Project Report

On

Design and Analysis of Turgo

Turbine
By
Mr. Atharva P. Galange (BM 158)
Guide
Prof. Asma B. Parkar

Department of Mechanical Engineering

Marathwada Mitra Mandal’s
College of Engineering,
Karvenagar, Pune
[2023-24]
 Marathwada Mitra Mandal’s
College of Engineering,
Karvenagar, Pune

CERTIFICATE

This is to certify that Name of Students with Exam Seat No

have successfully completed the Project Stress Analysis on Shaft carrying Gear
and Pulley using ANSYS under my supervision, in partial fulfillment of Bachelor
of Engineering - Mechanical Engineering of Savitribai Phule Pune University.

Date:

Place:

Prof. A. B. Parkar External Examiner

Dr. V. R. Deulgaonkar Dr. V. N. Gohokar

HEAD Principal
Dept. of Mech. Engg. MMCOE, Pune
MMCOE, Pune
 ACKNOWLEDGEMENT

We take this opportunity here to thank all those who had helped us in making this project a
reality.

First of all, we express our deep gratitude to our project guide Prof. A. B. Parkar for their
valuable support, help & guidance from time to time during the project work. We are also
grateful to our Head of Department, Dr. V. R. Deulgaonkar and Principal Dr. V. N. Gohokar
for giving us this opportunity to present this project report.
Last but not the least; we would like to thank our entire teaching staff who assisted us directly
or indirectly throughout the duration of this project.

Name of student: Atharva P. Galange

Roll No: BM158

Exam Seat No.

ii
 ABSTRACT

The research outlines the process of designing Turgo turbine blades using Solidworks software,
followed by the utilization of Finite Element Simulation (FES) through Ansys 2021R1 for
stress and deformation analysis within the Turgo impulse turbine. FES is a powerful tool for
understanding how materials behave under different conditions, making it particularly useful
for studying strain and stress distribution.

Through the analysis, it was noted that the highest stress concentration manifests at the root of
the blade's suction side. This observation is crucial as it highlights a potential area of weakness
or concern within the turbine design. Identifying such stress concentrations enables engineers
to refine the design, potentially mitigating structural vulnerabilities and enhancing the turbine's
overall performance and reliability.

By leveraging FES techniques, researchers can gain insights into how the turbine blades
respond to various operational conditions, allowing for informed decisions in optimizing their
design for efficiency and durability. This iterative process of design refinement and analysis is
fundamental in engineering high-performance machinery like turbines, ensuring they meet

safety standards and operational requirements.

iii
 INDEX

CHAPTER NO. TITLE PAGE NO.

CERTIFICATE i

ACKNOWLEDGEMENT ii
ABSTRACT iii

INDEX iv

LIST OF FIGURES v

LIST OF TABLES vi

1 INTRODUCTION 1

2 LITERATURE REVIEW

3 OBJECTIVES

4 METHODOLOGY

5 MODELLING

6 SETUP

7 RESULT

8 CONCLUSION

9 REFERENCES

iv
 LIST OF FIGURES

Figure Title of Figure Page

No. No
1.3 Actual System of Shaft Carrying Gear & 4
Pulley
1.4 Diagram System of Shaft Carrying Gear 4
& Pulley
5.1 Geometry 10
5.2 Mesh 11
6.1 Boundary Conditions 12
7.2.1 Equivalent Stress 13
7.2.2 Total Deformation 14
7.2.3 Factor of Safety 14

v
 LIST OF TABLES

Table No Title of Table Page Number

5.2 Mesh Result 11
6.1.1 Boundary Conditions 12
7.1.1 Stress Table 13
7.1.2 Deformation Table 13

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Chapter 1
INTRODUCTION

1.1Turgo Turbine:
In hydroelectric power generation,Turgo turbines are a type of impulse turbine
that are used for harnessing the energy of water in medium and high head
applications. They are efficient and effective for hydropower plants with heads
from around 15 meters to several hundred meters. The turbine is named after its
inventor, Gordon Turgo.
1.2.1.1 Advantages of Turgo Turbines:
- High Efficiency: Turgo turbines have high efficiency,
especially in medium head ranges.
- Robust and Reliable: These turbines are robust and can operate
reliably for many years.
- Compact Design: The compact design of Turgo turbines makes
them suitable for a variety of installation sites.
- Range of Flows and Heads: Turgo turbines can operate across a
wide range of flows and heads.

1.2.1.2 Applications:

- Turgo turbines are commonly used in small to medium-sized

hydroelectric plants.
- They are ideal for sites with medium to high heads and
moderate flow rates.
In summary, Turgo turbines are an efficient and reliable option for
harnessing hydroelectric power in a range of environments, and their
design makes them particularly well-suited for medium head
applications.

