Stress & Experimental Analysis of Simple and Advanced Pelton Wheel

SU

1. M

2. M

3. M

4. M

GU

Mr

LEC

CKP

C

ST

SIM

UBMITTED

Mr. MITHA

Mr. PATEL

Mr. GAJER

Mr. VALA

UIDED BY

. SAMIP P

CTURER, (

PCET – SU

C. K. PITH

TRESS &

MPLE A

D IN PART

DEGRE

M

AIWALA C

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RA CHINT

KULDIP

P. SHAH

(M.E.D.)

URAT

HAWALLA

THE P

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SU

CHIRAG

L

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PROJECT E

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SURAT

ENTITLED

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OF ENGINE

NGINEER

ED BY

64913

64916

64920

5481

Mr. GAUR

NGINEER

T

NALYSI

TON WH

REQUIREM

EERING IN

RING

RANG C.

LEC

C

RING & TE

IS OF

HEEL

MENT FOR

N

CO-GUID

CHAUDH

CTURER, (M

CKPCET - S

ECHNOL

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DED BY

HARY

M.E.D.)

SURAT

OGY

THE PROJECT ENTITLED

STRESS & EXPPERIMENTTAL ANALLYSIS OF

SIMPPLE AND AADVANCED PELTONN WHEEL

SSUBMITTED IN PARTIALL FULLFILLM

BACHELO

MENT OF TH

OR OF ENG

HE REQUIRE

INEERING I

EMENT FOR

N

THE DEGREEE OF

MECHANICAL ENGINEERINNG

SUBMITTEDD BY

1. MMr. MITHAIWWALA CHIRRAG 649913

2. MMr. PATEL DDHAVAL 649916

3. MMr. GAJERA CHINTAN 649920

4. MMr. VALA KUULDIP 54881

GUIDED BY

Mr.

LEC

CK

C

. SAMIP P

CTURER,

PCET – SU

C. K. PITH

P. SHAH

(M.E.D.)

URAT

HAWALLA

A COLLEG

GE OF EN

SURAT

Mr. GAU

NGINEER

T

CO-GUIDDED BY

URANG CC. CHAUDDHARY

LECTTURER, (MM.E.D.)

CCKPCET - SSURAT

RING & TEECHNOLOGY

CERTIFICATE

This is to certify that the seminar entitled “STRESS & EXPERIMENTAL ANALYSIS

OF SIMPLE AND ADVANCED PELTON WHEEL” submitted by Mr. Mithaiwala

Chirag (64913), Mr. Patel Dhaval (64916), Mr. Gajera Chintan (64920), Mr. Vala

Kuldip (5481) in partial fulfillment for the award of the degree in “BACHELOR OF

ENGINEERING IN MECHANICAL ENGINEERING” of the C.K.Pithawalla college

of Engineering & Technology, Surat is a record of their own work carried out under my

supervision and guidance. The matter embodied in the report has not been submitted

elsewhere for the award of any degree or diploma.

GUIDED BY: CO-GUIDED BY:

Mr. SAMIP P. SHAH Mr.GAURANG C. CHAUDHARI

Lecturer, Lecturer,

(M.E.D.) (M.E.D.)

C.K.P.C.E.T. C.K.P.C.E.T.

Mr.ANISH H. GANDHI

Asst.Professor,

Head of Mechanical Engineering Department

C.K.P.C.E.T.

EXAMINER’S CERTIFICATE OF APPROVAL

This is to certify that the project entitled “STRESS & EXPERIMENTAL ANALYSIS

OF SIMPLE & ADVANCED PELTON WHEEL” submitted by Mr. Mithaiwala

Chirag (64913), Mr Patel Dhaval (64916), Mr. Gajera Chintan (64920), Mr. Vala

Kuldip (5481), in partial fulfillment of the requirement for award of the degree in

“BACHELOR OF ENGINEERING IN MECHANICAL ENGINEERING” of the

C.K.Pithawalla college of Engineering & Technology, Surat is hereby approved for the

award of the degree.

EXAMINERS:

1.

2.

3.

4.

ACKNOWLEDGEMENT

It has been great privilege for me to work under estimated personality respected Mr.

Samip P. Shah Sir highly intelligent, experienced and qualified lecturer in Mechanical

Engg. Dept. C.K.P.C.E.T. Surat. It is my achievement to be guided under him. He is a

constant source of encouragement and momentum that any intricacy becomes simple. I

gained a lot of in valuable guidance and prompt suggestions from him during entire

project work. I will be indebted of him for ever and I take pride to work under him.

We are thankful to Mr. Gaurang C. Chaudhary Sir who has guided us and helped us

during project work.

W are also thankful to Mr.Anish H. Gandhi (H.O.D.) to provide us facility like

laboratory & workshop and being kindly helpful in this project.

Mr. Mithaiwala Chirag

Mr. Patel Dhaval

Mr. Chintan Gajera

Mr. Vala Kuldip

CONTENTS

-ABSTRACT I

-NOMENCLATURES II

-LIST OF FIGURE IV

-LIST OF PLATES VI

-LIST OF GRAPHS VII

1. INTRODUCTION 1-13

1.1 INTRODUCTION TO HYDRO POWER PLANT 1

1.2 GENERAL LAYOUT OF A HYDRO POWER PLANT 2

1.2.1 GROSS HEAD 3

1.2.2 NET HEAD 3

1.3 CLASSIFICATION OF HYDRAULIC TURBINES 4

1.4 PELTON WHEEL TURBINE 5

1.4.1 HISTORY OF PELTON WHEEL 5

1.4.2 THE PELTON TURBINE OPERATING PRINCIPLE 7

1.5 LAYOUT OF PELTON WHEEL 8

1.5.1 NOZZLE AND FLOW REGULATING ARRANGEMENT 9

1.5.2 RUNNER WITH BUCKETS 9

1.5.3. CASING 10

1.5.4. BREAKING JET 11

1.6 EFFICIENCIES OF TURBINE 11

1.6.1 HYDRAULIC EFFICIENCY (ɳh) 11

1.6.2 MECHANICAL EFFICIENCY (ɳm) 12

1.6.3 VOLUMETRIC EFFICIENCY (ɳV) 12

1.6.4 OVERALL EFFICIENCY (ɳO) 12

1.7 COMPARISION BETWEEN SIMPLE & ADVANCE PELTON WHEEL 13

1.7.1 SIMPLE PELTON WHEEL 13

1.7.2 ADVANCE PELTON WHEEL 13

2. LITRATURE REVIEW 14-27

2.1 LITRATURE REVIEW RELATED TO THEORETICAL APPROACH 14

2.2 LITERATURE REVIEW RELATED TO ADVANCE PELTON WHEEL 18

2.3 OBJECTIVE OF PRESENT WORK 27

3. DIMENSIONAL DETAIL OF PELTON WHEEL 28-30

3.1 FORCE CALCULATION 30

4. MODELING OF PELTON WHEEL 31-37

4.1 INTRODUCTION TO PRO/ENGINEER 31

4.2 MODULES IN PRO/ENGINEER 32

4.3 FEATURES OF PRO/ENGINEER 33

4.3.1 PARAMETRIC DESIGN 33

4.3.2 FEATURE-BASED APPROACH 33

4.3.3 PARENTS CHILLED RELATIONSHIP 34

4.3.4 ASSOCIATIVE AND MODEL CENTRIC 34

4.4 GRAPHIC USER INTERFACE OF PRO/ENGINEER 34

4.4.1 MENU BAR 34

4.4.2 TOOLCHESTS 35

4.4.3 NAVIGATION AREA 35

4.4.4 GRAPHIC WINDOWS 35

4.4.5 DASHBOARD 36

4.4.6 INFORMATION AREA 36

4.5 MODELING OF BUCKET 36

5. STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 38-43

5.1 INTRODUCTION 38

5.2 MODELING 38

5.3 TRADITONAL RUNNER 38

5.4 ADVANCED OR HOOPED RUNNER 41

5.5 MECHANICAL CALCULATIONS 41

5.5.1 STRUCTURAL BEHAVIOR 42

5.5.2 STATIC STRESSES RESULTS 43

6. MANUFACTURING OF HOOP PELTON WHEEL 44-48

6.1 BUCKET CASTING PROCESS 44

6.1.1 BENCH MOULDING 44

6.1.2 CASTING PROCESS 44

6.1.3 BUCKET CASTING SPECIFICATION 46

6.1.4 MACHING PROCESS 46

6.2 MANFACTURING OF RUNNER 47

6.3 MANUFACTURING OF HOOP 47

7. PERFORMANCE EVALUATION 49-52

7.1 DATA OF PRACTICAL SET UP 50

7.2 SAMPLE CALCULATION 50

8. RESULT AND DISCUSSION 53-74

9. CONCLUSION 75

10. FUTURE SCOPE 76

APPENDIX - A STRESS ANALYSIS OF SIMPLE AND 77

ADVANCED PELTON WHEEL

APPENDIX – B EXPERIMENTAL DATA & RESULTS OF SIMPLE

PELTON WHEEL

APPENDIX – C EXPERIMENTAL DATA & RESULTS OF ADVANCED

PELTON WHEEL

APPENDIX – D EXPERIMENTAL ANALYSIS OF SIMPLE & ADVANCED

PELTON WHEEL

REFERANCES

ABSTRACT

In this project we have checked newly develop design known as hooped runner or

advanced pelton wheel in which there are two hoops which supports the bucket from back

side and giving it to rest on it. The new design is based on redistribution of the function of

different parts of pelton wheel. In conventional runner the jet of water is directly strike to

splitter of the bucket and transfers the force to it than buckets convert it into momentum

by which the shaft is rotate and giving us power. Whereas in advanced pelton wheel

bucket does not directly transport the force to the runner but transfer the force via these

hoops and these hoops is connected to shaft and by that producing the power so due to

hooped runner bucket act as simply supported beam comparing to simple pelton wheel so

stress developed in hooped pelton is less due to this construction. In this project we want

to achieve some critical data like stress developed and efficiency by which we can choose

that which have batter overall performance. For stress analysis we use ANSYS

workbench v11.0 and for finding the efficiency we made the advanced pelton wheel from

this data and carried out detailed experiment.

The project entitled “STRESS AND EXPERIMENTAL ANALYSIS OF SIMPLE &

ADVANCED PELTON WHEEL” is broadly divided in to ten chapters. The chapter one

discuss about the general layout of hydro electrical power plant and the classification of

hydraulic turbines. The objective of work and necessary literature are reviewed pertaining

to present topic are discussed in chapter two. The dimensional detail of pelton wheel use

in this project is given in chapter three. Use of Pro/Engineer software & its modules are

discussed in chapter four. Chapter five is discussed about stress analysis which we have

done. The manufacturing of bucket is discussed in chapter six. The performance evolution

carried out on pelton wheel is given in chapter seven. In the chapter eight the results

achieved from stress analysis and by the practical are discussed. The conclusion of whole

project is mentioned in chapter nine and the Future scope of present work is given chapter

ten.

I

NOMENCLATURES

d = Inlet pipe diameter (m)

dj = Jet diameter (m)

D = Mean diameter of runner (m)

Fu = Force on runner (N)

g = Gravitational force (m/sec2)

H = Net Head (m)

Hg = Gross Head (m)

Hf = Friction Head (m)

Kv1 = Velocity of co-efficient

m = Jet Ratio

N = Speed (rpm)

Ns = Specific Speed (rpm)

P = Produced Power (kW)

Q = Flow rate of water (m3/sec)

Re = Extreme dia of runner (m)

Ri = Mean radius of runner (m)

v1 = Velocity of flow at inlet

v2 = Velocity of flow at outlet

u = Runner speed (m/sec)

Z = No. of buckets

II

III

Greek Symbols

β1 = Inlet angle of bucket

β2 = Outlet angle of bucket

δ = Half length of bucket

ɳh = Hydraulic Efficiency

ɳm = Mechanical Efficiency

ɳv = Volumetric Efficiency

ɳo = Overall Efficiency

ρ = Density of water (1000 kg/m3)

Ψ = Angle (in general)

LIST OF FIGURE

FIGURE NO.

NAME PAGE NO.

1.1 Hydraulic turbine and electrical generator 2

1.2 General layout of hydraulic power plant 3

1.3.1 Classification according to action of fluid on moving fluid 4

1.3.2 Classification according to direction of flow of fluid in runner

4

1.4.1 Pelton turbine original patent document 7

1.4.2 Bucket geometric definitions 8

1.5.1 Straight flow nozzle 9

1.5.2 Runner of pelton wheel 10

2.1.1 Turbine housing modification in and pelton runner dimensions

14

2.1.2 Coanda effect 15

2.1.3 Casing with cylindrical dome 16

2.1.4 Casing with rectangular dome 16

2.1.5 Effect of the casing on unit discharge, efficiency and

efficiency behavior factor

17

2.1.6 Jet needle tip and nozzle seat ring modifications for jet

quality improvement

17

2.1.7 Jet diameters in the observation area of nozzle 1 measured

from the images at three observation angles

18

2.2.1 Hooped Pelton runner for Beaufort power plant 19

2.2.2 Tangential displacement from FEA on 3D model 20

2.2.3 Buckets fixed on the hoops 21

IV

V

2.2.4 Arrangements of the hoops 21

2.2.5 Hydraulic efficiency of traditional runner and hooped

runner with no adaptation of the hoops.

22

2.2.6 Comparison of efficiency between a traditional runner and

a modified hooped runner

22

2.2.7 Tangential displacement of the hoops at synchronous speed 23

2.2.8 Equivalent stress at synchronous speed 24

2.2.9 Displacement of Traditional Runner of Pelton Wheel 25

2.2.10 Tangential Displacement of the Hoop (Double hoop) 26

2.2.11 Equivalent Stress (Double Hoop) 26

3.1 Construction of pelton runner blade 28

3.2 Bucket used in this project 29

4.1.1 Pro/Engineer in the industry 31

4.2.1 Modules in Pro/ENGINEER foundation 32

4.4.1 Menu bar of pro-engineering 35

4.5.1 Model of bucket created in Pro/Engineer 37

5.3.1 Model of pelton wheel 39

5.3.2 Constrains given to pelton wheel 39

5.3.3 Displacement of Traditional pelton wheel 40

5.3.4 Stress developed in the Traditional pelton wheel 40

5.5.1 Tangential Displacement of the advanced pelton wheel 42

5.5.2 Equivalent Stresses developed in the advanced pelton

wheel

43

6.1 Classification of sand moulding process 44

6.1.2 A metal casting poured in a sand mould 45

LIST OF PLATES

PLATE NO. NAME PAGE NO.

1 Front and back view of Bucket used in this model 46

2 Hooped pelton wheel 47

3 Hooped pelton wheel after balancing 48

4 Test rig used for experiment 49

5 Hooped runner mounted on shaft. 50

VI

LIST OF GRAPHS

GRAPH

NO.

NAME PAGE

NO.

8.1 Max eq. Stress v/s Speed at Q = 0.01 m3/sec (simple pelton

wheel)

53

8.2 Min eq. stress v/s Speed at Q = 0.01 m3/sec (simple pelton

wheel)

54

8.3 Max displacement v/s Speed at Q = 0.01 m3/sec (simple

pelton wheel)

54

8.4 Max eq. stress v/s Speed at Q = 0.00666 m3/sec (simple

pelton wheel)

55


wheel)

55


pelton wheel)

56

8.7 Max eq. stress v/s Speed at Q = 0.005 m3/sec (simple pelton

wheel)

56


wheel)

57


pelton wheel)

57

8.10 Max eq. stress v/s Speed at Q = 0.0033 m3/sec (simple pelton

wheel)

58


wheel)

58

8.12 Max displacement v/s Speed at Q = 0.0033m3/sec (simple

pelton wheel)

59

8.13 Max Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton

wheel)

59

8.14 Min Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton

wheel)

60

VII

VIII

8.15 Max displacement v/s Speed at Q = 0.01 m3/sec (Advance

pelton wheel)

60


wheel)

61


wheel)

61


pelton wheel)

62


wheel)

62


wheel)

63


pelton wheel)

63


wheel)

64


wheel)

64


pelton wheel)

65

8.25 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.01 m3/sec

(Advance pelton wheel)

66

8.26 Unit power (Pu) v/s Unit speed (Nu) at Q = 0.01 m3/sec


67

8.27 Efficiency (η) v/s Unit speed (Nu) at Q = 0.01 m3/sec


67

8.28 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.006 m3/sec


68



68



69

8.31 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.005 m3/sec 69

IX




70

8.33 Efficiency (η) v/s Unit speed (Nu) at Q = 0.005

m3/sec(Advance pelton wheel)

70

8.34 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.0033

m3/sec(Advance pelton wheel)

71



71



72

8.37 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and

20 % opening

72


40 % opening

73


60 % opening

73


80 % opening

74


100 % opening

74

INTRODUCTION

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION TO HYDRO ELECTRIC POWER PLANT [1]

The purpose of a Hydro-electric plant is to produce power from water flowing under

pressure. As such it incorporates a number of water driven prime-movers known as Water

turbines.

The world’s First Hydroelectric Power Plant Began Operation September 30, 1882.When

you look at rushing waterfalls and rivers, you may not immediately think of electricity.

But hydroelectric (water-powered) power plants are responsible for lighting many of our

homes and neighborhoods. On September 30, 1882, the world's first hydroelectric power

plant began operation on the Fox River in Appleton, Wisconsin. The plant, later named

the Appleton Edison Light Company, was initiated by Appleton paper manufacturer H.F.

Rogers, who had been inspired by Thomas Edison's plans for an electricity-producing

station in New York.

In 1933, the U.S. government established the Tennessee valley Authority (TVA), which

introduced hydroelectric power plants to the south’s troubled Tennessee River Valley.

