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LMH Laboratory for Hydraulic Machines
Mechanical Engineering Bachelor: 6th Semester Introduction to Hydraulic Turbomachines
-1- Hydraulic Turbomachines:Different Types and Application Areas
Prof. François [email protected]
Laboratory for Hydraulic MachinesSwiss Federal Institute of Technology Lausanne
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Content
Pumps and TurbinesHydropower
Turbines: Pelton, Francis, Kaplan, BulbsStorage pumps and Pump-Turbines
Power GenerationPumps for Thermal Power GenerationPumps for Oil & GasDesalinationPumps for Rocket EnginesPower Hydraulic
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Hydraulic Turbines
Driving Machines
Driving Power defined as positiveP Machine PowerPh Available Hydraulic PowerTurbine Efficiency
DischargeSpecific Energy
ω
ηρ
= ⋅ >
= ×
= × ×
0T
h
h
P TP PP Q E
T
h
PP
η =−
−
⎡ ⎤⋅⎣ ⎦⎡ ⎤⋅⎣ ⎦
…
…
3 1
1
m s
J kg
Q
E
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Pumps
Work Absorbing Machines
Pump Power defined as negativeP Machine PowerPh Resulting Hydraulic PowerMachine Efficiency
ω
ηρ
= ⋅ <
= ×
= × ×
0P
h
h
P TP PP Q E
P hPP
η =
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Specific Energy BalanceTurbine
BZ
BZ
II
Hydrodynamics
( )= −
= − −∑I I
TB rB
E gH gH
g Z Z gH
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Machine Nomenclature
Hydrodynamics
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Runner or Impeller Power Transfer
Traversing Discharge
Transferred SpecificEnergy
Power Transfer
Driving (Turbines)
Being Driven (Pumps)
tQ
⎡ ⎤⋅⎣ ⎦… 3 -1m stQ
⎡ ⎤− = ± ⋅⎣ ⎦… -11 1 J kgt rbgH gH E E
[ ]ρ= …t t tP Q E MW
1
1
> 0P
< 0P
Brillant Extension Project, British Columbia, Canada, Kaplan Turbine CAD Model, PF2 EPFL Test Righttp://www.columbiapower.org/projects/brilliantdam.asp
Energy Conversion
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Classification of Hydraulic Runners
Specific Energy TransferSubscript 1: High Energy SideSubscript -1: Low Energy Sideρ ρ
ρ ρ
= −
⎡ ⎤⎡ ⎤= + + − + +⎢ ⎥⎢ ⎥⎣ ⎦ ⎣ ⎦
⎡ ⎤⎡ ⎤= − + − + −⎡ ⎤ ⎢ ⎥⎢ ⎥⎣ ⎦
⎣ ⎦ ⎣ ⎦
1 1
221 1 1 1
1 1
221 1 1 1
1 1
Water WheelDisplacement Machine Impulse Turbine
Reaction Machine
2 2
2 2
tE gH gH
p Cp CgZ gZ
p Cp CgZ gZ
: Elevation: Gravity
Zg ρ
: Absolute Pressure: Density
p: Flow VelocityC
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ρ ρ⎡ ⎤⎡ ⎤
= − + − + − ±⎡ ⎤⎢ ⎥⎢ ⎥ ⎣ ⎦⎣ ⎦ ⎣ ⎦
Reaction
221 1 1 1
1 1
Water WheelDisplacement Impulse Turbine
2 2t rb
p Cp CE gZ gZ E
Types of Energy ConversionTransfer Modes
Energy Conversion
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3 Types of Water Wheels
Overshot
Undershot
Norse Mill
Energy Conversion
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Seqia, Al Jazzari, XIII Iraq
Water Supply
Noria
Energy Conversion
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The Water Wheel:Medieval Roots of the Industrial-Revolution
Main Medieval Prime Movers8th Century
Labor Saving Potential
Monastic Orders
> 40 Industrial Processes16th Century
Industrial Revolution Precursor
18th CenturyPrime Mover of Cotton Mills
200 kW Max. Power
Georgius Agricola, "De re metallica", 1556
Energy Conversion
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Hydroelectric Power Development
Water Turbine Development
Fourneyron (1830s)Francis Turbine (1840s)Pelton (1880s)Kaplan (1910s )
Trend to High Specific Power
Machines
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Largest Hydropower Plants in the World
Hydropower Plant Country Capacity EPFL 3 Gorges China (2009) 18'200 MW
Itaipú Brazil / Paraguay 12'600 MW Guri (Raúl Leoni) Venezuela 10'000 MW
Grand Coulee USA 6'494 MW Sayano – Shushensk Russia 6'400 MW
Krasnoyarsk Russia 6'000 MW Churchill Falls Canada 5'428 MW
La Grande 2 Canada 5'328 MW Bratsk Russia 4'500 MW
Ust-llim Russia 4'320 MW Tucurui Brazil 4'245 MW
Tucurui Dam & Power Plants
http://www.eln.gov.br/
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World ClassExperimental
Infrastructure
Complying IEC 60193 StandardsEfficiency Uncertainty <2 ‰
PF 1 PF 2 PF 3Max Head: 100 mCE 120 mCE 100 mCEMax Discharge: 1.4 m3/s 1.4 m3/s 1.4 m3/sGenerating Power: < 300 kW < 300 kW < 300 kWMax Speed: 1'500 rpm 2'500 rpm 2'500 rpmPumping Power: 900 kW 1000 kW 2 x 400 kW
EPFL Testing Facilities
• Research• Education• Experimental
Validation
Machines
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Scale Model
PF2 EPFL Test RigMachines
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Piccard-Pictet ~1850
Niagara Falls
Classification of Hydraulic RunnersFourneyron’s Turbine
Machines
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Classification of Hydraulic Runners
Pelton Wheel
Impulse turbineTangential flowHigh head
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Pelton’s Turbine
Machines
