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H Y D R A U L I C T U R B I N E SP E L T O N
F R A N C I S
K A P L A N
FRANCO TOSI MECCANICA - A COMPANY THAT HAS
ALWAYS BEEN A REFERENCE STANDARD IN THE POW-
ER GENERATION INDUSTRY - IS DEDICATED TO SERVE
YOUR THERMAL AND HYDRO POWER GENERATION
NEEDS WITH THE QUALITY AND ATTENTION YOU EXPECT
AND DESERVE. SINCE THE BEGINNING OF THE INDUS-
TRIAL AGE THE NAME FRANCO TOSI WAS CONSIDERED
A LEADER FOR RELIABLE TECHNOLOGY AND LEADING
EDGE DEVELOPMENT.
After a period of significant work abroad, particularly in
Germany, in 1876 the young engineer Franco Tosi was
called to Legnano to manage “Cantoni Krumm & C.”,
a steam engine and boiler manufacturer, which
thanks to Tosi’s work remarkably expanded its opera-
tions. Franco Tosi, an industrial pioneer, devoted him-
self to study and build reciprocating steam engines
that in a few years gained a reputation both in Italy
and internationally.
THE FIRST “TOSI ENGINE”, WITH A POWER OF 3 HP,
DATES BACK TO 1877 AND IN 1881 THE FIRST 40
TO 50 HP RYDER STEAM ENGINE WAS PRODUCED.
Tosi’s entrepreneurial vision and undisputed design
skills found their accomplishment with the advent of
the first power plants. His steam engines definitely
conquered both the domestic and the international
markets. In a few years Franco Tosi became a share-
holder and then, in 1884, the sole owner of a pio-
neer company in the energy sector that has borne his
name since 1881.
A name that still today is renowned all over the world.
Besides having excellent technical skills and being an
eminent industrialist, Franco Tosi was also a model
citizen who carried out outstanding philanthropic
work through his health insurance, social security and
professional training initiatives. An entrepreneurial
style whose signs are still visible and present today
in Legnano.
The industrial development of the Company “Franco
Tosi” followed the ups and downs of the European his-
tory in the early twentieth century, through two world
wars, the post-war recovery and the 1960s economic
boom including a strong internationalisation of the
Company’s markets.
T H E C O M P A N YC E N T U R I E S O F E X P E R I E N C E
3
FOSSIL
COMBINED CYCLES
HYDRO
SOLAR-THERMAL
GEOTHERMAL
BIOMASS
WASTE TO ENERGY
NUCLEAR
CHEMICAL
FOOD PROCESSING
PAPER MILLS
PETROLCHEMICAL
COGENERATION CHP
OIL & GAS
DISTRICT HEATING
SINCE IT WAS ESTABLISHED IN 1881, THE NAME OF
FRANCO TOSI IS RECOGNIZED AND APPRECIATED IN THE
WORLD OF POWER GENERATION AND IS SYNONYMOUS
WITH HIGH QUALITY AND RELIABILITY.
The results achieved by Franco Tosi and his technical
excellence are well known to all of its customers.
Franco Tosi Meccanica, through its experience and ex-
pertise, is willing to serve the needs of Power Genera-
tion with all the care its customers need and deserve.
Our product portfolio includes steam turbines up to
850 MW, hydraulic turbines up to 500 MW and heat
exchange apparatuses.
FTM has been focused on a long lasting policy of in-
vestment in R&D, with important results in terms of
products efficiency and reliability. In addition, Franco
Tosi Meccanica has been very active in the field of Re-
newable Energy such as Hydraulic, Geothermal, Solar
Thermal and Waste-To-Energy.
As a dedicated and competent Company, our primary
goal is Customers’ satisfaction. We want to achieve
this objective through an entrepreneurial approach fo-
cused on international markets. We will be delighted
to make our know-how and experience available to
our clients.
Franco Tosi Reference List has been realized through
130 years of experience on a global scale. The compa-
ny accounts for 75,000 MW of installed capacity, 1,000
turbines in more than 40 countries.
G L O B A L P O W E RS A L E S A N D M A R K E T A P P L I C A T I O N
“ W E S I N C E R E L Y P L A N O N D E V E L O P I N G F U T U R E P R O J E C T S T O G E T H E R ” .
