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NEW YORK POWER AUTHORITY

NIAGARA POWER PROJECT

RM SCALED MODEL OF A FRANCIS TURBINE WITH GENERATOR

SCOPE OF WORK

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TABLE OF CONTENTS

GENERAL ......................................................................................................................................... 2

BACKGROUND ................................................................................................................................. 2

SCOPE OF WORK ............................................................................................................................. 2

APPENDIX A – REFERENCE DRAWINGS ......................................................................................... 10

APPENDIX B – GENERATOR DIAGRAMS ........................................................................................ 14

APPENDIX C – PHOTOS.................................................................................................................. 19

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1. GENERAL

This scope of work establishes requirements and options for creating a miniature scaled model of a vertical Francis turbine with generator for the Niagara Robert Moses Power Plant (NRMPP) at the New York Power Authority (Authority). In addition, a digital 3D model and assembly/disassembly movie shall be developed to serve as an educational tool.

2. BACKGROUND

The Authority’s NRMPP is a hydroelectric generating facility located in Lewiston, New York, approximately 4.5 miles from Niagara Falls. It consists of thirteen hydroelectric generating units, each equipped with a vertical shaft, single runner Francis reaction turbine, and were designed jointly by Baldwin-Lima-Hamilton Corp. in Eddystone, PA and Newport News Shipbuilding and Dry Dock Co. in Newport News, VA. All thirteen units have undergone a performance upgrade in the early 1990’s which included new stainless steel runners and significant modifications to the stay ring and discharge ring.

The Authority is soliciting a proposal to build a scaled model that can be taken apart or have parts removed in order to teach, train, and demonstrate how major work or routine maintenance is conducted. The objective is to have a model than can be partially or fully disassembled and easily put back together to show the sequencing and processes behind the assembly and disassembly of these units.

The Vendor is encouraged to propose, as options, additional functionality not included in this Scope of Work (SOW) where these additions would benefit the Authority. Options thus proposed shall include sufficient supporting details and pricing to allow the Authority to fully evaluate the potential benefits of these options. Any proposed deviations from this SOW shall be handled in a similar manner, with a full explanation of the benefits of the proposed deviation.

Pertinent information about the main features of the turbine system and associated equipment descriptions are provided in Figure 1 and Table 1.

3. SCOPE OF WORK

A. Scaled Model 1. The Vendor shall provide all labor, material, software, and equipment required to

complete the specified work.

2. Scaled model will be 1/28 scale and shall include the following components. Components are numbered in accordance with Figure 1 and Table 1.

1 Rotor including rotor poles 3 Rim (Spider) 4 Stay Vanes 5 Stay Ring 6 Wicket Gates 7 Brush Rigging Assembly (Exciter) 8 Upper Bracket

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10 Stator Frame 11 Generator Shaft 12 Lower Bracket 13 Coupling (where generator shaft meets turbine shaft) 14 Turbine Shaft 15 Operating ring with servomotors 16 Guide Bearing 19 Spiral Casing 20 Runner 21 Draft Tube 22 Pit Liner

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DRAFT TUBE

PIT LINER

21

22

FIG. 1 - VERTICAL FRANCIS TURBINE WITH GENERATOR

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Table 1 – Component Description

# Component Description

I Rotor Poles Poles are built up of steel laminations riveted or bolted together under high pressure. Rotor poles are spaced around the rotor rim and are magnetized by direct current flowing in the turns of the field coil around each pole. Each unit is equipped with 60 poles. Diameter of the rotor is 408.2”.

2 Pressure Plate Holds the stator core laminations.

3 RIM (Spider) The spider is the main structural piece of the rotor and is what connects the shaft and the rotor poles. The spiders used in the Robert Moses generators have 12 “legs” or connecting beams between the shaft and rim. The poles are then mounted on the rim.

4 Stay Vanes Converts the pressure energy of the fluid into momentum energy. It also serves to direct the flow at design angles to the runner blades true the wicket gates.

