Week 5 Tutorial
Thermal-Fluid System Design
Tutorial by: Abhijit Date
1
A remote costal community in Australia with a population of 50 people relies on diesel generators to fulfil their electrical energy demand and
they are far away from national electrical grid. Due to environmental concerns and rapidly increasing cost of fuel this community has decided
to explore the option of using renewable energy. You are part of this community and has necessary knowledge and skills to conduct
feasibility study of using solar PV with pumped hydro for storage. The electrical energy demand profile and solar energy availability has been
provided below. There is a small hill close to the coast that can be used for pumped hydro storage. The gross head is 30m and the site survey
has shown that the minimum length of the penstock will be 50m, and the sum of k-factors for all the necessary fittings will be 4.2. Use PVC
pressure pipes for penstock and select suitable penstock size (diameter) from AS/NZ-1477. The velocity of water in the penstock should be
𝜀
limited to 4m/s. Use single penstock for pumping and hydro turbine to limit the capital cost. PVC pipe is smooth hence, 𝐷 = 0. Assume
𝑖
𝑘𝑔 𝑁.𝑠
velocity correction factor to be equal to 1. Properties of water, 𝜌 = 1000 𝑚3 , 𝜇 = 0.89 × 10−3 𝑚2 . Assume 𝑃1 = 𝑃2 = 𝑃𝑎𝑡𝑚 .
Design Francis turbine and Centrifugal pump impeller for this site as part of feasibility study. For hydro power unit assume the generator
efficiency of 70% and Mechanical efficiency of 75% and Hydraulic efficiency of 100%. Assume flow ratio 0.2 and speed ratio 0.58. Assume the
flow velocity at the outlet is equal to flow velocity at the inlet. Assume generator rotating at 1500rpm for the design purpose.
For pumping unit assume impeller inlet diameter is 125mm and the slip factor is 1. The outer diameter of the impeller is 3 time the inlet
diameter. Electric motor that drives the pump has motor electric efficiency 50% over a wide range of rotational speed. Use rotational speed
of 1500 rpm for the design of the pump impeller and assume the pump has manometric efficiency of 55% and mechanical efficiency of 58%.
Also assume the flow at inlet is axial.
Assume solar PV panels have energy conversion efficiency of 15%.
Solar Energy
available on inclined
Time Electrical demand
surface at local
latitude
W/m2 kW
1 pm 685 0
2 pm 793 0
8pm 0 3.47
9pm 0 11.28
Demand and Supply Analysis
Hydraulic reaction turbine:
Francis Turbine ℎ𝑓
𝑉12
2
𝐻0 𝑔𝑟𝑜𝑠𝑠 ℎ𝑒𝑎𝑑
𝑃1
𝜌𝑔 𝐻 = 𝑛𝑒𝑡 ℎ𝑒𝑎𝑑
𝐻1
𝑝𝑟𝑜𝑑𝑢𝑐𝑖𝑛𝑔 𝑤𝑜𝑟𝑘
𝑉32
2𝑔
𝑃1 𝑉12 𝑃1 𝑉12
∴ 𝐻0 = + + 𝑧 + ℎ𝑓 ∴ 𝐻1 = 𝐻0 − ℎ𝑓 = + +𝑧
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔
𝑉32 𝑉32
∴ 𝐻 = 𝐻1 − = 𝐻0 − ℎ𝑓 −
2𝑔 2𝑔
𝒉𝒇 ℎ𝑒𝑎𝑑 𝑙𝑜𝑠𝑡 𝑑𝑢𝑒 𝑡𝑜 𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑖𝑛 𝑡ℎ𝑒 𝑝𝑖𝑝𝑒𝑙𝑖𝑛𝑒 𝑎𝑛𝑑
𝑓𝑖𝑡𝑡𝑖𝑛𝑔𝑠 𝑐𝑜𝑛𝑛𝑒𝑐𝑡𝑖𝑛𝑔 𝑟𝑒𝑠𝑒𝑟𝑣𝑜𝑖𝑟 𝑎𝑛𝑑 𝑡ℎ𝑒 𝑡𝑢𝑟𝑏𝑖𝑛𝑒.
