Overview on Pump Turbine Technology - · PDF fileEnvironmental aspects All Hydro Turbines...
Transcript of Overview on Pump Turbine Technology - · PDF fileEnvironmental aspects All Hydro Turbines...
Overview on Pump Turbine TechnologyTechnology Seminar, Brasilia, November 2014Peter Magauer, Vice President Global Sales TurbinesANDRITZ HYDRO Gmbh, Ravensburg, Germany
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Pump Turbine TechnologyPresentation Content
Hydropower as Integrator in the future Renewable Energy MixEurope: new EU targets 2030 for renewable energyIncreasing demand in new markets
Changing requirements for the equipment, design criteria
The classical Pumped Storage solution: Fixed speed single stage reversible units
Special configurations
Variable Speed Applications
Ternary sets, Hydraulic short circuit
Multi Stage Pump Turbines
Sea Water Pumped Storage
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Pump Turbine TechnologyGlobal Trend, EU targets
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The EU states have defined their2030 targets
Hydro generation (+8% in 2010-2020) and Pumped storage (pumping +35% in 2010-2020) will remain importantfor energy security
e.g. Portugal: Wind & Hydro expansion plan reconfirmed
New EU Targets 2030Renewables-Electricity >50%!
40% 27% 27%
Global Trend to increase share of Renewable Energy
� Presently 16% of world electricity generation is renewabl e, mainly Hydro
� Replacing fossile plants, saving limited ressources
� Reducing greenhouse gas emissions
� Replacing nuclear power (Germany)
EU:
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Increasing variety and complexity of requirements for our e quipment:
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� Frequent load changes All Hydro Turbines
� Frequent start / stops Storage / Pumped storage plants
� Wide operation range Francis, Pump TurbinesStability over a wide range Pump Turbines
� Fast changeover times Pump Turbines
� Safe Operation, robust design All Hydro Turbines
� High efficiencies All Hydro Turbines
� Cost optimized dimensions/design All Hydro Turbines
� Environmental aspects All Hydro Turbines
Pump Turbine TechnologyMultiple requirements for Hydroelectric equipment
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� Much more part load operation� Much more Start-Stop events� Dynamic stresses drastically
increased
CFD / FEM AnalysesVerification by prototype measurementsEstimation of lifetime for criticalcomponentsInvestigations currently for all 4 turbine types
Frequent Start – StopsOperation over full range
Measured blade stress
Startup/SNL full load SNL
Pump Turbine TechnologyEquipment Requirements
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Research on Unsteady Phenomena in Pump turbines
Pump stability at high head� Drop of head-flow characteristics at high
heads� Unstable operation or start-up possible ?
The behavior will be stable for a negative slope of the characteristic curve at the operating point, but for a positive slope the behavior will be unstable.
From P. Dörfler, M. Sick, A. Coutu. Flow-Induced Pulsation and Vibration in Hydroelectric Machinery. Springer Verlag (2013). Chapter 6.4.2
Pump Turbine TechnologyEquipment Requirements
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Layout always is a compromise between several aspects� High efficiencies over a wide range� Safety against cavitation damage� Dimensions and geometry favourable for manufacturing and c ost� Impact on civil works (dimensions, setting level)� Stability� Robustness
Tender processes are often focussing on cost and efficiency
Especially on Pump turbines, Robustnessis crucial.
What is the incentive for robust solutions?
(e.g. adjustable wicket gate bearings ����
low vibrations)
Pump Turbine TechnologyEquipment Requirements
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Pump Turbine TechnologyThe classical concept
Single stage, reversible,fixed speed Pump Turbine
Pump starting with SFC in dewatered condition
Often with Synchronouscondenser mode(Labyrinth cooling!)
Earlier NowDay / Night FrequentCycle part load
Changeover times 7-8 min 5-6 min(Fast changeover PUMP � TUR ~ 90 sec
very rough condition!)Double peak test
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avoid:
pit diameterreduction needs a split headcover
(not valid for middledismantling)
include:
prestressed bearings
include:
partly concrete around draft tube cone
avoid:
breakingelements
include:
segment type radial bearing
include:
access to lower wicket gate bearing
include:
axial hydrostaticshaft seal
Typical design features for a reversible Pump turbine
Prefer:
Individual servomotors forGuide vanes
Pump Turbine TechnologyThe classical concept – Design features
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Tong Bai
China
D = 4,800 mmn = 300 rpmH = 288 mP = 317 MW
4 units
ContractYear: 2002
Pump Turbine TechnologyReversible Pump Turbine – Recent examples
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Vianden / Unit 11
Luxemburg
Custiomer: SEO / RWE
1 Pump turbine 200 MW
D1 = 4400 mm H = 300 m
Contract year: 2010
Second extension of the existing
Pump storage plant
Scope of supply ANDRITZ Hydro:
Pump turbine, Motor generator
Pump Turbine TechnologyReversible Pump Turbine – Recent examples
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Baixo Sabor MontanteCustomer: EDP, Portugal
Runner Diameter 4112 mm
Head range H 68.8 m – 104.6 m
Max power P = 76.9 MW
Speed n = 214.29 rpm
Scope of supply:
2 Pump Turbines
Motor/Generator
Ancillary equipment
Wide head variation
Equipped with ring gate
Pump Turbine TechnologyReversible Pump Turbine – Recent examples
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Baixo Sabor Jusante
Customer: EDP, Portugal
Runner Diameter D1 3948 mm
Head range H 26.2 m – 35.2 m
Max. power P 17.8 MW
Speed 150 rpm
Scope of supply:
2 Pump Turbines
Motor/Generator
Ancillary equipment
Wide head variation
Pump Turbine TechnologyReversible Pump Turbine – Recent examples
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Large Hydro
Foz Tua
Portugal
2 Pump turbines 124 MWH = 96 mD = 3460 mmN = 187 rpm
Motor generators, Penstock, gates
Electrical power Systems
Cranes, Auxiliaries
Equipped with ring gate
Contract: November 2011
Model test,
adaptation to increased operating range
Portugal
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New concept for standardized solution� Reduced project specific cost
(engineering, assembly, …)
� No individual model test
� Standardized equipment
� Simple installation
� Variable Speed, Full Converter
� Competitive W2W solution
High head applications:
Multi stage pump (ANDRITZ Graz)
with separate Pelton Turbine
Standardization
Range:
5 – 50 MW / unit
25 – 250 m Head
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Pump Turbine TechnologyStandardized concept
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Special concepts – Why?