U T I L I T I E S A N D I N D U S T R I A LP O W E R G E N E R A T I O N
6
P R O D U C T S A N D S E R V I C E S O F F E R E D B Y F T M
H Y D R A U L I C T U R B I N E S
PELTON
Head from 200 to 1300 m
up to 300 MW
FRANCIS
Head from 30 to 600 m
up to 500 MW
KAPLAN
Head from 5 to 70 m
up to 150 MW
BULB up to 20 MW
PUMPS AND PUMP TURBINES up to 250 MW
AGGREGATE PLANT SUPPLY
Hydro Turbine and Generator
Electrical and Mechanical BOP
Instrumentation and Control
Hydro Mechanical
Complete Hydro Electrical
Mechanical Package
Field Erection and Commissioning
S E R V I C E A C T I V I T I E S
Repowering
Electro Mechanical for Hydro and Steam Turbines
Revamping & Retrofitting
Conventional Maintenance
Long Term Service Agreements
24/7 Support Hotline
Monitoring
Diagnostic & Spare parts
Plant Simulators
Plant Management
Training
Rehabilitation Feasibility & Plant study
Remote Equipment Operation
Buy-Back of Old Machineries
S T E A M T U R B I N E S
Power generation
Cogeneration
Condensing
Back-Pressure
Single or Double Reheat
Single or Double Flow
Single or Double Extraction
Steam Induction
Upward, Downward, Lateral and Axial Exhaust
AGGREGATE PLANT SUPPLY
Steam Turbine Generator and Condenser
Thermal Cycle
Turbine Island
Electrical and Mechanical BOP
Instrumentation and Control
Field Erection and Commissioning
D E S I G N F E A T U R E S
FTM philosophy is to organize its product line in dif-
ferent standard turbine modules arranged alone or
together to tailor our solutions to customer specific
needs. Dedicated design solutions are thought to give
FTM steam turbines the best fitting to every market
range, from industrial to pure power generation.
SOME OF THEM:
• Back Pressure or Condensing Configuration
• Integral steam chest / Separated valve assemblies
(directly connected to cylinders or with pipe
connections)
• High back pressure LSB families
up to 5 m2 annular exhaust area
• LSB up to 9 m2 annular exhaust area (50 Hz).
• Fully 3D stator and rotor reaction blading for the
highest level blade path efficiency
• Any kind of controlled extraction
or induction / bleeding
• Skid supplied solutions (industrial), any
direction exhaust casings and high recovery and
efficiency axial ones
• Rotor Welding technology for optimized shaft
material combination
8 9
H Y D R A U L I C T U R B I N E S
T U R B I N E S A N D R A N G E O F A P P L I C A T I O N
H Y D R O M A C H I N E R Y
PELTON:
Head from 300 to 1300 m
up to 300 MW
nq from 5 to 20
FRANCIS:
Head from 30 to 600 m
up to 500 MW
nq from 20 to 110
KAPLAN:
Head from 5 to 70 m
up to 150 MW
nq from 100 to 250
VALVES:
BUTTERFLY
up to DN 3000 and PN 30
SPHERICAL
up to DN 2500 and PN 160
Thanks to its long and diversified experience in hy-
dro power machinery, today Franco Tosi Meccanica is
able to cover a full range of market applications for
the power generation industry. Advanced engineering
and standardization methods are the strengths of our
approach. Nature is the most important interface for
hydroelectric power plants configuration and raises al-
ways new challenges for the engineering.
1 1
APPLICATION RANGE
Our Company has delivered important projects to the
market through decades of international experience.
We acquired specific experience in Pelton configuration
and design with heads above 1000 meters.
NET HEAD FROM 300 m TO 1300 m
OUTPUT POWER UP TO 300 MW
nq FROM 5 TO 20
EXAMPLE OF PELTON APPLICATION RANGE
The above chart of a 2 jets Pelton shows the rela-
tion between head, speed, diameter and maximum
reachable power for a typical 2 jets Pelton turbine.
Moving along one of the red continuous lines, a rota-
tional speed value is chosen and kept fixed, therefore
the curve reflects the optimal ratio between head and
Pelton runner impulse diameter. All the area below the
chosen curve is the possible operational field, where
the given power is proportional to the extracted flow.
Therefore, the curve represents the maximum power
extractable for the given conditions of rotational speed
and head. Moving along the dashed lines, which are in
an infinite number, the runner impulse diameter is kept
fixed, therefore they show the variation in maximum
attainable power with the different combinations of
rotational speed and head values.
For higher or lower number of jets configurations, the
above graph can be simply scaled up or down in max-
imum power according to the ratio between the actual
number of jets and two.
For example, at the same head and rotational speed,
when a 2 jet Pelton produces a maximum power of
10000 kW, a 4 jet Pelton produces a maximum power
of 20000 kW.
10000
20000
30000
40000
50000
60000
70000
Constant D, speed increase
Constant speed, D increase
MAX
IMUM
POW
ER [k
W]
120010008006004002000
0
1400
HEAD [m]
P E L T O NH Y D R A U L I C T U R B I N E S
1 4 1 5
DESIGN
Our engineering department can ensure the best
practices and solutions to our customers since we have
developed a large range of projects and delivered
Pelton Turbines up to six jets. 3D standardization of
main turbine components is used for quick modular
and parametric design.
