Turbine Testing Lab

Kathmandu University
Dhulikhel, Kavre, Nepal

Detail Document

On

Floor and Tank Coating of Turbine Testing Lab

Ravi Koirala
Research Fellow, TTL
Prepared by ravikoirala@ku.edu.np
+977-9855081391

April, 2017
1. Introduction
Turbine Testing Lab

The Turbine Testing Lab [TTL] at Kathmandu University [KU] is a one-of-a-kind

laboratory facility established with a vision of aiding hydropower development in Nepal
through research, testing and simulation, validation and other technical support. Located
at the foothill of Kathmandu University at Dhulikhel, Nepal, the lab operates within the
academic environment of the university and collaborates with the industries and private
sectors to address technical and societal aspects of hydropower development and
turbine-related issues. Capable of testing the turbine upto 300 kW, the lab is equipped
with the state-of-the-art technology, computers and spacious office space for academic as
well as commercial purpose. It has carried out a lot of research activities regarding
turbine design, development and simulations. TTL is working towards becoming a center
of excellence for research activities regarding turbines and hydropower in Nepal. To
achieve this target, it is rigorously conducting various academic and commercial research
activities.

TTL is the only lab in the world which can perform tests with 30 m natural head. The
location and topography of KU has provided the opportunity to place an upper reservoir
so as to create a 30 m natural head. The lab has two centrifugal pumps each of 250 kW
with variable frequency drive (VFD) for each pump. Each pump can produce maximum
flow of 0.25 m3/s and maximum head of 75 m. The pumps can be connected in series and
parallel combination producing a maximum head of 150 m and maximum flow of 0.5
m3/s respectively. TTL has the capacity to perform prototype test up to 300 kW turbines
and perform model test for larger turbines. The lab has provision to have four test rigs at
a time, along with notches and water volume measurement arrangements for calibration
of measuring instruments.

For more information logon to

http://www.ku.edu.np.
 Figure 1 Planned system in TTL Floor (attached is the floor geometry)

Figure 2 Current layout of TTL

2. Background
TTL is aiming to develop an international standard testing facility for which, the available
tank of 300 m3 is to be coated in order to prevent self-generation of sandy particles from
concreate wall, floor and ceiling. We expect the coating to be well finished and durable.
On this regard this document has been prepared inorder to select best possible option for
us.
3. Activities
3.1. Tank Coating
Region Area [m2]
Floor 131.4
Ceiling 131.4
Walls 263.592
Columns 78.52
Total 605
Details as per attached drawing
3.2. Floor Maintenance
According to the applicator, the reason behind current damage in floor coating is
surface preparation measure. Earlier applicator has used cement mortar for base
preparation, but Epoxy coating are usually applied on mother concrete. In case of too
many roughness on the surface, epoxy mortar is applied.
For current activity, continuous round segment will be cut from each damaged
regions and maintenance will be done with epoxy mortar and epoxy coat. The color
can be prepared as per the need.

(i) (ii)
Figure 3 Cracks on the Epoxy Coating

4. Proposed Type of Coating

Type: Nitocote CM210

Provides Cementitious, elastomeric coating with inherent crack-bridging ability

Cost: 3000 + VAT (23 KG)

Application areas:

 Potable water retaining structures

 Potable water excluding structures
 Water proofing
Advantages:

 Withstands high positive and negative hydrostatic pressures

 Excellent crack accommodation before and after immersion
 Approved for us in contact with portable water
 Excellent bond to concrete and masonary
 Long working life (7-10 years)
 Application possible with brush, towel or spray

 Cracked substrate cyclic movement from 0 – 300 – 0 microns at 15 oC for 6,000 cycles
without failure.
 Can resist positive water pressure of 5 bar and negative water pressure of 2 bar

Wall Coating Wall Coating

Ceiling Coating
Figure 4 Photos are from an underground tank coating of Kathmandu Valley Drinking Water Project in Khumaltar
About the Applicator

The applicator has the contract of coating whole drinking water tank of Kathmandu
Valley Drinking Water Supply Project.

5. Threats to Coating
Because of timely floods, muds have been deposited to at the entrance of Turbine
Testing Lab. The height of deposit is around 500 mm.

Figure 5 Mud deposition at TTL entrance

In next rainy season (after the coating), it is likely that again flood will enter the lab, at
that time the water in the coated tank may get dirty which makes it impossible to perform
PIV experiments.

During our AEPC project, there was construction going on in Block 9. At that time we
had to pay a lot just for transportation from infront of Block 9 to TTL as we needed a
crane to do so. Since the construction is complete now it may be essential to make a road
way to come down to TTL. We are likely to have our Pressure Tanks, VFD and Motors
within next 3 months, particularly for these we will need the way down.
Figure 6 At TTL entrance
Fosroc Nitocote CM210 constructive solutions

Elastomeric cementitious coating.

