THE EFFICIENT CONDITIONS
OF A

HYDRY—ELECTRIC POWER UNIT

Thesis for the Degree of B. S.
Harold 1. Rich
I927

 

 

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(I‘Ltt'E

JP

T773 EFFICIENT CCIIDITIOI‘IS
OF A
HYDEO-YL?C¢?IC 0773 UNIT.

SUBTITTED TO THE FACULTY OF
THE FICHIGAN STATE COLLEGE OP

AGRICULTUZ? LIED AP??LI.ZID 3 131303.

By j‘
Inflow I“. RICH

Candidates
for the degree of

Bachelor of science.

June 1927.

(TH 55's

Machine design is based on a correct mathematical theory. In
the construction of any machine, however, theoretical lines cannot
be followed in all details, and, even if this were possible, the
truth of the theory must be demonstrated by actual trial under
such conditions as the machine is required to run, for there are
usually many factors involved which cannot be theoretically con-
sidered and yet effect the results. Much depends upon the chara-
cter of the workmanship, cla s of materials used, and on all the
details of construction, installation and Operation as well as
design. All of these matters can not be included in the thenreti-
cal, and it therefore becomes necessary to determine the actual

results by a trial of the maChine under working conditions.

The ease with which such determinations are made is usually
a criterion of the rapidity with which improvements in the design
and construction of a particular machine take elace. There the
determinations require a large expenditure of time and money, the
resulting delays and expense usually so limit such determinations

that good results are attained but slowly.

The value of testing water whells was recOgnized by Smeaton
who tested various water wheels about the middle of the Eighteenth
Century. The invention of the turbine also brought methods of
testing, which have been potent factors in the improvement of tur-
bines. While the methods of testing has improved since that time,
they have not yet reached that point which assures tne high grade

of design and workmanship in their manufacture as in other machinery

103432

where testing is more generally and easily practiced.

The principle causes of this backward condition are the
difficulties and expense of making an accurate test in place,
and the unsatisfactory results of testing a turbine in a testing
flume where the head and capacity are so limited as to confine
satisfactory tests to heads seventeen feet or less and to wheels
of a capacity of abou 350 cubic feet per second or less. Appar-
ently slight variations in turbine construction produces radical
changes in its performance, and the high results of a wheel do
not assure equal results in a wheel of the same make and size,
even though they be of the same pattern, This is especially true
when the contingencies of competition and im-possibility an
improbability of the wheel being tested of er a premium on careless

construction and cheap work.

It is unfortunate for progress that the records and conditions
of failures are not kept and published. The records of failures
are of the most benefit to the engineer from an educational stand-
point, but they injure the reputation of the manufactor. Onfy
the best results after years of trials are preserved. So that
these results are in no way indicative of the performance of the
wheel in use, but they do promote development of the type of wheel

in general.

Water turbines may be tested for various purposes among which
may be named:
(1) To establish the general principles of the operation of

such wheels.

-3-

(2) To ascertain the most favorable condition for the opera-
tion of a particular type of wheel.
(3) To ascertain the results of operating a particular
wheel or size , or type of wheel, under particular con-
ditions.
(4) To investigate the various losses in the turbine in
.crder that such losses may be reduced as low as possible.
The wheel which is the subject of this paper is to be tested
for the second purpose mentioned; that is, to find the most favor-
able Operating conditions within the limits of the supply.
There are three methods of testing wheels, namely:
(1) Prony brake method.
(8) hemical method.
(3) Indirect method.
By far the most com only used of these three methods is the
Prony Brake method, which gives the generated power or brake horse
power direct and accurately. It is almost positive in its results

for either high or low speed wheels, impulse or reaction wheels.

The second or Chemical method applies only to the reaction
turbine and is a means of measuring the efficiency of the wheel

by studying the flow of the water used on each side of the wheel.

The third method, which is the indirect method, and the one
which was used in this case is really the best for testing wheels
in place. The generated energy is the electric power produced

by the generator as it is attached to the wheel. In this method,

-4’

the wheel is operating under its normal conditions and produces

its required power.

Some of the disadvantares of this method however, consist
of the dif iculty of measuring the water discharged and the deter-
mination of the electrical losses together with the increased
friction losses, all of which are possible, but inconvenient and

expensive to obtain.

