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Voith Hydro Hydro Power PlantsDr. Jiri Koutnik, 2013-11-04 AGCS, Munich
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1867 €5.7 billion
Sales
5Markets
42,000Employees
50In over
4.7 %
R&D ratio Family-owned since
Voith in figures
countries
Stand: 2011/12
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
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Energy
A quarter of all electricity generated by hydro power worldwide is produced with technologies and services from Voith.
Pumped Storage Plant
Run of River Plant Storage Plant
4AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
140 Years of Major Projects
1873 First Voith Francis turbine1903 First Pelton turbine1912 Niagara Falls, Canada1934 Pedreira, Brazil1938 Sungari, China1964 Roenkhausen, Germany1970 Raccoon Mountain, USA1995 First fish-friendly turbine design1997 Three Gorges, China1998 Goldisthal, Germany2000 Guangzhou II, China2010 Frades II, Portugal2011 Belo Monte, Brazil
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Flow Q and Head H are decisive for the power
OUT
IN
ηρ ××××= gHQP
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
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Head H is mainly influencing the turbine type
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Hea
d (
m)
100
1
10,000
100 10,000 1,000,000
Power (kW)
10 1,000 100,000
1,000
2,000
Pelton:
~200m to 2.000m
Francis
~50m to ~700m
Kaplan
~2m to ~50m
Bulb
~2m to ~20m
Pit ~2m to ~10m
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
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Head H is mainly influencing the turbine type
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Pelton
~200 m to 2,000 m
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Head H is mainly influencing the turbine type
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Francis (pump turbine)
~50 m to 700 m
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Head H is mainly influencing the turbine type
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Kaplan
~2 m to 50 m
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Head H is mainly influencing the turbine type
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Ohio River. Cannelton, USA
Bulb
~2 m to 20 m
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Complete Plant Systems Pump Storage Powerhouse using full 3D CAD Capabilities
12AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
History of hydro power turbines and pump-turbines
Paulo Afonso II(Brazil)
Gordon (Australia)
IIha Solteira(Brazil)
Three Gorges (China)
1960 1970 1980 1990 2000
800
700
600
500
400
300
200
100
50
0
Year
900
2010
Gokcekaya (Turkey)
Longtan (China)
Bath County(USA)
Guangzhou II(China)
Itaipu (Brazil/ Paraguay)
Dworshak(USA)
Xiao Wan (China)
Limberg II(Austria)
Ingula(S. Africa)
Xi Luo Du (China)
storage sets
turbines
Goldisthal(Germany)
Palmiet(S. Africa)
BHT(China)(in planning)
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History of hydro power generators and motor-generators
Bath County (USA)(2000)
Xi Luo Du (China)
900
800
700
600
500
400
300
200
100
0
Year
1000
GURI II (Venezuela)
Itaipu (Brazil)
Three Gorges (China)
Raccoon (USA) Bath County (USA)
(1976)
Water cooled
Air cooled
1900 1920 1930 1940 1960 1970 1990 2000 20101910 1950 1980
BHT(China)(in planning)
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
14AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Logistic Challenge: 400t Stainless Steel Runner
15AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Rotor Assembly – Precision with > 2000t
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Pumped Storage
• Wind, Solar and Hydro Integration
– Reserves
– Frequency regulation
Energy Frequency Storage
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Wind Production in Denmark in 2009
0
500
1000
1500
2000
2500
3000
3500
4000
MW
average(765 MW)
actual
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
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Major pumped storage projects of Voith Hydro
Aguayo
Bad Creek
Bath County
Cheongpyung
Coo II
Estangento
Ghatghar
Helms
Herdecke
Ingula
La Muela I
Limberg II
Mingtan
Mount Elbert
Palmiet
Rio Grande
Saeckingen
Samrangjin
Shi San Ling
Siah Bishe
Tai An
Tedorigawa
Castaic
Velebit
Waldeck I
Venda Nova II
Wallace Dam
Zhang He Wan
Guang Zhou II
Pan Jia Kou
San Giacomo
Wehr
Goldisthal Malta
Haeusling
Kops II
La Muela II
Fairfield
SenecaRacoon
Mountain
Muddy Run
Flat Iron
Smith Mountain
JocasseeRodund
Yang Zhou YongFrades II
Hong Ping
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
18AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Possible Unit Configurations Depending on Regulation Responsiveness and Grid Needs
• Conventional reversible unit
• Fast & frequent response reversible unit
• Conventional units in short circuit arrangement
• Variable Speed reversible unit
• Ternary unit arrangement
SlowerLess Flexible
FasterMore Flexible
19AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Pump Turbine time [seconds]T Mode change A B C D E
1 90 75 90 90 652 340 160 230 85 805 70 20 60 40 206 70 50 70 30 258 420 470 45 259 190 90 280 60 25
Mode change times for various Unit concepts -“Flexibility”
Standstill TU-Mode
Standstill PU-Mode
TU-Mode
PU-Mode
PU-Mode
TU-Mode
SC-Mode
SC-Mode
PU-Mode
TU-Mode
Reversible PTA – advanced conventional B – extra fast response conventionalC – VarSpeed, Ternary setD – with hydraulic torque converter + hydr. short circuit, horiz, with Francis TurbineE – same as E but vertical with Pelton Turbine
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Time [sec] 20 15 10 5 0
[p.u
.]