5 Stay Ring The stay ring is the primary structural member of the Francis turbines. Each unit’s stay ring is designed to carry the membrane loading from the spiral case shell plates, the net up-thrust loading from the turbine head cover, the weight of the pit liner, and a major portion of the superimposed loading from

FIG. 2 – RM UNIT ARCHITECTURAL DRAWING WITH ELEVATIONS

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the powerhouse structure which includes the mass of the generator stator, generator thrust bridge, weight of the turbine and generator rotating parts, and the hydraulic thrust loading on the turbine runner. The stay ring consists of upper and lower crown sections which are connected by twenty-three (23) stay vanes. The design contours of the water passage surfaces of the crown sections, and the profile of the stay vanes is a combined result of hydraulic and mechanical design. The stay vanes transmit the entire loading from the upper crown into the lower crown and ultimately into the lower powerhouse foundation. The curved surfaces of the crown sections, and the profile and angle of attack of the stay vanes directs the flow of water to the wicket gates and into the runner.

6 Wicket Gates The turbines are equipped with twenty-four (24) wicket gates, sometimes referred to as guide vanes. The wicket gates are airfoil shaped blades located in the distributor opening between the head cover and bottom ring facing plates, positioned radially between the stay vanes and the runner. They are distributed equally around the periphery of the runner. Each wicket gate consists of a leaf (or blade), a relatively long upper stem which is guided by the intermediate and upper bushings in the head cover, and a short lower stem which is located and guided by the bushing in the bottom ring. The wicket gates are rotated in synchronism by a lever and link mechanism connecting the upper stem to the operating ring. In the “closed” position, the wicket gates are rotated so that they are in contact with each other thus acting as a valve to shut off the water flow to the runner, which causes the unit to stop rotating. As the wicket gates are rotated toward the “open” position the opening between the adjacent leaf surfaces form variable nozzles allowing water to flow to the runner. Further opening of the wicket gates admits more water to the runner.

7 Brush Rigging Assembly (Exciter)

An assembly that allows the rotor pole to be supplied with energy (field current) while rotating. The brush rigging is supported by a steel rocket ring, which fits into a groove machine into arms welded to the commutator end of the frame. This ring is held in position by a bolt and washer in each supporting arm.

8 Upper Bracket Holds the rotor shaft in a vertical position. Together with the lower bracket forms the structural backbone that houses the rotor and stator.

9 Core Stud Clamps the core to the stator frame.

10 Stator Frame The stator frame is stationary and has either windings or permanent magnets and is the motor's electromagnetic circuit. The stator core is made up of many thin metal sheets, called laminations. Laminations are used to reduce energy losses that would result if a solid core were used. The diameter of the stator frame is 476.5”.

11 Generator Shaft Generally, the shafts transmit the rotational movement from turbine runner to

generator runner. Has a diameter of 50.0”.

12 Lower Bracket Holds the rotor shaft in a vertical position and supports the generator.

13 Coupling Connection elements between generator and turbine shafts (flanges and bolts). They are drilled and align bored for eighteen (18) fitted coupling bolts. The lower end flange boltholes are also counter-bored to accommodate coupling bolts with round heads obviating the need for a rotating nut guard.

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The upper end flange (generator coupling) and the lower end flange (runner coupling) are each 83.0” in diameter, and 10.0” thick.

14 Turbine Shaft The turbine main shaft is a one piece alloy steel forging having a body diameter of 50.0”, a center bored hole of 12.0” diameter and an overall length of 16’-3”.

15 Operating Ring The twenty-four wicket gates are operated in synchronism by the gate mechanism, which consists of a series of levers, links and pins, and a single gate operating ring. Each wicket gate is connected to the operating ring by its dedicated linkage set. The operating ring is connected with adjustable links to the two gate servomotors, which provide the mechanical force to move and position the wicket gates.

16 Guide Bearing Used to maintain alignment of rotating parts. The turbine guide bearing is of the hydrodynamic, pressure fed, oil lubricated shell type journal bearing.

