/data/sites/grandcou/grandcou.html

http://www.usbr.gov/power/data/sites/grandcou/grandcou.html

http://www.usbr.gov/power/data/sites/grandcou/grandcou.html


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3 Gorges Project (Yang Tse River)


31

3 Gorges Project

14 + 12 Francis Turbines

700 MW Unit Max Power

110m Head


32

3 Gorges ProjectSpiral Casing


33

3 Gorges ProjectRunner Unit #3


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3 Gorges ProjectRunner Outlet


35

3 Gorges ProjectDraft Tube Cone


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Kaplan Turbine

Reaction machineAxial flowLow head


37

Kaplan Turbine


38

Bulb Turbine


39

Gezhouba

Kaplan Turbine

176-129 MW Unit Max. Power

~ 420 t Runner Mass


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Yacyretá Power Plant

20 Kaplan Units


9. 5 m Runner Dia.

3200 MW


41

IEC 60193 Validation Tests:e.g. Brilliant Expansion Project

Cavitation TestsPF2 EPFL Test Rig, 2003

120 MW Kaplan


42

La Rance Tidal Power Plant

24 Bulb Units


5.35 m Runner Dia.

540 GWh/year


43

Source of EnergyKey World Energy Statistics 2007

Source of EnergyAfrica America Asia

OceaniaEurope Total

Comb. Fossil 2'001 12'086 14'227 13'356 41'670 90.4%Nuclear 7 712 348 1'039 2'106 4.5%

Hydraulic 55 1'072 542 689 2'358 5.0%Other 2 31 25 24 82 0.1%Total 2'065 13'901 15'142 15'108 46'216

4% 30% 33% 33%

World Resources TWh/y

http://www.iea.org/textbase/nppdf/free/2007/key_stats_2007.pdf


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Electrical Energy

Source of EnergyAfrica America Asia

OceaniaEurope Total

Comb. Fossil 275 2'663 2'457 2'271 7'666 62.9%Nuclear 7 712 348 1'039 2'106 17.5%

Hydraulic 55 1'072 542 689 2'358 19.1%Other 1 28 11 10 50 0.5%Total 338 4'475 3'358 4'009 12'180

3% 37% 28% 33%

World Consumption TWh/y


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Hydroelectric Powerplants

AreaTotal Potential

Used Potential

Stocked Potential

TWh / yNorth America 1'100 61% 39%South America 2'300 19% 81%

Europe 800 65% 35%Africa 1'000 7% 93%

Asia 3'600 20% 80%Australia/Oceania 105 40% 60%

Total 8'905 27% 73%TWh / y 2'438 6'467


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World Hydro in 2003


2006 EnergyConsumption

Balancein Switzerland

“Statistique globalesuisse de l’énergie2006” Office fédéralde l’énergieStatistiques 2006

47

http://www.bfe.admin.ch/php/modules/publikationen/stream.php?extlang=fr&name=fr_206756139.pdf


Swiss Power GenerationStatistique suisse de l'électricité 2006

48

‐

10'000

20'000

30'000

40'000

50'000

60'000

70'000

1970 1975 1980 1985 1990 1995 2000 2005 2010

[GWh]

Run‐off Power Plants

Total Annual Power Generation

Storage Power Plants

Swiss Annual Power Consumption

http://www.bfe.admin.ch/php/modules/publikationen/stream.php?extlang=fr&name=fr_434551765.pdf


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Power Generation in SwitzerlandPompage; 4%

Centrales au fil de l'eau; 26%

Centrales à accumulation;

28%

Centrales thermiques

nucléaires; 38%

Centrales thermiques classiques

Centrales hydrauliques

16%

Centrales thermiques classiques

45%Centrales

thermiques nucléaires

39%


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Swiss Large Dams

Grande DixenceMauvoisin

L’Hongrin


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Types of Swiss Power Stations

Run-of Hydro-Power Plants

Storage Hydro-Power Plants

Pumping Storage Hydro-Power Plants

Nuclear Power Plants

Thermal Power Plants


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Run-Off Hydro Power Plant


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Storage Power Plant


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Annual Water Storage


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Hydraulic Machines: Application AreasPower Generation

