Raabe J. Hydro power - the design, use, and function of hydromechanical, hydraulic, and electrical еquipment

Fig. 3.4.33. Isogyre. The horizontal Isogyre of thc pumped storage plant tlandeck 111, at Aare,

Switzerl;lnd (owner Oberhasli

AG.

Inl?crtkirchen) built by Vcvcy Charniilles Engineering ivorks.

11

=

1000

rpm;

IT,,,

=

1660 rpln. Turbining:

11

=

3i0 to 400 In;

Pm',,

.=

55

bl\fr.

Pumping:

M

=

475

m.

P

=

55

MW.

The largc rotor-generator distance in this dcsign

decreases

the critical speed. 1-1er.c:

overcritical runat\.ay speed. (Dr;i\ving courtesy Vevey Charnlilles Engineering Works,

Switzerland)

For heads below 450 m, the spiral casing with vertical axis n~ay have a retracted outer diameter with

parallel plate stay ring. according to

Piguct

(3.1281,

see Fig. 3.4.16. Above a head of 15 m, sinaller

ITS

may have a spiral casing. At lower head this is made of cast iron with prestressed bolts through

tlie stay vanes. With rising head and size the casing is made of steel, cast, riveted or welded.

In

horizo~ltal Francis turbines the admission flange of the casing can be above the shaf!

(see Fig. 3.4.42) or underneath

it

(see Fig. 3.4.43). Owing to the long moment arm via

which any load from the penstock

inay

attack the casing support, an Escher Wyss load

compensator (see Fig. 3.4.44) seems advisable for admission above the shaft

j3.1291.

The

distance between neighbouring groups depends on the type of turbines and guide

apparatus.

Typical

values are:

(2

to

2,5)

-

D,

(D

=

runner tip diameter) for

TT,

3

-

D

for turbines with

semi-spiral casing, 4

-

D

for turbines with spiral casing (Fig. 3.4.45).

Thc

main crane of the plant must

be

capab!e of lifting the heaviest continuous part. This is the

Gcncrator rotor in a direct driven set. To avoid the shaft being out of round, the latter should have

3s

few couplings as possible. klencc for a.not too large-sized machine (3.1301,

(D

<

6

m) thc shaft

is

1"

onc pice. For

a

vertical sct !he shaft length gives the clcvation of the crane hook above thc upper

of thc gcncrator rotor. Thc main cranemust be capable of lifting the shaft from the stator bore

means of

a diagonal pull. which lowers the elevation of the crane runway (3.1301.

In

the classical

tall

hall desi211 of power house the interior has to be sufficiently higl~, to

house

n

crane of this capability in its walls (see Fig. 3.4.46).

I'ig.

3.21.35.

Vcr~icnl pllrlll>-

~urhinc of thc

pumped

slclr-

i

pl;1111 at. Vouglal~s.

Frullcu (owncr IllcctricilL;

t!c

17snncc) built Ily Vcvcy

Charmillcs.

11

=.

150 rpni.

'rurbining:

)I

=

99,5 in:

P=

65

b1W. Pumping:

ti

=

100,2 ni;

P

=

60

b1W.

(Drilwing courtcsy Vcvcy

Cl~armillcs

Engineering

Works, Switzcrlnnd.)

Fig.

3.4.36.

2-stage, gate adjasted reaction machine. The vertica!

pump-turbinc of pumped storage plant Trucl, France (owner ~lcc-

triciie de France), design Neyrpic.

tr

=

75Urpm;

HT

=

438

m;

P,

=

35

PJW;

H,

=

440

m.

Contrary to the maltistr~ge non adjust-

able

pump-ti~rbinc, this type requires access to the head and bottom

cover for thc linkage of both gates. Ilighly stresszd design.

If

gate of

the

2nd

stag2

is

closed

and

that of the 1st stage leaks, the whole

casing is

subjected

to

the maximum total pressure of machine. For

a

widcr hish efficiency characteristic. Prototype with rclative mo-

dest head, since

dcsisn sccms to fit into

I!

up to 1500

nl.

