Types of Hydraulic Machines

LMH Laboratory for Hydraulic Machines
-1- Hydraulic Turbomachines:

Different Types and Application Areas
Prof. François Avellan

francois.avellan@epfl.ch
Laboratory for Hydraulic Machines
Swiss Federal Institute of Technology Lausanne
Mechanical Engineering Bachelor:

6th Semester Introduction to Hydraulic Turbomachines
Content
Pumps and Turbines

Hydropower
9 Turbines: Pelton, Francis, Kaplan, Bulbs
9 Storage pumps and Pump-Turbines
Power Generation
Pumps for Thermal Power Generation
Pumps for Oil & Gas
Desalination
Pumps for Rocket Engines
Power Hydraulic
2
Hydraulic Turbines
Driving Machines
9 Driving Power defined as positive P = ω ⋅ T > 0
9 P Machine Power P = η T × Ph
9 Ph Available Hydraulic Power Ph = ρ × Q × E
9 Turbine Efficiency
P
ηT =
Ph
Q … ⎡⎣m3 ⋅ s−1 ⎤⎦
9 Discharge
9 Specific Energy E … ⎡⎣J ⋅ kg−1 ⎤⎦
3
Pumps
Work Absorbing Machines

9 Pump Power defined as negative P = ω ⋅ T < 0
9 P Machine Power Ph = η P × P
9 Ph Resulting Hydraulic Power Ph = ρ × Q × E
9 Machine Efficiency
Ph
ηP =
P
4
Specific Energy Balance
Turbine
ZB E = gHI − gH I
= g ( ZB − ZB ) − ∑ gHrT
ZB
I
I
Hydrodynamics 5
Machine Nomenclature
Hydrodynamics
Runner or Impeller Power Transfer

Traversing Discharge
Qt … ⎡⎣m3 ⋅ s-1 ⎤⎦
Transferred Specific
Energy
gH1 − gH 1 = Et ± Erb … ⎡⎣J ⋅ kg-1 ⎤⎦ 1
Power Transfer 1
Pt = ρQt Et …[MW ]
9 Driving (Turbines) Qt
P >0 Brillant Extension Project, British Columbia, Canada,
Kaplan Turbine CAD Model, PF2 EPFL Test Rig
9 Being Driven (Pumps) http://www.columbiapower.org/projects/brilliantdam.asp
P <0
Energy Conversion
Classification of Hydraulic Runners

Specific Energy Transfer
Et = gH1 − gH 1 9 Subscript 1:
High Energy Side
⎡ p1 C12 ⎤ ⎡ p1 C12 ⎤ 9 Subscript -1:
= ⎢ + gZ1 + ⎥ − ⎢ + gZ 1 + ⎥ Low Energy Side
⎣ρ 2 ⎦ ⎣ρ 2 ⎦
⎡ p1 p1 ⎤ ⎡ C12 C12 ⎤
= ⎣⎡gZ1 − gZ 1 ⎤⎦ + ⎢ρ − ρ ⎥ +⎢ − ⎥
Water Wheel
⎣ ⎦ ⎣ 2 2 ⎦
Displacement Machine Impulse Turbine
Reaction Machine
Z : Elevation p : Absolute Pressure

g : Gravity ρ : Density C : Flow Velocity
8
Types of Energy Conversion

Transfer Modes
Reaction
⎡ p1 p1 ⎤ ⎡ C12 C1 ⎤
2
Et = ⎢ − ⎥ + ⎢ − ⎥ + ⎡⎣gZ1 − gZ 1 ⎤⎦ ± Erb
⎣ρ ρ ⎦ ⎣ 2 2 ⎦
Water Wheel
Displacement Impulse Turbine
Energy Conversion
3 Types of Water Wheels

Overshot
Norse Mill
Undershot
Energy Conversion 10
Water Supply
Noria
Seqia, Al Jazzari, XIII Iraq
The Water Wheel:
Medieval Roots of the Industrial-Revolution
Main Medieval Prime Movers
9 8th Century
Labor Saving Potential
Monastic Orders
> 40 Industrial Processes
9 16th Century
Industrial Revolution
Precursor
9 18th Century
Prime Mover of Cotton Mills
200 kW Max. Power
Georgius Agricola, "De re metallica", 1556
Hydroelectric Power Development
Water Turbine Development

9 Fourneyron (1830s)
9 Francis Turbine (1840s)
9 Pelton (1880s)
9 Kaplan (1910s )
Trend to High Specific Power
Machines 13
Largest Hydropower Plants in the World

Hydropower Plant Country Capacity EPFL
3 Gorges China (2009) 18'200 MW
Itaipú Brazil / Paraguay 12'600 MW 9
Guri (Raúl Leoni) Venezuela 10'000 MW 9
Grand Coulee USA 6'494 MW 9
Sayano – Shushensk Russia 6'400 MW
Krasnoyarsk Russia 6'000 MW
Churchill Falls Canada 5'428 MW
La Grande 2 Canada 5'328 MW 9
Bratsk Russia 4'500 MW
Ust-llim Russia 4'320 MW
Tucurui Brazil 4'245 MW 9
Tucurui Dam & Power Plants

http://www.eln.gov.br/
World Class
Experimental
Infrastructure
• Research
• Education
• Experimental
Validation
EPFL Testing Facilities

