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Hydro Power
Georg Woeber
23.11.1967
Technical Highschool in Moedling: precision engineering
Graduation 1988
Relationship, 1 child
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Overview
ANDRITZ HYDRO
Case studies
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ANDRITZ HYDRO
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Company Profile
A world market leader in most business areas
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Facts and Figures
in MEUR 2010
4.000
Order Intake: 1,870 MEUR
3.500 3.376
Sales: 1,579 MEUR
3.000 2.895 Order Backlog: 3,376 MEUR
2.590
Employees: 6,530
2.500
2.000
1.500
1.000
500
0
2008 2009 2010
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Our global Presence
Hammerfest
Nälden
Tampere
Jevnaker
Västerås
Glasgow
Moscow
Kiew
Lachine Ravensburg Praha
Vancouver Pointe Claire Zurich,
Vevey, Kriens Vienna, Linz,
Peterborough
Grenoble Weiz, Graz,
Spokane Schio Tiszakécske
Chambly
Lewiston Madrid Ankara Beijing
Charlotte Teheran
Chengdu Hangzhou
Faridabad Hanoi Foshan
Morelia
Bhopal
Manila
Caracas Kuala Lumpur
Bogota
Jakarta
Araraquara
Lima
Campinas
Sao Paulo
Johannesburg
Santiago de Chile
Melbourne
Local Set-ups
Local Set-ups with Manufacturing
02/2012
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Our Experience
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Our History
Waplans
Ateliers de Construction Andritz VA TECH HYDRO
Méchanique de Vevey (ACMV) SAT
Andritz
GE HYDRO inepar
Bell ELIN
GE HYDRO
Pichlerwerke Sulzer Hydro Møller
KVAERNER
Escher Wyss
C.E.G.B.
Tampella
English Electric Boving
Sorumsand
KAMEWA Veksted
KMW
NOHAB Dominion
Finnshyttan Engineering
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Overview
ANDRITZ HYDRO
Case studies
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Installed Hydropower Capacities
≈ 3.900 GW Technical Potential *
937 GW global installed capacity North Africa
America 7%
Africa 12% China
South
3% 19%
North China America
America 22% 13%
18%
Europe
8%
Asia
Asia 41%
South 23%
America Europe
15% 19%
China
Africa 32%
7%
Asia
South
36% * Technical Potential, considering the region
America Europe
18% specific Capacity Factors of power plants
3%
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Potential for Rehabilitation
Source: Alstom; Platts – UDI; Figures of 2009
But actual ageing process results in 16GW p.a. reaching 40 years age.
The “10GW p.a.” rate is not sufficient to stop ageing of existing fleet !!
30 GW p.a. necessary
To face the coming wave and
To stop the ageing process and to avoid dramatic incidents.
02/2012
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Worldwide installed capacity and ANDRITZ HYDRO fleet
Total 243 GW
125 GW
51%
Total 169 GW
71 GW
42%
Total 332 GW
64 GW
19%
Total 42 GW 15GW
35%
Total 139 GW
44 GW
32%
Data based on World Atlas Hydro Power and Dams 2010; ANDRITZ references
Europe includes Turkey, Russia, Armenia, Azerbaijan, Georgia, Kazakhstan, Kyrgyzstan, Tajikistan, Turkmenistan, Uzbekistan
Africa includes Near and Middle East
02/2012
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Overview
ANDRITZ HYDRO
Case studies
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Do you see a difference?
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Multiple reasons for modernizing a
Hydro Power Station
HPP in Ural / Russia, >100 yrs, noisy, but working HPP Sayano–Shushenskaya / Russia, 6400 MW, 2009
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3 major options to achieve
improvement of plant performance
Rehabilitation or refurbishment
including improved maintenance.
This option will bring your systems /
components back to original status (only).
