Practice of Quality Control and Measurement Standards at Turbine Testing

Lab in Kathmandu University

1
Biraj Singh Thapa*, 1Bhola Thapa, 1Bim Prashad Shrestha
1
Department of Mechanical Engineering, Kathmandu University, Nepal
*
Corresponding author: Tel.: +977-9842137934; fax: + 977-11-661443
E-mail address: bst@ku.edu.np

Abstract:
Kathmandu University (KU) is an autonomous, not-for-profit, non-government institution dedicated to
maintain high standards of academic excellence. With technical support from Norwegian Institute of
Science and Technology (NTNU), KU has been upgrading its competency to support the ambitious plan
of Government of Nepal (2010) to develop 38,000 MW of Hydropower in 25 years. KU is collaborating
with national and international experts and institutions for this venture.
Turbine Testing Lab (TTL) has been recently constructed at KU with the major financial assistance from
NORAD, Norway. TTL aims to deliver its facilities to local and international developers and consultants
for research and development activities of hydro turbines and pumps. With 30 meter open head and 150
meter closed head, TTL is capable of testing different range of prototypes up to 300kW and conduct
model tests for larger sizes. In coming years, TTL intends to include state of the art technologies such as
Computational Fluid Dynamics (CFD), Finite Element Method (FEM) analysis, innovative design of
hydro-mechanical components for power plants, and specialized trainings to engineers and technicians.
TTL has been putting quality into practice since its construction phase. In order to meet the testing
standards of the similar facility at NTNU, the quality control (QC) tests were conducted during several
stages of construction. Major emphasis was given to hydro mechanical installations. The installations not
passing the QC were redesigned and tested to maintain the standard. During the operation of the lab, the
internationally recognized certification endorsed by International Electro technical Commission (IEC-
60193) will be maintained at TTL for model tests. Similarly for calibration of measuring tools and
facilities at TTL, the ISO standards will be maintained.
This paper introduces the KU-TTL with its past experiences and future ambitions in regards to research
and development of hydraulic turbines. It also discusses the quality control activities undertaken during
the testing of hydro-mechanical installations at TTL, with the problems encountered and solutions
extracted. The IEC-60193 standards of model test and ISO standards for calibration will also be described
with its applications at TTL and utility in Nepal.
Key Words: Turbine Testing Lab, Quality Control, Model Test, IEC, ISO
Introduction
Kathmandu University (KU) has been continuously working on R&D of hydro turbines so as to improve
its quality. Research works are being carried out at Pico-turbine laboratory and water power laboratory at
KU. Pico-turbine lab has been able to design and fabricate a low cost 800W Pico set which has an overall
efficiency of 90% (Fig 1a) [1]. Water power laboratory has been used for research on sand erosion which
is a major problem of the Nepalese hydropower industry. Using a rotating disc apparatus, tests have been
performed for stainless steel and HVOF coated WC-Co-Cr coating used in Kaligandaki hydropower
project in Nepal (Fig 1b) [2]. Also test for impact and flow visualization of five different Pelton bucket
designed at KU has been conducted in this lab (Fig 1c) [3]. Center of excellence for production and
transportation of electrical energy at KU has developed a 130kW Francis runner (Fig 1d) [4]. The newly
constructed Turbine Testing Lab is the continuation to further conduct R&D. The purpose of this lab is to
conduct research of the hydro-mechanical components and solve problems with new design philosophy.
This will help to develop new turbines with better performance. Also TTL aims to be the center for
performance measurement of hydraulic machines [5]. This will help to improve the quality and maintain
standard of the hydraulic machines in Nepal.

(a) (b) (c) (d)

