“development of test rig for study of sediment erosion in...

“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

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE

UNLESS OTHERWISE SPECIFIED DIMENSIONS AREACCORDING TO:

2:1 CHECKED

3D CAD

DRAWNDATE

kg eachNAME, TYPEPT.NO.QTY.

Number

RAVI KOIRALA

OF

REV.

TEST LOOP

2015.12.16

TR-201517-TL-001

A0SHEET NO:

1 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT

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


MATERIAL

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

TEST SETUP

2015.12.16

TR-201517-TS-001

A0SHEET NO:

2 SHTS.16

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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


FLANGE 1


MATERIAL

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

DIFFUSER 1

2015.12.16

TR-201517-D1-001

A0SHEET NO:

3 SHTS.16

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Diffuser 1

Girdle 1

Girdle 2

Flange 1


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


5


Segment 2

Segment 1

Girdle

GirdleNOTE:1. All Dimensions are in mm.

MATERIAL

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

DIFFUSER 1

2015.12.16

TR-201517-D1-002

A0SHEET NO:

4 SHTS.16

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Segment 1

Segment 2

90.55

6 83.49R

762.42

30.82

31.17

23.06

11.33

7 65.4


80

200.15

1 629.82R

279.05

R


5

156.96


160

74

297.46R

179.33

R

1 9.38

55.48

19.19

36.96


5

130.29



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

DIFFUSER 2

2015.12.16

TR-201517-D2-001

A0SHEET NO:

5 SHTS.16

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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


5


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


Thickness of the Lining = 1.829 mm i.e. 15 Gauge

Cross Girdle


Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

DIFFUSER 3

2015.12.16

TR-201517-D3-001

A0SHEET NO:

6 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

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REPLACEMENT






Flange 2 Overlap

Flange 3

Diffuser 3

Edge Rib

82.67

4R

Numb

er 1

2

10

57.091 0

41.33

208.38


5


97.7102.7

18.4

174.2

18.3

190

208.4

5

14.5


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



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-001

A0SHEET NO:

7 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT






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



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-002

A0SHEET NO:

8 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT






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



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-003

A0SHEET NO:

9 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

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REPLACEMENT






A

A

B

B

Section view A-AScale: 1:1

Section view B-BScale: 1:1


Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-004

A0SHEET NO:

10 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT








Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-006

A0SHEET NO:

11 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT






A

A

B

B




Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-006

A0SHEET NO:

12 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT





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


53.5


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


2 TOP COVER SEGMENTS ARE TO BE MANUFACTURED

5 3.5



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-008

A0SHEET NO:

13 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT





9

7 HOLE

S

9

8 HO

LES

30


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.



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-009

A0SHEET NO:

14 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT





57.1

112.2

167.1

30.9

37.5

29.6

9

7 HO

LES4

HOLE

S 7

4HOLES 4

9

HOLES 8


2 SUCH PLATES FOR UPPER AND LOWER COVERS OF THE CASCADE

A A

BB

5

3.5


5

3.5


NOTE:1. All Dimensions are in mm.2. 18 Samples of Guide Vane, Material is Aluminum

Aluminum

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE

kg eachNAME, TYPEPT.NO.QTY. 18

Number

RAVI KOIRALA

OF

REV.

CADCADE

2015.12.16

TR-201517-CD-009

A0SHEET NO:

15 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

2

3

REPLACEMENT





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


4

3 HOLES

19R

9R

11

R 14

R

24R


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


11R 9R7R


42.07

3

11.3

45.07

51.02

61.02

83.57


245

R

260

R

50.33

28

9R

3.5

R


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



Mild Steel

MS-TTL-2015-17

MANUFACTURER.

PROJECT NO.

SIZE

TITLE:

SCALE


2:1 CHECKED

3D CAD

DRAWNDATE


Number

RAVI KOIRALA

OF

REV.

DRAFT TUBE

2015.12.16

TR-201517-DT-001

A0SHEET NO:

16 SHTS.16

RAVI KOIRALA

RAVI KOIRALA

1

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REPLACEMENT





92.67

1 29.45

8

12 H

OLES

16.98

40.85

114.45

15

46.33

77.67


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



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