IAHR

AIIH
INTERNATIONAL SYMPOSIUM ON HYDRAULIC STRUCTURES
CIUDAD GUAYANA, VENEZUELA, OCTOBER 2006
PRELIMINARY TESTS OF NEW RUNNERS FOR THE TURBINES OF
GURI HYDROPOWER PLANT
Ing. Pedro Zambrano CVG EDELCAVENEZUELA pezambrano@edelca.com.ve
Ing. Egda Caldern CVG EDELCAVENEZUELA ecalderon@edelca.com.ve
Ing. Antonio Mrquez CVG EDELCAVENEZUELA amarquez@edelca.com.ve
Ing. Fidel Arzola CVG EDELCAVENEZUELA farzola@edelca.com.ve

ABSTRACT
With the objective to eliminate the cavitation of the runners, to increase the efficiency, to
reduce the vibration, to repair or replace the worn components, and to put the turbines in as new
condition the processes for rehabilitations of Units 7, 8, 9 and 10 of Powerhouse I and Units 12, 15,
16, 18 and 20 of Powerhouse II of Guri have been made. In both processes the Bid documents
included as a part of the technical evaluation, the realization of Competitive Model Tests with the
purpose of demonstrating that the hydraulic design of the Bidders fulfills the guaranteed values of
their Bid and the requirements of the technical specifications, as well as determining the best
performance of each model. The present work shows the experience obtained during the
accomplishment of these competitive model tests, which were made in the Independent Laboratory
of ASTR in Graz, Austria, for the case of the Units of the Powerhouse I and in the Independent
Laboratory of EPFL in Lausanne, Switzerland, for the case of the Units of the Powerhouse II. In
both tests the efficiencies of the turbines, cavitation limits, hydraulic axial thrust and pressure
pulsations for each one of the operation conditions of the participant models were determined.
KEY WORDS: Hydraulic Turbine; Model Test; Hydraulic Laboratory
INTRODUCTION
The Hydroelectric Powerplant of Guri is the first of four hydroelectric stations built by
EDELCA on the lower reaches of the Caron river, which discharges into the Orinoco river, in
eastern Venezuela. The Guri Project consists of two Powerhouses, each one integrated by ten units
with Francis type turbines, that conform a total installed capacity of 10.000 MW, with a 162 m high
dam, 85.400 million cubic meters in volume reservoir, and a spillway controlled by nine radial gates
with a total discharge capacity of 30.000 m3/s.
The Units 7 to 10 of Powerhouse No. 1 went into commercial operation between the years 1976 and
1978. This Units were designed to operate with a nominal net head (net head for most frequent
operation) of 128 meters.
The Powerhouse No. 2 units went into commercial operation between 1984 and 1987, and were
conceived to operate with a nominal head of 130 m, with a rated and guarantee output of 610 MW
for each Unit.

Nevertheless, during the first years of service the turbines operated under reduced heads, due to
various reasons: low reservoir level during construction; late conclusion of the transmission lines;
and design problems of the main power transformers limited the operation of the units.
Due to the different hydraulic conditions, appeared in the runners pronounced secondary flows that
caused high intensity cavitation and excessive damages by cavitation pitting in the runners blades,
which required massive and periodic repairs by welding, which in turn caused a distortion in the
profile of the blades and, in consequence, a loss of efficiency accompanied with high vibrations.
REHABILITATION SUBJECT
With the aim to increase the units efficiency (and output for Powerhouse No. 2), eliminate
cavitation, reduce vibration, replace the worn components, and moreover to get the turbines in an
as new condition, EDELCA decided to initiate two bidding process, including model testing.
COMPETITIVES MODEL TEST
After the accomplishment of the established corresponding steps in each one of the Bids Documents
of CVG EDELCA, two manufacturers were qualified to participate in the competitive model tests,
to be carried out in an Independent Hydraulic Laboratory, in order to demonstrate that their
hydraulic designs fulfill with all the values guaranteed in their Bids and with the requirements of the
Technical Specifications, as well as to determine the best performance of each model, that served
later in the bid evaluation.
For the Powerhouse No. 1 process the Laboratory ASTR (Anstalt fr Strmungs-machinen
GMBH) in Graz, Austria, was selected as an independent laboratory, in order to carry out
competitive tests on the models of both qualified manufacturers.
For the Powerhouse No. 2 process the Laboratory EPFL (Laboratory for Hydraulic Machines of the
Ecole Polytechnique Fdrale de Lausanne), in Lausanne, Switzerland, was selected as an
independent laboratory, in order to carry out competitive tests on the models of both qualified
manufacturers.
GENERAL DESCRIPTION OF THE HYDRAULIC MACHINES LABORATORIES
The ASTRO laboratory contains two test rigs, the turbine test rig and the four quadrants test rig.
The turbine test rig was used for the competitive model tests of Units 7, 8, 9 and 10 of Guri.

Figure 1.- Schematic diagram of the test rig - ASTR Hydraulic Machines Laboratory

On the other hand the EPFL laboratory contains three universal test rigs, denominated PF1, PF2 and
PF3. The test rig PF2 was used for the competitive model tests of Units 12, 15, 16.18 and 20 of
Guri.
Both test rigs are equipped with high precision measuring instruments, so that they are adapted for
acceptance and development tests, according to orders code IEC 60193.
These rigs are used in closed hydraulic circuit for the tests of efficiency and cavitation. The air
cushion on the level of the water in the water discharge tank is connected to a pressurized air
supply, as well to a vacuum pump for pressure variation during the tests.
In general, with the equipment of these test rigs can reproduce the required conditions of generation
for the evaluation of the guarantees presented by the Bidders and of the global behavior of their
hydraulic turbine, respecting the hydraulic similarity between model and prototype.

Figure 2.- Schematic diagram of the test rig - EPFL Hydraulic Machines Laboratory
NORMATIVE FRAME OF THE COMPETITIVE MODEL TESTS PROCESS
The standards that regulated the competitive models tests processes were established
according to following documents:
Powerhouse I:

Biding document of the Contract N 2.2.102.003.00 of CVG EDELCA (February 2002).

Model Tests Procedure (January 2004).

International Standard IEC Publication 60193, Second edition 1999-11.
Powerhouse II:

Biding document of the Contract N 1.1.102.012.01 of CVG EDELCA (June 2003).

Model Tests Procedure (January 2005).

International Standard IEC Publication 60193, Second edition 1999-11.
TEST
The tests executed in both physical models and testified by CVG EDELCA and the
respective manufacturers, as much in the ASTR Laboratory like in the EPFL Laboratory, included
the following activities:

Calibrations



Preliminary test
Official test
Calibration check
Dimensional Check

CALIBRATIONS
The calibrations of the measuring instruments of the test rigs were made before and after carrying
out the tests to each model with the purpose of guaranteeing that the measurements registered
during the same ones were within the allowed rank of uncertainty with which they were considered
like valid the obtained results of the tests. In case that differences greater had happened than those
of the defined systematic uncertainty in the procedure, in several points between the two
calibrations, the affected tests had been repeated at laboratory cost. The calibrations include:

Flow measurement

Specific Hydraulic Energy Manometer

Main Torque

Friction Torque

Suction Head Manometer

Axial Thrust Measurement

Rotational Speed Measurement

Dynamic Pressure Transducers
PRELIMINARY TEST
The preliminary tests consisted of measurements that the bidder made in the independent
laboratory in a way to verify the correct assembly of his model, in order to assure a smooth and
stable operation. The preliminary test results were not used like official test results.
OFICIAL TEST
Each Bidder has the opportunity to testify the official tests of its model, to be executed in the
independent laboratory.
The official tests included axial hydraulic thrust, efficiency, cavitation, pressure and torque
pulsations, with and without air admission, according to the established program.
Axial Hydraulic thrust
The axial hydraulic thrust tests were made for the speed factors of the model corresponding to the
net head for the prototype established in the tests procedure. The hydraulic thrust tests included
measurements from 20% to the guide vanes maximum opening in increases of 1 to 2 for each head
of test.
The model axial hydraulic thrust value turned to the corresponding prototype value, was compared
with the guaranteed axial hydraulic thrust of the prototype like with the maximum indicated
acceptable value in the Technical specifications in agreement with the capacity of the existing
bearing.
Cavitation
The cavitation tests were made for the speed factors of the model corresponding to the net head for
the prototype established in the tests procedure, and in the number of required points to determine

