[email protected]1 Introduction of Technologically Advanced Modular Hydropower System for Pulangi IV Hydroelectric Plant ENGR. RUDY P. BRIOSO National Power Corporation-Pulangi IV Hydroelectric Plant Philippines SUMMARY The Philippine Archipelago is consists of three (3) main island grids, namely; Luzon, Visayas and Mindanao. The Department of Energy (DOE) have formulated methods to avert any problem in the power supply specifically in Luzon and Mindanao and these are: locating and making use of every capacity and energy available to the system; and revisiting the power development plan modeling and process. Although it was projected that for 2011, Mindanao Grid which basically comprise 50% hydro in the generation mix, would have a better condition that in 2010 since the current water level in the region is favorable for hydro plants but it still has thin reserve and short of 300MW. The power situation in Mindanao Grid can be address through capacity addition and the DOE is encouraging the participation of local and foreign investors, particularly those in the Renewable Energy (RE) business to consider the market potential and opportunities in the Philippines. For the Philippines’ National Power Corporation (NAPOCOR), a study was recommended sometime on 2005 through the auspices of the so called capacity recovery and improvement program in order to maximize the operational capability of its existing hydropower plants. For Pulangi IV Hydroelectric Plant, there were studies undertaken to further provide additional capacity, namely: 1. Uprating of the existing plant capacity by as much as 10%; and 2. Utilization of the existing potentials through the introduction of technologically- advance modular bulb turbine. Installation of the technologically advanced modular hydropower system provides an option for development of hydropower at low-head site condition with existing dam or gate structures. The low head modular hydropower system design utilizes a factory assembled grid or “matrix” of small propeller turbine-generators units. The system requires no major excavations, foundations, channel modifications, or civil works and therefore enables small hydroelectric power plants to be developed at investment levels below those normally required in some conventional hydropower plants. Since the turbine-generator units are shipped to site in pre-assembled condition, construction and start-up schedules can be reduced significantly. By using existing civil structures, this low head modular hydropower Oct.26-28, 2011, Thailand RE-05 CIGRE-AORC 2011 www.cigre-aorc.com
Hydropower System for Pulangi IV Hydroelectric Plant
ENGR. RUDY P. BRIOSO
National Power Corporation-Pulangi IV Hydroelectric Plant
Philippines
SUMMARY
The Philippine Archipelago is consists of three (3) main island grids, namely; Luzon, Visayas and Mindanao. The Department of Energy (DOE) have formulated methods to avert any problem in the power supply specifically in Luzon and Mindanao and these are: locating and making use of every capacity and energy available to the system; and revisiting the power development plan modeling and process. Although it was projected that for 2011, Mindanao Grid which basically comprise 50% hydro in the generation mix, would have a better condition that in 2010 since the current water level in the region is favorable for hydro plants but it still has thin reserve and short of 300MW. The power situation in Mindanao Grid can be address through capacity addition and the DOE is encouraging the participation of local and foreign investors, particularly those in the Renewable Energy (RE) business to consider the market potential and opportunities in the Philippines. For the Philippines’ National Power Corporation (NAPOCOR), a study was recommended sometime on 2005 through the auspices of the so called capacity recovery and improvement program in order to maximize the operational capability of its existing hydropower plants. For Pulangi IV Hydroelectric Plant, there were studies undertaken to further provide additional capacity, namely:
1. Uprating of the existing plant capacity by as much as 10%; and 2. Utilization of the existing potentials through the introduction of technologically-
advance modular bulb turbine. Installation of the technologically advanced modular hydropower system provides an option for development of hydropower at low-head site condition with existing dam or gate structures. The low head modular hydropower system design utilizes a factory assembled grid or “matrix” of small propeller turbine-generators units. The system requires no major excavations, foundations, channel modifications, or civil works and therefore enables small hydroelectric power plants to be developed at investment levels below those normally required in some conventional hydropower plants. Since the turbine-generator units are shipped to site in pre-assembled condition, construction and start-up schedules can be reduced significantly. By using existing civil structures, this low head modular hydropower
system installation requires little or no additional land area and has the potential to minimize environmental impact, particularly during construction phase.
