kevin marshall, pe gc pud hydro engineering manager nwha conference february 18, 2014 grant county...
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Kevin Marshall, PEGC PUD Hydro Engineering Manager
NWHA Conference
February 18, 2014
Grant County PUDPlant Upgrades at Wanapum and Priest Rapids
Dams
Ongoing Upgrades for Wanapum Dam
Turbine Replacement (Note: GCPUD took advantage of CREB bonds and a DOE design/development grant) Work is complete.
Generator replacements New exciters Digital Governors Transformers
Reasons for Turbine Upgrades
Original turbine runners had reached the end of their useful life Blade crack repairs Trunnion seal issues Operating linkage failures Cavitation repair costs -
$75,000/unit/year (1987-1993 average costs)
Performance improvements
Improved fish passage survival
Wanapum Turbine Upgrades Design Features
Semi to fully spherical Larger diameter: 20 inch increase Deeper setting : 3.315 feet deeper
Performance Improvements Increased capacity: 120khp to 150khp Efficiency improvement: 3% average weighted
efficiency Cavitation repair costs: $0
Reasons for Generator Upgrades
Replace components at the end of their life.
Capture increased output of new turbines
Wanapum Generator Upgrades
New Parts Complete Rotor Complete Stator Generator Shaft Ventilation System Excitation System Air-Gap Monitoring
Rotor spider arrives in 3 sections, stator frame in 4
Wanapum Governor/Unit Control Upgrades
What Mechanical governors
replaced with digital Dynamic exciters
replaced with static exciter and digital controllers
Why Spare parts no longer
available Serviceman knowledge not
transferred with retirements
Improved control/efficiency Improved protection More info/better trouble
shooting Lower costs to maintain
Existing Wanapum Mechanical Governors
New Wanapum Digital Governors
10th turbine, 4th generator, 4th exciter, and 3rd governor complete and put into service October 2013
5th generator, 5th exciter, and 4th governor under construction
10th generator and exciter to be completed in 2019 New turbines have a averaged, weighted efficiency
gain of 3% As tested new generators have an increased efficiency
from 98.0% to 98.5% 2 of 5 transformers replaced, 3rd transformer in process
Current Wanapum Status
Priest Rapids Dam Upgrades
Planned Upgrades for Priest Rapids Dam
Turbine Replacement or life extension
Generator rewinds New exciters Digital Governors Transformers
already replaced
Efficiency improvement Life Extension Aging equipment
First unit in service in 1959 Generators
Rotor pole problems including pole to pole connection failures (as pictured)
Stator Winding age (oldest unit = currently 27 years old)
Exciters are obsolete Turbines starting to exhibit problems
Increased cycling of governor oil pumps
Wicket gate operating ring wear
Reason for Upgrades
Goals Utilize lessons learned from Wanapum project Obtain as many qualified bids as possible Competitive turbine hydraulic model testing Integrate biological considerations into design
effort
Turbine Upgrade Process
Turbine Upgrade Process
Step 1: Hydraulic design contract Professional Services Agreement Prequalification process – three
contractors prequalified All design solutions finalized by
contractors ahead of bidding All design solutions verified by
independent hydraulic laboratory Step 2: Manufacture and supply
contract Bidders must participate in
hydraulic design contract to bid Performance guarantees verified
prior to bidding
Turbines Model testing was completed last week in Lausanne,
Switzerland for the 3 qualified vendors Bids are due March 5th Contract award this summer (if economics are
favorable) Generators: Pre-qualification of Vendors in process Controls: Governor specifications are in process Field work for upgrades is scheduled for 8/1/2016
Status of Priest Rapids Upgrades
QUESTIONS
Priest Rapids and Wanapum Upgrades
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