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March 1983
Department of
Mechanical Engineering
-.-
•=
Eindhoven University of Technology
Report WPS3-83.03.R351
BANKI TURBINE BLADE CALCULATIONS
By P.Verhaart
Department of Mechanical Engineering
Eindhoven University of Technology
9 March 1982
SUMMARY
Introduction
During the years 1977 and 1978 a number of small (8 to 30 kW) Banki
turbines was designed and built in Indonesia under the responsibility of
personel of the Eindhoven University of Technology at the time employed in
a cooperation project with the Bandung Institute of Technology. Not long
after installation cracks developed in the runner blades starting from the
periphery and near the supporting flanges. Further use of the turbine
resulted in breaking of the affected blades. A little later similar
troubles occurred in Nepal where a Swiss team had been developing the same
type of water turbine.
In response to this problem a calculating procedure was developed which is
quite amenable to further refinement but which has, so far as we know,
resulted in longer blade life of existing machines and a better design for
newly produced machines. In this paper, details about the calculation of
the fatigue strength of blades are given.
The runner geometry is best explained with the aid of Fig. 1. From
Banki's article [1] we derive the following ratios:
o = 2r
1
= 6,1236g
r
2 = 2,0177g
R = 2,2516g
830321 Banki Turbine Blade Calculations 2
-------
rM 8\
-< -<
L .J
I
I
I
i ...:I
i
!
! ...
,
L.J
~-A
2
830321 Banki Turbine Blade Calculations 3
that the bending stress due to hydraulic forces on the blade can be kept
at a safe value.
The number of blades n is also a compromise. From a fluid dynamics point
of view a large number of blades is desirable but in practice only a
limited number can be accomodated due to manufacturing constraints.
The pitch circle radius R is a purely manufacturing parameter. It needs
to be known in order to be able to scribe the slots for the blades on the
supporting disks.
The inner radius r is another constructive dimension. It fixes the
2
position of the inner ends of the blades on the supporting disks. It is
good practise to drill holes of a diameter equal to the blade thickness t
to obtain well defined end positions for the blade slots in the supporting
disks.
The width of the channel s1 formed by two successive blades is a very
important dimension determining the distributed load on the blades.
The blade thickness t not only has its influence on the bending strength
of the blade, it also decreases the theoretical channel width between
blades. In order to admit a certain volume flow of water the real runner
has a slightly greater length than the theoretical one where no allowance
was made for blade thickness.
The radius of curvature of the inside of the blade Q is needed to scribe
the blade slot outlines on the supporting disks.
The pitch [ is used to set out the n blade slots on the pitch circle.
The peripheral velocity of the runner u. With the values of the angles of
entry and relative velocity as set out in Banki's article [1] the ratio:
u/c = 0,484
The relative velocity w of the water in a blade channel at the entry of
the runner normally satisfies the condition that the ratio:
w/c = 0,5546
The angle between the absolute and peripheral velocity a is taken as:
a = 0,2792 rad or 16 0
The angle between relative velocity and peripheral velocity ~ is taken as:
~ = 0,5236 rad or 30 0
The angle of pipe section forming the blade profile 6 is taken as:
6 = 1,2828 o
rad or 73,5
3
830321 Banki Turbine Blade Calculations 4
3 Outline of the Procedure
After a brief description of the quantities that have been taken
into account the relations that are assumed to exist between them are
defined. In the succeeding section the final expression is derived in
detail. The calculator program is described in a separate section.
a) The hydraulic force, periodic in nature, resulting from the water jet
entering the runner.
e) Bending moment from the entry of the water jet into the runner.
3.2 Discussion
Component b) in most cases turns out to be insignificant compared
to component a) but was easy to include into the calculator program.
Component c) is of the same magnitude as in the shaft of the runner.
The latter has been designed to withstand the combined stress resulting
from torsion as well as from bending.
Component d) is constant at constant power output and angular velocity.
It is the result of the parallel displacement of the blade supports when
the latter undergo angular displacement as the result of torque
transmission to the shaft. This component was dismissed without thorough
examination. It would add a constant amount of tensional stress near some
of the supporting flanges.
- - - - - - - -- - - ----
- compression
~E:::·=-~r-·--- -- - ------r-' ~.