𝐹𝑜𝑟 𝑛𝑒𝑔𝑙𝑖𝑔𝑖𝑏𝑙𝑒 𝑉3 ∴ 𝐻 = 𝐻1 = 𝐻0 − ℎ𝑓 𝐻𝑛𝑒𝑡 𝐹𝑟𝑎𝑛𝑐𝑖𝑠 = 𝐻𝑔𝑟𝑜𝑠𝑠 − ℎ𝑓 4
Piping Systems example: Pumped Hydro
𝑧2
P1 𝑉12𝑎𝑣𝑔 P2 𝑉22𝑎𝑣𝑔
+∝1 + 𝑧1 + 𝐻𝑝𝑢𝑚𝑝 = +∝2 + 𝑧2 + 𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒 + 𝐻𝐿𝑜𝑠𝑠
ρg 2𝑔 ρg 2𝑔
𝐻𝑝𝑢𝑚𝑝 = (𝑧2 − 𝑧1 ) + 𝐻𝐿𝑜𝑠𝑠
𝐻𝑝𝑢𝑚𝑝 = 𝐻𝑔𝑟𝑜𝑠𝑠 + 𝐻𝐿𝑜𝑠𝑠
𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 𝑧2 − 𝑧1 − 𝐻𝐿𝑜𝑠𝑠
𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 𝐻𝑔𝑟𝑜𝑠𝑠 − 𝐻𝐿𝑜𝑠𝑠 𝜌𝑄𝑔𝐻𝑝𝑢𝑚𝑝
𝑊ሶ 𝑝𝑢𝑚𝑝, 𝑠ℎ𝑎𝑓𝑡 =
𝜂 𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑝𝑢𝑚𝑝
𝑊ሶ 𝑡𝑢𝑟𝑏𝑖𝑛𝑒, 𝑠ℎ𝑎𝑓𝑡
= 𝜂𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑡𝑢𝑟𝑏𝑖𝑛𝑒 × 𝜌𝑄𝑔𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒
𝑧1
𝑊ሶ 𝑝𝑢𝑚𝑝, 𝑠ℎ𝑎𝑓𝑡
𝑊ሶ 𝑒𝑙𝑒𝑐𝑡, 𝑖𝑛𝑝𝑢𝑡 =
𝜂𝑚𝑜𝑡𝑜𝑟
𝑊ሶ 𝑒𝑙𝑒𝑐𝑡, 𝑜𝑢𝑡𝑝𝑢𝑡 = 𝑊ሶ 𝑡𝑢𝑟𝑏𝑖𝑛𝑒, 𝑠ℎ𝑎𝑓𝑡 × 𝜂𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟
Efficiencies of fluid machines
𝐹𝑜𝑟 𝑃𝑢𝑚𝑝 𝑎𝑛𝑑 𝑐𝑜𝑚𝑝𝑟𝑒𝑠𝑠𝑜𝑟
𝑈𝑠𝑒𝑓𝑢𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑔𝑎𝑖𝑛𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑 𝑎𝑡 𝑡ℎ𝑒 𝑜𝑢𝑡𝑙𝑒𝑡
𝜂ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 =
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟 𝑡𝑜 𝑓𝑙𝑢𝑖𝑑
𝑈𝑠𝑒𝑓𝑢𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑔𝑎𝑖𝑛𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑 𝑎𝑡 𝑡ℎ𝑒 𝑜𝑢𝑡𝑙𝑒𝑡
𝜂𝑜𝑣𝑒𝑟𝑎𝑙𝑙 =
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑚𝑜𝑡𝑜𝑟 𝑡𝑜 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡
𝐹𝑜𝑟 𝑇𝑢𝑟𝑏𝑖𝑛𝑒
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑠𝑢𝑝𝑝𝑙𝑖𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟
𝜂ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐_𝑡𝑢𝑟 =
𝐸𝑛𝑒𝑟𝑔𝑦 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑑𝑒𝑙𝑖𝑣𝑒𝑟𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑟𝑜𝑡𝑜𝑟 𝑡𝑜 𝑡ℎ𝑒 𝑠ℎ𝑎𝑓𝑡
𝜂𝑜𝑣𝑒𝑟𝑎𝑙𝑙 =
𝐸𝑛𝑒𝑟𝑔𝑦 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑓𝑟𝑜𝑚 𝑡ℎ𝑒 𝑓𝑙𝑢𝑖𝑑
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦
𝜂𝑜𝑣𝑒𝑟𝑎𝑙𝑙 𝑆ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 − 𝑡𝑢𝑟𝑏𝑖𝑛𝑒
𝜂𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 = =
𝜂ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐 𝑅𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 − 𝑡𝑢𝑟𝑏𝑖𝑛𝑒