(Drawing

courtesy Neyrpic.

(;renoble, France)

rig. 3.4.37. Non-adjustable vertical multistage radial pump-

Here 3-stn_cc-machine

of

the pumped storage plant at

~l~iotas, Itilly (owner Italian state power board

ENEL),

dc

prclto Sulzcr Escher Wyss design.

A

similar set was built by

jiydroart, blilano.

11

=

600 rpm. Turbining:

[I,

=

1047

rn;

P,

=

j49,5

MW.

Pumping:

II,

=

1070

m;

P,

=

151,7

MW.

(Drawing

courtesy Sulzer Escher Wyss, Switzerland)

Fig. 3.4.38. Elevation

of

horizontal ternary set in pumped storage plant Sickingen, West Germany

(o~l~~r Schluchsee

AG

Freiburg). 4

FT

(Sulzer Escher Wyss):

H

=

408 m;

n

=

600

rpm;

=

928

MW.

2-guide bearings enablc dctachment undcr pumping. Four 2-stage storage pumps.

If

=

408

m;

P

=

70,6

M

W

(Voith); liilcd start by torquc converter (Voith). Back to back arrangc-

rncnt

of

pump i~npcllcr compensates axial thrust. Hence high cficiency. (Drawing courtesy Voith)

Fig.

3.4.39.

Sectional view of power house with vertical ternary scts of combincd peak load aid

pumped storage plant Hiusling, Ziller, Austria (owner Tauernkraftbvcrke AG Solzburg). 2 FTs

H

=

620 to

744

m (to date the highest head for

a

FT),

n

=

600 rpm;

P

=

2

-

180

MW

(Sulzer Escher

\\fyss).

2-stage

single flow pumps:

P

=

2

-

IS0

b1W;

Q

=

2

.

22,5 m3/s, filled start up

by

torque

coqvertcr (Voith).

1

access tunnel from the horizontal section of the main tunncl;

2

Ziller;

2

transformer;

3

motor generator;

5

turbinc;

6

torque

converter;

7

PUIDPS;

8

penstock;

9

suction line

10 Ziller undercrossed by lcvellcd tun~el; 11 20 kV station. AIIII~J,?~ productivity 175,6 GWh.

Annual consumption by pumping 508 GWh. From

Miit~~atr~~

[1.76].

In the so-called chamber design, due to

Mosonyi

[1.53]

(see Fig.

3.4.47)

the main crane is

located outside the power house, which consequently is reduced in height.

A

removable

and split hatch on the chamber roof facilitates also transportation

of heavy parts through

the opening.

In the so-called pit design with a removable cover or the generator in the open air this

chamber is reduced to the pit of the set (see Fig.

3.4.48).

For plants needing a large submergence, because of cavitation, in unreliable ground at

site the "pit" power house (see

Fig.

3.4.49)

may be an economical solution

[3.131].

The main

part

of the set, the runner, must be made easily to zssemble, dismantle and

transport by crane. This can be achieved for

high head FTs by providing

a

door in the

draft tube wall (see Fig.

3.4.50).

This door gives access to the runner and if repair

i:

required ecables it to be dismantled. It

is

then transported

by

means of a special rail cal

to

a

works11cp With a suitable crane.

For reasons

of

submergence

a

reaction turbine is always put underneath the alternator when thc

shaft is vertical. Since the weight ratio of the alternator to the turbine rotor increases rapidly wit1

the head, it seems advisable to support the thrust bearing in different ways according to the head

For the highest head and

medium sized sets, the alternator stator is ~lsually located on a separatc

floor, capable of carrying this extremely heavy load (see Fig.

1.6.4

b). The thrust bearing is supportcc

here by a spicier on the top of the alternator stator.

I:ig.

3.4.40.

1)

Vertical ternary

of combined pc;ik load ;~nd

storage pl:~nt

hlalta.

Austria (owner Draukrnft-

,crke Klagen furt). 6-nonle

pT:

N

=

1030

m;

11

=

500 I-~III;

p

=

4

-

208

MW;

n,,

=

890 rpm.

+stage storage pumps;

11,

=

1100

rn;

P,

=

2

-

145

M

W:

spiral

casing shrunk onto the diifuscr

ring Synchronizin_g torque con-

verter (75

MW)

for

st:lrting

~ith

filled

pump. Air suspension of

impulse wheel and suction rc-

quirement of pump lead to

ex-

trcn~cly long shaft. Hydraulic

eqi~ipmcnt Voith. Motor-

generator and alternator

4.220MVA; 13,SkV;

cosrp

=

0,9;

GD2

=

2100 tm'. Stator

and rotor water cooled. built

by

BBC.

Elevation of set,

axially

shortened. (Drawing courlcsy

Voith and Draukraft\verkc

Klagenfurt).

Fig.

3.3.40.

2)

i.ongitudin;il section of powcr house, ternary (tandem) pumped-storage set, tailwater

iniskc and Farcliay. Kotlau, Drau. Austria, nnain stasc

of

Malta schcme

(owner:

Draukraftwerke,

Klagenfilrt. :\r:jtri~t. Outdoor power house of tall hall desigli ivith

the

milill crane in its interior,

!oc:ttcd

at

tlif:

basc

or'

the vallcy slops, founclccl on mica

2nd

scricite slate.

2

ternary pumped-storage

scts

3s

sh~\\.il

i:i

tt~c lig~~rc,

2

szis \r-ithout storage pump. Thc rather long vertical extension of the

tzrrl?:irq. sets rss;-Its or, the cne

'nand

fro111 thc n::ed to plucc thc impulse wlleel above the maximum

tail~v:itcr Ic:.rl

and

on the other hand from thc necdcd s~~brnergcncc of the lowest first pump stage

(Iicrc

3!

.I

1h1

~lliJ~'~~lri~tll

;he minimum :nil\vatcr Ic~cl.

1

220

bIVA

al!ernator, Stator and rotor,

ciircctl;i :\;atcr cooled;

2

6-nozzle impulsc turbine:

3

tailwatrr channel exit;

4

maximum permissible

raiiw:~ter Icvel:

5

minimum pcrmissiblc t:lil?v;!ter Icvcl;

6

toreb:?y;

7

:rash rack;

8

relieve zone;

9

cooii~!g ivatcr iiltakc:

10

distributor m;~.in:

11

tai1w;ircr ct~anncl;

12

torque convcrtcr;

13

pump

inrakc:

li

1

-flov:,

4-stage storage pump,

144

kl

W;

IS

rniiin transformer

220

hlVA.

(Drawing courte-

sy

Draukrzftt\cr:cc, Klagcnfurt, tlustris)

The ruriiler

of

thesc turbines is nccessiblc aftcr removal of the head cover. Then thc shaft needs an

i:ltcrm~:clia-lrc

aad

r:niovab!c piece to facilitaic the disma~l!li~lg of ihc runner without moving the

hs;ivy rotor of the ;iI?:rnator (Fig.

1.6.4

b).

,

In

thc case

of

lov er heads and larger sets the thrust bearing is

preferably

supported underneath the

altcri?ator

by

3

spider, on thz collcrcte of pit. This also prestresses thc concretz around the spiral

casing.

1-0:

hc;lds below

3C0

m

the thrusr bearing in Europe-influenced designs

is

usually supported

on

thc

!:cad

cover. \vhich ihen is released from its uplift.

lis~12lly in plnnt~ u-ith

a

penstock the valve chamber with its manifolds, bifurcations and

befids.

is

upstrczm of

the

power house,

see

Figs. 3.4.51 and 3.4.52.

At

!argei sub~nergence, such

a

valve

chamber is also down-stream of the power house

(Fi?.

3.4.52).

The

usual

bifurcations have stiffeners ill

the

form of external or internal ribs

(see

FIs.

3-4.533

and 53 b), or

a

spherical

shell (see Fig. 3.4.53~) to transmit the tensile

stress

itlong

the

periphery of the

pipe

into a solid support with a sufficient sectional

modillus. 'These bifurcations

and

the adjilcent pe:istock have been carefully investigated

with

respect to stress and flow loss

f3.132

to 3.1391.

Fig.

3.4.41.

Flbrilontal !ernary set with

;llll)i~lsc turh~nc, plant

S.

Masscnza, Italy

(o\~ner

ENEL).

Suspension

of

inp pulse

wllecl

in thc air, and suctiorl rccluircments

of

storngc pilmp nccds app11c;ition of

3

flo\\l boastcr pump.

H

=

596

ni,

=600rpm;

P

=4-32MW,

D

=

1,7m.

Turbine 1-nozzle twin

PT

with

a

runncr

overhung at both ends of the shaft.

H

=

5283

111;

P

=

4

.

32,5

M

W. All built

by Hydroart, Milan. (Drawing courtesy

Hydroart, Milan).

Fig.

3.4.42.

Welded spiral casing for

a

horizontal ma-

chine. Flow admission above shaft requires load com-

pensator (see Fig.

3.4.44).

Without this dcvice, force

F,,

induced by pressure and thermal expansion of the

penstock attacks spiral casing by a

long moment arm

against its supporting points,

and

hencc would de-

form

spiral

casing.

In

the power houses at the base of a dam (see Fig.

3.4.54)

the flow admission is usually

Perpendicular

to the axis of the power house. In underground stations, or in power houses

a1

the base of a slope, along which the penstock comes down, the admission of water may

Perpendicular to or along the axis of

the power house. The first may protect

an

open

air

Power house against

a

pipe failure on the line as the pipe jet (in case of a rupture)

not strike the

po\vcr house.

Fi:.

3.4.43.

Spiral casing for

:I

horizontal machine. Flow admission undernc;lth the shaft requires thc

intro~lriction oi

a

forcc

FD

(~ee Fig.

3.4.42)

at

spiral inlet into thc surrounding concrc!e, correspond-

ing!y n:inforccd. Spiral inlet riceds interruption and thus

weakening

olthe casing's supporting beam.

Herc

the storage pump of a ternary set in

a

numped storage plar~t at Leitzach, West Germany (owner

St~~dtn crke

M

iinchcn)

H

=

126

m:

n

=

428,6

rpm;

P

=

2

-

24

MW,

design Sulrcr Esclicr Wyss.

(Drawing courtesy

Sulzer Escher Wyss)

Fig.

3.4.44.

Escher Wyss typc load compensatort

if the inlct of the spiral cnsiilg is not enlbeddcd in

concrete, the casing

is

liberaled from

the

penstock

force induced by

presslire and thcrmal expansion.

----

+

Fig.

3.4.46.

Run-of-ritcr power plant Birsfclden, Swiss Germail Rhine with main crane accom-

modated in the powcr house (tall

hall design).

H

=

4

to

8

m;

P

=

4

15,6

MW,

KTs.

1

fish ladder;

2

Rhine:

3

boat harbodr;

4

lock;

5

inclined clevator for boats;

6

m~ximum pe~~nissible head water

le\~el:

7

powcr house. From

E.

Ilic~sonvi:

Die

neueste Elitwicklung im Bau

von

Niederdruckwasser-

kraftan1ag.w. Wasserwirtschaft

54

(1964)

No

7,

p.

186.

Fig.

3.4.45.

J>istancc of adjacent sets

in

relation to the runner diameter in p!an and space require-

ment in the

elr\~ation:

1

tubular turbine;

2

turbine with admission

by

selnispiral casing;

3

turbine

wit11 admission

by

spiral casing.

D

runner diameter. (Drawing partly from Sulzer Escher Wyss)

Fig.

3.4.48.

Perspective view of out-

door

pumped storage plant with

pump-turbincs. By-pass outlet

as

a

surge relieving device. (Drawing

courtesy

Allis Chaln~crs, Milwau-

kee,

Wisconsins,

USA)

Raabe J. Hydro power - the design, use, and function of hydromechanical, hydraulic, and electrical еquipment

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