Pelton Design

Design & Analysis of Pelton Wheel Turbine
P M V Subbarao
Professor
Mechanical Engineering Department
Internal Details of the Machine.
Koyna Hydro Electric Project

Koyna Dam from the
catchment area of about
891.78 Sq. Km
Koyna river rises in the

Mahabaleshwar, a famous hill
station in the hill range of Sahyadri.
It flows in a north - south direction
almost parallel to the Arabian Sea
coast for a distance of 65 Kms.
Details of Koyna Hydro Electric Project

Number of units: 4
Capacity of each unit=250MW
Head
Normal Head=415m
Maximum Head=510m
Creation of Reservoir
Specific speed in rpm
Ns
N P
H
MORE ADAPTED TYPE OF TURBINA IN FUNCTION OF

THE SPECIFIC SPEED.
Specific Speed in
Turbine type
Jump height in m
r.p.m.
Until 18
Pelton of an injector
800
From 18 to 25
800 to 400
From 26 to 35
400 to 100
From 26 to 35
Pelton of two injectors
800 to 400
From 36 to 50
Pelton of two injectors
400 to 100
From 51 to 72
Pelton of four injectors
400 to 100
Selection of Speed of A Turbo Machine
3000
N
zp
for
f 50 Hz
Zp : Number of pairs of poles of the generator
Questions to be Answered
Is it possible to change number of units in Stage

IV?
What is the allowable speed of the generator for
each unit, if number of units is 2, 5, 6 or 7?
Design of Any Selected Pelton Wheel Unit
Different capacities for each sub-group.

Design for Normal Head.
Assume an overall efficiency: 90 94%
Calculate the required flow rate.
P pelton Q g H
General Layout of A Hydro Power Plant
THE CONDUIT SYSTEM

Water from the storage is diverted into the main conduit
system through a 3,370ft long intake channel and an intake
tower, trash racks and two intake gates each 21ftX8ft.
The head race tunnel is 12,000ft long and 21ft in diameter.
It is concrete lined for the whole of the length expect for
the last 1600ft at the surge end where 17ft diameter steel
lining is provided.
The diameter of the tunnel, in the stretch of steel lining is
reduced on ground of economy
Pipe Material
Open Channel Gravity

Channel
drawn brass
Bed drawn
Slopecopper
commercial steel
wrought iron
2
asphalted cast iron
galvanized iron
h cast iron
wood stave
4 fV
S0
2 gD
4A
Dh
P
Absolute Roughness, e
micron
Flow(unless
noted)
1.5
1.5
45
45
120
150
260
0.2 to 0.9 mm
concrete
0.3 to 3 mm
riveted steel
0.9 to 9 mm
Design of Penstock
Q V penstock
2
penstock
In general
Vpenstock 2 gH
But maximum allowable value is 10 m/s
Maximum allowable head loss in Penstock =2 to 4% of
available head
General Design of Under Ground Power Tunnels/Penstocks
h friction x H
f
2
Pipe Material
penstock
4 fLV
2 gd penstock
drawn brass
drawn copper
commercial steel
2
wrought iron
asphalted cast iron
galvanized
0.9iron
hcast iron
wood stave
0.0625
k
5.74
log
3.7 D Re
concrete2 gH
Vpenstock kv, penstock
riveted steel
micron
(unless noted)
1.5
1.5
45
45
120
150
260
0.2 to 0.9 mm
0.3 to 3 mm
0.9 to 9 mm
kv , pestock : 0.2 to 0.15 (inversly proportion al to Specific Speed)
Design of Penstock
Group No.
Unit Size
MW
1.
500
2.
333.3
3.
200
4.
166.7
5.
142.85
6.
125
7.
111.1
8.
100
Qp
Dp
Head loss
Distributor : Only for multi jet Wheel
Design of Distributor
Penstock
Q V penstock
2
penstock
The Nozzle and Jet : A Key Step in Design

b
djet,VC
Free Surface Shape for Maximum Power
d0
Initial guess for Diameter of the Jet at the outlet, do
2
Q d o K vo 2 gH
4
0.81 K vO 0.83
It is important to find out the VC and outlet jet
diameters/areas
Geometrical Relations for Nozzle

1.1dO 1.3dO
2dO 2.4dO
dO
0.8dO 0.9dO
5dO 9dO
1.2dO 1.4dO
Performance Analysis of Nozzle-Spear Valve

Ideal Nozzle-spear Valve:
2
V
p
gz constant Along flow direction
2
Real Nozzle-spear Valve:
2
p V
ptotal constant- p friction

2
p friction
f
4 fLV
2
penstock
2d penstock
0.0625Pipe Material
2
k

5
.
74
drawn
brass
log
0.9
Recopper
3.7 Dhdrawn
commercial steel
wrought iron
asphalted cast iron
galvanized iron
cast iron
wood stave
micron
(unless noted)
1.5
1.5
45
45
120
150
260
0.2 to 0.9 mm
concrete
0.3 to 3 mm
riveted steel
0.9 to 9 mm
Numerical Computation of Total Pressure Variation
Efficiency of Spear Nozzle Valve
ptot inlet ptot exit

spearvalve 1
100
ptot inlet
Acceptable Range: 97.5% -- 99%
Design of Penstock
Group No.
Unit Size
MW
1.
500
2.
333.3
3.
200
4.
166.7
5.
142.85
6.
125
7.
111.1
8.
100
djet
Head loss
spearvalve
Geometrical Relations for Nozzle
The values of varies between 20 to 30

whereas varies from 30 to 45.
Industrial Correlations for Jet Area variation with

stroke
Optimal value of Outlet jet area, ao
ao As Bs
s is the displacement of spear
b a
A 2ro sin a
sin b a
2
b a sin b sin a sin a
B
2
sin b a
Computation of Variation Jet Area with stroke
Mean Diameter of Pelton Runner

Mean diameter or
Pitch circle diameter:
Dwheel
Circumferential
velocity of the wheel,
Uwheel
U wheel 2gH
U wheel Kuwheel 2 gH
Experimental values of Wheel diameter to jet diameter

Dwheel /djet,VC
6.5
7.5
10
20
Ns (rpm)
turbine
35
0.82
32
0.86
24
0.89
10
0.90
Higher ratios are preferred for better efficiency.

