Ambient Pressure Water Turbine

Technical Field

This disclosure relates to an ambient pressure turbine for production of efficient power from water flow heads of relatively small size. It accomodates substantial water flow and low available heads.

• Background Art Turbines conventionally are classified in two primary groups,. reaction turbines ^' and impulse turbines.

The reaction, turbines include the Kaplan, type or propeller turbine, which is similar to the propeller of a ship operating in reverse. Water flows through the turbine and causes the propeller to rotate. The water rotates axially through the propeller and such turbines are typically referred to as axial-flow turbines. Fran¬ cis or radial-flow turbines are a pressure differential turbine and divert water at right angles to the direction of entry, causing the turbine rotor to revolve. Water fills an entrance volute which surrounds the runner and then flows between fixed guide vanes to enter the runner and flow toward its center. The g ide vanes largely convert the water energy into rotary motion. The vanes and runners are typically filled with flowing water and a relatively high head is required for efficient opera¬ tion.

Impulse type turbines are velocity differential turbines and are represented by the Pelton wheel, which utilizes jets of water directed at cups or buckets on

the periphery of a water wheel.

Disclosure of Invention

The present turbine utilizes a runner exposed to ambient atmospheric pressure and mounted for rota¬ tional movement about a central vertical axis. Vanes are fixed about the runner. Each has a radially curved concave rear face and an apposited directed front face between inner and outer radial vane ends. Water dis- charge means beneath the runner receives water from the inner vane ends. Water infeed means surrounding the runner delivers moving water through descending ambient pressure chutes leading to the runner periphery at a flow rate, velocity and angle relative to the runner such that each vane is subjected to supercritical flow condi¬ tions and superelevation of water across the rear face of each vane.

The present improvement uses principles involved in both reaction and impulse type turbines. In common . with reaction type turbines, the water flow changes radius and direction,- resulting in centrifugal forces. These forces cause superelevation of the water on the vanes in the present turbine. In common with the impulse type turbine, one of the determinants of the amount of this superelevation is the difference between the for¬ ward speed of the rotating vane and the velocity (under ambient pressure) of the flow entering the runner. These reaction and relative velocity characteristics are close¬ ly interrelated in the operation of the present turbine. However, by utilizing supercritical flow conditions at the vane, efficient power transfer from a volute to a runner vane is accomplished under head requirements not practically suitable for existing turbine designs.

Brief Description of Drawings

Fig. 1 is a schematic perspective showing use of the turbine adjacent to a river;

Fig. 2 is an enlarged schematic perspective looking toward the infeed of the turbine;

Fig. 3 is an enlarged schematic perspective look¬ ing toward the discharge of the turbine; Fig. 4 is a simplified plan view of the turbine;

Fig. 5 is a simplified sectional view taken along line 5-5 in Fig. 4;

Fig. 6 is a plan view of a first structural embodiment of the turbine; Fig. 7 is a sectional view taken along line 7-7 in Fig. 6;

Fig. 8 is a plan view of a second structural embodiment;

Fig. 9 is a sectional view taken along line 9-9 in Fig. 8;

Fig. 10 is a schematic plan view showing velocity vectors at the turbine vanes;

Fig. 11 is a schematic perspective view of a vane showing the area of water delivered thereto; Fig. 12 is a simplified schematic view illustra¬ ting the superelevation slope across the vane; and.

Fig. 13 is a perspective view of a vane, illus¬ trating the water configuration flowing across it.

Best Mode for Carrying Out the Invention

The general features of the turbine are illus¬ trated in Figs. 1 through 5. A simplified static mathe¬ matical model of water velocity and flow across a vane is illustrated in Figs. 10 through 13. Two illustrative structural arrangements of the turbine are shown in Figs. 6 and 7 and in Figs. 8 and 9, respectively.

The design concept of this turbine involves the use of an open or ambient pressure turbine for development of power from a supply source of water that has a total energy head from approximately 1.0 feet to 20 feet (0.3 meters to 6.1 meters), and flows ranging from approximately 1 cubic foot per second to 30,000 cubic

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feet per second (0.02 cubic meters per second to 849 cubic meters per second) .