Hydro-Power

Turbine, Storage Pumps & Pump-Turbines

Nuclear Power and Thermal Power Station

Reactor Circulation PumpsBoiler Feed PumpsBoosterBoiler Circulation PumpsCooling Water PumpsCondensate Extraction PumpsEmergency Cooling PumpsAuxiliary Pumps


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Steam Generator


57

Power Generation


58

Leibstadt, BWR 990 MW Gösgen, PWR 950 MWhttp://www.kkg.ch/home2/home.cfm

http://www.kkg.ch/home2/home.cfm


59

Pumps for Nuclear Power Plants

Main Circulating Pumps

Reactor Cooling Pumps

Boiler Feed Pumps


60

PWR Nuclear Power Plant


61

Reactor Circulating Pump


62

Boiler Feed Pump


63

Hydraulic Machines AreasOnshore & Offshore Oil and Gas

Water Injection Pumps

Sea Water Lift Pumps

Multiphase Pumps

Pipeline Pumps

Fire Fighting Pumps

Process PumpsDesalination, Water Treatmant

Auxiliary Pumps…


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Deep Sea


65


66


67

Multiphase Pump MPP

Total volume flow up to 4000 m3/h

Differential pressure up to 80 bar

Gas liquid ratio up to 95 %

Power up to 5000 kW

MPP for Total Dunbar

Installation on Dunbar platform

Multiphase Pump MPP


68

Helico-axial multiphase pump

Present status

Up to 15 stages

Up to 6.6 MW


69

Injection Barrel Pumps


70

Injection Barrel Pump GSG

New features

New twist lock cover closure

Opposed impeller design

New radial inlet


71

Reverse Osmosis DesalinationHigh Pressure Feeding System

68 Bars Membrane Pressure

Brine Flow Power Recovery

8-150 10-3 m3/s

>70 % of the Sea Water Flow


72

Ariane V Rocket Engine Propulsion

Vulcain Engine


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Vulcain Rocket Engine


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Ariane V Liquid Propulsion

815 kN

255 kg/s

105 bars

LOX ~ 3 MW @ 13’500 rpm

LH2 ~11 MW @ 34’900 rpm

Vulcain Engine


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LOX Pump


76

LH2 Pump


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LH2 Inducer Cavitation Development


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SARRAF, C., AIT-BOUZIAD, Y., DJERIDI, H., FARHAT, M., DENISET, F., BILLARD, J.Y. (2006). "Effect of cavitation on the structure of the boundary layer in the wake of a partial cavity" CAV2006, Wageningen.AIT BOUZIAD Y., (2005): "Physical modeling of leading edge cavitation: computational methodologies and application to hydraulic machinery", EPFL Doctoral Thesis N° 3353.AIT-BOUZIAD, Y., FARHAT, M., KUENY, JL, AVELLAN, F., MIYAGAWA, K., (2004): "Evaluation of Physical Models for Cavitation Simulation of an Industrial Inducer". Proceedings of the 22nd IAHR Symposium on Hydraulic Machinery and Systems, Stockholm, Sweden, June 29 - July 2, 2004

Industrial Inducer

80%nQ Q = 120%nQ Q =100%nQ Q =

0.20cψ =


Power Hydraulics

DisplacementMachines

79


Gear PumpExternally Toothed

Speed Range

300-3’500 rpm

Displacement volume1.2-250 cm3

Nominal pressure 63-160 bars

Total Efficiency

80-91%


Gear pumpInternally Toothed

Speed Range

500-3’500 rpm

Displacement volume4-250 cm3


Total Efficiency

80-91%


Screw Pump

Speed Range

500-4’000 rpm



Total Efficiency

70-84%


Rotary Vane Pump

Speed Range

960-3’000 rpm



Total Efficiency

80-93%


Axial Piston Pump

Speed Range

750-3’000 rpm



Total Efficiency

80-92%


Radial Piston Pump

Speed Range

960-3’000 rpm



Total Efficiency

90%

Documents

Types of Hydraulic Machines