Power Hill Chart NamKong3 Rev 01 Fina

Technical Report No.
: HAL/2018-0278
Code name: IEC 60193-1999
Author: Florian Brungraber
Date: 29.11.2018 Lunzerstrasse 78

Postfach 28
4031 Linz, Austria
Phone: +43 (732) 6986-0
M ODEL T EST T RANSPOSITION R EPORT

Nam Kong 3
Summary
This model test transposition report describes the derivation of Nam Kong 3 prototype based on an
existing model test including the following aspects:
• Efficiency
• Cavitation
• Runaway
• Pressure-Fluctuation
Compl. Page 1 Compl. Page 1

Copies to Report only Copies to Report only Signatures
Customer name - - Author
- - -
- - -
Florian Brungraber
Checked by:
Peter Grafenberger
This report comprises:

69 Pages
Page No.: Page 1 of 69

Contents
1 Objective of Test 3
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 Unit Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Model Test Program 5

2.1 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Runaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Pressure Fluctuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 Main Test Results - Summary and Conclusion 7

3.1 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Runaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 Model Turbine 9
4.1 Model Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Test Items 14
5.1 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2 Cavitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Runaway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.4 Pressure fluctuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6 General Description of the Test Stand 58

6.1 Hydraulic Laboratory of ANDRITZ HYDRO GmbH Linz . . . . . . . . . . . . . . . . . . . . . . 58
6.2 Main data of test rig L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
6.3 General Layout of test rig L1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7 Measuring equipment and calibrations 60

7.1 Acceleration due to gravity - gM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.2 Flow - QM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
7.3 Guide vane angle - Alpha . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
7.4 Head and energy - HM, EM and HSM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7.5 Oxygen content - O2sat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.6 Pressure fluctuations - pMxx_StdDevRel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.7 Speed - nM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.8 Torque - TmM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
7.9 Water temperature - twM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Andritz HYDRO GmbH Linz Date Page

Nam Kong 3, Model Test Transposition Report, No. HAL/2018-0278 29.11.2018 2 of 69
The copyright of this document and all attachments remains with the company
1 Objective of Test
1.1 General
The hydraulic characteristics of the Compact Francis turbines are based on already performed model tests.
The selected model turbine base test for Nam Kon 3 has been performed in the hydraulic laboratory of
ANDRITZ HYDRO in Linz (Austria) in accordance the "International Code for Model Acceptance Tests of
Hydraulic Turbines" IEC 60193-1999. The step-up is performed according to IEC 60193-1999.
• Efficiency
• Cavitation
• Runaway
• Pressure Fluctuation

1.2 Unit Data
1.2 Unit Data
Turbine type and number
Number of units 3
Type of turbine Francis, horizontal shaft
Direction of rotation clockwise viewed from generator side to runner
Reference diameter and scale
All unit values refer to the runner blade exit diameter D2.
Figure 1.1: Reference diameter
The scale ratio is the relationship of the reference diameters of model and prototype.
DP 1534.8mm
Scale = = = 4.363 (1.1)
DM 351.74mm

Nam Kong 3, Final Model Test Report, No. HAL/2018-0278 21.11.2018 4 of 69
2 Model Test Program
Based on a model test following prototype conditions are used for the transposition:
• Gravity gP = 9.782m/s2
• Water density ρP = 997.5kg/m3
• Reference level for Sigma zr = CLR
• Reference value for Sigma calculation zr = 434.07m
• Minimum tail water level T W L = 437.18m
• Ambient - Vapor pressure head B∗ = 9.56m
• Prototype Speed nP = 500rpm
2.1 Efficiency
This test is done for Sigma , -High conditions for a prototype speed of nP = 500 rpm, with the following
parameters:
Model speed nM = 1150 rpm
• nED (-) = 0.457; 0.417; 0.431; 0.401; 0.391
• HP (m) = 79.9; 96.4; 90.0; 104.2; 109.4
• QP (m3/s) = 20.26; 20.26; 21.40; 18.96; 20.65
• HM (m) = 22.19; 26.65; 24.95; 28.82; 30.31
2.2 Cavitation
This test is done for Sigma variation for a prototype speed of nP = 500 rpm, with parameters which are
close to the operation range.
2.3 Runaway
This test is done for Sigma , -High , -Plant conditions , with the following parameters:
• HPR (m) = 104.2

• Alpha (◦ ) = Various

2.4 Pressure Fluctuation
2.4 Pressure Fluctuation
This test is done for Sigma conditions for a prototype speed of nP = 500 rpm, with parameters which are
close to the operation range.
Model speed nM = 1150 rpm

3 Main Test Results - Summary and Conclusion
3.1 Efficiency
Efficiency correction In the Compact Hydro segment, some simplifications between measured model tur-
bine and prototype are applied. Such deviations in the geometrical homology have an influence on pro-
totype efficiency and are considered in the layout. The corrections are based on loss analysis for Francis
units with formulas reproducing the results of comparison measurements on model and prototype turbines.
For Nam Kong 3 modifications for the following items are applied:
Guide vane gaps Labyrinth clearance Aeration pipe Based on these modifications an efficiency correction
of −0.35% is calculated for the best efficiency point.
As the corrections depend on turbine discharge, the following proportionalities are considered:
Type of modification and Proportionality
• Guide vane gaps 1/Q
• Labyrinth clearance 1/Q
• Aeration pipe Q2
The total weighted prototype efficiency is achieved and fulfills the guaranteed. See tabeles below and for
detailed results see chapter 5.1.
Head [m] 96.4 96.4 96.4 96.4
Speed factor (nED) [-] 0.417 0.417 0.417 0.417
Corresponding discharge [m^3/s] 20.26 18.234 16.208 14.182
Discharge factor (QED) [-] 0.280 0.252 0.224 0.196
Discharge in % of rated discharge [%] 100 90 80 70
Expected prototype turbine efficiency Eta-P [%] 94.90 93.00 91.68 89.44
Guaranteed prototype turbine efficiency [%] 94.90 93.00 91.68 89.44
Output corresponding to guaranteed prototype efficiency [MW] 18.085 15.950 13.978 11.931
Table 1: Prototype efficiency determination at Hnet,rated = 96.4 m
Head [m] 79.9 85.0 90.0 95.0
Speed factor (nED) [-] 0.458 0.444 0.431 0.420
Corresponding discharge [m^3/s] 20.26 20.26 20.26 20.26
Discharge factor (QED) [-] 0.308 0.298 0.290 0.282
Discharge in % of rated discharge [%] 100 90 80 70
Expected prototype turbine efficiency Eta-P [%] 94.15 94.46 94.64 94.87
Guaranteed prototype turbine efficiency [%] 94.15 94.46 94.64 94.87
Output corresponding to guaranteed prototype efficiency [MW] 14.872 15.873 16.838 17.817
Table 2: Prototype efficiency determination at Qrated = 20.26 m3/s

