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INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

MODEL TESTING, HYDRAULIC TURBINE R&D LABORATORY

Sponsored by : Alternate Hydro Energy Centre


Ministry of New and Renewable Energy Indian Institute of Technology
Government of India Roorkee
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

INTRODUCTION
OBJECTIVES OF ESTABLISHING HYDRO – TURBINE CENTRE/LABORATORY
OF INTERNATIONAL LEVEL (IEC 60193) :
• MODEL TESTING OF HYDRAULIC TURBINES, REVERSIBLE TURBINE AND
PUMP
• HUMAN – RESOURCE DEVELOPMENT,
• DESIGN AND R&D IN THE AREAS OF HYDRO-TURBINES, OTHER HYDRO-
MECHANICAL EQUIPMENT, CONTROL AND INSTRUMENTATION FOR
SMALL HYDROELECTRIC POWER PLANTS.
• GENERATION OF DESIGN DATA
• DESIGN VALIDATION THROUGH CFD ANALYSIS
• THIRD PARTY EVALUATION
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

Laboratory Inauguration by :
Shri R K Singh
Minister of State (Independent Charge)
Power , New and Renewable Energy,
Government of India
On 10th April, 2018

Minister’s keen interest in


observing part load vortex
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

BASICS OF MODEL TESTING

• FUNDAMENTAL EQUATION “Navier-Stoke’s” OF FLUID MECHANICS


HAS NOT BEEN SOLVED TILL DATE.
• APPROXIMATE SOLUTION ARE CARRIED OUT BY ASSUMING CERTAIN
CONDITION HENCE THE ABSOLUTE RESULTS ARE APPROXIMATE.
• TO GET EXACT RESULTS MODEL TESTING IS MUST.
• ALL PROTOTYPE ARE NEW DESIGN TO VERIFY DESIGN MODEL TESTING
IS CARRIED OUT AS PER IEC 60193
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

HYDRAULIC SIMILITUDE
• THEORETICALLY ALL THREE SIMILITUDE TO BE MET:
• GEOMETRIC SIMILITUDE
• KINEMATIC SIMILITUDE
• DYNAMIC SIMILITUDE
SIMILITUDE NUMBERS
Number Forces Ratio Definition
Reynold (Re) Inertia /Viscous VL/ν; VD/ν
Froude (Fr) Inertia /Gravity V/(gL)0.5;(gH/gD) 0.5
Mac (Mc) Velocity of Fluid / Velocity of sound V/C

Number Definition Definition


Reynold (Re) (VD/ν)p = (VD/ν)m (VD)p = (VD)m ; Vp < Vm
Froude (Fr) (V/(gD)0.5)p = (V/(gD)0.5)m (V/D) 0.5p = (V/D) 0.5m ; Vp > Vm
Mac (Mc) (V/C)p = (V/C)m Vp=Vm
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

HYDRAULIC SIMILITUDE
• IT IS NOT PRACTICAL TO MEET ALL SIMILARITIES
• PARTICULAR SIMILARITY NOT RELEVANT IS IGNORED.
• MAC NUMBER IS NOT RELEVANT IN HYDRO TURBINE
• REYNOLDS NO. IS CHOSEN ABOVE SPECIFIED VALUE
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

HYDRAULIC SIMILITUDE
• GEOMETRIC SIMILITUDE IS MAINTAINED
• IDENTICAL DISCHARGE AND SPEED FACTORS AND THOMA
COEFFICIENT TO BE MAINTAINED.
• TESTING IS DONE ABOVE CONDITIONS SPECIFIED BY IEC 60193
• SPECIFIC SPEED IS MAINTAINED IS KEPT SAME IN MODEL

Ns = NP0.5 / H1.25
= NDP0.5 /(D2)0.5H1.25
= ND(ρgQH.η)0.5 /(D2)0.5H1.25
= (ρgη)0.5 (ND/H0.5 )(Q/(D2H) )0.5
= (ρgη)0.5 (N11)(Q11)0.5
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