1) Enhance flexibility- Variable speed applications- Ternary sets
2) Utilize very high heads (> ~700m)- Two stage regulated pump turbine- Multi stage pump turbine
3 Exploit additional project sites- Sea Water Pumped Storage
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Pump Turbine TechnologySpecial concepts
Variable Speed unit with
Full Size Converter
Ternary Set (2 x 180 MW Obervermunt II)
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max. head
min. head
max. speed
min. speed
cavitation limit,high pressure side
cavitation limit,low pressure side
stability limit
Variable speed unitshave a substantiallywider operating rangeboth in Turbine andPump mode
BUT: Even with FullSize Converter,- Hydraulic limits have
to be considered(cavitation, stability)
- High flexibility effectonly with regulatedturbines (wicketgates and speed)
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Pump Turbine TechnologyVariable Speed Units
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� In operation since 2002� 4x 265 MW Reversible Pump-Turbine units� 2 units with variable speed� Advantages:
� regulation of pump power � fast dynamic response times� higher efficiency for variable head
Example Goldisthal, Germany
Pump-Turbine common design and supply by
Andritz Hydro & Voith
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Double fed
Asynchronous
motor generators by
Andritz Hydro
Pump Turbine TechnologyVariable Speed Units
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Maximum flexibility byHydraulic Short Circuit
to tailwater
Hydraulic short circuitPartly to tailwater, partly to pump
To and from headwater
Hydraulic short circuitPartly to headwater, partly to turbine
from tailwater
Example: Kops II / Austria
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Both for Vertical and and horizontal shaft arrangement
Geesthacht / Germany –since 1997
Pump Turbine TechnologyTernary Units
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Kops 2, AustriaUnique Ternary concept
Pressurized downstream chamber
In operation since 2009
3 x 200 MVA / 180 MW Tu / 150 MW Pu500 rpm
Full load in 20-30 s (Tu and Pu mode)
> 8000 operating hours / year!
Pump Turbine TechnologyTernary Units
Typical operation curve over 12hoursPUMP
TUR
Hydraulic TorqueConverter allows maximum flexibility
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Two stage reversible units: 2 regulated distributors����flexibility in turbine modeFor heads < 1000m Smaller dimensions thanternary sets
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Pump Turbine TechnologyMulti Stage Units
Shop assembly in theRavensburg workshop
Nestil, Switzerland
Customer: AXPO (former NOK)
1 four stagereversible
Pump turbine, MIV,motor generator
P = 130 MW
H = 1062 m
n = 600 rpm
Contract year: 2005
For high headsNo part load operationFlexibility only ifcombined in a ternary set
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Projects are promoted with sea water PSP. One pilot plant in Japan exists.
PRO CONTRA
Saving of Downstream Reservoir Stainless steel for many tu rbine partsAdditional sites possible Austenitic steel - Lower blade
strength ���� bigger unitNo evaporation problem Corrosion resistant penstock
Gates subject to high corrosionProjects in dry hot , areas will anyway Salt water in h eadpond may createneed desalination or salt content grows environmental problems
Marine life in water circuit (cooling)Increased maintenance & repairCathodic protection system
Substantial additional cost !
We consider the economic benefit of sea water PSPs question able
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Pump Turbine TechnologySea water applications
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Main Presentation TitleSummary & Conclusion
� Hydroelectric power will play an important role in a future renewable enegry mix
� Storage Hydro and Pumped Storage provide the necessary re gulating power
� Additional requirements for the equipment become more imp ortant
� Flexibility and fast load changes are particularly import ant for pump turbines
� Actual market for PSP in Europe is low, increasing d emand in growing
economies
� A variety of special solutions allow faster regulati on and additional potential sites
� ANDRITZ HYDRO is well prepared for future Pumped Storage opportunities
Thank you for your attention !
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