Modern wheels for high heads use ratios as high as 30!
Ns
d jet ,VC
4Q
K v1 2 gH
N wheel P
4
H5
0.98 K v1 0.99
Optimal values of Wheel diameter to jet diameter

30
25
20
Dwheel
15
d jet
10
0
0
10
15
20
25
30
Ns
35
40
45
50
Group No.
Unit Size
MW
1.
500
2.
333.3
3.
200
4.
166.7
5.
142.85
6.
125
7.
111.1
8.
100
Geometric Details of Bucket

The hydraulic efficiency
depends more on the main
bucket dimensions (length
(A), width (B) and depth
(C)).
The shape of the outer part
of its rim or on the lateral
surface curvature also has
marginal effect on
hydraulic efficiency.
Empirical Geometry of Bucket Shape

III
II
C
IV
V
I
DW
2 bi
A
be
B
Empirical Relations for Bucket Geometry
A = 2.8 djet,VC to 3.2 djet,VC

B = 2.3 djet,VC to 2.8 djet,VC
C= 0.6 djet,VC to 0.9 djet,VC
bi = 50 to 80
be is varied from section I to section V
I: 300 to 460
II: 200 to 300
III: 100 to 200
IV: 50 to 160
V: 00 to 50
Number of Buckets
d jet ,O
Dwheel
cos
2d
1
Dwheel
ku ,wheel
d
y
21
sin
kvO Rwheel
dO,
Vj,O
d
RP
RW w
q
lj
Maximum allowable angle between two successive buckets
q 2 y
Minimum number of buckets
360
Dr Taygun has suggested an empirical relation for z
Dwheel
z 0.5
15
d jet ,VC
Group No.
Unit Size
MW
1.
500
2.
333.3
3.
200
4.
166.7
5.
142.85
6.
125
7.
111.1
8.
100
Absolute and Relative Paths of Jet : Orthogonal Interactions
Vjet
Ublade
be
ae
Vrel,jet,exit
Vjet,exit
Ublade
cos b e
2U Vai cosa i U k
1
cos bi
d
2
Vai
2
U
cos b
d 2 cosa i k
1
Vai
Vai cos bi e
Define Blade Speed Ratio,
cos b e
d 2 cosa i k
1
cos bi
Approximate Velocity Triangles: Pelton Bucket
d ,max 2 k cosbe 1
Pb mU Vre cos b e Vri
Start of Jet Bucket Interactions
Sequence of Jet Bucket Interactions
q50
q150
q250
q350
Bucket Duty Cycle

Compute angles of onset and close of
interactions.
Select few locations during bucket jet interaction.
Compute mass of jet intercepted by the bucket and
corresponding blade exit angles.
Numerically integrate the work done by a bucket
per rotation.
Compute Average Power developed by bucket
and efficiency.

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Design & Analysis of Pelton Wheel Turbine

Internal Details of the Machine.

Koyna Hydro Electric Project

Koyna river rises in the

Details of Koyna Hydro Electric Project

Specific speed in rpm

MORE ADAPTED TYPE OF TURBINA IN FUNCTION OF

Selection of Speed of A Turbo Machine

Zp : Number of pairs of poles of the generator

Is it possible to change number of units in Stage

Design of Any Selected Pelton Wheel Unit

Different capacities for each sub-group.

General Layout of A Hydro Power Plant

THE CONDUIT SYSTEM

Open Channel Gravity

General Design of Under Ground Power Tunnels/Penstocks

kv , pestock : 0.2 to 0.15 (inversly proportion al to Specific Speed)

Distributor : Only for multi jet Wheel

The Nozzle and Jet : A Key Step in Design

Free Surface Shape for Maximum Power

Initial guess for Diameter of the Jet at the outlet, do

Geometrical Relations for Nozzle

Performance Analysis of Nozzle-Spear Valve

ptotal constant- p friction

Numerical Computation of Total Pressure Variation

Efficiency of Spear Nozzle Valve

ptot inlet ptot exit

Acceptable Range: 97.5% -- 99%

Geometrical Relations for Nozzle

The values of varies between 20 to 30

Industrial Correlations for Jet Area variation with

s is the displacement of spear

Computation of Variation Jet Area with stroke

Mean Diameter of Pelton Runner

Experimental values of Wheel diameter to jet diameter

Higher ratios are preferred for better efficiency.

Optimal values of Wheel diameter to jet diameter

Geometric Details of Bucket

Empirical Geometry of Bucket Shape

Empirical Relations for Bucket Geometry

A = 2.8 djet,VC to 3.2 djet,VC

Maximum allowable angle between two successive buckets

Dr Taygun has suggested an empirical relation for z

Absolute and Relative Paths of Jet : Orthogonal Interactions

Define Blade Speed Ratio,

Approximate Velocity Triangles: Pelton Bucket

Pb mU Vre cos b e Vri

Start of Jet Bucket Interactions

Sequence of Jet Bucket Interactions

Bucket Duty Cycle

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