17 Turbine Shaft Seal Prevents water from flowing from the runner into the turbine.

18 Discharge Ring Make connection between stay ring and draft tube.

19 Spiral Casing The spiral case for the Robert Moses turbines is a toroidal shell forming the conduit for delivery of the head water uniformly around the periphery of the stay ring. The design of the spiral case resembles that of a snail shell. A spiral case extension was also provided as a transition from the twenty-one foot (21’) diameter penstock to the nineteen foot (19’) diameter spiral case inlet. The extension was fabricated in the factory in three 120° sections, and field welded together to the inlet of the spiral case. A mandoor having a clear opening measuring 24” wide X 30” high was provided as an integral part of the spiral case for access into the unit for inspection and maintenance of the interior surfaces of the spiral case, stay ring, wicket gates, head cover and bottom ring facing plates, and the entrance areas of the runner. The mandoor is accessed via a passageway from the spiral case gallery at El. 248.0’ located on the downstream side of the unit. The spiral casing around the runner of the turbine is known as the scroll case. All throughout its length, it has numerous openings at regular intervals to allow the working fluid to impound on the blades of the runner. These openings convert the pressure energy of the fluid into momentum energy.

20 Runner Blades that are the heart of any turbine as these are the centers where the fluid strikes and the tangential force of the impact causes the shaft of the turbine to rotate and produce electricity. The blade angles at inlet and outlet as these are the major parameters affecting power production. Each runner is equipped with 13 blades. Diameter of runner is 213.562”.

21 Draft Tube Each turbine assembly has a full elbow type draft tube to direct the water as it leaves the runner to discharge out the downstream face of the powerhouse.

22 Pit Linear The turbine pit liner is a 25’ diameter, .50” thick, cylindrical steel shell, ribbed on the outside. The pit liner was fabricated in two sections, an upper section which is 9’-11” high and a lower section having a height of 11’-10.5”. Both sections were manufactured in three pieces due to shipping limitations. The

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split joints on all six pit liner sections were provided with bolting flanges for field assembly. In addition, the seams were all seal welded for water tightness. The pit liner mates with the uppermost flange on the stay ring, and was field welded with full strength fillets.

3. The Vendor shall provide a transparent cylindrical case to house and transport the

scaled model. This case shall serve as the physical model housing and shall open as described below in bullet 4.

4. Many of the components that normally wrap around the shaft (for example, components 11 &14) are required to open up to give viewers a 180 degree cross sectional view along the vertical plane of the individual components. This requirement will further be known as the “cross sectional requirement”.

5. When the actual units are taken apart, the components are removed vertically. The scaled model should mimic this process and all removable components will be removable along the vertical axis.

6. Components/parts shall be different colors to allow for them to be easily distinguished from one another. In addition to color differentiation of parts, there shall be small but legible engravings or labels on each part identifying the various components.

Table 2 – Model Expectations

Component Numbers &

Names

Minimum Requirements Preferred Option

21 – Draft Tube Only the vertical portion of the draft tube will be included. This is the section of the draft tube located directly below the runner before the tube starts to curve. This will be utilized as a pedestal for the entire structure.

The curved portion of the draft tube is provided as a separate attachment that can be connected to the bottom of the vertical portion of the draft tube.

11 – Generator Shaft 13 - Coupling 14 – Turbine Shaft 20 - Runner

The generator and turbine shafts, along with the coupling, will all be one piece called the shaft. The shaft and runner must be connected and removable from the entire model as a single piece.

The shaft and runner can be separated from each other.

19 – Spiral Casing The spiral casing will not wrap around the entire turbine, a 90 to 120 degree cut-away view will be left open (similar to Figure 1 configuration). It must also be removable so that the wicket gates and stay ring are exposed.

Not Applicable (n/a)

4 – Stay Vanes 5 – Stay Ring

The stay ring consists of upper and lower crown sections, which are connected by 23 stay vanes. The stay ring and 23 stay vanes should all be one piece of the model. Cross sectional requirement applies to this one piece.

Stay rings and vanes are removable from the model as a singular piece.

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6 – Wicket Gates 15 – Operating Ring

The wicket gates and operating will be one piece. The cross sectional requirement applies to this piece.

The wicket gates will be able to move from their opened to closed positions just like in the actual unit.

16 – Guide Bearing

Cross sectional requirement applies to the guide bearing.

Guide bearing is removable from the model.

