Chanju-I Model Test Report

B FOURESS
PRIVATE
LIMITED
MODEL TEST REPORT

PROJECT : CHANJU-I
(3 x 12000 KW + 17% OL)
Doc No: CHANJU-I-MTR
Rev. : - Nil -
Date : 9-12-2011
Page: 1 of 18

Prepared by : MSC Checked by : MNR Approved by : G.S Nagprakash

Model Test Report of
Vertical Type Francis Turbine

Project: CHANJU-I
(3 x 12000 Kw Rated +17% OL)

B FOURESS PRIVATE LIMITED
Plot No. 7 , Post Box No. 11
K.I.A.D.B Industrial Area,
Hoskote - 562 114,
Bangalore District, Karnataka, INDIA.
Phone: +91-80-27971641 to 646
Fax: +91-80-27971455
Email: info@bflhydro.com
Web : www.bflhydro.com

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INDEX

Clause No. Title
1.00 Introduction to Laboratory facilities
2.00 Model turbine
2.01 Similarity Criteria
2.02 Selection of Turbine model for Chanju-I
2.03 Model Description
2.03.1 Spiral Casing
2.03.2 Guide Vane
2.03.3 Draft Tube
2.03.4 Runner
2.03.5 Shaft and Bearings
2.04 Model Details
3.00 Experimental Investigations
3.01 Test Objectives
3.02 Model Installation
3.03 Experiments
3.03.1 Normal Performance Tests
3.03.2 Runaway Tests
3.03.3 Cavitations Tests
4.00 Efficiency Scale Effect
5.00 Prototype turbine details
6.00 Computation of prototype turbine efficiency
7.00 Conclusions

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PROJECT : CHANJU-I
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NOMENCLATURE
Symbol Description Unit
H Net Head across the turbine Metres
Q Discharge m/s
N Speed rpm
D Runner Diameter Metres
q
Efficiency Percent

Guide Vane opening Degree
Fr
Froudes Number
V
Absolute velocity m/s
g
Acceleration due to gravity m/s
Re
Reynolds Number
v
Coefficient of kinematics viscosity m/s
Cp
Pressure coefficient
P
Pressure kgf/m

Density kg/m
U
Peripheral Velocity m/s
Aq
Efficiency Scale Effect Percent
Pt
Output or mechanical power HP or kW
c/D
Surface roughness expressed in terms
of runner diameter

o/D
Tip clearance expressed in terms of
runner diameter

o
Thoma cavitation parameter

Subscripts
p
Prototype turbine
m
Model turbine
11
Unit value
Formulae:
1. Ns = Specific Speed = N \Pt / H
1.25

2. N
11
= Unit Speed = ND / \H
3. Q11 = Unit Discharge = Q / D \H
4. Moodys Formula = (1-q
m.peak
) {1-(Dm/Dp)
0.2

List of Illustrations:
Fig. 1: L-202-22-712 Page 10: Model turbine general efficiency characteristics
Fig. 2: L-202-712 H 8354: Cavitation limit curves
Fig. 3: L-202-22-712 Page 49: Model runaway test results
It should be noted that the above curves also contains the markings for the prototype
turbine characteristics also.

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1.00 INTRODUCTION TO LABORATORY FACILITIES:

Today no hydraulic machine can be manufactured and put into successful operation
without a preceding phase of theoretical and experimental research. The complexity of
the hydraulic phenomena occurring in the machinery under different operating
conditions and the required accuracy of the performance date necessities careful testing
of models in special test stands. The results of mode test investigations can be used:

(a) As original and main data for selection of main full-scale turbine parameters and
prediction of efficiency, cavitations, force and pulsation characteristics.
(b) For the stress calculations of the turbine and hydro generator coupled with turbine.
(c) For the verification and improvement of the applied hydro - dynamic methods of
calculations.
(d) To check and improve the existing scale-up formulae.
Our Technology provider M/s. G.E.Energy Ltd., Sweden, operate an extensive
hydraulic research facility. Since 1914, this laboratory is responsible for basic
hydraulic research and development and maintains highest level of research facilities.
Today it is one of the best of its kind in the World and often they are engaged for
contractual model testing and experimental research in the field of hydraulics, including
cavitation studies.