MINIMUM MODEL SIZE AND TEST PARAMETERS


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

MAJOR TESTING TERMS & DEFINITIONS


• REFERENCE DIAMETER AND BUCKET WIDTH STANDARDIZED.
• SPECIFIC HYDRAULIC ENERGY(E=gH) TO BE USED INSTEAD OF
HEAD
• MANY TERMS HAVE BEEN MADE DIMENSIONLESS eg.
SPEED FACTOR = ND/E 0.5.
DISCHARGE FACTOR = Q/ D2 / E 0.5.
ENERGY COEFFICIENT = E/(ND)²
DISCHARGE COEFFICIENT = Q/ND³
• TERMS USED EARLIER
UNIT SPEED = ND/H0.5
UNIT DISCHARGE = Q/ D2 / H 0.5.
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

REFERENCE DIMENSIONS
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

TYPICAL VIEW OF TYPICAL VIEW OF


KAPLAN TURBINE FRANCIS TURBINE
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
COMPUTATION OF TEST RESULT
FORMULA FOR EFFICIENCY :
 = (2 *  * N * T)/( * g* Q * H )
Where,  = DENSITY OF WATER ; g=ACCELERATION DUE TO GRAVITY
Q = DISCHARGE ; H = HEAD
N = ROTATIONAL SPEED ; T = TORQUE
MAIN PARAMETERS TO BE MEASURED FOR HYDRAULIC PERFORMANCE :
 DISCHARGE MEASUREMENT
 PRESSURE MEASUREMENT
 SHAFT TORQUE MEASUREMENT
 ROTATIONAL SPEED MEASUREMENT
 TEMPERATURE MEASUREMENT FOR DENSITY CALCULATION
COMPUTATION OF PROTOTYPE PERFORMANCE
 SERIES OF TESTS ARE PERFORMED TO GET THE OPTIMUM VALUE OF
HYDRAULIC EFFICIENCY AT CORRESPONDING REYNOLDS NUMBER.
 ONLINE PROTO OUTPUT V/S PROTO EFFICIENCY CURVES ARE PLOTTED.
 UNIVERSAL CHARACTERISTICS/HILL CURVE IS THEN DRAWN BY POST
PROCESSING THE DATA
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

TYPICAL UNIVERSAL CHARACTERISTICS


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

LABORATORY MAIN FEATURES “FIRST INDEPENDENT


FACILITY IN THE REGION”
o BUILDING 15X24m; HEIGHT – 6.5m to +13.5m
o WATER STORAGE 600 m³
HYDRAULIC CIRCUIT OF THE HYDRAULIC TURBINE R&D LABORATORY
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

MAIN LAB PARAMETERS


• MAXIMUM TEST HEAD 60 m
• TYPICAL MODEL DIA. 350mm
• MAXIMUM DISCHARGE 1.0 m3/s
• PUMPS CAPACITY 2 x 160 kW
• DYNAMOMETER MAX SPEED 1400 RPM
• DYNAMOMETER CAPACITY 132 kW
• OVERALL UNCERTAINTY + 0.25 %
• NABL ACCREDITATION FOR MODEL TESTING AS PER IEC 60193
AND IEC 17025
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