12 – Lower Bracket

Cross sectional requirement applies to the lower bracket.

n/a

1 – Rotor 3 - Rim 10 - Stator

Rotor equipped with rim/spider and poles will all be one piece that fits inside the stator. The stator will be a second piece including the coils and frame. Both pieces will be removable and follow the cross sectional requirement.

n/a

8 – Upper Bracket The upper bracket will follow the cross sectional requirement.

n/a

7 – Brush Rigging Assembly (Exciter)

The exciter will be removable from the model. n/a

22 – Pit Liner The only component that will not be color coded or labeled is the Pit Liner. It will be made of a transparent material, and will enclose the turbine shaft, operating ring, and guide bearing. It will cover the area from the upper stay ring all the way to the bottom of the lower bracket. This piece will be removable from the model.

n/a

7. The model must be made from a sturdy and durable material that can handle wear

and tear, as it will be handled frequently, disassembled and reassembled on a regular basis.

B. Digital 3D Model

The Vendor shall create a 3D digital model of the Francis turbine with generator using the attached reference drawings to determine appropriate dimensions. This model must contain at a minimum all of the same components as the physical model or more parts. It will display the disassembly and reassembly of the entire unit. Potential ideas are to create a digital 3D interactive model or 3D generated movie to show the function of the hydroelectric unit, however the Authority is open to any digital model that meets the requirements. A good example of a 3D movie can be shown at this link,

https://www.youtube.com/watch?v=1VRE8cMd6Tg, however it only shows the turbine components, and does not have any assembly or disassembly.

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Appendix A – Reference Drawings

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Drawing Number Drawing Title

General Drawings

2A-309 RM NIAGARA POWER PLANT ARCHITECTURAL

510F919 GENERATOR OUTLINE

510F925 GENERAL ASSEMBLY

(1) Rotor

175B5289 ROTOR RING SEGMENT

268B051 ROTOR & SHAFT REMOVAL DIAGRAM

381C932 ROTOR ERECTION PEDESTAL

517D410 POLE ASSEMBLY

517D428 POLE ASSEMBLY

(3) Rim(Spider)

516D444 SPIDER RIM ASM

515D521 SPIDER ASSEMBLY

(4) Stay Vanes/ (5) Stay Ring

227525 STAY RING PLAN

227526

STAY RING SECTIONS

(6) Wicket Gates

227562 WICKET GATE

(7) Brush Rigging Assembly (Exciter)

