Supriya Koirala et al.: Collaboration for Establishing Francis Turbine Manufacturing and Testing Facility in Nepal
Collaboration for Establishing Francis Turbine Manufacturing
and Testing Facility in Nepal
Supriya Koirala*1, Sudip Adhikari1, Biraj S. Thapa1, Bhola Thapa1, and Ole G. Dahlhaug2
1
Turbine Testing Laboratory, Kathmandu University, Nepal
2
Water Power Laboratory, Norwegian University of Science and Technology, Norway
Abstract— In Nepal, the feasible hydropower potential is
about 42000 MW. The installed power plants in the country till
the date is only 650MW. In 2010 AD the government of Nepal
has announced its intentions to develop 38,000 MW of
hydropower in next 25 years. This means that in Nepal alone,
the new turbine company will have a large market. However,
rivers in Nepal and the region contain high amounts of
sediments, which cause rapid erosion of turbine components.
Design of turbines to handle large amount of sediments without
much erosion has not been established successfully so far.
II. CHALLENGES AND TESTING FACILITY
Turbines in Nepal mainly erode due to the presence of
sand particles in rivers. This causes high efficiency drop and
sediment erosion in turbines. Fig. 1 shows damaged runner
of Jhimruk Hydropower Plant. The chart represents the
decrease in thermodynamic efficiency during three months
period at Jhimruk Hydropower Plant [3].
The NORAD supported RenewableNepal program has
started a project that will design a new Francis turbine suitable
to handle sediment erosion. The developing results have shown
a very convincing possibility to cut down erosion in turbines
considerably. The ultimate goal of the RenewableNepal project
is to start manufacturing of the new Francis turbines in Nepal.
This article will provide background and progress of
ongoing RenewableNepal project at Turbine Testing Lab in
KU. The future directions of the commercial activities to
implement the new findings will be the central theme. The
immerging new partnership and challenges projected will also
be discussed.1
Index Terms— Hydropower, Turbine Testing Lab (TTL),
Francis turbine, Manufacturing, Kathmandu University (KU),
Norwegian University of Science and Technology (NTNU)
Runner Damaged by Sediment Erosion in a Nepalease Power Plant
I. INTRODUCTION
Development in Hydropower sector of Nepal has both
opportunities and challenges. With 42000MW of feasible
potential the prospect for its growth is vast. In 2010
government of Nepal has pronounced its intention to
generate 38000MW in next 25 yrs[1].Already 22,172MW
has been planned and proposed. However Nepal is currently
facing inefficiencies from the sediment erosion due sand
particles in hydro turbines. Hydropower status in Nepal will
only improve from the innovation through technology as
Hydro turbines are particularly designed to suit specific
parameters and usually imported turbines are not designed to
withstand sediment erosion. Kathmandu University with
technical collaboration from Norwegian University of
Science and Technology (NTNU) has established a Turbine
Testing Lab. This lab intends to develop competence in
efficiency measurement, performance test and design
optimization of hydro turbines. This lab is aimed to have a
major role in research and development in the project
“Development of Francis Turbine manufacturing and testing
facility in Nepal”, which is the extension of the RENP
project “Development of Hydraulic Turbines with new
Design philosophy as a foundation for Turbine
manufacturing in Nepal”.
* Corresponding author: supriya.koirala@ku.edu.np
Rentech Symposium Compendium, Volume 3, September 2013
Thermodynamic efficiency measurement at Jhimruk HPP
Guidevanes Damaged by Sediment Erosion in an Indian Power
Plant
Fig. 1: Hydropower Challenges of Nepal [3]
The challenge to minimize this will be counteracted by
developing a new design philosophy of turbine suited for the
real site conditions of Nepal. Turbine Testing Lab at
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Supriya Koirala et al.: Collaboration for Establishing Francis Turbine Manufacturing and Testing Facility in Nepal
Kathmandu University will serve as a competence for all
types of research related to hydro turbines. TTL provides
30m natural static head which gives the natural flow
conditions to the test. 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 0.25 m3/s 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 0.5m3/s
respectively.This lab is equipped with state of art control
system with electromagnetic flow meters, pressure
transducers and sensors. With this system, the largest
prototype turbine that can be tested is 300 kW and there is
also provision for model test for larger turbines. All the tests
in the lab will be performed following IEC 60193 standard.