- tension
4
830321 Banki Turbine Blade Calculations 5
4 Developing the Strength Product Concept.
The strength product concept enables one to do the fatigue strength
calculation for the blade beforehand as it were. Usually the blades for a
Banki type turbine are made from steel pipe which is sectioned lengthwise.
When the outer diameter and the wall thickness of the pipe with which one
intends to build a Banki runner is known, the strength product can be
calculated. This enables the turbine manufacturer to specify the maximum
head of water for which his turbine is suited. Conversely it gives him
the safe length of blades between supports if the head of water under
which the turbine is going to be used is specified. As steel pipes come
in standardised sizes it is also possible to give a turbine builder a list
of pipe sizes with the associated strength product for each pipe size.
4.1 Assumptions
2
Wl
M= ( 1)
12
where:
A further relation exists between the bending momemt and the flexural
stress:
Me
a = (2)
I
where:
a is the flexural stress
e is the maximum fibre distance from the
neutral plane in the blade cross section m
I is the area moment of inertia of the blade
cross section
The distributed load W from (1) with fixed runner geometry is equal to the
force on the concave side of a blade divided by its length. The force on
the concave side of the blade is a result of the change in moment of
momentum of the part of the water jet that enters a blade channel. As the
moment of momentum can be expressed in the square of the relative velocity
of the water on entering the blade channel the distributed load can be
'. ,
5
830321 Banki Turbine Blade Calculations 6
written in the following form:
2 2
W = Aw A(B/(2gZ» (3 )
where:
(4 )
where:
C is a constant of proportionality
Combining (4) with (2) we obtain an expression for the bending stress a in
terms of the blade geometry quantities (I, e and 1) and the head Z e.g.
2
CZl e
a = (5 )
I
(6)
When from literature or experiment a safe value for the bending stress a
can be found and substituted in the expression (6), it will produce a
maximum value for the head times the square of the blade section length
when the blade quantities e and I are substituted. In this way the safe
section length for given blade dimensions and a given head can be
calculated. The term between brackets on the left of the = sign we call
"Strength product".
Qmc = Qw lS 1W (7 )
where:
6
830321 Banki Turbine Blade Calculations 7
In order to find an expression in known quantities for s1 we look again at
Fig. 1. We see that the channel width s1 is the projection of the chord
of the arc between two successive intersections of blade skeleton lines
with the runner perimeter.
The arc length 1 is equal to the circumference divided by the number of
a
blades.
where:
Now in practice the number of blades is always above 20. When the chord
length is substituted for the arc length a very small error is made. The
angle between the tangent to the concave blade surface at its intersection
with the runner periphery and the tangent to the runner periphery at that
same spot is p. From the figure we see that:
This is without taking into account the blade thickness t. When blade
thickness is taken into account the expression changes into:
lTDsinp
= ------ - t (8)
n
The channel width s1 is only one of the two dimension of the cross section
of the blade channel. The other is the length of the blade section 1.
The cross sectional area is the product:
A= s 1 (9 )
1
The relative velocity can be found from the velocity triangle, see
Fig. 3.
w2 22
= u t C - 2uccoscr
u = O,484c
7
830321 Banki Turbine Blade Calculations 8
a = 0,2792 rad
So that, substituting these values in the cosine expression and working it
out, we obtain:
2 2
w = O,3038c
or:
w = O,5511c
w = O,7794f(gZ) ( 10)
Combining equations (8), (9) and (10) we get an expression for the volume
flow Q through a blade channel of width s1 and length 1
vc
lfOsin~
= O,7794( ------ - t)lf(gZ)
n
where:
3
is the volume flow per blade channel m /s
To obtain the massflow Q per blade channel the volume flow is multiplied
mc
by the density of water Q . Expressing the massflow per channel section in
w
known quantities and ratios we obtain:
c = ccosa
u
u =
2
Expressing u 2 in c we get:
8
830321 Banki Turbine Blade Calculations 9
The moment transmitted by a blade channel then becomes:
2
0,484r
2
T = Q c(r cosa- -------)
c mc 1 r 1
substituting (11) for Q and the current values for the proportions,
mc
expressing the radii in Q we get:
9,619Q
Tc = 24842,1(--n--- - t)QZI (12)
F---_-.-...t.