Fig 1. Research at the turbine laboratory at Kathmandu University: (a) 800 W Propeller
Turbine designed and tested at Pico turbine test laboratory [1] (b) Sand erosion test of
stainless steel and HVOF coating [2] (c) Flow visualization in Pelton bucket at water power
laboratory [3] (d) 130 kW Francis turbine waiting for model test at new TTL[4]
Turbine Testing Lab (TTL) has completed its
construction phase with support from NORAD
and local hydropower industries. The lab can
be operated either in open loop or close loop.
TTL can perform test with natural head of 30
m in open loop. The lab has two centrifugal
pumps each of 250kW with variable
frequency drive (VFD) for each pump. Each
pump can produce variable flow with
maximum flow of and variable
head with maximum head of 75 m. Also the
pump can be connected in series and parallel
combination producing a maximum head of
150 m and flow of respectively. TTL
Fig 2. 3D model of Turbine Testing Lab
has the capacity to perform prototype test up
to 300 kW turbines and perform model test for larger turbines following International Electro technical
Commission (IEC)-60193. Further, the lab intends to include state of art technologies such as
Computational Fluid Dynamics (CFD) and Finite Element Method (FEM) analysis. These mathematical
modeling technologies will give a clear picture about the performance of the design. Test rigs will be
installed in the lab to perform the tests of the hydro-mechanical components. TTL is working in close
cooperation with NTNU, Norway. Technical support and guidance will be provided by NTNU in further
development of TTL. TTL also aims to provide specialized training to engineers and technicians so as to
share the output of the lab.
Quality Control during TTL Installations
Throughout the construction phase of TTL, Quality Control has been put into practice. All the
components of TTL have passed through the Quality Control process. Component that did not pass the
quality test were not accepted and further modifications were done until they passed the test.

Test of Pump:
Two 250kW pumps were tested at the test
center of ITT, Austria in presence of the
representatives from TTL. Graphs of the
test showing discharge versus head, shaft
power, NPSH and efficiency were
obtained. These graphs showed a positive
result and acceptance was done according
to the EN ISO 9906 Class I (Fig 3).
Test of Pipes:
Hydrostatic tests of the High density
polyethylene (HDPE) pipes and the
stainless steel (SS) pipes were done at site
after its installation.
Pressure test of High density polyethylene
(HDPE) pipe:
During test, each of the three pipes was
completely filled with water and pressure
was increased until the required test
pressure was reached. As per the Fig 3. Test sheet showing the performance graph of a pump
requirement of TTL the pipes had to be at TTL
able to withstand pressure of 3 bar,
whereas the test was performed for 4.2 bar considering the safety margin. The test pressure was held for
20 min so as to detect for defects and leaks (Fig 4a).
Pressure test of Stainless steel (SS) pipe:
All the internal piping of the lab was done using SS-304 of 400 mm diameter and 5mm thickness. While
running the pump in series the maximum pressure in the lab will reach up to 15 bar. Initial pressure test
showed that there was design failure as leakage was observed at 14.1 bar pressure. Thinner flange and
low grade bolts were identified as the cause of this failure. Modification in design was done using SS
stiffener around the flange and using 10.9 grade bolts. Finally pressure test was done for 19.7 bar pressure
successfully (Fig 4b).
Test of welding joints:
Dye penetration test were performed for the internal piping of the lab, i.e. welding joints of the SS pipes.
Cleaner, Penetrant and Developer were the chemicals used for the test. The test results were positive and
there were no flaws in the welding joints (Fig 4c).
 Test of the Electrical overhead travelling (EOT) crane:
Deflection test of the EOT crane of capacity 5 ton was conducted. Test was conducted giving a load of 6
ton. The allowable deflection for this test was 5 mm whereas only 2 mm was the measured deflection (Fig
4d).

(a) (b) (c) (d)

Fig 4. Quality control during TTL installation (a) Pressure test of HDPE pipes (b) Pressure test of the SS pipe
(c) DPT test of the welding joints (d) 6 ton load for the crane test
Commissioning of the Lab
Technicians from Water power laboratory, NTNU and ITT Norge AS did the final commissioning of the
lab. Service Engineer from ITT did the inspection and test of the wiring of the lab, rotation check of the
pumps, preprogramming and set up of process function, start up and final test of the whole system. He
also conducted staff training for the TTL personals. Senior Lab Engineer of the Water power laboratory
did the final overall check of the lab commissioning. Feedbacks were positive though minor
modifications were suggested for better operation of the lab. The lab was commissioned successfully on
9th November 2011by running a 15 kW cross flow turbine and was inaugurated on 10th November 2011.
Performance Measurement at TTL
Performance test of Hydraulic turbines is done so the owner is sure that the performance is in accordance
with the guarantee. The performance test in TTL will be made in accordance with IEC-60193. Some of
the methods in IEC document refer to ISO documents. In such cases the specific ISO document will be
followed. For performance measurement it is necessary to measure the primary parameters such as
discharge, pressure, head, torque and speed. Knowing these values we can calculate specific hydraulic
energy, power and efficiency.