The system will be able to test both reaction and impulse
turbines.
CFD analysis with new test design [3]. The erosion in the
design blade Design_BS1 is much less as compared to the
reference blade with red spots showing the erosion affecting
region. This project was carried out as a MS by Research
Work and will possibly continue for the model test of the
same design.
Fig. 3: Design Optimization of Francis Blade
Fig. 2: Turbine Testing Lab at Kathmandu University
The partners in this project are Kathmandu University,
NTNU, NHE and Dyne Vec[3].The output from this project
will be the baseline for starting Francis Turbine
manufacturing in Nepal. In order to meet this goal, it is
apparent that the development of a manufacturer has to be
parallel with the development of the new Francis turbine
design at Kathmandu University and NTNU. However, the
RenewableNepal Project does not include activities to
achieve the long term objectives neither it has sufficient
resources needed for those activities. Therefore an additional
project is needed as an extension to the ongoing
RenewableNepal project Fig. 4.
Turbine testing lab will prove invaluable for hydropower
development in the country, particularly in symbiosis with
research and academia.
III. RENEWABLENEPAL PROJECT AT TTL
RenewableNepal Project is supporting for the
development of hydraulic turbines with new design
philosophy as a foundation for Turbine Manufacturing in
Nepal.
Objectives of RenewableNepal Project :
• Develop a new design philosophy of Francis Turbine
to minimize losses due to sediment erosion by
Technology Transfer and Innovation.
• Create a Center of Excellence at TTL for Research
and Development of Hydraulic Turbines as a
foundation for a new Turbine Manufacturer in Nepal.
• Prepare technical background and understanding
between local and international institutions and
industries for establishing a new turbine
manufacturer in Nepal.
With a reference case of sediment erosion in Francis
blade of Jhimruk Hydro Power Plant, the CFD analysis for
erosion patterns is shown in Fig. 3. This shows the results of
Rentech Symposium Compendium, Volume 3, September 2013
Fig. 4: Extension of RenewableNepal Project [1]
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Supriya Koirala et al.: Collaboration for Establishing Francis Turbine Manufacturing and Testing Facility in Nepal
IV. TURBINE MANUFACTURING AND TESTING
FACILITY IN NEPAL
Hydro turbines play vital role in electricity generation
and a small amount of efficiency drop in large power plant is
accounted as a major loss. A suitable design considering all
the effecting parameters for the specific site condition is
required before manufacturing and installing it. There are
many manufacturing industries in Nepal for micro hydro
turbines but high power turbines are imported. Such turbines
get eroded due to high amount of sediment in Nepalese river
and efficiency drop abruptly.
Currently the research on new design philosophy of
Francis turbine to minimize losses due to sediment erosion
will serve as a backdrop for establishing Francis Turbine
manufacturing industry. Turbine Testing Lab with technical
support from Waterpower Lab/ NTNU will work on
research, design verification, development phase while
feasible industry will produce/ manufacture the turbine
within the nation. This project has already been planned and
proposed. The specific objective for the project is as
follows:
1.
Prepare technical background and foundations for
establishing a turbine manufacturing facility in Nepal
for new design of Francis turbine.
• Detailed market study and survey in the Himalayan
region.
• Establish new design new technology and prepare
procedures for its commercial applications.
• Formation of business team for commercializing
the new technology.
• Develop manufacturing facilities in Nepal for
production of the model and prototype turbines.
2. Establish new design of Francis turbine to minimize
losses due to sediment erosion
• Develop infrastructure in newly built turbine testing
laboratory at KU as a research center for turbine
manufacturer in Nepal.
• Verify hydraulic performance of new design by
model tests verification.
• Validate results of model tests and reduction in
erosion rates by prototype testing.
Table I shows the cost estimation/ budget and activities of
the project.
The budget allocated for establishing turbine
manufacturing company is estimated to be 55% of the total
cost which is USD 6.15 million. Some leading
manufacturing companies like Nepal Hydro & Electric Ltd
has been showing their interest in this project which will
reduce the cost for establishing new manufacturing
company. With this partnership both the industry and
academia will share their technical understanding for
hydropower growth in nation.