the values of the cavitation margin for the average weighed efficiency test points required in the
Technical specifications and to confirm the guaranteed cavitation limits.
During the cavitation tests the oxygen content dissolved in the water was measured constantly with
the intention of maintaining it within 2 to 5 ppm.
An expert in cavitation of the independent laboratory personnel made the visual observations,
documentation and evaluation (sketch and written documentation) of the cavitation behavior for
both models. The interpretation and official evaluation of the cavitation behavior of the expert in
cavitation were presented by sketch, drawings and written documentation.
The sigma break curves were done ( - ). For each sigma break curve the behavior of the
cavitation was observed at sigma plant, to check the presence of cavitation bubbles in the runner.
The critical sigma, for the determination of the cavitation margin for these Contracts, was sigma 1,
according to defines IEC 60193, Clause 1.3.3.6,9, page 37. The number of Thoma one (Sigma 1) is
equal to the value of the Thoma number for which a fall of a point of percentage in efficiency is
obtained compared with the efficiency to the Thoma zero number, see Figure 3
The test report of the model showed the cavitation margin available ((sigma plant - sigma 1) x net
head) for each test head and power output, expressed in meters of water column between the down
stream level corresponding to sigma the 1 and minimum down stream level corresponding to the
cavitation limit. The cavitation margin must be equal or greater to the established one in the Biding
document for all the points within the continuous operation range of the turbine.

Figure 3.- Graphic definition of Sigma 1

For all the sigma plant values it took place sketch of the cavitation patterns and the runner vortex. A
stroboscope and boroscope was settled in the model to allow the inlet cavitation observation in the
critical points of operation.
The cavitation occurrence in the pressure side and in the suction side, the formation and
disintegration of vortex at low load were located, analyzed and registered in terms of the
corresponding operation conditions.
Efficiency, power and flow
The efficiency tests of the turbine model were made with the speed factors of the model
corresponding to the following net head for the prototype established in the tests procedure; and at
the minimum down stream levels (minimum sigma plant) corresponding to each one of the points
included in the turbine efficiency, power output and flow guarantees. The tests to each net head

included guide vanes openings from 20% to the maximum opening, made in the points required for
the preparation of the efficiency curves specified and hill diagram to be provided for the prototype
turbine.
In order to check the stability of the measurement, a test point near to the peak efficiency was
repeated several times every day during the efficiency tests. The maximum deviation of the result
was lower than 0.10% of the efficiency, in agreement with the Annex L of IEC 60193.
The water temperature of the model was maintained within 1C for each test of efficiency, and the
variation in the water temperature was maintained within 2C for the tests of all the models.
Pressure and torque fluctuations
The pressure pulsations tests were made for the speed factors of the model corresponding to the
established prototype net head in the tests procedure. The pressure and torque pulsations in the
corresponding shaft were measured between a 20% guide vanes opening until the Maximum
opening, in increases of 1 for each head of test.
The pressure and torque fluctuations were measured to determine their frequencies and amplitude.
The tests were made with the admission of variable amounts of air through cone of the runner, in
order to reduce the fluctuations.
The air admission tests were made for the speed factors of the model corresponding to the
established prototype net head in the tests procedure, and the points selected according to the
obtained results of the tests without air admission. The admission of the air was measured with a
measurer of volume (device of floating element) like a percentage of the water volume.
Dimensional check
Before beginning the installation of the model in the independent laboratory, the geometry of the
two sections of measurement, upstream and down stream, as well as the gaps of the runner seals
(length and radial gap of the seals) were checked.
After completing the model tests a detailed dimensional check of the new and modified components
of the model was made (excepting the profiles of the runner), in the presence of CVG EDELCA and
the corresponding Bidder of each turbine model, to confirm that each model on scale will be
homologous to the rehabilitated prototype and to confirm that the models of each Bidder were
geometrically within the limits of Code IEC 60193.
UNCERTAINTIES MEASUREMENT
For determination the individual uncertainties of the main parameters characterizing the hydraulic
performance were considered the following:
ASTR:
Flow
a) Calibrating tank 0.04%
b) Error in density of water, presumably
c) Calibration of Venturi tubes 0.15%
fQS =