The TVA built dams, managed flood control and soil conservation programs and more. It

greatly boosted the region’s economy. And this development happened in other place as

well. Soon, people across the country were enjoying electricity in homes, schools, and

offices, reading by electric lamp instead of candlelight or kerosene. New electricity-

powered technologies entered American homes, Including electric refrigerators and

stoves, radios, televisions, and can openers. Today, people take electricity for granted, not

able to imagine life without it.

Hydraulic machines are defined as those machines which convert either hydraulic energy

[energy possessed by water] into mechanical energy [which is further converted into

electrical energy] or mechanical energy into hydraulic energy. The hydraulic machines,

which convert the hydraulic energy into mechanical energy, are called turbines.

STRESS & EXPERIMENTL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 1

INTRODUCTION


This mechanical energy is used in running an electric generator which is directly coupled

to the shaft of the turbine. Thus the mechanical energy is converted into the electrical

energy. The electric power which is obtained from the hydraulic energy [energy of water]

is known as Hydro-electric power. At present the generation of hydro-electric power is

the cheapest as compared by the power generated by other sources such oil, coal etc.

Fig 1.1 Hydraulic turbine and electrical generator [1]

1.2 GENERAL LAYOUT OF A HYDRO-ELEC. POWER PLANT [2]

Fig.1.2 shows a general lay-out of a hydro-electric power plant which consists of

(1) A dam constructed across a river to store water.

(2) Pipes of large diameters called penstocks, which carry water under pressure from

the storage reservoir to the turbines. These pipes are made of steel or reinforced

concrete.

(3) Turbines having different types of vanes fitted to the wheels.

(4) Tail race, which is a channel which carries water away from the turbines after the

water has worked on the turbines. The surface of water in the tail race is also

known as tail race.

INTROODUCTION

STRE

1.2.1 GR

The

kno

1.2.2 NET

It is

turb

frict

as lo

sma

frict

ESS & EXPERI

ROSS HEAD

e different b

own as gross

T HEAD [2

s also calle

bine. When

tion betwee

oss due to b

all magnitud

tion betwee

IMENTL ANAL

Fig 1

D [2]

between the

s head. It is

2]

ed effective

water is f

en the water

bend, pipe f

de as compa

en penstocks

H=

Hf

YSIS OF SIMPL

1.2 General

e head race

denoted by

head and

flowing from

r and pensto

fittings, loss

ared to head

s and water

=Hg - Hf

=

PLE AND ADVA

l layout of h

level and ta

y ‘Hg’.

is defined

m head rac

ocks occurs

s at the entr

d loss due t

than net he

ANCED PELTO

hydraulic po

ail race leve

as the head

ce to the tu

s. Though th

rance of pen

to friction. I

eat on turbin

Where, V=

ON WHEEL

ower plant

el when no

d available

urbine, a lo

here are oth

nstock etc.,

If ‘hf’ is th

ne is given b

Where

= velocity o

L=

D=diame

[2]

water is flo

at the inle

oss of head

her losses a

yet they are

he head los

by

e, Hg = gro

of flow in p

= length of

owing is

et of the

d due to

lso such

e having

ss due to

ss head,

enstock,

the pen,

eter of the penstock.

3

INTROODUCTION

STRE

1.3

The

of t

spec

turb

If a

kno

from

ener

flow

ESS & EXPERI

CLASSI

e hydraulic t

the turbine,

cific speed

bine:

F

Fig 1.3.2

at the inlet

own as impu

m inlet to ou

rgy as well

ws through

Tangen

Flow Tur

IMENTL ANAL

IFICATIO

turbines are

direction o

of the turb

Fig 1.3.1 Cla

2 Classifica

of the turbi

ulse turbine

utlet of the

as pressure

the runner,

tial

rbine

Outwar

Radia

Flow Turb

YSIS OF SIMPL

ON OF H

e classified

of flow thro

ines. Thus

assification

ation accord

ine, the ene

. As the wa

turbine. If a

e energy, th

, the water

Imp

Turb

Radial

Flow Turb

rd

l

bine

PLE AND ADVA

YDRAUL

according t

ough the va

the followi

according

ding to dire

ergy availab

ater flows ov

at the inlet o

he turbine is

is under p

Turb

ulse

bine

Hydrau

Turbin

bine

Inward

Radial

Flow Turbi

ANCED PELTO

LIC TUR

to the type o

anes, head

ing are the

to action of

ection of flo

ble is only

ver the vane

of the turbin

s known as

ressure and

bine

Rea

Tur

ulic

ne

ine

Axial

Flow Turbin

ON WHEEL

RBINES [2

of energy a

at the inlet

important c

f fluid on m

ow of fluid i

kinetic ene

es, the pres

ne, the wate

reaction tu

d the pressu

ction

rbine

ne

2]

available at

of the turb

classificatio

moving blad

in the runne

ergy, the tu

sure is atmo

er processes

urbine. As th

ure energy

the inlet

bine and

on of the

des

Mixed

Flow Turbin

er

urbine is

ospheric

s kinetic

he water

goes on

e

4

INTRODUCTION


changing in to kinetic energy. The runner is completely enclosed in and air tight casing

and the runner and casing is completely full of water.

If the water flows along the tangent of the runner, the turbine is known at tangential flow

turbine. If the water flows in the radial direction through runner, the turbine is called

radial flow turbine. If the water flows from outwards to in wards, radially the turbine is

known as inward radial flow turbine, on the other hand, if water flows radially from

inwards to out wards, the turbine is known as outward radial flow turbine if the water

flow through the runner along the direction parallel to axis of the rotation of the runner,

the turbine is called axial flow turbine. If the water flows through the runner in the radial

direction but leaves in the direction parallel to axis of rotation of the runner, the turbine is

called mixed flow turbine.

1.4 PELTON WHEEL TURBINE [1]

The pelton wheel is a tangential flow impulse turbine. The water strikes the bucket along

the tangent of the runner. The energy available at the inlet of the turbine is only kinetic

energy. The pressure at the inlet and outlet of the turbine is atmosphere. This turbine is

used for high head and is named after L.A.PELTON, an American engineer.

1.4.1 HISTORY OF PELTON WHEEL [1]

Lester A. Pelton was an American inventor who successfully developed a highly efficient

water turbine, for a high head, but low flow of water operating in many situations. Most

notable today the hydro-electric power stations. Little is known of his early life. Pelton

embarked on an adventure in search of gold. He came to California from Ohio in 1850, he

was 21 years old. In 1864 after a failed quest for gold he was working in the gold mines

as a millwright, and carpenter at Camptonville, Yuba County, California. It was here that

he made a discovery which won for him a permanent place in the history of water power

engineering. In the mines, Pelton saw water wheels were being used to provide

mechanical power for all things mining, air compressors, pumps, stamp mills and

operating other machines. The energy to drive these wheels was supplied by powerful

jets of water which struck the base of the wheel with flat-faced vanes. These vanes

eventually evolved into hemispherical cups, with the jet striking at the center of the cup

on the wheel. Pelton further observed that one of the water wheels appeared to be

rotating faster than other similar machines. It turned out initially that this was due to the

INTRODUCTION


wheel had come loose, and moved a little on its axle. He noticed the jet was striking the

inside edge of the cups, and exiting the other side of the cup. His quest for improvement

resulted in an innovation. So Pelton reconstructed the wheel, with the cups off center

only to find again that it rotated more rapidly. Pelton also found that using split cups

enhanced the effect. By 1879 he had tested a prototype at the University of California,

which was successful. He was granted his First patent in 1880. By 1890, Pelton turbines

were in operation, developing thousands of horsepower, powering all kinds of equipment.

In 1889 Pelton was granted a patent with the following text. Pelton water turbine or

wheel is a rotor driven by the impulse of a jet of water upon curved buckets fixed to its

periphery; each bucket is divided in half by a splitter edge that divides the water into two

streams. The buckets have a two-curved section which completely reverses the direction

of the water jet striking them.

The first wheel that Pelton put to practical use was to power the sewing machine of his

landlady, Mrs. W. G. Groves in Camptonville. This prototype wheel is on display at a

lodge in Camptonville. He then took his patterns to the Allan Machine Shop and Foundry

in Nevada City (now known as the Miners Foundry). Wheels of various types and sizes

were made and tested. Hydro-electric plants of thousands of horsepower running at

efficiencies of more than 90 per cent were generating electric power by the time of his

death in 1910. The Pelton wheel is acclaimed as the only hydraulic turbine of the impulse

type to use a large head and low flow of water in hydro-electric power stations. Pelton

wheels are still in use today all over the world in hydroelectric power plants. The Pelton

Wheel Company was so successful that it moved to larger facilities in San Francisco, in

1887. Pelton went to San Francisco and worked out an arrangement with A. P. Brayton,

Sr. of Rankin, Brayton and Company, and together they organized the Pelton Water

Wheel Company. Later Pelton sold out, but stayed on as a consulting engineer and later

retired Oakland.

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INTRODUCTION


Fig 1.4.2 Buckets Geometric Definitions [3]

1.5 LAYOUT OF PELTON WHEEL [2]

The Pelton wheel or Pelton turbine is a tangential flow impulse turbine. The water strikes

the bucket along the tangent of the runner. The energy available at the inlet of the turbine

is only kinetic energy. The pressure at the inlet and outlet of the turbine is atmosphere.

This turbine is used for high heads and is named after L.A. Pelton, an American Engineer.

Figure1.2.1 shows the lay-out of a hydro-electric power plant in which the turbine is

Pelton Wheel. The water from the reservoir flows through the penstocks at the outlet of

which a nozzle is fitted. The nozzle increases the kinetic energy of the water flowing

through the penstock. At the outlet of the nozzle, the water comes out in the form of a jet

and strikes the buckets (vanes) of the runner. The main parts of the Pelton turbine are

1. Nozzle and flow regulating arrangement (spear),

INTRODUCTION


2. Runner and buckets,

3. Casing, and

4. Breaking jet.

1.5.1 NOZZLE AND FLOW REGULATING ARRANGEMENT [2, 4]

The amount of water striking the buckets (vanes) of the runner is controlled by providing

a spear in the nozzle as shown in figure1.5.1 the spear is a conical needle which is

operated either by a hand wheel or automatically in an axial direction depending upon the

size of unit. When the spear is pushed forward into the nozzle the amount of water

striking the runner is reduced. On the other hand, if the spear is pushed back, the amount

of water striking the runner increases.

Fig 1.5.1 Straight flow nozzle [4]

1.5.2 RUNNER WITH BUCKETS [2]

Figure 1.5.2 shows the runner of a Pelton wheel. It consists of a circular disc on the

periphery of which a number of bucket evenly spaced are fixed. The shape of a cup is like

INTRODUCTION


a double hemispherical cup or bowl. Each bucket is divided into two symmetrical parts by

a dividing wall which is known as splitter.

Fig 1.5.2 Runner of pelton wheel

The jet of water strikes on the splitter. The splitter divides the jet into two equal parts and

the jet comes out at the outer edge of the bucket. The buckets are shaped in such a way

that the jet gets deflected through 160 or 170. The buckets are made of cast iron, cast steel

bronze or stainless steel depending upon the head at the inlet of the turbine.

1.5.3 CASING [2]

The function of the casing is to prevent the splashing of the water and to discharge water

to tail race. It also acts as a safeguard against accidents. It is made of cast iron or

fabricated steel plates. The casing of the Pelton wheel does not perform any hydraulic

function.

INTRODUCTION


Power delivered to the runnerPower supplied at the inlet

1.5.4. BREAKING JET [2]

When the nozzle is completely closed by moving the spear in the forward direction, the

amount of water striking the runner reduces to zero. But the runner due to inertia goes on

revolving for long time. To stop the runner in a short time, a small nozzle is provided

which directs the jet of water on the back of the vanes. This jet of water is called breaking

jet.

1.6 EFFICIENCIES OF TURBINE [2]

The following are the important Efficiencies of a turbine.

(A) Hydraulic efficiency (ɳh)

(B) Mechanical efficiency(ɳm)

(C) Volumetric efficiency(ɳv)

(D) Overall efficiency (ɳo)

1.6.1 HYDRAULIC EFFICIENCY (ɳH)

It is defined as the ratio of the power given by water to the runner of a turbine (runner is a

rotating part of a turbine and on the runner vanes are fixed) to the power supplied by the

water at the inlet of the turbine. The power at the inlet of the turbine is more and this

power goes decreasing as the water flow over the vanes of the turbine due to hydraulic

losses as the vanes are not smooth. Hence the power delivered to the runner of the turbine

will be less than the power available at the inlet of the turbine. Thus mathematically, the

hydraulic efficiency of the turbine is written as

ɳh = = . .. .

=

kW

Power supplied at inlet of turbine and also called water power

W.P. =

kW

INTRODUCTION


1.6.2 MECHANICAL EFFICIENCY (ɳM)

The power delivered by water to the runner of turbine is transmitted to the shaft of the

available at the shaft of the turbine is less turbine. Due to mechanical losses, the power

than the power delivered to the runner of a turbine. The ratio of the power available at the

shaft of the turbine (known as S.P. or B.P.) the power delivered to the runner is define as

mechanical efficiency. Hence, mathematically, it is written as

ɳm =

=

. .. .

1.6.3 VOLUMETRIC EFFICIENCY (ɳV)

The volume of the water striking the runner of a turbine is slightly less than the volume of

e volume of the water is discharged to the

the water supply to the turbine. Some of th

tailrace without striking the runner of the turbine. Thus the ratio of the volume of the

water actually striking the runner to the volume of water supplied to the turbine is defined

as volumetric efficiency. It is written as

ɳv =

1.6.4 OVERALL EFFICIENCY (ɳO)

It is define as the ratio of power available at the shaft of the turbine to the power supplied

is written as

by the water at the inlet of the turbine. It

ɳo =

. .. .

= = . . .

. . . = ɳm x ɳh

INTRODUCTION


1.7 COMPARISON OF SIMPLE AND AVANCED PELTON WHEEL

1.7.1 SIMPLE PELTON WHEEL

phery.

m.

(3) In the flow analysis resist by bucket’s inner surface.

cover the bucket an also act

ts by bucket surface and also by the slot which consist the bucket.

ple pelton wheel due to simply supported

(1) It is the conventional pelton wheel with the runner having bucket on peri

(2) In this bucket act as cantilever bea

(4) The stresses produce in bucket is high due to the cantilever structure.

(5) Assembly is light due to having single plate as a runner.

1.7.2 ADVANCED PELTON WHEEL

(1) It has a hoop runner made of two plates as a hoop which

as a runner.

(2) In this runner bucket act as a simply supported beam which have its one end hinged.

(3) Flow is resis

(4) In bucket stress is lesser than the sim

structure.

(5) Assembly is heavier due to having two plates as runner.

LITERATURE REVIEW

CHAPTER 2

LITERATURE REVIEW

The subject of stress analysis contains a wide variety of process and phenomena. Even a

brief summary of the vast amount of material that has been published on stress analysis

would be well beyond the scope and intention of this chapter. Our attention is focused on

few key aspect of stress analysis that is considered important and relevant to the pelton

turbine along with advanced Pelton runners.

2.1 LITERATURE REVIEWS RELATED TO THEORETICAL

APPROACH J. Vesely, M. Varner [4] has conducted the upgrading of 62.5 MW pelton turbine.

During that they have investigate that With refurbished runner and nozzles the rated

capacity will be increased up to 68.2 MW from 62.5 MW at net head of 624.8 m The

power of the new runner increases by 9 % and efficiency increases by 1.4%. The power

and efficiency improvement of the mentioned turbine were reached with application of

runner, new design of straight flow nozzle tips, straight nozzles strike enlargement and

modification of turbine housing. The commercial CFD software Fluent was used for the

flow simulations through the other parts of rehabilitated turbine. Finite element stresses

analysis of the runner and some components of straight flow nozzle were used as well.

Fig 2.1.1 Turbine housing modifications and Pelton runner dimensions

STRESS & EXPERIMENTAL ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL 14

LITERATURE REVIEW


They have modified the casing of turbine and also adopt the new design of pelton wheel

which made by some modification in old one. So by this they showed that the casing of

has great affect on the operation of a Pelton turbine and so it is very important to include

the casing as an important factor in all investigations.

Alexandre Perrig [3] says that the Pelton turbines combine 4 types of flows: (I)

confined, steady-state flow in the piping systems and injector, (ii) free water jets, (iii) 3D

unsteady free surface flows in the buckets, and (IV) dispersed 2-phase flows in the casing.

They have conducted the series of practical and derive some important conclusion like the

impact pressure strongly depends on the energy coefficient, i.e. the angle of impact. The

high-pressure pulse is strongly affected by the initial jet/bucket interaction. Its influence

on the bucket torque and power signal should be kept in mind at the stage of performing

mechanical dimensioning of the bucket. The initial jet/bucket interaction evidences the

probable occurrence of compressible effects, generating an outburst of the jet and leading

to erosion damages. When the jet impacts the bucket inner surface, a high-pressure pulse,

which amplitude is larger than the equivalent stagnation pressure, is generated, and

caused by compressible effects. The bucket backside acts as the suction side of a

hydrofoil undergoing the Coanda effect, generating a depression, and in turn a lift force

contributing positively to the bucket and runner torques. The Coanda effect may be

described as the phenomenon by which the proximity of a surface to a jet stream will

cause the jet to attach itself to and follow the surface contour. When such a surface is

placed at an angle to the original jet or nozzle exit, the jet stream will be deflected. Figure

2.1.2 illustrates the Coanda effect between a cylinder and a vertical jet.

Fig 2.1.2 Coanda effect

LITERATURE REVIEW


Heinz-Bernd Matthias, Josef Prost and Christian Rossegger [5] have done experiment

to estimate the influence of the splashed water distribution and Catch of the splash water

in the casing on the turbine efficiency. Further they showed that the casing has great

influence to the operation of a Pelton turbine and so it is very important to include the

casing as an important factor in all investigations. The tests were made on 9 different

casings. Figure 2.1.3 shows one of the casings with cylindrical dome. The radius and the

width of the dome have been varied. Figure 2.1.4 shows an example of a tested casing

with a rectangular dome. Modifications were made on the width of the dome.