3.2 Cavitation
3.2 Cavitation
The cavitation observations shows cavitation free operation in the operating range area and therefore the
cavitation guarantee on the prototype is fulfilled.
For detailed results see chapter 5.2.
3.3 Runaway
The runaway tests without sigma-influence show a maximum steady point which is lower than the guarantee
943rpm. The curves under sigma conditions are lightly higher but also in the guarantee range.
For detailed results see chapter 5.3.

4 Model Turbine
4.1 Model Drawings
The model drawings are attached to the final report.

The following table gives an overview.
Title Drawing Number

Cross Section MB9-924.5000
General Arrangement MB9-924.5001
Hydraulic Contour 891243815
Francis Runner MB9-925.2390

4.1 Model Drawings

4.1 Model Drawings

4.1 Model Drawings

4.1 Model Drawings

5 Test Items
5.1 Efficiency
5.1.1 Test Procedure
By measurement of the specific hydraulic energy between intake and draft tube outlet and measurement of
discharge the hydraulic power Ph is obtained.
The mechanical power Pm is measured with torque and speed.
Pm
The hydraulic efficiency is calculated by η = Ph .
During efficiency tests the performance of the turbine is investigated over the entire operation range of the
prototype turbine.
With the net heads of the prototype the speed factor nED used for the model is calculated.
n·D
nED = √ (5.1)
g·H
The efficiency test is performed at sigma-high conditions. The efficiency curves for turbine operation are
measured for a constant speed factor by varying the guide vane angle (see 5.1). This procedure is repeated
for the different speed factors. By means of these efficiency curves for different speed factors an efficiency
hill chart can be generated with lines of constant efficiency, guide vane angle and in case of a double
regulated machine also with the runner blade angle.
Guide vane angle 
Efficiency
Efficiency 
Guide vane angle
HM = const
Discharge factor QED no scale on the coordinate axis
Figure 5.1: Propeller curve (schematically)

5.1 Efficiency
Based on these results prototype efficiency and output can be calculated and presented.
5.1.2 Results
For detailed results see the following diagrams, which are listed in table 5.1.
Description Drawing number

Expected Prototyp Efficiency Hill Chart D0120-RDL-0010
Expected Model Efficiency Hill Chart D0120-RDL-0015
Expected Prototyp Efficiency Chart D0120-RDL-0011
Expected Model Efficiency Chart D0120-RDL-0016
Table 5.1: Test results for Efficiency

5.1 Efficiency
Expected Prototype Hillchart
Efficiency [%] Power [MW] Layout Sheet Min. net head [m]
Gate Opening [deg] Best Efficiency Point Limit 1 Power limit [MW]
25
90
32
Q [m³/s]
Andritz HYDRO GmbH Linz

34 24
23
30
28
21
20
24 94.
19
94
20
94.25 94.5 18.1 94.75
93
93 17
16 22
92
15 20
91
14
90
15
18
Nam Kong 3, Final Model Test Report, No. HAL/2018-0278

12
89
88
16
86
Date
79.9 11
10
9 14
21.11.2018
8
10
7
80 85 90 95 100 105 110

H [m]
D2 = 1.535 [m] ρ = 997.5 [kg/m³] Prep. Date
D th = 1.502 [m] g = 9.78200 [m/s²] S. Fischer 21-November-2018
Site El. = 434.07 [m] B* = 9.56 [m] Checked Dwg.
fr01 - E_COLATO n = 500.00 [rpm] Re D2 = 67.547E6 [-] M. Kautt
Page
16 of 69
5.1 Efficiency
Model Hillchart
Gate Opening [deg] Best Efficiency Point Limit 1 Efficiency [%]
0.35
34
32
Q ED [-]

30
28
0.3
93
24
93.64 92.5
93.5
93.25 92 91
0.25
22
20
90
89
18
0.2
88

16
86
84
Date
82 14
80
0.15
75
12
21.11.2018
10
60
0.1
0.38 0.39 0.4 0.41 0.42 0.43 0.44 0.45 0.46 0.47
n ED [-]
D2 = 0.352 [m] ρ = 999.1 [kg/m³] Prep. Date
Site El. = 434.07 [m] Checked Dwg.
fr01 - E_COLATO n = 1149.61 [rpm] Re D2 = 7.422E6 [-] M. Kautt
Page
17 of 69
5.1 Efficiency
Expected Prototype Chart

预期的原型
H = 109.39 m
Efficiency Gate Opening Power

45

η [%]
α [deg]
P [MW]
90
40
25
35
80
20
30
70
25
15
60

20
10
15
Date
50
5
10
21.11.2018
40
5
5 10 15 20 25 30
Q [m³/s]
D2 = 1.535 [m] ρ = 997.5 [kg/m³] Prep. Date
fr01 - E_COLATO n = 500.00 [rpm] Re D2 = 67.547E6 [-] M. Kautt /1
Page
18 of 69
5.1 Efficiency
H = 104.20 m

45

η [%]
α [deg]
P [MW]
90
40
25
35
80
20
30
70
25
15
60

20
10
15
Date
50
5
10
21.11.2018
40
5
5 10 15 20 25 30
Q [m³/s]
D2 = 1.535 [m] ρ = 997.5 [kg/m³] Prep. Date
Page
19 of 69
5.1 Efficiency
H = 90.00 m

45

η [%]
α [deg]
P [MW]
90
40
25
35
80
20
30
70
25
15
60

20
10
15
Date
50
5
10
21.11.2018
40
5
5 10 15 20 25 30
Q [m³/s]
D2 = 1.535 [m] ρ = 997.5 [kg/m³] Prep. Date
Page
20 of 69
5.1 Efficiency
H = 96.40 m

