092717 b7c6a va tech hydro bulb turbines generators

VA TECH HYDRO

BULB TURBINES & GENERATORS

Water. Power. Large.

www.vatech-hydro.com

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Today low heads can be used for powergeneration very economically feasible.M o r e t h a n 3 0 0 u n i t s s u p p l i e d b yVA TECH HYDRO for heads up to30 m, a maximum runner diameter of7,700 mm and outputs up to 55 MWtestify the exper ience in th is seg-ment of hydropower generation.

VA TECH HYDRO is the leader in Bulb-turbine / Generator units with a marketshare of more than 50% in the lastdecades. The application range includesdirect-driven units, pit turbines using astep-up gear to the generator and the socalled STRAFLO™ turbines, a special de-velopment by VA TECH HYDRO. The to-tal installed capacity worldwide amountsto approximately 4,500 MW.Bulb turbines have the advantage of ast ra ight in f low to the d ist r ibutor andrunner and also the outflow through theconical draft tube has no bend. This results in a minimum of losses in theentire application range and thereforehigher efficiencies.

In VA TECH HYDRO’s hydraulic test lab-oratory in Linz, Austria, Bulb turbines areoptimized in this respect to ensure high-est energy generation for all applications.Bulb turbines can be double or singleregulated as far as the wicket gates or therunner blades are concerned.

Directly coupled Bulbturbine / Generatorunits are economically feasible for high-er heads of up to 25 m thus offering a suf-ficent high generator speed. For lowerheads pit turbines with step-up gears canbe used to allow for high turbine effi-ciencies at low speeds. High speed gen-erators need less space and are alsocheaper. For low heads and small outputsBulb turbines with bevel gears are usedin accordance with our COMPACT HYDROturbine program. For special applicationsBulb turbines with S-shaped draft tubescan be used with the advantage of havingthe generator outside the waterway.

General Concept ofBulb Turbines

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Another special application is theSTRAFLO™ turbine. This turbine is atrademarked design having non regulatedrunne r b l ades and t he gene ra to r i slocated outside the turbine runner on arotor rim.

This allows for a very compact and shortdesign, wi th excel lent access ib i l i tya n d h i g h ro t o r i n e r t i a . S T R A F L O ™turbines are in many cases the onlyf eas ib l e so l u t i on f o r upg rad ing o ldpower stat ions.

For the generator, the arrangement in anenclosed bulb imposes certain condi-tions and constraints necessitate anappropriate design. VA TECH HYDROhas more than 30 years of experiencewith this type of generator and approx-imately 170 Bulb generators are inoperation in 50 power plants all overthe world.

Bulb generator, they are transferred to thepower house structure via a short and welldefined path. Especially for larger units, arigid vertical column is recommended toconnect the inner and the outer cone ofthe bulb casing and it also serves as anaccess shaft. The generator stator, forming part of thebulb, is bolted to the rigid upstream flangeof the inner cone of the bulb casing, whichalso supports the combined generatorthrust and guide bearing. This providesadditionally significant advantages such

The river water flowing around the unit isan ideal cooling agent for the heat prima-rily distributed by forced air. VA TECHHYDRO has additionally introduced acooling system with a closed intermediatecooling water circuit and surface coolerswhich are either mounted in the water pas-sage or form an integral part of the bulb.Basic advantages of this cooling systeminclude an excellent heat transfer capabil-ity, the possibility of integrating bearingand transformer cooling, maintenance freewater/water heat exchanger, improved ef-ficiency by staggered operation of watercirculating pumps and an elimination ofthe cooling water system in the powerhouse (pumps, etc.).Looking at the forces generated by the

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Design Concept ofBulb Generators

as clear separation of generator and tur-bine areas, straightforward generator andturbine alignment, adequate access spaceand a simple installation sequence.

The main erection phase starts after theshaft with turbine and generator bearingshas been aligned in its final position. Bulbnose, rotor and stator are lowered oneafter the other into the water passage andmounted.

