turbine engineering for hydropower plants -...

LMH Laboratory for Hydraulic Machines

Turbine Engineering for Hydropower Plants

Prof. Franois [email protected]

Itaipu Power Plant

mailto:[email protected]


Scope

Basic Concepts

Turbine Specific Energy

Specific Speed

Specifications

Pelton Turbines

Francis Turbines

OutlookUnit 4

2Turbine Engineering for Hydropower Plants


Hydroelectric Power Plant:Storage or Run-of-River Power Station

3Turbine Engineering for Hydropower Plants


Hydropower: Turbine Driving an Electrical (Synchronous) Generator

Machine Power Output

Available Hydraulic Power

Turbine Efficiency

Driving Power Defined as Positive :

4

; 100 %T ThP P =

( )WP T=

( )3

3

J Jkg ms kgsm

WhP Q E

=

0P

( )

( )

1J kgI I

h

I I

E gH gH

P Q E

Q gH gH

=

=

I I

I

I

gHQ

I

I

gHQ

T

( ) = + N meldJ T Tdt

Basic Concepts


5

Rotating train dynamics

Rotating train angular momentum equation

Synchronous conditions :

Power failure : runaway speed

Synchronous speed relation :

: Grid frequency : Number of poles : Rotating frequency

5

( )

= +

N m

eldJ T Tdt

= elT T

= = >. 0 0l

dT Tdt

( )

=2

Hzgridp

fn

z

gridf

pzn

= 23 16 Hz; 50 Hz; 60 Hzgridf

Basic Concepts


Discharge - Head Chart of Hydropower Plant Capacity

6

= hP Q gH

Basic Concepts


Definition of State Variables

Mean Flow Local Specific Energy

Discharge: Extensive Variable

Mean Flow Specific Energy: Intensive Variable:

7

( )3 1m sA

Q C ndA

( )2

-10 J kg2

h

A

P p C C ngH gZ dAQ Q

= + +

Basic Concepts

( )2

-1

Gravity Potential KineticPressure

J kg2t

p Ch g Z Cste

= + + +

= 1 2V A A

2n2A

1A

1C

=

On

0C n

V

1n


Hydraulic System: Specific Energy and Discharge Budgets

Specific Energy Budget

Steady Flow ? Straight Stream Lines, free of Secondary Flow

Flow Budget

DischargeDischarge Velocity

8

( )1 21 2

r igH gH gH

= +

11

1

gHA

Q

22

2

gHA

Q

1 2

1 1 2 2

Q QA C A C

= =

Basic Concepts


Runner/Impeller Specific Energy Transfer

Traversing Discharge

Transferred Specific Energy

Power Transfer

Drive: Turbines

Brake: Pumps, Propellers

9

( )3 -1m stQ

( ) = -11 1 J kgt rbgH gH E E

( )= Wt t tP Q E

> 0P

< 0P

Brillant Extension Project, British Columbia, Canada, Kaplan Turbine CAD Model, PF2 EPFL Test Rig

1

1

tQ



Specific EnergyTransfer

10

[ ]

( )

= + +

Reaction

221 1 1 1

1 1

Water WheelDisplacement Impulse

-1

2 2

J kg

t rb

Loss

p Cp CE gZ gZ E

( )

= + + 2

-1J kg2

p CgH gZ



Dimensional Analysis

Power Plant Conditions

Discharge

Specific Energy

Unit Characteristic

Angular Speed

Turbine/Pump Dimension

[ ] ( ) 3 1 3 -1 = m sQ L T

( )

= 2 2

2 2 -1= J kgI IML TE gH gH L T

M

[ ] ( ) 1 -1= sT

[ ] ( )= mD L

1111

/

Specific Speed


Dimensional Analysis(Contd)

Dimensionless Angular Speed Condition

Yields Linear System

Dimension of Time

Dimension of Length

Solution

[ ]

= = =

0 0 0

0 0 1 3 2 2

Q E M T L

T L T L T L T

=1 2 0

+ =3 2 0

= =1 3;2 4

1212

=

12

1 3 32 4 4

2

Q

E/

Specific Speed


Dimensional Analysis(Contd)

Discharge Coefficient

Energy Coefficient

Specific Speed

Unit Specific SpeedRotating Speed

Discharge Factor

Speed factor

= =

12

34

U Cmk k

= CmU

= 22EU

1313

=2Cm

CmkE

=2UUk

E

( )= = 12

34

157.7 S.I.QQn NH

( )1minNSpecific Speed


Selecting Hydraulic Turbines

14

Highest eff. 96% 97%Head

Specific Speed

( )( )( )