In this test, an attempt was made to determint the electrical
and bearing losses in the generator by running he unit as a motor
at the same speed as found in the test and with the sens field
current excited separatly, but it was found impossible to repro-
duce the speeds because of the size of the machine. Any direct
reading tacheometer required so much power to run that the speed
was decreased considerably. If time were taken to count the re-

volutions, the current would fluctuate, giving imperfect results.

The unit tested in this paper, is a 4 inch "Doble" wheel
with fixed buchets and a one-quarter inch "Doble” needle nozzle
as in plate 1. Attached to the wheel is a 0.075 Kilowatt genera-
tor rated at 1800 v.p.m., 110 volt, 0.68 amperes.

As shown in the accompanying photOgraphs the unit was connec-
ted to the mains of the college water supply by means of a three-
quarter inch pipe and hose with a pressure gage between the con-

necting valve and the needle nozzle.

The end of the case was fitted with a glass plate to enable

-5-

visibility of the wheel while in motion. It was necessary to drill
a hole through this plate opiosite the end of a shaft to facilitate

the use of a revolution counter in obtaining the speed of tee wheel.

The water discharged through the base and was caught in a
tank on scales by means of which the sater discharged in a given
interval of time could be weighed to give the velocity and quantity

of water in jet.

The generator is equipped for both direct and alternating cur-
rent 0! which direct current was used. Since the genrator is
shunt wound the current used in the field of the machine could be
measured as a start toward 3 the losses of the machine. The arma-
ture was connected to a bank of lamps with an ammeter in series

and voltmeter across the brushes.

Since the action of the wheel is affected by the speed of the
jet and the speed of the wheel, it was decided to vary the pressure
head, the size of jet and the load on the machine. To accomplbsh
this, three pressure heads were used, the greatest of which was
the largest that could be attained with the needle nozzle fully
Open and lowest at 104 feet.

At each head the nozzle was opened to amounts varied by one-
half turn of the needle valve from two full turns to four turns,
and the head adjusted by means of the connecting walve at the mains.
With a set head and a given nozzle opening, the loads were varied

from very small load to the maximum of the bank which was 130 watts

and beyond rating.

Iere let it be explained what is meant by load. Load is the
power consumed by the lamp bank. The power consumed in the machine
is not known. It is true that the machine losses increase as the
load decreases. Decrease in load caused and increase in spe d
which caused an increase in voltage. An increase in voltage in-
creases the field current. Electrical losses such as hysteresis,
heat, core, an eddy currents vary as the speed and field current
or flux density, bearing and brush friction and windage increase
as the speed. Therefore at speeds which produced less than 120
volts, the field loss alone varied anywhere from small quantity
to approzihately equal to the line load, at voltages above 180
the field losses exceeded the line load to say nothing of the

other losses.

the each load was applied, the pressure head was adjusted and
recorded; the water was collected in the tank in quantities of 200
to 300 pounds and the required time of discharge recorded; the
revolutions of the wheel were counted for three consecutive minutes
from which the average was obtained; and the load was determined

in watts from the an eter and voltmeter.

It was decided to decrease the load to keep the speed in-
creaeing rather than decreasing, and a short interval of time
left to enable it to become stable before beginning to count revol-

utions.

Of prime importance in obtaining the velocity of jet was the
determination of the diameter and for such small diameters,

extreme accuracy had to be maintained. To do this accurately, it
was conceived to pass the Jet between two pieces of sheet iron
which could be closed together at the vena contracta until each
Just touched the Jet as shown by a small hand lens. The distance
between edges was measured to one-one hundredth of an inch by means

of the had lens.

The effective diameter of the wheel was measured fron center
to the point of impact of the jet and found to be three and three

quarter inches.

The angle of returns or bucket angle of the wheel was not
supplied, but was obtained by using the average angle as observed
and measured for all buckets and was found to be 1600 or 20°

clearance.

As stated before, three heads of lO4,llS.5 and 129.5 feet
were used, all of which were above and below the head recommended
by the manufacoor. This made fifteen sets of data with an aver~

age of severn conditions in each or a total of 100 conditions.

In computing this material; the first step was to plot curves,
as shown in plates 11, 111, and 1V, of_load and speed. Each
nozzle openingand each head had its own curve. Smooth curves were
drawn through this data as it see heleived the smooth curve gave

I

more accurate conditions.

-9-

From these curves were then taken loads correspondi g to
epe de ranging by fifty revolution per minute within the range of
recorded speeds, to make up the tables 1 to XV. The different
values of these tables were then plotted and the conditions pro-
duoing the greatest efficiency curve were taken as the most

efficient operating conditions.

