rehabilitation of medium-head hydropower · pdf filerehabilitation of medium-head hydropower...

REHABILITATION
OF MEDIUM-HEAD HYDROPOWER PLANTS
WITH EXPLOITED TWIN-FRANCIS TURBINES.
Maciej Kaniecki, PhD
Andrzej ojek, PhD
Marusz Hajdarowicz, M.Sc.Eng
Congress SHP, Grenoble 9-10 April 2014
ZRE Gdask S.A.
ul. Litewska 14A
80-719 Gdask

ZRE GDANSK Company Profile
ZRE Gdask S.A., st. Litewska 14A, 80-719 Gdask
E-mail: [email protected]
1. Production of hi-efficiency, ecological water
turbines up to 10 MW (Francis and Kaplan)
2. Upgrades of Hydro Power Plants
up to 800 MW
3. Diagnostics services
(DT & NDT testing)
4. Turnkey projects, repairs, servicing

ZRE Gdask S.A., st. Litewska 14A, 80-719 Gdask
AGENDA
1. Main reasons for rehabilitation
2. Refurbishment vs. complete
rebuilding
3. Rehabilitation project stages
4. Case study 1:
upgrade of HPP Grdek,
5. Case study 2:
upgrade of HPP Kamienna.

Main reasons for rehabilitation
of old twin Francis turbines
Bad condition of metal parts and flow passages
Erosion and cavitation damages in the flow passages
Low efficiency of whole generating set
Low energy production
ZRE Gdask S.A., ul. Litewska 14A, 80-719 Gdask

Minimized scope of civil works
Re-use of existing generator
Following cultural heritage
protection policies
Refurbishment vs. complete rebuilding
of the power plant

Stages of the rehabilitation project
3D Design process
Manufacturing and assembly
of new parts

Performance guarantees, confirmed in acceptance tests
Refurbishment unit-by-unit, without complete plant outage

Case study 1: upgrade of HPP Grdek
Turbine type 2 x Twin Francis
Gross head H 18 [m]
Rated output power P 2 x 1.45 [MW]
Installed discharge Q 2 x 9.7 [m3/s]
Rotational speed 300 [rpm]

New, re-engineered runners and guide vanes,
Refurbishment of the bearings,
Repairs of other parts:
shafts,
camelback suction pipes
guide vanes control system
Upgrade of control and power output systems .

Design solutions 3D project
based on CFD designed flow passages

Manufacturing of the runners

Guide vanes system for HPP Grdek

Acceptance tests of HPP Grdek Weighted efficiency
Guaranteed value Measured value
84.0 % 86.2 %
65
70
75
80
85
90
3 4 5 6 7 8 9 10 11
[%]
Measured efficiency
Q [m3/s]

Bearing type:
Vibrations velocity
[mm/s]
Measured values of vibrations velocity
Reference values
ISO 7919-1
Thrust bearing 0.3

Case study 2: upgrade of HPP Kamienna
Turbine type Twin Francis
Gross head H 7.3 [m]
Rated output power P 2 x 0.52 [MW]
Installed discharge Q 2 x 9.5 [m3/s]
Rotational speed 100 [rpm]

Design solutions
based on CFD analysis of flow passages
Upgrade of flow systems:
new runners
new guide vanes
new camelback draft tubes
Manufacturing of new shafts
Refurbishment of bearings
Repairs of guide vanes control system
Rewinding and upgrade of generators
Renovation of the concrete

Old fashion runner with 32 blades
Brand new runner with 13 blades
Runners in HPP Kamienna

Old fashion guide vane Brand new guide vane
Guide vanes of HPP Kamienna

New camelback draft tubes
New casted parts
Damaged parts of old camelback draft tubes

Installation of new units (HPP Kamienna)

Acceptance tests of HPP Kamienna
combined weighted efficiency
Guaranteed value Measured value
82.8 % 85.4 %
60
65
70
75
80
85
90
3 5 7 9 11
Q [m3/s]
[%]
Measured values of efficiency
Measured values of efficiency prior to rehabilitation

Considerably low civil engineering activities,
re-use of many parts and equipment of twin-Francis
= significant reduction of investments costs of HPP modernization.
Choice between twin-Francis upgrade and complete plant rebuilding with use of full Kaplan turbines
should be considered due to lower investment costs, legal limitations and cultural heritage protection
Summary

Thank you
for your attention!

rehabilitation of medium-head hydropower · pdf filerehabilitation of medium-head hydropower...

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