45

η [%]
α [deg]
P [MW]
90
40
25
35
80
20
30
70
25
15
60

20
10
15
Date
50
5
10
21.11.2018
40
5
5 10 15 20 25 30
Q [m³/s]
D2 = 1.535 [m] ρ = 997.5 [kg/m³] Prep. Date
Page
21 of 69
5.1 Efficiency
H = 79.90 m

45

η [%]
α [deg]
P [MW]
90
40
25
35
80
20
30
70
25
15
60

20
10
15
Date
50
5
10
21.11.2018
40
5
5 10 15 20 25 30
Q [m³/s]
D2 = 1.535 [m] ρ = 997.5 [kg/m³] Prep. Date
Page
22 of 69
5.1 Efficiency
Model Chart
nED = 0.39100 -
Efficiency Gate opening

45

η [%]
α [deg]
90
40
35
80
30
70
25
60
20

50
15
Date
10
21.11.2018
40
5
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Q ED [-]
D2 = 0.352 [m] ρ = 999.1 [kg/m³] Prep. Date
Page
23 of 69
5.1 Efficiency
Model Chart
nED = 0.40100 -

45

η [%]
α [deg]
90
40
35
80
30
70
25
60
20

50
15
Date
10
21.11.2018
40
5
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Q ED [-]
D2 = 0.352 [m] ρ = 999.1 [kg/m³] Prep. Date
Page
24 of 69
5.1 Efficiency
Model Chart
nED = 0.43100 -

45

η [%]
α [deg]
90
40
35
80
30
70
25
60
20

50
15
Date
10
21.11.2018
40
5
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Q ED [-]
D2 = 0.352 [m] ρ = 999.1 [kg/m³] Prep. Date
Page
25 of 69
5.1 Efficiency
Model Chart
nED = 0.41700 -

45

η [%]
α [deg]
90
40
35
80
30
70
25
60
20

50
15
Date
10
21.11.2018
40
5
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Q ED [-]
D2 = 0.352 [m] ρ = 999.1 [kg/m³] Prep. Date
Page
26 of 69
5.1 Efficiency
Model Chart
nED = 0.45700 -

45

η [%]
α [deg]
90
40
35
80
30
70
25
60
20

50
15
Date
10
21.11.2018
40
5
0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4

Q ED [-]
D2 = 0.352 [m] ρ = 999.1 [kg/m³] Prep. Date
Page
27 of 69
5.2 Cavitation
5.2 Cavitation
The variation of the Thoma number σ (Sigma) at a certain point of operation is reached by varying the
pressure respectively the suction head of the closed test circuit.
For a sigma break curve the efficiency, discharge and power output are measured in dependence on the
sigma values. Operation conditions such as guide vane angle, head and speed are kept constant. Model
suction head respectively Thoma number σ (Sigma) correspond to a certain prototype tail water level.
model efficiency
1%
QED
unit discharge
PED
unit output
1 i plant
Figure 5.2: Sigma break curve (schematically)
The flow can be observed through a Plexiglas window at the draft tube inlet. Visual observation of the cavi-
tation phenomena is performed in selected operation points and recorded by means sketches, photographs
and videos for every observed points.
Comment on Sigma:
The Sigma definition of IEC193 is used. A comparison of the Sigma definitions according IEC 193 and IEC
60193 is presented in the enclosures, demonstrating how both definition lead to the same test conditions.

5.2 Cavitation
5.2.2 Similarity law
For similarity of model and prototype operation conditions the Thoma number σ has to be equal.
σM = σP
pamb,M −pva,M pamb,P −pva,P

ρ M · gM − HS,M ρ P · gP − HS,P
σ= = (5.2)
HM HP
At the prototype the suction head is the difference between reference level and tail water level
HS,P = zr − T W L. (5.3)
In the model this suction head is measured by means of the pressure difference between draft tube mea-
suring section and reference water level
HS,M = −p2/(ρg). (5.4)
The suction head to be adjusted at the model is calculated:

pamb,M − pva,M
HS,M = − σP · HM (5.5)
ρM · gM
The σ plant values are calculated by the formula:
B ∗ − HS B ∗ − (zr − T W L)
σP = = P (5.6)
H HP
5.2.3 Results

Cavitation Characteristic Curves D0120-RDL-0020
Cavitation Characteristic Sketches D0120-RDL-0021
Table 5.2: Test results for Cavitation

5.2 Cavitation
Nam Kong 3 F15/1053B, D2=0.35174

SP344, FSR210, FLA236B, AS456
L5917 nED=0.4205 ReM*=7.10^6
92
91
EtahM* [%]
90
89
5917 / 42 alpha=33.5°
88 5917 / 43 alpha=36.5°
87
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
sigma193 [1]
0.365
0.36
0.355
QED [1]
0.35
0.345
0.34
0.335
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
sigma193 [1]
0.325
0.32
PED* [1]
0.315
0.31
0.305
0.3
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
sigma193 [1]
D0120-RDL-0020

5.2 Cavitation
Nam Kong3 F15/1053B, D2=0.35174

SP344, FSR210, FLA236B, AS456
L5917 nED=0.4124 ReM*=7.10^6
92
91
90
EtahM* [%]
89 5917 / 44 alpha=35.5°
5917 / 45 alpha=40°
88 5917 / 46 alpha=32.5°
87
86
85
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
sigma193 [1]
0.385
0.38
0.375
0.37
0.365
QED [1]
0.36
0.355
0.35
0.345
0.34
0.335
0.33
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
sigma193 [1]
0.34
0.33
PED* [1]
0.32
0.31
0.3
0.29
0.05 0.15 0.25 0.35 0.45 0.55 0.65 0.75
sigma193 [1]
D0120-RDL-0020

