Assessment of Hydro Turbine Runner Manufacturing Capabilities in Nepal: Challenges, Opportunities, and Future Prospects

Nepal has a significant potential for producing hydropower, with an estimated 83000 MW of theoretical potential and about 42000 MW of economically viable hydropower. With this considerable potential and aiming to support sustainable energy development, Nepal has increasingly prioritized the domestic manufacturing of hydraulic turbines to reduce dependency on imports. This paper explores the feasibility and current status of 5 MW unit-size turbine manufacturing in Nepal, aligning with the country's needs for small and medium-sized hydropower projects. The manufacturing techniques of turbines, such as casting, forging, and CNC machining, are critically analysed. As per the Nepalese turbine manufacturers, production lead time can be reduced by 30% with the investment in advanced Computerized Numerical Control (CNC) machining tools and skilled human resources. Single-piece castings of up to 9 metric tons (MT) of cast iron and 4.5 MT of cast steel and stainless steel in weight can be produced by Metals Cast Pvt. Ltd. Additionally, in collaboration with other industries in Nepal, they possess the expertise to produce single-piece casting up to 25 MT. Nepal Hydro & Electric Limited (NHE) has a vertical lathe with a turning diameter of up to 4.5 m to machine turbine runners, highlighting the potential for localized hydro turbine manufacturing in Nepal. Nepal has imported around 70% of its small hydropower turbines, indicating a potential change through localization. To promote turbine manufacturing in Nepal, there should be reforms in existing policies, including subsidies for advanced manufacturing equipment and R&D. The general implications of the study are to provide techno-economic insights about the feasibility of scaling up local turbine production in Nepal for policymakers, investors, and manufacturers.