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Pelton Turbine
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Cleuson-Dixence
Pelton Turbine, 5 jets
423 MW Unit Max. Power
~28 t Runner Masshttp://www.cleuson-dixence.ch/home.htm
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Classification of Hydraulic Runners
Francis Turbine
Reaction machineRadial flowMedium Head
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Francis Turbine
Voith - 1880
Machines
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Pump-Turbine
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Francis Turbine
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Itaipu (Brazil, Paraguay)
18 Francis Turbines
740 MW Unit Max. Power
~ 300 t Runner Masshttp://www.itaipu.gov.br
PF1 EPFL Test Rig
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Columbia Basin
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Columbia Basin
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Grand Coulée Dam9+9 125 MW Francis Units
3 x 690 MW + 3 x 805 MWhttp://www.usbr.gov/power/data/sites/grandcou/grandcou.html
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3 Gorges Project (Yang Tse River)
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3 Gorges Project
14 + 12 Francis Turbines
700 MW Unit Max Power
110m Head
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3 Gorges ProjectSpiral Casing
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3 Gorges ProjectRunner Unit #3
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3 Gorges ProjectRunner Outlet
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3 Gorges ProjectDraft Tube Cone
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Classification of Hydraulic Runners
Kaplan Turbine
Reaction machineAxial flowLow head
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Kaplan Turbine
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Bulb Turbine
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Gezhouba
Kaplan Turbine
176-129 MW Unit Max. Power
~ 420 t Runner Mass
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Yacyretá Power Plant
20 Kaplan Units
120 MW Unit Max Power
9. 5 m Runner Dia.
3200 MW
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IEC 60193 Validation Tests:e.g. Brilliant Expansion Project
Cavitation TestsPF2 EPFL Test Rig, 2003
120 MW Kaplan
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La Rance Tidal Power Plant
24 Bulb Units
10 MW Unit Max Power
5.35 m Runner Dia.
540 GWh/year
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Source of EnergyKey World Energy Statistics 2007
Source of EnergyAfrica America Asia
OceaniaEurope Total
Comb. Fossil 2'001 12'086 14'227 13'356 41'670 90.4%Nuclear 7 712 348 1'039 2'106 4.5%
Hydraulic 55 1'072 542 689 2'358 5.0%Other 2 31 25 24 82 0.1%Total 2'065 13'901 15'142 15'108 46'216
4% 30% 33% 33%
World Resources TWh/y
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Electrical Energy
Source of EnergyAfrica America Asia
OceaniaEurope Total
Comb. Fossil 275 2'663 2'457 2'271 7'666 62.9%Nuclear 7 712 348 1'039 2'106 17.5%
Hydraulic 55 1'072 542 689 2'358 19.1%Other 1 28 11 10 50 0.5%Total 338 4'475 3'358 4'009 12'180
3% 37% 28% 33%
World Consumption TWh/y
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Hydroelectric Powerplants
AreaTotal Potential
Used Potential
Stocked Potential
TWh / yNorth America 1'100 61% 39%South America 2'300 19% 81%
Europe 800 65% 35%Africa 1'000 7% 93%
Asia 3'600 20% 80%Australia/Oceania 105 40% 60%
Total 8'905 27% 73%TWh / y 2'438 6'467
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World Hydro in 2003
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2006 EnergyConsumption
Balancein Switzerland
“Statistique globalesuisse de l’énergie2006” Office fédéralde l’énergieStatistiques 2006
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Swiss Power GenerationStatistique suisse de l'électricité 2006
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‐
10'000
20'000
30'000
40'000
50'000
60'000
70'000
1970 1975 1980 1985 1990 1995 2000 2005 2010
[GWh]
Run‐off Power Plants
Total Annual Power Generation
Storage Power Plants
Swiss Annual Power Consumption
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Power Generation in SwitzerlandPompage; 4%
Centrales au fil de l'eau; 26%
Centrales à accumulation;
28%
Centrales thermiques
nucléaires; 38%
Centrales thermiques classiques
Centrales hydrauliques
16%
Centrales thermiques classiques
45%Centrales
thermiques nucléaires
39%
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Swiss Large Dams
Grande DixenceMauvoisin
L’Hongrin
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Types of Swiss Power Stations
Run-of Hydro-Power Plants
Storage Hydro-Power Plants
Pumping Storage Hydro-Power Plants
Nuclear Power Plants
Thermal Power Plants