For purposes of this disclosure, the total energy head includes the su of the fluid heads pro- ducεd by pressure and velocity plus the elevation head. The total energy head of the water at the supply source is directed to the volute. It is transformed in the volute to a maximum velocity head value at which the water is in a supercritical flow condition. In relation to flow in open channels, "critical" flow is that regime of flow for which the specific energy of the water is minimum for a given discharge. At velocities greater than critical, the flow is typically described as being "supercritical", "rapid" _or "shooting". In the present turbine, supercritical flow is attained at the entrance to the turbine vanes, and is maintained across the working faces of the tur¬ bine. The stiff nature of water under supercritical flow conditions is. used to assure that a controlled quantity of water is maintained across the working or rear face of each vane. It also substantially reduces or prevents water contact with the front face of the following or succeeding vane. The disclosed turbine is not completely filled with water, as is conventional with enclosed, radial-flow turbines.

The turbine has been designed to obtain maximum power from low energy head water supplies by proces¬ sing large quantities of water in relation to the heads used. It is an ambient pressure water turbine with characteristics of both impulse turbines and mixed flow reaction turbines. It can permit use of otherwise unusable flows or rivers by constructing a diversion and canal system for obtaining the required energy head. It also can be used in conjunction with small drops in existing irrigation canals having energy had ranges below the effective requirements of existing turbines. The turbine design uses a velocity head approach

and supercritical flow through the turbine vanes, water is supported on the vanes by a runner floor that rotates in unison with them or is separate and stationary. Power generation can be achieved- through a ring spur gear drive to an induction alternator or other generating equipment. Smaller units can utilize a center support shaft for the runner. In larger size, the design can provide for a peripheral track and rol¬ ler support with top-mounted vanes and a stationary run- ner floor. A portion of the large diameter runner floor might also revolve with the vanes.

The vanes are designed to obtain a maximum water directional change and a resultant water elevation and static pressure change within the runner of the turbine, d _U e to' superelevation as caused by the centrifugal action of the water. The water enters the runner at a given distribution depth and flows along the rear face of each vane, increasing in elevation to a location of maximum centrifugal effect. This substantially.reduces _or - eliminates water contact with the forward faces of the succeeding vanes. Discharge at the center of the turbine is a combined axial and rearward tangential flow, with the required cross-sectional dimensions at the discharge area being determined by this flow so as to not impede it in any way.

The infeed volute flutes which lead to the runner define multiple chutes that increase the water velocity to the maximum obtainable value for the particular flow requirements and provide supercritical flow conditions across the rotating vanes. The volute configuration al¬ so assures even water velocity and distribution at the runner periphery. Seasonal flow variations of 50 to 75% of the maximum design flow can be accomodated by use of head control gates leading to the volute or by clos- i g off alternate chutes leading to the runner periphery. Referring now to Figs. 1 through 5, the turbine is generally illustrated in a simplified form. No

connection is shown to a power generator, and it is to be understood that the mechanical drive to the genera¬ tor unit can be at a central turbine shaft, at a ring gear at the outer periphery of the runner or at a rotatable power connection at any other point about the runner. The mechanical interconnection to the generator unit is of no consequence with respect to the understanding of the present invention.

As shown, the turbine can be used alongside a river or canal 10. It is assumed that the total energy head along the selected stretch of river 10 is inade¬ quate for conventional turbine generating facilities. However, there are many stretches along rivers and canals where large flow is available at a relatively low energy head. It is this combination of available water energy to which the present invention effort has been directed.

Water is diverted from river 10 by an upstream diversion wall pr dam 11 that directs a portion of the water into a power canal-12. The width of the power canal 12 is less than the width of the diverted river water, which increases water speed and allows a smaller canal structure to meet the volume requirements of the downstream turbine assembly. The power canal 12 must be designed in shape and size so as to be capable of maintaining the required maximum constant flow of water along its full length without impeding water velocity. The slope of the power canal 12 is typically more shallow than that of the normal adjacent ground and river slope, permitting canal 12 to gain elevation in relation to river 10. As shown, the power canal 12 will typically run paral¬ lel to the adjacent bank of the river 10. The length of the canal 12 is determined by the amount of eleva- tion required through the turbine.