CONCLUSION/RECOMMENDATION Recent study by the Philippines’ Department of Energy (DOE) revealed that the island of Mindanao has a thin power reserved for 2010 and will experience shortfall of capacity if there will be no new power plants will be installed. Although there are two (2) hydro projects committed for Mindanao for 2010, there is a need for the government to step up its effort and encourage private investor in putting up the needed capacity. If the Philippine Government through the Public Private Partnership (PPP) will push for the installation of state-of-the-art technologically advanced modular hydro power system which is expected to provide an incremental capacity of 16MW which could translate to all additional annual energy generation of about 71.48 GWH of cheaper source of power to the Mindanao Grid.
CONTRIBUTION OF THE PROPOSED MODULAR TYPE HYDROPOWER TO MINDANAO
GRID The modular type hydropower will provide an incremental capacity of 16 MW which could translate to an additional annual energy generation of about 71.48 GWh of cheaper source of power to the Mindanao Grid. DOE’s Philippine Energy Plan (2007-2014)
TECHNICAL DESCRIPTION The power generation of the existing Pulangi IV Hydropower Plant is conveyed through a 9-km open channel which carries discharge capacity of 276 cms. Reservoir levels vary within the range from 283.0 m and 285.0 m, while water level in the canal varies between 276.0 m and 277.0 m. This gives rise to gross heads in the range of 6.0 m to 9.0 m. Using the flow into the canal a new hydro generating capacity of up to about 16 MW could be considered. One of the new technologies being developed is an integrated turbine generator to produce electricity economically in a free flow environment that operates at lower speeds and does not require high head or pressure. These turbines can use the flow of water coming from the existing facilities of Pulangi IV HEP, thus generating additional electricity. The low head turbine technology makes it possible to utilize existing dam structures without making major changes to the surrounding structures. See Figure 5.1: Figure 5.1: Modular Hydropower Plant Application Range and Figure 5.2: Cross Section of a Modular Hydropower Plant (Sample).
The installation of modular low-head turbine will inquire no major excavations, foundations, channel modifications, or civil works. This technology may therefore enable small hydroelectric power plants to be developed at investment levels below those normally required in conventional hydropower plant. Also, construction and start-up schedules can be reduced significantly. In addition, this type of hydropower development requires little or no additional land area and has the potential to minimize environmental impact, particularly during the construction phase.
1. PROJECT LAYOUT AND DESIGN 1.1 General The existing Pulangi IV power station has a long-term average plant factor of about 55%, but the proposed low-head modular power facility, which will essentially utilize the same flows as the main plant, is expected to have lower plant factor due to the variation in head under which it will operate. Assuming an average head of 8.0 m and an installed capacity of 16 MW, the plant factor would be around 51% and the annual energy production should be around 71.48% GWh per year.
Figure 5.1
Modular Hydropower Plant Application Range
Figure 5.2
Cross Section of a Modular Hydropower Plant (Sample)
1.2 Access Road The proposed modular project shall similarly use the existing road access to the dam site and water diversion facilities. 1.3 River Diversion Construction No major river diversion works will be required for this construction. A simple half-circular steel caisson, both at upstream and downstream side of the intake site, will be needed to keep water from the specific construction area. 1.4 Generating Units Given the range of heads and flows under which the scheme will operate, the most suitable and least-costly four (4) units turbine-generator per module (per intake) is considered. For the purpose of this assessment, a total of four (4) modules turbine-generator sets will be installed in four (4) intakes utilizing some 8.6 m net head. 1.5 Transmission Line and Interconnection Generation output will be conveyed via a new 9.5 km long x 69 KV transmission line to the existing sub-station adjacent to Pulangi IV powerhouse. The transmission line will follow the existing headrace canal over most of its length. The sub0station will be extended to accommodate the new incoming transmission line.
2. ENVIRONMENT AND SOCIAL IMPACTS The Pulangi IV Headrace Canal Intake hydropower facility is an efficiency enhancement rather than a typical greenfield construction project. The works could therefore be contained within the existing premises of the Pulangi IV property boundaries and the development can occur within the context of the environmental management plan of Pulangi IV HEP. Social impacts will also be minimal with a relatively small amount of workforce required for a limited duration. Since the total power production capacity is greater than 5 MW but less than 30 MW, an Initial Environmental Examination (IEE) Report is required to support the Environmental Compliance Certificate (ECC) application and the processing will be performed by the concerned Department of Environment and Natural Resources (DENR)/Environmental Management Bureau (EMB) regional office.