1.1
1
0.9
0.8
0.7
0.6
0.5
0.4
0.3
[mw
c]
230
220
210
200
190
180
170
160
150
rotor speed
GVO
Spiral case pressureactive power
DC link voltage
Fast control of var. speed units Effect on water hammer
TVA PS Forum | 2011-09-13 | 34 AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
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Start up – Pump Turbine
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
1 min
22AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Ancillary Services of Conventional and Pumped Storage Power Plants
• Frequency regulation
• Voltage / Power Factor control
• Load Following
• Reduced system minimum loading (i.e. many base load units run below minimum load; resulting inefficiency and voltage & frequency problems)
• Black Start capability
• Regulation Up (in the generating direction)
• Fast Regulation Up & Down with variable speed pumped storage power plants (in the generating and pumping directions)
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The Voith Hydro Policy for Plant Operational Safety
24AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Objective and goals
The Voith Hydro Safety Policy is deduced from the idea of Engineered reliability.
The goal of this policy in Voith Hydro is to sustain highest protection of:
• Human lives
• Environment
• The capital investment of our customers
25AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Basic philosophy
One major failure tolerant in areas with high energy flow or where the loss of
protection is not acceptable.
Voith Hydro requires for emergency situations and/or in case of failure of
one safety element a second
countermeasure.
Safe region Unsafe / hazard region
Tolerable risk region Non-tolerable risk region
Risk
Start of the non-tolerable risk region
26AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Risk reduction process
Assess and document all risks
Eliminate or reduce risk by inherent safe design measures
Install necessary protective systems
Inform owner about residual risks
Step 1
Step 2
Step 3Step 4
Ris
ks
Project life cycle
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Hydro power plant – water ways
T
G
12
3
4
5
6T
G
12
3
4
5
6
Plant safety –water closing devices
1. Gate or roller stop log
2. Gate or butterfly valve
3. Butterfly valve or spherical valve
4. Distributor or nozzles
5. Gate or stop log or butterfly valve
6. Gate or stop log
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
28AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Hydro power plant
Example of 1 major failure tolerance in the water ways.→ Minimum requirement of two closing devices.
Complete failure of the distributor
Cutting the water flow via inlet valve (2nd measure)
29AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Hydro power plantExample of 1 major failure tolerance in the power train.
→ Minimum requirement of two circuit breaker levels, for interrupting each current -even in short circuit condition.
Generator breaker failure
Grid breaker opens(2nd measure)
HV transmission line
30AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Example of penstock buckling
Safety Policy requires redundant aeration valves or natural aeration for the penstock.
After a penstock pressure test the valve for the penstock dewatering has been opened. Either the aeration valve was not able to open or it was too small designed.
The same accident happens, if an emergency valve in the upstream section closes and the aeration valve does not open.
Source: From a publication of Vattenfall Europe (former HEW): „Strom vom Strom – 40 Jahre Pumpspeicherwerk Geesthacht“.
31AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Basic philosophy
VH requires in special cases also a mitigation system in order to limit the damage extent. Penstock rupture and landslide in Scotland.
no intake gate
no emergency butterfly valve
Source: International water power and dam construction, Oct. 2006
32AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
Voith Hydro Safety Policy
Our Safety Policy is a crucial element in the supply of our products to owners and operators. Highest reliability and safety of our equipment safeguard capital investment of owners on a long-term basis and sustain the balance of state-of-the art technological standards with highest demands in this area. Technological, economical, environmental and social responsibility are incorporated in our values of engineered reliability.
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Contact:
Dr. Jiri KoutnikHead of Basic Development,Voith Hydro Holding, Heidenheim, [email protected]
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |