GROUPS ARE ASSIGNED TO WORK BASED ON THE FOLLOWING
PROBLEMS
o GROUP ONE (# 9)
o GROUP TWO (# 9.4 solved example)
o GROUP THREE (# 17)
Design Work Using One-Dimensional Analysis and CFD Simulation
Based on Problem # 9, # 17, and Solved Example # 9.4 in Your Text
(Dixson), CHAPTER 9.
1. Kaplan Runner Design Procedure Using Analytical method (1-D,
Free Vortex theory), ANSYS BladeGen, TurboGrid, and CFX
(Runner with Guide vane - no spiral casing, no draft tube)
1.1. Runner Parameters (for example, from # 9), you have.
Tip diameter = 4.4 m, hub diameter = 2.0 m
Net head = 20 m, rotational speed = 150 rpm
Hydraulic eff. = 90%, mechanical eff. = 99%
The absolute flow at the runner exit is axial
Design option/intent:
Target for runner outlet absolute tangential velocity ≈ 0 (axial flow).
Assumptions:
Density water 1000 kg/m3
Acceleration due to gravity 9.8 m/s2
Negligible incidence and deviation
Selection
Select the number of blades of your choice – the number of blades for a Kaplan
turbine is usually 4 - 6.
Consider applicable spacing/chord ratio 1-1.5.
Definitions of Axial Turbine Parameters – It is essential to understand these terms.
SOLIDITY: Solidity is the ratio of the chord length to the blade spacing. This
parameter indicates how closely the blades are packed. It depends on the number
of blade selections.
HUB TO TIP RATIO: rh/rt is the ratio of the radius of the rotor at the hub to the
radius of the rotor at the blade tip. This parameter indicates the relative blade
height. For this specific design problem, the value can be calculated easily.
ASPECT RATIO is the ratio of the blade height to the chord length of the blade.
This parameter indicates the blade size.
STAGGER ANGLE is the angle between the blade chord line and the axial
direction of the turbine. This angle indicates how much the blade is turned
relative to the turbine axis.
WORK OR LOADING COEFFICIENT is used to quantify the aerodynamic
loading of the blades.
The flow COEFFICIENT is defined as the ratio of the axial velocity component
to the blade velocity. This parameter quantifies the degree of blade stagger.
Calculate absolute and relative values.
Determine the runner inlet and outlet flow angles, both the relative and absolute,
from hub to tip (spanwise direction) in five positions using free vortex theory.
Use an Excel spreadsheet to calculate these parameters.
Draw flow angles (a, b) versus normalized radius (ri/rt), similar to your text on
page #328. You may use MATLAB, Python, or Microsoft Excel.
1.2. Workflow of Runner design using analytical (1-D) and
numerical methods (ANSYS CFX)
1.3. Runner Geometry Modeling in ANSYS BladeGen
Create a meridional profile. The initial window will allow you to specify the 1D
geometry of the runner.
Define the hub and shroud contours using the given diameters (for example, from
#9, you have a tip radius of 2.2 m and a hub radius of 1.0 m).
Enter all your values in mm, not m.
Define spanwise stations: The second window will allow you to specify the number
of blades and their thickness
Enter all your values in mm, not m.
Set angles and thickness.
Next
Define the shroud and hub curves
The top left panel shows the meridional view of the runner.
The hub and shroud each have five control points that allow you to modify the
curves.
outlet channal
Tip radius in mm. All four
Inlet
points, small square, have
channal
the same values
Hub radius in mm. All
four points, small square,
have the same values
The impeller's top right corner should
have a zero Z value, and all other Z
values should be negative
Extend the inlet and outlet to include a short channel.
Double-click on the points that define the outlet to change their values.
Typically, a value of 1.25r2 or more is recommended.
Define the blade angles and curvature.
The bottom panel shows the “Beta distribution” or curvature of the blade at
different layers.
Under tools on the main menu, click layer, and you will find five layers
positioned from hub to tip. Activate each turb by turn, and any parameters can be
adjusted there for each layer.
Select the impeller’s hub: Layer → Span: 0.0000
Typical layers are set at: 0% (hub), 25%, 50%, 75%, 100% (tip). Use the
arithmetic radius to calculate the parameter at these spanwise positions.
Preview the blade in 3D and correct any geometric irregularities.
Set the inlet stagger angle to match the incoming swirl from the guide vanes.
Set the outlet absolute flow angle to zero so that the absolute flow is axial (zero
swirl).
Apply relative flow angles from hub to tip according to the calculated values.
Inlet
flow
angle
outlet flow
angle
Stagger
angle
Leading edge
thickness
1.4. Mesh Generation in TurboGrid -Exporting the files for
TurboGrid
File → Export → TurboGrid Input Files…
Creates four files: .inf, _shroud.curve, _hub.curve, _profile.curve
1.5. Using ANSYS TurboGrid
1.5.1. Open ANSYS TurboGrid
File → Load BladeGen… Find the .inf file, which should automatically load the
other three files.
You should see a single “slice” of the impeller, with the blade in the center of a
flow passage.
Use the scale at the bottom to check that your units are correct.
For non-shrouded impellers, add a tip clearance of about 5 mm.
In the Objects menu, double-click on Shroud Tip to open its menu.
Select Normal Distance in the Tip Option drop-down, enter the tip clearance you
want, and click Apply.
Topology selection:
Choose “Single-Passage Turbine” topology (or full 360°).
Apply a structured grid around the blade for better boundary-layer resolution.
Mesh settings:
Apply blade boundary-layer inflation (10–15 prism layers).
Target y⁺ < 30.
Refine mesh at leading edge, trailing edge, and tip.
Quality check:
Skewness < 0.9, smooth transitions near hub and shroud.
Generate 2–3 mesh densities for grid-independence testing/optional.
1.6. CFX Setup for Runner Simulation
Domain definition:
Single rotating domain for the runner at ω = 15.708 rad/s.
Add inlet and outlet extensions (short cylindrical sections).
Boundary conditions:
Inlet plane: impose mass flow rate or total pressure.
Outlet plane: set static pressure to achieve the required net head.
Walls: no-slip on blades and hub; shroud rotates with runner.
Periodic boundaries.
Solver settings:
Steady RANS → k–ω SST turbulence.
High-resolution advection scheme.
Frozen-rotor interface if using a single passage.
Convergence targets:
Residuals < 1×10⁻⁵
Stable torque and mass-flow balance
1.7. Post-Processing & Runner Performance
1.5.1 Extract torque → compute shaft power P=τω.
1.5.2 Compare with hydraulic power ρgQH to determine hydraulic efficiency.
1.5.3 Check outlet absolute flow: tangential component ≈ 0 (design requirement).
1.5.4 Inspect flow features: separation, pressure distribution, and velocity
distribution in blade-to-blade view.
1.5.5 Identify low-pressure zones for cavitation risk.
1.8. Validation & Optimization (optional)
Perform mesh-independence study (coarse, medium, fine).
Adjust blade angles, camber, and chord in BladeGen if efficiency or outlet flow
is not adequate.
Iterate geometry → TurboGrid → CFX loop until performance meets
expectations.
Resources:
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[Link]