The test equipment is located in the laboratory main block, which has a length of 40m,
a width of 12m and a height of 12m.

The basement provides the main water storage area with a capacity of about 1000m.
There is also a continuously operating mechanical water filter, an auxiliary basis for
filtered water and two pipe lines for the inter-connection of the open flume with either
of the cavitations tunnels for calibration purposes.

The building proper has a steel framework with floors on three levels. The upper floors
are partly made up of movable sections to permit maximum flexibility for new or
temporary installations.

A wing to the main building comprises offices for the laboratory staff. On one side of
the main building there is a transformer and converter station, where all converters,
electronic governors and main switches for pump motors and dynamometers are
grouped. On the ground floor, in direct connection with the laboratory hall, there is a
small workshop suitably equipped for the preparation and pre-assembly of the test
models. Advanced measuring equipment is installed at the different test stands. The
specialists at the companys electronic department are available for service, design and
construction of such equipment.

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The laboratory has various test facilities available as given below: (Refer annexure 4)

1. Open flume test stand for testing of Kaplan and low head Francis models.
2. Low head cavitation tunnel for efficiency and cavitation testing of low head turbines.
3. High head cavitation tunnel for Francis and reversible pump turbines.
4. Pump test tunnels for axial, diagonal and mixed flow pumps.
5. Various other facilities for simulation studies and other hydraulic research activities.

2.00 MODEL TURBINE :

2.01 SIMILARITY CRITERIA

Homologous model tests on water turbines are based on well proven similitude criteria
which can be summed up into the relation :

Cp : Pressure coefficient
Fr : Froude number
Re : Reynolds number
U : Peripheral velocity
V : Absolute velocity
c/D : Surface roughness expressed in terms of runner diameter
o/D : Tip clearance expressed in terms of runner diameter
o : Thoma Cavitation parameter
Subscript m : for model

Where the geometric parameters represent such aspects as surface roughness (c/D) and
tip clearances such as o/D. For turbo machines the geometric similarity does not
generally extend to surface roughness and clearance magnitudes and for this reason
alone, no agreement is expected in these forms of correlation between the model and
prototype. Reynolds number is a second order parameter and concerns only the scaling
up of efficiency from model to prototype. Its effects are assumed to be insignificant if
the tests are carried out above the critical range of transition i.e. 2x10
6
. All the norms
stipulated by the international test code are followed rigorously for the entire test
programme. Froude number has always been considered an essential parameter since
gravity forces are the only external forces acting. Froude Scaling is favoured in the
international practice especially for model studies on low head machines as scale
effects are analogous to Froude criterion.

The similarity relations for model and prototype are as follows:

Qm / (Dm
2
\Hm) = Qp / (Dp
2
\Hp)
(Nm Dm) / \Hm = (Np Dp) / \Hp

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Where
Q = Discharge in m/s.
D = Diameter of runner in metres.
H = Head in Meters.
N = Speed in rpm

Subscripts :
m = Model Turbine
p = Prototype

2.02 SELECTION OF TURBINE MODEL FOR CHANJU-I

Extensive research and development activities undertaken have resulted in many model
turbine configurations. As such our collaborators have designed various models
suitable for low head applications. Deciding model size and testing parameters was
done adhering to the recommendations of International Electro- technical Commission
(IEC 193 & IEC 995)

On the basis of site data indicated, we have chosen L-202-22-712 model among various
models available. A detailed design was carried out to arrive at the main turbine
parameters such as runner diameter, speed and determining the general layout of the
hydro unit from these model test reports.

Our endeavours in choosing L-202-22-712 model characteristics for this project site
was to have an efficient and high specific speed machine to tap the large hydro
potential available based on the available head and discharge.