A second contraction in width is provided at the downstream end of the power canal 12 at a volute

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transition area 13. This reduction in width further in¬ creases water velocity. It is preferred that the water velocity along the canal 12 reach the critical stage for the particular depth of water just prior to entering the volute 14. It must achieve supercritical flow prior to entrance onto the runner.

As the water enters volute 14, it begins descent along a steeper slope within individual chutes 15. Chutes 15 are bounded by upright flutes 16 arranged in a con- verging spiral pattern leading to open inner ends spaced equiangularly about the runner periphery. This descent results in supercritical flow conditions.

The chutes 15 lead to the circular periphery about the rotatable runner 18, which, rotates about a center vertical axis. The inner end of each chute 15 preferably terminates along a horizontal floor section to provide a constant initial depth of water having a ^' substantially rectangular cross-sectional shape between each set of adjacent runner vanes 20. Water enters runner 18 in a supercritical flow state and maintains this state at all times while in contact with the rear faces 21 of the respective vanes 20. The supercritical flow condition is assured by proper control of incoming water flow rate, water velocity at the discharge of volute 14 and the approach angle of the water along the guide vanes or inner ends of flutes 16 in relation to the periphery of the runner 18. Control of these actors also assures that the backwater line of the water moving across the rear face 21 of a vane 20 substantially reduces or prevents water contact with the adjacent front face 22 of the succeeding vane. The minimal contact between the water flowing through runner 18 and the vane front faces substantially reduces or eliminates back pressure of water against the vanes, which would create an energy loss within the tur¬ bine. The effective pressure of the water against each vane is therefore proportional to the full depth or

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height of the water across rear face 21. Counteraction by the water depth and back pressure against the succeed¬ ing vane front face is substantially reduced or pre¬ vented altogether. Water is supported elevationally across the vanes

20 by a runner floor 23. Runner floor 23 is annular and can be either stationary and separately supported beneath vanes 20 or can be fixed to vanes 20 so as to rotate in unison with them. The annular width of the runner floor 23 defines the effective radial working width across the vanes 20. Water exits the runner 18 through the center of the turbine ^' by dropping axially from the runner floor 23. It is received gravitationally within a recessed discharge canal 24 which returns it to river 10 at close to its original velocity. The discharge from the turbine can also be fed to a second downstream turbine, which would require additional elevation and canal length, but would permit further power production from a single diversion. The above-described general design concepts are speci ically incorporated into structural arrangements of the turbine as illustrated in Figs. 6 and 8. Fig. 6 shows a relatively large diameter apparatus with track and roller supports for the vanes. Fig. 8 shows a smal- ler unit with a central shaft support. Both operate according to the principles described above.

Fig. 6 shows a recessed base 25 which supports a fixed central shaft 26 and concentric inner and outer stationary circular tracks 27 and 28. The tracks 27, 28 are respectively engaged by inner and outer sets of rollers 30, 31 rotatably journalled about radial shafts 32. Shafts 32 are connected to a central hub 33 mounted about shaft 26 by bearings 34. The shafts 32 form a radial spider or frame and are fixed apart by circular frame members 35 which suspend the individual vanes 36. Adjustable guide vanes 37 are arranged about the peri¬ phery of the runner to permit adjustment of the entry

angle of the water at the discharge of the volute. The runner floor 38 is stationary and is formed about the open section of the base 25 that defines the discharge canal beneath the runner. Floor 38 is an open hori- zontal annular surface.

Fig. 8 shows a similar base 40 and a fixed center shaft 41. In place of the tracks and rollers, the runner frame is rotatably journalled about the shaft 41 by a series of bearings 42 and hubs 43. The rigid runner frame, including radial members 44, fixedly supports the individual vanes 45 in an open radial structure. The runner floor 46 in this example is fixed to the runner frame and vanes 45 to rotate in unison with them. Ad¬ justable guide vanes 47 (optional) are again shown about the periphery of the runner outwardly adjacent to the runner vanes 45.

