Ravi Koirala et al.

: Design and Development of a Reversible Pump Turbine Test Rig

Design and Development of a Reversible Pump Turbine Test

Rig
Ravi Koirala*1, Sailesh Chitrakar1, Niroj Maharjan1, Nikhel Gurung1, and Bishnu Prasad Aryal1
1

Turbine Testing Laboratory, Kathmandu University, Nepal

AbstractTurbine testing for the performance analysis of the

design has been one of the mostly accepted and widely used
methods in the current trend of Research and Development.
Reversible Pump Turbine [RPT] is a new concept in turbine design
for Nepalese scenario, which addresses the need of the pump
storage and its role for compensating the current demand. In this
paper, an RPT designed for Chilime Hydropower Plant is scaled
down to a small model, fabricated and an RPT test rig is designed
and developed for testing of the turbine in dual (turbine and pump)
mode.

There are several sites in Nepal, having two rivers flowing

close to one another at different head. By using an RPT unit
as a link between such rivers, water can be pumped from
lower reservoir to the upper reservoir during dry season to
meet the flow of the turbine in the main unit with less
amount of energy needed to pump, due to the head
difference. While in monsoon when the water supply is
more, the excess amount of water is sent through the RPT
generating an excess amount of electricity [2].

This paper explains the model down methodology along with

the test rig design and testing of the model turbine in the rig. The
scaling down process was performed following the basic norms of
the IEC 60193 guideline for the model testing. Although the rig is
designed to be operated in dual mode, theinitial priority in this
paper has been given to the turbine mode, wherean initial
measurement has been completed. The measuring equipment like
pressure transducers, flow meter, torque transducer and
tachometers are installed in the rig and data are taken through the
Data Logger. Moreover, design and development of the test rig and
testing strategies have been focused, which will provide a platform
for rigorous testing of the turbine in future.

Particularly, operational process of turbine is a complex

phenomenon, but testing it is another complex issue. Setting
a laboratory facility to estimate the performance of a turbine
requires the flow loop, head and flow control, safety
systems, load control, turbine and moreover measuring
equipment like flow meter, pressure transducers, tachometer,
and torque transducer.

Index TermsTurbine testing, Performance analysis, RPT,

IEC, Turbine Mode

Under this project, an RPT was designed considering the

case of Chilime Hydropower Plant [3]. In this paper, the
details regarding the model development, test facility setup
and testing in turbine mode are presented. A chart showing
the details of the whole project and the scope of this paper is
clarified in Figure 1.

I. INTRODUCTION
There has always been a vast difference between the
design and operational point of turbines. Majority of
turbines are designed at Best Efficiency Point (BEP), but are
mostly operated in off design conditions because of varying
load and flow on seasonal and/or daily basis. Under this
operational scenario, it is always difficult to predict the
performance of a turbine on site since this may vary with the
conditions. Hence, it is of great importance to carry out
laboratory testing to measure the performance of the turbine
at several operating conditions.
This study is a part of Renewable Nepal Project carried
out at Turbine Testing Lab, Kathmandu University, which is
related to the capacity development of utilization of
Reversible Pump Turbine (RPT) in Nepalese Hydropower.
RPT or Pump storage are the systems designed to take
benefit of the load variation in daily load cycle, where it
fulfills the peak demand by utilizing the excess energy at off
demand time to pump the water to upper reservoir [1].
Hydropower plants in Nepal during monsoon have an excess
amount of water supply while in dry season, it is difficult to
meet the minimum of water required to run all the units.

*Corresponding author: ravikoirala@ku.edu.np

Rentech Symposium Compendium, Volume 4, September 2014

II. MODEL TURBINE DESIGN AND

FABRICATION
The prototype RPT turbine was designed based upon the
major design parameters from Table 1. The design was
performed on a MATLAB based Graphical User Interface
[GUI] program designed to provide the 3D runner profile as
output [4].
TABLE I: DESIGN PARAMETER FOR
PROTOTYPE
Symbol
H
Q
Zpoles
h

Parameter
Head
Flow
Number of poles
Efficiency

Unit
m
m3/s
-

Value
270
4
3
0.96

The model turbine for the RPT was designed following

the similarity of dimensionless numbers between prototype
model based on IEC 60193 guideline. Although the design
prepared afterwards lacks some of the basic features of IEC,
this approach can provide an estimation of the performance.
For a model and prototype to be similar, following
dimensionless numbers must be conserved in the two
designs [5].

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Ravi Koirala et al.: Design and Development of a Reversible Pump Turbine Test Rig

Fig. 1: Workflow of the overall project and scope of this paper

R = 2gH

Same discharge factor, (QED)A = (QED)B

Where discharge factor is given by;
Q =

Once this reducing parameter is multiplied to the reduced

velocity component then the magnitude of velocity is
obtained where the direction is similar to the prototype. The
velocity triangle is shown in Figure 2.

