Overview on Pump Turbine Technology Technology Seminar, Brasilia, November 2014 Peter Magauer, Vice President Global Sales Turbines ANDRITZ HYDRO Gmbh, Ravensburg, Germany 05/2012 2 The copyright of this document and all attachments remains with the company Pump Turbine Technology Presentation Content Hydropower as Integrator in the future Renewable Energy Mix Europe: new EU targets 2030 for renewable energy Increasing demand in new markets Changing requirements for the equipment, design criteria The classical Pumped Storage solution: Fixed speed single stage reversible units Special configurations Variable Speed Applications Ternary sets, Hydraulic short circuit Multi Stage Pump Turbines Sea Water Pumped Storage
Transcript
Overview on Pump Turbine TechnologyTechnology Seminar, Brasilia, November 2014Peter Magauer, Vice President Global Sales TurbinesANDRITZ HYDRO Gmbh, Ravensburg, Germany
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2 The copyright of this document and all attachments remains with the company
Pump Turbine TechnologyPresentation Content
Hydropower as Integrator in the future Renewable Energy MixEurope: new EU targets 2030 for renewable energyIncreasing demand in new markets
Changing requirements for the equipment, design criteria
The classical Pumped Storage solution: Fixed speed single stage reversible units
Special configurations
Variable Speed Applications
Ternary sets, Hydraulic short circuit
Multi Stage Pump Turbines
Sea Water Pumped Storage
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Pump Turbine TechnologyGlobal Trend, EU targets
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The EU states have defined their2030 targets
Hydro generation (+8% in 2010-2020) and Pumped storage (pumping +35% in 2010-2020) will remain importantfor energy security
e.g. Portugal: Wind & Hydro expansion plan reconfirmed
New EU Targets 2030Renewables-Electricity >50%!
40% 27% 27%
Global Trend to increase share of Renewable Energy
� Presently 16% of world electricity generation is renewabl e, mainly Hydro
� Wide operation range Francis, Pump TurbinesStability over a wide range Pump Turbines
� Fast changeover times Pump Turbines
� Safe Operation, robust design All Hydro Turbines
� High efficiencies All Hydro Turbines
� Cost optimized dimensions/design All Hydro Turbines
� Environmental aspects All Hydro Turbines
Pump Turbine TechnologyMultiple requirements for Hydroelectric equipment
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� Much more part load operation� Much more Start-Stop events� Dynamic stresses drastically
increased
CFD / FEM AnalysesVerification by prototype measurementsEstimation of lifetime for criticalcomponentsInvestigations currently for all 4 turbine types
Frequent Start – StopsOperation over full range
Measured blade stress
Startup/SNL full load SNL
Pump Turbine TechnologyEquipment Requirements
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Research on Unsteady Phenomena in Pump turbines
Pump stability at high head� Drop of head-flow characteristics at high
heads� Unstable operation or start-up possible ?
The behavior will be stable for a negative slope of the characteristic curve at the operating point, but for a positive slope the behavior will be unstable.
From P. Dörfler, M. Sick, A. Coutu. Flow-Induced Pulsation and Vibration in Hydroelectric Machinery. Springer Verlag (2013). Chapter 6.4.2
Pump Turbine TechnologyEquipment Requirements
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Layout always is a compromise between several aspects� High efficiencies over a wide range� Safety against cavitation damage� Dimensions and geometry favourable for manufacturing and c ost� Impact on civil works (dimensions, setting level)� Stability� Robustness
Tender processes are often focussing on cost and efficiency
Especially on Pump turbines, Robustnessis crucial.
What is the incentive for robust solutions?
(e.g. adjustable wicket gate bearings ����
low vibrations)
Pump Turbine TechnologyEquipment Requirements
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Pump Turbine TechnologyThe classical concept
Single stage, reversible,fixed speed Pump Turbine
Pump starting with SFC in dewatered condition
Often with Synchronouscondenser mode(Labyrinth cooling!)
