MECHANICAL DESIGN AND OPERATION OF HPP

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MECHANICAL DESIGN AND OPERATION OF HPP

Ferrara – November 15 2018


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How the discharge affects the design of HPP?

Turbine type for specific HPP

A simple tool for Hydro Power Plant design

Low head turbines

Francis turbines

Pelton turbines

Scada system

Gates

Example

Lesson program


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*only on electromechanical equipment

Technical aspects *:

Economic aspects :

Type of turbines Major dimension Efficiency of turbine Energy production

Energy production Cost of equipment Investment profitability

How the discharge affects the design of HPP?

Environments aspects: Maximize the exploitation of the

hydraulic potential of the water resources


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Design data for a HPP

H: Net head [m] Q: Design discharge [m3/s]


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Q: Flow duration curve


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!Net head in low head HPP is very important!

H: Head duration curve


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H: Head duration curve


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-N° of turbines? -Type of turbines? -Q design?

Different flow duration curve


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Total energy in a year

Principal dimension and NPSH

Total cost of equipment

NPV and IRR Tch

nic

al

asp

ects

E

con

om

ic asp

ects

Specific speed

Total earn of HPP

Multiobjective method


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Multiobjective method: result – curve 1


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Technical aspects :

Design data

Type of HPP

Major dimension

Efficiency of turbine

Reliability of HPP

Turbine type for specific HPP


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Large hydro turbines

Low impact of cost of turbine

High efficiency

Pelton turbine 5 jets

H= 1870m

Q=25mc/s

Dp=3993m

N=428.5 rpm

P=423MW

Andritz Hydro


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Small hydro turbines

High impact of cost of turbine

Good efficiency

Simple construction

Pelton turbine 4 jets

H= 146m

Q=2mc/s

Dp=0.7m

N=600 rpm

P=2.2MW

Tamanini Hydro


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Pelton turbine design

Feasibility study

Q , H

Principal dimensions of turbine

Customer needs

Francis - Kaplan turbine design

Feasibility study

Q , H

Principal dimensions of turbine

Costumer need

n n N° Jets

How to choose a turbine


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Turbine type diagram


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Low head turbines


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Typical layout


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Typical layout


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• Single regulated

• Double regulated

• Fixed

• Direct-coupled

• Gear box - belt

• PMG e variable speed

Configuration of low head turbines


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Single regulated

Double regulated

Fixed blade

Low head typical efficiency

0

10

20

30

40

50

60

70

80

90

100

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6

Efficiency%

Q/Qmax


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+ - -

Efficiency Operation Capex

Direct-coupled

• Specific speed (Q/H)

• Velocity / n° poles

• Generator capex


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- + +


Gear box/Belt

-Specific speed(Q/H) -Velocity / n°poles -Generator capex


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+ - +-


PMG variable speed

-Velocity / n° poles -Generator capex

BP


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In low head HPP must pay particular attention the design of the intake and the draf tube

The loss of net head is the principal cause of malfunction


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Francis turbines


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Typical layout Vertical axis

Horizontal axis


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Francis typical efficiency

Low speed Francis

High speed Francis

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40

Efficiency[%]

Q/Qnom

K<=0.4 K<=0.5 K<=1 K<=1.5 K<=2.0


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Pelton turbines

Tecnohydro de Guatemala


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Typical layout

Vertical axis Horizontal axis

6 jets 5 jets

4 jets 3 jets

2 jets

1 jet


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Pelton typical efficiency

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

0.00 0.20 0.40 0.60 0.80 1.00 1.20

Efficiency[%]

Q/Qmax

Pelton1J Pelton2J Pelton3J Pelton4J Pelton5J Pelton6J


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SCADA SYSTEM


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SCADA SYSTEM


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SCADA SYSTEM


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SCADA SYSTEM


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RADIAL GATES: Commonly used for Spillway and River Barrage