D gh

Same speed factor, (nED)A = (nED)B

Where speed factor is given by;
n =

nD

gh

Same Thomas number, A = B

Where Thomas number is given by;
=

NPSE
gh

From the above equations, the parameters of a model

with 1.6 kW and 1500 rpm were calculated and major
operating variables as shown in Table 2 were obtained.
TABLE II:
OPERATING VARIABLES OF THE MODEL
Symbol
N
P
Hm
Qm
Dmo
SF

Parameter
Speed
Power
Model Head
Model flow
Outer diameter
Scale factor

Unit
rpm
kW
m
m3/s
m
-

Value
1500
1.6
12.06
0.02043
0.117
0.17

Fig. 2: Velocity triangle of the model turbine

Based on the above calculated basic operational features,

the guide vanes, draft tube and spiral casing were designed.
All these components were provided with other mechanical
features as shown in Figure 3.

The model turbine thus generated are to be tested in lab

hence it is important to calculate the velocity triangle to
identify the test conditions. Velocity triangles in the model
and the prototype are related to each other by a factorial
term called Reducing Parameter [RP] which is numerically
given by,
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Ravi Koirala et al.: Design and Development of a Reversible Pump Turbine Test Rig
A test rig for hydraulic turbine is designed to test the
behavior against the exposed conditions where they are
provided with constant flow maintaining the flow features
along with the measuring equipments. The rig is installed
with the Pressure Transducers, Flow-meter, Torque
Transducer and Tachometer.
3.1 Measuring Equipment in the rig
i. Pressure transducer and gauge
Pressure transducer from Sensys was installed at the inlet
of the turbine to measure the pressure. A Data Logger of
Graphtec was used along with an excitation adapter for data
acquisition of the excited system. Figure 6a) shows the
pressure transducer used and its arrangement. The pressure
given by this transducer is identified using the equation
P=

Fig. 3: Cross sectional view of the model turbine

The designed model turbine was manufactured in a local

industry in Nepal. The runner blade with an allowable
casting tolerance was initially printed with a 3D printer
available in the lab and later, this pattern was used as a
reference while forging a metal block. Figure 4 explains the
methodology for runner manufacturing together with the
final product. Similarly, the guide vanes were casted and the
developed surface of the draft tube and spiral casing were
bent and welded. Other supporting parts were machined.

I4
8

Where, I is the current reading from the data logger and

P is the respective pressure. At the outlet of the runner, a
vacuum gauge was used to measure the suction pressure.
ii.

Flow meter

An ultrasonic flow meter of Shenitech 200H was used

for the flow measurement. This model has a feature to get
attached at the outer diameter of the pipe with the help of
strong magnet on its sensor. The receptor ends of the sensor
are applied with grease to prevent disturbances in the
ultrasound created and receive the proper signal.
iii. Torque transducer and tachometer

III. TEST RIG DESIGN AND DEVELOPMENT

For the hydro-mechanical facility, two 5 Hp pumps were
used to generate the head in the loop. The head delivered by
the pump is controlled using a by-pass valve as shown in
Figure 5. The diameter of the pipe was selected based on the
pump rating considering the static head delivered by the
pump. Two diffusers were fitted in the loop at the pump
outlet and spiral casing inlet to match the flow and minimize
the losses. All these components are mounted over a
rectangular sump tank and water is circulated in the loop.
TABLE III:
DESCRIPTION OF THE HYDRO-MECHANICAL COMPONENTS
S.N.
Particular
Description
Unit
Feed Pump
1
Power
5
Hp
2
Head
24
m
3
Flow
16 & 6
lps
Piping specification
4
Pipe diameter
75
mm

The electromechanical features are governed by a 2 kVA

synchronous generator connected to loads at its output. This
feature makes the test rig flexible in terms of estimation in
part load and full load conditions as well. Turbine is
connected to the generator using a flexible spider coupling
system. The turbine has a facility to manually operate the
guide vane.

Rentech Symposium Compendium, Volume 4, September 2014

Torque transducer with the range of operation from 0

30 Nm and tachometer with the required range are used to
measure the torque and speed in the system. Since both of
them have their respective data logger, the display can be
observed on it.

