Development of Efficient Cross Flow Turbine for Hilly Region
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Project Completion Report on R&D PROJECT Development of Efficient Cross Flow Turbine for Hilly Region Name and Address of PI Prof. R.P. Saini, Professor, Department of Hydro and Renewable Energy (HRED) (Formerly Alternate Hydro Energy Centre) Indian Institute of Technology Roorkee Roorkee -247667, Uttarakhand Grantee Institutions/organization Indian Institute of Technology Roorkee Roorkee (Uttarakhand) Submitted to: Ministry of New and Renewable Energy (MNRE) Govt. of India, New Delhi Prepared By: Department of Hydro and Renewable Energy (HRED) (Formerly Alternate Hydrology Energy Centre) Indian Institute of Technology Roorkee Roorkee – 247 667 (Uttarakhand) May 2019 1. Title of the Project: Development of Efficient Cross Flow Turbine for Hilly Region 2. Principal Investigator(s) and Co-Investigator(s) Principal Investigator Prof. R.P. Saini Professor Department of Hydro and Renewable Energy (HRED) (Formerly Alternate Hydro Energy Centre) Indian Institute of Technology Roorkee Roorkee -247667, Uttarakhand, India Phone : 01332-285841, Fax : 01332-273517, 273560 E-mail : [email protected], [email protected] Co-Investigator Prof. S.K. Singal Department of Hydro and Renewable Energy (HRED) (Formerly Alternate Hydro Energy Centre) Indian Institute of Technology Roorkee Roorkee -247667, Uttarakhand, India Phone : 01332-285167, Fax : 01332-273517, 273560 E-mail : [email protected], [email protected] 3. Implementing Institution(s) and other collaborating Institution(s) Department of Hydro and Renewable Energy (HRED) (Formerly Alternate Hydro Energy Centre) Indian Institute of Technology Roorkee Roorkee -247667, Uttarakhand 4. Date of commencement of Project 18 March, 2014 5. Approved date of completion March 17, 2017 extended upto June 30, 2018 6. Actual date of completion June 30, 2018 7. Objectives of the Project i) Broad Objectives In hilly region micro hydro plant capacity up to 100 kW have momentous role in utilization of mechanical power and electricity generation. The capacity of micro i hydro power plant up to 5.0 kW is considered under development of water mill program by Ministry of New and Renewable Energy (MNRE), Govt. of India. The popularity of the turbines under micro hydro lies in the fact that they are less costly and can be fabricated locally. There are various types of turbines that can be used in micro hydro. Among them, cross-Flow turbine has been considered techno- economically viable for such sites. Cross flow turbine runner can be fabricated locally, but has the poor efficiency. Also this type of runner may be work for low discharge low & high head conditions, which is a common case in the hills. A cross flow type runner has a drum shape consisting of two parallel discs connected together by a series of curved vanes or blades. The water from the nozzles strikes the blades and convert 2/3rd part of the potential into the mechanical power. Water comes out from blades at first stage then strikes diametrically opposite blades and transfers its remaining 1/3rd energy at second stage. Water flows from stage I to stage II and remains unguided inside the runner and this may be the main cause of its low efficiency. It is aimed to develop standard designs of improved cross flow turbines. The cross flow runner shall be modified in order to improve the efficiency of the turbine. It is proposed to provide a flow control mechanism inside the runner. Flow analysis shall be done using CFD. It is expected that about 5% increment in the efficiency of the turbine can be achieved. CFD results shall be validated with the laboratory test and a prototype is proposed to be fabricated and installed at a suitable site for its field performance monitoring. ii) Specific Objectives It is proposed to develop a prototype of improved cross flow turbine. The design of the improved turbine is proposed to analyze through CFD in order to determine blade profile and design guide mechanism under different operating conditions of turbine. Following are the specific objectives; (a) To carry out CFD based design of runner with guide mechanism of cross flow turbine. (b) To design and fabricate the runner along with guide mechanism and other components of a turbine for a capacity of 5.0 kW. (c) To test the turbine performance in laboratory for design validation. (d) To install the modified turbine at a selected site for field test and performance monitoring. 8. Output of the Project a) Details of proposed Scientific output: i) Technical Documents : Completion report of the project ii) Research Papers : Research component of the project output is proposed to be published. iii) Awareness Camps: During development of turbines, two awareness Camps. ii b) Product/ process quantifiable performance output proposed: A prototype of 5.0 kW capacity with upto 5% more efficient cross- turbine is proposed to be developed. 