SALIENT FEATURES OF HT R&D LAB


1 MAX HEAD M 60m WITH DISCHARGE 150 L/s (PUMP IN SERIES )

2 MAX, DISCHARGE L/S 950 L/s AT HEAD OF 15m (PUMP IN PARALLEL )


3 RATED SPEED OF MAIN PUMP’S 985 RPM

4 SIZE OF TURBINE MODEL (TYPICAL) 350 mm IN DIA FOR FRANCIS AND KAPLAN TURBINE
6 DYNAMO-MOTOR VFD SPEED UPTO1400 RPM, 415 V,132 KW AC DRIVE AND MOTOR
FOUR QUADRANT (SIEMENS MAKE)
8 HYDRO STATIC BEARING VOITH, GERMANY MAKE
10 FLOW METER ELECTROMAGNETIC FLOW -METER, DISCHARGE 50-950 L/s
(ABB MAKE )
11 HEAD MEASUREMENT TRANSMITTERS YOKOGAWA MAKE DIFFERENTIAL PRESSURE TRANSMITTER
12 TORQUE AND SPEED MEASUREMENT T12 TORQUE METER AND Z6 LOAD CELL (HBM MAKE )
13. MEASURING TANK AND CALIBRATOR MEASURING TANK :3 X 22TON CAPACITY RTN (HBM) LOAD
TANK WITH LOAD CELL CELL, CALIBRATOR TANK: 1NO. 2TON CAPACITY S-TYPE
(HBM) LOAD CELL
14. MAIN PUMP-MOTOR -2 NOS. PUMP: SUCTION 400NS,DISCHARGE 350NS,SPEED 985RPM,
CAP 1440 M3/HR , TOTAL HEAD 24 M (WPIL MAKE)
MOTOR: 160 KW,985 RPM, V415 V, 50HZ (SIEMENS MAKE)

15. SUMP SIZE AND CAPACITY 12.1mX7.1mX4.45m, VOLUME 300.69m3


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE
EFFICIENCY TEST COMPARISON CAVITATION TEST COMPARISON
BETWEEN VOITH RESULTS AND AHEC RESULTS BETWEEN VOITH RESULTS AND AHEC RESULTS
95 94
90 92
85 90
Model Efficiency (%)

Efficiency (%)
80 88
75 86
70
84
65
82
60
80
55
0.05 0.07 0.09 0.11 0.13 0.15 0.17 0.19 0.21
0.1 0.2 0.3 0.4 0.5 0.6
SIGMA
Qwd AHEC VOITH

RUNAWAY TEST
COMPARISON
BETWEEN VOITH RESULTS
AND AHEC RESULTS
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

OBSERVATION OF THE CHANNEL OBSERVATION OF INCIPIENT CAVITATION


VORTEX FROM RUNNER INLET ON RUNNER BLADE

PLC SCADA SYSTEM PART LOAD VORTEX ROPE


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

MODEL AND
DYNAMOMETER ON
TEST STAND
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

SPECIAL TESTS
• NEW IEC INCLUDES SPECIAL REQUIREMENTS FOR MODEL AND
INSTRUMENTATION REQUIRED FOR SPECIAL TESTS

SPECIAL TEST CARRIED OUT AT HT R&D LAB

• PRESSURE PULSATIONS
• SHAFT TORQUE FLUCTUATION
• AXIAL THRUST
• GUIDE VANE TORQUE
• DIFFERENTIAL PRESSURE MEASUREMENT IN VIEW OF
PROTOTYPE INDEX TEST
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

PRESSURE PULSATIONS & SHAFT TORQUE FLUCTUATIONS


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

GUIDE VANE TORQUE AXIAL THRUST


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

VIEW OF TEST BED


INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

HIGH PERFORMANCE COMPUTATIONAL SERVER (HPC) FOR CFD

HPC Server Is also Accessible through


I/P Address of Master Node from
Remote Location
Master • Intel XEON processor
Node: 1 no’s E5 2680 (20 cores) @
IBM x3550 2.8 GHz, 1200 MHz
M4 Server • 64GB DDR3 1866 MHz

Compute • Intel XEON processor


Node: 12 no.
of IBM x3550
E5 2680 (24X12 core)
M5 Compute @ 2.5 GHz, 2500 MHz
node • 96 GB DDR4 2133 MHz

Storage
Node: Two • 50 TB
SOFTWARE –FLUENT, CFX no. of IBM • 32 GB DDR3 1833
x3550 M4 MHz
(ANSYS-R15) Server
INDIAN INSTITUTE OF TECHNOLOGY ROORKEE

THANK YOU

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