Download - G. Charles Allen, P.E
SAYANO-SHUSHENSKAYA
G. Charles Allen, P.E.Chief, Turbomachinery Section
Hydroelectric Design CenterHydroelectric Design Center
Southwestern Federal Hydropower C fConference
Branson, Missouri
10 June 2010
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Russian Hydropower Accidenty p
The slides that follow were taken from many different sources and represent the facts as we know them (Note: Information is sparse
d k h ) Thi i i fand sketchy). This presentation is for internal use only.
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Sayano-ShushenskayaU it 2 F ilUnit 2 Failure
Sayano-Shushenskaya, Russian Hydro Powerhouse
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The PlantThe Plant
Powerhouse: Sayano-Shushenskaya
Owner / Operator: RusHydro
Installed Capacity: 6400 MW. Largest power plant in
Russia and the world's sixth-largest hydroelectric plant by average
power generation.
Construction started in 1968Construction started in 1968
Power on Line (POL): 1978
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The DamThe Dam
Type: Arch (Looks like Hoover)Type: Arch (Looks like Hoover)
Height: 245.5 meters (805 ft) high
Crest Length: 1,066 meters (3,500 ft)
Crest Width: 25 meters (82 ft)
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Sayano-Shushenskaya
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Sayano-Shushenskaya, Russian Hydro Powerhouse
The DamThe Dam
Sayano Shushenskaya Russian Hydro Powerhouse
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Sayano-Shushenskaya, Russian Hydro Powerhouse
The TurbineThe Turbine
Francis type turbinesyp
Unit Rating: 640 MW each
N b f U it 10Number of Units: 10
Rated Head: 194 meters (640 ft) (275 psi)
Max Head: 220 meters (720 ft) (310 psi)
Unit Flow: 340 to 360 m3/s (12 000 cfs to 12 700 cfs)Unit Flow: 340 to 360 m3/s (12,000 cfs to 12,700 cfs)
Unit Speed: 142.8 RPM
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VideosVideos
Eyewitness Video - http://www.youtube.com/watch?v=egeABBr5hyA
CCTV Footage - http://www.youtube.com/watch?v=R1q-tiSWudw
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VideosVideos
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VideosVideos
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Major Issues of the DamMajor Issues of the Dam
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Inside of the Powerhouse
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Sayano-Shushenskaya, Russian Hydro Powerhouse
Turbine Unit
Sayano-Shushenskaya, Russian Hydro Powerhouse
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The net result is the unit was ejected from the turbine pit…
The Head Cover Studs Failed
Sayano-Shushenskaya, Russian Hydro Powerhouse
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The unit weighs 2960 tons (US) and the rotor weight is 995 tons (US). e g s 995 o s (US)
There are reports that the Unit was ejected verticallySayano-Shushenskaya, Russian Hydro Powerhouse
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There are reports that the Unit was ejected vertically 3 meter’s (about 10 feet)……..
….resulting in this.
Sayano-Shushenskaya, Russian Hydro Powerhouse
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Inside of the Powerhouse
Sayano-Shushenskaya, Russian Hydro Powerhouse
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The Damage
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Sayano-Shushenskaya, Russian Hydro Powerhouse
Sayano Shushenskaya Russian Hydro Powerhouse
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Sayano-Shushenskaya, Russian Hydro Powerhouse
Sayano-Shushenskaya, Russian Hydro Powerhouse
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Sayano-Shushenskaya, Russian Hydro Powerhouse
Sayano-Shushenskaya, Russian Hydro Powerhouse
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Aggravating Factors Before Th A id tThe Accident
Severed communications from Bratsk powerhouse.17 August 1:20 am, fire at Bratsk powerhouse downstream of Sanyo. The ability of Bratsk to provide AGC and other ancillary y y p yservices to the power grid operator lost.
AGC is moved from Bratsk to Sanyo a high head plantAGC is moved from Bratsk to Sanyo a high head plant.
Design of the studs & no inspection requirements.g
No pretension on the studs.
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Aggravating Factors Before Th A id t C t’dThe Accident, Cont’d
New Governor controls on Units 2, 5 & 6.
W t id b i t ib t d t hi h ib tiWorn out guide bearings contributed to higher vibration.
Cavitation had contributed to vibration / unbalanced runner.
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What Happened?What Happened?
The accident was primarily caused by the head cover t d f ilistuds failing.
80 studs held the head cover down.41 studs had fatigue cracks2 t d d t d b t i2 studs were destroyed by tension6 studs completely undamaged, leading to the conclusion that no nuts were present.
Average fatigue damaged area exceeded 65% of the total stud cross section.
The cause of the failure is still being debated. Leading candidates are unit vibration, load rejection, or governor failure.
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a u e
Contributing FactorsContributing Factors
Studs not prestressed—or perhaps inferior steelFailure to monitor Head Cover Stud ConditionFailure to shut down upon increased vibrationCorporate Culture stressing profit/operation at the expense
of safetyof safetyInadequate vetting of new governorsAccepting as ‘normal’ the operation of the machine outside p g p
design specifications
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Could an Accident Like This Happen to the Corps?
YES
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IT’S NOT ONLY SAYANO !!IT S NOT ONLY SAYANO !!
THREE BREACHES IN PAST 20 YEARS
Manitoba Hydro Grand Rapids Unit 4Unnamed European PlantSayano ShushenskayaSayano-Shushenskaya
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THE BIG PICTURE LESSONTHE BIG PICTURE LESSON
IT IS NOT: MONITOR THE HEADCOVER STUDS
IT IS: MONITOR WHATEVER CONTAINS THEIT IS: MONITOR WHATEVER CONTAINS THE DEADLY ENERGY
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Recommendations to HQ USACE
Inspect all turbine head cover studs and nutsInspect all turbine head cover studs and nuts.
Verify that the emergency closure systems function at all plants and test the emergency closure gates under full unit flow.and test the emergency closure gates under full unit flow.
Verify all governor shut down and timing (wicket gate closure speeds).
Review Emergency Plans and Procedures
Maintain Staff CompetencyMaintain Staff Competency
Inspect turbine runners for cracks.
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Recommendations to HQ USACEUSACE
Inspect head covers for structural integrity.
Inspect penstocks for structural integrity.
Develop vibration limits and install vibration monitoring systems.
Re-examine the COE guidance on emergency gate closing time.
Provide adequate back up power capability to maintain plant control.
Assure that adequate engineering oversight is applied when major repair is performed or when energy containing components are disassembled or reassembled
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QUESTIONS?
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