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Run-Off Hydro Power Plant
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Storage Power Plant
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Annual Water Storage
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Hydraulic Machines: Application AreasPower Generation
Hydro-Power
Turbine, Storage Pumps & Pump-Turbines
Nuclear Power and Thermal Power Station
Reactor Circulation PumpsBoiler Feed PumpsBoosterBoiler Circulation PumpsCooling Water PumpsCondensate Extraction PumpsEmergency Cooling PumpsAuxiliary Pumps
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Steam Generator
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Power Generation
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Leibstadt, BWR 990 MW Gösgen, PWR 950 MWhttp://www.kkg.ch/home2/home.cfm
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Pumps for Nuclear Power Plants
Main Circulating Pumps
Reactor Cooling Pumps
Boiler Feed Pumps
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PWR Nuclear Power Plant
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Reactor Circulating Pump
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Boiler Feed Pump
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Hydraulic Machines AreasOnshore & Offshore Oil and Gas
Water Injection Pumps
Sea Water Lift Pumps
Multiphase Pumps
Pipeline Pumps
Fire Fighting Pumps
Process PumpsDesalination, Water Treatmant
Auxiliary Pumps…
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Deep Sea
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Multiphase Pump MPP
Total volume flow up to 4000 m3/h
Differential pressure up to 80 bar
Gas liquid ratio up to 95 %
Power up to 5000 kW
MPP for Total Dunbar
Installation on Dunbar platform
Multiphase Pump MPP
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Helico-axial multiphase pump
Present status
Up to 15 stages
Up to 6.6 MW
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Injection Barrel Pumps
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Injection Barrel Pump GSG
New features
New twist lock cover closure
Opposed impeller design
New radial inlet
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Reverse Osmosis DesalinationHigh Pressure Feeding System
68 Bars Membrane Pressure
Brine Flow Power Recovery
8-150 10-3 m3/s
>70 % of the Sea Water Flow
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Ariane V Rocket Engine Propulsion
Vulcain Engine
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Vulcain Rocket Engine
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Ariane V Liquid Propulsion
815 kN
255 kg/s
105 bars
LOX ~ 3 MW @ 13’500 rpm
LH2 ~11 MW @ 34’900 rpm
Vulcain Engine
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LOX Pump
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LH2 Pump
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LH2 Inducer Cavitation Development
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SARRAF, C., AIT-BOUZIAD, Y., DJERIDI, H., FARHAT, M., DENISET, F., BILLARD, J.Y. (2006). "Effect of cavitation on the structure of the boundary layer in the wake of a partial cavity" CAV2006, Wageningen.AIT BOUZIAD Y., (2005): "Physical modeling of leading edge cavitation: computational methodologies and application to hydraulic machinery", EPFL Doctoral Thesis N° 3353.AIT-BOUZIAD, Y., FARHAT, M., KUENY, JL, AVELLAN, F., MIYAGAWA, K., (2004): "Evaluation of Physical Models for Cavitation Simulation of an Industrial Inducer". Proceedings of the 22nd IAHR Symposium on Hydraulic Machinery and Systems, Stockholm, Sweden, June 29 - July 2, 2004
Industrial Inducer
80%nQ Q = 120%nQ Q =100%nQ Q =
0.20cψ =
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Power Hydraulics
DisplacementMachines
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Gear PumpExternally Toothed
Speed Range
300-3’500 rpm
Displacement volume1.2-250 cm3
Nominal pressure 63-160 bars
Total Efficiency
80-91%
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Gear pumpInternally Toothed
Speed Range
500-3’500 rpm
Displacement volume4-250 cm3
Nominal pressure 160-250 bars
Total Efficiency
80-91%
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Screw Pump
Speed Range
500-4’000 rpm
Displacement volume4-630 cm3
Nominal pressure 25-160 bars
Total Efficiency
70-84%
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Rotary Vane Pump
Speed Range
960-3’000 rpm
Displacement volume5-160 cm3
Nominal pressure 100-160 bars
Total Efficiency
80-93%
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Axial Piston Pump
Speed Range
750-3’000 rpm
Displacement volume25-800 cm3
Nominal pressure 160-320 bars
Total Efficiency
80-92%
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Radial Piston Pump
Speed Range
960-3’000 rpm
Displacement volume5-160 cm3
Nominal pressure 160-320 bars
Total Efficiency
90%