where:
y equals 2Qsin(6/4) m
9
830321 Banki Turbine Blade Calculations 10
--------------- - - - - - - - - -
F----~_,_~
or:
222
r +
Q - R
~ = arccos(---2rg--- )
~ = 1,0049 rad
Fc cos1 = F
or:
F
6~8443 = 1,1847F ( 14)
10
830321 Banki Turbine Blade Calculations 11
The force F can be found from (12) dividing the torque T by
c
r:
T
c
F =
r
Using the current values we obtain:
9,619Q
F = 9468,7(------ - t)Zl
n
9,619Q
Fc - 11217,4(--n--- - t)Zl N
( 15)
where:
\
\
y
'1
830321 Banki Turbine Blade Calculations 12
is employed using Steiner's theorem.
2
I I - Ay ( 16)
x Y
where:
6t(2g + t)
A = ----------
2
y = ~il~_±_~l:_:_~=!~~~l~L~l
6t(2g + t)
I = ilQ_±_~l~:_e~!l~_±_~!~~l
y 8
The extreme fibre distance from the neutral plane e is found to be:
e =y - gcos(6/2)
Substituting the current values into the above equations we obtain the
following:
A = 0,6414(2g + t)t
y = QL§~!~ile_±_tl=:_e=l
(2g + t)t
I y = 0,2231{(g+t) 4 - g
4
}
e =
12
830321 Banki Turbine Blade Calculations 13
Adapting the well known equation from applied mechanics for this case we
can write for the bending moment:
2
W{6X(1 - X) - 1 }
M = ----------------- Nm
12
M = ( 17)
Which means that the highest values for the bending moment occur near the
ends of the blade sections. The negative sign means that the topside of
the beam near the supports (in Fig. 7) is subjected to tensional stress.
The tensional stress that occurs in the beam can be expressed in known
quantities:
(J = ( 18)
a =( 22 N/mm 2
for mild steel seems in the correct order of magnitude. When this value
is substituted for a in (18), the expression can be rewritten as follows:
13
830321 Banki Turbine Blade Calculations 14
This expression gives the safe value of the product of the net head Z
(in m) and the square of the length 1 (in m) of a runner blade section
between supporting discs (if the fatigue stress of 22 N/mm2 is considered
safe) .
In practice runner dimensions are given in mm and the head is given in m.
How does (19) change in that case?
Expressing 1 in mm requires the part to the right of the = sign to be
6
multiplied by 10 .
. . 4 -12
Expresslng I ln mm produces a factor 10
x
6
Expressing Q, t and e in mm gives a factor 10- in the denominator and thus
6
10 in the numerator.
Adding these powers of 10 together we get exactly zero which means that
4
(19) is also valid for Z in mi 1, Q, t and e in mm and I in mm. This
x
gives manageable figures.
In (18), on the other hand, all powers of 10 cancel out when the above
mentioned quantities (except Z) are expressed in mm and thus 0 remains ln
2
N/m .
NOT E
The expression (19) is not dimensionallY homogenous. In the
numerical coefficients the numerical values of the acceleration of gravity
and the density of water have been used. In the unlikely case of anyone
wishing to rewrite (19) in other units conversion has to start from
equation (10) ..
1) Strength Product:
e =
With the aid of the above collection of formulae it should not be too
difficult to calculate the strength product, especially if a modern
programmable pocket calculator is used.
14
830321 Banki Turbine Blade Calculations 15
If the head under which the turbine has to work is known, the safe section
length is easily calculated.
If the head is not known, as in the case of a series production, it is
easy to indicate the maximum permissible head.
or, expressed in g:
Thus the program can run after the dimensions of the pipe, the blades are
going to be made from, are entered.
under number:
15
830321 Banki Turbine Blade Calculations 16
When ordered the program description comes complete with two magnetic
cards, one containing the 220 program steps, the other containing a number
of constants to be entered into the memories.
As the program, at the time it was composed, used a different method to
calculate the distributed load W, the resulting strength product is some
58 % higher than with the calculation method just described. To remedy
this it is sufficient to change the value of the constant that goes into
memory A to:
6.2.1 Description
The program consists of 4 parts under the labels A through D.