a2 + b2 + c 2 =

0.163%

0.05%

Net Head
a) Dead weight tester 0.022 %
b) Calibration 0.100 %
2
2
f HS = a + b = 0.102 %
Torque:
a) Length of lever arm 0.02%
b) Calibration of test weights 0.01%
c) Calibration of force measuring device
2
2
2
f TS = a + b + c =
0.102 %

0.10

Speed
fnS = 0.02
Density of water
f W =
0.05
According to the definition of the efficiency the systematic uncertainty of the efficiency is
composed of the individual errors of flow, head, torque, speed and water density:

fS = fQS2 + fHS2 + fTS2 + fnS2 + fW 2 =

0.224 %

According to IEC 60193 code the random uncertainty must be limited so that in the higher
efficiency region does not exceed:
fR =

0.10

This is the value that will be used in all of the measurement uncertainty calculations.
The total uncertainty of the measured efficiency hence is:

fTOT = fS + fR =
2

0.246 %

EPFL:
Flow
a) Calibrating tank 0,09%
b) Error in density of water, presumably 0,05%
c) Calibration of electromagnetic flow meter 0,1%

fQS = a2 + b2 + c 2 = 0,14% (Q=0,2 -1,4m3/s)

Specific Hydraulic Energy
a) Pressure gauge 0,08%
b) Calibration 0,1%
2
2
f HS = a + b = 0,13% (E=50 1000 J/kg)
Torque:
a) Length of lever arm
b) Calibration of test weights
c) Calibration of force measuring device
2
2
2
f TS = a + b + c =
Rotational speed:

0,03%
0,02%
0,1%
0.106%

fnS = 0.01%
Density of Water:
f W =

0.05%

According to the definition of the efficiency the systematic uncertainty of the efficiency is
composed of the individual errors of flow, head, torque, speed and water density:

fS = fQS2 + fHS2 + fTS2 + fnS2 + fW 2 =

0.226 %
According to IEC 60193 code the random uncertainty must be limited so that in the higher
efficiency region does not exceed:
f R =

0.10

This is the value that will be used in all of the measurement uncertainty calculations.
The total uncertainty of the measured efficiency hence is:
fTOT = fS + fR =
2

0.247 %

PERSONNEL
In addition to the participant personnel of each one of the laboratories and of the Bidder, the tests
counted with the presence of external consulters and by CVG EDELCA the personnel of the
Mechanical Projects Department, Plant Guri Modernization Project and the Applied Research
Center.
CONCLUSIONS
In the present article have been shown relevant aspects of the experience of the technical mission
sent by CVG EDELCA to testify and to lead the process of tests that was carried out in physical
models corresponding to the manufacturers selected by CVG EDELCA for the manufacture and
provision of new hydraulic components for the rehabilitation of Guri turbines.
In this process it allowed to the technical personnel of CVG EDELCA:

To deeply know and evaluate the models of the runner proposed for the solution of the
problems that at the moment present the Francis type hydraulic turbines of Guri
Hydroelectric Complex.

To select the manufacturers who fulfilled in their proven design with the technical
requirements of the guarantees specified by CVG EDELCA.

To evaluate before the manufacture of the new runners, its behavior in all the range of
operation of the generation units.

To obtain experience testifying and leading of the process to be used in next model tests to
be developed by CVG EDELCA.
REFERENCES
[1] Procedimiento para Pruebas de Modelo (Enero 2004).
[2] Procedimiento para Pruebas de Modelo (Enero 2005).
[3] Norma Internacional IEC Publicacin 60193, Segunda edicin 1999-11.
[4] Pliego de Licitacin del Contrato No. 2.2.102.003.00 de CVG EDELCA.
[5] Pliego de Licitacin del Contrato No. 1.1.102.012.01 de CVG EDELCA.