Fig 2.1.3 Casing with cylindrical dome

Fig 2.1.4 Casing with rectangular dome

For each casing they determined the characteristic of the turbine. For a constant position

of the needle of the nozzle and a constant head (constant unit discharge Qu) the best

efficiency point and the corresponding unit speed Nu can be located. The best efficiency

LITERATURE REVIEW


and the corresponding unit discharge now can be estimated. The results for all casings are

presented in Fig. 2.1.5. In order to rate the performance of the turbine in partial load and

overload conditions (variation of discharge Q res. unit discharge Q11) we defined an

efficiency behavior factor. This factor is the radius of curvature at the vertex of the

efficiency characteristic. High values of this factor mean high efficiency out of the

optimum.

Fig 2.1.5 Effect of the casing on unit discharge, efficiency and efficiency behavior

factor

T. Staubli and H.P. Hauser [6] have concluded that the quality of a jet of a Pelton

turbine has major impact on the overall efficiency of the turbine.

Fig 2.1.6 Jet needle tip and nozzle seat ring modifications for jet quality improvement

LITERATURE REVIEW


They modify jet needle tip angle and nozzle seat ring to achieve higher efficiency that

modification we can see in fig 2.1.6 above. And also they observed that the jet on the

video sequences showed unsteadiness of the jet’s surface structures, which appear to

develop directly at the nozzle exit. These structures entrain air, whereby precise jet

observation becomes impossible further downstream. However, the jet’s contours can still

be determined and measured on the images. The resulting data clearly show a jet diameter

considerably larger than the theoretical values which we can see in fig 2.1.7 a second

means of determining the jet’s diameter is by measuring the position of the first

appearance of the bucket splitter tip when cutting through the jet. This procedure also

demonstrated that the jet diverges. With nozzle modifications the quality of the jet could

be improved, which showed increased turbine efficiency. At full load a 1.2 percent higher

efficiency was measured after the modifications.

Fig 2.1.7 Jet diameters in the observation area of nozzle 1 measured from the images at

three observation angles

2.2 LITERATURE REVIEW RELATED TO ADVANCE PELTON

WHEEL

Maryse Francois, Pierre and Yves Lowys [7] of ALSTOM power hydro has developed

new design of pelton wheel called hooped pelton turbine which is based on redistribution

of function. Classically, in Pelton runners, the buckets are encased onto a central rim,

LITERATURE REVIEW


either in case of a one piece runner or of mechanically fixed separated buckets. The

attachment zone is then subjected to cycled high bending stresses as the bucket repeatedly

passes into the jets. Furthermore, once the pressure on the bucket has been released, its

cantilever structure gets vibrating according to its natural modes and, if not properly

designed and/or manufactured, a resonance may occur and severely increase the dynamic

stress amplitude.

In the new design, the separated buckets keep their main hydraulic function which is the

transformation of the jet’s kinetic energy into a tangential force, but their structures are

not solicited to also transform this force into torque by involving shear and bending at

their connections with the rim. This latter function is accomplished by two hoops on

which the buckets are mounted, allowing stresses to be more efficiently distributed all

around the runner.

Fig 2.2.1 Hooped Pelton runner for Beaufort power plant

Calculations (Fig 2.2.2) show that the tangential displacement of the hoops is global: its

value on the outer diameter in the non-loaded area is still more than half the maximum

value on the opposite side within the jets influence. Therefore the whole structure

participates in supporting the jets loads.

So far as stresses are concerned, the results must be analyzed in term of maximum stress

range over time at any point of the structure of the hoops, to be then compared to fatigue

limits. The full modeling allows obtaining the evolution of stress vs. time by its spatial

counterpart considering the evolution of the stresses at homologous locations near

successive buckets.

LITERATURE REVIEW


Fig 2.2.2 Tangential displacement from FEA on 3D model

Bernard Michel, Georges Rossi, Pierre Leroy, Pierre and Yves Lowys [8] a new

development in Pelton runner design, the hooped runner, is based on a redistribution of

functions between the buckets and the hoops, and thus allows stresses to be minimized

and distributed more efficiently. This design which combines advantages from the

mechanical point of view as well as from the manufacturing aspect without any special

drawback from the hydraulic point of view confirms the interest of this new solution. This

paper presents in detail the mechanical aspects as well as the results of the hydraulic

comparison between traditional runners and hooped runners. This new design has been

patented by Alstom Power Hydro.

In the old design, the bucket had two functions:

• transformation of the jet’s kinetic energy into a tangential force,

• transmission to the runner rim of the torque generated by this force.

The new design separates the functions:

• the bucket still transforms the kinetic energy into a tangential force,

• the transformation of this force into torque is carried out by hoops on which the buckets

rest.

This uncoupling allows the forces to be borne up by specific components in an improved

way.

LITERATURE REVIEW


Fig 2.2.3 Buckets fixed on the hoops

Due to the geometry of the bucket, the seat of these stresses is in the connection radius

between the rim and the centre edge in the upper part of the bucket thereby generating

traction stresses.

As shown on fig 2.2.4, the two hoops are located on both sides of the jet, close to the

natural position of the reinforcing ribs on traditional pelton runners.

Fig 2.2.4 Arrangements of the hoops

LITERATURE REVIEW


Fig 2.2.5 Hydraulic efficiency of traditional runner and hooped runner with no

adaptation of the hoops.

After the modification at internal and external fillets of slot we have better optimization

which we can see in fig 2.2.6

Fig 2.2.6 Comparison of efficiency between a traditional runner and a modified hooped

runner

LITERATURE REVIEW


Also in the structural behavior Displacements results prove the validity of the concept.

Calculation at synchronous speed shows the participation of the entire hoops to support

the water jet forces. The tangential displacement of the hoops is global and higher in the

area where the jet pressure is applied. Fig 2.2.7 shows this tangential displacement of the

hoops at synchronous speed.

Fig 2.2.7 Tangential displacement of the hoops at synchronous speed

This distribution of the water jets forces on the entire hoops involves a decrease of the

stress level in the runner. The following fig shows the equivalent stress distribution (VON

MISES) at synchronous speed in the structural parts of the runner, it means the hoops.

Maximal stresses are localized in the internal and external radius of the buckets’

openings. The maximal VON MISES stress is equal to 144 MPa.

LITERATURE REVIEW


Fig 2.2.8 Equivalent stress at synchronous speed

The main part of this stress is a static traction stress created by the centrifugal forces

(rotational synchronous speed). It is localized in the internal radius of buckets’ opening,

at the intersection with the buckets’ internal attaches.

Dr.S.A.Channiwala & Mr.Gaurang C. Chaudhari [9] have done the experimental as

well flow analysis on advanced pelton wheel and shows that The stress analysis carried

out on the traditional runner and designed hooped runner shows the stress distribution. At

internal and external radius of buckets, the percentage reduction of VON MISES stresses

is of the order of 1.98 %, using Single hoop while the percentage reduction of VON

MISES stresses is of the order of 14.22 % using Double hoop. Similarly, at the buckets,

the percentage reduction of VON MISES stresses is of the order of 67.19 %, using Single

hoop while the percentage reduction of VON MISES stresses is of the order of 73.57 %

using Double hoop. This means that the use of hoop, allows stresses to be minimized and

distributed more effectively.

The CFD simulation carried out on pelton wheel shows that the velocity of flow is very

high at nozzle outlet and there after decrease. Further, the highest pressure encountered is

3.9E005 Pascal in the middle of the bucket where the impact is the most direct. First there

is a rise in pressure level in the middle of the bucket. Then the pressure level decreases.

LITERATURE REVIEW


The experimental results prove that the power developed and efficiency in traditional

runner as well as hooped runner is nearly same which shows good hydraulic behavior of

the hooped pelton runner. In nutshell, the achievement of new hooped runner design is

based on the redistribution of functions between the buckets and the hoops. This allows

stresses to be minimized and distributed more efficiently. The design is created using

simple interchangeable components, making maintenances easier without affecting

hydraulic performance.

They have done modeling & stress analysis with the help of Ideas-11 and for flow

analysis they have use CFD code CFX-10.0

Fig 2.2.9 Displacement of Traditional Runner of Pelton Wheel

LITERATURE REVIEW


Fig 2.2.10 Tangential Displacement of the Hoop (Double hoop)

Fig 2.2.11 Equivalent Stress (Double Hoop)

Maximum stresses are localized in the internal and external radius of the buckets’

openings. The maximum VON MISES stress is equal to 1.15 N/mm2.Below; Fig.2.2.11

shows the isometric view of equivalent stress of double hoop. In the single hoop the VON

LITERATURE REVIEW


MISES stresses is 37.6 N/mm2.While, VON MISES stresses in double hoop is 1.15 N/

mm2 which are very low as compared to single hoop.

2.3 OBJECTIVE OF PRESENT WORK

Based on literature review following objective is derived

1. To design a pelton wheel from obtained data.

2. Carry out the stress analysis of simple and advanced pelton wheel using ANSYS

workbench v11.

3. To perform the practical on designed pelton wheel and obtain results like efficiency

and characteristic curves.

4. To make the comparative assessment the simple and advanced pelton wheel with

respect of stresses developed and overall efficiency.

DIMENSIONAL DETAIL OF PELTON WHEEL

CHAPTER 3


Fig 3.1 Construction of pelton runner blade [10]




The dimension of bucket is decided by these empirical relations

Length L = 2.3 to 2.8 times d1, where d1 = diameter of jet

Width B = 2.8 to 3.2 times d1

Depth T = 0.6 to 0.9 times d1

Inlet Angle β1 to 8 5

Outlet Angle β2 10 to 20 at centre

The dimension of our bucket which is used in stress analysis and performance evaluation is given below.

The jet diameter is d1 = 23.90 mm

L = 66.94 mm

B =76 mm

T = 20 mm

S = 25.3 mm

δ1 = 5.78 mm

Fig 3.2 Bucket used in this project



2

3-D model of this bucket is given in next chapter named modeling of pelton wheel. The other dimension of pelton wheel like runner diameter is given in 3.1.

3.1 FORCE CALCULATION

Here we shown sample force calculation for one flow rate only, whole data including readings and results at different flow rate & different opening is given in Appendix-A

The jet of water is comes out from nozzle and strikes on splitter of the bucket. The force which transferred by jet to the bucket is calculated below

Flow rate Q = 10x10-3 m3/sec

Runner mean diameter D = 360 mm

Head H = 40 m

Speed N = 680 rpm

V1 = Kv1

= 0.985×√2 9.81 40

= 27.54 m/sec

U1 = = 12.817

15

m3/sec

Vw1 = v1-u1 = 14.773 m/sec

Vw2 = 0.85 × Vw1 = 12.55705 m/sec

Vu2 = u2 – Vw2 cos

= 0.68786 m/sec

So, Force applied by jet on bucket

Fu = ρ × Q × (Vu1-Vu2)

= (Vu1 – Vu2)

= 26.912

Fu = 269 N

MODEELING OF PELTT

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4.3 FEATURES OF PRO/ENGINEER [11]

Pro/ENGINEER is a one-stop store for any manufacturing industry. It offers effective

feature, incorporated for wild variety of purpose. Some of important feature are as

follows.

• Parametric design

• Feature. based approach

• Parent chills relationship

• Associative and model centric

4.3.1 PARAMETRIC DESIGN

Pro/ENGINEER designs are parametric. The term “parametric” means that design

operation that are captured, can be stored as the take place. They can be used

effectively in the future for modeling and editing the design. These types of modeling

helping faster and easier modification of deign.

For example, you can see a concentric a hole drilled for the base feature. If the model

is not parametric, and if there are any design changes (say, in the diameter of the

hole), you will have to edit each hole individually, in addition the based sketch will

vary, there for, a definite number of stapes are required for the change.

If the model is the parametric and related properly, a change in one value,

automatically edits the related values, for example, if the diameter of the hole and

dimensions of the arc are related, a change in the diameter of the hole will

automatically edit the arc radius

4.3.2 FEATURE-BASED APPROACH

Features are the basic building blocks required to create an object. Pro/ENGINEER

modules are based on a series of feature. Each feature builds upon the previous

feature, to create the model (only one single feature can be modified at a time).each

feature may appear simple, individually, but collectively forms a complex part and

assemblies.



The idea behind feature-based modeling is that the designer constructs an object,

composed of individual feature that described the manner in which the geometry

supports the object, if its dimensions change. The first feature is calls the base feature.

4.3.3 PARENTS CHILLED RELATIONSHIP

The parent chilled relationship is a power full way to capture your design intent in a

model. This relationship naturally occurs among feature, during the modeling process,

when you create a new feature, the existing features that are reference, become

parents to the new feature.

Consider the example the hole is drilled at 15mm from the two edges of the

rectangular block. This hole is the chilled feature and the block is the parent. If we

make any changes in block, the hole adjusts itself to maintain the specified relation

with the parent.

4.3.4 ASSOCIATIVE AND MODEL CENTRIC

Pro/ENGINEER drawings are model centric. This means that Pro/ENGINEER

models that are represented in assembly or drawings are associative. If changes are

made in one module these will automatically get updated in the referenced module.

4.4 GRAPHIC USER INTERFACE OF PRO/ENGINEER [11]

The Pro/ENGINEER main window consists of a navigation area, Manu Bar, Tool

chests, Browsers, and Information Areas, you can open multiple windows in

Pro/ENGINEER but only one window will be active at a time.

4.4.1 MENU BAR

The Menu Bare, also known as the pull-down menu, contents commands for all the

actions to be performed. We can customize the menu bar according to our

requirement. When a group of actions is stored inside a particular command; it is

called the Stacked Menu.



Fig 4.4.1 Menu bar of pro-engineering

4.4.2 TOOL CHESTS

The Tool chests are usually located at the top, on the right side of the Main Window.

It contains Toolbars and Buttons for operation. You can customized the contains and

location of the Tool chests, using the customize dialog box.

4.4.3 NAVIGATION AREA

The Navigation Area includes the Model Tree, Layer Tree, Folder Browser, and

Connection.

4.4.4 GRAPHIC WINDOWS

Graphic Windows is the work area, where the models are drawn and modified. The

Graphic Window contains Datum Plane and Coordinate Systems for drawing

reference. We can control the view in the Graphic Window, using the Orientation

Command.



1⁄

4.4.5 DASHBOARD

A Dashboard is a dialog box usually located at the bottom of the screen. It is consists

selective area that guide us through the modeling process as we select the geometry

and set our preferences, it also contains some option.

4.4.6 INFORMATION AREA

The Information contained the message area and a States Bar. The message area

displays a system message that prompts us for required information. The Status Bar

displays the necessary information wherever applicable. The following information is

usually displays

• Warning and errors

• Number of items selected in the current model

• Available selection filters

• Model regeneration status, which indicates that the model must be

regenerated

• Indication that the current processes has been halted

• Screen tips

4.5 MODELING OF BUCKET

In pro/engineering we should start first by revolve operation. By executing revolve

command we get sketches mode. In it we draw an elliptic arc of 180 deg according to

dimension revolve it to 90 deg with respect to is own axis.

After that we create datum plane with reference to on of flat surface 4 th of

hemispherical shape at the distance according to dimension.

Now, that we mirror the hemispherical feature about this plane and joint this two

plane by extruding ,apportion of it plate surface up to this we get a hollow bowl

which acts as a bucket inner face.



Fig 4.5 Model of bucket created in Pro/Engineer

After this we extrude a sketch with reference of this bowl’s upper surface. Portion

like as “T” this’ll make our splits for bucket then create a datum plane with Angular

reference of bowl’s upper surface, and create a shape upper like “W” and extrude it

and by this cut the bowl’s one end and than fillet the bucket’s inner face where

splitter’s and bucket surface is matched this will make smooth curvature for following

of water. Up this our bucket is ready.

STRESS ANALYSIS OF SIMPLE AND ADVANCED PELTON WHEEL

CHAPTER 5

STRESS ANALYSIS OF SIMPLE AND ADVANCED

PELTON WHEEL

5.1 INTRODUCTION

By the use of ANSYS work bench, PRO-E and other computational techniques, we

prepared the model of pelton wheel. In our present work modeling of the pelton wheel in

PRO-Engineer and stress analysis carried out in ANSYS workbench. The stress analyses

of the traditional and hooped runner carried out and compare stress level.

Models of traditional and hooped runner have same number of buckets and tip diameter

which is used in present numerical simulation, models showing in this chapter. This

model is available in our institute’s laboratory.

5.2 MODELING

In a traditional runner the bucket is work as a cantilever beam subjected to the force

generated by the jet. These alternated forces lead to fatigue stresses. Due to the geometry

of the bucket, the seat of these stresses is in the connection radius between the rim and the

centre edge in the upper part of the bucket thereby generating traction stresses.

In a hooped runner the arms are worked as an embedded beam. By this type of design

decrease stress at a most failure zone and the transformation of traction stresses by

compression stresses, as the geometry of the discharge radius is inverted. The hoop is

connected with buckets on a runner where buckets are fitted.

5.3 TRADITIONAL RUNNER

Fig.5.3 shows the 3D–Model of traditional runner. The tangential displacement of the

traditional runner is higher in the area where the jet pressure is applied.




Fig.5.3.1 Model of pelton wheel

Fig.5.3.2 Constrains given to pelton wheel



Fig.5.3.3 Displacement of Traditional pelton wheel

Fig.5.3.3 shows this tangential displacement of traditional runner at synchronous speed.

Fig.5.3.4 Stress developed in the Traditional pelton wheel



Fig.5.3.4 shows that the stress are localized where, the bucket are attached with the

runner. The maximum VON MISES stresses are 17.66 N / mm2.The Maximum stresses

are localized at the point where the jet is striking to the bucket.