The efficiency of a machine is the ratio of energy delivered
by the machine to that which was supplied to it and it may have
various significations. In the impulse wheel there are hree

of these significations.

In an impulse wheel the theoretical power of the water in the

forebay or per stock in horse-power is!-

E- Wh

" 5;.30

(1)The power just inside the outlet of the pipe is:-

E g: W‘i‘i ‘hh'z

’ 550
(2)The power of the Jet is:-
E’= WC”

 

2g X 550
(3)and the theoretical power delivered to the bucket is:-

P = wic-v)(l-cosx}v
(4) g X 550

11,0 represents the actual power delivered by the wheel then

(5) N - g,- efficiency of entire installation including pipe,
E nozzle, Jet, wheel, etc..

(3) N‘ g,- efficiency of water wheel including nozzle and

25/
bUCkEtBo

-9-
(7) Né 9»- efficiency of the runner, and Jet.
E

(8) Nfi- E - hydraulic efficiency of.the bucket.

P

P
In the testing of water wheels, the efficiency (8), g? is the
ratio ordinarily determined since it involves the losses in the
nozzle, Jet, and buckets as well as ther residual evergy in the
water discharged by the buckets, all of which are properly charge-
able to the operation of the wheel. In this case since the head
is measured at the nozzle and the velocity of approach to the

nozzle is negligible efficiency (5) _.and efficiency (6), 2V, are

e
E, It

equal.

Hominclature used.
a. Area of Jet at vena contracta.
“3 Angle of return of Jet 3 130°

Velocity of Jet.

C
D. Effective diameter of wheel 3 3.75"
E

. Power of water in pipe = E2.
550

E. Power of Jet I no
2g X 550
e. Generated power

P. Theoretical hydraulic power 3 W‘C-VIl—cos°°)v
g x 550
N. Overall efficiency :

eflo

N. Efficiency : g"

N. Theoretical hydraulic efficiency 3 g,
V. Peripheral velocity of wheel

W. Weight of water used per second

h. Effective head ofl water at nozzle.

i

-10-
f
By an examination of tables 1 to XV and plates V1 to Xl it

was ovserved that the most eff cient condition or that which gave
the highest efficiency, in relgtion to head of water in forebay,
for the range of loads was a head of 139.5 fevt or 56 pounds per
aquare inch, a nozzle opening of two and one-half turns and a
speed of 2400 to 2450 revolutions per minute. The same conditions
produced the maximum efficiency with respect to the power of the
Jet. But the efficiency with relation to the theoretical hydrau-
lic power at the buckets required a smaller nozzle opening by
one-half turn and an increase of wheel speed to about BSOdrevol-

utione per minute.

It was attempted to determint the ratio of efficiency to the
specifid speed of the wheel but the variation in electrical losses
in the generator destroyed all relations as well as those between

efficiency and nozzle openings.

in observation of plates V1 to X1 will show that in all
conditions of setting except one, that which gave maximum theoret-
ical power efficiency, there in almost a constant difference in
efficiencies between that with relation to Jet energy and that
with relation to theoretical hydraulic power at the buckets or
’between N' and N’ , and the difference is quite small in all
cases. In the one case with afhead of 129.5 feet, a nozzle opening
of two turns (half open) and agapeed of 2500 revolutions per minute
the difference between N' andrg” is practically equal to that

betwe n N. and NI . it

I,
1
l ‘.

In concluding let it be said that, though the results seem

-ll-:

rather interesting and near those which might be expected, it might
have been more interesting and perhaps more accurate if the wheel
were equipped with a Prony Brake rather than the electric generator.
It would be Just as convenient, if it were possible to determint
the actual electrical and mechanical los es in the electric gener-
ator for each condition. Let it be further state that, It is

hoped that this meagre attempt will instill in the mind of those
who-follow an idea and an ambition to conitnue and improve the
method of construction and testing hydraulic turbines and to pub-

lish all results.