Earlier NowDay / Night FrequentCycle part load
Changeover times 7-8 min 5-6 min(Fast changeover PUMP � TUR ~ 90 sec
very rough condition!)Double peak test
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avoid:
pit diameterreduction needs a split headcover
(not valid for middledismantling)
include:
prestressed bearings
include:
partly concrete around draft tube cone
avoid:
breakingelements
include:
segment type radial bearing
include:
access to lower wicket gate bearing
include:
axial hydrostaticshaft seal
Typical design features for a reversible Pump turbine
Prefer:
Individual servomotors forGuide vanes
Pump Turbine TechnologyThe classical concept – Design features
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2) Utilize very high heads (> ~700m)- Two stage regulated pump turbine- Multi stage pump turbine
3 Exploit additional project sites- Sea Water Pumped Storage
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Pump Turbine TechnologySpecial concepts
Variable Speed unit with
Full Size Converter
Ternary Set (2 x 180 MW Obervermunt II)
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max. head
min. head
max. speed
min. speed
cavitation limit,high pressure side
cavitation limit,low pressure side
stability limit
Variable speed unitshave a substantiallywider operating rangeboth in Turbine andPump mode
BUT: Even with FullSize Converter,- Hydraulic limits have
to be considered(cavitation, stability)
- High flexibility effectonly with regulatedturbines (wicketgates and speed)
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Pump Turbine TechnologyVariable Speed Units
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� In operation since 2002� 4x 265 MW Reversible Pump-Turbine units� 2 units with variable speed� Advantages:
� regulation of pump power � fast dynamic response times� higher efficiency for variable head
Example Goldisthal, Germany
Pump-Turbine common design and supply by
Andritz Hydro & Voith
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Double fed
Asynchronous
motor generators by
Andritz Hydro
Pump Turbine TechnologyVariable Speed Units
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Maximum flexibility byHydraulic Short Circuit
to tailwater
Hydraulic short circuitPartly to tailwater, partly to pump
To and from headwater
Hydraulic short circuitPartly to headwater, partly to turbine
from tailwater
Example: Kops II / Austria
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Both for Vertical and and horizontal shaft arrangement
Geesthacht / Germany –since 1997
Pump Turbine TechnologyTernary Units
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Kops 2, AustriaUnique Ternary concept
Pressurized downstream chamber
In operation since 2009
3 x 200 MVA / 180 MW Tu / 150 MW Pu500 rpm
Full load in 20-30 s (Tu and Pu mode)
> 8000 operating hours / year!
Pump Turbine TechnologyTernary Units
Typical operation curve over 12hoursPUMP
TUR
Hydraulic TorqueConverter allows maximum flexibility
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Two stage reversible units: 2 regulated distributors����flexibility in turbine modeFor heads < 1000m Smaller dimensions thanternary sets
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Pump Turbine TechnologyMulti Stage Units
Shop assembly in theRavensburg workshop
Nestil, Switzerland
Customer: AXPO (former NOK)
1 four stagereversible
Pump turbine, MIV,motor generator
P = 130 MW
H = 1062 m
n = 600 rpm
Contract year: 2005
For high headsNo part load operationFlexibility only ifcombined in a ternary set
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Projects are promoted with sea water PSP. One pilot plant in Japan exists.
PRO CONTRA
Saving of Downstream Reservoir Stainless steel for many tu rbine partsAdditional sites possible Austenitic steel - Lower blade
strength ���� bigger unitNo evaporation problem Corrosion resistant penstock
Gates subject to high corrosionProjects in dry hot , areas will anyway Salt water in h eadpond may createneed desalination or salt content grows environmental problems
Marine life in water circuit (cooling)Increased maintenance & repairCathodic protection system
Substantial additional cost !
We consider the economic benefit of sea water PSPs question able
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Pump Turbine TechnologySea water applications
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Main Presentation TitleSummary & Conclusion
� Hydroelectric power will play an important role in a future renewable enegry mix
� Storage Hydro and Pumped Storage provide the necessary re gulating power
� Additional requirements for the equipment become more imp ortant
� Flexibility and fast load changes are particularly import ant for pump turbines
� Actual market for PSP in Europe is low, increasing d emand in growing
economies
� A variety of special solutions allow faster regulati on and additional potential sites
� ANDRITZ HYDRO is well prepared for future Pumped Storage opportunities
Thank you for your attention !
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