( )

=

=

=

=

3 1

1

Head m

Discharge m s

Speed min

2Hzgrid

p

H

Q

N

fn

z

Specific Speed


Hydro Turbines International Market

Breakdown by Types of Turbines

1038 GW Installed Capacity in 2012Modernization Market

1000 GW to be built before 2050Greenfields Project

15

Pelton8%

Francis61%

Kaplan17%

Bulb2%

Pump-Turbine

12%

Turbine Specifications


1

10

100

1'000

1 10 100Percentage of time discharge was exceeded

m3/s

%

Total Flow

Diverted Flow

Matching Turbine Specific Speed to Site Conditions

Site Potential Specific Energy

Site Specific Energy

Data Science: Flow Duration Statistics

Average Discharge

16

( )B Bg Z Z( ) ( ) = -11 1 J kgB rBgH gH g Z Z gH

( )3 -1Instal. m sQ


Graphique3

Percentage of time discharge was exceeded

Total Flow1009590807060504030201050.112.6813.3214.6518.14999999999999921.3725.6933.47999999999999740.1750.3265.23999999999999584.41100.84164.56Total Flow1009590807060504030201050.16.346.988.3111.80999999999999915.03000000000000119.35000000000000127.13999999999999733.8343.98000000000000458.89999999999999178.06999999999999394.5158.22

Annual Energy Variation Order 1

LA HIGUERA POWER PLANT- GUARANTEED ANNUAL NET ENERGYEnergy Losses

Variation order 1Source Attachement II: Energ PowergHr = K Q2/2A2inlet (J/kg)

Latitude34.20C273.15KStatistical parametersERROR:#VALUE!ERROR:#VALUE!

Distr. CL Elevation704mCoefficientsERROR:#VALUE!ERROR:#VALUE!

Gravity9.7945648183m/s2Lambda0.01Coef. Standard DeviationERROR:#VALUE!ERROR:#VALUE!

pstandard93,150PaD11R2, SEERROR:#VALUE!ERROR:#VALUE!q =9C

kilo1,000L17500Twater =282.15K

1 day24hrelative2.1%r* =1001.52kg/m3

1 year 365daysBeing SortedAverage15.837%1,263.6644

ExceedDaysMonthsTotal FlowEnvir. FlowDivert. FlowGross HeadHead LossesNet HeadEff. TurbineEff. Gen.Gross PowerServiceElectric LossNet PowerEff. TransfoPower @ 154 kVGross EnergyOutage (1%)Net energySpecific Energy LossesSpecific Kinetic Energy*Unit Divert. FlowEffect. TurbineSorted Divert. FlowEffect. TurbineGross PowerdP/Pr

%m3/sm3/sm3/smmm%%MWMWMWMW%GWhGWhGWhJ/kgJ/kgm3/s%m3/s%MWkg/m3

100365.0012.0012.686.346.343830.04382.9682.1094.7031.860.20.000631.6699.631.530.35ERROR:#REF!6.3482.1010.9682.1018.5241.875%1,723.14

95346.7511.4013.326.346.983830.04382.9686.3096.0035.910.20.001235.7199.635.5614.690.1514.550.42ERROR:#REF!6.9886.3011.6086.3021.7239.502%1,655.55

90328.5010.8014.656.348.313830.06382.9490.2096.7042.080.20.001541.8899.641.7116.920.1716.750.60ERROR:#REF!8.3190.2012.9390.2027.2335.292%1,547.84

80292.009.6018.156.3411.813830.12382.8893.1097.3055.310.20.002455.1199.554.8342.290.4241.861.20ERROR:#REF!11.8193.1015.2492.5040.1827.350%1,378.63

70255.508.4021.376.3415.033830.20382.8094.1097.7066.830.20.004566.6299.666.3653.080.5352.551.95ERROR:#REF!15.0394.1016.4393.1051.8922.355%1,289.94

60219.007.2025.696.3419.353830.33382.6793.8097.9080.780.20.009080.5899.680.2564.220.6463.573.23ERROR:#REF!19.3593.8017.9593.6066.7117.424%1,212.91

50182.506.0033.486.3427.143830.65382.3592.5097.1099.000.20.014498.7899.698.3978.240.7877.466.35ERROR:#REF!13.5792.5019.6594.1091.437.644%1,084.47

40146.004.8040.176.3433.833831.01381.9993.6097.40116.560.20.0330116.3399.5115.7593.790.9492.859.87ERROR:#REF!16.9293.6023.0293.40115.570.847%1,010.12