In Bulbturbine / Generator power plants,maintenance is much simpler than in ver-tical Kaplan units. Maintenance tasks onthe turbine can be carried out independ-ently of the generator and so no large-scale dismantling of the generator is re-quired. The main generator parts can easily beaccessed for inspections and the removalof stator bars and field poles is possiblewithout dismantling of major components.

Contrary to earlier trends towards smallbulb diameters, nowadays larger diametersof up to 1.3 times the turbine runner areused offering the following advantages:• High inertia constant• High generator efficiency• Simple and effective cooling system• Reduced mechanical stress and

increased bulb nose space.

Recently a new and highly competitive con-cept of a directly driven generator has beendeveloped by VA TECH HYDRO especiallyfor low heads and ratings up to 15 MVA. ThisBULB 2000 concept with its superb effi-ciency includes only one common accessshaft and is very economical.

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1936 First Kaplan Bulb turbine with inside generator at Rostin, Poland

1937 First four Straflo units for Iller VII, Germany

1940 Development of the cascade with more than 60 Straflo units on the river Lech, Germany

1954 First Bulb turbine with a runner diameter of 1,800 mm and an output of 14.4 MW at Argentat, France

1958 Large Bulb turbine with a runner diameter of 4,600 mm at Trier, Germany

1963 Four Bulb turbines with a runner diameter of 5,600 mm and an output of 23.5 MW at Gerstheim, France

1969 First large Bulbturbine / Gene-rator units on the river Danubeat Ottensheim, Austria

1973 Largest Bulbturbine / Genera-tor with a runner diameter of6,000 mm and an output of40.7 MW at Altenwörth, Austria

1977 Largest Bulbturbine / Genera-tor units in the world with a runner diameter of 7,700 mmat Racine, USA

1990 Highest output of 15.4 MW for gear driven pit turbine at Swan Falls, USA

1993 Largest output for a Bulbturbine / Generatorunit in Europe with a maximum of 55 MW,unit No.7 of Ybbs Persenbeug, Austria

1996 Four Bulbturbine / Generator units with largest stator diameter of 9,000 mm at Da Yuan Du, China

2000 Commissioning of six large Bulb generators with an output of 34.8 MVA at Karkamis, Turkey

Highlights

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This power station is located on a bypasscanal of the Traun River near Linz in Up-per Austria. It is a good example for theconcept of a low head power station inan urban area fitting excellent and envi-ronmentally friendly into the landscape.

BULB TURBINE & GENERATOREXPERIENCE

Technical data:Output: 6.2 MW / 6.6 MVAVoltage: 3.5 kVHead: 10.5 mSpeed: 166.7 rpmRunner diameter: 3,150 mmStator diameter: 3,600 mm

KleinmünchenAustria

Offering high efficiency and optimized an-nual energy generation, this power plantsupplies electricity to many households inthis area. The scope of supply of VA TECHHYDRO included model testing, design,manufacturing and installation of two Bulbturbines with electronic-hydraulic speedgovernors and directly coupled generatorsincluding excitation. After a short imple-menta t ion t ime th i s power p lan t wasconnected to the grid in December 1977.

This power plant is located downstreamof Linz in Upper Austria on the riverDanube. It was the third large Bulb tur-bine power station on the river and wasbuilt between 1976 and 1979.

The power plant includes nine Bulbturbine/Generator sets and was bui lt in the dry.After completion of construction the riverwas diverted through the power station. VA TECH HYDRO supplied six turbines andnine generators including excitation andvoltage regulation, protection equipment,

step-up transformers, auxiliary systems,controls, measuring and monitoring sys-tems and cabling. Design and manufacturingas wel l as insta l lat ion were completedaccording to schedule and commissioningwas successful ly performed in 1979.

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Technical data:Output: 19.4 MW / 20 MVAVoltage: 8 kVHead: 8.15 mSpeed: 93.75 rpmRunner diameter: 5,700 mmStator diameter: 6,450 mm

Abwinden-AstenAustria


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units. Commissioning and start of com-m e rc i a l o p e r a t i o n t o o k p l a c e i nJanuary 1983.