MACCHERONIS SPILLWAY RADIAL GATE 15X12m

ABU SUKHAIR RIVER BARRAGE RADIAL GATE 12x8m

-SEE FARAHANTSANA PLAN VIEW -SEE VRANDUCK PROJECT RADIAL GATE ASSEMBLY


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FLAP GATES: Commonly used for River Barrage

SAN PELLEGRINO – FLAP GATE 11,5X2m


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SLIDING OR FIXED WHEEL GATES: used at water intake

VRANDUK HPP – INTAKE SECTION


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SLIDING OR FIXED WHEEL GATES: used at dam bottom outlet

RAVEDIS DAM – BOTTOM OUTLET

KARAHNJUKAR DAM BOTTOM OUTLET


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BUTTERFLY VALVES: tipically used as penstock protection or turbine inlet

LOS NEGROS BUTTERFLY VALVE DN3000 PN6


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SPHERICAL VALVES: tipically used as turbine inlet valves

MONTEBELLO SPHERICAL VALVES DN700 PN45


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HOWELL BUNGER VALVES: tipically used as free flow discharge


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Example


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Portata massima Q=3.900 mc/s


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Caduta idrica disponibile lorda 450m

Caduta idrica disponibile netta a Qmax 436m


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Numero macchine stabilite 3

Caduta idrica disponibile netta a Qmax 436m

Portata di progetto singola macchina 1300 l/s


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Q , H

0.5

0.7530 ( )

n Qk

gh

0.96 0.98u

0.88 0.90id

2

idu

u

k

2.1 2u uk iD

d k

10 14D

d

n

i

1 2uc gH

1

4 Qd

i c

2uu k gH

60 uD

n

Flow chart for feasibility study of a Pelton turbine


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Generatore


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2 Getti orizzontale

np Ngiri Omega Ngetti K Ns C1 d u Dp D/d Z B2 D/B2

[giri/min] 2 [m/s] [mm] [m/s] [mm] [mm]

10 720.0 75.40 2.00 0.16 20.79 90.68 94.05 43.49 1153.6 12.3 21 300.97 3.83

n poli n giri Potenza Peso Gir Forza t 1g Forza t 2g 90° Numero f bocchello Corsa Angolo sp Angolo bocc Spinta molle N molle

[rpm] [kVA] [kN] [kN] [kN] [mm] [mm] [°] [°]

10.00 720.00 0.960 5857.69 18.72 56.12 79.37 2.00 120.39 120.39 50.00 90.00

D/b Rho/B B2 altezza profond. Rho pala Diametro Cassa DN Valvola PN Valvola DN curva 1g DN curva 2g DN curva 3g DN curva 4g DN curva 5g

[mm] [mm] [mm] [mm] [mm] [mm] PN [mm] [mm] [mm] [mm] [mm]

3.83 0.36 301.00 258.65 84.65 108.65 2846.53 731.27 25.00 566.44 400.53 327.04 283.22 253.32

Dati palettatura

Dati generatore

Curva

Iniettori

Valvola

Macchina scelta


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Vivier, 1966

Nechleba, 1957

B2=(2.6÷3) d0

B2=(2.8÷4) d0

L=(2.25÷2.8) d0

L=(2. 5÷2.8) d0

Pr=(0.8÷1.3) d0

Pr=0.95 d0

B1=(1.2÷1.25) d0

B1=1.2 d0 + 5mm

y=(0.9÷1.2) d0

2 0<3.4B d

Lo Presti, 1922

Rubbo, 1957

B2=(3.5÷4) d0

B2=(3.5÷4) d0

L=(2.45÷2.8) d0

L=(2.5÷3) d0

Pr=(0.9÷1.2) d0

Pr=(0.9÷1.2) d0

Büchi, 1957

Zacchè, 1999

B2=(3.5÷4) d0

B2=(3÷4) d0

L=(0.8÷0.85) B2

D1/B1>2.8

Pr=(0.25÷0.3) B2

De=D1+1.1B2

De=D1+3.5d0

B1=(5÷10)mm+ d0

e=0.056 B2

x=0.4714 B2

2 03.4 <3.8B d


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MECHANICAL DESIGN AND OPERATION OF HPP

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