Complying IEC 60193 Standards
Efficiency Uncertainty <2 ‰
PF 1 PF 2 PF 3
Max Head: 100 mCE 120 mCE 100 mCE
Max Discharge: 1.4 m3/s 1.4 m3/s 1.4 m3/s
Generating Power: < 300 kW < 300 kW < 300 kW
Max Speed: 1'500 rpm 2'500 rpm 2'500 rpm
Pumping Power: 900 kW 1000 kW 2 x 400 kW
Machines
Scale Model
PF2 EPFL Test Rig

Machines

Fourneyron’s Turbine
Piccard-Pictet ~1850
Niagara Falls
Machines 17

Pelton Wheel
9 Impulse turbine
9 Tangential flow
9 High head
18
Pelton’s Turbine
Machines 19
Pelton Turbine
20
Cleuson-Dixence
Pelton Turbine, 5 jets

423 MW Unit Max. Power
~28 t Runner Mass
http://www.cleuson-dixence.ch/home.htm
21

Francis Turbine
9 Reaction machine
9 Radial flow
9 Medium Head
22
Francis Turbine
Voith - 1880
Machines 23
Pump-Turbine
24
Francis Turbine
25
Itaipu (Brazil, Paraguay)
18 Francis Turbines
740 MW Unit Max. Power
~ 300 t Runner Mass
http://www.itaipu.gov.br
PF1 EPFL Test Rig
26
Columbia Basin
27
Columbia Basin
28
Grand Coulée Dam
9+9 125 MW Francis Units
3 x 690 MW + 3 x 805 MW
http://www.usbr.gov/power/data/sites
/grandcou/grandcou.html
29
3 Gorges Project (Yang Tse River)
30
3 Gorges Project
14 + 12 Francis Turbines
700 MW Unit Max Power
110m Head
31
3 Gorges Project
Spiral Casing
32
3 Gorges Project
Runner Unit #3
33
3 Gorges Project
Runner Outlet
34
3 Gorges Project
Draft Tube Cone
35

Kaplan Turbine
9 Reaction machine
9 Axial flow
9 Low head
36
Kaplan Turbine
37
Bulb Turbine
38
Gezhouba
Kaplan Turbine
176-129 MW Unit Max.
Power
~ 420 t Runner Mass
39
Yacyretá Power Plant
20 Kaplan Units
9. 5 m Runner Dia.
3200 MW
40
IEC 60193 Validation Tests:

e.g. Brilliant Expansion Project
Cavitation Tests
PF2 EPFL Test Rig, 2003
9 120 MW Kaplan
41
La Rance Tidal Power Plant
24 Bulb Units
5.35 m Runner Dia.
540 GWh/year
42
Source of Energy
Key World Energy Statistics 2007
World Resources TWh/y
Africa America Asia Europe Total

Source of Energy Oceania
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%
43
Electrical Energy
World Consumption TWh/y
Africa America Asia Europe Total

Source of Energy Oceania
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%
44
Hydroelectric Powerplants
Total Used Stocked

Area Potential Potential Potential
TWh / y
North 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
45
World Hydro in 2003
46
2006 Energy
Consumption
Balance
in Switzerland
9 “Statistique globale
suisse de l’énergie
2006” Office fédéral
de l’énergie
Statistiques 2006
47
Swiss Power Generation
Statistique suisse de l'électricité 2006
70'000
[GWh]
60'000
Total Annual Power Generation
50'000
Swiss Annual Power Consumption
40'000
Storage Power Plants
30'000
20'000
Run‐off Power Plants
10'000
‐
1970 1975 1980 1985 1990 1995 2000 2005 2010
48
Power Generation in Switzerland
Pompage; 4%
Centrales au fil
Centrales de l'eau; 26%
thermiques
classiques
Centrales Centrales à
thermiques accumulation;
nucléaires; 38% 28%
Centrales
thermiques
classiques
45%
Centrales
thermiques
nucléaires
39% Centrales
hydrauliques
16%
49
Swiss Large Dams
L’Hongrin
Mauvoisin
Grande Dixence 50
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
51
Run-Off Hydro Power Plant
52
Storage Power Plant
53
Annual Water Storage
54
Hydraulic Machines: Application Areas
Power Generation
Hydro-Power
9 Turbine, Storage Pumps & Pump-Turbines
Nuclear Power and Thermal Power Station
9 Reactor Circulation Pumps
9 Boiler Feed Pumps
9 Booster
9 Boiler Circulation Pumps
9 Cooling Water Pumps
9 Condensate Extraction Pumps
9 Emergency Cooling Pumps
9 Auxiliary Pumps
55
Steam Generator
56
Power Generation
57
Leibstadt, BWR 990 MW Gösgen, PWR 950 MW

http://www.kkg.ch/home2/home.cfm
58
Pumps for Nuclear Power Plants
Main Circulating Pumps