2.03 MODEL DESCRIPTION

The Francis turbine is basically a mixed flow reaction turbine, specifically designed and
developed for medium head applications. It derives the advantage of maximum
efficiencies at different staggered angles by provision of movable guide vanes. The
model under consideration is having a runner diameter of 250 mm whereas the
prototype has 910 mm. The turbine essentially consists of Spiral casing, Guide Vane,
Draft tube, Runner, Shaft, Bearings.

2.03.1 Spiral Casing:

Spiral casing of carbon steel. It is of volute type complete with stay-ring with 12 Nos
stay vanes, the stay-ring besides guiding the flow into guide vanes, gives structural
rigidity to the spiral casing against the hydraulic forces.

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2.03.2 Guide Vane

The Guide Vane serves to change the discharge through turbine. It consists of a system
of evenly arranged 24 Nos. of guide vanes along its circumference. These vanes are
designed with appropriate shape & profile. Turning all the vanes on the same angle by
means of special Kinematics mechanism will vary the angular momentum and the flow
pattern before the runner resulting in the variations of the discharge.

The Guide Vane is circular in shape and hence supplies water to the runner in the
oblique direction decreasing the velocity unevenness in the flow at the entrance of the
runner. The axes of the vanes are located on a cylindrical surface and each vane has
different sections of the Guide Vane, varying cross sections of the vanes, overall shape
of the Guide Vane offers specific hydraulic advantages.

2.03.3 Draft Tube

The draft tube is the last hydraulic element of a reaction turbine which considerably
effects both the turbine performance and the arrangement. In general the hydraulic
characteristics of draft tube depends on its shape and dimensions as well as flow
patterns at its entrance. The most important suction element of the turbine i.e. draft
tube serves the following purposes :
(a) to conduct the flow from the runner to the tailrace with minimum energy losses
(b) to facilitate setting of the runner above the tailrace without loss of head
(c) to transform the kinetic energy of flow at the exit of runner into additional vacuum
behind it; that is to considerably decrease the kinetic energy losses at the exit of a
turbine.
Especially in case of Axial flow machines, the kinetic energy of flow leaving runner
being substantially high, it is all the more essential that draft tube should be designed
for highest possible efficiency in serving the purpose of pressure recovery. As such, the
draft tube in case of tubular turbine has more influence on the turbine performance.
The downstream bend in tubular turbine with smooth transition of velocity at various
sections directs flow into tailrace through diffuser.

2.03.4 Runner

Runner has 15 Nos. of vanes (blades) with a nominal tip diameter of 250mm. The
critical parameters like solidarity ratio, hub-tip ratio, the twists maintained by
staggering various cross section profiles of the blades along its span, were accurately
chosen to maintain the maximum possible energy transfer. These were hydro
dynamically designed with combination of optimum lift and drag characteristics for
their best performance under various conditions. The profiles of the blades were
ground smooth to keep frictional losses at minimum.

2.03.5 Shaft and Bearing

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The turbine shaft transmits the torque and is subjected to axial and torsional loads. The
axial load is mainly due to axial water pressure force. The shaft could also be subjected
to lateral forces because of unbalance in the rotating parts. The shaft is designed for
critical speed of well above the expected runaway speed of the turbine. Suitable
bearings to absorb the axial thrust and other radial loads are provided.

2.04 MODEL DETAILS

RUNNER
Number of Runner vanes

15
Tip diameter 250 mm
Vane height 47 mm

SPIRAL CASING
Spiral inlet dia. 463 mm
No of stay vanes 12 Nos
Stay vanes pitch circle dia 415 mm

Guide Vane
Shape and included angle Aerofoil
Guide vane PCD 415 mm
No. of guide vane 24
Vane height 47 mm
Vane clearance at outer end 0.1 mm
Vane clearance at inner end 0.1 mm

Note: = 0 = closed guide vanes.

DRAFT TUBE
Suction cone inlet dia 250 mm
Bend inlet dia 328 mm
Bend exit dimension 245 mm(H) x 518 mm (W)
Tail section exit dimension 438 mm (H) x 518 mm (W)
Distance between shaft centre
line & draft tube exit
1580 mm

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3.0 EXPERIMENTAL INVESTIGATIONS

3.01 TEST OBJECTIVES

Advanced and reliable model investigations are employed for identifying the
performance characteristics of the turbine that can also form basis to develop new
designs with better efficiency, cavitation, pulsation and other characteristics and
advanced turbine spaces, modern hydro dynamic methods of calculations. Since the
accuracy of model investigations influence considerably the reliability of turbine
characteristics and guarantees for full-scale turbines, the demands on the tests stands
and their instrumentation are increasing.

