“Development of Test Rig for
Study of Sediment Erosion in Guide Vanes of Francis Turbine”
Manufacturer’s Guide
Prepared by Ravi Koirala Checked by Dr. Baoshan Zhu
Dr. Hari Prasad Neopane
State Laboratory of Hydroscience and Engineering, Tsinghua University, Beijing, China Turbine Testing Lab, Kathmandu University, Dhulikhel, Nepal
Abstract
Sediment Erosion has been a crucial issue for sustainability of hydraulic turbine structures operating in sand laden water. The study of the phenomena and it effect on the flow has become a crucial issue for identifying resistant solution to the problem. Turbine Testing Lab, with an aim of becoming center of excellence for erosion test has been performing erosion analysis on turbine components. This approach is focused on the erosion study in the stationary component i.e. Guide Vanes.
The study is focused on the effect of guide vane erosion on flow around it. Hence, here guide vane are to be eroded first and then is to be studied for effect on flow. A model turbine parameter has been selected for the analysis. Three guide vane cascade arranged in the manner similar to the prototype turbine will be installed and tested at different laboratory conditions. This part of the work is for the development of the test rig and to manufacture the test rig for completion of this research work.
1. Introduction
For a part of the Masters of Science in Mechanical Engineering (By research) work at Turbine Testing Lab, a test rig needs to be developed for erosion test in guide vanes.
The test rig will have 3 guide vane cascade system with the facility to perform the test at different guide vane openings. The arrangements of the guide vanes and the dimension of the flow passage were determined from the series of the Computational Calculations. The rig should consist of:
S.N. Particular Description Remarks 1 Test setup As per drawing 2 Pressure Tank 3 Test Bench 4 Guide Vanes
2. Operating Conditions
Fluid Type Water Density 997 kg/m3 Head 42.8 m Flow 0.0555 m3/sec
3. Work Description
The manufacturer has to perform following works:
i. High Precision manufacturing of the test setup ii. Installation of the test setup at Turbine Testing Lab iii. Materials required for manufacturing will be managed by the manufacturer himself
4. Installation Facilitation
Following facilities and materials required for installation will be provided:
a. Welding machine b. Electrodes [Please specify the grades] c. Hand grinder d. Hand cutter e. Pipe cutter f. Pipes of required dimensions g. Thread cutting facility is not available but we can arrange it from some where h. Measuring instruments and gauges
5. Test Methodology
5.1 Test Variables
i. Sand Concentration ii. Water Flow Rate
iii. Sand Diameter iv. Guide Vane Angle
5.2 Study of Interest
i. Sediment Erosion in Guide Vanes of Francis Turbines
Variable Point 1 Point 2 Point 3 Point 4 Point 5 Concentration Cs1 Cs2 Cs3 Particle diameter Dp1 Dp2 Dp3 Dp4 Flow rate Q1 Q2 Q3 Guide Vane Angle α1 α2 α3 α4 α5
Hence Total Set of Experiment will be around 180
And at least 182 guide vanes will be needed
180 Guide Vanes of Aluminum
2 Guide Vanes of Stainless steel
ii. Effect of Guide Vane erosion Particle Diameter will be fixed Dp= Constant
Variables Point 1 Point 2 Point 3 Concentration Cs1 Cs2 Flow rate Q1 Q2 Guide Vane Angle α1 α2 α3
Total 12 sets of experiment is necessary for this work With repetition, twice total number of guide vanes required will be 26 24 guide vanes of aluminum and 2 guide vane of Stainless steel Test Counts
Cs1, Q1, α1 Cs1, Q1, α2 Cs1, Q1, α3 Cs1, Q2, α1 Cs1, Q2, α2 Cs1, Q2, α3
Cs2, Q1, α1 Cs2, Q1, α2 Cs2, Q1, α3 Cs2, Q2, α1 Cs2, Q2, α2 Cs2, Q2, α3
6. Cascade Development
05
1015202530354045505560
0 5 10 15 20 25
Velo
city
Position in Guide Vane
Velocity Matching at Runner Inlet Diameter
CuCmCuaCmaCu-turbineCm-turbine
7. Mechanical Design of Cascade Fluid Structural Analysis was peformed with the computational result to identify the maximum stress in the material used in this geometry. Iterative design method was followed by periodically changing the thickness and arrangements.