The ambient pressure water turbines described herein incorporate characteristics of both reaction and impulse turbines, which will vary somewhat depending upon selected runner width and vane configuration. Its opera¬ ting ef iciency depends substantially upon the achieve¬ ment of a significant pressure differential within the runner between the rear face of each vane, which is con¬ tacted by the moving water at supercritical flow condi- tions, and the front face of each vane, which is sub¬ stantially or totally clear of water contact.

The energy developed by the water within volute 14 is gradually changed, due to elevation changes, to a maximum velocity head for the flowing depth of water that is being delivered to the runner. This is achieved by designing each chute 15 to have progressively lowered elevation and progressively reduced width in the direc¬ tion of the water flow. The diversion, power canal and volute are designed to achieve maximum water velocity at the inner ends of the volute chutes with respect to the available flow and elevation head at the river or other supply of water in hydraulic communication with volute

14 ,

As the water, at supercritical flow conditions, travels across the rear face 21 of each moving vane 20, it is free to change its cross-sectional dimensions on the vane. These changes occur in response to changes in the direction of the water flow as it traverses the curved vane surface. The resulting cross-sectional area of the water is determined by the. superelevation of the water due to centrifugal forces as its direction of movement changes. The superelevation on the vane will be approximately forty percent greater for supercritical flow than subcritical flow.

The height of each vane above the runner floor must be designed to accomodate the changes in water cross section (see Fig. 13) . In general, since super¬ elevation occurs, the maximum elevation of the rear face of each vane must be greater than the average depth of water directed onto the runner floor at the periphery .of the runner by the infeed volute, it must have suf— ficient elevation above the runner floor to accomodate the maximum resulting superelevation of the water against the vane.

The high inertia of the water entering the runner causes a centrifugal action on the vane. The entry of the water at the exit of volute 14 is in an angular direction determined by the resultant vector of the tangential water velocity of the chute and the gravi¬ tational acceleration in a radial direction. In addi¬ tion, the adjustable guide vanes arranged about the run¬ ner are preferably set at an angle to impart a definite radial component of movement to the entering stream of water. They should be set to streamline the flow of water and prevent energy losses due to the resultant shock that would otherwise be caused by an abrupt change of water direction. Tests have shown that there is no tendency for the water to be reflected with a radially outward component. As the water velocity along the

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curved vane is greater than the tangential movement of the vane, the water is forced inward through the runner with an increasing radial component to a point along each vane where it is turned and this -radial component becomes an increasing tangential vector in a negative direction. This vector is dependent upon the discharge vane angle at the inner vane end 48. The radial width of the runner floor 23 beneath the vanes 20 should be adequate ϊor maintaining water against the back face of the vane through a maximum directional change to its discharge at the inner vane end 48.

It is to be noted that there is no rapid direc¬ tional change of the water as it enters the runner, nor is there any rapid directional change of the water along the width of the vanes. The vanes are arranged about the runner to provide smooth entry of water from volute 14.

Although frictional flow losses are related to the square of the water velocity, the range of water veloci¬ ties contemplated in use of this turbine are not extreme— ly high and the frictional losses will be relatively small, due primarily to the relative roughness in rela¬ tion to the volume of water.

Figs. 10 through 13 diagrammatically illustrate the mathematical theories relating to superelevation of the water across the individual vanes. The hypothetical example used in this model is a runner having an outside diameter of 75 feet (22.9 meters) and 24 vanes. The vane radius (r) across the runner floor is 10 feet (3.0 meters) and the minimum distance between the vanes is 9.81 feet (2.9 meters). The flow entering the runner is assumed to be 12,544 cubic feet per second (355 cubic meters per second). 522 cubic feet per second (14.8 cubic meters per second) of water will be directed onto each vane.