Part A:
Calculates the new pitch [ and Strength Product when a new value for the
number of blades n is entered.
Part C:
Calculates the bending stress a at the edge of the blades near the
supports resulting from the hydraulic load when the head Z and the blade
section length I are entered.
Part D:
16
830321 Banki Turbine Blade Calculations 17
6.2.2 User Instructions
18 Initialize D D 54435
19 Enter rotational frequency
f (Hz) f (Hz) ENTER f (Hz)
20 Input blade section length
1 (mm) 1 (mm) 1 (mm)
21 Restart program R/S S (N/mm)
c
17
830321 Banki Turbine Blade Calculations 18
6.2.3 Example
In this example all the possible calculations will be done. This
enables the user to check the program.
The following data are from one of the turbines that broke down.
Head: 5,3 m ; Blades made from pipe of 174,8 mm outside diameter and
4,4 rom wall thickness. The section length was 640 mm.
18
0321 Banki Turbine Blade Calculations 19
COMMENT
- ------
STEP KEY
---.....---.....---_
,-..--.......
KEY COMMENT
....._.~.. --_ ....._-_.. _-.
ENTRY CODE ENTRY CODE
001 f LBL A 31 25 .11 056 h y"x 35 63
002 h RAD 35 42 057 - 51
003 2 02 058 RCL 0 34 00
004
005 ··5TO 2
81
33 02
059
060
2
*
02
71
006 h x<=>Y 35 52 061 ENT 41
007 STO 1 33 01 062 f sin 31 62
008 - 51 063 + 61
009 STO 3 33 03 064 * 71
010 RCL 4 34 04 065 8 08
011
012
· STO 6
81
33 06
066
067
:
STO 8
81
33 08
013 RCL 5 34 05 068 RCL 2 34 02
014 *STO C 3371 069 3 03 ---.--
015 13 070 h y"x 35 63
016 9 x"2 32 54 -- .. ---.-
071 RCL 3 34 03
017 RCL 3 34 03 072 3 03
018 9 x"2 32 .54 •
,
073 h y"x 35 63
.,•
019 + 61 c-.:J 074 - 51 ....o
020 f Vx 31 54 075 ENT 41 (II
021 STO D 33 14 "l:)
c: 076 9 x"2 32 54 ....L
022 RCL 6 34 06 cu
077 RCL 2 34 02 /'-CU
023 h PI 35 73 ar:
, 078 9 x"2 32 54 ...
00.
• "l:)
024 71 079 RCL 3 34 03 • c:
025 *RCL 6 34 06 ~
N
080 9 x"2 32 54 0-• cu
L
, -4")(
026
027 · 1
83
01
•
... c
•• c: ,
081
082
-
ENT
51
41
en
0. ....
LLlO
.....
030 34 01 I-
en 085 : 81 ....cu
031 + 61 ....0 086 2 02 ~
032 · 81 087 * 71 ~
:J
u
033
034 ·5
83
05
c:
0
....cu
.~
088
089
3
:
03
81
cu
u
035 + 61 ~ 090 RCL 0 34 00
036 h CF 1 35 61 01 :::J
u 091 : 81
037 f LBL 0 31 25 00 ~
cu 092 RCL 0 34 00
038 f INT 31 83 u 093 f sin 31 62
039 STO 7 33 07 094 * 71
040 h 1/x 35 62 095 h Rv 35 53
041 h PI 35 73 096 : 81
042 *f sin 71 097 RCL 0 34 00
043 31 62 098 f sin 31 62
044 RCL D 34 14 099 9 x"2 32 54
045 *2 71 100 * 71
046
047 *STO E 33
02
71
101
102
4
*
04
71
~.-
· -4"
i
: ...
-----
., .
048
049 h F? 1 35
15
71 01
103
104
9
:
09
81
!.-'+-,
· • 0
,
, • c:
.
050 GTO 2 22 02 105 RCL 0 34 00 '00 0
051 RCL 2 34 02 106 : 81 !~~
052 4 04 107 STO - 8 33 51 08 I en ~
i 0. :::J
053 h y"x 35 63 108 h R" 35 54 · LLI
I-
u·
~.