IV. TEST METHODOLOGY

Experimental study refers to the controlled study of
expected phenomena and suitable presentation of acquired
data. It is almost impossible to control and relevantly
represent data unless a protocol plan is made. Unlike other
technical approaches, testing methodology in a rig is not
always similar. It mainly depends on the design of the rig.
Hence, a clear and concise methodology before conducting
the test was defined.
The operating head, flow, speed and torque are major
topics of interest, whose measurements are necessary to
compute the performance of the turbine. Figure 7 shows the
detail methodology for testing and computation.
An initial stage testing has been completed till date. The
testing was performed at a full guide vane opening and a
part flow condition. The mechanical efficiency was
calculated from the flowchart as shown in Figure 8. An
efficiency of 67 % was achieved in the given operating
condition. Next step in this project will be to conduct testing
at various operating conditions of head, flow and guide vane
angles, and to draw a hill chart diagram through
combination of the results.
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Ravi Koirala et al.: Design and Development of a Reversible Pump Turbine Test Rig

Plastic Model

Forging Process

Forged Structures

Blades generated after

Forging

Fabricated turbine

Final product from manufacturers

Fabricated runner

Fig. 4: Turbine Fabrication Processes and final product

Flow meter

Pressure sensor

Torque Transducer

Fig. 5: Schematic view of rig and Developed rig system

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Ravi Koirala et al.: Design and Development of a Reversible Pump Turbine Test Rig

a) Pressure Transducer

c) Tachometer

b) Flow meter

d) Torque meter

Fig. 6: Measuring equipment used in the rig

Fig. 7: Methodology of conducting the test

Fig. 8: Calculation of mechanical efficiency for each sampling

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Ravi Koirala et al.: Design and Development of a Reversible Pump Turbine Test Rig

REFERENCES

V. CONCLUSION
This paper presents an approach of conducting scale
down model turbine testing in the lab. The works presented
in this paper was a part of a project which contains design
and development of Reversible Pump Turbines. Such a
turbine was designed in the earlier activities of the project,
whereas in this paper, a test rig for the scale down turbine
was designed and developed. The scale down model turbine
was locally manufactured and the test rig setup was prepared
in the lab using measuring equipment needed for testing.
A rigorous testing procedure was developed in this
paper, which is suitable for preparing a hill chart diagram of
the turbine when operated at several ranges of operating
conditions. This paper also showed an initial stage test value
of efficiency at one operating condition. With few
modifications in the current rig, this rig is capable of testing
even in the pump mode. This includes a motor in the place
of generator, guide vane and draft tube modifications.
However, the work done in this paper was successful in
establishing a skeleton for conducting a systematic,
thorough and accurate testing in future.

ACKNOWLEDGEMENT
The authors express their sincere gratitude to Kathmandu
University and Renewable Nepal Program for providing the
funding needed for this project. The authors are grateful to
all the personnel, experts, technicians, students and
companies who were involved in this project. A special
thanks to Chilime Hydropower for motivating research
oriented activity and supporting in all possible ways.

Rentech Symposium Compendium, Volume 4, September 2014

[1]
[2]

[3]

[4]

[5]

B. Steffen, "Prospects for pumped-hydro storage in Germany,"

University of Duisburg-Essen (Campus Essen), Germany, 2011
N.Maharjan, S. Chitrakar, N. Gurung, R.Koirala, "Pumped storage
concept and its potential application in Nepalese hydropower context
A case study of Chilime Hydropower Plant, Rasuwa, Nepal,"
APCMET-Emerging Energy Technology Perspectives - A Sustainable
Approach, ISBN: 978-93-83083-73-2, New Delhi, 2014.
N. Maharjan, S. Chitrakar, R. Koirala, Design of Reversible Pump
Turbine for its prospective application in Nepal, International Journal
of Scientific and Research Publications, 2014.
Eltvik, M.,Thapa, B.S., Dahlhaug, O.G., and Gjosaeter, K.,
Numerical analysis of effect of design parameters and sediment
erosion on a Francis runner, Fourth International Conference on
Water Resources and Renewable Energy Development in Asia,
Thailand, 2012
IEC-60193 document, Guideline for model testing of Hydraulic
Turbines and Pumps

BIOGRAPHIES
Mr. SaileshChitrakar is currently working as a Project Co-ordinator in
Turbine Testing Lab. He completed his Masters from a Erasmus Mundus
Program in Turbomachinery and Aeromechanics from Royal Institute of
Technology, Sweden and University of Liege, Belgium.
Mr. Ravi Koirala is a graduate of Mechanical Engineering from
Kathmandu University. He is currently working as a Researcher in Turbine
Testing Lab.
Mr. NirojMaharjan is a graduate of Mechanical Engineering from
Kathmandu University and past Researcher in Turbine Testing Lab.
Mr. NikhelGurung is a graduate of Mechanical Engineering from
Kathmandu University and past Researcher in Turbine Testing Lab.
Mr. Bishnu Prasad Aryal is a graduate of diploma in Mechanical
Engineering from BTI. He is currently working as a Technician in Turbine
Testing Lab.

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