A

Synopsis Report

On

Design and Analysis of Physics Based Circular Conical Draft Tube

Submitted to the

Department of Mechanical engineering

in partial fulfillment of the requirements
for the degree of
Bachelor of Technology
By

Ajeet Kumar (220010001)

Utkarsh Vashishtha (210110072)
Rajat Rathore (210110050)

Under the Guidance of

Mr. Keshav Gupta

Harcourt Butler Technical University

Kanpur
 Table of content

1. Introduction

2. Problem identification and problem formulation

3. Objective of study

4. Scope of study

5. Data collection

6. Research tools/ methodology to be used

7. Limitation of study

8. Cost and benefit analysis

9. References
 1. Introduction

 Topic overview

A circular conical draft tube is a crucial component in various engineering applications, particularly in
hydroelectric power plants. It serves to efficiently convert the kinetic energy of the flowing water into
potential energy, thereby improving the overall efficiency of the turbine. The design and analysis o f these
tubes are critical to ensure optimal performance and minimize energy losses.

 Industry and competitive landscape

The hydroelectric power industry is a significant contributor to global renewable energy production.
Companies involved in this sector, including turbine manufacturers and hydroelectric plant operators, are
constantly seeking innovative solutions to improve the efficiency and sustainability of their operations.

 Competitive companies in this field include:

Andritz
GE Renewable Energy
Voith Hydro
Siemens Gamesa Renewable Energy
These companies invest heavily in research and development to create advanced draft tube designs that
enhance energy capture and reduce environmental impact.

 Need for Study

The design and analysis of circular conical draft tubes are essential for several reasons:

Efficiency Improvement: Optimizing the tube's geometry and flow characteristics can significantly increase
the overall efficiency of hydroelectric power plants.
Energy Conservation: By minimizing energy losses in the draft tube, valuable energy resources can be
conserved.
Environmental Impact: Well-designed draft tubes can help reduce environmental impacts, such as fish
entrainment and sediment transport.
Economic Benefits: Improved efficiency and reduced energy losses can lead to substantial economic benefits
for hydroelectric plant operators.

 Historical Context

The development of draft tubes has been closely linked to the evolution of hydroelectric power generation.
Early designs were relatively simple, but advancements in fluid mechanics and materials science have led to
more sophisticated and efficient tubes.
 2. Problem identification and problem formulation
 Core problem: The efficient design and analysis of circular conical draft tubes, particularly in the
context of hydroelectric power generation, to maximize energy recovery and minimize losses.

 Key challenges:

 Complex Fluid Dynamics: The flow within draft tubes is complex, involving turbulent flow, vortices,
and cavitation. Accurate modeling and analysis of these phenomena are essential for optimal design.
 Geometric Optimization: The shape and dimensions of the draft tube significantly influence its
performance. Optimizing these parameters to achieve maximum energy recovery and minimize
losses is a challenging task.
 Material Selection: The choice of material for the draft tube affects its durability, corrosion
resistance, and overall efficiency. Selecting the appropriate material is crucial for long-term
operation.
 Installation and Maintenance: The installation and maintenance of draft tubes can be complex and
costly, requiring careful planning and execution. Core problem: The efficient design and analysis of
circular conical draft tubes, particularly in the context of hydroelectric power generation, to
maximize energy recovery and minimize losses.

 Related Problems and Brief Solutions

3. Flow Visualization and Measurement

Problem: Understanding the flow patterns within the draft tube to identify areas of inefficiency and
optimize design.
Solution: Employing experimental techniques such as particle image velocimetry (PIV), laser
Doppler velocimetry (LDV), and pressure measurements to visualize and quantify the flow field.
4. Computational Fluid Dynamics (CFD) Analysis
Problem: Simulating the complex fluid dynamics within the draft tube to evaluate its performance
and identify design improvements.
Solution: Using advanced CFD software to model the flow, accounting for turbulence, cavitation,
and other relevant phenomena.
5. Structural Analysis
Problem: Ensuring the structural integrity of the draft tube under various loading conditions,
including hydrodynamic forces, weight, and seismic loads.
Solution: Conducting finite element analysis (FEA) to assess the stress distribution and deformation
of the draft tube.
6. Cavitation Prevention
Problem: Preventing cavitation, which can lead to erosion, noise, and reduced efficiency.
Solution: Designing the draft tube to minimize pressure fluctuations and avoid regions of low
pressure. Implementing cavitation mitigation techniques such as air venting or gas injection.
7. Vortex Mitigation
Problem: Reducing the formation of vortices, which can cause energy losses and vibrations.
Solution: Optimizing the draft tube geometry, using vortex suppressors, or incorporating swirl
breakers to minimize vortex formation.
8. Noise Reduction
Problem: Mitigating noise generated by the flow within the draft tube, which can be a nuisance to
nearby communities.
Solution: Implementing noise-reducing measures such as acoustic treatment, vibration isolation, and
proper installation techniques.
9. Environmental Impact Assessment
Problem: Assessing the potential environmental impacts of the draft tube, including effects on
aquatic life and water quality.
Solution: Conducting environmental impact studies to identify potential risks and develop
mitigation strategies.
 3. Objective of study

