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Innovative Design of Francis Turbine for Sediment Laden Water Krishna Prasad Shrestha 1 Bhola Thapa 1, Ole Gunnar Dahlhaug 2 Hari P. Neopane 1 Biraj Singh.

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Presentation on theme: "Innovative Design of Francis Turbine for Sediment Laden Water Krishna Prasad Shrestha 1 Bhola Thapa 1, Ole Gunnar Dahlhaug 2 Hari P. Neopane 1 Biraj Singh."— Presentation transcript:

1 Innovative Design of Francis Turbine for Sediment Laden Water Krishna Prasad Shrestha 1 Bhola Thapa 1, Ole Gunnar Dahlhaug 2 Hari P. Neopane 1 Biraj Singh Thapa 1 1 Dept. Mechanical Engineering, Kathmandu University, P.O. Box 6250, Dhulikhel, Nepal 2 Dept. Energy&Process Engineering, Norwegian University of Science and Technology, NTNU, Trondheim, 7491, Norway 1 International Conference on TIM, 2012, Nepal

2 Outline Introduction Objectives Methodology – Design of Francis runner – Core design process – Fluid Structure Interaction (FSI) Limitations Results and Discussion Conclusions and Recommendation 2 International Conference on TIM, 2012, Nepal

3 Introduction Hydro turbine running in the Himalayas and Andes Mountain of the South America are facing the same challenges of sediment erosion Jhimruk power plant can be considered a severe one in Nepal Renewable Nepal project, KU and Water power Laboratory, NTNU has developing Matlab based software called Khoj Khoj facilitates to produce preliminary design data for Francis turbine with accountability of sediment erosion CFD and FSI analysis has greater roll on improvement of hydraulic machine design and performance analysis 3 International Conference on TIM, 2012, Nepal

4 Runner blade 4 International Conference on TIM, 2012, Nepal Francis turbine Runner blade after one year of operation at Jhimruk Power plant, Nepal Runner assembly of Telva Power Plant Power plant Stay vane, Scroll casing, runner inspection at Telva Power Plant Norway

5 Objectives To analysis the impact of sand erosion on Francis turbine. To identify the possible solution for the minimizing effect of erosion on turbine. To innovate optimization on Francis Turbine design. To design and develop new Francis turbine. 5 International Conference on TIM, 2012, Nepal

6 Design of Francis runner 6 Khoj software generated the data in terms of guide curves, blade curves, hub curve erosion factor, Velocity components, characteristic parameters, turbine dimensions and corresponding domains for the CFD analysis On the basis of data prevailed by the software, turbine blade, hub and shroud data were imported to Pro/Engineer software Hub Shroud 3D Runner Assembly Blade International Conference on TIM, 2012, Nepal

7 Core design process 7 SNParametersValueUnit 1Net design head(H)201.5m 2Net discharge per unit(Q)2.35m 3 /s 3Runner efficiency(  )96% Basic design parameter for JHC SNP1P3P4P5P6P Optimized values for P1-vel R and head-H International Conference on TIM, 2012, Nepal

8 Core design process 8 Optimization Layout in ANSYS workbench International Conference on TIM, 2012, Nepal

9 Core design process 9 Pressure distribution R1 Blade R2 blade Velocity distribution International Conference on TIM, 2012, Nepal

10 Core design process 10 Pressure distribution R3 Blade R4 Blade R5 blade Velocity distribution International Conference on TIM, 2012, Nepal

11 Core design process 11 International Conference on TIM, 2012, Nepal Efficiency, head, Shaft power and Velocity component Vel-R Optimized trade-off charts 1

12 Core design process 12 Optimized trade-off charts 2 Efficiency, Flow, Shaft Power and Velocity component Vel-R International Conference on TIM, 2012, Nepal

13 Core design process 13 FEM analysis Pressure distribution on top cover Pressure distribution on bottom cover International Conference on TIM, 2012, Nepal

14 Core design process 14 FEM analysis FSI Analysis Guide vane Boundary condition location Stress distribution on runner Assembly International Conference on TIM, 2012, Nepal

15 Core design process 15 Deformation on runner (Vone Mess ) Stress distribution on blade assembly (Vone Mess) Stress distribution on single blade International Conference on TIM, 2012, Nepal

16 Limitations Optimization was performed only one set of blade profile. FSI analysis was performed only on Francis turbine runner assembly. During the FSI analysis, Unidirectional Coupling was chosen, considering there was no large deformation on runner. 16 International Conference on TIM, 2012, Nepal

17 Results and Discussion Optimization was performed on CFD that signifies reducing simulation and cost of design Trade-off chart determines the trade-off points which is used to show the relation between variables Pressure distribution and velocity at trailing were observed by using CFD analysis R2 Blade was selected for FSI analysis since it has found uniform pressure distribution as well as relatively lower velocity FEM analysis was performed on guide vane, upper and lower cover Unidirectional coupled FSI analysis prevailed that total deformation of runner assembly was m which is safe for structural steel 17 International Conference on TIM, 2012, Nepal

18 Conclusion and Recommendation Erosion problem on Francis turbine due to sand laden water cannot be stopped completely by current technology but it can be minimized to the acceptable limit. Use of FEM, CFD and FSI tool reduce the design process and simulation time meticulously. New design processes found to be more sophisticated than the traditional way of design for the Francis turbine. Simulated result predicted that the new design method can accommodate sand erosion problem in more sophisticated way. It is recommended that simulation should be done in whole turbine unit and for better prediction two-way simulation is more reliable. 18 International Conference on TIM, 2012, Nepal

19 Recommendation It is recommended that simulation should be done in whole turbine unit and for better prediction two-way simulation is more reliable. Technological challenges and opportunities that recognize due to innovative design of Francis turbine should adopt by the turbine manufacturers. 19

20 Thank you very much for your time and attention!!! Any queries??? 20 International Conference on TIM, 2012, Nepal


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