PROJECT COST The estimated total project cost is equivalent to P 1,404.99 million (exclusive of price contingency & interest during construction) or equivalent of US$ 28.67 million in foreign currencies. The cost includes the supply and installation of major electro-mechanical equipments and auxiliary equipment; civil works; transportation; insurance; engineering and supervision; and physical contingencies.
All costs are expressed in August 2009 level at an exchange rate of P 49.0/US$. The project cost is further broken down as follows:
Table 7.1
Cost Estimate
In Millions . Forex Local Local US$ P M THB M
A. Preliminary and General Items 0.90 0.00 0.00 (Includes Mobilization and Pre-Con Cost) B. Civil Works 1.98 291.68 205.28 (Includes Intake, Control Station, Tailrace and Tailrace Bridge) C. Electro-Mechanical (E/M) Equipment 16.80 0.00 0.00 (Includes Power Station Equipment, Intake, Draft Tube and Transmission Facilities) D. Engineering and Administration 0.91 0.00 0.00 E. Physical Contingencies 1.41 35.00 24.63 (Civil Works 12% and E/M equipment 7%)
TOTAL 22.00 326.68 229.96
TOTAL IN US$ 28.67 Forex Rate 1 US$ = 49
KEYWORDS
Modular Bulb Turbine for Renewable Energy. State of the Art Technology Utilizing Hydromatrix
Short Bio-data of Main Author
Rudy P. Brioso received his master in Management from Asian Institute of Management in 1990. He also attended the Energy Management Program from Australia International Development Bureau in Australia, 1994. He is a Professional Electrical Engineer by profession and a Career Executive Service Officer. He joined the National Power Corporation in 1977 and was holding several key positions in its power transmission and the power generation functions of the Corporation. From 1991 to present he was tasked to managed Pulangi IV Hydroelectric Plant where he gained various expertise in the field of operations and maintenance of large hydro power complex.
INTRODUCTION OF TECHNOLOGICALLY-
ADVANCED MODULAR HYDRO POWER
SYSTEM FOR PULANGI IV HYDRO-
ELECTRIC POWER PLANT
RUDY P. BRIOSOPLANT MANAGER,
PULANGI IV HE PLANT
AORC Technical Meeting 2011–Chiang Mai, Thailand
INTRODUCTION OF TECHNOLOGICALLY ADVANCED MODULAR
HYDRO POWER SYSTEM FOR PULANGI IV HYDROELECTRIC
POWER PLANT, PHILIPPINES
•Philippine Power Profile
•Pulangi IV HE Plant Profile
•The Concept of Modular Hydropower System
•Advantages of Modular Bulb Turbine
•Application Criteria
•Design Criteria
•Peak Efficiencies of Modular Bulb Turbine
•Operational Features
•Project Layout and Design
•Impacts of Modular Hydropower System
•Environmental and Social Impact
•Project Cost
Oil-Based
Hydro
Geothermal
Coal
Nonconventional
Natural Gas
PHILIPPINE POWER PROFILE
•Hydroelectric plants make up about 20% of the total installed generating capacity in the Philippines.
• In 2005, Hydroelectric plants contributed about 15% of the total power generation in the Philippines.
Oil-BasedHydroGeothermalCoalRenewableNatural Gas
* Dept of Energy Philippine Power Statistics 2005
* Dept of Energy Philippine Power Statistics 2005
* The Philippine Energy Sector: “Three Years of Reforms”, Oct 2004
“Pulangi IV HEP is expected to deliver through plant enhancement programs.”
Agus & Pulangi Capacity
Enhancements
LARGE HYDROELECTRIC
PLANTS IN THE PHILIPPINES
Bakun A/C Hydro
70 MW
Binga Hydro
100 MW
San Roque Hydro
345 MW
Casecnan Hydro
140 MW
Pantabangan Hydro
100 MW
Magat Hydro
360 MW
Angat Hydro
245 MW
Kalayaan Hydro
300 MW
Kalayaan 3&4 Hydro
350 MWAgus 1 (Units 1&2) Hydro
80 MW
Agus 2 Hydro
180 MW
Agus 4 Hydro
158 MW
Pulangi 4 Hydro
255 MW
Agus 6 Hydro
200 MW
Agus 5 Hydro
55 MW
Agus 7 Hydro
54 MW
PULANGI IV HE PLANT PROFILE
• The largest single-operated HE plant in Mindanao in terms of Dependable Rated Capacity.