5.4 ADVANCE OR HOOPED RUNNER

The design of the hooped runner is intended to achieve easy maintenance, and the

separation of functions facilitates optimization. This runner is composed of two half

hoops and buckets.

The definition of the attachment of the various elements to each other is obtained from

the stresses transmitted to the various components. The attachment of the buckets is

defined based on the centrifugal forces and the jet load. The bucket is modeled as an

Inner beam simply supported, resting on its central section and subjected to a force

generated by a pre- stressed screw on the outer side. The centrifugal forces are completely

taken up by a compound pin (hinge) fixed to the hoops. For the jet force, the Screw load

is multiplied by a lever arm effect so as to exert a contact load of the bucket to the rim

that is much higher than that of the jet. The stresses transmitted to the hoops are

tangential and symmetrical only, the attachment of the hoops to each other is therefore

simply a classical assembly using studs. To sum up, buckets are enclosed between two

hoops.

5.5 MECHANICAL CALCULATIONS

Static analyses as carried out by solid finite element calculation have confirmed that the

above hypotheses are well founded. These calculations were carried out using ANSYS

workbench version 11 software. The calculations hypotheses are based on 18 buckets

with a particularly high rated speed of 680 rpm and different jet. The large scale of the

calculation carried out has allowed all the development constraints to be integrated in a

single model and provides a mechanical model similar to the real runner.

• Conical pin between bucket and hoops at the interior fixation.

• supporting centre area of the bucket on the hoops under the water jet.

• pre-stressing screw between bucket and hoops at the exterior fixation.



5.5.1 STRUCTURAL BEHAVIOR

Displacements and stress results prove the validity of the concept. Calculation at

synchronous speed shows the participation of the entire hoops to support the water jet

forces. The tangential displacement of the hoops is global and higher in the area where

the jet pressure is applied. Fig. 5.1.1 shows this tangential displacement of the hoops at

synchronous speed.

Fig. 5.5.1 Tangential Displacement of the advanced pelton wheel



5.5.2 STATIC STRESSES RESULTS

This distribution of the water jets forces on the entire hoops involves a decrease of the

stress level in the runner. The following figure shows the equivalent stress distribution

(VON MISES) in the structural parts of the runner, it means the hoops.

Fig. 5.5.2 Equivalent Stresses developed in the advanced pelton wheel

Maximum stresses are localized in the internal and external radius of the bucket’s

openings. The maximum VON MISES stress is equal to 10.88 N/mm2.

MANNUFACTURING OOF HOOP PELTT

STR

6.1

Mai

6.1.

1. T

2. T

3. S

In w

A sa

sand

then

the

6.1.

1. P

2. In

3. R

4. F

5. A

6. B

m

ESS & EXPERIM

MAN

BUCKE

in classifica

.1 BENCH

Two box ben

Three box be

Stucked ben

which we us

and casting

d mixture a

n cooled un

mold. Ther

.2 CASTIN

Place a patte

ncorporate a

Remove the

Fill the mold

Allow the m

Break away

bench

moulding

MENTAL ANALYS

NUFACT

T CASTI

ation of cast

Fig 6

MOULDIN

nch mouldin

ench mould

ch mouldin

se two box b

or a sand m

and pouring

ntil the meta

e are six ste

NG PROCE

ern in sand t

a gating sys

pattern.

d cavity with

metal to cool

the sand mo

flo

mou

SIS OF SIMPLE A

C

TURING

ING PRO

ting in fig.6

6.1 Classific

NG

ng.

ding.

ng.

bench moul

molded cast

molten liqu

al has solid

eps in this p

ESS

to create a m

stem.

h molten m

l.

old and rem

oor

ulding

AND ADVANCED

CHAPTE

G OF HO

OCESS

6.1,

cation of san

lding proces

ting is a cast

uid metal in

dified. In th

process,

mold.

metal.

move the cas

sand mouldin

plate

mouldin

D PELTON WHE

ER 6

OOP PEL

nd mouldin

ss for castin

t part produ

nto the cavi

he last stage

sting.

g

ng mo

EEL

LTON WWHEEL

ng process

ng this buck

uced by form

ity in the m

e the casting

pit

oulding

kets.

ming a mold

mould. The m

g is separat

machi

mould

ON WHEEL

44

L

ne

ing

d from a

mould is

ted from

E

MANUFACTURING OF HOOP PELTON WHEEL


There are two main types of sand used for molding. "Green sand" is a mixture of silica

sand, clay, moisture and other additives. The "air set" method uses dry sand bonded to

materials other than clay, using a fast curing adhesive. When these are used, they are

collectively called "air set" sand castings to distinguish these from "green sand" castings.

Two types of molding sand are natural bonded (bank sand) and synthetic (lake sand),

which is generally preferred due to its more consistent composition.

Fig 6.1.2 A metal casting poured in a sand mould

With both methods, the sand mixture is packed around a master "pattern" forming a mold

cavity. If necessary, a temporary plug is placed to form a channel for pouring the fluid to

be cast. Air-set molds often form a two-part mold having a top and bottom, termed Cope

and drag. The sand mixture is tamped down as it is added, and the final mold assembly is

sometimes vibrated to compact the sand and fill any unwanted voids in the mold. Then

the pattern is removed with the channel plug, leaving the mold cavity. The casting liquid

(typically molten metal) is then poured into the mold cavity. After the metal has solidified

and cooled, the casting is separated from the sand mold. There is typically no mold

release agent, and the mold is generally destroyed in the removal process.

The accuracy of the casting is limited by the type of sand and the molding process. Sand

castings made from coarse green sand impart a rough texture on the surface of the casting,

and this makes them easy to identify. Air-set molds can produce castings with much

http://en.wikipedia.org/wiki/Cope_and_drag

http://en.wikipedia.org/wiki/Cope_and_drag



smoother surfaces. Surfaces can also be ground and polished, for example when making a

large bell. After molding, the casting is covered in a residue of oxides, silicates and other

compounds. This residue can be removed by various means, such as grinding, or shot

blasting.

During casting, some of the components of the sand mixture are lost in the thermal

casting process. Green sand can be reused after adjusting its composition to replenish the

lost moisture and additives. The pattern itself can be reused indefinitely to produce new

sand molds. The sand molding process has been used for many centuries to produce

castings manually. Since 1950, partially-automated casting processes have been

developed for production lines.

6.1.3 BUCKET CASTING SPECIFICATION

Material --- Pig iron cast iron (scrap) +silicon

Furnace-----Oil fired furnace Temp----1200 c Capacity—100 kg/lot.

6.1.4 MACHINING PROCESS

Grinding process-------------Amery wheel-Carbon drum 8 inch diameter

Drilling process--------------Speed 360 rpm

Electro plating process---- Chromium

Plate 1 Front and back view of Bucket used in this model

http://en.wikipedia.org/wiki/Bell_(instrument)



6.2 MANUFACTURING OF RUNNER

The centre part of the pelton wheel is runner which is prepared from mild steel. Runner

prepared from circular plate which is turned and faced on lathe. The hole for connecting

the bucket is drilled by vertical drilling machine. To fix the pelton wheel with the shaft of

our setup the boss is necessary which is made by welding, drilling and boring process.

The key way is made by vertical shaper machine. To give the better surface finish and

appearance the runner is coated with zinc.

Plate 2 Hooped pelton wheel

6.3 MANUFACTURING OF HOOP

Hoop is locating at runner and gives the back support to buckets. Hoop was

manufacturing from galvanize iron. In G.I. plate we got the slot with using the chisels by

creating pattern of bucket’s slot. To give the better surface finish hoop is coated with

chromium.



After all this parts assemble doing the balancing cause this wheel rotating higher speed.

This balancing is showing in figure. In balancing, somewhere removing the weight by

drills the holes. And somewhere increase material by nut and washer at runner.

Plate 3 Hooped pelton wheel after balancing

PERRFORMANCE EVVALUATI

We

used

run

rota

capa

imp

ESS & EXPERIM

want to co

d pelton wh

the pelton

ameter, torq

acity of pum

peller diame

MENTAL ANALYS

PER

ompare the e

heel with eig

n wheel. W

que using b

mp which i

eter is 208 m

SIS OF SIMPLE A

C

RFORMA

efficiency o

ghteen buck

We have m

break dyna

is used to ru

mm, input po

Plate 4 Tes

AND ADVANCED

CHAPTE

ANCE E

of simple an

kets as well

measured sp

amometer a

un the turb

ower is 12.5

st rig used f

D PELTON WHE

ER 7

EVALUA

nd advance

as having h

peed using

and pressur

ine having

5kw and sp

for experim

EEL

ATION

pelton whe

hoop on it. S

tachomete

re using pr

size of 85

eed of impe

eel for this w

Single jet is

r, flow rat

ressure gau

mm, head i

eller is 2880

ON

49

we have

s used to

te using

uge. The

is 44 m,

0 rpm.

ment

STRE

PERFORMANCE EVALUATION


Plate 5 Hooped runner mounted on shaft.

7.1 DATA OF PRACTICAL SETUP

Rope diameter = 20 mm = 0.02 m

Diameter of entry Pipe = 50 mm = .05 m

Break drum radius r = 150 mm = 0.15 m

Flow rate Q = 0.01 m3/sec

Pressure in entry pipe Pi = 4 kg/cm2

The reading at a different flow rate & at a different openings have been taken and it is

given in Appendix-A

7.2 SAMPLE CALCULATION

The sample calculation for one reading is given below.

41000 9.81 40

A 4

C/S Area of pipe

50 10A =



0 = 1.9634 1

Inlet velocity Vi = = .

= 5.0932 m/sec

..

= 0.3305

Total head available at inlet

H = .

..

41.3267

= 6.867 N

Input Power =

= 1000 9.81 10 10 41.3267

= 4054.14

Torque produced T = W = 6.867 0.16 1.09872 N m

Power output from the turbine

Po =

Net weight apply to the dynamometer

W = (weight – spring balance reading) 9.81

= (1 – 0.3) 9.81

= 0.7 9.81

. .136.1132

Overall efficiency

= ..

= 3.36 %



/

Unit speed

Nu =

= . / = 184.021

Unit discharge

Qu = /

= .

. /

.00077

Un

= 0 8

it power

Pu = /

= .

. /

.5123

= 0

RESULTS AND DISCUSSION

CHAPTER 8


We have done stress analysis of simple and advanced pelton wheel with the help of

ANSYS Workbench v11 and also done the practical for effect of hoop on efficiency. We

have done analysis at different speed ranging from 100 rpm to 680 rpm and also for

different flow rate ranging from 0.0033 m3/sec to 0.01 m3/sec. also by applying force

from different direction like single, two, four and six nozzle we get wide range of stress

development in pelton wheel and displacement at the tip of bucket. The data of applied

force and used flow rates are given in Appendix-A for simple and advanced pelton wheel

respectively. These results are shown by graph as following.

0

2

4

6

8

10

12

14

16

18

20

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six

Graph 8.1 Max eq. Stress v/s Speed at Q = 0.01 m3/sec (simple pelton wheel)




0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

4.50E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six

Graph 8.2 Min eq. stress v/s Speed at Q = 0.01 m3/sec (simple pelton wheel)

0

2

4

6

8

10

12

14

16

18

100 200 300 400 500 600 680

Dis

plac

emen

t ( m

m)

Speed (rpm)

single two four six

Graph 8.3 Max displacement v/s Speed at Q = 0.01 m3/sec (simple pelton wheel)



0

2

4

6

8

10

12

14

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six

Graph 8.4 Max eq. stress v/s Speed at Q = 0.00666 m3/sec (simple pelton wheel)

0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

4.50E-04

5.00E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six




0

2

4

6

8

10

12

100 200 300 400 500 600 680

Dis

plac

emen

t (m

m)

Speed (rpm)

single two four six

Graph8.6 Max displacement v/s Speed at Q = 0.00666 m3/sec (simple pelton wheel)

0

1

2

3

4

5

6

7

8

9

10

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six




0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

4.50E-04

5.00E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six


0

1

2

3

4

5

6

7

8

9

100 200 300 400 500 600 680

Dis

plac

emen

t ( m

m )

Speed (rpm)

single two four six

Graph 8.9 Max displacement v/s Speed at Q = 0.005 m3/sec (simple pelton wheel)



0

1

2

3

4

5

6

7

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six


0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

4.50E-04

5.00E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six




0

1

2

3

4

5

6

7

100 200 300 400 500 600 680

Dis

plac

emen

t ( m

m )

Speed (rpm)

single two four six

Graph 8.12 Max displacement v/s Speed at Q = 0.0033m3/sec (simple pelton wheel)

0

2

4

6

8

10

12

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six

Graph 8.13 Max Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)



0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six

Graph 8.14 Min Stress v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

100 200 300 400 500 600 680

Dis

p;ac

emen

t ( m

m)

Speed (rpm)

single two four six

Graph 8.15 Max displacement v/s Speed at Q = 0.01 m3/sec (Advance pelton wheel)



0

1

2

3

4

5

6

7

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six


0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six




0

0.2

0.4

0.6

0.8

1

1.2

100 200 300 400 500 600 680

Dis

plac

emen

t (m

m)

Speed (rpm)

single two four six


0

1

2

3

4

5

6

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six




0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six


0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

100 200 300 400 500 600 680

Dis

plac

emen

t ( m

m )

Speed (rpm)

single two four six




0

0.5

1

1.5

2

2.5

3

3.5

100 200 300 400 500 600 680

Eq.

Str

ess M

ax (M

Pa)

Speed (rpm)

single two four six


0.00E+00

5.00E-05

1.00E-04

1.50E-04

2.00E-04

2.50E-04

3.00E-04

3.50E-04

4.00E-04

100 200 300 400 500 600 680

Eq.

Str

ess M

in (M

Pa)

Speed (rpm)

single two four six




0

0.1

0.2

0.3

0.4

0.5

0.6

100 200 300 400 500 600 680

Dis

plac

emen

t ( m

m )

Speed (rpm)

single two four six


The graph 8.1 to graph 8.24 shown above is mainly three types

(1)Max eq. stress v/s Speed at different flow rates

(2)Min eq. stress v/s Speed at different flow rates

(3)Max displacement v/s Speed at different flow rates

In that we can see that max eq. stress developed in advanced pelton wheel is less than the

simple advanced wheel and also the difference is high. Although the difference between

min eq. stress are less. And the difference between max displacements is also high.

Now the following graph shown is known as characteristics curves (or known as constant

head curves) which are mainly three types

(1) Qu (unit discharge) v/s Nu (unit speed)

(2) Pu (unit power) v/s Nu (unit speed)

(3) η (efficiency) v/s Nu (unit speed)



We have done experimental analysis on both the type of pelton wheel first simple and

then advanced pelton wheel. The data of experiment viz. readings and results for simple

and advanced pelton wheel are given in Appendix-B and Appendix-C respectively. The

comparison between important parameters like speed, torque, output power and efficiency

of simple and advance pelton wheel is given in Appendix-D.

The graphs shown below (graph 8.25 to 8.36) are for advanced pelton wheel.

After that graph 8.37 to 8.41 shows comparison of efficiency of the simple and advanced

pelton wheel at different opening for same flow rate. The graphs shows that the efficiency

of the advanced pelton wheel is less than the simple pelton wheel because of hoop

attached on it.

1.50E-03

1.55E-03

1.60E-03

1.65E-03

1.70E-03

1.75E-03

1.80E-03

1.85E-03

1.90E-03

150 160 170 180 190 200 210

Qu

Nu

20% 40% 60% 80% 100%

Graph 8.25 Unit discharge (Qu) v/s Unit speed (Nu) at Q = 0.01 m3/sec




0

1

2

3

4

5

6

150 160 170 180 190 200 210

Pu

Nu

20% 40% 60% 80% 100%

Graph 8.26 Unit power (Pu) v/s Unit speed (Nu) at Q = 0.01 m3/sec


0

5

10

15

20

25

30

35

150 160 170 180 190 200 210

η(%

)

Nu

20% 40% 60% 80% 100%

Graph 8.27 Efficiency (η) v/s Unit speed (Nu) at Q = 0.01 m3/sec




1.10E-03

1.15E-03

1.20E-03

1.25E-03

1.30E-03

1.35E-03

1.40E-03

1.45E-03

1.50E-03

1.55E-03

1.60E-03

110 120 130 140 150 160 170 180 190 200 210 220

Qu

Nu

20% 40% 60% 80% 100%



0

1

2

3

4

5

6

7

8

9

100 120 140 160 180 200 220

Pu

Nu

20% 40% 60% 80% 100%






0

5

10

15

20

25

30

35

40

45

50

100 120 140 160 180 200 220

η

Nu

20% 40% 60% 80% 100%


8.00E-04

8.50E-04

9.00E-04

9.50E-04

1.00E-03

1.05E-03

1.10E-03

1.15E-03

1.20E-03

110 130 150 170 190 210

Qu

Nu

20% 40% 60% 80% 100%






0

1

2

3

4

5

6

7

8

110 120 130 140 150 160 170 180 190 200 210

Pu

Nu

20% 40% 60% 80% 100%


0

10

20

30

40

50

60

70

110 120 130 140 150 160 170 180 190 200 210

η

Nu

20% 40% 60% 80% 100%





5.30E-04

5.40E-04

5.50E-04

5.60E-04

5.70E-04

5.80E-04

5.90E-04

6.00E-04

6.10E-04

165 170 175 180 185 190 195 200 205

Qu

Nu

20% 40% 60% 80% 100%



0

1

2

3

4

5

6

165 170 175 180 185 190 195 200 205

Pu

Nu

20% 40% 60% 80% 100%





0

10

20

30

40

50

60

70

80

90

100

165 170 175 180 185 190 195 200 205

η

Nu

20% 40% 60% 80% 100%



0

5

10

15

20

25

30

35

40

45

110 120 130 140 150 160 170 180 190 200 210 220 230 240

η

Nu

20 simple 20 advanced

Graph 8.37 Efficiency (η) v/s Unit speed (Nu) at Q = 0.0066 m3/sec and 20 % opening



0

10

20

30

40

50

60

120 130 140 150 160 170 180 190 200 210 220 230 240 250

η

Nu

40 simple 40 advance


0

5

10

15

20

25

30

35

40

45

50

120 130 140 150 160 170 180 190 200 210 220 230 240

η

Nu





0

5

10

15

20

25

30

35

40

45

100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250 260

η

Nu



0

10

20

30

40

50

60

130 140 150 160 170 180 190 200 210 220 230 240 250 260 270

η

Nu



CONCLUSIONS

CHAPTER 9

CONCLUSIONS

The development of hooped runner and subsequent numerical and experimental

investigation carried out on Pelton wheel during the course of this work leads to the

following conclusions.