As shown in Fig. 10, the water enters the runner at an angle of 40° from a line tangential to the runner periphery. In the illustrated example, the absolute ve¬ locity of the water entering the runner (v^) is 24 feet

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per second (7.3 meters per second) . The tangential com¬ ponent of this velocity (v _t ) is 18.4 feet per second (5.5 meters per second) . The radial component of water velocity at the entrance to the runner (V _m ) is 15.4 feet per second (4.7 meters per second) . Relative velocity (V _r ) is identical to radial velocity at this location.

The radial flow width entering the runner between successive vanes is equal to the vane separation at entry (9.81 feet or 3.0 meters). The absolute entry flow width 51 will be approximately sine α- _j _ times the radial flow width, or 6.3 feet (1.9 meters) (Fig. 11). The water depth 52 at entry equals the total flow per vane (522 CFS or 14.8 cubic meters per second) divided by the absolute entry velocity (24 feet per second or 7.3 meters per sec- ond) times the absolute entry flow width, or 3.45 feet

(1.1 meters) . This is the pressure head of the incoming water delivered, to the runner. The areal cross section (A) of the entering water is the pressure head or entry water depth (3..45 feet or 1.1 meters) multipled by the absolute entry flow width (6.3 feet or 1.9 meters), or 21.73 square feet (2.0 square meters) .

Referring to Fig. 12, one can approximate the slope(s) or tangent of angle 53 by use of the super crit¬ ical superelevation formula: s = 2 ^v where: g is the acceleration force of g~r gravity (32.2 feet per second square or 9.8 meters per second square) , V _r is the relative velocity, and r is the radius of curvature of the vane. Applying this formula to the above figures: s = 2(15.4)2 = 1.473 or s = 2(4.7) ² = 1.473 32.2(10) 9.8(3)

By simple trigonometry based on an approximate right triangular cross section, the height (h) and the base (b) can be calculated as follows: h = -l/2As = 1/2(21.73) (1.473) = 8.0 feet or h = /2Ai = 1/2 (2.0) (1.473) = 2.4 meters

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b = h = 8^0. = 5. 43 feet s 1. 473 or b =- n_ — 2.4 = 1.6 meters s 1.473

As shown in Fig. 13, the. incoming water resting against the rear vane face and runner floor will gradu¬ ally "climb" the vertical face as it traverses the vane, to an apex at which its height and width will approximate the above calculations. The water height will then taper off until it drops from the inner annular edge of the runner floor or an equivalent extension. The highest point on the simulated water path is designated by the reference numeral 54.

The ideal amount of superelevation required in the water as it crosses each vane back surface must be suf¬ ficient to prevent the backwater line 55 from contacting the forward face of the following vane. The amount of superelevation is partially dependent upon the entry water velocity at the periphery of the runner. Secondly, ■ the superelevation of the water will also be dependent upon the rate of forward motion of the vane, due to rev¬ olution of the runner about its central axis, since the ability of the water to climb the vane face depends upon relative velocity values. The superelevation is also a function of the radius or curvature of the vane in the radial direction with respect to the runner axis and the entry angle- of the incoming water (α^) . The water entry angle for smooth entry determines the amount of forward motion imparted to a vane by the impulse forces of the water as well as the resultant relative velocity of the water across the vane surface it contacts.

In general, as the water flows across a vane, an upward axial velocity component is imparted to the water due to the superelevation forces discussed above. This upward water flow vector is unique to this particular turbine structure and method of operation. Conversely, at its discharge from the vane, the water achieves a

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downward axial component of flow or downward relative velocity which carries it into the receiving tail race. Because of the vane curvature, the discharged water also has a negative relative velocity component directed op- posite to the direction of rotation of the runner, which has been imparted to it by the vane curvature or radius.

Head attainment methods or systems which might be utilized upstream of the volute may be divided into four categoriest the use of a dam or other impounding struc- ture, the use of an existing canal having an elevation drop, the use of a diversion structure and power canal, and the use of a power canal without a diversion struc¬ ture. As used herein, head attainment refers only to the method used for providing a supply of water, regardless of the combination of heads used at the volute entry, which might include the pressure head, the velocity head and elevation.