• The first Hydroelectric Plant in the country to be IMS Certified, certifiable on ISO 9001 (Quality), ISO 14001 (Environment) and OHSAS 18001(Safety and Health).
• A 255-MW Hydroelectric Plant and the 4th largestHydroelectric Plant in the Philippines
• Pulangi 4 contributes roughly 20% of HydroGeneration Mix for Mindanao Grid.
• In 2005-2010 data, it generated a total of5,106.189 GWH to the System.
• Average Production Cost for 2005-2010 wasPhP 0.358/kwh.
• On 2005, a study was made for the capacityrecovery and improvement program:
•Uprating proposals to attain 10% increase in the existing capacity;
•Introduction of technologically advanced modular bulb turbine.
Advantages
• Clean and environmentally friendly energy (KYOTO-protocol)
• Use of existing weir structures
• Standardize modular concept
• Compressed project schedule
• Modules removable at flood conditions
• Keep existing river flow pattern
• High availability
no major civil construction
no geological risk
no additional land usage
Concepts of Modular Bulb Turbine
Application criteria
• Available plant discharge from – 100 m3/s (3,500 cfs)
• Available head from 3 m up to 30 m (10 – 100 feet)
• Minimum submergence 1.5 m (5 feet) below tailwater
• Unit output from 200 kW up to – 800kW
• Close grid connection
• Structure available & suitable for HYDROMATRIX®
Concept of Modular Bulb Turbine
Application range
Cross Section of a Modular Hydropower Plant
Design Criteria
• Unregulated propeller turbine
• Direct driven induction generator
• Traditional hydraulic steel structure
• Mechanical face seal
• Roller type bearings
• Modular switchgear
• Flexible concept
• Minimum maintenance
Concept of Modular Bulb Turbine
Kaplan-type turbine with horizontal shaft, fixed guide vanes, fixed runner blades and a submerged
generator
Test Installation of TG - unit
Installation of TG units at Verona, Italy
Modular bulb
turbines installed
in matrix – top
view
Installation of TG units at Verona, Italy
Inlet structure
showing the
modular bulb
turbine installed
in matrix
Diversion
canal
Trash rack
Installation of TG units at Verona, Italy
Type Turbine Generator Total
Conventional Bulb 95% 98% 93%
Bulb Turbines 90% 95% 85.5%
Difference: 7.5%
Peak Efficiencies of Modular Bulb
Turbines
Potential Applications
Influences on Dam Structure
Civil works
Horizontal dam loads
Vertical dam loads
• Statical loads less than without HYDROMATRIX®
• Dynamical load identical
• Additional weight through modules
• Additional weight through new crane and trash rack
cleaning machine
• Anchors for guiding rails, supports and platforms
• Protection pipes, cable trays
Concept of Modular Bulb Turbine
Operational Features
Maintenance intervals
• According to maintenance schedule
Accessibility
• Easy access to all components without disturbance of
overall plant operation
Expected life time
• Identical to conventional hydropower concepts
Concept of Modular Bulb Turbine
Based on a study, assuming with average head of 8.0m and an
installed capacity of 16MW:
Layout and Design of Modular Bulb Turbine
•Plant factor would be around 51%;
•Annual energy production should be around
71.48% GWH per year;
Environmental Impact
•Proposed introduction of modular bulb turbine for Pulangi IV HE
Plant is an efficiency enhancement;
•Proposed bulb turbine installed in matrix is not a typical greenfield
construction project;
•Installation works is contained within the existing headworks weir
structure;
•Development is within the context of environmental
management plan of Pulangi IV HE Plant;
•Social impacts will also be minimal with a relatively small
amount of workforce;
Project Cost
• The cost includes the supply and installation of major electro-mechanical equipments
and auxiliary equipment; civil works; transportation; insurance; engineering and
supervision; and physical contingencies.
• All costs are expressed in August 2009 level at an exchange rate of Php 49.0/US$.
• The project cost is further broken down as follows:
Conclusion and Recommendation
•Based on a study conducted by NPC, the proposed installation of
modular bulb turbine is technically, economically and financially
viable hence, the implementation is worth undertaking.
•Financial sensitivity analysis was also conducted which also shows
that proposed installation of bulb turbine will be viable even if
subjected to 20% increase in cost or loss in energy generation.
•Modular bulb turbine is a feasible hydropower system,