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Fig 1.1 Turgo Turbine

1.2 Parts of Turgo Turbines:

Parts of Turgo Turbines are as follows-

1.2.2.1 Bucket:
In the context of a turgo turbine, a bucket is a key component of
the turbine runner. Turgo turbines are a type of impulse turbine
that are used for hydroelectric power generation. Here's an
overview of how buckets function in a turgo turbine:
- Function of Buckets: Buckets are the curved, spoon-shaped
components attached to the turbine runner. Their primary function
is to capture the kinetic energy of the water jet and convert it into
rotational energy of the runner. As the water jet strikes the buckets,
the water changes direction, imparting energy to the runner.
- Design of Buckets: The shape and design of the buckets are
crucial for efficient energy transfer. They are designed to optimize
the angle at which the water jet strikes them, ensuring maximum
energy transfer and minimal energy loss.
- Material and Construction: Buckets are typically made of
strong, durable materials such as stainless steel to withstand the
high impact and continuous flow of water. The design must also
account for resistance to erosion and cavitation.

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- Arrangement on the Runner: Buckets are mounted around the

perimeter of the runner in a precise arrangement. The spacing and
angle of the buckets ensure the water jet strikes them at the correct
angle to maximize energy transfer.
- Interaction with Water Jet: In a turgo turbine, the water jet
strikes the buckets at an angle, typically around 20 degrees, rather
than directly onto the runner. This angled impact allows for a more
efficient conversion of the water's kinetic energy into mechanical
energy.

Overall, the design and functioning of the buckets in a turgo

turbine play a critical role in the efficiency and performance of the
turbine. The shape and arrangement of the buckets are carefully
engineered to optimize energy transfer and turbine performance.

1.2.2.2 Hub:
The hub in a Turgo turbine is an essential component of the
runner, which is the rotating part of the turbine that converts the
kinetic energy of the water into mechanical energy. The hub serves
as the central structure of the runner, to which the blades are
attached.
Characteristics of the Hub
- Central Support: The hub acts as the central support structure
for the runner blades. The blades are mounted around the hub
and project outward.
- Material: The hub is typically made of strong and durable
materials such as stainless steel or other metals that can
withstand the pressures and stresses of high-speed rotation and
the impact of water.
- Design: The design of the hub can vary depending on the
turbine manufacturer and the specific application of the turbine.
Its shape and size are optimized to maximize the efficiency of
the runner and ensure smooth operation.

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- The hub connects the runner to the turbine shaft, which

transmits the mechanical energy to a generator for conversion
to electrical energy.

Role of the Hub:

- Structural Integrity: The hub provides structural integrity and
stability to the runner, ensuring that the blades are securely
attached and positioned correctly for efficient energy
conversion.
- Balancing: The hub helps maintain the balance of the runner,
which is crucial for the smooth operation of the turbine and to
minimize vibrations.
- Transmission: The hub is the point where the rotational force
generated by the water jet striking the blades is transferred to
the shaft and subsequently to the generator.
- Cleaning and lubrication: Keeping the hub clean and properly
lubricated can help prevent corrosion and ensure smooth
operation.
In summary, the hub in a Turgo turbine plays a crucial role in
supporting the runner blades, transmitting energy to the turbine
shaft, and maintaining the structural integrity and balance of the
runner. Proper maintenance of the hub is important for the reliable
and efficient operation of the turbine.
1.4 Working Principle:

The working principle of a Turgo turbine involves converting the kinetic

energy of a high-velocity water jet into mechanical energy through the rotation
of the runner, which in turn drives a generator to produce electrical energy.
This makes Turgo turbines an effective choice for hydropower generation in
appropriate settings.

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1.6 Stress Analysis (FEA):

Stress analysis is a branch of engineering mechanics that involves the study of

how materials and structures respond to external loads or forces. The main goal
of stress analysis is to determine the internal stresses and deformations within a
structure under applied loads, and to assess whether the structure can withstand
these loads without failure. Here's an overview of stress analysis:

1.6.1 Types of Stress:

- Normal Stress: Normal stress acts perpendicular to the surface of a material
and can be either tensile (stretching) or compressive (squeezing).
- Shear Stress: Shear stress acts parallel to the surface of a material and tends to
cause adjacent layers of material to slide past each other.
- Von Mises Stress: A combined measure of both normal and shear stresses,
commonly used to evaluate yielding and failure in ductile materials.
1.6.2 Types of Loading:
- Static Loading: Loads that are applied slowly or held constant over time, such
as dead loads, live loads, and wind loads.
- Dynamic Loading: Loads that vary with time or are applied suddenly, such as
impact loads, vibration, or seismic loads.
1.6.3 Applications:
- Stress analysis is used in a wide range of engineering disciplines and
applications, including structural engineering, mechanical engineering,
aerospace engineering, civil engineering, and materials science. It is applied in
the design, analysis, and optimization of structures, components, and systems to
ensure they meet safety, performance, and durability requirements.
Overall, stress analysis plays a crucial role in engineering design and ensures
that structures and components are designed to withstand expected loads and
operating conditions without failure. It helps engineers make informed
decisions about material selection, structural design, and safety considerations
in various engineering applications.