Reactor Cooling Pumps
Boiler Feed Pumps
59
PWR Nuclear Power Plant
60
Reactor Circulating Pump
61
Boiler Feed Pump
62
Hydraulic Machines Areas
Onshore & Offshore Oil and Gas
Water Injection Pumps
Sea Water Lift Pumps
Multiphase Pumps
Pipeline Pumps
Fire Fighting Pumps
Process Pumps
9 Desalination, Water Treatmant
Auxiliary Pumps…
63
Deep Sea
64
65
66
Multiphase Pump MPP

Multiphase Pump MPP MPP for Total Dunbar
Totalvolume flow up to
4000 m3/h
Differential pressure up
to 80 bar
Gasliquid ratio up to
95 %
Power up to 5000 kW
Installation on Dunbar platform

67
Helico-axial multiphase pump
Present status
Up to 15 stages
Up to 6.6 MW
68
Injection Barrel Pumps
69
Injection Barrel Pump GSG
New features
New twist lock cover closure
Opposed impeller design
New radial inlet
70
Reverse Osmosis Desalination
High Pressure Feeding System
68 Bars Membrane Pressure

Brine Flow Power Recovery
8-150 10-3 m3/s
>70 % of the Sea Water Flow
71
Ariane V
Rocket Engine Propulsion
Vulcain Engine
72
Vulcain Rocket Engine
73
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
74
LOX Pump
75
LH2 Pump
76
LH2 Inducer Cavitation Development
77
Industrial Inducer
Q Qn = 80% Q Qn = 100% Q Qn = 120%
ψ c = 0.20
9 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.
9 AIT BOUZIAD Y., (2005): "Physical modeling of leading edge cavitation: computational
methodologies and application to hydraulic machinery", EPFL Doctoral Thesis N° 3353.
9 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
78
Power Hydraulics
Displacement
Machines
79
Gear Pump
Externally Toothed
Speed Range
9 300-3’500 rpm
Displacement volume
9 1.2-250 cm3
Nominal pressure
9 63-160 bars
Total Efficiency
9 80-91%
Gear pump
Internally Toothed
Speed Range
9 500-3’500 rpm
Displacement volume
9 4-250 cm3
Nominal pressure
9 160-250 bars
Total Efficiency
9 80-91%
Screw Pump
Speed Range
9 500-4’000 rpm
Displacement volume
9 4-630 cm3
Nominal pressure
9 25-160 bars
Total Efficiency
9 70-84%
Rotary Vane Pump

Speed Range
9 960-3’000 rpm
Displacement volume
9 5-160 cm3
Nominal pressure
9 100-160 bars
Total Efficiency
9 80-93%
Axial Piston Pump

Speed Range
9 750-3’000 rpm
Displacement volume
9 25-800 cm3
Nominal pressure
9 160-320 bars
Total Efficiency
9 80-92%
Radial Piston Pump

Speed Range
9 960-3’000 rpm
Displacement volume
9 5-160 cm3
Nominal pressure
9 160-320 bars
Total Efficiency
9 90%

Types of Hydraulic Machines

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Types of Hydraulic Machines

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LMH Laboratory for Hydraulic Machines

-1- Hydraulic Turbomachines:

Prof. François Avellan

Mechanical Engineering Bachelor:

 Pumps and Turbines

 Work Absorbing Machines

Runner or Impeller Power Transfer

Classification of Hydraulic Runners

Z : Elevation p : Absolute Pressure

Types of Energy Conversion

3 Types of Water Wheels

Seqia, Al Jazzari, XIII Iraq

Hydroelectric Power Development

 Water Turbine Development

 Trend to High Specific Power

Largest Hydropower Plants in the World

Tucurui Dam & Power Plants

EPFL Testing Facilities

 PF2 EPFL Test Rig

Classification of Hydraulic Runners

Classification of Hydraulic Runners

 Pelton Turbine, 5 jets

Classification of Hydraulic Runners

3 Gorges Project (Yang Tse River)

Classification of Hydraulic Runners

IEC 60193 Validation Tests:

Africa America Asia Europe Total

Africa America Asia Europe Total

Total Used Stocked

World Hydro in 2003

Types of Swiss Power Stations

 Run-of Hydro-Power Plants

Leibstadt, BWR 990 MW Gösgen, PWR 950 MW

Pumps for Nuclear Power Plants

 Main Circulating Pumps

Multiphase Pump MPP

Installation on Dunbar platform

Helico-axial multiphase pump

Injection Barrel Pumps

 68 Bars Membrane Pressure

Vulcain Rocket Engine

LH2 Inducer Cavitation Development

Q Qn = 80% Q Qn = 100% Q Qn = 120%

Rotary Vane Pump

Axial Piston Pump

Radial Piston Pump

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Work Absorbing Machines

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PF2 EPFL Test Rig

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Run-of Hydro-Power Plants

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68 Bars Membrane Pressure