03 Koutnik - Hydro Power Plants

Voith Hydro
Hydro Power Plants

Dr. Jiri Koutnik, 2013-11-04
AGCS, Munich
Voith in figures
50 42,000 5
4.7 % 1867 5.7 billion
In over
countries
R&D ratio
Employees
Family-owned since
Markets
Sales
Stand: 2011/12
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
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
140 Years of Major Projects

1873
1903
1912
1934
1938
1964
1970
1995
1997
1998
2000
2010
2011
First Voith Francis turbine

First Pelton turbine
Niagara Falls, Canada
Pedreira, Brazil
Sungari, China
Roenkhausen, Germany
Raccoon Mountain, USA
First fish-friendly turbine design
Three Gorges, China
Goldisthal, Germany
Guangzhou II, China
Frades II, Portugal
Belo Monte, Brazil
4
Flow Q and Head H are decisive for the power
P = Q H g
IN
OUT
Head H is mainly influencing the turbine type

Pelton:
10,000
~200m to 2.000m
2,000
Francis
1,000
~50m to ~700m
100
Kaplan
~2m to ~50m
Head (m)
10
Bulb
1
~2m to ~20m
10
100
1,000
10,000
Power (kW)
100,000
1,000,000
Pit ~2m to ~10m

6

Pelton
~200 m to 2,000 m

Francis (pump turbine)
~50 m to 700 m

Kaplan
~2 m to 50 m

Bulb
~2 m to 20 m
Ohio River. Cannelton, USA
10
Complete Plant Systems

Pump Storage Powerhouse using full 3D CAD Capabilities
11
History of hydro power turbines and pump-turbines

BHT(China)
(in planning)
turbines
900
800
Three Gorges
(China)
Itaipu
(Brazil/ Paraguay)
700
Longtan (China)
600
Xiao Wan (China)
Xi Luo Du (China)
500
storage sets
400
Bath County
(USA)
300
Gordon (Australia)
200
100
Paulo Afonso II
(Brazil)
Dworshak
Gokcekaya
(USA)
(Turkey)
50
IIha Solteira
(Brazil)
Palmiet
(S. Africa)
Guangzhou II
(China)
Goldisthal
(Germany)
Ingula
(S. Africa)
Limberg II
(Austria)
0
1960
1970
1980
1990
2000
2010
Year
12
History of hydro power generators

and motor-generators
BHT(China)
(in planning)
1000
Itaipu (Brazil)
900
Water cooled
Air cooled
800
GURI II (Venezuela)
Xi Luo Du (China)
Three Gorges (China)
700
600
Bath County (USA)

(2000)
500
Raccoon
(USA)
400
Bath County (USA)

(1976)
300
200
100
0
1900
1910
1920
1930
1940
1950
1960
1970
1980
1990
2000
2010
Year
13
Logistic Challenge:
400t Stainless Steel Runner
14
Rotor Assembly Precision with > 2000t
15
Pumped Storage
Wind, Solar and Hydro Integration

Reserves
Frequency regulation
MW
Wind Production in Denmark in 2009
4000
3500
3000
2500
actual
2000
1500
1000
average
500
0
(765 MW)
Jan Feb Mar Apr May Jun Jul
Aug Sep Oct Nov Dec
Energy
Frequency
Storage
16
Major pumped storage projects of Voith Hydro

Wehr
Castaic
Wallace Dam
Mount Elbert
Herdecke
Saeckingen
Malta
Goldisthal
Waldeck I
Haeusling
Bath County
Coo II
Helms
Bad Creek
Frades II
Aguayo
Jocassee
Guang Zhou II
Kops II
Venda Nova II
Yang Zhou Yong
Racoon
Seneca Mountain
La Muela I
Tedorigawa
Velebit
Hong Ping
Estangento
Fairfield
Shi San Ling
Pan Jia Kou
Limberg II
Rodund
Zhang He Wan
Tai An
San
Giacomo
Mingtan
La Muela II
Cheongpyung
Samrangjin
Muddy
Run
Ghatghar
Smith
Mountain
Flat Iron
Ingula
Siah Bishe
Palmiet
Rio Grande
17
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
Slower
Less Flexible
Faster
More Flexible
18
Mode change times for various Unit concepts Flexibility

