REHABILITATION OF MEDIUM-HEAD HYDROPOWER PLANTS WITH EXPLOITED TWIN-FRANCIS TURBINES.

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

2 ZRE Gdańsk S.A., st. Litewska 14A, Gdańsk ZRE GDANSK Company Profile 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

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

4 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

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

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

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

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

9 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.

10 Design solutions 3D project based on CFD designed flow passages

11 Manufacturing of the runners

12 Guide vanes system for HPP Gródek

13 Acceptance tests of HPP Gródek Guaranteed value Weighted efficiency Measured value 84.0 % 86.2 % ƞ [%] Measured efficiency Q [m3/s]

14 Vibration levels: HPP Gródek after upgrade Bearing type: Vibrations velocity [mm/s] Measured values of vibrations velocity Reference values ISO Thrust bearing 0.3 Turbine guide bearing 0.2 <1.6 Generator guide bearing

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

16 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

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

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

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

20 Installation of new units (HPP Kamienna)

21 Acceptance tests of HPP Kamienna combined weighted efficiency Guaranteed value Measured value 82.8 % 85.4 % ƞ [%] Measured values of efficiency Measured values of efficiency prior to rehabilitation Q [m3/s]

22 Summary ZRE Gdańsk S.A., ul. Litewska 14A, Gdańsk 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

23 Thank you for your attention!