19
830321 Banki Turbine Blade Calculations 20
.-~ .-_' .. _._--- ---<-- ----- . "- --". -, -- ---' ... -- - _.---._-
STEP KEY KEY COIIIfIIIENT STEP KEY KEY CO ....ENT
ENTRY CODE ENTRY CODe
111 RCL 3 34 03 166 71
112 71
'" -- --- - _.
• 167
*h RTN 35 22
-*STO 9
N
c
113 51 N -' 168 f LBL D 31 25 14
fO"I -II,
114 33 09 169 RCL 0 34 00
·• ....
.- N
.. 173
*RCL 9 34 09
CL. 1'0
119 *RCL A 71 W -' 174 + 61
.... ::J
120 34 11 ! (I) U 175 ENT 41
-'
121 *RCL 6 71 ;
u
1'0 176 ENT 41
122 34 06 177 RCL 0 34 00
123 h PI 35 73 ._.- - 178 f sin 31 62
124 *2 71 • 179 71
125 02 1oo,J'
180 *RCL C 34 13
126
127
·
RCL 7
81
34 07 1J
I 181
182
+ 61
h x<=>y 35 52
-_ .. ~---
c
128
129
·
RCL 1
81
34 01 fO"Ia::
1'0 183
184
RCL 0
f cos
34 00
31 63
130 - 51
11\
.- , 185 71
*CHS
131
132
·
STO B
81
33 12
• N
•• L,
fO"I
186
187 RCL 3
42
34 03
133 h F? 1 35 71 01 .- c,
fO"I
188 + 61 U
•
134 GTO 3 22 03 189 0(1)
(l)Q 9 ->P 32 72
135 RCL 3 34 03
CL.
w , 190 h x<=>y 35 52
N
N
• 0
....
.... Ci
136 DSP 1 23 01 (I)
191 CHS 42 •
137
138
139
RIS
RCL 6
RIS
84
34
84
06 1'0
-'
Q.
>-
192
193
194
+
h PI
RCL 0
35 73
61
34 00
aO~
-0
.-
(I) - '
.
.~
1'0
CL. ::J
140
141
DSP 0
RCL 7
23
34
00
07 ......
.~
Q
(I)
195
196
- 51 wu
.... -'
1'0
f cos 31 63 (I)
u
c•
142
143
144
RIS
DSP 1
RCL C
84
23
34
01
13
..c
41
197
198
199
*RCL 2
9 )("2
71
34 02
32 54
145 RIS 84 L 200 RCL 3 34 03
146 RCL D 34 14 ........41 201 9 xA2 32 54
147
148
RIS
f LBL 3
84
31 25 03
C01J
.~
202
203
- 51
.-
11\
L
RCL 0 34 00
149
150
RCL E
RIS
34
84
15
04'N
·• ....
• 0 204
205 *
*RIS
71
71
151 RCL B 34 12 11\ C
.- -'
206 84
152 DSP 0 23 00 -II 207 71
153 h RTN 35 22
(l)N
CL. 208 *2 02
w ....
154 f LBL B 31 25 12 .... 0 209 71
155 DSP 1 23 01
(I)
c *h PI
156
157
h SF 1
GTO 0
35
22
51 01
00
..
. 0
~
1'0
---
,.... t)
•
210
211
212 *9 x"2
35 73
71
32 54
....
·• ....
-' -0
158 h RTN 35 22 ::J 213 71
159 f LBL C 31 25 13 -'
U
• 0 214 *RCL 9 34 09
1'0
9 xA2
160
161
162
*RCL B
32
71
34 12
54 u coc
11\0
.-
(I)
CL.-'
.
.~
1'0
215
216
217
*RCL
. 8
71
34 08
81
163
164
·
2
81
02
W::J
....
(I) - '
U
218
219
h RC 1 35 34
71
165 2 02
1'0
u 220
*h RTN 35 22
830321 Banki Turbine Blade Calculations 21
6.3 Bibliography
1. Banki, D. (1918 )
Neue Wasserturbine.
Zeitschrift fuer das Gesamte Turbinenwesen.
Vol. 15 Nr 21 (30 July 1918)
R.Oldenbourg Verlag. Berlin, Munich.
21
830321 Banki Turbine Blade Calculations 22
6.4 List of Symbols and Units
22