Uses UK potable water approvals

Nitocote CM210 provides a cementitious, elastomeric coating
with inherent crack-bridging ability. Typical applications include:
 Potable water retaining structures.
 Potable water excluding structures.
 Internal basement waterproofing.
 Drainage culverts.
 Podium slabs.
In the case of contracts requiring Water Byelaws Scheme
certification, Nitocote CM210 should be applied as per
the datasheet. The product must be allowed to cure for a
minimum of 7 days at 7oC or greater. Tanks with a surface
area less than 250m2 should be flushed with water prior to
filling. The tank should be disinfected in accordance with
local regulations before re-connection to the public water
supply.
Description

 Wet areas: Kitchens, bathrooms, shower rooms.
 Foundations in contact with ground water under saline
conditions.
Advantages
 Withstands high positive and negative hydrostatic pressures
 Excellent crack accommodation before and after immersion
 Approved for use in contact with potable water
 Excellent bond to concrete and masonary
 Long working life
 Easy application by brush, trowel or spray
 Bonds to green or damp concrete
Nitocote CM210 two-component polymer modified cementi-
tious coating is supplied in pre-packaged form. The product
is designed to be easily mixed on site using a slow speed drill
fitted with a mixing paddle and then applied to the substrate
using a trowel for best results.
Nitocote CM210, available in grey and white, cures to form an
elastomeric impermeable membrane.
Specification
The waterproofing coating shall be Nitocote CM210, an elas-
tomeric cementitious coating approved under the UK WBS
(WRc Listed) Scheme No. 0510522. The cured coating, after
immersion, shall be capable of withstanding

cracked substrate cyclic movement from 0 - 300 - 0 microns at

Standards compliance
15°C for 6,000 cycles without failure. It shall have the capability
Nitocote CM210 complies with: to resist a positive water pressure of 5 bar and a negative water
pressure of 2 bar when tested to ITM / FTM-181.
BS 6920: 1990 Effect on Water Quality.
Properties
Water Byelaws Scheme approved, product listing
Typical properties of mixed material
No. 0510522 Pot life at 20°C : 2 hours

DIN 1048: Water Penetration Test. Pot life at 35°C : 1 hour

Fire Tested to BS 476: 1987 Parts 6 and 7. Colour : Grey or white

Mixed density : 1950 kg/m3

Minimum application temperature : 5°C

Properties of cured coating (21 days cure at 23°C, followed

by 28 days immersion at 23°C).
The values obtained are for Nitocote CM210 when applied in
two coats each of 1 mm wet film thickness

Resistance to positive : 5 bar

water pressure (DIN 1048)Pt 5 (50 m head of water)

Resistance to negative : 2 bar

water pressure (ITM / FTM-181) (30 m head of water)

Static crack accommodation : 0.9 mm

page 1 of 4
Fosroc Nitocote CM210

Dynamic crack1 accommodation When the concrete surface is damp, apply the material using
capability 0 - 300 - 0 microns a trowel The first coat should be applied at a minimum wet
cycling after 28 days immersion film thickness of 1 mm (approximate coverage is 1.9 kg/m2)
(University of Surrey method) – and should be well brushed into the surface.
15°C : 6,000 cycles (no failure)
Finish in one direction for a neat appearance. Application
0°C : 6,000 cycles (no failure)
may also be made by roller, however it is recommended to
-12°C : 6,000 cycles (no failure)
finish the surface with a trowel for best results.
Abrasion resistance : Wear Index
The first coat should be allowed to cure for a minimum of 5
(ASTM D4060) (equivalent to 40 N conc.)
hours at 20°C or 3 hours at 35°C and longer at lower tem-
CO diffusion resistance peratures. The material should not be applied at tempera-
(Taywood method) : > 50 m tures below 5°C. All the mixed material should be used within
after 5,000 hrs QUV2 2 hours at 20°C or 1 hour at 35°C.
NOTE 1 : Nitocote CM210 will bridge an existing crack of up The second coat should also be applied at a minimum wet
to 0.5 mm in width. film thickness of 1 mm and finished in one direction. Pre-
NOTE 2 : UV test required coating to be exposed to 4 hrs. dampening of the surface is not necessary when applying
condensation at 50°C followed by 4 hrs. UV light at 50°C. the second coat.
Total exposure time was 5,000 hours. Spray application
Instructions for use For spray application the substrate should be prepared in
Preparation the same manner as for trowel application and the material
should again be applied in two coats. Each coat should be
All surfaces which are to receive the coating, must be free a minimum of 1 mm thickness. Allow a minimum of 5 hours
from oil, laitence, grease, wax, dirt or any other form of for- cure at 20°C or 3 hours at 35°C between the first and second
eign matter which could affect adhesion. Typically, concrete coats, or longer at lower temperatures. For further details on
surfaces can be cleaned using high pressure water jet or grit the selection of spraying machines and nozzles consult the
blasting. Spalled surfaces or those containing large blow- local Fosroc office.
holes, cracks and other such defects up to 10 mm depth,
should be repaired using Nitocote CM210. For further advice Disposal
on suitable repair mortars for larger scale repairs, contact the Waste mixed material should be allowed to harden overnight
local Fosroc office. then disposed of as non-hazardous waste.
Mixing Cleaning
The liquid polymer (5 kg) is poured from the plastic container Immediately after application is completed clean all tools
into a plastic or metal drum having a volume of at least 20 and equipment with clean water. Hardened material can be
litres. To this, the powder is gradually added (18 kg) whilst removed by mechanical means and by use of Fosroc Solvent
mixing with an approved spiral paddle attachment on a slow 102.
speed drill. Mixing is continued until a lump free slurry is
obtained. This should take a minimum of 3 minutes and a Limitations
maximum of 5 minutes. - Nitocote CM210 should not be applied if the air or substrate
Application temperature is greater than 45°C. This may result in different
colour shades.
Pre-dampen the substrate surface with water . High po-
rosity substrates will require more dampening than dense - Do not proceed with application when rainfall is imminent
substrates. Any condensation should be removed using a unless in a sheltered or protected location. The product
sponge. Any running water should be stopped with Renderoc should not be exposed to moving water during application.
Plug. Contact the local Fosroc office for further advice on - Nitocote CM210 should not be used on external surfaces
other suitable water stopping materials. where aesthetic appearance is critical as differences in cure/
drying rate may cause slight colour differences in the final
surface.

