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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


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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


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Pelton

~200 m to 2,000 m

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Francis (pump turbine)

~50 m to 700 m

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Kaplan

~2 m to 50 m

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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


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)



Logistic Challenge: 400t Stainless Steel Runner


Rotor Assembly – Precision with > 2000t

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Pumped Storage

• Wind, Solar and Hydro Integration

– Reserves

– Frequency regulation

Energy Frequency Storage


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



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


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


1 min


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


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


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


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



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)


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


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“.


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


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]


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