1. The stress analysis is carried out on simple and advanced pelton wheel which shows

significant results clearly mentioned that stress developed in hooped runner is less

than simple pelton wheel. At the flow rate of 0.01 m3/sec the VON MISES stresses

developed in simple pelton wheel is 16.92 MPa whereas at same flow rate VON

MISES stress developed in hooped runner is 9.55 MPa which shows that reduction in

stress development is 43.35%.This means that the use of hoop, allows stresses to be

minimized and distributed more effectively.

2. The experiment carried out on advanced pelton wheel which gives characteristic

curves which shows that the influence of hoop on overall efficiency of pelton turbine

is very less.


FUTURE SCOPE

CHAPTER 10

FUTURE SCOPE

The analysis carried out in this project is just one step towards optimization. There is

large scope of work in this subject.

• Hoop optimization can be done by parametric study of hoop in which by varying

the thickness of hoop it can be achieved.

• The fatigue analysis of pelton wheel can be done.

• By conducting experiment Life cycle prediction of pelton wheel is also possible.


REFERENCES

[1] http://en.wikipedia.org/wiki/Pelton_wheel.

[2] Dr. R.K.Bansal, “Fluid Mechanics and Hydraulic Machine”, Published By Laxmi

Publication(p) Ltd.Eighth edition 2002.

[3] Alexandre Perrig, “Hydrodynamics of the free surface flow in pelton turbine

buckets”, Lausanne, Epfl,2007.

[4] J. Vesely and M. Varner, “A Case Study of Upgrading of 62.5MW Pelton

Turbine”, CKD Blansko Strojírny a.s., Czech Republic.

[5] Heinz-Bernd Matthias, Josef Prost and Christian Rossegger, “Investigation of the

Flow in Pelton Turbines and the Influence of the Casing”, Austria, 11 April 1997.

[6] T. Staubli and H.P. Hauser, “Flow visualization - a diagnosis tool for pelton

turbines”, Switzerland , 2004.

[7] Mayse Francois, Pierre Yves Lowys and Gerard Vuillerod, “Developments and

Recent Projects for Hooped Pelton Turbine”. ALSTOM Power, Turkey, 4-7

November 2002.

[8] Bernard Michel, Georges Rossi, Pierre Leroy and Pierre Yves Lowys, “Hooped

Pelton Runner”, ALSTOM Power.

[9] Dr.S.A.Channiwala and Mr.Gaurang C. Chaudhari, “Analysis, design and flow

simulation of advanced pelton wheel”, SVNIT, Surat, June 2008

[10] Dr. Jagdish Lal, “Hydraulic Machines”, published by Metropolitan Book Co.

Privet Ltd. Sixth Edition 1975. Chapter-4, 5, 9.

[11] CADD Center, “Introduction to Pro/Engineer”

[12] Etienne Parkinson, “Developments in numerical flow simulation applied to

Pelton turbines”, VA Tech Hydro Ltd., Switzerland, Summer 2003.

[13] Hydroplan UK and Gilbert Gilkes & Gordon Ltd., “Low Cost Pelton Turbine

Design and Testing”, 2003.

[14] John S. Anagnostopoulos and Dimitrios E. Papantonis, “Flow Modeling and

Runner Design Optimization in Turgo Water Turbines”, Proceedings of World

Academy of Science, Engineering and Technology, volume 22, July 2007.

[15] Yodchai Tiaple and Udomkiat Nontakaew, “The Development of Bulb Turbine

for Low Head Storage Using CFD Simulation”, Thailand

[16] Reiner Mack, “Comet supports the design of Pelton turbines”, Voith Siemens

Hydro Power Generation GmbH & Co., KG, Heidenheim Germany

APPENDIX – A

Stress Analysis of Simple and Advanced Pelton Wheel

Q = 0.01 m3/sec

SR

NO.

Speed

(rpm) Force

(N)

Stress

% reduction in stress

Deformation

% reduction in deformation

(Simple) (Advanced) (Simple) (Advanced)

Max

(MPa)

Min

(MPa)10-06

Max

(MPa)

Min

(MPa)10-06

Max

(mm)

Max

(mm)

Single nozzle

1 100 269 16.92 6.38 9.5538 6.29 43.53 15.36 1.5132 90.14

2 200 269 16.97 3.05 9.556 2.57 43.68 15.42 1.5164 90.16

3 300 269 17.05 8.08 9.56 2.79 43.92 15.51 1.5216 90.18

4 400 269 17.17 1.53 9.566 5.30 44.28 15.65 1.529 90.23

5 500 269 17.31 2.33 9.574 8.81 44.69 15.82 1.5385 90.27

6 600 269 17.5 3.32 9.583 1.60 45.24 16.03 1.5503 90.32

7 680 269 17.66 4.25 9.59 2.33 45.69 16.23 1.5614 90.37

Two nozzle

8 100 134.56 8.66 6.36 4.779 5.05 44.81 7.75 0.757 90.23

9 200 134.56 8.71 3.05 4.782 1.15 45.09 7.91 0.76 90.39

10 300 134.56 8.8 8.08 4.786 2.62 45.61 7.91 0.765 90.32

11 400 134.56 8.91 1.53 4.792 6.85 46.21 8.04 0.773 90.38

12 500 134.56 9.06 2.33 4.799 1.33 47.03 8.22 0.782 90.48

13 600 134.56 9.24 3.32 4.809 2.13 47.95 8.43 0.795 90.56

14 680 134.56 9.4 4.25 4.818 2.88 48.74 8.63 0.806 90.66

Four nozzle

15 100 67.28 4.37 6.34 2.389 7.17 45.33 3.98 0.378 90.50

16 200 67.28 4.428 3.05 2.392 1.22 45.98 4.04 0.382 90.54

17 300 67.28 4.51 8.08 2.397 4.47 46.85 4.13 0.387 90.62

18 400 67.28 4.62 1.53 2.403 9.55 47.98 4.27 0.395 90.74

19 500 67.28 4.77 2.33 2.411 1.61 49.45 4.44 0.405 90.87

20 600 67.28 4.95 3.32 2.421 2.42 51.09 4.67 0.418 91.04

21 680 67.28 5.12 4.25 2.431 3.17 52.51 4.87 0.442 90.92

Six nozzle

22 100 44.86 2.91 6.33 1.593 6.30 45.25 2.71 0.252 90.70

23 200 44.86 2.96 3.05 1.596 1.90 46.08 2.77 0.255 90.79

24 300 44.86 3.046 8.08 1.6 5.43 47.47 2.87 0.261 90.90

25 400 44.86 3.16 1.53 1.606 1.05 49.17 3 0.269 91.03

26 500 44.86 3.41 2.33 1.615 1.71 52.63 3.18 0.279 91.22

27 600 44.86 3.75 3.32 1.626 2.52 56.64 3.41 0.341 90

28 680 44.86 4.07 4.25 1.636 3.27 59.80 3.62 0.44 87.84

Q = 0.0066 m3/sec

SR

NO.

Speed

(rpm)

Force

(N)

Stress

% reduction

in stress

Deformation

% reduction in deformation


Max

(MPa)

Min

(MPa)10-06

Max

(MPa)

Min

(MPa) 10-06

Max

(mm)

Max

(mm)

Single nozzle

1 100 179.23 10.729 6.52 6.188 5.86 42.32 10.222 0.98 90.41

2 200 179.23 10.78 3.14 6.191 8.85 42.56 10.279 0.983 90.43

3 300 179.23 10.863 8.25 6.195 3.16 42.97 10.374 0.988 90.47

4 400 179.23 10.981 1.40 6.2 5.64 43.53 10.508 0.996 90.52

5 500 179.23 11.13 1.76 6.209 1.17 44.21 10.681 1.005 90.59

6 600 179.23 11.32 2.46 6.218 1.96 45.07 10.894 1.017 90.66

7 680 179.23 11.48 3.21 6.22 2.71 45.81 11.093 1.029 90.72

Two nozzle

8 100 89.61 5.499 6.50 3.182 7.89 42.13 5.178 0.504 90.26

9 200 89.61 5.549 3.14 3.185 1.39 42.60 5.235 0.508 90.29

10 300 89.61 5.633 8.25 3.19 3.62 43.36 5.331 0.513 90.37

11 400 89.61 5.75 1.40 3.196 8.60 44.41 5.466 0.52 90.48

12 500 89.61 5.902 1.76 3.204 1.52 45.71 5.642 0.53 90.60

13 600 89.61 6.087 2.46 3.214 2.32 47.19 5.858 0.542 90.74

14 680 89.61 6.26 3.21 3.223 3.07 48.51 6.06 0.554 90.85

Four nozzle

15 100 44.86 2.772 6.49 1.594 6.30 42.49 2.699 0.2526 90.64

16 200 44.86 2.822 3.14 1.596 1.90 43.44 2.757 0.256 90.71

17 300 44.86 2.907 8.25 1.6 5.43 44.96 2.853 0.261 90.85

18 400 44.86 3.024 1.40 1.607 1.05 46.85 2.989 0.269 91.00

19 500 44.86 3.215 1.76 1.615 1.71 49.76 3.168 0.279 91.19

20 600 44.86 3.535 2.46 1.625 2.52 54.03 3.388 0.342 89.90

21 680 44.86 3.838 3.21 1.636 3.27 57.37 3.597 0.44 87.76

Six nozzle

22 100 29.87 2.018 6.49 1.0612 4.47 47.41 1.853 0.168 90.93

23 200 29.87 2.116 3.14 1.063 2.54 49.76 1.91 0.172 90.94

24 300 29.87 2.28 8.25 1.068 6.11 53.15 2.007 0.177 91.18

25 400 29.87 2.509 1.56 1.075 1.12 57.15 2.145 0.185 91.37

26 500 29.87 2.805 2.50 1.0833 1.78 61.37 2.325 0.236 89.84

27 600 29.87 3.167 3.66 1.095 2.59 65.42 2.549 0.342 86.58

28 680 29.87 3.505 4.73 1.106 3.34 68.44 2.761 0.442 83.99

Q = 0.005 m3/sec

SR

NO.

Speed

(rpm)

Force

(N)

Stress

% reduction

in stress

Deformation

% reduction

in deformation


Max

(MPa)

Min

(MPa)10-06

Max

(MPa)

Min

(MPa)10-06

Max

(mm)

Max

(mm)

Single nozzle

1 100 134.56 8.054 6.51 4.779 5.05 40.66 7.668 0.757 90.12

2 200 134.56 8.104 3.14 4.782 1.15 40.99 7.726 0.76 90.16

3 300 134.56 8.187 8.25 4.786 2.62 41.54 7.821 0.766 90.20

4 400 134.56 8.305 1.40 4.792 6.85 42.29 7.956 0.773 90.28

5 500 134.56 8.457 1.76 4.799 1.33 43.25 8.13 0.782 90.38

6 600 134.56 8.641 2.46 4.809 2.13 44.34 8.343 0.795 90.47

7 680 134.56 8.813 3.21 4.818 2.88 45.33 8.544 0.806 90.56

Two nozzle

8 100 67.28 4.139 6.49 2.425 7.25 41.41 3.903 0.384 90.16

9 200 67.28 4.188 3.14 2.427 1.21 42.04 3.959 0.387 90.22

10 300 67.28 4.273 8.25 2.432 4.43 43.08 4.056 0.393 90.31

11 400 67.28 4.389 1.40 2.438 9.50 44.45 4.191 0.4 90.45

12 500 67.28 4.541 1.76 2.446 1.61 46.13 4.368 0.423 90.31

13 600 67.28 4.739 2.46 2.457 2.42 48.15 4.586 0.441 90.38

14 680 67.28 5.044 3.21 2.466 3.17 51.11 4.791 0.441 90.79

Four nozzle

15 100 33.64 2.088 6.49 1.195 6.04 42.76 2.057 0.19 90.76

16 200 33.64 2.139 3.14 1.198 2.37 43.99 2.114 0.193 90.87

17 300 33.64 2.223 8.25 1.202 5.94 45.92 2.211 0.198 91.04

18 400 33.64 2.355 1.40 1.208 1.10 48.70 2.349 0.206 91.23

19 500 33.64 2.617 1.76 1.217 1.76 53.49 2.529 0.236 90.66

20 600 33.64 2.937 2.46 1.228 2.57 58.18 2.753 0.341 87.61

21 680 33.64 3.236 3.21 1.239 3.32 61.71 2.964 0.441 85.12

Six nozzle

22 100 22.41 1.556 6.48 0.7963 7.18 48.82 1.426 0.126 91.16

23 200 22.41 1.654 3.14 0.7988 2.70 51.70 1.484 0.13 91.23

24 300 22.41 1.817 8.25 0.8033 6.45 55.78 1.581 0.135 91.46

25 400 22.41 2.047 1.56 0.8099 1.16 60.43 1.72 0.149 91.33

26 500 22.41 2.343 2.50 0.819 1.82 65.04 1.902 0.236 87.59

27 600 22.41 2.706 3.66 0.831 2.62 69.29 2.129 0.343 83.88

28 680 22.41 3.044 4.73 0.843 3.37 72.30 2.344 0.443 81.10

Q = 0.0033 m3/sec

SR NO.

Speed (rpm)

Force (N)

Stress

% reduction

in stress

Deformation

% reduction

in deformation


Max

(MPa)

Min

(MPa) 10-06

Max

(MPa)

Min

(MPa) 10-06

Max

(mm)

Max

(mm)

Single nozzle

1 100 89.61 5.362 6.50 3.183 7.89 40.63 5.1 0.504 90.11

2 200 89.61 5.412 3.14 3.185 1.39 41.14 5.157 0.508 90.14

3 300 89.61 5.495 8.25 3.19 3.62 41.94 5.253 0.513 90.23

4 400 89.61 5.613 1.40 3.196 8.50 43.06 5.387 0.52 90.34

5 500 89.61 5.764 1.76 3.204 1.52 44.41 5.563 0.53 90.47

6 600 89.61 5.949 2.46 3.214 2.32 45.97 5.778 0.543 90.60

7 680 89.61 6.122 3.21 3.223 3.07 47.35 5.981 0.554 90.73

Two nozzle

8 100 44.86 2.772 6.49 1.394 6.30 49.71 2.623 0.253 90.35

9 200 44.86 2.822 3.14 1.596 1.90 43.44 2.679 0.256 90.44

10 300 44.86 2.906 8.25 1.6 5.43 44.94 2.776 0.261 90.59

11 400 44.86 3.024 1.40 1.607 1.05 46.85 2.912 0.269 90.76

12 500 44.86 3.206 1.76 1.615 1.52 49.62 3.091 0.279 90.97

13 600 44.86 3.533 2.46 1.626 1.71 53.97 3.313 0.341 89.70

14 680 44.86 3.838 3.21 1.636 3.27 57.37 3.521 0.44 87.50

Four nozzle

15 100 22.41 1.405 6.48 0.7962 7.18 43.33 1.413 0.126 91.08

16 200 22.41 1.455 3.14 0.7988 2.70 45.09 1.472 0.13 91.16

17 300 22.41 1.554 8.25 0.8033 6.43 48.30 1.57 0.135 91.40

18 400 22.41 1.756 1.40 0.8099 1.16 53.87 1.709 0.15 91.22

19 500 22.41 2.018 1.76 0.819 1.82 59.41 1.892 0.236 87.52

20 600 22.41 2.339 2.46 0.831 2.62 64.47 2.12 0.343 83.82

21 680 22.41 2.639 3.21 0.843 3.37 68.05 2.336 0.443 81.03

Six nozzle

22 100 14.93 1.093 6.48 0.5306 1.21 51.45 0.998 0.08437 91.54

23 200 14.93 1.19 3.14 0.5332 2.73 55.19 1.056 0.08758 91.70

24 300 14.93 1.355 8.25 0.5378 6.61 60.30 1.155 0.0933 91.92

25 400 14.93 1.584 1.56 0.5447 1.19 65.61 1.296 0.149 88.50

26 500 14.93 1.881 2.50 0.5546 1.85 70.51 1.482 0.2368 84.02

27 600 14.93 2.244 3.66 0.5679 2.66 74.69 1.713 0.344 79.91

28 680 14.93 2.583 4.73 0.624 3.41 75.84 1.93 0.445 76.94

APPENDIX - B

Experimental Data & Results of Simple Pelton Wheel

Q = 0.01 m3/sec

Sr. No.

Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

spring

balance

reading

(kg)

Speed

(rpm)

Pi/2g

m

(Vi)2

/2g

m

H

m

Power

(input)

watt

Net

Weight

(N)

Torque

(N m)

Power

(output)

(watt)

η

%

Unit Speed

(Nu)

Unit

Discharge

(Qu)

10-03

Unit

Power

(Pu)

20 % opening

1 4 600 1 0.40 1378 32 0.59 32.59 2129.01 5.90 0.94 136.13 3.36 214.36 1.56 0.51

2 4 600 2 0.90 1347 32 0.59 32.59 2129.01 10.83 1.73 244.28 6.03 209.53 1.56 0.92

3 4 600 4 1.40 1256 32 0.59 32.59 2129.01 25.55 4.09 537.36 13.25 195.38 1.56 2.02

4 4 600 5 1.59 1241 32 0.59 32.59 2129.01 33.41 5.35 694.31 17.13 193.04 1.56 2.61

5 4 600 6 1.04 1206 32 0.59 32.59 2129.01 48.61 7.78 981.79 24.22 187.60 1.56 3.70

6 4 600 7 0.61 1180 32 0.59 32.59 2129.01 62.67 10.03 1238.42 30.55 183.56 1.56 4.66

40 % opening

7 3.4 600 1 0.30 1384 24 0.59 24.59 1606.34 6.84 1.09 158.54 4.57 232.85 1.68 0.76

8 3.4 600 2 0.50 1356 24 0.59 24.59 1606.34 14.76 2.36 335.17 9.67 228.14 1.68 1.60

9 3.4 600 4 0.66 1324 24 0.59 24.59 1606.34 32.79 5.25 727.14 20.98 222.76 1.68 3.46

10 3.4 600 5 0.89 1316 24 0.59 24.59 1606.34 40.32 6.45 888.57 25.64 221.41 1.68 4.23

11 3.4 600 6 0.58 1264 24 0.59 24.59 1606.34 53.13 8.50 1124.57 32.45 212.66 1.68 5.36

12 3.4 600 7 0.63 1270 24 0.59 24.59 1606.34 62.45 9.99 1328.11 38.32 213.67 1.68 6.33

60 % opening

13 3.2 600 1 0.22 1348 22 0.59 22.59 1475.67 7.61 1.22 171.79 5.25 233.50 1.73 0.89

14 3.2 600 2 0.21 1322 22 0.59 22.59 1475.67 17.59 2.82 389.51 11.91 229.00 1.73 2.02

15 3.2 600 4 1.01 1293 22 0.59 22.59 1475.67 29.32 4.69 634.91 19.42 223.98 1.73 3.30

16 3.2 600 5 0.54 1281 22 0.59 22.59 1475.67 43.77 7.00 938.96 28.72 221.90 1.73 4.88

17 3.2 600 6 0.96 1233 22 0.59 22.59 1475.67 49.46 7.91 1021.18 31.24 213.58 1.73 5.31

18 3.2 600 7 1.26 1226 22 0.59 22.59 1475.67 56.26 9.00 1155.14 35.33 212.37 1.73 6.00

80 % opening

19 3 600 1 0.53 1320 20 0.59 20.59 1345.00 4.62 0.74 102.22 3.33 235.84 1.79 0.58

20 3 600 2 0.72 1299 20 0.59 20.59 1345.00 12.51 2.00 272.16 8.86 232.09 1.79 1.55

21 3 600 4 1.29 1265 20 0.59 20.59 1345.00 26.57 4.25 562.88 18.32 226.01 1.79 3.21

22 3 600 5 1.09 1254 20 0.59 20.59 1345.00 38.34 6.13 805.07 26.20 224.05 1.79 4.59

23 3 600 6 1.24 1211 20 0.59 20.59 1345.00 46.71 7.47 947.24 30.82 216.36 1.79 5.40

24 3 600 7 1.35 1206 20 0.59 20.59 1345.00 55.46 8.87 1120.16 36.45 215.47 1.79 6.39

100 % opening

25 2.8 600 1 0.29 1305 18 0.59 18.59 1214.33 7.01 1.12 153.11 5.32 240.98 1.85 0.96

26 2.8 600 2 0.46 1281 18 0.59 18.59 1214.33 15.07 2.41 323.27 11.24 236.55 1.85 2.04

27 2.8 600 4 0.81 1247 18 0.59 18.59 1214.33 31.27 5.00 652.92 22.69 230.27 1.85 4.11

27 2.8 600 5 1.52 1240 18 0.59 18.59 1214.33 34.16 5.47 709.43 24.66 228.98 1.85 4.47

29 2.8 600 6 1.29 1187 18 0.59 18.59 1214.33 46.25 7.40 919.36 31.96 219.19 1.85 5.79

30 2.8 600 7 1.05 1137 18 0.59 18.59 1214.33 58.36 9.34 1111.25 38.63 209.96 1.85 7.00

Q = 0.0066 m3/sec

Sr.

No.

Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

Spring

balance

reading

(kg)

Speed

(rpm)

Pi/ g

(m)

(Vi)2

/2g

(m)

H

(m)

Power

(input)

(watt)

NET

Weight

(N)

Torque

(N m)

Power

(output)

watt

η

(%)

Unit

Speed

(Nu)

Unit

discharge

(Qu)

10-03

Unit

Power

(Pu)

20 % opening

1 3.2 400 1 0.07 1326 32 0.58 32.58 2129.01 9.06 1.45 201.27 9.54 232.28 1.08 1.08

2 3.2 400 2 0.65 1264 32 0.58 32.58 2129.01 13.20 2.11 279.55 13.25 221.42 1.08 1.50

3 3.2 400 4 1.09 1162 32 0.58 32.58 2129.01 28.46 4.55 553.83 26.25 203.55 1.08 2.97

4 3.2 400 5 0.91 1095 32 0.58 32.58 2129.01 40.03 6.40 734.22 34.8 191.82 1.08 3.94

5 3.2 400 6 1.21 963 32 0.58 32.58 2129.01 46.90 7.50 756.33 35.85 168.69 1.08 4.06

6 3.2 400 7 0.91 870 32 0.58 32.58 2129.01 59.73 9.55 870.30 41.25 152.40 1.08 4.67

40 % opening

7 2.4 400 1 0.30 1237 24 0.58 24.58 1606.33 6.85 1.09 141.90 8.91 249.47 1.11 1.16

8 2.4 400 2 0.64 1171 24 0.58 24.58 1606.33 13.30 2.12 260.92 16.39 236.16 1.11 2.14

9 2.4 400 4 1.23 1085 24 0.58 24.58 1606.33 27.08 4.33 492.18 30.91 218.81 1.11 4.03

10 2.4 400 5 1.12 977 24 0.58 24.58 1606.33 38.03 6.08 622.34 39.09 197.03 1.11 5.10

11 2.4 400 6 1.56 956 24 0.58 24.58 1606.33 43.49 6.95 696.37 43.74 192.80 1.11 5.71

12 2.4 400 7 1.16 828 24 0.58 24.58 1606.33 57.25 9.16 793.94 49.87 166.98 1.11 6.51

60 % opening

13 2.2 400 1 0.67 1129 22 0.58 22.58 1475.66 3.21 0.51 60.71 4.152 237.55 1.14 0.56

14 2.2 400 2 0.38 1066 22 0.58 22.58 1475.66 15.79 2.52 281.98 19.28 224.30 1.14 2.62

15 2.2 400 4 1.14 1045 22 0.58 22.58 1475.66 28.04 4.48 490.75 33.55 219.88 1.14 4.57

16 2.2 400 5 1.22 918 22 0.58 22.58 1475.66 37 5.92 568.94 38.90 193.16 1.14 5.30

17 2.2 400 6 1.72 886 22 0.58 22.58 1475.66 41.94 6.71 622.36 42.55 186.42 1.14 5.79

18 2.2 400 7 1.93 808 22 0.58 22.58 1475.66 49.67 7.94 672.10 45.95 170.01 1.14 6.26

80 & opening

19 2 400 1 0.36 1149 20 0.58 20.58 1345 6.20 0.99 119.32 8.95 253.23 1.17 1.27

20 2 400 2 0.72 1019 20 0.58 20.58 1345 12.50 2 213.45 16.01 224.58 1.17 2.28

21 2 400 4 1.52 919 20 0.58 20.58 1345 24.25 3.88 373.22 28 202.54 1.17 3.99

22 2 400 5 1.96 767 20 0.58 20.58 1345 29.73 4.75 381.98 28.65 169.04 1.17 4.08

23 2 400 6 2.03 751 20 0.58 20.58 1345 38.92 6.22 489.50 36.72 165.52 1.17 5.24

24 2 400 7 1.68 640 20 0.58 20.58 1345 52.17 8.34 559.22 41.95 141.05 1.17 5.98

100 % opening

25 1.8 400 1 0.47 1128 18 0.58 18.58 1214.32 5.19 0.83 98.07 8.15 261.64 1.21 1.22

26 1.8 400 2 0.58 1087 18 0.58 18.58 1214.32 13.92 2.22 253.41 21.05 252.13 1.21 3.16

27 1.8 400 4 1.49 1026 18 0.58 18.58 1214.32 24.53 3.92 421.49 35.02 237.98 1.21 5.26

27 1.8 400 5 1.43 925 18 0.58 18.58 1214.32 34.96 5.59 541.67 45.01 214.55 1.21 6.76

29 1.8 400 6 2 830 18 0.58 18.58 1214.32 39.18 6.26 544.63 45.25 192.52 1.21 6.79

30 1.8 400 7 1.74 793 18 0.58 18.58 1214.32 51.59 8.25 685.15 56.93 183.94 1.21 8.55

Q = 0.005 m3/sec

Sr.

No.

Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

Spring

balance

reading

(kg)

Speed

(rpm)

Pi/2g

(m)

(Vi)2 /2g

(m)

H

(m)

Power

input

(watt)

Net

weight

(N)

Torque

(N m)

Power

(output)

(watt)

η

(%)

Unit

Speed

(Nu)

Unit

Discharge

(Qu)

10-04

Unit

Power

(Pu)

20 % opening

1 3.1 300 1 0.02 1188 31 0.33 31.33 1536.76 9.51 1.52 189.32 12.32 212.24 8.93 1.07

2 3.1 300 2 0.22 1070 31 0.33 31.33 1536.76 17.42 2.7 312.26 20.32 191.16 8.93 1.78

3 3.1 300 4 0.96 965 31 0.33 31.33 1536.76 29.77 4.76 481.20 31.31 172.40 8.93 2.74

4 3.1 300 5 1.30 943 31 0.33 31.33 1536.76 36.21 5.79 571.87 37.21 168.47 8.93 3.26

5 3.1 300 6 1.52 889 31 0.33 31.33 1536.76 43.89 7.02 653.47 42.52 158.82 8.93 3.72

6 3.1 300 7 1.45 819 31 0.33 31.33 1536.76 54.40 8.70 746.16 48.55 146.31 8.93 4.25

40 % opening

7 3.2 300 1 0.28 1255 32 0.33 32.33 1585.81 6.98 1.11 146.76 9.25 220.71 8.79 0.79

8 3.2 300 2 0.37 1219 32 0.33 32.33 1585.81 15.95 2.55 325.76 20.54 214.38 8.79 1.77

9 3.2 300 4 1.41 1129 32 0.33 32.33 1585.81 25.37 4.06 479.77 30.25 198.55 8.79 2.60

10 3.2 300 5 1.30 1079 32 0.33 32.33 1585.81 36.20 5.79 654.21 41.25 189.76 8.79 3.55

11 3.2 300 6 1.42 1019 32 0.33 32.33 1585.81 44.83 7.17 765.15 48.25 179.21 8.79 4.16

12 3.2 300 7 1.48 972 32 0.33 32.33 1585.81 54.11 8.65 880.82 55.54 170.94 8.79 4.79

60 & opening

13 2.6 300 1 0.40 1136 26 0.33 26.33 1291.51 5.81 0.93 110.61 8.56 221.38 9.74 0.81

14 2.6 300 2 0.72 1110 26 0.33 26.33 1291.51 12.52 2 232.80 18.02 216.31 9.74 1.72

15 2.6 300 4 1.40 1087 26 0.33 26.33 1291.51 25.01 4 455.33 35.25 211.83 9.74 3.37

16 2.6 300 5 1.47 986 26 0.33 26.33 1291.51 34.65 5.53 571.57 44.25 192.15 9.74 4.23

17 2.6 300 6 1.38 941 26 0.33 26.33 1291.51 45.28 7.24 713.63 55.25 183.38 9.74 5.28

18 2.6 300 7 1.30 901 26 0.33 26.33 1291.51 55.85 8.9 842.78 65.25 175.58 9.74 6.23

80 % opening

19 2.2 300 1 0.51 1132 22 0.33 22.33 1095.31 4.78 0.76 90.74 8.28 239.55 10.6 0.85

20 2.2 300 2 0.82 1083 22 0.33 22.33 1095.31 11.49 1.83 208.39 19.02 229.18 10.6 1.97

21 2.2 300 4 1.46 953 22 0.33 22.33 1095.31 24.88 3.98 397.10 36.25 201.67 10.6 3.76

22 2.2 300 5 1.42 919 22 0.33 22.33 1095.31 35.02 5.60 539.02 49.21 194.47 10.6 5.10

23 2.2 300 6 1.45 884 22 0.33 22.33 1095.31 44.58 7.13 659.97 60.25 187.06 10.6 6.25

24 2.2 300 7 1.47 836 22 0.33 22.33 1095.31 54.18 8.66 758.55 69.25 176.91 10.6 7.18

100 % opening

25 2 300 1 0.52 1106 20 0.33 20.33 997.21 4.61 0.73 85.40 8.56 245.29 11.1 0.93

26 2 300 2 0.87 1092 20 0.33 20.33 997.21 11.04 1.76 201.98 20.25 242.18 11.1 2.20

27 2 300 4 1.49 1025 20 0.33 20.33 997.21 24.54 3.92 421.36 42.25 227.32 11.1 4.59

27 2 300 5 1.32 891 20 0.33 20.33 997.21 36 5.76 537.29 53.87 197.60 11.1 5.86

29 2 300 6 1.40 878 20 0.33 20.33 997.21 45.08 7.21 662.93 66.47 194.24 11.1 7.23

30 2 300 7 1.42 830 20 0.33 20.33 997.21 54.70 8.75 760.42 76.25 184.07 11.1 8.29

Q = 0.0033 m3/sec

Sr.

No.

Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

Spring

balance

Reading

(kg)

Speed

(rpm)

Pi/2g

(m)

(Vi)2

/2g

(m)

H

(m)

Power

(input)

(watt)

Net

Weight

(N)

Torque

(N m)

Power

(output)

(watt)

η

(%)

Unit

Speed

(Nu)

Unit

Discharge

(Qu)

10-04

Unit

Power

(Pu)

20 % opening

1 3.8 200 1 0.51 1496 38 0.14 38.14 1234.83 4.72 0.75 118.39 9.58 242.22 5.39 0.50

2 3.8 200 2 0.72 1398 38 0.14 38.14 1234.83 12.54 2 293.76 23.78 226.35 5.39 1.24

3 3.8 200 4 1.27 1338 38 0.14 38.14 1234.83 26.71 4.27 598.62 48.47 216.64 5.39 2.54

4 3.8 200 5 1.42 1185 38 0.14 38.14 1234.83 35.06 5.61 695.93 56.35 191.86 5.39 2.95

5 3.8 200 6 1.30 1162 38 0.14 38.14 1234.83 46.03 7.36 895.84 72.54 188.14 5.39 3.80

6 3.8 200 7 1.45 1128 38 0.14 38.14 1234.83 54.41 8.70 1028 83.25 182.64 5.39 4.36

40 % opening

7 3.6 200 1 0.45 1404 36 0.14 36.14 1170.08 5.38 0.86 126.72 10.83 233.53 5.54 0.58

8 3.6 200 2 0.77 1369 36 0.14 36.14 1170.08 11.97 1.91 274.46 23.45 227.71 5.54 1.26

9 3.6 200 4 1.28 1294 36 0.14 36.14 1170.08 26.65 4.26 577.60 49.36 215.23 5.54 2.65

10 3.6 200 5 1.42 1202 36 0.14 36.14 1170.08 35.09 5.62 706.44 60.37 199.93 5.54 3.25

11 3.6 200 6 1.41 1175 36 0.14 36.14 1170.08 45 7.20 885.62 75.68 195.44 5.54 4.07

12 3.6 200 7 1.49 1115 36 0.14 36.14 1170.08 54.02 8.64 1008.73 86.21 185.46 5.54 4.64

60 % opening

13 3.4 200 1 0.33 1312 34 0.14 34.14 1105.34 6.55 1.04 143.93 13.02 224.53 5.70 0.72

14 3.4 200 2 0.53 1297 34 0.14 34.14 1105.34 14.41 2.30 313.04 28.32 221.96 5.70 1.56

15 3.4 200 4 1.31 1283 34 0.14 34.14 1105.34 26.34 4.21 566.12 51.21 219.56 5.70 2.83

16 3.4 200 5 1.39 1188 34 0.14 34.14 1105.34 35.38 5.66 703.99 63.69 203.31 5.70 3.52

17 3.4 200 6 1.44 1113 34 0.14 34.14 1105.34 44.71 7.15 833.39 75.39 190.47 5.70 4.17

18 3.4 200 7 1.49 1068 34 0.14 34.14 1105.34 53.98 8.63 965.62 87.36 182.77 5.70 4.83

80 % opening

19 3.2 200 1 0.38 1323 32 0.14 32.14 1040.59 6.05 0.96 134.17 12.89 233.35 5.87 0.73

20 3.2 200 2 0.61 1276 32 0.14 32.14 1040.59 13.62 2.18 291.18 27.98 225.06 5.87 1.59

21 3.2 200 4 1.08 1168 32 0.14 32.14 1040.59 28.56 4.57 558.69 53.69 206.01 5.87 3.06

22 3.2 200 5 1.09 1142 32 0.14 32.14 1040.59 38.31 6.12 732.68 70.41 201.42 5.87 4.02

23 3.2 200 6 1.43 1109 32 0.14 32.14 1040.59 44.78 7.16 831.75 79.93 195.60 5.87 4.56

24 3.2 200 7 1.51 1032 32 0.14 32.14 1040.59 53.78 8.60 929.47 89.32 182.02 5.87 5.1

100 % opening

25 3 200 1 0.53 1307 30 0.14 30.14 975.85 4.56 0.73 99.92 10.24 238.05 6.07 0.60

26 3 200 2 0.78 1287 30 0.14 30.14 975.85 11.93 1.90 257.23 26.36 234.41 6.07 1.55

27 3 200 4 1.45 1246 30 0.14 30.14 975.85 25.01 4 521.95 53.48 226.94 6.07 3.15

27 3 200 5 1.18 1131 30 0.14 30.14 975.85 37.37 5.98 707.96 72.54 205.99 6.07 4.27

29 3 200 6 1.40 1079 30 0.14 30.14 975.85 45.06 7.21 814.34 83.45 196.52 6.07 4.92

30 3 200 7 1.56 1007 30 0.14 30.14 975.85 53.29 8.52 898.75 92.1 183.41 6.07 5.43

APPENDIX - C

Experimental Data & Results of Advanced Pelton Wheel

Q = 0.01 m3/sec

Sr.

No. Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

spring

balance

reading

(kg)

Speed

(rpm)

Pi/ g

(m)

(Vi)2

/2g

(m)

H

(m)

Power

(input)

(Watt)

Weight

(N)

Torque

(N m)

Power

(output)

(Watt)

η

(%

Unit

Speed

( Nu)

Unit

Discharge

(Qu)

10-03

Unit

Power

(Pu)

20 % opening

1 4 600 1 0.3 1183 40 1.32 41.32 4054.15 6.86 1.09 136.11 3.35 184.02 1.56 0.51

2 4 600 2 0.55 1154 40 1.32 41.32 4054.15 14.22 2.27 275.03 6.78 179.51 1.56 1.03

3 4 600 4 1.1 1046 40 1.32 41.32 4054.15 28.44 4.55 498.59 12.29 162.71 1.56 1.87

4 4 600 5 1.2 1031 40 1.32 41.32 4054.15 37.27 5.96 643.96 15.88 160.37 1.56 2.42

5 4 600 6 1.45 1021 40 1.32 41.32 4054.15 44.63 7.14 763.58 18.83 158.82 1.56 2.87

6 4 600 7 1.7 980 40 1.32 41.32 4054.15 51.99 8.31 853.72 21.05 152.44 1.56 3.21

40 % opening

7 3.4 600 1 0.3 1189 34 1.32 35.32 3465.55 6.86 1.09 136.80 3.94 200.04 1.68 0.65

8 3.4 600 2 0.5 1163 34 1.32 35.32 3465.55 14.71 2.35 286.74 8.27 195.67 1.68 1.36

9 3.4 600 4 1 1114 34 1.32 35.32 3465.55 29.43 4.70 549.31 15.85 187.42 1.68 2.61

10 3.4 600 5 1.2 1106 34 1.32 35.32 3465.55 37.27 5.96 690.80 19.93 186.08 1.68 3.29

11 3.4 600 6 1.5 1079 34 1.32 35.32 3465.55 44.14 7.06 798.08 23.02 181.53 1.68 3.80

12 3.4 600 7 1.7 1060 34 1.32 35.32 3465.55 51.99 8.31 923.42 26.64 178.34 1.68 4.39

60 % opening

13 3.2 600 1 0.3 1153 32 1.32 33.32 3269.35 6.86 1.09 132.66 4.05 199.72 1.73 0.68

14 3.2 600 2 0.55 1129 32 1.32 33.32 3269.35 14.22 2.27 269.07 8.23 195.56 1.73 1.39

15 3.2 600 4 1.1 1083 32 1.32 33.32 3269.35 28.44 4.55 516.23 15.79 187.59 1.73 2.68

16 3.2 600 5 1.15 1071 32 1.32 33.32 3269.35 37.76 6.04 677.74 20.73 185.52 1.73 3.52

17 3.2 600 6 1.5 1048 32 1.32 33.32 3269.35 44.14 7.06 775.16 23.70 181.53 1.73 4.02

18 3.2 600 7 1.65 1016 32 1.32 33.32 3269.35 52.48 8.39 893.43 27.32 175.99 1.73 4.64

80 % opening

19 3 600 1 0.25 1125 30 1.32 31.32 3073.15 7.35 1.17 138.68 4.51 200.99 1.79 0.79

20 3 600 2 0.55 1106 30 1.32 31.32 3073.15 14.22 2.27 263.59 8.57 197.60 1.79 1.50

21 3 600 4 1.05 1055 30 1.32 31.32 3073.15 28.93 4.63 511.55 16.64 188.49 1.79 2.91

22 3 600 5 1.1 1044 30 1.32 31.32 3073.15 38.25 6.12 669.24 21.77 186.52 1.79 3.81

23 3 600 6 1.4 1026 30 1.32 31.32 3073.15 45.12 7.22 775.75 25.24 183.31 1.79 4.42

24 3 600 7 1.7 996 30 1.32 31.32 3073.15 51.99 8.31 867.66 28.23 177.95 1.79 4.94

100 % opening

25 2.8 600 1 0.35 1110 28 1.32 29.32 2876.95 6.37 1.02 118.59 4.12 204.97 1.85 0.74

26 2.8 600 2 0.5 1088 28 1.32 29.32 2876.95 14.71 2.35 268.24 9.32 200.90 1.85 1.68

27 2.8 600 4 1 1037 28 1.32 29.32 2876.95 29.43 4.70 511.34 17.77 191.49 1.85 3.21

27 2.8 600 5 1.1 1030 28 1.32 29.32 2876.95 38.25 6.12 660.26 22.95 190.19 1.85 4.15

29 2.8 600 6 1.35 1002 28 1.32 29.32 2876.95 45.61 7.29 765.84 26.61 185.02 1.85 4.82

30 2.8 600 7 1.6 977 28 1.32 29.32 2876.95 52.97 8.47 867.17 30.14 180.41 1.85 5.46

Q = 0.0066 m3/sec

Sr.

No. Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

spring

balance

reading

(kg)

Speed

(rpm)

Pi/ g

(m)

(Vi)2

/2g

(m)

H

(m)

Power

(input)

(Watt)

Weight

(N)

Torque

(N m)

Power

(output)

(Watt)

η

(%)

Unit

Speed

(Nu)

Unit

Discharge

(Qu)

10-03

Unit

Power

(Pu)

20 % opening

1 3.2 400 1 0.1 1131 32 0.58 32.58 2129.01 8.829 1.41 167.31 7.85 198.12 1.08 0.89

2 3.2 400 2 0.3 1071 32 0.58 32.58 2129.01 16.677 2.66 299.26 14.05 187.61 1.08 1.60

3 3.2 400 4 0.7 952 32 0.58 32.58 2129.01 32.373 5.17 516.37 24.25 166.77 1.08 2.77

4 3.2 400 5 0.7 885 32 0.58 32.58 2129.01 42.18 6.74 625.50 29.37 155.03 1.08 3.36

5 3.2 400 6 1.25 778 32 0.58 32.58 2129.01 46.59 7.45 607.42 28.53 136.28 1.08 3.26

6 3.2 400 7 0.9 660 32 0.58 32.58 2129.01 59.84 9.57 661.74 31.08 115.61 1.08 3.55

40 % opening

7 2.4 400 1 0.2 1038 24 0.58 24.58 1606.33 7.848 1.25 136.49 8.49 209.33 1.11 1.11

8 2.4 400 2 0.4 982 24 0.58 24.58 1606.33 15.69 2.51 258.25 16.07 198.04 1.11 2.11

9 2.4 400 4 0.75 916 24 0.58 24.58 1606.33 31.88 5.10 489.32 30.46 184.73 1.11 4.01

10 2.4 400 5 0.8 827 24 0.58 24.58 1606.33 41.20 6.59 570.91 35.54 166.78 1.11 4.68

11 2.4 400 6 1.45 783 24 0.58 24.58 1606.33 44.63 7.14 585.58 36.45 157.91 1.11 4.80

12 2.4 400 7 1 650 24 0.58 24.58 1606.33 58.86 9.41 641.03 39.90 131.08 1.11 5.25

60 % opening

13 2.2 400 1 0.7 979 22 0.58 22.58 1475.66 2.94 0.47 48.27 3.27 205.99 1.14 0.44

14 2.2 400 2 0.3 908 22 0.58 22.58 1475.66 16.67 2.66 253.71 17.19 191.05 1.14 2.36

15 2.2 400 4 0.9 856 22 0.58 22.58 1475.66 30.41 4.86 436.16 29.55 180.11 1.14 4.06

16 2.2 400 5 0.6 745 22 0.58 22.58 1475.66 43.16 6.90 538.79 36.51 156.75 1.14 5.01

17 2.2 400 6 1.5 713 22 0.58 22.58 1475.66 44.14 7.06 527.37 35.73 150.02 1.14 4.91

18 2.2 400 7 1 598 22 0.58 22.58 1475.66 58.86 9.41 589.75 39.96 125.82 1.14 5.49

80 % opening

19 2 400 1 0.25 960 20 0.58 20.58 1344.99 7.35 1.17 118.34 8.79 211.58 1.17 1.26

20 2 400 2 0.45 809 20 0.58 20.58 1344.99 15.20 2.43 206.10 15.32 178.30 1.17 2.20

21 2 400 4 0.9 726 20 0.58 20.58 1344.99 30.41 4.86 369.92 27.50 160.01 1.17 3.96

22 2 400 5 0.6 648 20 0.58 20.58 1344.99 43.16 6.90 468.64 34.84 142.81 1.17 5.01

23 2 400 6 1.5 626 20 0.58 20.58 1344.99 44.14 7.02 463.02 34.42 137.97 1.17 4.95

24 2 400 7 1.1 529 20 0.58 20.58 1344.99 57.87 9.26 513.00 38.14 116.59 1.17 5.49

100 % opening

25 1.8 400 1 0.3 939 18 0.58 18.58 1214.32 6.86 1.09 108.03 8.89 217.80 1.21 1.34

26 1.8 400 2 0.35 898 18 0.58 18.58 1214.32 16.18 2.58 243.54 20.05 208.29 1.21 3.03

27 1.8 400 4 1 837 18 0.58 18.58 1214.32 29.43 4.70 412.72 33.98 194.14 1.21 5.15

27 1.8 400 5 0.7 756 18 0.58 18.58 1214.32 42.18 6.74 534.32 44.00 175.35 1.21 6.66

29 1.8 400 6 1.6 732 18 0.58 18.58 1214.32 43.16 6.90 529.39 43.59 169.79 1.21 6.60

30 1.8 400 7 1.2 620 18 0.58 18.53 1214.32 56.89 9.10 591.06 48.67 143.81 1.21 7.37

Q = 0.005 m3/sec

Sr.

No. Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

spring

balance

reading

(kg)

Speed

(rpm)

Pi/ g

(m)

(Vi)2

/2g

(m)

H

(m)

Power

(input)

(Watt)

Weight

(N)

Torque

(N m)

Power

(output)

(Watt)

η

(%)

Unit

Speed

(Nu)

Unit

Discharge

(Qu)

10-04

Unit

Power

(Pu)

20 % opening

1 3.1 300 1 0.3 938 31 0.33 31.33 1536.76 6.86 1.09 107.92 7.02 167.57 8.93 0.61

2 3.1 300 2 0.45 877 31 0.33 31.33 1536.76 15.20 2.43 223.43 14.53 156.68 8.93 1.27

3 3.1 300 4 1 755 31 0.33 31.33 1536.76 29.43 4.70 372.29 24.25 134.88 8.93 2.12

4 3.1 300 5 1.1 733 31 0.33 31.33 1536.76 38.25 6.12 469.87 30.57 130.95 8.93 2.67

5 3.1 300 6 1.3 704 31 0.33 31.30 1536.76 46.10 7.37 543.86 35.39 125.77 8.93 3.10

6 3.1 300 7 1.6 634 31 0.33 31.33 1536.76 52.97 8.47 562.73 36.61 113.26 8.93 3.20

40 % opening

7 3.2 300 1 0.25 1056 32 0.33 32.33 1585.81 7.357 1.17 130.17 8.20 185.71 8.79 0.70

8 3.2 300 2 0.45 1030 32 0.33 32.33 1585.81 15.20 2.43 262.41 16.54 181.14 8.79 1.42

9 3.2 300 4 1.2 960 32 0.33 32.33 1585.81 27.46 4.32 441.82 27.86 168.83 8.79 2.40

10 3.2 300 5 1.4 929 32 0.33 32.33 1585.81 35.31 5.65 549.71 34.66 163.38 8.79 2.99

11 3.2 300 6 1.45 914 32 0.33 32.30 1585.81 44.63 7.14 683.55 43.10 160.74 8.79 3.71

12 3.2 300 7 1.6 897 32 0.33 32.30 1585.81 52.97 8.47 796.16 50.20 157.75 8.79 4.33

60 % opening

13 2.6 300 1 0.25 986 26 0.33 26.33 1291.51 7.35 1.17 121.55 9.41 192.15 9.74 0.89

14 2.6 300 2 0.45 952 26 0.33 26.33 1291.51 15.20 2.43 242.54 18.77 185.52 9.74 1.79

15 2.6 300 4 1 898 26 0.33 26.33 1291.51 29.43 4.70 442.80 34.28 175.00 9.74 3.27

16 2.6 300 5 1.25 881 26 0.33 26.33 1291.51 36.78 5.88 543.03 42.04 171.69 9.74 4.01

17 2.6 300 6 1.4 843 26 0.33 26.33 1291.51 45.12 7.22 637.38 49.35 164.28 9.74 4.71

18 2.6 300 7 1.65 816 26 0.33 26.33 1291.51 52.45 8.39 717.56 55.56 159.02 9.74 5.31

80 % opening

19 2.2 300 1 0.25 943 22 0.33 22.33 1095.31 7.35 1.17 116.24 10.61 199.55 10.6 1.10

20 2.2 300 2 0.5 917 22 0.33 22.33 1095.31 14.71 2.35 226.08 20.64 194.05 10.6 2.14

21 2.2 300 4 1.2 848 22 0.33 22.33 1095.31 27.46 4.39 390.27 35.63 179.45 10.6 3.69

22 2.2 300 5 1.25 834 22 0.33 22.33 1095.31 36.78 5.88 514.06 46.93 176.48 10.6 4.87

23 2.2 300 6 1.45 809 22 0.33 22.33 1095.31 44.63 7.14 605.03 55.23 171.19 10.6 5.73

24 2.2 300 7 1.6 771 22 0.33 22.33 1095.31 52.97 8.47 684.33 62.47 163.15 10.6 6.48

100 % opening

25 2 300 1 0.35 917 20 0.33 20.33 997.21 6.37 1.02 97.97 9.82 203.37 11.1 1.06

26 2 300 2 0.55 903 20 0.33 20.33 997.21 14.22 2.27 215.21 21.58 200.26 11.1 2.34

27 2 300 4 1.2 836 20 0.33 20.33 997.21 27.46 4.39 384.75 38.58 185.40 11.1 4.19

27 2 300 5 1.25 806 20 0.33 20.33 997.21 36.78 5.88 496.80 49.81 178.75 11.1 5.41

29 2 300 6 1.4 780 20 0.33 20.33 997.21 45.12 7.22 589.75 59.14 172.98 11.1 6.43

30 2 300 7 1.6 755 20 0.33 20.33 997.21 52.97 8.47 670.12 67.20 167.44 11.1 7.31

Q = 0.0033 m3/sec

Sr.

No. Pr.

Gauge

reading

(kg/cm2)

Flow

rate

(lpm)

Weight

(kg)

spring

balance

reading

(kg)

Speed

(rpm)

Pi/ g

(m)

(Vi)2

/2g

(m)

H

(m)

Power

(input)

(Watt)

Weight

(N)

Torque

(N m)

Power

(output)

(Watt)

η

(%)

Unit

Speed

(Nu)

Unit

Discharge

(Qu)

10-04

Unit

Power

(Pu)

20 % opening

1 3.8 200 1 0.3 1246 38 0.14 38.14 1234.83 6.86 1.09 143.36 11.60 201.74 5.39 0.60

2 3.8 200 2 0.45 1205 38 0.14 38.14 1234.83 15.20 2.43 306.99 24.86 195.10 5.39 1.30

3 3.8 200 4 0.85 1128 38 0.14 38.14 1234.83 30.90 4.94 584.03 47.29 182.64 5.39 2.47

4 3.8 200 5 1.2 1080 38 0.14 38.14 1234.83 37.27 5.96 674.56 54.62 174.86 5.39 2.86

5 3.8 200 6 1.5 1054 38 0.14 38.14 1234.83 44.14 7.06 779.59 63.13 170.65 5.39 3.30

6 3.8 200 7 1.6 1046 38 0.14 38.14 1234.83 52.97 8.47 928.41 75.18 169.36 5.39 3.94

40 % opening

7 3.6 200 1 0.2 1205 36 0.14 36.14 1170.08 7.84 1.25 158.45 13.54 200.43 5.54 0.72

8 3.6 200 2 0.5 1180 36 0.14 36.14 1170.08 14.71 2.35 290.93 24.86 196.27 5.54 1.33

9 3.6 200 4 1 1125 36 0.14 36.14 1170.08 29.43 4.70 554.74 47.41 187.12 5.54 2.55

10 3.6 200 5 1.4 1100 36 0.14 36.14 1170.08 35.31 5.65 650.89 55.62 182.96 5.54 2.99

11 3.6 200 6 1.65 1090 36 0.14 36.14 1170.08 42.67 6.82 779.35 66.60 181.30 5.54 3.58

12 3.6 200 7 1.7 1066 36 0.14 36.14 1170.08 51.99 8.31 928.64 79.36 177.31 5.54 4.27

60 % opening

13 3.4 200 1 0.2 1162 34 0.14 34.14 1105.34 7.84 1.25 152.79 13.82 198.86 5.70 0.76

14 3.4 200 2 0.55 1139 34 0.14 34.14 1105.34 14.22 2.27 271.46 24.55 194.92 5.70 1.36

15 3.4 200 4 1.1 1094 34 0.14 34.14 1105.34 28.44 4.55 521.47 47.17 187.22 5.70 2.61

16 3.4 200 5 1.4 1083 34 0.14 34.14 1105.34 35.31 5.65 640.83 57.97 185.34 5.70 3.21

17 3.4 200 6 1.65 1054 34 0.14 34.14 1105.34 42.67 6.82 753.61 68.17 180.37 5.70 3.77

18 3.4 200 7 1.7 1033 34 0.14 34.14 1105.34 51.99 8.31 899.89 81.41 176.78 5.70 4.51

80 % opening

19 3.2 200 1 0.3 1134 32 0.14 32.14 1040.59 6.86 1.09 130.47 12.53 200.01 5.87 0.71

20 3.2 200 2 0.5 1110 32 0.14 32.14 1040.59 14.71 2.35 273.67 26.29 195.78 5.87 1.50

21 3.2 200 4 1.05 1063 32 0.14 32.14 1040.59 28.93 4.63 515.43 49.53 187.49 5.87 2.82

22 3.2 200 5 1.2 1057 32 0.14 32.14 1040.59 37.23 5.96 660.20 63.44 186.43 5.87 3.62

23 3.2 200 6 1.45 1034 32 0.14 32.14 1040.59 44.65 7.14 773.30 74.31 182.37 5.87 4.24

24 3.2 200 7 1.75 1011 32 0.14 32.14 1040.59 51.52 8.24 872.42 83.83 178.32 5.87 4.78

100 % opening

25 3 200 1 0.25 1118 30 0.14 30.14 975.85 7.35 1.17 137.82 14.12 203.62 6.07 0.83

26 3 200 2 0.5 1098 30 0.14 30.14 975.85 14.71 2.35 270.71 27.74 199.98 6.07 1.63

27 3 200 4 1.1 1057 30 0.14 30.14 975.85 28.44 4.55 503.83 51.63 192.51 6.07 3.04

27 3 200 5 1.2 1046 30 0.14 30.14 975.85 37.27 5.96 653.33 66.94 190.51 6.07 3.94

29 3 200 6 1.45 1018 30 0.14 30.14 975.85 44.63 7.14 761.33 78.01 185.41 6.07 4.60

30 3 200 7 1.7 995 30 0.14 30.14 975.85 51.99 8.31 866.79 88.82 181.22 6.07 5.23

APPENDIX - D

Experimental Analysis of Simple & Advanced Pelton Wheel

Q = 0.01 m3/sec

Sr. No.

