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Guide on How to Develop a Small Hydropower Plant
ESHA 2004
CHAPTER 6: ELECTROMECHANICAL EQUIPMENT
CONTENTS
6
Electromechanical equipment.................................................................................................. 154
6.1
Powerhouse...................................................................................................................... 154
6.2
Hydraulic turbines............................................................................................................ 156
6.2.1
Types and configuration........................................................................................... 156
6.2.2
Specific speed and similitude................................................................................... 168
6.2.3
Preliminary design................................................................................................... 171
6.2.4
Turbine selection criteria......................................................................................... 174
6.2.5
Turbine efficiency.................................................................................................... 181
6.3
Speed increasers............................................................................................................... 184
6.3.1
Speed increaser types............................................................................................... 184
6.3.2
Speed increaser design............................................................................................. 185
6.3.3
Speed increaser maintenance................................................................................... 186
6.4
Generators........................................................................................................................ 186
6.4.1
Generator configurations.......................................................................................... 188
6.4.2
Exciters..................................................................................................................... 188
6.4.3
Voltage regulation and synchronisation................................................................... 189
Asynchronous generators......................................................................................................... 189
6.5
Turbine control................................................................................................................. 189
6.6
Switchgear equipment...................................................................................................... 192
6.7
Automatic control............................................................................................................ 193
6.8
Ancillary electrical equipment......................................................................................... 194
6.8.1
Plant service transformer......................................................................................... 194
6.8.2
DC control power supply......................................................................................... 194
6.8.3
Headwater and tailwater recorders........................................................................... 194
6.8.4
Outdoor substation................................................................................................... 195
6.9
Examples.......................................................................................................................... 196
LIST OF FIGURES

Figure 6.1 : Schematic view of a powerhouse \u2013Low head.............................................................. 155 Figure 6.2 : Schematic view of a powerhouse \u2013high and medium heads........................................ 155 Figure 6.3 : Schematic view of a hydropower scheme and of the measurement sections............... 157 Figure 6.4 : Cross section of a nozzle with deflector....................................................................... 158 Figure 6.5 : View of a two nozzles horizontal Pelton...................................................................... 159 Figure 6.6 : View of a two nozzle vertical Pelton............................................................................ 159 Figure 6.7 : Principle of a Turgo turbine......................................................................................... 160 Figure 6.8 : Principle of a Cross-flow turbine................................................................................. 160 Figure 6.9 : Guide vane functioning principle................................................................................. 162 Figure 6.10: View of a Francis Turbine........................................................................................... 162 Figure 6.11 : Kinetic energy remaining at the outlet of the runner.................................................. 163 Figure 6.12 : Cross section of a double regulated Kaplan turbine................................................... 164 Figure 6.13 : Cross section of a double regulated Bulb turbine....................................................... 164

152
Guide on How to Develop a Small Hydropower Plant
ESHA 2004

Figure 6.14 : Cross section of a vertical Kaplan.............................................................................. 166 Figure 6.15 : Cross section of a Kaplan siphon power plant........................................................... 166 Figure 6.16 : Cross section of a Kaplan inverse siphon power plant............................................... 166 Figure 6.17 : Cross section of an inclined Kaplan power plant....................................................... 166 Figure 6.18 : Cross section of a S Kaplan power plant.................................................................... 166 Figure 6.19 : Cross section of an inclined right angle Kaplan power plant..................................... 166 Figure 6.20 : Cross section of a pit Kaplan power plant.................................................................. 167 Figure 6.21 : Design of turbine runners in function of the specific speed ns................................... 169 Figure 6.22 : Specific speed in function of the net head Hn = E/g................................................... 170 Figure 6.23 : Nozzle characteristic.................................................................................................. 172 Figure 6.24 : Cross section of a Francis Runner.............................................................................. 172 Figure 6.25 : Cross section of a Kaplan turbine............................................................................... 173 Figure 6.26 : Turbines' type field of application.............................................................................. 175 Figure 6.27 : Cavitation limits......................................................................................................... 179 Figure 6.28 : Efficiency measurement on a real turbine built without laboratory development. .... 181 Figure 6.29 : Schematic view of the energy losses in an hydro power scheme............................... 182 Figure 6.30 : Typical small hydro turbines efficiencies................................................................... 183 Figure 6.31: Parallel shaft speed increaser....................................................................................... 185 Figure 6.32: Bevel gear speed increaser.......................................................................................... 185 Figure 6.33: Belt speed increaser..................................................................................................... 185 Figure 6.34 : Vertical axis generator directly coupled to a Kaplan turbine..................................... 188 Figure 6.35 : Mechanical speed governor........................................................................................ 191 Figure 6.36 Level measurement....................................................................................................... 195

LIST OF TABLES

Table 6.1: Kaplan turbines configuration........................................................................................ 165 Table 6.2: Range of specific speed for each turbine type................................................................ 170 Table 6.3: Range of heads................................................................................................................ 175 Table 6.4 : Flow and head variation acceptance.............................................................................. 176 Table 6.5: Generator synchronisation speed.................................................................................... 180 Table 6.6: Runaway speeds of turbines........................................................................................... 180 Table 6.7 : Typical efficiencies of small turbines............................................................................ 184 Table 6.8: Typical efficiencies of small generators......................................................................... 187

LIST OF PHOTOS

Photo 6.1 Overview of a typical powerhouse.................................................................................. 156 Photo 6.2: Pelton runner.................................................................................................................. 159 Photo 6.3: Horizontal axis Francis turbine....................................................................................... 161 Photo 6.4: Horizontal axis Francis turbine guide vane operating device......................................... 162 Photo 6.5: Francis runner................................................................................................................. 162 Photo 6.6 : Kaplan runner................................................................................................................ 164 Photo 6.7: Siphon Kaplan................................................................................................................ 167

153
Guide on How to Develop a Small Hydropower Plant
ESHA 2004
6
ELECTROMECHANICAL EQUIPMENT1

This chapter gives the main description of the electromechanical equipment, some preliminary design rules and some selection criterion. For more technical description, please refer to L. Vivier2, J. Raabe3 books and others publications4 5 6 7 8 9 10.

6.1
Powerhouse

In a small hydropower scheme the role of the powerhouse is to protect the electromechanical equipment that convert the potential energy of water into electricity, from the weather hardships. The number, type and power of the turbo-generators, their configuration, the scheme head and the geomorphology of the site determine the shape and size of the building.

As shown in figures 6.1 and 6.2, the following equipment will be displayed in the powerhouse:

\u2022Inlet gate or valve
\u2022Turbine
\u2022Speed increaser (if needed)
\u2022Generator
\u2022Control system
\u2022Condenser, switchgear
\u2022 Protection systems
\u2022DC emergency supply
\u2022Power and current transformers
\u2022etc.

Fig. 6.1 is a schematic view of an integral intake indoor powerhouse suitable for low head schemes. The substructure is part of the weir and embodies the power intake with its trashrack, the vertical axis Kaplan turbine coupled to the generator, the draft tube and the tailrace. The control equipment and the outlet transformers are located in the generator forebay.

In order to mitigate the environmental impact the powerhouse can be entirely submerged (see
chapter 1, figure 1.6). In this way the level of sound is sensibly reduced and the visual impact is nil.
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