From the road map (Fig. 5) it is shown that project is
divided into four phases i.e.: project initialization, establish
new design, create production centre and initiate business.
The startup activities and detail market study will show the
feasibility and background for sustainable turbine business
in the region. The parallel activity to develop resource in
Turbine Testing Lab will be accomplished after the
development and installment of Francis test rig maintaining
IEC 60193 and creating CFD competence in the lab. The
complete project duration is estimated to be seven years
starting from 2012 as a project initialization phase. The
model test of Francis turbine and establishing manufacturing
industry is developing parallel with each other. The
proposed business plan clearly shows the phase and
development activities (Fig. 6).
V. CONCLUSION
Hydropower development in Nepal and the region need new
technologies to meet the local design requirements. Norway
has the capability to promote hydropower development in
Nepal with mutual economic benefits. Turbine Testing Lab
at Kathmandu University is playing a leading role for R&D
of Hydraulic Turbines in Nepal. Recent research on design
optimization of Francis turbines has generated possibilities
for commercial applications. The major challenge for this
project is parallel coordination with national and
international hydropower developers. However project will
work with mutual economic benefits to promote hydropower
development within the nation in close cooperation with
National and International hydropower companies.
TABLE I
PROJECT ACTIVITY AND BUDGET [2]
S. N
1
Project Activity
Development of the turbine manufacturing
ACKNOWLEDGEMENT
Budget (USD)
In Millions
6.15(55%)
The authors gratefully acknowledge the contributions of
everyone involved during the planning and organizing the
background for this project.
Company in Nepal
2
Development of resources in Turbine Testing
REFERENCES
1.2(11%)
[1]
Laboratory at Kathmandu University
3
Prototype installation testing and maintenance
0.5(4.5%)
4
Background for sustainable turbine business
2.7(25%) [2]
in the region
5
Project management, administrative and
0.5(4.5%) [3]
miscellaneous costs
Total Budget for the entire Project
B. S. Thapa, B. Thapa, and O. G. Dahlhaug, “Center of Excellence at
Kathmandu University for R&D and Test Certification of Hydraulic
Turbines,” IGHEM-2010, Oct. 21-23, 2010, AHEC, IIT Roorkee,
India.
B.S. Thapa, “Project Pre-Proposal”,” Development of Francis Turbine
Manufacturing and Testing Facility in Nepal” May. 30, 2011,
Kathmandu University, Dhulikhel.
B.S. Thapa, “Hydraulic Design Of Francis Turbine To Minimize
Sediment Erosion,” Masters Thesis, Dec 2011, Kathmandu
University, Dhulikhel.
11.05(100%)
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Supriya Koirala et al.: Collaboration for Establishing Francis Turbine Manufacturing and Testing Facility in Nepal
Fig. 5: Road Map for the Project [2]
Fig. 6: Proposed Business Plan [2]
Rentech Symposium Compendium, Volume 3, September 2013
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BIOGRAPHIES
Ms. Supriya Koirala is a graduate of Mechanical Engineering from
Kathmandu University (KU). She worked at the Turbine Testing Lab as a
Supporting Researcher. She is currently enrolled in NORAD’s Masters
Program.
Mr. Sudip Adhikari is a graduate of Mechanical Engineering from
Kathmandu University (KU), and is working at the Turbine Testing Lab as
a Research Assistant.
Mr. Biraj Singh Thapa is a research fellow of the RenewableNepal
project. He completed his MS by Research on the topic “Hydraulic Design
of Francis Turbine to Minimize Sediment Erosion”.
Prof. Dr. Bhola Thapa has done PhD from NTNU in the topic “Sand
Erosion of Hydraulic Machinery” in 2004. Currently he is the Dean of
School of Engineering of Kathmandu University.
Prof. Ole Gunnar Dahlhaug obtained his PhD in Mechanical Engineering
at NTNU. From 1992 to 1998 he worked at SINTEF as Research Scientist,
with research and testing of pumps and turbines. Currently he is a Professor
at Norwegian University of Science and Technology