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n... 2 2 5 3 4 A. 5 P 3 5 4 A. 5 5 G
o .. or, Op 2 2 2 2 9w 0 2 9m 0m. 2 B 2 2
R R e .
no 00 0.0 to 00 00 00 00 00 00 o to 00 00 00 It 09.: 0.0 CO 06 .0 i6 QC 0.. s 00 0.0 00 00
e . c. A.
I S O 5 5 .. II no
5 O / 5 o 0 7 . 2
o 5 l 8 3 5 4 5 A... 8 O
5 5 n6 9» an . O 1 8 O» 5 0h 0
1 2 o no 0 0 .1 2 o 5 O C
1 o 0 o _ 8 O o m. o 2 o
O .. 1 7 o 0 1 no 0
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a . . . . . a o . .. .. .
e I . e .-
an an 3 ..,.. C a F. V... C a

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L

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m.
Valbe 3 1/2 turns onen.

4

5 2 6 n0 . OJ 8 o

H 0, 0 0 0 I 0 and

Mn... 9 9 8 7 fi 9.” .3
70 n0 5 5 n 00

.0 00 00 00 .0 00 .0 '0 0. 00 .0 .0 0. 00 00

9 8 n0 1 . 7 . 7 4.

I. 0 0 0 0. 0 0 0

H 7 7 7 6 5 1 R.

00 Q. Q. 00 00 O. 06 00 Q. 00 9. 0| .0 .0 00

H2221.974
5555222

00 0| .0 Q. .0 00 06 O. 00 CO to CO 06 06 on

0 0 0 0 0 C 0

5 r0 5,. 5. rd 5 5

P 2. 2 2 2 2 2 2
o o o o o o 0

0000000

00.000::::::.0.000:.000

2 0 5 AW. 3 0 PD
8 8 6 n. 7 n1 run
a 9 04 G... 9 8 b 7
0 0 0 n O O 0

0.0.0000
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2 1 0,5 9... 3 0

5.. 5 2 9.31 5
777060.65

d
3 c In. 0 .. o o o ..
o
b

0.0.0 00 00 00 00 00.0 00 '0 00 00 00 00 00

0 .
. . m 0 0 0 0 0 0 0
o 0 5 0 5 0 5 0
n; 5 no A. 4. 5 5 6
o 2 2 2 9w 3 2 2

3
II... 00 O. 06 00 O. O. 00 O. O. O. I. .0 o. o.
I. .0
5 0 0 B 8
o 0 Cu n B 2
5 0 5 n0 /0
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1 0 O .0 o 0
0 0 1 8 o
.d . 0
a - . n
0 a. c
H E E "I. C a

4] 1L

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Valve Open 4 turns

0 9 5 O 4 5 7
n 0 0 0 0 0 0 0
N 1 2 3 5 l .8 5
4 4. 4. A. A. 5 n0

0. 0.. .0 0.0 0.0 0-0 00 0’ .0 00 0,0 .0 .0 00 00

A. no lfiwoa 9 0

I. 0 0 0 0 0 0
N 0, 1 2 1 .J 6 2
4. .a .4 A? mu no .5

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2 1 5 0 8 6 9

O O O O O . O O

N 0 1 1 l 9 7 5
no no 3 5 2 2 2

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5 5 0 5 5 5 0

2 on. 2 1 _ 0 9 8

u; 2 2 2 2 .3 1 1
2 0,... a 2 2 mu. 2

O O O O O 0 O

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on

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3 5 .0 5 1 A. . mu

6 9 0,. 9 OJ 9 8 "I
0 0 0 0 0 0 0

o o o o o

o o .

0 0 0. 0 0 0 0
O. Q. on O. 90 Q. O. 06 O. O. O. O. O. 9! 0.
d 2 A. 2 2‘4. 5.10
Cu. .0 0 0 0 0 0 0

0 OJ 1 n6 1 CC 70 5
L 0 "I 7 "I .0 n0 5

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0

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. :B.P.H.:Lg"fl._ : .0 s P

n..4.g 129,57: 2400 : 70,1 § 0,0940 § 0,1645
5 -0,200 i 2450 :70,& i 010947 : 0,1655
E'-,0,171 i 2500 3 70,0 5 0,0940 i 0.1625
0 - 1.10} ‘ x 2550 3 70,2 3 0,0940 3 0,1615
0 . 71.4 :2. i 2600 i 60,1 i 0,0914 : 0,1600
. - 0.000265 : 2650 § 64.5 i 0,0065 i 0,1500
§ 2700 i 59.0 : 0.0790 3 0.1565

55515 111 _

_ Valve Open 2 1/2 tum.
. , 8R.P.M}: 100d 3 0 x P 8
0.04 - 129.5: 2400 §'79,4 : 0.1061 i 0.207 :
0 - 0.509 E 2450 E 79.1 E 0:1060 2 8,307 2
E' -O.214. : 2500 a 78.5 x 0.1052 x 0.206 7
0 - 1.51% § 5550 i 77.5 : 0.1050 : 0.206 g
0 "72-1 :5 § 2600 : 75,0 i 0.1015 i 0,205 :
a - 0.000276; 2650 E,75,2 330.0900 2 0,205 2
3 2700 2 69.7 x 0.0954 x 0.202 2

TABLE X1

V0170 open.2 turns.