30109.503.6050.326.3443.983831.70381.3093.4097.70144.370.20.0600144.1199.5143.39113.501.13112.3616.69ERROR:#REF!21.9993.4023.9793.80150.11-3.979%963.24

2073.002.4065.246.3458.903833.06379.9492.6097.80153.010.20.1200152.6999.5151.93129.351.29128.0529.93ERROR:#REF!29.4592.6025.0092.60198.81-29.935%770.81

1036.501.2084.416.3478.073835.37377.6392.6097.80153.010.20.1200152.6999.5151.93133.091.33131.7639.0492.60261.91-71.175%585.10

518.250.60100.846.3494.503837.87375.1392.6097.80153.010.20.1200152.6999.5151.9366.540.6765.88*Reference area: Turbine inlet47.2592.60314.93-105.826%486.59

0.10.37- 0164.566.34158.2238322.05360.9592.6097.80153.010.20.1200152.6999.5151.9365.210.6564.56AI =ERROR:#REF!m279.1192.60507.32-231.561%302.05

Annual Total870.928.71862.21

*Average water density for water pressure computation to compute actual water density !

Percentage of time discharge was exceeded

Total Flow1009590807060504030201050.112.6813.3214.6518.14999999999999921.3725.6933.47999999999999740.1750.3265.23999999999999584.41100.84164.56Total Flow1009590807060504030201050.16.346.988.3111.80999999999999915.03000000000000119.35000000000000127.13999999999999733.8343.98000000000000458.89999999999999178.06999999999999394.5158.22


Matching Turbine Specific Speed to Site Conditions

Targeted Unit Specific Speed

Rated Head Specification of Unit Number Specification of rotating frequency

Runaway Speed Limitation

Limitation of Apparent Power per Poles

Air cooling < 28 MVA < Water cooling < 35 MVA

17

=

12

.34

1 instalQ

units

Qn N

z HE gH=

2 60 sgridp

fN

z

=unitsz



1'269 MW Bieudron Power Plant3 Pelton Turbines

500 MVA Generators 428.5 min-1

14 poles, 35.7 MVA/pole*Water Cooled

423 MW Pelton* Turbines, 5 injectors 1'883 mWC Head* 25 m3/s DischargeD1 = 3.993 m ~28 t Runner Mass

Pelton Turbines 18


Pelton Turbines

Impinging Jet on Pelton BucketsFVPM Flow Numerical Simulations

19Christian VESSAZ, EPFL Doctoral Thesis N 6470, 2014


Silt Erosion of Turbine Components: 4 x 100 MW Pelton, 900 m Head

Silt Erosion

Bucket

Needle

Needle Severe Erosion Erosion Ripples

on Buckets ~2'500 Total Hours

of Operation

20Pelton Turbines


SPHEROS Finite Volume Particle Method SolverMulti Scale Silt Laden Flow Erosion Simulation

21

LEGUIZAMON Sebastin, EPFL Doctoral Student, CTI Project GPU-SPHEROS

Pelton Turbines

Copper sample

3 mm slurry jet, 10 m/s


Giga Hydropower Plantsare Francis Powered

22

Hydropower Plant Country Capacity

(MW) Energy (TWh)

Capacity Factor

EPFL Model Testing Type

Three Gorges China 22'500 98.5 0.50 Storage Itaip Brazil-Paraguay 14'000 98.3 0.80 Storage

Xiluodu China 13'860 57.1 0.47 Storage Belo Monte Brazil 11'233 - Run-of-River

Guri (Ral Leoni) Venezuela 8'850 53.4 0.69 Storage Tucurui Brazil 8'370 41.4 0.56 Storage

Grand Coulee USA 6'809 20.0 0.34 Storage Longtan China 6'426 18.7 0.33 Storage

Xiangjiaba China 6'400 NA NA Storage Krasnoyarsk Russia 6'000 20.4 0.39 Storage

Robert Bourassa (LG2) Canada 5'616 26.5 0.54 Storage Churchill Falls Canada 5'428 35.0 0.74 Storage

Tucurui Dam, Eletro Norte

Francis Turbines

Hydropower Plant

Country

Capacity (MW)

Energy(TWh)

CapacityFactor

EPFL Model Testing

Type

Three Gorges

China

22'500

98.5

0.50

Storage

Itaip

Brazil-Paraguay

14'000

98.3

0.80

Storage

Xiluodu

China

13'860

57.1

0.47

Storage

Belo Monte

Brazil

11'233

-

Run-of-River

Guri (Ral Leoni)

Venezuela

8'850

53.4

0.69

Storage

Tucurui

Brazil

8'370

41.4

0.56

Storage

Grand Coulee

USA

6'809

20.0

0.34

Storage

Longtan

China

6'426

18.7

0.33

Storage

Xiangjiaba

China

6'400

NA

NA

Storage

Krasnoyarsk

Russia

6'000

20.4

0.39

Storage

Robert Bourassa (LG2)

Canada

5'616

26.5

0.54

Storage

Churchill Falls

Canada

5'428

35.0

0.74

Storage


Xiangjiaba Power Station (Jinsha River, Yunnan)

8 Francis Turbines

825 MW Max. Power

10.5 m Diameter

406 000 kg

23What level of p fluctuations to be expected for a 800 MW turbine ?


