Innovative Low Head Hydro - · PDF fileInnovative Low Head Hydro – The StreamDiver...

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Innovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Transcript of Innovative Low Head Hydro - · PDF fileInnovative Low Head Hydro – The StreamDiver...

Page 1: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Innovative Low Head Hydro –The StreamDiver® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Page 2: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Agenda

1. StreamDiver® Introduction

2. Design Concept and Testing

3. Nussdorf Pilot Plant Operations

4. Summary, Results and Outlook

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 3: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Worldwide, there is still tremendous potential for the use of

low head hydropower for power generation.

Decentralized hydropower generation is sustainable, renewable

and supports economic development of remote areas.

However, decentral, low head power plants have specific

requirements regarding commercial viability, availability,

maintenance and environmental aspects.

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 4: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

StreamDiver® Application Range Covers

Heads From 2 - 8 m (up to 26 ft.)

Turbine classification

Application by head and flow range

A single unit generation ranges from below

50 kW up to above 750 kW depending on

the available head and flow.

The StreamDiver® covers the low

head, low power range next to

conventional designs like Kaplan,

Francis or Pelton.

StreamDiver® application range (single unit)

5 different runner sizes (modules)

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 5: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Reduction of O&M Costs is One Key

Premise and Today’s Focus

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Reduced O&M Cost & Risk

Oil-free Plant Solution

Ease of Project Execution

Reduction of Civil Cost

Page 6: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Clarity: The Simplified Design of the

StreamDiver® Ensures the Highest Reliability

Generator & terminals

Stator vane

Runner

Housing

Shaft, bearing assembly

1

2

• Turbine housing with guide vanes

• Radial and axial bearing

• Shaft ends

• PMG generator

• Runner

• Bulb nose

1

2

3

4

5

6

3

2

3

4 5

6

Standard version: Non-regulated, direct-driven turbine generator unit

No dynamic seals, cooling water system, lubrication oil system, excitation system, or runner or guide vane regulation

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 7: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Two Unique Features are Most Relevant:

Bearing Lifetime and Cooling Concept (1/2)

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Lubrication

Water flow

Heat transfer

Water inlet

Water inlet

Water flow

Heat transfer

Page 8: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Two Unique Features are Most Relevant:

Bearing Lifetime and Cooling Concept (2/2)

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

1. Water exchange• Bulb fills with river water before start-up

• Minimal exchange during operation (minimal sediment exchange)

2. Water circulation• Shaft rotation will circulate water in bulb to avoid hotspots

• Circulation transports heat to the housing elements

3. Heat transfer• Discharged flow passes the bulb and housing

• Passive, convective cooling of the bulb

4. Lubrication• River water inside the bulb generates lubrication film• Contained sediments are processed by hard coated shaft

Page 9: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Bearing Performance and Lifetime:

Endurance Tests at the Test Rig in Heidenheim

Test rig assembly and installation

Scaled model with same drive-train dimensions

Intermediate measurements of wear (interval of 6 w)

Hard-coated surface at shaft, soft shells and pads

• >18,000 hours of operation

• Tested with different densities

of quartz in bulb1

• Brenz river installation

• Low head of 2 meter results in

relatively low bearing load factor

1 Due to the high hardness rate (Brinell scale), quartz is considered as most relevant sediment which causes wear of the shaft coat The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 10: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

0 3,000 6,000 9,000 12,000 15,000 18,000 21,000

Re

lati

ve

we

ar

[%]

Operating hours [hrs]

axial bearing

radial bearing DE

radial bearing NDE

Results Indicated Wear on Hard Coat with No

Significant Correlation with Quartz Density

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

NDE DEHydraulic force

(runner)

Weight

(drive train)

The axial thrust bearing shows most significant wear

Degradation of hard coat on thrust ring by a factor of 2.7 compared to radial bearing at the non-driven end (NDE)

0,5 g/l 1 g/lriver water

<< 0.5 g/l

2 g/l

Quartz

content

3.50

3.00

2.50

2.00

1.50

1.00

0.50

0.00

Relative wear:

Ax 2.7

rad DE 1.7

rad NDE 1.0

Page 11: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Test Rig Configuration Transferred to

Nussdorf Prototype Design

Bearing lifetime influencing factors: test rig compared to prototype design Nussdorf (module size SD 13.10)

Additional factors: capacity factor (full load hours per year, number of start & stops, ambient conditions (temperatures, ...)

Factor Test rig Nussdorf

Stationary loads1 different sizes + generator

Load factor (hydraulic) Head = 2 m, 7.7 kW Head = 3.6 m, 314 kW

Water quality2 Up to 2 g/l (Quartz) < 0.5 g/l (Quartz)3

NDE DEHydraulic force

(runner)

Weight

(drive train)

1 Considers design dimensions (bearing distance, clearances, size), stationary loads from drive-train

2 Due to the high hardness rate (Brinell scale), quartz is considered as most relevant sediment, which causes wear of the shaft coat

3 Based on assessment report about sediment transport in the Danube river

Expected relative wear (average)

Factor compared to test rig

• Axial 2 - 3

• Radial DE 6 - 7

• Radial NDE 4 - 5

Expected lifetime (in years, full load)

75% wear allowed, max. value applied

• Axial 16

• Radial DE 11

• Radial NDE 26

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 12: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Prototype in Nussdorf (Austria) Now Completing

4 Years of Maintenance-free Operation

Turbine Data:

• Power Unit: SD 13.10 (Ø 1310 mm)

• Power: 314 kW / max. 450 kW

• Net head: 3.58 m / max. 4.68 m

• Flow: 9.96 cms

• Generator speed: 333 rpm, 50 Hz

Project Status:

• In operation since August 2012

• Operating hours: > 30,000 hrs 1

• Exported electricity: > 8.0 GWh 1

• On-site inspections: 2 (down: 3 days)

• Maintenance services: 0

Status: April 2016The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 13: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Housing After 42 Months of Operation Shows

Slight Organic Layer, but Intact Coating

• Generator leakage test okay, temperature and leakage sensors in function

• Anti-corrosion coating intact (covered by thin organic layer)

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 14: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

The Stainless Steel Runner is in Excellent

Condition and Shows No Notable Abrasion

• Runner blade condition excellent, no issue with clearances of rotating

parts (blade tip, runner housing, ...)

• Guide vane coating intact with some impacts on leading edge

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 15: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

The Power Output Versus

Measured Gross Head Per Year

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

The performance of the machine has been stable (constant slope); tendency to have improved over the years (A)

(B): Power spread (bias of data for same gross head) mainly influenced by intake conditions (head losses due to pollution level)

A

B

Page 16: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

A. Delta of 25°C between hottest

and coldest period (river water)

B. Linear correlation of generator

temperature and power

Temperature Levels in Bulb and Generator

Stator Confirm Passive Cooling Concept

Generator phase temperature vs. power output

Seasonal effects (quarter 1 to 4)

Generator phase temperature vs. water temperature in bulb

Temperature rise of generator below design value (class F/B)

A. Temperature rise of

up to ~40°C (design

class B: 80°C)

A

B

B A

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 17: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Measured Wear at the Radial Bearing (NDE)

Confirms Projections from Endurance Test

Expected replacement of the radial NDE shaft end is required after 23 years (initial projection: 26 years)

Replacement is recommended when 25% of the remaining layer is reached – extrapolated: 30,000 x 75/11 = 204,000 hours = 23 yrs

Profile 1

3 2

• Wear is not constant over measured profiles on shaft line

• Relative wear with maximum of 7 - 11% after 30,000 operating hours

• Additional sensors detect wear limit for predictable and planned replacement

7 – 11 %

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 18: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Summary and Outlook

• StreamDiver® low head technology for heads up to 8 m

• The innovative design minimizes support systems to maximize reliability

• Passive cooling concept and bearing design are core features

• Test and proof of design successful

• Lifetime projections exceed initial design values

• Full-scale Nussdorf prototype now goes into its fifth year of operation

• Full load operation, no maintenance required so far

• Retrieval and detailed inspection planned after 5 years

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Page 19: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

Bearing Lifetime Projection and Monitoring:

Project Application Band for 50 - 100 % full load

Application

• Content of hard particles

< 2 g/l (e.g. quartz)

• Water temperature up to 30°C

• Maximum wear is monitored:

• Maximizing lifetime

• Predictive maintenance

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21

Standard design configuration (SD 7.90 – SD 13.10)

Recommended replacement at 25% of the remaining hard coat layer

Radial DE

Axial

Radial NDE

Lifetime Projection (Radial DE):

Full load 3 m head 8 m head

50% 24 yrs 14 yrs

100% 12 yrs 7 yrs

Page 20: Innovative Low Head Hydro -   · PDF fileInnovative Low Head Hydro – The StreamDiver ® in Action NWHA Small Hydro Workshop 2016, Wenatchee , WA USA

The StreamDiver® in Action | NWHA Small Hydro Workshop 2016, Wenatchee , WA USA | 2016-09-21