”-”~”““““"““"“-”

I
34.4
54.4
34.1
53.6
52.8
51.7
30.2

25,1
2522
25,5
25,1
24.4
25.1
21.1

ofiuflunvfittuuuufiflun

II
41.0
41,5
41.4
41.0
59.0
57,7
54.5

QquO-.uun.cuuununu

N:
49.6
49.5
49.2
48.4
47.5

0. N”~“”“-“““

57,1
57,9
50,5
50,1

“““~”””“”“””

'5

1!
3 50.5

In
51.‘
61.2
51.0
50.4
49.5

I

‘508 3 48.5
I

43.6 3 46.1

57.1

Head 129.5'
E - 0.5511-
3' 00.224

W - 1.405;
C n 75.5 ft.
3 0.908288

Head 129.5'
E 0.545
5' 0.274
1.465%
c 01.5 ft.

W

O. C. O. O. I! O. O. O. O. C. C.

3301,0340,

.. O. C. .0 .0 CD

0. a. .0

:RQPJJ.‘

2
8
I
3
3
8

t
2400

2450
2500
2550
2600

3 0.000288 §:2650

3
x 2700

o. .0 o. to to on O. .0 .0 on O. o. .0 O.

00 o. .0 I. 0.

TABLE X111

Valve Open 5 turns.

Load
78.9
80.7
81.8
82.1
81.4
79.8
77.7

..uuunun-O«nauuuu

o z , P
0.1055 : 0.2175
0.1000 g 0.2175
0.1095 i 0.2170
0.1100 : 0.2160
0.1090 g 0 .2150
0.1070 : 0.2150
0.1040 § 0.2115

54212 117

C.“....”.‘

00'...“

valve Open 5 1/2 turns.

Load
84.4
84.6
85.6
81.7
70.5
76.2

72.7

uuuuuoonuuuuuuu”

0
0.1130
0.1155
0.1120

0.1095

0.1062
0.1020
0.0975

o. no .4 r. o. o. .0 Q. 0. I. U.

0. on c. to

1"

-h

0.266
0.266
0.266
0.266
0.266
0.265

0.264

.0 ‘0 .0 on .0 a. 0' 60 0» a. o.

O. I. O.

N
52,0
52,9
52,4
51.0
50.0
29.6
20.5

C. O. C. C. C. O. O. O. O. .0 O. 0‘ O. C.

O. C. O. C. 0‘ O. O. O. O. I. O. O. C. D. 0.

HI

47.2
18.5
48.9
49.2
48.7
47.8
46.5

N!
41.7
41.8
41.4
4041
59.2
57.6
55.6

0. O. O. .0 0‘ O. O. O. O. .0 O. O. O. O. O.

.0.‘

O. .0 C. O. C. O. O. 0‘ O. O. O. O. O.

Na
48.5
49.7
58.5
51.0
50.7
50.5

H"
42.5
42.6
42.1
41.2
40.0
58.4
56.8

TELBIH XV

78.1170 Open 4 turns.

 

28.9.8.7 Load: 9 z 1’ s N 3 N' a N"
Head 129.5' : 2400 : 81.8 : 0.1095 g 0.275 : 50.6 i 58.5 i 59.9
0 0.358: g 2450 4 85.8 4 0.1120 g 0.275 g 51.5 : 59.4 4 40.7
5' 0.284' g 2500 : 84.9 4 0.1155 g 0.275 : 51.7 : 59.9:: 41.2
7. 1.52}; i 2550 i 85.0 : 0.1159 : 0.275 : 51.8 g 40.1 i 41.4
c 81.5 _ i 2600 :'05,9 : 0.1121 : 0.275 § 51.4 i 50.5 g 40.0
3 0.00050 : 2050 i 82.0 : 0.1100 g 0.275 : 50.7 i 58.7 i 40.0

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