Turbine Testing Lab Kathmandu University

Dhulikhel, Kavre, Nepal

Detail Document

On

Floor and Tank Coating of Turbine Testing Lab

Prepared by

Ravi Koirala

Research Fellow, TTL

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

constructive solutionsFosroc Nitocote CM210

page 1 of 4

Elastomeric cementitious coating.

Uses

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 waterproofi ng.

Drainage culverts.

Podium slabs.

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

Standards compliance

Nitocote CM210 complies with:

BS 6920: 1990 Effect on Water Quality.

Water Byelaws Scheme approved, product listing

No. 0510522

DIN 1048: Water Penetration Test.

Fire Tested to BS 476: 1987 Parts 6 and 7.

UK potable water approvals

In the case of contracts requiring Water Byelaws Scheme certifi cation, 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 fl ushed with water prior to fi lling. The tank should be disinfected in accordance with local regulations before re-connection to the public water supply.

Description

Nitocote CM210 two-component polymer modifi ed cementi-tious coating is supplied in pre-packaged form. The product is designed to be easily mixed on site using a slow speed drill fi tted 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.

Specifi cation

The waterproofi ng 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 15°C for 6,000 cycles without failure. It shall have the capability to resist a positive water pressure of 5 bar and a negative water pressure of 2 bar when tested to ITM / FTM-181.

Properties

Typical properties of mixed material

Pot life at 20°C : 2 hours

Pot life at 35°C : 1 hour

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 fi lm 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

constructive solutions page 2 of 4

Fosroc Nitocote CM210

Dynamic crack1 accommodation capability 0 - 300 - 0 microns cycling after 28 days immersion (University of Surrey method) – 15°C : 6,000 cycles (no failure) 0°C : 6,000 cycles (no failure) -12°C : 6,000 cycles (no failure)

Abrasion resistance : Wear Index (ASTM D4060) (equivalent to 40 N conc.)

CO diffusion resistance (Taywood method) : > 50 m after 5,000 hrs QUV2

NOTE 1 : Nitocote CM210 will bridge an existing crack of up to 0.5 mm in width.

NOTE 2 : UV test required coating to be exposed to 4 hrs. condensation at 50°C followed by 4 hrs. UV light at 50°C. Total exposure time was 5,000 hours.

Instructions for use

Preparation

All surfaces which are to receive the coating, must be free from oil, laitence, grease, wax, dirt or any other form of for-eign matter which could affect adhesion. Typically, concrete surfaces can be cleaned using high pressure water jet or grit blasting. Spalled surfaces or those containing large blow-holes, cracks and other such defects up to 10 mm depth, should be repaired using Nitocote CM210. For further advice on suitable repair mortars for larger scale repairs, contact the local Fosroc offi ce.

Mixing

The liquid polymer (5 kg) is poured from the plastic container into a plastic or metal drum having a volume of at least 20 litres. To this, the powder is gradually added (18 kg) whilst mixing with an approved spiral paddle attachment on a slow speed drill. Mixing is continued until a lump free slurry is obtained. This should take a minimum of 3 minutes and a maximum of 5 minutes.

Application

Pre-dampen the substrate surface with water . High po-rosity substrates will require more dampening than dense substrates. Any condensation should be removed using a sponge. Any running water should be stopped with Renderoc Plug. Contact the local Fosroc offi ce for further advice on other suitable water stopping materials.

When the concrete surface is damp, apply the material using a trowel The fi rst coat should be applied at a minimum wet fi lm thickness of 1 mm (approximate coverage is 1.9 kg/m2) and should be well brushed into the surface.

Finish in one direction for a neat appearance. Application may also be made by roller, however it is recommended to fi nish the surface with a trowel for best results.

The fi rst coat should be allowed to cure for a minimum of 5 hours at 20°C or 3 hours at 35°C and longer at lower tem-peratures. The material should not be applied at tempera-tures below 5°C. All the mixed material should be used within 2 hours at 20°C or 1 hour at 35°C.

The second coat should also be applied at a minimum wet fi lm thickness of 1 mm and fi nished in one direction. Pre-dampening of the surface is not necessary when applying the second coat.

Spray application

For spray application the substrate should be prepared in the same manner as for trowel application and the material should again be applied in two coats. Each coat should be a minimum of 1 mm thickness. Allow a minimum of 5 hours cure at 20°C or 3 hours at 35°C between the fi rst and second coats, or longer at lower temperatures. For further details on the selection of spraying machines and nozzles consult the local Fosroc offi ce.

Disposal

Waste mixed material should be allowed to harden overnight then disposed of as non-hazardous waste.

Cleaning

Immediately after application is completed clean all tools and equipment with clean water. Hardened material can be removed by mechanical means and by use of Fosroc Solvent 102.

Limitations

- Nitocote CM210 should not be applied if the air or substrate temperature is greater than 45°C. This may result in different colour shades.

- Do not proceed with application when rainfall is imminent unless in a sheltered or protected location. The product should not be exposed to moving water during application.

- Nitocote CM210 should not be used on external surfaces where aesthetic appearance is critical as differences in cure/drying rate may cause slight colour differences in the fi nal surface.

page 3 of 4constructive solutions

Fosroc Nitocote CM210

- Nitocote CM210 should not be used for applications subject to direct contact of tidal marine conditions eg. sea wall defences, sea water inlet channels.

- If any doubts arise concerning temperature or substrate condi-tions, consult the local Fosroc Offi ce.

Technical support

Fosroc offers a comprehensive technical support service to specifi ers, end users and contractors. It is also able to offer on-site technical assistance, an AutoCAD facility and dedicated specifi cation assistance in locations all over the world.

Estimating

Supply

Powder component (grey or white) : 18 kg bags

Liquid polymer component : 5 kg container

Coverage1 (at nominal 1 mm thickness)

Brush, roller, trowel application : 10.8-11.7 m2 per 23 kg

Spray application : 9.0-11.7 m2 per 23 kg

NOTE 1 : A minimum coverage of 3.8 kg/m2 applied in not less than 2 coats is recommended.

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 classifi ed 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

Additional Information

Fosroc manufactures a wide range of complementary products which include :

Potable water retaining structures

Waterproofi ng membranes & waterstops.

Joint sealants & fi ller boards.

Cementitious & epoxy grouts.

Specialised fl ooring materials.

Fosroc additionally offers a comprehensive package of prod-ucts specifi cally designed for the repair and refurbishment of damaged concrete. Fosroc’s ‘Systematic Approach’ to concrete repair features the following :

hand-placed repair mortars.

spray grade repair mortars.

fl uid micro-concretes.

chemically resistant epoxy mortars.

anti-carbonation/anti-chloride protective coatings.

chemical and abrasion resistant coatings.

For further information on any of the above, please consult your local Fosroc offi ce – as below

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 specifi cation 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, specifi cation, recommendation or information given by it.

Fosroc Chemicals (India) Pvt. Ltd.Head Offi ce“Sapthagiri Palace”, No.38,II & III Floor, 12th Cross,CBI Road, Ganganagar North, Bangalore 560 024

page 4 of 4

www.fosroc.com

Fosroc Nitocote CM210

INDIA/2014/0827/A

telephone fax e-mail

++91 80-42521900 ++91 80-23551510 enquiryindia@fosroc.com

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