Cascade
Diffuser 2 and Guide Vane
Diffuser 3 and Draft tube
8. Drawing - All dimensions in Drawing are in MM. - Components Diffuser 1, Diffuser 2, Diffuser 3 and Draft Tube has thickness of 2 mm
and Cascade has thickness of 5 mm. - Detail about support has not been provided in the drawing and will be installed as per
the need. o Materials required for the support during installation will be provided at KU.
- The layout of the piping and other component’s drawing will be provided at the time of installation.
- AutoCAD drawing will be provided to estimate the missing dimensions.
NOTE:1. All Dimensions are in mm.
MATERIAL
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TEST LOOP
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TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Front viewScale: 1:6
PRESSURE TANK
VALVE 1
VALVE 2
VALVE 3
PRESSOR SENSOR 1 PRESSOR SENSOR 2
TEST BENCH
SAND HOOPER
PUMP
TEST SETUP
NOTE:1. All Dimensions are in mm.
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:2
DIFFUSER 1
DIFFUSER 2 DIFFUSER 3
CASCADE
DRAFT TUBE
PRESSURE SENSOR 3
PRESSURE SENSOR 4
PRESSOR SENSOR 5
PRESSOR SENSOR 6
3 GUIDE VANES
Isometric viewScale: 1:4
FLANGE 1
NOTE:1. All Dimensions are in mm.
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TURBINE TESTING LABORATORY
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Front viewScale: 1:2
Diffuser 1
Girdle 1
Girdle 2
Flange 1
Front viewScale: 1:2
10
Bottom viewScale: 1:2
Right viewScale: 1:2
2569.5
92.7
4R
NUMBER
12
51
12
3 4.3312
25
203.4
228.4
Front viewScale: 1:1
5
Right viewScale: 1:1
Segment 2
Segment 1
Girdle
GirdleNOTE:1. All Dimensions are in mm.
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:3
Segment 1
Segment 2
90.55
6 83.49R
762.42
30.82
31.17
23.06
11.33
7 65.4
Front viewScale: 1:2
80
200.15
1 629.82R
279.05
R
Front viewScale: 1:1
5
156.96
Right viewScale: 1:1
160
74
297.46R
179.33
R
1 9.38
55.48
19.19
36.96
Front viewScale: 1:1
5
130.29
Right viewScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:1
Flange 1-Overlapping Shape
Flange 3
Diffuser 2Cross Girdle
10476
5
Flange 2 Side
B
B
14
5
Section cut B-BScale: 2:1
12
46.3
12
63.1
228.4
4R
Number
12
Front viewScale: 1:1
5
Right viewScale: 1:1
117
99.5
101.6
136.1
117
115.3
113.1
96.7
4 2.7
221.1
263.7
441.4
42.7
210.1
252.7
417.5
Front viewScale: 1:1
Thickness of the Lining = 1.829 mm i.e. 15 Gauge
Cross Girdle
NOTE:1. All Dimensions are in mm.
Mild Steel
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TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:1
Flange 2 Overlap
Flange 3
Diffuser 3
Edge Rib
82.67
4R
Numb
er 1
2
10
57.091 0
41.33
208.38
Front viewScale: 1:1
5
Right viewScale: 1:1
97.7102.7
18.4
174.2
18.3
190
208.4
5
14.5
Front viewScale: 1:1
18 17
Scale 2:1
Edge Rib
Thickness 5 mm
93.1
4 2.7
194.6
236.6
375.9
42.7
210.4
252.5
406.3
14.6
79.9
87
149
Front viewScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
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REPLACEMENT
TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:1
Flange 3- Overlap
3 Guide Vanes
Flange 4
Cascade Flow Passage
Hub Plate
Upper Wall
Lower Wall
95.5
148.9
196.6
156.3
171.3
199.7
Front viewScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
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REPLACEMENT
TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:3
SIDE WALL-1
SIDE WALL - 2
TOP COVER SEGMENT - 1
TOP COVER SEGMENT 2
BUTTOM COVER SEGMENT - 1
BUTTOM COVER SEGMENT - 2
TOP COVER
BUTTOM COVER
LOWER BUSHING OF GUIDE VANE
UPPER BUSHING OF GUIDE VANE
GUIDE VANES
GUIDE VANE CONTROL LINKS
Isometric viewScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
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TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Front viewScale: 1:1
A
A
B
B
Section view A-AScale: 1:1
Section view B-BScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
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TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Isometric viewScale: 1:2
Isometric viewScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
MS-TTL-2015-17
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TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
Front viewScale: 1:1
A
A
B
B
Section view A-AScale: 1:1
Section view B-BScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
MS-TTL-2015-17
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TURBINE TESTING LABORATORY
DMATRIX ENGINEERING SERVICES PVT. LTD.
Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
10
97.8
135.5
140.5
5
385.5
R
5.6
9.8
3 6.423.3
37.9
4DEPTH
3
7 HOLE
S
Front viewScale: 1:1
53.5
Bottom viewScale: 1:1
10
71.1
7.9
2 58.1
R
7.9
47.6
63.5
2 8.9
302.1
R
28.7
25.4
44 HOLES
DEPTH 3
Front viewScale: 1:1
2 TOP COVER SEGMENTS ARE TO BE MANUFACTURED
5 3.5
Bottom viewScale: 1:1
NOTE:1. All Dimensions are in mm.
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
9
7 HOLE
S
9
8 HO
LES
30
Front viewScale: 1:1
This Part is the most essential part of the setup, hence I would suggest you to please trace the drawing so that high precision can be achieved.
Isometric viewScale: 1:1
NOTE:1. All Dimensions are in mm.
Mild Steel
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
57.1
112.2
167.1
30.9
37.5
29.6
9
7 HO
LES4
HOLE
S 7
4HOLES 4
9
HOLES 8
Front viewScale: 1:1
2 SUCH PLATES FOR UPPER AND LOWER COVERS OF THE CASCADE
A A
BB
5
3.5
Section view A-AScale: 2:1
5
3.5
Section view B-BScale: 2:1
NOTE:1. All Dimensions are in mm.2. 18 Samples of Guide Vane, Material is Aluminum
Aluminum
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
19R 4
3 HO
LES
12
R 15
R
25R
3 GUIDE VANE LOWER CAPS ARE REQUIRED
IN THE GOVED HOLE, IT IS EXPECTED TO HAVE A PLAIN BEARING FOR EASE OF LOWER CONTROL
A
A
69
3
Section view A-AScale: 1:1
4
3 HOLES
19R
9R
11
R 14
R
24R
Front viewScale: 1:1
3 GUIDE VANE TOP BUSHING ARE REQUIRED
GROOVES HAS BEEN MADE TO INSTALL DOUBLE ORING. YOU CAN ALTER THE DRAWINGS OF THIS CAP TO ADJUST THE GROOVE AND THE REQUIRED ORING
B
B2025
9 11
34.5
Section view B-BScale: 1:1
11R 9R7R
Front viewScale: 1:1
42.07
3
11.3
45.07
51.02
61.02
83.57
Bottom viewScale: 1:1
245
R
260
R
50.33
28
9R
3.5
R
Front viewScale: 1:1
AT THIS POINT A SCREW CAN BE INSTALLED WHICH CAN BE USED TO CHANGE GUIDE VANE ANGLE
AT THE TOPCOVER 18 HOLES CAN BE MADE IN EACH ANGUALR INTERVAL
THIS SCREW CAN BE TIGHTEN AT EACH OF THE HOLE IN EACH IN OPENING
5
5
Right viewScale: 1:1
NOTE:1. All Dimensions are in mm.
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Turbine Testing LabKathmandu University
Sediment Erosion in Guide Vanes of Francis Turbines
92.67
1 29.45
8
12 H
OLES
16.98
40.85
114.45
15
46.33
77.67
Front viewScale: 1:1
A COPY OF THIS FLANGE WILL BE USED WITH CASCDE OUTLET TO MESH WITH THIS
FLANGE - 4
A COPY OF IT WILL BE FITTED WITH CASCADE OUTLET
5
145
1 32
46.14
Bottom viewScale: 1:1
Isometric viewScale: 1:1