5.2 Cavitation
Nam Kong 3 F15/1053B, D2=0.35174

SP344, FSR210, FLA236B, AS456
L5917 nED=0.3729 ReM*=7.10^6
92
91
90
5917 / 54 alpha=36°
EtahM* [%]
5917 / 55 alpha=30°
89
88
87
86
0.05 0.15 0.25 0.35 0.45 0.55
sigma193 [1]
0.37
0.36
0.35
QED [1]
0.34
0.33
0.32
0.05 0.15 0.25 0.35 0.45 0.55
sigma193 [1]
0.32
0.31
PED* [1]
0.3
0.29
0.28
0.05 0.15 0.25 0.35 0.45 0.55
sigma193 [1]
D0120-RDL-0020

Cavitation Observation – incipient area cavitation
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

LS/MP No. alpha(°) nED(1) QED(1) Sigma193 LS/MP No. alpha(°) nED(1) QED(1) Sigma193
84 32 26 0.4724 0.2778 0.095 84 33 26 0.4443 0.2810 0.083

Date
21.11.2018
84 34 26 0.4121 0.2856 0.099 84 35 26 0.3906 0.2876 0.095
D0120-RDL-0021
Page
33 of 69
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

84 36 26 0.3729 0.2894 0.104 55 12 30 0.3730 0.3208 0.131

Date
21.11.2018
56 12 30 0.3905 0.3194 0.133 56 5 30 0.4125 0.3167 0.124
D0120-RDL-0021
Page
34 of 69
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

56 4 30 0.4444 0.3154 0.137 56 3 30 0.4726 0.3143 0.145

Date
21.11.2018
56 13 30 0.5002 0.3100 0.161 56 8 33 0.3731 0.3405 0.145
D0120-RDL-0021
Page
35 of 69
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

56 11 33 0.3905 0.3402 0.140 46 13 32.5 0.4126 0.3345 0.131

Date
21.11.2018
LS/MP No alpha(°) nED(1) QED(1) Sigma193 LS/MP No. alpha(°) nED(1) QED(1) Sigma193
42 12 33.5 0.4207 0.3410 0.141 49 15 33.5 0.4444 0.3406 0.148
D0120-RDL-0021
Page
36 of 69
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

56 2 33 0.4729 0.3372 0.159 54 11 36 0.3732 0.3598 0.160

Date
21.11.2018
53 11 36 0.3907 0.3585 0.153 44 12 35.5 0.4124 0.3540 0.146
D0120-RDL-0021
Page
37 of 69
Cavitation Observation – incipient leading edge cavitation suction side
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

83 11 26.0 0.3834 0.2883 0.094 83 10 26.0 0.3729 0.2887 0.185

Date
21.11.2018
83 8 26.0 0.3625 0.2897 0.282 83 7 26.0 0.3536 0.2906 0.436
D0120-RDL-0021
Page
38 of 69
Cavitation Observation – incipient leading edge cavitation suction side
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

82 4 30.0 0.3730 0.3209 0.110 82 3 30.0 0.3629 0.3225 0.242

Date
21.11.2018
82 2 30.0 0.3536 0.3231 0.388 83 9 34.0 0.3630 0.3476 0.140
D0120-RDL-0021
Page
39 of 69
Cavitation Observation – incipient interblade cavitation
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

83 12 22.0 0.3731 0.2506 0.152 83 14 22.0 0.3632 0.2509 0.282

Date
21.11.2018
83 15 22.0 0.3536 0.2517 0.367 83 16 18.0 0.3540 0.2076 0.840
D0120-RDL-0021
Page
40 of 69
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

83 17 18.0 0.3634 0.2060 0.464 83 19 18.0 0.3731 0.2047 0.303

Date
21.11.2018
83 20 18.0 0.3833 0.2036 0.239 83 21 18.0 0.3954 0.2022 0.161
D0120-RDL-0021
Page
41 of 69
L5917
F15/1053B, SP344, FSR210, FLA236B, AS456, D2=0.35174
5.2 Cavitation

83 24 14.0 0.3950 0.1551 0.477 83 25 14.0 0.3834 0.1569 0.783

Date
21.11.2018
83 26 14.0 0.3728 0.1576 0.913
D0120-RDL-0021
Page
42 of 69
5.3 Runaway
5.3 Runaway
The runaway speed tests are carried out covering the operating range. Runaway is the turbine’s hydraulic
condition of zero shaft torque. This can be obtained at the turbine model by increasing the speed and/or
decreasing the test head.
A typical diagram shows runaway speed factor and guide vane angle in dependence of discharge factor.
speed factor
guide vane opening

nED,R
Alpha
discharge factor
Figure 5.3: Runaway speed (schematically)

C:\Report\chapters\TI\Diagrams\Runaway.xls

5.3 Runaway
5.3.2 Similarity Law
For the computation of the prototype runaway conditions, the similarity laws for speed and discharge factor
can be applied.
nR,M · DM nR,P · DP
nED,R = √ = √ (5.7)
gM · HM gP · HP
√
nED,R · gP · HP
nR,P = (5.8)
DP
QR,M QR,P
QED,R = 2
√ = 2 √ (5.9)
DM · gM · HM DP · gP · HP
p
QR,P = QED,R · DP2 · gP · HP (5.10)
5.3.3 Results

Runawa High Sigma D0120-RDL-0030
Runaway Sigma D0120-RDL-0031
Table 5.3: Test results for Runaway

5.3 Runaway
KAREBBE Runaway
SP344 FSR210 FLA236B AS456
0.9
0.8
0.7
0.6
nED(-), QED(-)
0.5
nED L5917 F15/1053B

0.4 QED L5917 F15/1053B
0.3
0.2
0.1
0
0 5 10 15 20 25 30 35 40 45 50
alfa (°) D0120-RDL-0030

5.3 Runaway
KAREBBE Runaway-sigma
L5917 F15/1053B SP344 FSR210 FLA236B AS456
0.9

0.85
0.8
0.75
0.7
nED(-), QED(-)

