Hydraulic Turbine R and D Lab
| Hydraulic Turbine R & D Laboratory Brochure |  |
INTRODUCTION
Real turbines can be tested at site in real conditions for which it is designed, only after installation and that too with relatively high inaccuracy. Practically no improvement can be done once the machine has been installed. The tests are therefore conducted on scaled models, on scaled hydraulic conditions. Such model tests process is a time consuming job and it demands well calibrated precision instruments, which are costly and often tailor made. Larger turbine manufactures such as BHEL, Andritz, Voith, GE and Dongfang have their own test facilities. However, smaller developers and consultants concerned with hydro power cannot afford such a big investment. Consequently, several projects have faced surprises during their operation.
HYDRAULIC TURBINE R&D LABORATORY, HRED, IIT ROORKEE |
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| A fully automatic SCADA based Hydraulic Turbine R&D Laboratory sponsored by Ministry of New and Renewable Energy, Government of India has been commissioned in 2017 at HRED, IIT Roorkee, Uttarakhand. HRED is a center of excellence for small hydropower in the country, to validate the homologous | hydro turbine models designed & fabricated by various turbine manufacturers. IIT Roorkee is one of the oldest technical institute set up in 1847 and has played an important role in the development of Water resources in India, both through education of competent engineers as well as research work. | |
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OBJECTIVESThe laboratory shall support the Indian small hydropower industry (government as well as independent) to grow and compete in the International market in various aspects of hydroelectric power development:
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The method used is simulating conditions similar to those around the runner of the turbine in a real hydro power plant. Two VFD driven large pumps are used for varying the water discharge, head and measuring various parameters such as power, discharge, head and speed in complete operating range.
HIGH-TECH FACILITYBoth CFD and experimental tests are carried out to validate the forecast performance and output test results obtained by calculation methods. The experimental tests are conducted for Francis, Kaplan and Pelton turbine by using a scaled model of the turbine. This stage of the hydraulic testing process provides a unique opportunity to verify the complete turbine operating range, taking into account complex operating phenomena, which are not covered in the theoretical calculation and tests carried out in previous CFD stages. This high-tech scaled model test laboratory is designed to test model of Turbine/ Reversible Pump Turbine/Large Pumps. The test rig is capable of simulating Conditions identical to those in a real hydropower plant.The guiding parameters in setting up this Lab are as follows:
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The key parameters measured on this test-rig are Input hydraulic power i.e. head & discharge, output power i.e. runner speed and torque. This test-rig can measure mechanical power up to 132 kW, for speeds up to 1600 rpm, with maximum test heads of 60m with discharge 75 l/s and minimum test head of 10m with 907 l/s.
Electromagnetic Flowmeter TESTS ON SCALED MODEL
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SALIENT FEATURES OF TEST RIG
| Max Head m | 60 m with discharge 150 lt./s. (Both pump in series) |
| Max Discharge l/s | 907 lt./s. at head of 15 m (Both Pump in parallel) |
| Max Speed | 1600 RPM |
| Hydro Static Bearing | Voith, Germany Make |
| VFD | Siemens Make |
| Universal Frequency counter/timer | Agilent Make, 350 MHz, 12 digits, 100 PS |
| Weights | Calibrated F2-Class Standard weights |
| Flow Calibration | Gravimetric (Weighing) |
| Flow Measurement | ABB Make Electromagnetic Flow meter, Velocity Range 0-10m/s (max.) |
| Head Measurement | Yokogawa Make Differential Pressure Transmitter |
| Torque Measurement | By HBM Make T12 torque meter capacity of 2kNm and HBM Make Z6 Load cell capacity of 10kg |
| Speed Measurement | By HBM Make T12 torque meter |
| Measuring Tank and calibrator tank calibration with load cell | Measuring tank; 3 Nos., 22T capacity RTN Type, HBM Make load cell, Calibrator tank; 1No. 2T Capacity, S-type HBM Make load cell |
| Cavitation Coefficient Measurement | Yokogawa Make Diff. pressure transmitter for suction pressure |
| Typical Runner Size of Turbine Model | Francis Turbine 250 mm - 350 mm up to 385 mm Kaplan Turbine 250- 350 mm for Kaplan Turbine Pelton Turbine Bucket size 80 mm - 90 mm Reversible Turbine Inlet Diameter 250mm - 350 mm |
| Flow Calibration Loop | Can also be configured as calibration loop by bye-passing the rig through diverter unit in measuring tank/discharge tank. |
| Model Testing | Closed loop. |
| Reservoir size and capacity | 12.1m X 8m X 4.45m, Volume 217.8m3 |
| Sump size and capacity | 12.1m X 7.1m X 4.45m, Volume 300.69m3 |
| Transfer pumps motors-4 Nos. | WPIL Make, Water lubricated, Speed 1450 rpm, Cap 900 m3/hr, total head 3.0m Motor: ABB Make |
| Main pump-motor-2 Nos. | WPIL Make, Pump: Suction 400NS, Discharge 350NS, Speed 988rpm, Capacity 1440 m3/hr, total head 24m Motor: 160 kW,988 rpm, V415 V, Siemens Make |
| Dynamo-motor and Fourth quadrant VFD | Simens Make 132kW AC Drive and induction motor |