9. Summary of the Project work In micro-hydro potential sites, cross flow hydro turbine is the suitable alternative to provide the energy due to its low initial cost, easy construction, installation and maintenance. However, cross flow turbine suffers the problem of low performance as compared to conventional hydro turbines. Under the present study, an attempt has been made to enhance the cross flow turbine efficiency by improving the flow conditions/direction inside the turbine runner. A guide mechanism having different types of airfoils (Symmetrical and unsymmetrical) has been investigated and the performance in term of efficiency of the modified turbine is compared with the conventional cross flow turbine design. In order to investigate the turbine performance at different operating conditions, numerical simulation (CFD) using commercially available software (ANSYS) was used. Further, the numerical results have been validated with the experimentation carried out in the Hydraulic Measurement Laboratory, Department of Hydro and Renewable Energy, Indian Institute of Technology Roorkee, India. Based on the numerical simulations, it is found that the guide tube/vane improves the flow characteristics inside the runner and hence the efficiency. The placement angle of the guide vanes affects the flow behavior which in turn flow condition over guide vane. It is, therefore, the placement angle for both symmetrical and unsymmetrical vane was required to be optimized and it is found that the cross flow turbine provides better performance with symmetrical and unsymmetrical guide vane having placement angle of 55º and 45º respectively. The positioning of the guide vanes has also been optimized by placing the guide vanes at left, center and right positions and it has been observed from the numerical simulations that the ‘right’ position of the guide vane yields better performance corresponding to given operating conditions. Further, in order to attain the optimum placement angle and placement position for both symmetrical and un-symmetrical vanes, it was desired to select the suitable airfoil from the two. Therefore, both airfoils have been simulated under similar operating conditions and it has been found that the cross flow turbine at 125% of design discharge and with unsymmetrical guide vane yields the maximum efficiency 76.61% which is about 5.84% higher than the conventional design cross flow turbine without guide vane and 4.50% higher than the turbine with symmetrical guide vane. The numerical results of the cross flow turbine have been validated by rigorous experimental testing in laboratory. Therefore, a cross flow turbine model was fabricated and tested under different operating conditions. Based on the experimental investigations it was found that numerical results are on similar lines and a maximum of 4.57% deviation in results was observed which may be due to instrumental or measurement error. Further, in order to test the prototype of modified cross flow turbine a pico hydro power site was identified at Balkhila River in Chamoli District near Mandal village. The turbine is deployed. Further, the modified turbine was tested at site and it has been found that the turbine yields its maximum performance as 71.28% corresponding to 0.151 m3/s discharge. iii 10. Detailed progress report giving relevant information on work carried out, experimental work, detailed analysis of results indicating contributions made towards increasing the state of knowledge in the subject: Attached with at Annexure-I. 11. S&T benefits accrued i) Patents taken, if any : NIL ii) List of Research publications : Sl. Authors Title of Name of the Volume Pages Year No paper* Journal i) Saini R.P. and Singal S.K., “Development of cross flow turbine for pico hydro”, International Conference on Hydropower for Sustainable Development, Feb.05- 07, 2015, Dehradun. ii) Saini R.P. and Singal S.K, “CFD simulation of cross flow turbine using AcuSolve”, Altair Technology Conference, 2015. iii) Saini R.P. and Singal S.K, Saini Gaurav, “Numerical and Experimental Investigations for Flow Characteristics and Performance Improvement of Cross Flow Turbine” Journal of Renewable and Sustainable Energy [Submitted on Feb. 03, 2019]. ii) List of Technical Documents prepared : Final report attached. iii) Manpower trained under the project (a) Research Scientists/ Research Associates : 03 (b) No. of M. Tech. Dissertation produced : 02 nos. iv) Awareness, training camps, etc. organized: 02 12. Details of work which could not be completed (if any) N.A. 13. Suggestions on further work on the subject of research Further scope of research on the subject is to analyse the combined effect of guide tube and draft tube on the performance of cross flow turbine. For this, separate research project proposal may be submitted in due course. iv 14. Project Expenditure The utilization certificate and statement of expenditure has been submitted separately. The summary details are as follows: No Financial Position/ Amount Actual Committed Budget Head Sanctioned Expenditure Liabilities (Rs. in lacs) (Rs. in lacs) (Rs. in lacs) 1. Travel 1.60 2.93 2. Manpower 14.40 10.83 3. Equipment 6.00 4.78 4. Consumables 6.00 5.90 1.37 5.