Speed

( rpm ) % diff

Speed

Torque

( N m ) % diff

Torque

Power (output)

( watt ) % diff

Power

(output)

Efficiency

η % diff

Efficiency Simple Adva. Simple Adva. Simple Adva. Simple Adva.

20 % opening

1 1378 1183 14.15 0.94 1.09 -15.49 136.13 136.11 0.01 3.36 3.35 0.01

2 1347 1154 14.33 1.73 2.27 -31.01 244.28 275.03 -12.59 6.03 6.78 -12.59

3 1256 1046 16.72 4.09 4.55 -11.31 537.36 498.59 7.21 13.25 12.29 7.21

4 1241 1031 16.92 5.35 5.96 -11.50 694.31 643.96 7.25 17.13 15.88 7.25

5 1206 1021 15.34 7.78 7.14 8.20 981.79 763.58 22.23 24.22 18.83 22.23

6 1180 980 16.95 10.03 8.31 17.13 1238.42 853.72 31.06 30.55 21.05 31.06

40 % opening

7 1384 1189 14.09 1.09 1.09 0.40 158.54 136.80 13.71 4.57 3.94 13.71

8 1356 1163 14.23 2.36 2.35 0.49 335.17 286.74 14.45 9.67 8.27 14.45

9 1324 1114 15.86 5.25 4.70 10.43 727.14 549.31 24.46 20.98 15.85 24.46

10 1316 1106 15.96 6.45 5.96 7.61 888.57 690.80 22.26 25.64 19.93 22.26

11 1264 1079 14.64 8.50 7.06 16.94 1124.57 798.08 29.03 32.45 23.02 29.03

12 1270 1060 16.54 9.99 8.31 16.83 1328.11 923.42 30.47 38.32 26.64 30.47

60 % opening

13 1348 1153 14.47 1.22 1.09 10.48 171.79 132.66 22.78 5.25 4.05 22.78

14 1322 1129 14.60 2.82 2.27 19.36 389.51 269.07 30.92 11.91 8.23 30.92

15 1293 1083 16.24 4.69 4.55 3.01 634.91 516.23 18.69 19.42 15.79 18.69

16 1281 1071 16.39 7.00 6.04 13.75 938.96 677.74 27.82 28.72 20.73 27.82

17 1233 1048 15.00 7.91 7.06 10.78 1021.18 775.16 24.09 31.24 23.70 24.09

18 1226 1016 17.13 9.00 8.39 6.80 1155.14 893.43 22.66 35.33 27.32 22.66

80 % opening

19 1320 1125 14.77 0.74 1.17 -58.14 102.22 138.68 -35.67 3.33 4.51 -35.67

20 1299 1106 14.86 2.00 2.27 -13.40 272.16 263.59 3.15 8.86 8.57 3.15

21 1265 1055 16.60 4.25 4.63 -8.91 562.88 511.55 9.12 18.32 16.64 9.12

22 1254 1044 16.75 6.13 6.12 0.22 805.07 669.24 16.87 26.20 21.77 16.87

23 1211 1026 15.28 7.47 7.22 3.39 947.24 775.75 18.10 30.82 25.24 18.10

24 1206 996 17.41 8.87 8.31 6.36 1120.16 867.66 22.54 36.45 28.23 22.54

100 % opening

25 1305 1110 14.94 1.12 1.02 9.01 153.11 118.59 22.55 5.32 4.12 22.55

26 1281 1088 15.07 2.41 2.35 2.53 323.27 268.24 17.02 11.24 9.32 17.02

27 1247 1037 16.84 5.00 4.70 6.05 652.92 511.34 21.68 22.69 17.77 21.68

27 1240 1030 16.94 5.47 6.12 -11.96 709.43 660.26 6.93 24.66 22.95 6.93

29 1187 1002 15.59 7.40 7.29 1.49 919.36 765.84 16.70 31.96 26.61 16.70

30 1137 977 14.07 9.34 8.47 9.29 1111.25 867.17 21.96 38.63 30.14 21.96

Q = 0.0066 m3/sec

Sr. No.

Speed

( rpm ) % diff

Speed

Torque

( N m ) % diff

Torque

Power (output)

( watt ) % diff

Power

(output)

Efficiency

η % diff


20 % opening

1 1326 1131 14.71 1.45 1.41 2.78 201.28 167.31 16.88 9.54 7.86 17.62

2 1264 1071 15.27 2.11 2.67 -26.36 279.55 299.27 -7.05 13.25 14.06 -6.09

3 1162 952 18.07 4.55 5.18 -13.75 553.83 516.38 6.76 26.25 24.25 7.60

4 1095 885 19.18 6.41 6.75 -5.37 734.22 625.50 14.81 34.80 29.38 15.57

5 963 778 19.21 7.50 7.46 0.59 756.37 607.42 19.69 35.85 28.53 20.42

6 870 660 24.14 9.56 9.57 -0.13 870.31 661.75 23.96 41.25 31.08 24.65

40 % opening

7 1237 1038 16.09 1.10 1.26 -14.96 141.91 136.49 3.82 8.91 8.50 4.68

8 1171 982 16.14 2.13 2.51 -17.90 260.93 258.26 1.02 16.39 16.08 1.92

9 1085 916 15.58 4.33 5.10 -17.67 492.19 489.32 0.58 30.92 30.46 1.48

10 977 827 15.35 6.09 6.59 -8.28 622.35 570.92 8.26 39.10 35.54 9.09

11 956 783 18.10 6.96 7.14 -2.59 696.37 585.59 15.91 43.75 36.45 16.67

12 828 650 21.50 9.16 9.42 -2.83 793.94 641.04 19.26 49.88 39.91 19.99

60 % opening

13 1129 979 13.29 0.51 0.47 8.53 60.72 48.27 20.49 4.15 3.27 21.21

14 1066 908 14.82 2.53 2.67 -5.65 281.98 253.72 10.02 19.28 17.19 10.83

15 1045 856 18.09 4.49 4.87 -8.54 490.75 436.17 11.12 33.56 29.56 11.92

16 918 745 18.85 5.92 6.91 -16.70 568.95 538.80 5.30 38.91 36.51 6.15

17 886 713 19.53 6.71 7.06 -5.20 622.36 527.38 15.26 42.56 35.74 16.03

18 808 598 25.99 7.95 9.42 -18.53 672.10 589.75 12.25 45.96 39.97 13.04

80 % opening

19 1149 960 16.45 0.99 1.18 -18.92 119.33 118.35 0.82 8.95 8.80 1.72

20 1019 809 20.61 2.00 2.43 -21.42 213.45 206.11 3.44 16.01 15.32 4.31

21 919 726 21.00 3.88 4.87 -25.51 373.22 369.93 0.88 28.00 27.50 1.78

22 767 648 15.51 4.76 6.91 -45.22 381.98 468.65 -22.69 28.66 34.84 -21.58

23 751 626 16.64 6.23 7.06 -13.37 489.50 463.03 5.41 36.73 34.43 6.26

24 640 529 17.34 8.35 9.26 -10.92 559.23 513.01 8.26 41.96 38.14 9.09

100 % opening

25 1128 939 16.76 0.83 1.10 -32.41 98.08 108.04 -10.16 8.15 8.90 -9.16

26 1087 898 17.39 2.23 2.59 -16.28 253.42 243.54 3.90 21.06 20.06 4.76

27 1026 837 18.42 3.92 4.71 -20.00 421.50 412.73 2.08 35.03 33.99 2.96

27 925 756 18.27 5.59 6.75 -20.65 541.68 534.33 1.36 45.01 44.00 2.25

29 830 732 11.81 6.27 6.91 -10.22 544.64 529.40 2.80 45.26 43.60 3.67

30 793 620 21.82 8.25 9.10 -10.24 685.15 591.07 13.73 56.94 48.67 14.51

Q = 0.005 m3/sec

Sr. No.

Speed

(rpm) % diff

Speed

Torque

(N m) % diff

Torque

Power(output)

(Watt) % diff

Power

(output)

Efficiency

η % diff


20 % opening

1 1188 938 21.04 1.52 1.09 28.41 189.33 107.92 43.00 12.32 7.02 43.00

2 1070 877 18.04 2.79 2.43 12.85 312.27 223.43 28.45 20.32 14.53 28.45

3 965 755 21.76 4.76 4.70 1.35 481.21 372.29 22.63 31.31 24.25 22.63

4 943 733 22.27 5.79 6.12 -5.63 571.88 469.87 17.84 37.21 30.57 17.84

5 889 704 20.81 7.02 7.37 -4.94 653.48 543.86 16.77 42.52 35.39 16.77

6 819 634 22.59 8.70 8.47 2.69 746.17 562.73 24.58 48.55 36.61 24.58

40 % opening

7 1255 1056 15.86 1.12 1.17 -4.72 146.76 130.17 11.30 9.25 8.20 11.30

8 1219 1030 15.50 2.55 2.43 4.83 325.76 262.41 19.45 20.54 16.54 19.45

9 1129 960 14.97 4.06 4.32 -6.40 479.77 441.82 7.91 30.25 27.86 7.91

10 1079 929 13.90 5.79 5.65 2.47 654.22 549.71 15.97 41.25 34.66 15.97

11 1019 914 10.30 7.17 7.14 0.48 765.15 683.55 10.66 48.25 43.10 10.66

12 972 897 7.72 8.66 8.47 2.17 880.82 796.16 9.61 55.54 50.20 9.61

60 % opening

13 1136 986 13.20 0.93 1.17 -25.76 110.62 121.55 -9.88 8.57 9.41 -9.88

14 1110 952 14.23 2.00 2.43 -21.27 232.80 242.54 -4.18 18.03 18.77 -4.18

15 1087 898 17.39 4.00 4.70 -17.44 455.34 442.80 2.75 35.26 34.28 2.75

16 986 881 10.65 5.54 5.88 -6.17 571.57 543.03 4.99 44.26 42.04 4.99

17 941 843 10.41 7.25 7.22 0.35 713.64 637.38 10.68 55.26 49.35 10.68

18 901 816 9.43 8.94 8.39 6.12 842.79 717.56 14.86 65.26 55.56 14.86

80 % opening

19 1132 943 16.70 0.77 1.17 -52.76 90.75 116.24 -28.10 8.29 10.61 -28.10

20 1083 917 15.33 1.84 2.35 -27.83 208.39 226.08 -8.49 19.03 20.64 -8.49

21 953 848 11.02 3.98 4.39 -10.27 397.10 390.27 1.72 36.25 35.63 1.72

22 919 834 9.25 5.60 5.88 -4.93 539.03 514.06 4.63 49.21 46.93 4.63

23 884 809 8.48 7.13 7.14 -0.10 659.98 605.03 8.33 60.25 55.23 8.33

24 836 771 7.78 8.67 8.47 2.30 758.56 684.33 9.79 69.25 62.47 9.79

100 % opening

25 1106 917 17.09 0.74 1.02 -38.25 85.41 97.97 -14.71 8.56 9.82 -14.71

26 1092 903 17.31 1.77 2.27 -28.45 201.98 215.21 -6.55 20.25 21.58 -6.55

27 1025 836 18.44 3.93 4.39 -11.77 421.37 384.75 8.69 42.25 38.58 8.69

27 891 806 9.54 5.76 5.88 -2.06 537.29 496.80 7.54 53.88 49.81 7.54

29 878 780 11.16 7.21 7.22 -0.09 662.93 589.75 11.04 66.48 59.14 11.04

30 830 755 9.04 8.75 8.47 3.24 760.42 670.12 11.87 76.25 67.20 11.87

Q = 0.0033 m3/sec

Sr. No.

Speed

(rpm) % diff

Speed

Torque

(N m) % diff

Torque

Power (output)

(Watt) % diff

Power

(output)

Efficiency

η % diff


20 % opening

1 1496 1246 16.71 0.76 1.09 -44.16 118.39 143.36 -21.09 9.59 11.60 -21.09

2 1398 1205 13.81 2.01 2.43 -21.04 293.76 306.99 -4.51 23.79 24.86 -4.51

3 1338 1128 15.70 4.27 4.94 -15.57 598.63 584.03 2.44 48.48 47.29 2.44

4 1185 1080 8.86 5.61 5.96 -6.22 695.93 674.56 3.07 56.36 54.62 3.07

5 1162 1054 9.29 7.37 7.06 4.15 895.85 779.59 12.98 72.55 63.13 12.98

6 1128 1046 7.27 8.71 8.47 2.72 1028.00 928.41 9.69 83.25 75.18 9.69

40 % opening

7 1404 1205 14.17 0.86 1.25 -44.96 126.72 158.45 -25.04 10.83 13.54 -25.04

8 1369 1180 13.81 1.92 2.35 -22.68 274.47 290.93 -6.00 23.46 24.86 -6.00

9 1294 1125 13.06 4.26 4.70 -10.21 577.60 554.74 3.96 49.36 47.41 3.96

10 1202 1100 8.49 5.62 5.65 -0.62 706.45 650.89 7.86 60.38 55.62 7.86

11 1175 1090 7.23 7.20 6.82 5.29 885.63 779.35 12.00 75.69 66.60 12.00

12 1115 1066 4.39 8.64 8.31 3.86 1008.73 928.64 7.94 86.21 79.36 7.94

60 % opening

13 1312 1162 11.43 1.05 1.25 -19.26 143.93 152.79 -6.16 13.02 13.82 -6.16

14 1297 1139 12.18 2.31 2.27 1.56 313.05 271.46 13.28 28.32 24.55 13.28

15 1283 1094 14.73 4.22 4.55 -7.93 566.13 521.47 7.89 51.22 47.17 7.89

16 1188 1083 8.84 5.66 5.65 0.21 703.99 640.83 8.97 63.69 57.97 8.97

17 1113 1054 5.30 7.15 6.82 4.67 833.40 753.61 9.57 75.40 68.17 9.57

18 1068 1033 3.28 8.64 8.31 3.80 965.63 899.89 6.81 87.36 81.41 6.81

80 % opening

19 1323 1134 14.29 0.97 1.09 -12.49 134.18 130.47 2.76 12.89 12.53 2.76

20 1276 1110 13.01 2.18 2.35 -7.79 291.18 273.67 6.01 27.98 26.29 6.01

21 1168 1063 8.99 4.57 4.63 -1.31 558.70 515.43 7.74 53.69 49.53 7.74

22 1142 1057 7.44 6.13 5.96 2.77 732.68 660.20 9.89 70.41 63.44 9.89

23 1109 1034 6.76 7.17 7.14 0.36 831.76 773.30 7.03 79.93 74.31 7.03

24 1032 1011 2.03 8.60 8.24 4.24 929.47 872.42 6.14 89.32 83.83 6.14

100 % opening

25 1307 1118 14.46 0.73 1.17 -60.17 99.93 137.82 -37.92 10.24 14.12 -37.92

26 1287 1098 14.69 1.91 2.35 -23.06 257.23 270.71 -5.24 26.36 27.74 -5.24

27 1246 1057 15.17 4.00 4.55 -13.69 521.95 503.83 3.47 53.49 51.63 3.47

27 1131 1046 7.52 5.98 5.96 0.34 707.96 653.33 7.72 72.55 66.94 7.72

29 1079 1018 5.65 7.21 7.14 0.98 814.35 761.33 6.51 83.45 78.01 6.51

30 1007 995 1.19 8.53 8.31 2.55 898.76 866.79 3.56 92.10 88.82 3.56

Stress & Experimental Analysis of Simple and Advanced Pelton Wheel

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Transcript of Stress & Experimental Analysis of Simple and Advanced Pelton Wheel