0.65 alfa=16°
alfa=20°
alfa=25°
Date
0.6 alfa=30°
alfa=35°
alfa=42°
21.11.2018
0.55
0.5
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
sigma IEC193(-)
D0120-RDL-0031
Page
46 of 69
5.4 Pressure fluctuation
The pressure fluctuations are tested for various net heads at sigma plant condition. At each point the
dynamic pressure signal is recorded and at least statistically analyzed. The standard evaluation is the
peak-to-peak evaluation for the non-normally distributed signals using post-processing. First the signal’s
samples are sorted in ascending order and then the highest and lowest 1.5% of the samples are neglected,
which are assumed to be statistical outliers, resulting in the peak to peak value. For an immediate overview
at the test rig the 97% standard deviation is used. Assuming a normally distributed signal, the standard
deviation multiplied by the factor of 2*2.17 gives the peak to peak value neglecting the highest and lowest
1.5% of the signal, which are supposed to be statistical outliers (see figure 5.5). In case of normally
distributed signals, the 97% histogram evaluation and the 97% standard deviation give equal results.
Figure 5.5: Normal distribution
Figure 5.4: Example of summarizing diagram for pressure

pulsations for a constant head
Suitable positions for mounting sensors and to measure pressure fluctuations are located as shown in
figure 5.6

KAREBBE Runner F15/1053B
SP344 FSR210 FLA236B AS456
Transducers for Pressure Fluctuation Measurement
D2= 0.35174 m
5
1
2 4
815mm 3
260.9mm
908.8mm
1
2 3 4
Scanrate: 500Hz for 20000 samples

Figure 5.6: Typical locations of pressure transducers
Transducer: Kulite Calbration 4bar 10V, 5V Ub
Transducer No. Type SN Range(bar) Range (mV/V) Zero(mV) Name channel slope U/V offset U
1 Kulite XTM-190 05 020 134 0-7 0.9989 0.0899 spiral case inlet 0 70 0
The pressure pulsations are measured from speed-no-load conditions up to full load conditions in suitable
Transducer: Kistler
increments of the guide vane
Transducer No. Type
angle Alpha.
SN
In selected
Range(bar)
operation
bar/V
pointsName
Sens.(pc/bar)
which show channel
theslope
highest
U/V
fluctuations
offset U
control aeration 3with different
2 Kistler amounts
7031
Kistler 7031
of air 0-250
126832
1277180
is performed
0-2.5 1.0
1.0
to get an indication
-54.80
-58.62
Upstream cone
Right shore cone
of the2 impact100of air on00 pressure
1 100
fluctuations. If air
4 admission is necessary
Kistler 7031 1277187 at0-250
site has 1.0
to be determined
-59.11 during
Downstream cone commissioning
3 100 phase.
0
5 Kistler 7031 1277183 0-250 1.0 -58.76 Left shore cone 4 100 0
6 Kistler 7031 1277182 0-250 1.0 -59.11 elbow 5 100 0
Testprogram:Test Series: 5917
5.4.2 ResultsLS
24
Test
propeller σp
nED
0.4443
HM
23.47
σ
0.361
nM
1150
HP
63.4
25 propeller σp 0.4228 25.92 0.222 1150 70.0
26 propeller σp 0.4072 27.95 0.196 1150 75.5
For detailed results see the following diagrams.
27 σ−influence 0.4228 25.92 α =17° 1150 70.0
28 σ−influence 0.4228 25.92 α =21° 1150 70.0
29 central aeration 0.4228 25.92 α =17° 1150 70.0
30 central aeration 0.4228 25.92 α =21° 1150 70.0
Description 31 cirumf.aeration 0.4228 25.92 α =17° 1150 70.0
Drawing number
Pressure Fluctuation32 cirumf.aeration 0.4228 25.92 α =21° 1150 70.0 D0120-RDL-0040
MB9-907.2416/1.1
Table 5.4: Test results for Pressure Fluctuation
P:\KAREBBE\MT Modeltest\Auswertung\Druckschwingungen\Kar_Druckschw.xls

RD
Research and F15/1053B, SP344, FSR210, FLA236B, AS456
Development
inlet left side downstream right side upstream elbow

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
10
(%)
9
8
FFT deltaH/H_max peak-peak
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
20
97% conf deltaH/H peak-peak (%)
18
16
14
12
10
8
6
4
2
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Q ED (-)
testseries
D M=0.35174 m n ED =0.4443, Sigma=0.361
D0120-RDL-0040
/logsheet
n M=1150 rpm
5917/24 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
20
18
16
14
12
10
8
6
4
2
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Q ED (-)
testseries
D M=0.35174 m n ED =0.4228, Sigma=0.222
D0120-RDL-0040
/logsheet
n M=1150 rpm
5917/25 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
20
18
16
14
12
10
8
6
4
2
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Q ED (-)
testseries
D M=0.35174 m n ED =0.4072, Sigma=0.196
D0120-RDL-0040
/logsheet
n M=1150 rpm
5917/26 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
20
18
16
14
12
10
8
6
4
2
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Sigma (-)
testseries
D M=0.35174 m n ED =0.4228, alpha=17°, sigma infl.
D0120-RDL-0040
/logsheet
n M=1150 rpm
5917/27 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0.1 0.125 0.15 0.175 0.2 0.225 0.25 0.275 0.3
10
(%)
9
8
7
6
5
4
3
2
1
0
0.1 0.125 0.15 0.175 0.2 0.225 0.25 0.275 0.3
20
18
16
14
12
10
8
6
4
2
0
0.1 0.125 0.15 0.175 0.2 0.225 0.25 0.275 0.3
Sigma (-)
testseries
D M=0.35174 m n ED =0.4228, alpha=21°, sigma infl.
D0120-RDL-0040
/logsheet
n M=1150 rpm
5917/28 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
20
18
16
14
12
10
8
6
4
2
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4
air (%Q)
testseries
D M=0.35174 m n =0.4228, alpha=17°, Sigma=0.222, centr. aer. D0120-RDL-0040
/logsheet
n M=1150 rpm ED
5917/29 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.05 0.1 0.15 0.2 0.25
20
18
16
14
12
10
8
6
4
2
0
0 0.05 0.1 0.15 0.2 0.25
air (%Q)
testseries
D M=0.35174 mn =0.4228, alpha=21.5°, Sigma=0.222, centr. aer. D0120-RDL-0040
/logsheet
n M=1150 rpm ED
5917/30 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.1 0.2 0.3 0.4 0.5 0.6
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.1 0.2 0.3 0.4 0.5 0.6
20
18
16
14
12
10
8
6
4
2
0
0 0.1 0.2 0.3 0.4 0.5 0.6
air (%Q)
testseries D0120-RDL-0040
D M=0.35174 m n =0.4228, alpha=17°, Sigma=0.222, circ. aer.
/logsheet ED
n M=1150 rpm
5917/31 ART - 2006/01