HYPERBOLE Turbine Case Study Hill Chart and Operating Range

Deep Part Load Part Load Full Load

EDn

EDQ

Francis Turbines 24


Unsteady Flow in Francis Draft Tube

25

Mller et al., Experiments in Fluids n 54 : 1514, 2013.

Allign et al., Journal of Hydraulic Research, Vol. 51, 6, 2010.

Simon Pasche PhD Work, SNF GRANT N 200021_149818

Francis Turbines


Machine Setting Level

IEC 60193 Definitions Specific Energy

Net Positive Suction Specific Energy

Setting Level

26

= s ref Bh Z Z

( )

1J kg

vrefI

pNPSE gH gZ

( ) > 10 J kgI IE gH gH

IEC 60193 Standard, "Hydraulic Turbines, Storage Pumpsand Pump-Turbines-Model Acceptance Tests". International Electrotechnical Commission; Geneva,Nov. 1999.



HYPERBOLEERC/FP7-ENERGY-2013-1-Grant N 608532

HYdropower plants PERformance and flexiBleOperation"towards Lean integration of new renewable Energies

Dynamic Assessment of Francis Turbines & Pump-Turbines 42 Months, EUR 6.3 Mio EUR 4.3 Mio Supported by European Commission 1st Sept. 2013 28th Feb. 2017

Consortium coordinated by EPFL

27


28

Headwater reservoir

Tailwater reservoir

Surge Tank

Hydraulic Eng.

Mechanical Eng.

Electrical Eng.

System ApproachHYPERBOLEERC/FP7-ENERGY-2013-1-Grant 608532

HYdropower plants PERformance and flexiBle Operationtowards Lean integration of new renewable Energies


System Approach Methodology

29Francis Turbines


Deep part load operatingconditions Q


Deep part loadInter blades vortices

Visualization

Hollow guide vaneswith window

Boroscopewith swiveling prism

High Speed CameraHigh intensity Xenon flashCompact power LED

DPL2: nED = 0.317

HYPERBOLE

31Francis Turbines


Deep part load Inter blades vortices

Flow Numerical Simulations

Void Fraction 10% Isosurface

32

HYPERBOLE

32Francis Turbines


Hydroelectric Plants Generate17% of the World Electricity

33Luciano dos Santos, "Digital Disruption of Hydroelectricity", HYPERBOLE Conference, Porto, February 2-3, 2017


THANK YOU FOR YOUR ATTENTION

34

http://lmh.epfl.ch/

Turbine Engineering for Hydropower PlantsScopeHydroelectric Power Plant:Storage or Run-of-River Power StationHydropower: Turbine Driving an Electrical (Synchronous) GeneratorRotating train dynamicsDischarge - Head Chart of Hydropower Plant CapacityDefinition of State VariablesHydraulic System: Specific Energy and Discharge BudgetsRunner/Impeller Specific Energy TransferDiapositive numro 10Dimensional AnalysisDimensional Analysis(Contd)Dimensional Analysis(Contd)Selecting Hydraulic TurbinesHydro Turbines International MarketMatching Turbine Specific Speed to Site ConditionsMatching Turbine Specific Speed to Site Conditions1'269 MW Bieudron Power Plant3 Pelton TurbinesImpinging Jet on Pelton BucketsFVPM Flow Numerical SimulationsSilt ErosionSPHEROS Finite Volume Particle Method SolverMulti Scale Silt Laden Flow Erosion SimulationGiga Hydropower Plantsare Francis PoweredXiangjiaba Power Station (Jinsha River, Yunnan)HYPERBOLE Turbine Case Study Hill Chart and Operating RangeUnsteady Flow in Francis Draft TubeMachine Setting LevelHYPERBOLEERC/FP7-ENERGY-2013-1-Grant N 608532HYdropower plants PERformance and flexiBle Operationtowards Lean integration of new renewable EnergiesSystem Approach MethodologyDeep part load operatingconditions Q

turbine engineering for hydropower plants -...

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