TOTAL PRESSURE(contour)
5.643e+006
5.003e+006
4.364e+006
3.724e+006
3.084e+006
2.444e+006
1.805e+006
1.165e+006
5.250e+005
- 1.148e+005
- 7.546e+005
NUMERICAL SIMULATION
Completely CFD unsteady biphase simulation is perfor-
med to study the jet impact on the bucket, in order to
maximize the turbine efficiency. Finite Element Mecha-
nical simulation and fatigue analysis are performed to
find the most critical regions and to reduce the stress.
[Pa]
1 6
EXAMPLE: LOW SPECIFIC SPEED
FRANCIS APPLICATION RANGE
One of the most important parameter to fit a turbine
model into a given plant configuration is the maximum
installation depth. An example of typical Francis con-
figuration can be defined by the charts above which
clearly express the relationship among head, diameter,
revolutions per minute and power of our turbines.
The first chart describes the application range from 40
m to 160 m. Diameters change in relationship to the
head and the desired configuration in terms of revolu-
tions per minute.
The second chart describes the power in terms of kW at
the change of diameter and revolutions per minute. In
between the two limits at lower and upper rotational
speeds all generator number of poles configuration are
feasible. For example, with a head of approximately
160 m and 250 rpm, the diameter of the turbine is
approximately 3,4 meters with a corresponding maxi-
mum power greater than 45 MW.
LOW Ns FRANCIS: HEAD VS. RUNNER DIAMETER GIVEN A
MAXIMUM INSTALLATION DEPTH
APPLICATION RANGE
Natural conditions are never the same. Thanks to our
wide experience, we have developed a set of solutions
for the configuration of the most challenging environ-
mental conditions. The application range for our Francis
Turbines could be best defined as follows:
NET HEAD FROM 30 m TO 600 m
OUTPUT POWER UP TO 500 MW
nq FROM 20 TO 110
F R A N C I SH Y D R A U L I C T U R B I N E S
LOW Ns FRANCIS: POWER VS. RUNNER DIAMETER GIVEN A
MAXIMUM INSTALLATION DEPTH
POW
ER [k
W]
DIAMETER [m]
0
10000
20000
30000
40000
50000
0 1
600 rpm
250 rpm
2 3 4
4
DIAMETER [m]
HEAD
[m]
0
0 1
600 rpm 250 rpm
3
20
40
60
80
100
120
140
160
180
1 8 1 9
[Pa]
ABSOLUTE PRESSURE
1966909.51861709.01756508.51651308.01546107.51440907.11335706.61230506.11125305.61020105.2
914904.7809704.2704503.8599303.3494102.8388902.3283701.8178501.3
73300.9
VOLUME FRACTION
0.990.940.880.830.770.720.660.610.550.500.440.390.330.280.220.170.110.060.00
DESIGN
FTM is able to design the entire turbine and to study
new components to fit existing installed parts. In case
of lack of original drawings, FTM can perform reverse
engineering in order to get the 3D model of the turbine
components. This gives the possibility to estimate the
efficiency improvement due to the replacement of the
hydraulic active parts.
CFD ANALYSIS
Complete hydraulic channel is simulated in order to
estimate the turbine performances depending on the
wicket gates opening. Specific analysis is performed to
identify the regions which can be affected by cavitation
problems. Complete unsteady simulation is performed to
detect and reduce instability phenomena at partial load.
2 0
APPLICATION RANGE
Our Company has delivered important projects to the
market through decades of international experience.
We acquired specific experience in configuration and
design both for Vertical and Horizontal Kaplan.
K A P L A NH Y D R A U L I C T U R B I N E S
VERTICAL SHAFT
NET HEAD FROM 5 m TO 70 m
OUTPUT POWER UP TO 150 MW
HORIZONTAL SHAFT
NET HEAD FROM 5 m TO 15 m
OUTPUT POWER UP TO 15 MW
KAPLAN TURBINE MODELS APPLICATION RANGE
The most characteristic feature of a Kaplan turbine,
which immediately permits to identify a standard
model, is the number of runner blades. Due to the
limited load carrying capability of each runner blade,
the more the turbine head increases, the greater num-
ber of blades is needed to convert the water pressure
into mechanical energy. The close correlation between
the turbine head H and the specific speed nq permits
to reflect the just explained function into a relationship
between the specific speed and the number of turbine
blades, which is expressed in the chart above.
In the graph are reported real-case application data
of FTM turbines, which lay on the chart space with
a typical hyperbolic shape, as the specific speed nq
grows with the turbine flow and decreases with the
turbine head. Three typical zones are identifiable: the
high head zone on the left, typically corresponding to
relatively low specific speed Kaplan turbines (below
100) and great number of blades (7-8), the interme-
diate central zone with 5 blades solutions and the high
specific speed (above 200) zone on the right, with few
blades (3-4) and typically horizontal applications. It is
clear also from the number of applications that the 5
blades type is the most flexible design in terms of dif-
ferent environmental conditions coverage capacity.