Pump Turbine
Mode change
T
1
2
5
6
8
9
Standstill
TU-Mode
Standstill
PU-Mode
SC-Mode
TU-Mode
SC-Mode
PU-Mode
TU-Mode
PU-Mode
PU-Mode
TU-Mode
time [seconds]
A B C D E
90 75
340 160
70 20
70 50
420
190 90
90
230
60
70
470
280
90
85
40
30
45
60
65
80
20
25
25
25
Reversible PT
A advanced conventional
B extra fast response conventional
C VarSpeed,
Ternary set
D with hydraulic torque converter + hydr. short circuit, horiz, with Francis Turbine
E same as E but vertical with Pelton Turbine
19
Fast control of var. speed units

Effect on water hammer
1.1
DC link voltage
230
220
0.9
rotor speed
active power
200
Spiral case pressure
0.7
190
0.6
180
0.5
170
0.4
160
[mwc]
[p.u.]
0.8
210
GVO
150
0.3
0
TVA PSExpert
AGCS
ForumDays
| 2011-09-13
| Voith - Dr.
| 34Jiri Koutnik | 2013-11-04 |
10
Time [sec]
15
20
20
Start up Pump Turbine
1 min
21
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)
22
The Voith Hydro Policy for

Plant Operational Safety
23
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
24
Basic philosophy
Start of the non-tolerable risk region
Safe region
Unsafe / hazard region
Risk
Tolerable risk region
Non-tolerable
risk region
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.
25
Risk reduction process
Risks
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 3
Step 4
Project life cycle

26
Hydro power plant water ways

Plant safety
water closing devices
1
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
G
4
3
T
5
27
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)
28
Hydro power plant

HV transmission line
Grid breaker
opens
(2nd measure)
Generator
breaker failure
Example 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.
29
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.
30
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
31
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.
32
Contact:
Dr. Jiri Koutnik
Head of Basic Development,
Voith Hydro Holding, Heidenheim, Germany
jiri.koutnik@voith.com
33

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03 Koutnik - Hydro Power Plants

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Voith Hydro

Hydro Power Plants

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Pumped Storage Plant

Run of River Plant

140 Years of Major Projects

First Voith Francis turbine

Flow Q and Head H are decisive for the power

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Head H is mainly influencing the turbine type

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Pit ~2m to ~10m

Head H is mainly influencing the turbine type

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Head H is mainly influencing the turbine type

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Head H is mainly influencing the turbine type

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Head H is mainly influencing the turbine type

Ohio River. Cannelton, USA

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Complete Plant Systems

History of hydro power turbines and pump-turbines

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

History of hydro power generators

Bath County (USA)

Bath County (USA)

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Rotor Assembly Precision with > 2000t

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Wind, Solar and Hydro Integration

Wind Production in Denmark in 2009

Jan Feb Mar Apr May Jun Jul

Aug Sep Oct Nov Dec

Major pumped storage projects of Voith Hydro

Yang Zhou Yong

Shi San Ling

Pan Jia Kou

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Possible Unit Configurations Depending on

Conventional reversible unit

Fast & frequent response reversible unit

Conventional units in short circuit arrangement

Variable Speed reversible unit

Ternary unit arrangement

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Mode change times for various Unit concepts Flexibility

Fast control of var. speed units

Spiral case pressure

Start up Pump Turbine

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Ancillary Services of Conventional and

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

The Voith Hydro Policy for

Objective and goals

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

Unsafe / hazard region

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |

One major failure tolerant in areas with

Risk reduction process

Project life cycle

Hydro power plant water ways

Gate or roller stop log