The values given each available head entering the volute will necessarily be determined by the best pos- sible combination at the site selected, taking into con¬ sideration the available flow of water, flow variations, and relative elevations between the source and volute. The volute provides a 360° flow entry onto the runner periphery. Its overall design, and its size, will be determined by the combination of available heads at its entry and the total flow of water. The chutes de¬ fined by the upright flutes supply water flow to the run¬ ner in equal amounts at equiangularly spaced discharge locations arranged about its periphery. The flow of water to the runner is supplied at approximately the same velocity at each angular location about, it. The flutes also serve to reduce the amount of superelevation of the water that occurs within the volute structure itself. The descending elevation of the chutes prevents water from backing up due to the deceleration that would occur if the floor were level. The minimum slope used should be sufficient to prevent the water from attaining

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uniform flow prior to reaching the runner periphery. The sloped floors of the individual chutes permit much larger flows through the volute than would otherwise be possible. Superelevation through the chutes, which is con- sidered detrimental to the achievement of even flow dis¬ tribution of water onto the runner, is reduced by using a transition curve with the proper length and radius from entry in the direction of flow. This reduces the amount of superelevation of supercritical flows to that which would be expected with a subcritical flow.

The final transition portions of the chutes immedi¬ ately prior to discharge of the water flow onto the run¬ ner provide an even depth and velocity distribution of water under supercritical flow conditions. The volute design must control outside superelevation along the curved flutes and provide a smooth transition from each chute to the runner. The volute also must assure equal distribution of water flow with respect to both depth and velocity at all po ^' ints about the runner periphery. Shock- losses which may occur due to final directional changes at the guide vanes or exits of the chutes should also be minimized.

To design a turbine system for accommodating sea¬ sonal flow fluctuations, efforts must begin with the en- vironmental considerations for a particular installation site. If a power canal system is used, with or without a diversion structure, the minimum flow requirements for the section of stream affected must be considered. If a head attainment structure is used, impoundment and its related problems must be considered.

If a diversion system is used, the flow into the system will typically allow for a minimum flow bypass downstream for the length of the power canal. Therefore, minimum seasonal flow less the required minimum stream flow will determine the maximum design limits of the sys¬ tem, provided the user is seeking a constant power out¬ put. Where the power output is variable, the maximum

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design limits can be increased to the maximum seasonal flow in the canal less the required minimum stream flow. Flow control for the turbine is limited to a di¬ version system. However, two methods of head control have he&n designed into the system. First, the multiple channel volute permits the closing of alternate chutes for operation of the turbine at the same total heads with reduced amotints of flow. Second, variable sloped weirs (not shown) can be provided to vary the head upstream from the volute by raising or lowering the effective floor elevation of the volute entry. In this way, one can maintain the same total head using all channels dur¬ ing reduced flow conditions. Both methods could be. used simultaneously under extreme flow variations. Either method helps to maintain the desired final velocity of the water as it is fed onto the runner to assure constant speed of revolution of the runner itself.

The turbine described above has been found to suc¬ cessfully attain relatively high efficiencies from very low heads in the water supply, using high velocities, supercritical flow, and superelevation of the water along the runner vanes. By using the optimum flow entry angle, runner vane radius and curvature, runner rotational speed, and number of vanes, the resulting superelevation of the water across the vanes will substantially reduce or pre¬ vent any back pressure from occurring at the forward faces of the vanes. Supercritical flow across the vanes is necessary, as the resulting superelevation on the rear face of each vane will be approximately 40% greater than that achieved under subσritical flow conditions.

As the turbine will typically have a relatively slow rotational speed of about four to fifty revolutions per minute, dependent upon its physical size, a power transfer method providing for a speed increase to a gen- erator is necessary. This can be in the form of a spur ring gear driving a smaller gear. The ring gear can be attached directly to the structure of the runner. The

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ring gear will also permit the driving of more than one power generator unit on a single runner and make it pos¬ sible to also drive pumps directly in addition to power generation systems. Smaller turbine units may use a chain or belt drive to the systems being driven.

Various modifications can be made in the struc¬ ture without deviating from the basic concepts described above.

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