Title

Collaboration for Establishing Francis Turbine Manufacturing and Testing Facility in Nepal

Authors (put * on first/corresponding author and indicate author affiliation by 1, 2, 3 …)

Supriya Koirala*1, Sudip Adhikari1, Biraj S. Thapa1, Bhola Thapa1, and Ole G. Dahlhaug2

Author affiliations

1Turbine Testing Laboratory, Kathmandu University, Nepal

2Water 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.

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.

Index terms or keywords

Hydropower, Turbine Testing Lab (TTL), Francis turbine, Manufacturing, Kathmandu University (KU), Norwegian University of Science and Technology (NTNU)

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”.

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].

Runner Damaged by Sediment Erosion in a Nepalease Power Plant

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 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.

Fig. 2: Turbine Testing Lab at Kathmandu University

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 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

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.

Fig. 4: Extension of RenewableNepal Project [1]

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.o Detailed market study and survey in the Himalayan region.o Establish new design new technology and prepare procedures for its commercial

applications. o Formation of business team for commercializing the new technology.o 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

o Develop infrastructure in newly built turbine testing laboratory at KU as a research center for turbine manufacturer in Nepal.

o Verify hydraulic performance of new design by model tests verification.o 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.

TABLE IPROJECT ACTIVITY AND BUDGET [2]

S. NProject Activity

Budget (USD)

In Millions

1 Development of the turbine manufacturing Company in

Nepal

6.15(55%)

2 Development of resources in Turbine Testing Laboratory at

Kathmandu University

1.2(11%)

3 Prototype installation testing and maintenance 0.5(4.5%)

4 Background for sustainable turbine business in the region 2.7(25%)

5 Project management, administrative and miscellaneous

costs

0.5(4.5%)

Total Budget for the entire Project 11.05(100%)

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).

Fig. 5: Road Map for the Project [2]

Fig. 6: Proposed Business Plan [2]

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.

ACKNOWLEDGEMENT

The authors gratefully acknowledge the contributions of everyone involved during the planning and organizing the background for this project.

REFERENCES

[1] 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.

[2] B.S. Thapa, “Project Pre-Proposal”,” Development of Francis Turbine Manufacturing and Testing Facility in Nepal” May. 30, 2011, Kathmandu University, Dhulikhel.

[3] B.S. Thapa, “Hydraulic Design Of Francis Turbine To Minimize Sediment Erosion,” Masters Thesis, Dec 2011, Kathmandu University, Dhulikhel.

BIOGRAPHIES (may include photograph of author, passport type)

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