REFURBISHMENT OF MEDIUM HEAD FRANCIS TURBINES

-TUNGATINAH CASE STUDYJoseph VIRONE, Anne CUVILLIER, Celine GARNIER, Nicolas JUHEL Claude BUCHI
Congrs SHF : Enhancing Hydropowerplant facilities, Grenoble

April 9-10, 2014

TUNGATINAH CASE STUDY

Location : Tasmania, Australia
Site Location
Hobart

Presentation title - 29/04/2014 P 2

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Power station description

Five vertical shaft Francis turbines,
designed for 28 MW limited to 26,1:
vibrations.
Turbine are of Boving design, directly
coupled to a GE generator.
Each turbine has a spherical inlet valve and
a relief valve discharging directly from the
spiral casing.
The generating sets were first installed and
put in operation between 1953 and 1956.

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Design characteristics :
Rated output at 289.56 m net head:
26.100 MW Corresponding flow at rated
output:10.36 m3/s
Maximum output: 28.076 MW (37 650
BHP)
Rated speed: 600 rpm
Maximum runaway speed: 1050 rpm

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Objectives of the refurbishment- 3 units

HYDRAULIC
MECHANICAL
ENVIRONMENTAL
SAFETY

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ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Site measurements - performances

CALCULATED EFFICIENCY CURVE
Efficiency
+1,5/2,5 %
Max output 31
MW
Designed for 28
Limited to 26,1

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ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

TURBINE SECTION
Air axial valve

Distributor

Presentation title - 29/04/2014 P 6

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Turbine general cross section

New components :
Spiral case
Distributor
Lower guide bearing
Turbine bearing & Shaft
seal
Turbine shaft
New coupling bolts with
Gen shaft
Runner with coupling
Air axial valve at the top
New Servomotor for PRV

Replacement of spiral case

Existing spiral case

Existing spiral case dismantling

Existing spiral case evacuation

Exceptionnal replacement

New spiral case : installation

Presentation title - 29/04/2014 P 7
ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

New spiral case : concreting

Pressure relief valve solution

Existing pressure relief valve with mechanical link to the

operating ring
New servomotor for oil transfert
Presentation title - 29/04/2014 P 8
ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Distributor new design for medium head Francis

turbines

One of the servomotors

Distributor top view during
installation
Distributor before refurbishment
Distributor with turbine shaft

Distributor during trial assembly at

woorkshop

Presentation title - 29/04/2014 P 9

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

RUNNER
Old runner
Single casted parts:
- 17 blades
- Less than 3 t
- Outlet dia 1135 mm
- Dynamically balanced

Casting advantages :
Reduced delivery time.
Solves the welding access problem for
small runners.
Suppresses the risk of weld defects.
Runner during dynamic balancing

Runner during dye

penetrant test
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Runner at workshop

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

European foundries with :

High tec process
Very accurate model 5 axis machining
Overthicknesses reduced
Until to 5 m

AIR AXIAL VALVE

Air axial valve : cross section

The air valve is fully integrated in
existing cover.
aeration through the shaft line
automatic with possibility to be piloted.
This arrangement improves unit stability.

View from the installation bay

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ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Hydrostatic water bearing

Compact
stiffen

Maintain the shaft in position: spring effect

Compact
Stiffen
Wearing rings gaps optimized

Presentation title - 29/04/2014 P 12

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Hydrostatic water bearing deflection

The max allowable deflection transmitted

by the structure, through the head cover,
to the hydrostatic bearing was calculated
using finite elements method.

Full assembly behavior checked by finite elements calculation

Presentation title - 29/04/2014 P 13

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Hydrostatic water bearing

Hydrostatic turbine water bearing in reverse position

Turbine shaft & sleeve with ceramic coating

New automatic strainer 50m

Presentation title - 29/04/2014 P 14
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that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Lower generator bearing

Presentation title - 29/04/2014 P 15

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

CONCLUSIONS

Finally we can retain :

- efficiency & output > increased
- limitation due to vibrations removed
- CFD expectations confirmed

Major innovation has been used : hydrostatic water bearing

rare replacement has been performed : embedded spiral case
Unit instabilities have been suppressed ( new air axial valve )
Environment has been preserved thanks to the new hydrostatic water bearing.
Safety of the power plant has been increased
suppressing oil vapour contamination ( lower bearing)
using modern & simplified distributor design and failure detection
Using new oil transfert operating mode for pressure relief valve

Presentation title - 29/04/2014 P 16

ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on
that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without
liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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