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The benefits of rehab
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Optimization of choices
Decision:
Rehab or Upgrading
Potential of improvements:
CFD Diagnosis
Tools:
Feasibility
Graphic Comparison
of Variants
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Overview
ANDRITZ HYDRO
Case studies
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The 3 Phase Approach
the ANDRITZ HYDRO Process for Modernisation of HEPPs
Diagnosis
Analysis
Therapy
generation
lifetime
availability
reliability
safety
maintenance
environment
02/2012
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The 3 Phase Approach
Modernisation Process
02/2012
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The 3 Phase Approach
Tasks, Tools and Services
State-of-the-art Delegation of
Economical Local
simulation and supervisors and
viability study service centers
design engineering erection teams
Strong On-site
Financial
modernization machining
engineering
project expertise equipment
02/2012
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02/2012
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CFD
FEM
2-D
Rotor Dynamic Potential flow
Analysis
1975
1975
Quasi-3-D
Static analysis of Euler
a Spiral Case
3-D Potential
1985
root transition
Vaned intake
stress analysis 3-D
Navier Stokes
analysis of a complete system
1995
1995
--- Stress analysis based on ---
CFD pressure field
Multistage
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Contact analysis
of a runner Navier Stokes
coupling
Modal Free surface
analysis in flow
water
2005
2005
Unsteady
Navier Stokes
Forced
response
analysis Multiphase flow
2015
30 years of CAE - From analysis of single component to a joint
Improvement Potential of Hydraulic Performance
95 %
90 %
+ 4%
Turbine Peak Efficiency
85 %
Pelton supplied
80 %
Kaplan
in 1950
Francis
Pelton
75 %
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Improvement Potential of Generator components
Potential output increase by replacement of generator components
approximate value
Stator winding ~ 5 – 10%
Stator winding + stator core ~ 7 – 15%
New stator + new pole winding ~ 10 – 20%
New stator + new poles ~ 10 – 25%
02/2012
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Achievements
Higher output and efficiency
Akosombo / Ghana
Customer: Volta River Authority
D = 5,650 mm Francis Turbine
n = 115.4 rpm
H = 65.0 m
P old = 139.3 MW Runner fabrication in the workshop
in Linz, Austria
P new = 173.1 MW ( + 25% )
6 new runners,
adaptation of components
Additional 200 MW
“renewable energy”
02/2012
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Achievements
Higher output and efficiency
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Achievements
Higher output and efficiency
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Achievements
Higher output and efficiency
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Overview
ANDRITZ HYDRO
Case studies
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Case Study
ROUNA II
02/2012
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HEPP Rouna 2 / Papua New Guinea
Modernization of Hydro Power Plants
Major scope
Automation & Control
Excitation
Power Plant Management
Protection
Synchronization
Turbine Governor
Major features:
Increased Reliabilty & Availability.
Increased HS&E Standards.
Reduced Capital Project Costs due to alternative
technical solution
Community Involvement
02/2012
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Challenges and benefits
Location
Papua New Guinea, power plant in a remote area,
one „direct“ flight per week to Port Moresby
Personal safety, security, travelling
Technical
Delivery of equipment, limited access required
specific design of the new generator
Logistics, local transportation, reinforcement of bridge
and repair of roads
Social aspects
700-1000 ethnic groups in PNG
Support of local community
Benefits
Increase of output and efficiency
Plant availability and reliability is important for the
power supply of Port Moresby
Optimized project costs
02/2012
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Transportation and Erection Challenges
Access during
Rehab via
a vertical shaft
~ 170m
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Technical considerations
Generator
Challenges
Transportation limitations of weight and
dimensions
Improvement of plant reliability
Benefits
Compact design - stator to lower through
vertical access shaft (2150 x 2300)
Cylindrical rotor design – No Externally
Mounted Rotor Poles
GD2 – Combined Brake Ring and Flywheel
Reducing the external auxiliary systems for the
generator (combined braking and jacking
system)
02/2012
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Technical considerations
Turbine and auxiliary systems
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Project social context
Challenges
Understand and interface with specific social environments effectively to deliver successful projects
in an unobtrusive manner
Respecting local cultures and needs to demonstrate visible local community interaction with the
project
Develop a Project Social Responsibility Policy to engage these responsibilities
Benefits
Under the Project Social Responsibility Policy, the Rouna II Upgrade Project created and executed
support projects in the local community
Rouna II Upgrade Project promoted PNG cultural diversity, the project features and the project social
responsibility policy
02/2012
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Security and Political Risk Forecast
02/2012
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What is Security?
What is Security not?
It is NOT placing a man at the entrance gate to open it every morning and greet you.
It is NOT throwing money at some local security company that simply hires a few men in a
old worn out uniforms sitting around.
It is certainly NOT giving the man at the entrance gate a big gun in the hope that it scares off
bad elements.
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Security assessment process
Threats Identification
Brainstorm possible security threats.
Consider the country.
Consider main & secondary locations of activities.
Consider transfer routes.
Consider facts & perceptions.
Transfer security threats into list.
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Case Study
EDEA I
02/2012
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Service & Rehab References
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Edea 1
Location
HPP EDEA
HPP SONGLOULOU
02/2012
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Challenges & benefits
Challenges
Location in Cameroun, poor developing country,
politically unstable, traveling is dangerous, local
procurement almost impossible
Climatic conditions, malaria threats
Personal safety, security, evacuation plan
Bureaucratic decisions
Transportation of equipment difficult due to poor
road conditions
Plant in operation during rehabilitation
Benefits
Increase of the turbines output will strengthen the
power supply in Cameroun
Increase of efficiency and improve water
management
Increase availability and reliability of Edea 1
02/2012
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Project Description
Intake Equipment
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Project Description
Turbine Equipment
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Project Description
Generator Equipment
Roebel bar
rotor
hub spider shrunk to the shaft
rotor poles
one piece core
poles fixed by yoke ring by bolts
bearings
upper combined bearing
lower guide baring
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Project Description
Governor system
Piston
accumulator
Servomotor Pumping unit
Position and
transducer automatic
isolating
valve
02/2012
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Project Description
Control and electrical balance of plant
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Project Description
Mechanical auxiliaries
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Overview
ANDRITZ HYDRO
Case studies
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Environment and Sustainability
Implementation of the
Hydropower Sustainability Assessment Protocol
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Rehabilitation needs experience
THANK YOU!
02/2012
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Thank you for Your attention !
Georg Woeber
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