6
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑔𝑒𝑛𝑒𝑟𝑎𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 𝑜𝑢𝑡𝑝𝑢𝑡 11.28
𝜂𝑔𝑒𝑛 = ∴ 𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 = = 16.11𝑘𝑊
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 0.7
𝑀𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑎𝑓𝑡 𝑝𝑜𝑤𝑒𝑟 16.11
𝜂𝑚𝑒𝑐ℎ𝑎𝑛𝑖𝑐𝑎𝑙 = ∴ 𝑅𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 = = 21.48 𝑘𝑊
𝑅𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 0.75
𝑅𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 𝑅𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟 21.48
𝜂ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐_𝑡𝑢𝑟 = 𝐹𝑙𝑢𝑖𝑑 𝑃𝑜𝑤𝑒𝑟 = = = 21.84 𝐹𝑢𝑖𝑑 𝑝𝑜𝑤𝑒𝑟 = 𝜌𝑄𝑔𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 21.48 𝑘𝑊
𝐹𝑙𝑢𝑖𝑑 𝑃𝑜𝑤𝑒𝑟 𝜂ℎ𝑦𝑑𝑟𝑎𝑢𝑙𝑖𝑐_𝑡𝑢𝑟 1
Penstock velocity must be limited to 4m/s
𝐻𝐹𝑟𝑎𝑛𝑐𝑖𝑠 = 𝐻𝑔𝑟𝑜𝑠𝑠 − ℎ𝑓
𝑓𝐿 𝑉𝑝2 𝑉𝑝2
𝐻𝑛𝑒𝑡_𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 𝐻𝑔𝑟𝑜𝑠𝑠 − × − Σ𝐾
𝐷𝑖 2𝑔 2𝑔
Turbine Design (Given /Estimated parameters)
𝐹𝑢𝑖𝑑 𝑝𝑜𝑤𝑒𝑟 = 𝜌𝑄𝑔𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒 = 21.48 𝑘𝑊
Gross Head m
Generator Eff
Mechanical eff 21.48 𝑘𝑊 𝑚³
Hydraulic eff 𝑄= =
𝜌𝑔𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒 𝑠
Overall Efficiency
Net Head (H_turbine) m
Peak electrical power kW 𝑉𝑓1 𝑈1
Flow ratio = 2𝑔𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒
Speed ratio =
Turbine Penstock diameter m 2𝑔𝐻𝑡𝑢𝑟𝑏𝑖𝑛𝑒
Flow Rate m3/s
Mass Flow Rate kg/s
𝑅𝑜𝑡𝑜𝑟 𝑝𝑜𝑤𝑒𝑟
Speed rpm 𝑉𝑤1 = 𝑈1 = 𝜔𝑅1 𝑈2 = 𝜔𝑅2
Speed ratio 𝑚𝑈
ሶ 1
Flow ratio
Rotor Power kW 𝑉𝑤1
𝑈1
Inlet Velocity Triangle 𝐶
𝐴 𝐷
Inlet Flow velocity (Vf1) m/sec 𝛼1
Inlet Blade velocity (U1) m/sec
𝑉𝑟1
Vw1 m/sec 𝑖𝑛𝑙𝑒𝑡 𝑉𝑓1
V1 m/sec 𝑇𝑎𝑛𝑔𝑒𝑛𝑡 𝑎𝑡 𝐵
β1 deg
Vr1 m/sec
Inlet guide vane angle (α1) deg
D1 m
Outlet Velocity Triangle 𝑅1
𝐸 𝑇𝑎𝑛𝑔𝑒𝑛𝑡 𝑎𝑡 𝐸
Vw2 m/s
Outlet Flow velocity (Vf2) m/s
Outlet diameter m 𝑜𝑢𝑡𝑙𝑒𝑡 𝑉2 = 𝑉𝑓2
U2 m/s 𝛼2
Vr2 m/s 𝐺
𝐻
β2 deg 𝑈2
Blade efficiency 𝜔
𝑂
Dimension
D1 m
𝜋
B1 m 𝑄 = 𝜋𝐷1 𝐵1 𝑉𝑓1 = 𝐷22 𝑉𝑓2
4
D2 m
Turbine part load operation
Iterations
Pump design 𝑓𝐿 𝑉𝑝2 𝑉𝑝2
𝐻𝑝𝑢𝑚𝑝 = 𝐻𝑔𝑟𝑜𝑠𝑠 + ℎ𝑓 𝐻𝑛𝑒𝑡_𝑝𝑢𝑚𝑝 = 𝑧1 − 𝑧2 + × + Σ𝐾
𝐷𝑖 2𝑔 2𝑔
Penstock velocity must be limited to 4m/s
Manometric efficiency
Pump Design (Given and estimated parameters)
Head m 𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝
Pump penstock diameter m 𝑉𝑤2 𝑈2 =
Speed rpm
𝜂𝑚𝑎𝑛𝑜
Peak Excess Power kW
𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝
𝜂𝑚𝑎𝑛𝑜 =
Pump Motor efficiency 𝑉𝑤2 𝑈2
Pump Shaft Power kW
Pump manometer eff
Pump Mech eff
Slip Factor
𝜌𝑄𝑉𝑤2 𝑈2 𝜌𝑄𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝 𝐹𝑙𝑢𝑖𝑑 𝑃𝑜𝑤𝑒𝑟
𝑊ሶ 𝑠ℎ𝑎𝑓𝑡 𝑖𝑛 𝜂𝑚𝑒𝑐ℎ = = =
𝜂𝑚𝑜𝑡𝑜𝑟 = 𝑊ሶ 𝑠ℎ𝑎𝑓𝑡 𝑖𝑛 𝜂𝑚𝑎𝑛𝑜 × 𝑊ሶ 𝑠ℎ𝑎𝑓𝑡 𝑖𝑛 𝜂𝑚𝑎𝑛𝑜 × 𝑊ሶ 𝑠ℎ𝑎𝑓𝑡 𝑖𝑛
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑝𝑜𝑤𝑒𝑟
Inlet Velocity Triangle
Vw1 m/sec
D_in mm
D_out mm
Volume Flow Rate m3/s
Mass Flow Rate kg/s
Vf1 m/s 𝛼2
𝑜𝑢𝑡𝑙𝑒𝑡 𝑉𝑓2
U1 m/s
Beta 1 Deg
𝑉𝑟2
𝛼2
𝜂𝑚𝑜𝑡𝑜𝑟 × 𝜂𝑚𝑒𝑐ℎ × 𝜂𝑚𝑎𝑛𝑜 × 𝑊ሶ elect
𝑄=
𝜌𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝
𝑄
𝑉𝑓1 = 𝜋 𝑈1 = 𝜔𝑅1 𝑅2
𝐷2
4 𝑖𝑛 𝜔
𝑇𝑎𝑛𝑔𝑒𝑛𝑡 𝑎𝑡 𝐸
𝐸
Outlet Velocity Triangle
𝑉1 = 𝑉𝑓1
Vf2 = Vf1 m/s
Vw2*U2 m2/s2
𝑖𝑛𝑙𝑒𝑡
U2 m/s
Vw2 m/s 𝑈1
Beta 2 Deg 𝑂
Alpha 2 Deg
Outlet Width mm
Theoretical Head m
𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝
𝑉𝑤2 𝑈2 = 𝑈2 = 𝜔𝑅2
𝜂𝑚𝑎𝑛𝑜
𝑄 = 𝜋𝐷2 𝐵2 𝑉𝑓2
𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝
Pump part load operation 𝑉𝑤2 =
𝜂𝑚𝑎𝑛𝑜 × 𝑈2
From outlet velocity triangle
𝑉𝑓2 𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝 𝑉𝑓2 𝜂𝑚𝑎𝑛𝑜 × 𝑈22 − 𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝 𝑉𝑓2
𝑈2 − 𝑉𝑤2 = 𝑈2 − = =
𝑡𝑎𝑛𝛽2 𝜂𝑚𝑎𝑛𝑜 × 𝑈2 𝑡𝑎𝑛𝛽2 𝜂𝑚𝑎𝑛𝑜 × 𝑈2 𝑡𝑎𝑛𝛽2
2
𝑉𝑓2 𝑉𝑓2 𝑉𝑓2
𝜂𝑚𝑎𝑛𝑜 × 𝑈22 − × 𝜂𝑚𝑎𝑛𝑜 × 𝑈2 − 𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝 = 0 − − × 𝜂𝑚𝑎𝑛𝑜 ± − × 𝜂𝑚𝑎𝑛𝑜 − 4 × 𝜂𝑚𝑎𝑛𝑜 × −𝑔𝐻𝑛𝑒𝑡 𝑝𝑢𝑚𝑝
𝑡𝑎𝑛𝛽2 𝑡𝑎𝑛𝛽2
𝑡𝑎𝑛𝛽2 ∴ 𝑈2 =
2 × 𝜂𝑚𝑎𝑛𝑜
So you can see that the total capacity of the pumping is only 24m³ while that storage needed is 454m³, so
we need larger solar panel area and hence larger pump to increase the pumping capacity. This is the next
iterative step that you should solve at home.
Learning outcome,
• Developed understanding of analysing demand and supply
and using this information to design a complex system