517D911 516D189

EXCITER ASSEMBLY & LEADS BRUSH RIGGING ASSEMBLY

(8) Upper Bracket

516D356 UPPER BRACKET

(10) Stator Frame

173A281 STATOR WINDING RING SUPPORT

173A282 STATOR WINDING COIL SUPPORT RING

381C554-9 STATOR CORE ASSEMBLY

510F889 STATOR WINDING ASSEMBLY PLAN VIEW

517D420 STATOR WINDING MACHINING

529D809 STATOR WINDING SUPPORTS

554E102 STATOR BAR WINDING

3811C86 STATOR WINDING DIAGRAM

6586D87 STATOR WDG ALTERATION DWG

6586D89 STATOR WINDING ASSEMBLY & PLAN VIEW

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(11) Generator Shaft

268B051 ROTOR & SHAFT REMOVAL DIAGRAM

383C389 MAIN SHAFT BAFFLE

(12) Lower Bracket

510F890 LOWER BRACKET ASSEMBLY & MACHING

517D166 LOWER BRACKET OIL POT

517D167 LOWER BRACKET ARM

517D849 LOWER BRACKET COVERS

(14) Turbine Shaft

227535 MAIN SHAFT

(15) Operating Ring

227564 GATE OPERATING RING

(16) Guide Bearing

227544 MAIN GUIDE BEARING

227546 MAIN BEARING HOUSING

(18) Discharge Ring

2631-106 DISCHARGE RING FIELD INSTALLATION 227559

DISCHARGE RING

(19) Spiral Casing

227528 SPIRAL CASE MANDOOR & FRAME

227530 SPIRAL CASE PLAN

227531 SPIRAL CASE SECTIONS

227533 SPIRAL CASE EXTENSION

(20) Runner

2632-0872 213” DIA R.H. RUNNER FAB. & MACHINE

(21) Draft Tube

227560 DRAFT TUBE

227561 DRAFT TUBE LINER

227570 24” X 36” MANDOOR FOR DRAFT TUBE LINER

(22) Pit Liner

227583 PIT LINER BOTTOM PLAN

227584 PIT LINER BOTTOM ELEVATION

227585 PIT LINER TOP PLAN"

227586 PIT LINER TOP ELEVATION"

Additional Drawings

227547 PACKING BOX

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227548 PACKING BOX GLAND AND LANTERN

227549 SERVOMOTOR ARRANGEMENT

227556 HEAD COVER PLAN

227557 HEAD COVER DETAILS

227558 BOTTOM RING

227563 GATE LEVER PINS AND LINKS

2622-2447 FACING PLATES FINAL MACHINE

2631-0110 SERVO ASSEMBLY

2632-0891 WEARING RING FOR RUNNER CROWN

2632-0894 WEARING RING FOR RUNNER BAND

2632-0914 DISCHARGE RING FAB. & MACHINE

2632-0995 WEARING RING FOR BOTTOM RING

2632-0996 WEARING RING FOR HEAD COVER

2633-0053 LOWER DECK PLATES FIELD ASSEMBLY

2633-0060 UPPER DECK PLATES FIELD ASSEMBLY

2638-0010 DISTRIBUTOR SECTION

837286 COUNTER CLOCKWISE ROTATION

837435 CLOCKWISE ROTATION

517D913 PIT ENCLOSURE & DECK DETAIL

517D914 PIT ENCLOSURE & DECK ASSEMBLY

384C234 GENERATOR GUIDE BRG. ASM (93 1/2 INCH)

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Appendix B – Generator Diagrams

Diagrams are not representations of actual components in the RMNPP but are being provided for the vendor’s reference. The model should not be based off these diagrams.

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FIG. 3 - CROSS SECTION VIEW OF CONVENTIONAL TWO-GUIDE. BEARING

GENERATOR. HIGHLIGHTED COMPONENTS ARE A FEW OF THE REQUIRED COMPOENTS FOR THE SCALED MODEL. (FIELD COIL IS ANOTHER WORD FOR

ROTOR POLES)

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FIG. 4 - CUTAWAY VIEW OF A SMALL VERTICAL WATER WHEEL GENERATOR

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FIG. 5 – TYPICAL FABRICATED STATOR FRAME

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FIG. 6 - VIEW OF LARGE LAMINATED RIM ROTOR WITH PART OF POLES AND COILS INSTALLED

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Appendix C – Photos

All photos show actual components from the RMNPP and can be used as a basis for the model.

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FIG. 7 – BRUSH RIGGING ASSEMBLY (EXCITER)

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FIG. 8 – STATOR ASSEMBLY WITH UPPER BRACKET

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FIG. 9 – TOP VIEW OF ROTOR SPIDER, RIM, AND STATOR

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FIG. 10 – COUPLING (CONNECTION ELEMENTS BETWEEN GENERATOR AND TURBINE SHAFTS)

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FIG. 11 – WICKET GATE LINKAGES AND LEVERS IN THE OPEN POSITION

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FIG. 12 – RIGHT HAND SERVOMOTOR IN RETRACTED POSITION WHICH PULLS THE OPERATING RING CLOCKWISE, WHICH CLOSES THE WICKET GATES

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FIG. 13 – TURBINE GUIDE BEARING THAT PROVIDES SUPPORT AND LUBRICATION TO KEEP THE TURBINE SHAFT UPRIGHT AND SPINNING

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FIG. 14 – INSIDE OF SPIRAL CASING VIEW OF STAY RING, STAY VANES, AND WICKET GATES

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FIG. 15 – INSIDE OF SPIRAL CASING VIEW OF STAY RING, STAY VANES, AND WICKET GATES

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FIG. 16 – VIEW OF A SCALE MODEL OF A FRANCIS TURBINE RUNNER DESIGNED AND FABRICATED BY VOITH HYDRO