As emphasised in Section 3.01, number of factors have influence on the similarity to
exist between model and prototype flows, the main idea is to fulfil the most important
similarity requirements and carryout the model investigations simulating the field
conditions as for as possible. Hydraulic parameters and turbines characteristics are
determined by various elements of the turbines space which are calculated or selected
on the basis of numerous assumptions. Moreover, they are designed usually without
taking into account the mutual influence on their individual characteristics. It is for
these reasons that the final assessment of the developed turbine can be made by careful
and detailed tests on the model.

On the basis of similarity laws, a number of turbine models for different heads (specific
speeds) have been developed in laboratories and are used for geometrically similar full-
scale turbines without repetition of model tests. For these purposes the following
investigations are fulfilled on model.

(a) Determination of efficiency and performance characteristics.
(b) Determination of cavitation characteristics including stroboscopic high speed
photographic and sonic studies.
(c) Determination of the Force and strength characteristics of distributor and runner for
stress analysis and the selection of servo motors mechanism.
(d) Determination of runaway characteristics and axial thrust which are of paramount
importance for the mechanical design.
(e) Flow measurements within the turbine space.
(f) Experimental investigations of pressure distribution within the rotating runner.
While some of the results on above investigations will be useful for further
modifications/ study on model design to improve its performance, results of other
investigations like efficiency, cavitation, runaway characteristics can be directly used
for deciding the prototype parameters.

3.02 MODEL INSTALLATION

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The assembly of the complete turbine model, which involved precise matching of
various components relative to recesses, clearance and water tightness, was
accomplished independently outside test rig. The total assembly along with its base
was then installed on the test rig accurately.

3.03 EXPERIMENTS
Exhaustive experimental studies were undertaken to establish the normal performance,
runaway features, and cavitation characteristics of the model in its entire operating
range. The model speeds are changed so as to cover a wide range of unit speeds
varying from 43 to 48. A test head of 35 m was chosen during normal performance test
of the model. For a good statistical average, more number of readings was recorded on
the parameters at a reasonable time interval. The values then were averaged out over a
period by noting small fluctuations if any due to supply voltage and frequency
fluctuations or any other reasons.

3.03.1 NORMAL PERFORMANCE TESTS:
These tests determine the normal efficiency characteristics of the model turbine under
non - cavitating conditions for various guide vane angle opening () ranging from 6 to
20. The general efficiency characteristics of the model corresponding to this are
enclosed in the report. The procedure adopted in the normal performance tests is
briefly recapitulated below.

For a predetermined value of unit speed, the individual performance test consisted of
operating the model at various angles. For every test point, readings were recorded
for model discharge, rotational speed, torque, etc., for determination of brake horse
power and hydraulic power. From the observations, computations were made to arrive
at the values of model efficiency and other related non dimensional parameters such as
unit speed and unit discharge for graphical depiction and analysis. Curves of model
efficiency versus unit discharge were then established by varying Guide vane angles at
constant unit speed. Several partial efficiency diagrams were required to be established
for different guide vane positions. All these results were then integrated for the
preparation of general efficiency diagram. (universal characteristic curve).

For every point on this general diagram (Universal characteristic curve) a definite value
of , q, N
11
and Q
11
was established for the runner under test. This is automatically
explained the variation of efficiency with the change of Guide vane angle or any other
parameters of importance, and optimum values of all these parameters were fixed, once
for all, for that runner profile on the general efficiency diagram. Fig 1 shows the
general efficiency diagram which depicts full set of normal performance characteristics
for the runner under non-cavitating conditions.

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3.03.2 RUNAWAY TESTS:

Runaway tests were conducted for various guide vane opening to find out the most
stringent conditions in respect of speed for the generators shaft design. A suitable test
head was adopted during these studies taking into consideration the mechanical strength
of various materials used, flow conditions in the draft tube as well as general limitations
imposed by safe model operation. Fig. 2 shows the results of the runaway tests for
various guide vane openings.

3.03.3 CAVITATION TESTS

These test series were conducted in respect of selected optimum cam conjugation points
established during normal efficiency tests, the main objective being the study of effects
of cavitation on the behaviour of the machine. The procedure adopted in a cavitation
test is briefly recapitulated below.

For a predetermined values of guide vane opening angles, and model speed, the
experimental programme commenced under non - cavitating conditions with a high
sigma value initially. Thereafter the operating sigma value was reduced step by step to
induce cavitation by lowering the absolute pressure in the test installation with the help
of auxiliary vacuum circuit. For each test point, output or mechanical power, input or
hydraulic power, unit speed, efficiency, unit discharge and the cavitation coefficient
were calculated. Curves were then plotted for establishing the relationship between
thoma sigma versus unit discharge for each set point of N
11
, . The effect of
cavitation on the turbine performance was also simultaneously noted. As cavitation
could occur and become dangerous before it impaired the machine performance, visual,
photographic and acoustic observations of incipient and developed cavitation were also
carefully made sequentially, during the test. At that time the characteristics of
cavitation development were also precisely defined by the statement of its extent,
nature and stability. The determination of the critical cavitation coefficient was done as
per the norms stipulated by the international test code on this subject. Fig. 3 shows the
cavitation characteristics of the model turbine.

4.0 EFFICIENCY SCALE EFFECT

Efficiency of the prototype turbine is greater in comparison with that of similar model
owing to different values of diameter, head and relative roughness of the machines
compared. The increase in prototype efficiency is called the Scale Effect. However,
the magnitude of prototype efficiency is to be estimated on the basis of model
experimental data by using the one of the numerous formulas suitable for the type of
turbine considered. During determination of prototype efficiency (q
p
) on the basis of
model data the hydraulic friction losses are assumed to be the main losses to be scaled
up. In general the magnitude of prototype efficiency is equal to
q
p
= q
m
+ A
q
where A
q
is the efficiency correction taking into account either the difference in
diameter or head or both.

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For arriving at values of prototype efficiencies and corresponding power outputs for
comparison with the guaranteed values, Moodys transposition formula was used in
calculating the majoration percentage at the point of peak efficiency on the model. This
majoration percentage correction was then applied equally at all other related measured
model efficiency values on the general efficiency values on the general efficiency
diagram for predicting prototype performance under the stipulated conditions.
Moodys formula which is widely adopted for Francis turbines and takes into account
variation in both head and diameters is as given below.
Moodys Formula = (1-q
m
) {1-(Dm/Dp)
0.2
}

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Annexure-I

Performance Calculations based on Model test Results
A. Data:
Turbine Type Vertical type Francis turbine
Model Turbine Data :
1. Model Number L 202-22-712
2. Model Head 35 m
3. Model Runner Diameter 0.250 m
Prototype Turbine Data :
1. No. of units x Rating 3 x 12000 kW
2. Rated turbine output Prat 12371.1 kW
3. Runner Diameter D 910 mm
4. Rated head Hrat 236.67 m
5. Rated speed n 750 rpm
6. Rated discharge Qrat 5.682 m/ s
7. Maximum turbine output Pmax 14474.2 kW
8. Maximum discharge Qmax 6.695 m/ s
9. Machine Center line elevation 1189.05 m
10. Minimum Tail Water Level 1192.05 m
11. Max Head Hmax 246.00m

B. Calculations :
1. Scale up factor Aq (1-qm.peak) [1- (Dm/ Dp)
0.2

Where qm.peak Peak model efficiency
Dm Model runner diameter
Dp Prototype runner diameter
therefore Scale up Aq = (1-0.920)[1-(0.250/ 0.91)
0.2
]
= 0.0182
= 1.82% (Scale up considered)
2. Unit speed (rpm) n11 N * D / H
0.5

Where n Turbine speed in rpm
D Runner diameter in meters
H Head in meters
therefore Unit speed n11 = n * D / H
0.5

= 750 * 0.910 / 236.67
0.5

= 44.36 rpm
3. Unit discharge (m/ s) Q11 Q / (D * H
0.5
)

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Where Q Discharge in m/ s
D Runner diameter in meters
H Head in meters
therefore Unit discharge Q11 = 6.695 / 0.91 * 236.67
0.5

= 0.526 m/ s
From General effic ienc y characteristic c urve L 202-22-712 (Fig.1),
for Q11 = 0.526 m/ s, model efficiency qm = 91.30%.
Then prototype efficiency q p = qm + Aq
= 91.30% + 1.82%
= 93.12%

Turbine rated output (kW) Prat = 9.81xQxHx q p kW
= 9.81 x 6.695 x 236.67 x 0.9312 kW
= 14474.2 kW.
4. Cavitation c oefficient o = {(Hb - Hv) - Hs}/ Hrat
where o = Cavitation coefficient corresponding to rated discharge at rated head (This
will be read from the model cavitation limit c urve L 202-712 (Fig. 2)and o in this case is
0.04 for Q11 = 0.526 m/ s.
Hb = Barometric pressure (8.92 m)
Hv = Vapor pressure of water (0.324 m)
Hs = Suction Head
Hrat = Rated head (40 m)
o = {(Hb - Hv) - Hs}/ Hrat
0.04 =
Hs =
Hs =
{(8.921 0.324) - Hs}/ 236.67
(8.921-0.324)- (0.04 x 236.67)
-0.8698
therefore Hs = -0.87 m

Runner Setting w.r.t Min TWL Z = Hs (DOD/ 1000)/ 2 1.675
-2.997 m (Taken value = -3.0 m)

Runner Centerline RC = Min TWL + Z
1192.05 + (-3.0)
1189.05 m
5. Runaway speed

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Where n11 = 70 corresponding to GV angle of 15.3% from the curve L 202-22-712 (Fig.3).
= N11 x sqrt (Hmax) / D

With 5% margin

=
1206 rpm
1266.8 rpm

6. Spiral Casing
The spiral casing is designed based on the design used in the model L 202-22-712 which is been
scaled up. From model the spiral casing diameter will be 1.016 x D =1.016 x 0.910 = 0.925m

7. Butterfly valve
The inlet of the spiral casing is the reference for the selection of the Butterfly valve size. Here the
spiral inlet comes to 925mm. However 1200 mm valve is considered based on tender
requirement.

Given below are the efficiencies at different % of loads at rated head:
Sl. % of Load/ Model Turbine Scale Prototype Turbine
No (Turbine out
put in kW)
Q11
(m/ s)
N11
(rpm)
Model
Efficiency
(%)
Effec t Considered
(%)
Q
(m/ s)
Prototyp
e
Efficienc
y (%)
1 117%
(14474.2)
0.526 44.36 91.30% 1.82 6.695 93.12%
2 110%
(13608.2)
0.4901 44.36 92.00% 1.82 6.247 93.82%
3 100%
(12371.1)
0.446 44.36 91.95% 1.82 5.682 93.77%
4 80%
(9896.9)
0.364 44.36 90.22% 1.82 4.631 92.04%
5 50%
(6185.6)
0.246 44.36 83.36% 1.82 3.128 85.18%

8.00 CONCLUSION :

Referring to the general efficiency characteristics of the model turbine (Refer Fig. 1) it
can be seen that the model turbine was tested for unit discharge range of 0.2 to 0.6 m/s
which covers the complete operating range for required turbine. Unit speeds are varied
from 43 to 48 rpm. The general efficiency characteristics represent the iso-efficiency
curves for various guide vane angles from 6 to 20.

With the typical method of computing prototype efficiency explained in Section - 7.00,
it is also seen that the prototype turbine performance characteristics (Efficiency values
given in Table - 1) estimated based on the model test results, are satisfying the
guaranteed values committed in our offer.

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