RD
Development

10
9
8
FFT f/n_max ampl
7
6
5
4
3
2
1
0
0 0.1 0.2 0.3 0.4 0.5
10
(%)
9
8
7
6
5
4
3
2
1
0
0 0.1 0.2 0.3 0.4 0.5
20
18
16
14
12
10
8
6
4
2
0
0 0.1 0.2 0.3 0.4 0.5
air (%Q)
testseries D0120-RDL-0040
D M=0.35174 m n =0.4228, alpha=21°, Sigma=0.222, circ. aer.
/logsheet ED
n M=1150 rpm
5917/32 ART - 2006/01

6 General Description of the Test Stand
6.1 Hydraulic Laboratory of ANDRITZ HYDRO GmbH Linz
The first hydraulic test rig in Linz was set into operation in 1963. In the meantime further test rigs were built
and nowadays the hydraulic laboratories of ANDRITZ HYDRO GmbH in Linz comprise five test rigs where
the newest one was commissioned in 2007.
Office WC
Meeting
WC
WC
L1
room
work shop
L4
L3
L5
L2
Figure 6.1: Hydraulic Laboratory of ANDRITZ HYDRO GmbH Linz

6.2 Main data of test rig L1
6.2 Main data of test rig L1
This test rig is suitable for testing of Francis, Kaplan and bulb turbines. The generator has a capacity of 425
kW and a maximum speed of 2000 rpm. The two pumps have a power of 330 kW each and can provide a
maximum discharge of 1.2 m3 /s or a maximum head of 50 m.
6.3 General Layout of test rig L1
The test rig is operated as a closed loop for performing all types of tests as indicated in IEC 60193-1999.
See figure 6.2.
Pressurized
Vacuum
air
M/G
TmM nM
p2 p12 twM
QM
Test Rig Schematic
STJ 2017-2-14
Two Pumps in Parallel
Figure 6.2: General layout of test rig
The model turbine is installed between head and tail water tank. The hydraulic energy for turbine oper-
ation is delivered by two parallel radial pumps, which can be operated at different speeds to set a model
head. The downstream tank is connected to a vacuum vessel and to compressed air as well. This allows
varying the pressure in the downstream tank for the simulation of different tail water elevations or cavitation
conditions, while keeping the model head constant.

7 Measuring equipment and calibrations
Measuring chain, sample rate and sample time
The instruments and amplifiers are connected to PXI and cDAQ systems from National Instruments - see
a typical measurement chain in figure 7.2.
Most of the instruments or their amplifiers have current or frequency outputs. Some devices like amplifiers
for pressure fluctuation use voltage signals. The sampling rates are all the same for tests like efficiency,
sigma-break, runaway, guide vane torque and others. The sampling rate of frequency signals depends on
the frequency itself. For transient signals like pressure fluctuations the sampling rate is typical around 6000
Samples/s. When the test rig is in a stable, quasi-stationary condition, the measurement with a sampling
time of typically 30s is started. After this a control parameter is changed - for example the guide vane angle
- and after the test rig is back in a stable condition the next measurement is started.
Calibration
The instrumentation at the test rig is calibrated according to the project specific measurement range and
can be traced back to primary or secondary normals.
Evaluation
From the measured transient raw values the average value is calculated. These average raw values are
used together with the calibration constants to calculate the physical values. Out of them many other
derived values like HM , nED ... are calculated.
Measure Groups Devices Calibrations CalcSet 1

Name, channelGroup, Lab, Brand, Type, A0, A1, A2, A3, A4, A5 TmM=FGen*LGen+FFri*...
driverType,... Serial,... ... ...
CalcSet Configuration CalcSet 2

Symbol TmM=FGen*LGen+FFri*... NPSEP=SigmacP*EP/z0
Channel TARA
NPSEP=SigmacP*... ...
...
Device Configuration TARAs CalcSet 3

Symbol, MeasureGroup, A0, A1, A2, A3, A4, A5 ...
Channel, Device,... r0 ...
RAWS Results View Data

CHN00 [mA], CHN06 [V], Calculation TmM, HM, EtahM*, TmM, EtahM*,
MEASURE
CHN25 [Hz],... EtahP,... ...
Test Series LayoutSpec

gM, DM, A1M, A2M, TmM , HM , EtahM* ,
LGen, LFri,... EtahP , QM ,...
Figure 7.1: Flow of Information in the DAQ system (schematically)

7 Measuring equipment and calibrations
Typical Measuring Chain
Generator Force FGEN

F -20 - 20 mA
(for vertical turbines) Amp
HBM Z30 HBM MP30
F
Bulb Force FBULB
(for horizontal/bulb turbines) -20 - 20 mA
Amp
HBM Z6C3/H3 HBM MP30
F
Friction Force FFRI
(for vertical turbines) -20 - 20 mA
Amp
HBM Z6FC6 HBM MP55
Static Pressure p12 4 - 20 mA

Rosemount
Low: 3051 S2 CD3
High: 3051 S1 CD4
Control: 3051 S2 CD4
4 - 20 mA
Suction Pressure p2
Rosemount
3051 S2 CD3
Control: 3051 S1 CD3
4 - 20 mA
Discharge QM 0-24 V, flow direction
Digital In
NI PXI 6239
Krohne Optiflux 2000
ABB FEP321
4 - 20 mA
Water Temperature twM
Pt100 Jumo
4 - 20 mA
Deflector Angle Defl_Angle
WayCon
WP-320-420A-3A
Deflector Impulse Defl_Impulse