( )

Where: n=rotational speed, is the mechanical torque, is the density, is the discharge, g is the
acceleration due to gravity, h is the head.
IEC-60193 explains the various methods for performance measurement, choice of a method to find a
parameter depends upon the requirement of the accuracy as each method has different degree of
uncertainty. Hence certainty of measurement of efficiency depends entirely upon the accuracy in
measuring each parameter required to compute the efficiency. Fig 5 shows the general test procedure of
laboratory model test of hydraulic turbines and pumps recommended by the IEC-60193 standards.
Discharge measurement for lab test can be done using the primary method and the secondary method. The
primary method is the most accurate. Weighing method, volumetric method and moving screen method
are the types that fall under
this method. The weighing Measurements at Measurements at
Re =constant=Re * ReM variable
method is explained in detail M M

in ISO 4185 whereas the Calculation Calculation

volumetric method is E, Q, h, nED, etc. E, Q, h, nED, etc.

explained in ISO 8316. The
secondary methods are
founded on various
principles. Although some of
them are standardized,
requirement of high accuracy
makes it mandatory to
calibrate the measurement
equipments. Weir,
differential pressure devices
and various types of flow
meters fall under this
method. ISO 1438-1 is
referred for the weir method
whereas ISO 5167-1 will be
Efficiency correction for Efficiency correction for
cavitations effect, if necessary cavitations effect, if necessary
Model results (hillcart) Correction from
at ReM and at agreed ReM Variable to ReM constant
Model results (hillcart)
at ReM and at agreed
Correction
ReM ReMsp
Correction
ReM ReMsp
Model results (hillcart)
at ReMsp and at agreed
Scale-up ReM Rep Scale-up ReM Rep
Results (hillchart) model efficiency Results (hillchart) model efficiency
at ReMsp and at agreed a function at ReMsp and at agreed a function
of prototype parameters of prototype parameters
(QP, EP, PP etc.) (QP, EP, PP etc.)

referred for the differential

Comparsion with model guarantees Comparsion with prototype guarantees
pressure method. The
pressure measurement can be
Fig 5: Procedures for calculating comparative test results
done by primary method and
the secondary method. Liquid column manometers, Dead weight manometers/ Piston manometers and
pressure weight beam are the types of primary manometers. Pressure transducers fall under the secondary
method. The torque can be measured using load cells or by using Torque-meter. The speed can be known
using a Tachometer. Knowing these primary values we can compute the efficiency of the prototype or
model in the lab [6].
Conclusion

Turbine Testing Lab will be useful for Research and Development and performance test of hydraulic
machines. This will help to improve the quality of the hydraulic machines. During the construction of the
lab quality control of each component has been conducted. Each of the components in the lab has passed
the quality test. Personals from Water power Laboratory, NTNU and ITT Norge AS commissioned the
lab. During the operation of the lab, test will be performed following IEC-60193 and related ISO
documents. The measuring standard will be followed so as to obtain reliable result and also for the
validation of the test results worldwide. It is expected that the lab will be successful to promote
hydropower developments in the country and the region inducing high quality R&D activities.
References:

[1] Cannell J.et al, 2005, Testing and development of Pico Hydro Turbines, International Journal
of Hydropower and Dams 12(3)
[2] Thapa B., P. Upadhyay, O.G. Dahlhaug, M. Timsina, R. Basnet, 2008, HVOF coatings for
erosion resistance of hydraulic turbines: Experience of Kaligandaki-A Hydropower Plant,
Water Resources and Renewable Energy Development in Asia, Danang, Vietnam
[3] K.C. B., Thapa B., 2009, Pressure distribution at inner surface of selected Pelton bucket for
micro hydro, Kathmandu University Journal of Science, Engineering and Technology Vol. 5,
No. II, 42-50
[4] Thapa B. S, Thapa B., Dahlhaug O. G., 2010, Center of Excellence at Kathmandu University
for R&D and test certification of hydraulic turbines, Proc. Int. Conf. on Hydraulic Efficiency
Measurement 2010; India.
[5] Thapa B. , Dahlhaug O. G., 2009, Turbine Testing Laboratory and its Role in Hydropower
Development, HydroNepal, Issue 5, 79-83
[6] IEC 60193, 1999, Hydraulic turbines, storage pumps and pump-turbines- Model acceptance
tests. Second Edition 1999-11, Published by the International Electro technical Commission.