1. Mathematical development of Circular Conical Draft Tube

2. Computation of geometrical and flow parameters along the draft Tube
3. CFD analysis of designed draft Tube
4. Evaluation of performance of draft tube

4. Scope of Study

 Companies:

Hydroelectric power generation companies: This study will focus on major hydroelectric power
plants and their associated draft tubes.
Turbine manufacturers: The research will include an analysis of draft tube designs and performance
characteristics from leading turbine manufacturers.
 Industry:

Hydropower industry: The scope will be limited to the hydropower industry due to the specific
application of circular conical draft tubes in this sector.

 Recent developments: The study will primarily focus on recent advancements in draft tube design
and analysis, including the past decade.
 Case studies: Historical case studies may be included to provide context and illustrate the evolution
of draft tube technology.

 Hydropower engineers and designers: The research will be primarily aimed at professionals
involved in the design, construction, and operation of hydroelectric power plants.
Academic researchers: The study will also be relevant to researchers in the fields of fluid mechanics,
hydraulic engineering, and renewable energy.
Policymakers: The findings may be useful for policymakers and regulatory bodies involved in the
hydropower sector. Academic researchers: The study will also be relevant to researchers in the fields
of fluid mechanics, hydraulic engineering, and renewable energy.
Policymakers: The findings may be useful for policymakers and regulatory bodies involved in the
hydropower sector.

 Variation of outlet Shape (ellipse)

The draft tube is modified to increase the pressure recovery. So that best model of different diffuser
angel is modified to elliptical shape keeping the area constant equal to the outlet area of optimum
model of diffuser angle. The major and minor axis is changed
for the different elliptical shape and study is carried for the best recovery of the pressure.

 Variation of diffuser angle

For a given inlet diameter and constant length of draft tube are studied with the variation of diffuser
angle ranging from 40
to 9.50. The variation of diffuser angle for different model is made with the variation of
0.50. The study will enhance how the diffuser angle affects on the performance of the draft tube. The
study will includes the pressure recover at different model at constant L/D ratio.
 5. Research Tools and Methodologies:

 Empirical Data
 Model testing: Experimental studies on physical models of draft tubes can provide valuable
insights into flow patterns, pressure distributions, and overall performance.
 Field measurements: Data collected from operating hydroelectric plants can be used to
validate design assumptions and refine analysis methods.
 Computational Tools
 Computational Fluid Dynamics (CFD): CFD software, such as ANSYS Fluent, STAR-
CCM+, or OpenFOAM, can be used to simulate flow conditions within a draft tube,
providing detailed information about velocity profiles, pressure distributions, and energy
losses.
 Finite Element Analysis (FEA): FEA can be used to analyze the structural integrity of the
draft tube under various loading conditions, ensuring its mechanical soundness.
 Design and Analysis Process
 Define design parameters: Determining the required flow rate, head recovery, and other
relevant parameters based on the specific application.
 Select draft tube geometry: Choosing a suitable geometry based on factors such as available
space, head recovery requirements, and construction constraints.
 Perform preliminary calculations: Estimate flow velocities, pressure drops, and other
relevant parameters using theoretical equations and empirical correlations.
 Conduct CFD simulations: Using CFD software to simulate flow conditions within the draft
tube, refining the design based on the results.
 Structural analysis: Performing FEA to assess the structural integrity of the draft tube under
different loading scenarios.
 Optimize design: Iterating on the design process, making adjustments to geometry, materials,
or operating conditions to improve performance or reduce costs.
 Experimental validation: If feasible, conduct model tests or field measurements to validate
the design and ensure it meets performance expectations.
 Additional Considerations
 Cavitation: Avoiding cavitation by ensuring adequate NPSH (Net Positive Suction Head) to
prevent the formation of vapor bubbles, which can cause damage to the draft tube and reduce
efficiency.
 Vortex formation: Minimizing vortex formation, which can lead to increased energy losses
and reduced efficiency.
 Material selection: Choosing a suitable material (e.g., concrete, steel) based on factors such
as cost, durability, and corrosion resistance.
 Maintenance: Considering the ease of maintenance and inspection during the design process
to minimize downtime and costs.
 Mathematical development of Circular Conical Draft Tube
 Conical Type Draft Tube: Taper angle of divergent portion of tube is great importance. If taper
angle is large it will be cause separation of flow from wall of draft tube. In case taper angle is small,
length of draft tube needed long. Angle ÆŸ is always less than or equal to 10. This type of draft has
more efficiency, which is 90%.The efficiency of hydraulic reaction turbine is enhanced by the draft
tube. In reaction turbines such as Francis and Kaplan turbines the diffuser tube is installed at the exit
of turbine known as draft tube. The draft tube at the end of turbine increase a pressure to a higher
extent without fear of back flow from the tailrace. The simplest design of draft tube is a pipe of
gradually increasing cross section area i.e. conical draft tube. One end of the draft tube is connected
to the outlet of the runner while the other end is submerged below the level of water in the tail race.
The draft tube has following two purposes. Firstly, it permits a negative head to established at the
outlet of the runner thereby increase the net head on turbine. Secondly, it converts a large proportion
of the kinetic energy rejected at the outlet of the turbine into useful pressure energy. The head
recovery is higher at smaller at lower L/D ratio while negligible improvement after L/D ratio greater
than 19. At L/D ratio above 19, the turbine is susceptible to cavitation as well as the draft tube is not
economically feasible.
 Physics setup