| Feed Pump-Motors-2 Nos. | Kirlosker Make, 415V, 50Hz, 0.85 pf, 11 kW, 1470 RPM |
| Side Channel Pump-1no. | Speck-Pumpen, Germany Make, 415V, 50Hz, 0.85 pf, 1.5 kW, 1440 RPM |
| Energy Dissipating Valve | Jash India Make, Dia-400mm in line valve with Auma Electric Actuator |
| Liquid Chiller | Drycool systems Make, 40TR, water temp. 31°C max. |
THREE DIMENSIONAL VIEW OF TEST RIG
| HIGH ACCURACY CALIBRATION SYSTEM | ||
| Flowmeter Calibration System | ||
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| Calibration tank with load cell | Measuring tank with load cell | |
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| Flow diverter | Control Panel with Precision timer | |
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| MEASUREMENT AND CALIBRATION FOR HEAD | ||
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| Head Measurement and Calibration SCADA Screen | ||
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| Pressure and Suction Transducers | Head Measurement Panel | |
| TORQUE MEASUREMENT AND CALIBRATION SYSTEM | ||
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| Shaft Torque Calibration System | Friction Torque Calibration system | |
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| SPEED MEASUREMENT AND CALIBRATION SYSTEM | ||
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| Measurement of Turbine Speed by rotary Speed transducer | Speed Calibration System | |
| VARIABLE FREQUENCY DRIVE WITH MOTOR | ||
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| Main Pump and motor with VFD (SINAMICS G120-Siemens) | ||
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| Dynamometer with VFD (SINAMICS S120-Simens) | ||
| SUPERVISORY CONTROL AND DATA ACQUISITION | ||
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| Control Room | Turbine Model Testing SCADA Screen | |
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| Four Quadrant Reversible Pump Turbine Characteristics | Model Hill Curve | |
| Data acquisition, control and operation of model testing are done by PLC based SCADA system. Results and graphs related to model as well as prototype are plotted simultaneously in NI-Labview System. | ||
| VORTEX AND FLOW PATTERN OBSERVATION SYSTEM | ||
| Latest image watching instruments like High speed camera, Stroboscope and Borescope are used for observation. | ||
| Observation of the Channel Vortex from Runner Inlet | Observation of the incipient Cavitation on Runner Blade | |
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| Observation of the Cavitation bubbles inside draft tube cone | Visualization of flow pattern inside draft tube using High Speed Camera | |
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| CFD SERVER ROOM | ||
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| System Details: | ||
| Master Node: 1 no. IBM X 3550 M4 Server | ||
| Intel XEON processor E5 2680 (20 cores) @ 2.8 GHz, 25MB Cache, 1200 MHz 2 numbers IBM 600GB HDD SAS 10K RPM 64GB DDR3 1866 MHz 1 No's Dual Port FDR HCA Infinite band 4 numbers Quad Gigabit Ethernet port 1 number IMM port 1 number DVD RW drives |
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| Storage Node: 2 nos. of IBM X 3550 M4 Server | ||
| Intel XEON processor E5 2609 V2 (2x4 core) @ 2.5 GHz, 10 MB Cache, 1200 MHz 2 No's IBM 300GB HDD SAS 2.5" 32 GB DDR3 1833 MHz 1 No's of HCA Infinite band quad port 2 numbers Gigabit Ethernet port 1 number IMM port |
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| Compute Node: 12 nos. of IBM X 3550 M5 Server | ||
| Intel XEON processor E5 2680 (2x12 core) @ 2.5 GHz, 30MB Cache, 2500 MHz 1 No's 500GB HDD 7200 RPM SATA 2.5" 96 GB DDR4 2133 MHz 1 No's Dual Port HCA FDR Infinite band Dual Gigabit Ethernet port 1 number IMM port |
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| Software installed on HPC Server: - | ||
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| RESEARCH SCOPES | ||
In hydraulic turbine R&D laboratory of HRED, IIT Roorkee, the research fields include multi-phase hydro dynamics, water power project, hydraulic machinery etc. At present, mostly research scopes are shown as follows:
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In hydraulic turbine R&D laboratory of HRED, IIT Roorkee, the research fields include multi-phase hydro dynamics, water power project, hydraulic machinery etc. At present, mostly research scopes are shown as follows:
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| NATIONAL ACCREDITATION BOARD FOR TESTING AND CALIBRATION LABORATORIES | ||
| ACCREDITATION CERTIFICATE | ||
| Hydraulic Turbine R&D Laboratory is accredited by National Accreditation Board for Testing and Calibration Laboratories (NABL) in accordance with ISO/IEC 17025:2017 for Hydro Turbine Model Testing and Fluid Flow Calibration since 2018; as per IEC 60193:1999 and ISO 4185:1980. Accreditation is renewed every two years. NABL is part of Asia Pacific Laboratory Accreditation Cooperation (APLAC) which in turn is part of International Laboratory Accreditation Cooperation (ILAC). |
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| Hydraulic Turbine R&D Laboratory, Department of Hydro and Renewable Energy, Indian Institute of Technology Roorkee, Roorkee 247 667 Tel : +91-1332-286133, 286134, 285821 Dist. Haridwar, Uttarakhand, India E-mail: hturbinelab@iit.ac.in, hturbinelab@gmail.com, arun.kumar@hre.iitr.ac.in Webpage:Hydraulic Turbine R&D Laboratory |
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