The Racine power plant is located on the Ohio River, 384 km south ofPittsburgh about 2.5 km downstreamof Letart Falls.The project includes a large spillway witheight taintor gates and a ship lock withtwo chambers. It was originally built forflood control and navigation purposes onthe Ohio River and operated by the USArmy Corps of Engineers as part of

river cascade. Later it was decided toinclude a powerhouse for electricity gen-eration operating as a base load schemeand a typical run-off river power station. VA TECH HYDRO was selected to supplytwo Bulbturbine / Generator units includingspeed governors and excitation systems.With a runner diameter of 7,700 mmthese turbines still hold the world recordfor directly coupled Bulbturbine / Generator

Technical data:Output: 24.6 MW / 25 MVAVoltage: 6.9 kVHead: 7.0 mSpeed: 62.1 rpmRunner diameter: 7,700 mmStator diameter: 8,640 mm

RacineUSA

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The Melk power station was built as a mult ipurpose project taking intoaccount all economic and ecologicalfactors.With the famous monastery of Melk, LowerAustr ia, in the background, the powerstation blends into the landscape in an environmental ly fr iendly way. The back-water area extends over a length of 22.5 kmfrom the barrage to the Ybbs-Persenbeug

power station. For reasons of countrysideconservation the generated electricity is fedinto to the high voltage grid via an under-ground cable. The powerhouse on the rightbank of the river includes nine horizontalshaft Bulbturbine / Generator sets includ-ing main transformers, excitation, controland protection systems and cabling.

Technical data:Output: 21.7 MW / 24 MVAVoltage: 9 kVHead: 8.2 mSpeed: 85.7 rpmRunner diameter: 6,300 mmStator diameter: 7,100 mm

MelkAustria

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Since 1938, VA TECH HYDRO has producedand put into commercial operation world-wide more than 110 STRAFLO™ units.

The Annapolis Royal Tidal plant fea-turing a STRAFLO™ unit is installed atthe Annapolis basin in the Bay of Fundyin the province of Nova Scotia, Canada.The STRAFLO™ unit was installed to har-ness the energy from the tides to a maxi-mum head of 15.8 m. This unit comprisesa combined turbine-generator aggregatewithout driving shaft, because the generatorrotor is located outside the turbine runneron a rim. This concept results in a verycompact design of the unit. The runner itself is not regulated using theconstant flow of the tides of the seawater.

Technical data: Output: 19.9 MWHead: 7.1 mSpeed: 50 rpmRunner diameter: 7,600 mm

AnnapolisCanada

The turbine is protected against seawatercorrosion by a cathodic system. The Annapolis Royal unit is unique in theworld as far as output and dimensions areconcerned. Another STRAFLO™ unit with outstandingperformance data was installed in Canadain the late 1990’s at the Pointe du Bois Gen-erating Station in the province of Manitoba.

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The power station consists of nine Bulb-turbine / Generator units and has a weirsystem of six radial spillway gates and adouble ship lock. The VA TECH HYDRO Bulbturbines are optimized to deliver maximumannual energy and the generators are also ofa highly advanced design. The stator coreclamping devices, the end windings and con-nection, as well as the field and damper wind-ing connections are conveniently accessible

and it is possible to remove field poles andstator bars without disassembly of majorcomponents. The VA TECH HYDRO scopeof supply included six Bulb turbines and ninethree phase generators, 10.4 kV switchgear,excitation, protection and control systemsand six radial spillway gates.

Technical data:Output: 35 MW / 38 MVAVoltage: 8 kVHead: 10.87 mSpeed: 93.75 rpmRunner diameter: 6,500 mmStator diameter: 8,750 mm

GreifensteinAustria

The Greifenstein Power Station near Tulln,Austria, was also built in the dry on a lefthand bend of the river Danube. It wascompleted within 30 months which is theshortest construction time ever for a run-off river power station of that size. Fur-thermore, special emphasis was placedon the protection of the environment dur-ing and after construction of the plant.