The inlet boundary condition is specified as a velocity inlet with the flow condition duplicating the
runner outlet. The outlet boundary condition is specified as atmospheric condition i.e. gauge pressure
of 0 atm. The inlet condition is taken with inlet velocity condition with magnitude of 10.1m/s.
Various conditions with axial and circumferential velocity conditions are taken into account during
the
simulation. The details of the geometry is given in figure 1. The wall of draft tube is considered as no
slip wall. No-slip conditions zero relative velocity between the first fluid layer and wall. The body
force on the fluid is acceleration due to gravity. The data for
the physics setup is summarized in the table.

S.N Name Boundary Type Values

1 Inlet Velocity 10.1 m/s
2 Outlet Avg. static pressure 0 Pa
3 Wall No slip wall NA
Table: Boundary conditions

6. Limitations of Study

 Potential Threats and Flaws

 Data Availability: Limited access to detailed data on draft tube performance, operating conditions,
and material properties may constrain the depth of analysis.

 Complexity of Fluid Dynamics: The complex nature of fluid flow within draft tubes can make
accurate modeling and simulation challenging, potentially leading to uncertainties in the results.

 Scale Effects: Laboratory experiments and computational simulations may not fully capture the scale
effects that occur in real-world draft tubes, potentially limiting the applicability of the findings
.
 Material Variability: Variations in material properties, manufacturing tolerances, and operating
conditions can affect draft tube performance, making it difficult to generalize results.

 Economic and Environmental Factors: The economic feasibility and environmental impacts of
different draft tube designs may not be fully considered in the study, limiting a comprehensive
evaluation.

 Ethical Considerations: Access to sensitive data, such as proprietary information from companies,
may pose ethical challenges and limitations.
8. Cost and Benefit Analysis: Approx. cost & contribution of the project to the
society
Cost and Benefit Analysis: Design and Analysis of Physics-Based Circular Conical Draft Tube
Approximate Costs

Material Costs:
Metals and Composites
Sealing and Insulation Materials

Labor Costs
Engineering Design and Prototyping Installation and Testing

Equipment Costs:
Simulation Software
Testing Equipment

Overhead and Miscellaneous Costs:

Administrative Costs
Contingency

Contribution to Society

Energy Efficiency:

Improved fluid dynamics can enhance energy extraction from water flow, contributing to more
efficient hydropower systems
.
Sustainability:

Promotes the use of renewable energy sources, reducing reliance on fossil fuels and lowering
greenhouse gas emissions.

Innovation in Design:
Advances in fluid mechanics can lead to new technologies and methods in various engineering fields,
fostering research and development.

Economic Benefits:
The project can create jobs during design, construction, and maintenance phases, contributing to
local economies.
Educational Impact:

Serves as a case study in applied physics and engineering, providing learning opportunities for
students and professionals.
In summary, the design and analysis of a circular conical draft tube has significant societal benefits
that can outweigh the initial costs, contributing to energy efficiency, sustainability, and economic
growth.
9. References

 Peer Reviewed ISSN: 2350-8914 (Online), 2350-8906 (Print) Year: 2020 Month: June
Volume: 8International Research Journal of Engineering and Technology (IRJET) Volume:
06 Issue:01 | Jan 2019
 Design & Study of Conical Draft Tube For Francis Turbine For Steady Flow
 Advances in Mechanical Engineering, 2015, Vol. 7(10) 1–11, The Author(s) 2015, DOI:
10.1177/1687814015606307
 Optimization of a Draft Tube Design Using Surrogate Modelling and Genetic Algorithm,
9 March 2021, The Institution of Engineers (India) 2021