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Chapter 2
LITERATURE REVIEW

1. Shpetim Lajqi’s “Design, implementation and analysis of the overall

performance of a hydro turgo turbine.”
https://www.researchgate.net/publication/
351211067_Design_implementation_and_analysis_of_the_overall_perfor
mance_of_a_micro_hydro_turgo_turbine
This paper studies, the increasing demand for energy and the concerns
regarding environmental protection have been driving forces toward the
exploitation of renewable energy sources as a better alternative compared
to conventional energy sources. Furthermore, renewable energy sources
enable an independent energy supply for isolated locations or communities
that lack access to the main electricity grid, and additionally, they offer the
possibility to use available energy sources for beneficial individual
purposes. Considering these statements, the use of micro hydropower
plants represents a convenient and advantageous option to implement. A
micro hydro Turgo turbine is used for analysis in this paper, due to its
simple design, structure, easy production and low installation cost. In this
manner, this paper deals with the use of Euler equations in detailed
analysis in designing and implementation of a micro hydro Turgo turbine.
The presented methodology will be based on numerical calculations of
micro hydro Turgo turbine characteristic parameters in various operating
regimes. The obtained results from numerical calculation will be compared
to the current performance of the real existing Turgo turbine. Accordingly,
based on obtained results, recommendations for improving the
performance of micro hydro Turgo turbines.

2. Sudish Gyanwali’s “DESIGN AND CFD ANALYSIS OF PICO HYDRO

TURGO TURBINE”
https://www.academia.edu/34879025/
CRHT_VII_DESIGN_AND_CFD_ANALYSIS_OF_PICO_HYDRO_TU
RGO_TURBINE

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This paper consists of the study, design and analysis of Turgo turbine. The
main aim of this study is to design a Turgo turbine with the available head
and flow as a constraint and analyze its performance by varying rpm and
discharge. The design of the different components like bucket, hub, shaft,
spear, and casing has been carried out with the aid of the Turgo manual
that has been available. The 3-D modeling has been carried out using the
different software like Creo Parametric and SolidWorks. The further
analysis of the performance of Turgo is carried out in the ANSYS 13 by
varying flow and RPM. The torque, mechanical power and pressure at inlet
of nozzle and outlet of casing and the efficiency has been calculated from
the simulation for different nozzle openings. Constant head characteristics
and Hill chart are developed based on the results obtained from the
simulation.

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Chapter 3
OBJECTIVES
3.1 Objectives:
Turgo turbines are used in hydroelectric power generation, particularly in small
to medium-sized hydroelectric plants with medium to high head and moderate
flow rates. The objectives of Turgo turbines include:

3.2.1 Efficient Power Generation: Turgo turbines aim to convert the kinetic
energy of water into mechanical and then electrical energy with high
efficiency.
3.2.2 Adaptability: Turgo turbines can operate efficiently across a range of
water flows and heads, making them versatile for various hydroelectric
projects.
3.2.3 Reliability
3.2.4 Cost-Effectiveness: Turgo turbines are compact, which reduces
installation and maintenance costs. The design and construction of Turgo
turbines require relatively low maintenance, resulting in lower long-term
operating costs.
3.2.5 Environmental Considerations: Hydropower is a clean energy source,
and Turgo turbines can be installed with minimal environmental impact.

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Chapter 4
METHODOLOGY
4.1 Process Flowchart:

4.1.1 Geometry & Mesh:

 To create geometry according to given dimensions (bucket & hub).
 Also, validating a mesh for fast computation is necessary too.

4.1.2 Setup:
 Applying Boundary Conditions
 Selecting the required result
parameters.

4.1.3 Result & Solution:

 To check the results and plot the graph

4

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Chapter 5
Design Calculations

5.1 Calculation of the Net Head:

For the pico-hydro scheme, hydraulic head H can be calculated at any
location where elevation z, pressure p, and velocity v are known using:
Hg = p/ρg + v2/2g+z
The net Head Hn = Hg - Hf

Where, Hg = The gross head which is the vertical distance

between water surface level at the intake to the turbine; Hf = Total
Head losses due to open channel. These losses approximately
equal to 6% of gross head.
We are going to design the turgo turbine for the head of 60m. For the
sample purpose we decided to go for 60m, 70m, 80m, 90m and 100m
as the Turgo turbines are operated for more than 50mhead.
5.2 Calculation of water flow rate:

The water flow rate can be calculated by the measuring the river or stream
flow velocity and its cross-sectional area, then
Q=A×V
Where, A= Area of channel; V=Velocity of stream
As we can’t find the actual parameters, we considered the flow rate for
60m head as 10l ps i.e 0.01 m3/s and for further calculations, we found
out the flow rate for respective heads.
5.3 Calculation of Power:
The available hydraulic power, PH, of a hydraulic turbine is a
function of the head and flow:

PH = ρ*g*H*Q

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5.4 Calculation of the Turbine Speed (N):

The Correlation between the specific speed (Ns) and the Net Head is given as
Ns= 85.49×√Nj/Hn0.243
Where, Nj =No. of jet N= Ns*H 1.25/√P
5.5 Runner Design:

The mean velocity of the free jet emerging from the nozzle of the
turbine is determined from the net head, by the equation
Vj = Cv√2gHn
At the best efficiency point the circumferential speed of the runner is
connected with the jet velocity via the relation.
u = (0.46) * Vj
Hence the Diameter or runner is
D = 60*u/πN
Where N is the speed of runner in rpm
5.6 Diameter of Nozzle or Jet:

d = √4Q/πVj
5.7 Number of Buckets:

Z = 15 + D/2d
5.8 Efficiency of turbine:

Torque T= Q*D*(Vj - U)
Power transferred by the
turbine shaft Ps= 2πNT/60
Efficiency ɳt = Ps /Pj

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For the turgo turbine design for head 60 m:

Power (W) 5000
Gross head 60
Net head 56.4
Speed Ratio (ku) 0.46
No. of Jet 1
Cv 0.98
Jet angle 200

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Chapter 6
MODELLING
6.1 Geometry:

Following is the geometry for Turgo turbine parts and its assembly

Fig 6.1.1 Turgo Bucket

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Fig 6.1.2: Turgo Hub

Fig 6.1.3: Assembly

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Fig 6.1.4 Geometry

6.2 Mesh:

The mesh used is a quadratic mesh for fast computation and better quality.

Domain Nodes Elements

All Domains

Table 5.2: Mesh Result

Fig 6.2: Mesh for shaft turgo turbine

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Chapter 7
SETUP

7.1 Setup:

7.1.1 Apply Boundary Conditions:

Here we select the condition type, compute from area and initialize and
run calculations.
Domain Boundaries
Remote Displacement Along the Shaft
Fixed Support Face of Gear
Moment 25 N mm along X-axis

Table 7.1.1 Boundary Conditions

Fig 7.1: Boundary Conditions

Chapter 8

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RESULT
8.1 Result Table:

Parameters Maximum Minimum Average

Stress(MPa) 4.5568 e-003 40.36 9.1805
Total Deformation(mm) 0 3.763 e-002 9.5312 e-002
Pressure 1.547 e+02 -2.612 e+02 -
Velocity 2.110 e+01 0 -

Table 8.1.1: Result Table

8.2 Result Analysis:

Fig 8.2.1: Equivalent Stress

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Fig 8.2.2: Total Deformation

Fig 8.2.3: Pressure Contour

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Fig 8.2.4: Velocity Contour

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Chapter 9
CONCLUSION

As discharge increases the specific speed also increases hence, they

are directly proportional. Also, as net head increases specific speed
decreases and power output increases.
Total deformation observed for cut out and survival speed ranges
from0.0022798 mm to 0.0046859 mm and stress values ranges from
29.466 N/mm to 30.38 N/mm for loading conditions of force 174 N
and rotating speed 116 rps at 22 0 C temperature. As per the review, it
is clear that stainless steel is most effective performance enhanced
material. This work of turgo turbine bucket analysis shows best
results for material stainless steel total deformation and titanium
alloys for equivalent (Von-Mises) shear stresses. But if we think,
according to some conditions like cost, efficiency, relatively high
strength, good corrosion resistance and large internal friction or
damping capacities and according to above analysis also in terms of
total deformation and stress(Von -mises) the stainless steel is the most
efficient and better material than any other materials for the turgo
turbine. At a force of 174 N, the design made on Solidworks software
is safe.
Thus, the turgo turbine is best for the pico hydro power generation for
rural electrification as it satisfies required specification for it.

Chapter 10
REFERENCES

9.1 Williams A, Simpson R. Pico hydro-reducing technical risks for ru-

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ral electrification Renew Energy 2009.

9.2 Sourabh KHURANA, Varun GOEL and Anoop KUMAR.FEM Anal-

ysis of Turgo Impulse Turbine Blade, Hmirpur, India, Walailak
Journal,28 march-2013.

9.3 Vipin Uniyal, Nikhil Kanojia, Kshitij Pandey Sivalik. Design of 5kw
hydro power plant using Turgo turbine, IJSER, Volume 7,Dec-2016

9.4 Mechanical Engineering Online Resources: Websites such as Mechanical

Engineering Portal (https://mechanical-engineering.in/) and Mechanical
Engineering Blog (https://mechanical-engg.com/)

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