constructive solutions page 2 of 4

Fosroc Nitocote CM210

- Nitocote CM210 should not be used for applications subject to Additional Information
direct contact of tidal marine conditions eg. sea wall defences,
Fosroc manufactures a wide range of complementary products
sea water inlet channels.
which include :
- If any doubts arise concerning temperature or substrate condi-
Potable water retaining structures
tions, consult the local Fosroc Office.
 Waterproofing membranes & waterstops.
Technical support
 Joint sealants & filler boards.
Fosroc offers a comprehensive technical support service to  Cementitious & epoxy grouts.
specifiers, end users and contractors. It is also able to offer
 Specialised flooring materials.
on-site technical assistance, an AutoCAD facility and dedicated
specification assistance in locations all over the world. Fosroc additionally offers a comprehensive package of prod-
ucts specifically designed for the repair and refurbishment of
damaged concrete. Fosroc’s ‘Systematic Approach’ to concrete
Estimating
repair features the following :
Supply
 hand-placed repair mortars.
Powder component  spray grade repair mortars.
(grey or white) : 18 kg bags
 fluid micro-concretes.
Liquid polymer component : 5 kg container  chemically resistant epoxy mortars.
1
Coverage (at nominal 1 mm thickness)  anti-carbonation/anti-chloride protective coatings.
Brush, roller, trowel application : 10.8-11.7 m 2 per 23 kg  chemical and abrasion resistant coatings.

Spray application : 9.0-11.7 m 2 per 23 kg

NOTE 1 : A minimum coverage of 3.8 kg/m2 applied in not For further information on any of the above, please consult your
less than 2 coats is recommended. local Fosroc office – as below
Storage

Shelf life is 6 months in unopened packs store between 35°C

and 10°C in a shaded environment. Protect the powder com-
ponent from the sources of moisture and humidity. The liquid
and powder components must not be allowed to freeze.

Precautions

Health and safety

Nitocote CM210 powder is irritating to eyes, respiratory system

and skin. Avoid inhalation of dust, wear suitable respiratory
protective equipment.

Nitocote CM210 liquid is not classified as dangerous.

Nitocote CM210, when mixed, becomes highly alkaline, wear

suitable protective clothing, gloves and eye protection.

For both components and mixed material avoid contact with

skin and eyes. In case of contact with eyes, rinse immediately
with plenty of water and seek medical advice

constructive solutions page 3 of 4

Fosroc Nitocote CM210
Fosroc Chemicals
(India) Pvt. Ltd.
Head Office
“Sapthagiri Palace”, No.38,
II & III Floor, 12th Cross,
CBI Road, Ganganagar North,
Bangalore 560 024
Chennai
No. 26(old no.33), 1st Floor,
1st Street Postal Colony,
West Mambalam,
Chennai 600 033.
Ph: 044-24899949-94
Fax: 044-24896641
www.fosroc.com
Important note :
Fosroc products are guaranteed against defective materials and manufacture and are sold
subject to its standard terms and conditions of sale, copies of which may be obtained on
request. Whilst Fosroc endeavours to ensure that any advice, recommendation specification
or information it may give is accurate and correct, it cannot, because it has no direct or
continuous control over where or how its products are applied, accept any liability either
directly or indirectly arising from the use of its products whether or not in accordance with
any advice, specification, recommendation or information given by it.
telephone fax e-mail
++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com
Regional Offices
Mumbai Noida Kolkata
1401/1402, 14th Floor, D-166 Sector 10 304, Jodhpur Park
A-Wing’The Great Eastern Summit’ Dist. Gautam Budha Nagar, Kolkata 700 068
Sector-15, CBD, Belapur Noida, Ph:033-65343188
Navi Mumbai 400 614 UP 201 301 Fax: 033-2499-0280
Ph: 022-43406800-04 Ph:0120-4270620-21
Fax: 022-27562423 Fax: 0120-4270622
page 4 of 4 INDIA/2014/0827/A