Parker
P1E-T200MS-0250 0-24V
OPC
PLC
Wicket Gate Angle Alpha
TR Electronic
CEV58S
4 - 20 mA
Axial Thrust FAM
Yokogawa
EJX110AS3
4 - 20 mA
Winter Kennedy dpWK1
Yokogawa
EJX110A
4 - 20 mA
Sealing pressure dpS2
Yokogawa
EJX110A
Oxygen Content O2sat 4 - 20 mA
Mettler Toledo Mettler Toledo

lnPro 6970i M400
Speed nM
PC running HTS
Hübner DAQ (ni PXI, cDAQ...)
HOG 163 D pulses
Pump speed
Sick pulses
IM18-08NDS-ZC1
digital communication
Ambient pressure Model pambM
Druck
DPI141
OPC Communication
Alpha
twM digital communication
Throttle Valve position Control System
TWT - Level
...
Blade Angle Beta User Input
Figure 7.2: Typical data acquisition system / Measuring chain (schematically)

7.1 Acceleration due to gravity - gM
7.1 Acceleration due to gravity - gM
Acceleration due to gravity is given as a function of latitude ϕ and altitude z - see IEC 60193-1993, chap-
ter 2.5.2:
gM = 9.7803 · (1 + 0.0053 · sin2 (ϕ)) − 3 · 10−6 · z (7.1)
The location of the laboratory in Linz/Austria is:

• 48◦ 16’ N latitude = 48.27596◦ N latitude
• 14◦ 20’ E longitude
• 262 m altitude
gM = 9.7803 · (1 + 0.0053 · sin2 (48.27596◦ )) − 3 · 10−6 · 262 · m (7.2)

m
gM = 9.8084 2 (7.3)
s
7.2 Flow - QM
The discharge or volumetric flow is measured with a magnetic inductive flow meter, the theoretical basis
for this device is the Faraday Induction Law.
The water flowing through the tube induces a voltage which is measured. This voltage is proportional to
the flow velocity which results together with the diameter of the pipe in the discharge.
Figure 7.3: Discharge measurement - Inductive flow meter (schematically, c Krohne)
For the volumetric calibration of the flow meter two tanks and a deflector device above the two tanks are
used. During flow calibration the test rig is an open circuit, see the light blue parts in figure 7.4.

7.3 Guide vane angle - Alpha
Pressurized
Vacuum
air
M/G
Flow Calibration Circuit
TmM nM
Diverter
Δt
Overflow
tank
Calibration
tank
p2 p12 twM
Overflow QM
pump
Test Rig Schematic
STJ 2017-2-14
Reservoir
Two Pumps in Parallel
Figure 7.4: General layout of test rig with flow calibration circuit (schematically)
One tank serves as calibration tank with a certified relation between level and volume (V = f (h)). The
certificate was created by the Austrian weights and measures office. The level can be read from the
outside with a ruler on a vertical tube. The suction head of the test rig pumps is kept constant through an
auxiliary circuit arranged in the second tank.
After reaching a steady condition of the operation point the deflector at the top of the two tanks is turned
from the auxiliary tank to the calibration tank. Exactly in the middle of this movement an impulse signal is
generated which starts a timer (t0 ). At the end of the calibration point the deflector turns back and the time
measurement is stopped (t1 ). The time difference between the in- and outward movement of the deflector
equals the filling time of the calibration tank. The level difference before and after calibration (h1 − h0 ) leads
to the volume change between t0 and t1 together with the certificate of the tank.
7.3 Guide vane angle - Alpha
An absolute angle encoder is connected to the stem of one wicket gate. The zero degree position is defined
as the closed position of the guide vanes without any squeeze.
The relation of guide vane angle α and the guide vane opening a is calculated by means of a computer
program using the theoretical shape of the guide vane. The guide vane position is calibrated in that way
that the opening between two neighboured guide vanes is adjusted to a calibration gauge and the angle is
measured with the encoder - see figure 7.5.
The result of a series of such measurements is then compared with the theoretical calculation.

7.4 Head and energy - HM, EM and HSM
Figure 7.5: Guide vane angle and guide vane opening, according to IEC 60193-1999
7.4 Head and energy - HM, EM and HSM
See also IEC 60193-1999 section 3.3 Pressure measurement
Model head and specific hydraulic model energy
According the Bernoulli’s principle the total pressure can be calculated by adding the static pressure to the
dynamic pressure. For evaluation of the model head or specific hydraulic model energy the static pressure
p12 is measured between two sections in the water path of the model, upstream of the turbine in the inlet
and downstream of the turbine near the end of the draft tube. The section in the inlet has the area A1 and
the one in the draft tube A2 - see figure 7.6. Using the simplifications described in the above mentioned
IEC chapter the specific hydraulic model energy can be calculated using:
p12 v12 − v22

E = g·H = + (7.4)
ρ̄ 2
p12 Q2

1 1
E = g·H = + · − (7.5)
ρ̄ 2 A21 A22
For measuring the static pressure a differential pressure transducer is used.

See also IEC 60193-1999 3.5.3.2.1 Measurement of differential pressure
Suction head
For measuring the suction head the pressure difference p2 between the measuring section "2" near the end
of the draft tube and a tube filled with water up to a reference level is used. This reference level is adjusted
to the contractual cavitation reference level.
The suction specific potential energy of the machine is calculated in the following way:
p2 + pamb − pva v22

N P SE = + (7.6)
ρ2 2
2
p2 + pamb − pva 1 Q
N P SE = + · (7.7)
ρ2 2 A2
(7.8)

7.5 Oxygen content - O2sat
∆p is measured with a differential pressure transducer.

The so called suction head HS (or ZS in IEC) is directly measured by the above mentioned pressure
transducer.
p2
HS = − (7.9)
ρ2 · g
See also IEC 60193-1999 page 269 figure 45 case C: Differential manometer connected with a pot situated
at the reference level of the machine
Figure 7.6: Pressure measurement for static and suction head (schematically)
Calibration
The calibration of the differential pressure transducers is performed in-situ with a primary pressure normal.
The normal is connected to the instrument and by applying several nominal pressured within the range of
later usage and by measuring the output of the instrument the calibration coefficients can be derived.
7.5 Oxygen content - O2sat
Oxygen content of water is measured with an optical probe. The optical measurement principle is based
on the so-called luminescence quenching. The luminescence of certain organic pigments (luminophore) is
quenched in the presence of oxygen. The luminophore absorbs the excitation light and releases a part of
the absorbed energy by emission of fluorescence. In the presence of oxygen, energy transfer takes place
from the excited luminophore to oxygen. The luminophore does not emit fluorescence and the measurable
fluorescence signal decreases.

7.6 Pressure fluctuations - pMxx_StdDevRel
Figure 7.7: Oxygen content measurement ( c Hamilton)
The function of the sensor can be checked with placing the sensor in a bottle half full with water which
results in full saturated environment (100%). Additionally the reading can be compared to a different instru-
ment.
7.6 Pressure fluctuations - pMxx_StdDevRel
Pressure transducers with a high resonance frequency are used for measurement of the pressure fluc-
tuations in the water-way. The transducers are installed flush with the inner surface to prohibit cavities.
The transducers are connected via an amplifier to the data acquisition. In the amplifier a filter fitting to the
Sampling rate is implemented.
For the pressure transducers a producer certificate is available. Additionally the transducers can be com-
pared among each other in a pressure chamber where a pressure surge is applied.
7.7 Speed - nM
Speed is measured by means of an incremental encoder which is mounted on top of the generator shaft.
See also figure in chapter 7.8. The output of the sensor are two square waves shifted by 90◦ which enables
the detection of the sense of rotation. The impulses per rotation are between 250 to 1000.
0°
90°
forward
backward
Figure 7.8: Signal from speed encoder
The speed measurement can be checked with a certified optical speed meter.

7.8 Torque - TmM
7.8 Torque - TmM
Primary and secondary hydrostatic bearing systems are used to measure the torque acting onto the turbine
shaft, see figure 7.9. The primary bearing system measures the main torque from the runner, while the
secondary bearing system measures the friction torque which is produced by the sealing and the roller
bearings guiding the turbine shaft.
speed encoder
generator
load cell
lever arm FGen
primary
(generator)
bearing
counter
weight
Δp load cell
FFRI secondary
axial thrust (model)
bearing
stationary lever arm
part
swimming part
Figure 7.9: Hydrostatic vertical bearing system
Primary hydrostatic bearing system
The generator has a hydrostatic bearing system to enable a direct measurement of the torque. The gener-
ator is floating on an oil film and only fixed by a load cell via a lever arm. The load cell measures the force,
which represents - in combination with the certified lever arm - the mechanical torque of the generator.
Secondary hydrostatic bearing system
By means of the secondary hydrostatic bearing system the friction torques of the sealing and roller bearings
are determined. The turbine shaft is guided by roller bearings arranged in the floating hollow shaft of the
hydrostatic bearing. The hollow part is fixed by a load cell via a certified lever arm on the static frame of
the bearing. The turbine shaft is connected to the generator shaft via a cardan shaft. The model runner is
fixed directly on the turbine shaft.

7.8 Torque - TmM
Calibration of primary and secondary bearing
The load cells used for force measurement are calibrated in-situ by means of certified 2, 5, 10 and 20 kg
dead weights which are applied to a rod.
Shaft friction loss
Figure 7.10 shows that the rotation of the shaft and its flanging with nuts and bolts reduces the torque
produced by the runner a little bit because of their losses. The blue hatch shows where this loss caused by
friction occurs.
Since this loss will not occur in the prototype, it was calibrated and taken into consideration in the evaluation
program. The friction loss is calculated as a function of the model speed and is calibrated prior to all tests.
Figure 7.10: Sketch showing where shaft friction loss occurs (schematically)
The shaft friction loss is measured as a function of the model speed. Since the shaft friction loss reduces
the torque transmitted from the flow to the runner, it is added to the measured torque in the evaluation
program. For the measurement a cylinder simulating the runner gap is installed instead of the runner, see
figure 7.11. By measuring the torque with this cylinder rotating in water at different speeds, the relation
between shaft friction torque and model rotational speed is obtained. This function is used to consider the
friction torque depending on shaft speed, when calculating the model torque.

7.9 Water temperature - twM
Figure 7.11: Measurement of shaft friction torque
7.9 Water temperature - twM
The Water temperature - necessary for the determination of density, kinematic viscosity and vapor pressure
of the circuit water - is measured with a PT100 thermometer.
The function of the sensor can be checked by comparing it with a certified thermometer.
A temperature difference of 4 ◦ C results in a density change of about 0.8 to 0.9 kg/m3 . A change of 0.9
kg/m3 results in a head difference of about 0.00009%. See IEC 60193-1999 Table B.2


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Technical Report No.

Code name: IEC 60193-1999

Author: Florian Brungraber

Date: 29.11.2018 Lunzerstrasse 78

M ODEL T EST T RANSPOSITION R EPORT

Compl. Page 1 Compl. Page 1

Customer name - - Author

This report comprises:

Page No.: Page 1 of 69

2 Model Test Program 5

3 Main Test Results - Summary and Conclusion 7

6 General Description of the Test Stand 58

7 Measuring equipment and calibrations 60

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1.2 Unit Data

Turbine type and number

Reference diameter and scale

Figure 1.1: Reference diameter

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• HPR (m) = 104.2

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2.4 Pressure Fluctuation

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4.1 Model Drawings

The model drawings are attached to the final report.

Title Drawing Number

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5.1.1 Test Procedure

Guide vane angle

Discharge factor QED no scale on the coordinate axis

Figure 5.1: Propeller curve (schematically)

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Description Drawing number

Table 5.1: Test results for Efficiency

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Expected Prototype Hillchart

Andritz HYDRO GmbH Linz

Nam Kong 3, Final Model Test Report, No. HAL/2018-0278

80 85 90 95 100 105 110

Gate Opening [deg] Best Efficiency Point Limit 1 Efficiency [%]

Andritz HYDRO GmbH Linz

Nam Kong 3, Final Model Test Report, No. HAL/2018-0278

Expected Prototype Chart

Efficiency Gate Opening Power

Andritz HYDRO GmbH Linz

Nam Kong 3, Final Model Test Report, No. HAL/2018-0278

Expected Prototype Chart

Efficiency Gate Opening Power

Andritz HYDRO GmbH Linz

Nam Kong 3, Final Model Test Report, No. HAL/2018-0278

Expected Prototype Chart

Efficiency Gate Opening Power

Andritz HYDRO GmbH Linz

Nam Kong 3, Final Model Test Report, No. HAL/2018-0278

Expected Prototype Chart

Efficiency Gate Opening Power

Andritz HYDRO GmbH Linz