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into commercial operation in 1985 and1986, respectively.The scope of supply of VA TECH HYDROincluded four sets of double-regulatedS-type turbines, epicyclic gears, highspeed synchronous generators and gov-ernor systems with electronic governorheads including oil supply system.

The units are designed for maximum en-ergy generation with double regulationand step-up gears enable high speed andvery compact designed generators. The use of an S-shaped draft tube allowsfor a very flat design of the powerhouseso that it blends well into the environ-ment. The hydropower stations went

Offenbach/KesselstadtGermany

Technical data: Offenbach/KesselstadtOutput: 2.1 / 2.4 MW Head: 3 / 3.5 mTurbine speed: 73.7 rpmGenerator speed: 750 rpmRunner diameter: 4,450 mm

Located on the river Rhine near Hanau,Germany, these two power stations aredesigned for base load generation andare typical run-off river power plants.

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Located at the Lock & Dam 9 and 13these two power stations are a majordevelopment on the river Arkansas inthe USA. The projects are of the multi-purpose type including electricity gen-eration, navigation and flood control.

Including stat ions No. 8 and 9 on theriver Allegheny, equipped with two pitturbine generating units, VA TECH HYDROhas supplied altogether ten large units ofthat type. The concept includes three-bladed pit turbines for very low headsfeaturing a planetary step-up gear asspeed increaser for a smal l and cost saving high speed generator.Electronic-hydraulic speed governors aswe l l as hydrau l ica l l y opera ted dra f ttube emergency ga t es we re pa r t o f VA TECH HYDRO’s scope of supply.

Technical data: Arkansas 9 / 13Output: 11.2 / 10 MW Output: 11.83 / 10.57 MVAVoltage: 4.16 kVHead: 4.9 / 4.8 mSpeed: 77 / 900 rpmRunner diameter: 5,800 mmStator diameter: 1,140 mm

Arkansas 9 & 13USA

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The completion of the PAK MUN hydro-electric project, located on the Mun River in the Ubon Ratchathani province,in the north-east of the Kingdom of Thai-land, represents a further milestone in theeconomic development of the country.

This remarkable achievement also set aprecedent in international circles by intro-ducing the first Bulbturbine / Generator unitsfor a run-off river power station ever installedin South East Asia. The scope of supply includes four Bulbturbines, generators, governors of digitaltype, protection, excitation and computer-ized control, monitoring and supervisionequipment, stoplogs and l i f t ing beams,intake trashracks.The four units were installed and commis-sioned in 1993/1994.

Technical data:Output: 35.4 MW / 35.8 MVAVoltage: 6 kVHead: 13.5 mSpeed: 100 rpmRunner diameter: 6,000 mmStator diameter: 6,750 mm

Pak MunThailand

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Built between 1910 and 1914 with tenhorizontal Francis units equipped withfour runners per shaft to generate48 MW from the headwaters of theRhine River, the Laufenburg power sta-tion was completely modernized from1988 to 1992.

The upgrading scheme comprised thereplacement of all existing units by tenSTRAFLO™ turbine-generator units to in-crease the plant´s output to 108 MW. Em-ploying new STRAFLO™ units to replaceold horizontal or vertical Francis turbinesis a tremendously successful concept toovercome space limitations and to meetrequirements with respect to minimizingpower plant alterations and investment

costs. Consequently, this concept hasbeen repeated for several power plantmodernizations such as Augst in Switzer-land and Wylen in Germany.

Technical data:Output: 11.6 MWHead: 10.0 mSpeed: 107.1 rpmRunner diameter: 4,250 mm

LaufenburgSwitzerland

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The Belleville power station is locatedon the east bank of the Ohio river nearParkersburg, West Virginia, approxi-mately 200 km south-west of Pittsburgh.The plant is a multipurpose installationproducing up to 52 MW for its 42 par-ticipating municipalities (AMP Ohio).

With a runner diameter of 7,500 mmthese two Bulb turb ines suppl ied byVA TECH HYDRO are among the largestin the world. The supply contract was de-cided by international competitive bid-ding after careful evaluation of the totalprice for equipment, energy generationand experience in the field of low headhydropower installations.

The scope of supply included two three-bladed Bulb turbines with electronic-hydraulic speed governors of digitaltype , d i rec t l y coup led th ree-phasegenerators, static excitation, supervisionof installation and commissioning.


BellevilleUSA

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The power stat ion with three large Bulb turbines was successfully commissioned in1999 and is the largest water power facilityowned and established by Arkansas ElectricCooperatives Corporation (AECC). The turbines are capable of operating overa wide flow and head range and areequipped with a self-regulating cathodicprotection system to protect the steel andstainless steel components against the salty,highly corrosive water.

Technical data:Output: 35 MWHead: 12.6 mSpeed: 72 rpmRunner diameter: 7,000 mm

Arkansas 2USA

The project site is located at the U.S.Army Corps of Engineer’s Lock andDam No. 2, the last on the Arkansasriver just 20 miles before the junctionwith the Mississippi river.

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protection and control systems. Easy main-tenance is a major aspect in particular withthe Bulb turbines and generators on ac-count of their compact design. This factwas already taken into consideration byVA TECH HYDRO at the design stage. Theplant was completed in 1997/98.

In addition to improving navigation canalsand groundwater levels, Freudenau also of-fers advantages in terms of urban planningand ecology. With an installed output of172 MW and an annual electricity generationof 1,037 GWh, the Freudenau hydroelectricpower plant supplies clean energy to theAustrian grid and to the city of Vienna.VA TECH HYDRO was involved in the sup-ply of main turbine components for six largeBulb turbines, four radial spillway gates withflap with a width of 24 m, five sets of portalstoplogs, one set of floating stoplogs andintake trashracks, six Bulb generators aswell as two four-winding 96 MVA maintransformers, 0.4 kV switchgear, excitation,

Technical data:Output: 30.3 MW / 32 MVAVoltage: 10.5 kVHead: 10.8 mSpeed: 65.2 rpmRunner diameter: 7,500 mmStator diameter: 8,750 mm

FreudenauAustria

In 1991 a referendum on the construction ofthe Freudenau hydropower plant was heldin Vienna, which was supported by a ma-jority of approximately 75 %. Just like all ex-isting power plants on the river Danube,Freudenau, which is located within the mu-nicipality of Vienna, is a multi-purpose plant.

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In 1996 VA TECH HYDRO was awarded acontract to supply four Bulbturbine / Gen-erator units with a total installed capacity of120 MW and annual energy of 556.5 GWh.The scope of supply included engineering,manufacturing and installation supervision

as well as commissioning of the electro-mechanical equipment: • Four Bulb turbines including electronic-

hydraulic speed governors of the digitaltype

• Four three-phase Bulb generators including excitation system

• 10.5 kV generator switchgear • Main transformers• Unit protection system • Power plant supervisory control system • SF6 circuit breakers and 110 kV cables• Cabling

The project was completed in November1999.


Da Yuan DuChina

The Da Yuan Du hydropower sta-tion, located on the Jiuliandeng, mainstream of the Xiangjiang River, HunanProvince, China, is part of the second-stage of the Xiangj iang Navigat ionMulti-purpose Project.

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time of 43 months, more than 1 monthahead of schedule.The project included apowerhouse, a spillway system with gatesand two earthfill dams.The scope of supply of VA TECH HYDRO comprised six Bulb generators, three maintransformers, protection, excitation and controlsystems, generator switchgear, a 154 kV

switchyard, AC station service, DC systemwith batteries, chargers and inverters, anemergency Diesel generator set, transformerfire fighting equipment, telecommunicationequipment, cables and a powerhouse crane.

The power plant is located on theEuphrates River in the south-eastern partof Turkey, approximately 80 km fromGaziantep, the district capital, near theSyrian border.

In the 1980s, Verbundplan and Temelsu –our engineering partners in the consortium– designed the project for the Governmentof Turkey. After the project had been shelvedfor some years, a consortium under theleadership of VA TECH HYDRO proposed tobuild this project on a turnkey basis in ac-cordance with the guidelines of the bilateralprotocol between Turkey and Austria for co-operation in the field of hydropower plants.After successful negotiations, the contractwith the General Directorate of State Hy-draulic Works (DSI) was signed in 1995 andconstruction work started in June 1996. Thepower plant commenced commercial oper-ation in December 1999 after a construction

Technical data:Output: 34.8 MVAVoltage: 9.0 kVSpeed: 88.2 rpmStator diameter: 7,500 mm

KarkamisTurkey

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The two powerhouses (north and south)were equipped with three vertical shaftKap lan tu rb ines each hav ing a we i r system in the middle and a double shiplock next to it. In the 1990s one additional unit was in-stalled while the power station was fullyoperable. This unit is the largest Bulbturbine installation in Europe with a max-imum output of 55 MW. It has all the advantages of a state-of-the-art low head installation and increasesthe annual energy generation in compar-ison to the other Danube r iver powerstations. VA TECH HYDRO supplied major parts ofthe turbine and the generator of this largeunit. Today this is considered a classicexample of increasing the efficiency ofexisting power plants.

Technical data:Output: 48.5 MW / 55 MVAVoltage: 8 kVHead: 12.1 mSpeed: 75 rpmRunner diameter: 7,500 mmStator diameter: 8,750 mm

Ybbs PersenbeugAustria

The power station Ybbs Persenbeug inLower Austria was built from 1954 to1959 and was the first hydroelectricstation on the river Danube in Austria.

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VA TECH HYDRO supplied the entireelectromechanical equipment includinghydraulic steel structures for this plant.

This power station is located on theriver Traun near Linz in Upper Austriaand features the latest development ofVA TECH HYDRO’s low head equipmentincluding two Bulbturbine / Generatorunits of the BULB 2000 design.

The BULB 2000 is a very efficient solu-tion for low head power stations devel-oped for medium-size power plants withfurther simplification and reduction ofauxiliary equipment including generatorcooling system. For this reason the overall efficiency ofthe units is very high and the investmentcost could be reduced drastically thus of-fering a very feasible solution for run-offriver power stations.

LambachAustria

Technical data:Output: 8 MW / 10 MVAVoltage: 6.3 kVHead: 8 mSpeed: 150 rpmRunner diameter: 3,600 mmStator diameter: 4,500 mm

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The main purposes of the project includeflood control, keep navigation level andpower generation. The structural arrange-ment of the project comprises the power-house, the navigation lock, the spillway andthe earth dam from the left to the right bank.The total length of the dam crest is 2,100 mand a maximum height of 50 m. The nor-mal storage level for power generation is24 m with daily regulation performance. Thepowerhouse is located in the river channel,equipped with four Bulb type units.

The scope of supply included four Bulbturbines with digi ta l governors, four generators, 17.5 kV medium voltageswitchgear, excitation, protection and controlequipment consisting of a SCADA system,

joint control with efficiency dependent opti-mization of unit operation, active mosaicboard in the main control room, bi-direction-al data communication with load dispatchcentre through gateway.

Fei Lai XiaChina

Technical data:Output: 39 MW / 43 MVAVoltage: 10.5 kVHead: 14 mSpeed: 83.3 rpmRunner diameter: 7,000 mmStator diameter: 8,600 mm

The Fei Lai Xia Water ConservancyProject is located in Shenpiing Town,Qingxing county, Qingyuan city ofGuangdond province, in China, 50 kmdownstream of Yingde city and 33 kmupstream of Qingyuan city. It is the 4thcascade of the cascade developmentplan for the main stream of the NorthernPearl river basin.

www.vatech-hydro.com

sustainable solutions. for a better life.

VA TECH HYDRO worldwide

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United Kingdom, Ukraine, USA, Venezuela and Vietnam.

VA TECH HYDROe-mail: [email protected]

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Phone: (++43/70) 6987 - 3451Fax: (++43/70) 6980 - 2554

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092717 b7c6a va tech hydro bulb turbines generators

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