For example a turbine with H = 20 m, Q = 50 m3/s
will be very likely to rotate at 187.5 rpm (if with direct
connection to the generator) and have a specific speed
nq of 140, leading to a 5 blades solution.
TYPICAL KAPLAN TURBINES APPLICATION RANGE
SPECIFIC SPEED [nq]
NET
HEA
D [m
]
0 10050 150 200 250 3503000
90
80
70
60
50
40
30
20
10
7-8 blades vertical5 blades vertical
or horizontal (S-type)
4 blades vertical or 3 blades horizontal
(bulb, open pit)
2 2 2 3
DESIGN
FTM product range covers axial turbines both in hori-
zontal and vertical layout, S-Type, steel and concrete
spiral case. The machining capability goes up to 10 m
of external runner diameter.
VELOCITY (LINE)
3.332e+001
2.499e+001
1.666e+001
8.333e-003
3.383e-003
[m s^-1]
NUMERICAL ANALYSIS
CFD analysis are performed to study the flow in the
hydraulic channel, in order to optimize the profile and
to get the best conjugation law between wicket gates
and runner blades opening.
The hydraulic pressure is imported from CFD to Mecha-
nical Finite Element simulation, to study the localized
stresses and to design the local relief grooves and the
fillet radius of the runner blades.
2 4
APPLICATION RANGE
Thanks to a well proven experience, FTM is able to de-
sign and produce customized main shut-off and pen-
stock valves as well as pressure relief valves.
The chart above can be used for a rapid evaluation of
the hydraulic torque acting on the rotor and therefore
for the design of the rotating system, starting from a
non-dimensional parameter obtained from the ratio
between the current and the reference flow. The refer-
ence valve characterization is obtained through a series
of CFD simulations.V A L V E SB U T T E R F L Y - S P H E R I C A L
P R E S S U R E R E L I E F V A L V E S
BUTTERFLY UP TO DN 3000 UP TO PN 30
SPHERICAL UP TO DN 2500 UP TO PN 160
FLUID TORQUE COEFFICIENTON THE ROTOR
80
VALVE OPENING [deg]
cC [-
]
0 20 40 60
0
1,5
3
4,5
6
cq=0.2cq=0.5cq=1cq=2
2 6 2 7
DESIGN
The selection of the valve typology is based on the
operating characteristics of the turbine. Advanced
design tool permits to find the solution to fit any ope-
rational requirement.
NUMERICAL ANALYSIS
Plant hydraulic transient analysis is performed in order
to optimize water column dynamic response in terms
of over-pressure and over speed. CFD and mechanical
finite element analysis are performed to study the flow
into the valve and to verify the structural integrity.
VELOCITY
14.6313.7212.8011.8910.9810.07
9.158.247.336.415.504.593.672.761.850.930.02
[m s^-1]
2 8
All rights reserved.
Subjects to change without prior notice.
Information in this document contains general descriptions which are not legally binding for Franco Tosi Meccanica.
Each turbine produced by Franco Tosi Meccanica is specifically tailored to the needs and requests of our client.
Each request shall be discussed with our Marketing & Sales Department.
O U R J O B F O R Y O U R P O W E RI N T H E W O R L D
ALBANIA
ARGENTINA
AUSTRIA
BAHRAIN
BELGIUM
BOPHUTHATSWANA
BRAZIL
BULGARIA
CHILE
CONGO
COSTARICA
EQUADOR
ETHIOPIA
FRANCE
GERMANY
GHANA
GREECE
GUADALUPE
GUATEMALA
INDIA
INDONESIA
IRAN
IRAQ
ITALY
JAMAICA
JORDAN
KOREA
LEBANON
LIBYA
MALTA
MEXICO
NETHERLANDS
NICARAGUA
PAKISTAN
PANAMA
PERÙ
PHILIPPINES
POLAND
PORTUGAL
QATAR
RUSSIA
SAUDI ARABIA
SOUTH AFRICA
SERBIA
SPAIN
TAIWAN
THAILAND
TURKEY
UAE - ABU DHABI
UAE - DUBAI
UNITED KINGDOM
UKRAINA
URUGUAY
U.S.A.
UZBEKISTAN
VENEZUELA
WWW.FRANCOTOSIMECCANICA.IT
FRANCO TOSI MECCANICA SPA
Piazza Monumento, 12 20025 Legnano (Mi) [email protected] [email protected]@francotosimeccanica.it
U.S.A. OfficeFranco Tosi/Energy Allied5847 San Felipe, Suite 4150Houston, TX 77057, U.S.A.Phone: +1 713 590-5370Fax: +1 713 [email protected]