technology - mavel

9/24/2011

Innovation and AdaptationTechnologies for Hydro Development

in the Pacific Northwest

Hydro Technology by Mavel

Contents

* Introduction

* Mavel Overview

* Pelton

* Francis

* Micro Turbine

* Kaplan Pit Turbine

* Vertical Kaplan Turbine

* Conclusion


Introduction

- Technology is an enabler

- Improve efficiency

- Improve reliability

- Reduce cost

- Design

- CFD

- Controls

- Manufacturing

- Optimize / customize for each site

- Proven Technology + Innovation + Adaptation = Success


Focus: Small Hydro – up to 30 MW

Product Expertise: Turbines: Kaplan, Francis, Pelton and Micro

Experience: 400+ turbines installed in 18 years

Ownership: 50% American / 50% Czech

Production Capability: Two European Facilities; 200 employees

Sales/Service Territory: Americas, Europe, Africa and Parts of Asia

Quality: ISO 9001:2008 Certified

Technical Capacity: 40 Engineers, 85 Proprietary Designs, In-house R&DCzech Technical University hydraulic lab

Mavel Overview


Mavel Turbines

Kaplan Turbines

PIT Turbine

Bulb Turbine

Vertical Turbine

“Z” Turbine

“S” Turbine

Francis Turbines

Horizontal

Vertical

Pelton Turbines

Horizontal

Vertical

Micro Turbines

3 kW – 30 MW


Mavel Manufacturing Headquarters


Mavel’s Final Assembly Hall


Pelton Turbines

• Runners: 300 mm to 2000 mm

• 1 to 6 Jets

• Vertical or Horizontal

• Head: 160 to 3300 ft (50 to 1000 m)

• Flow: 3.5 to 350 cfs (0.1 to 10 cms)

• Power Output: Up to 30 MW


Pelton Turbines

Innovation: • external distributor

• compact powerhouse

• reduced civil cost

• improved runner design

• CNC machined runners

• optimal runner size

• optimal jets

• match the site


Francis Turbines



• 6 specific speeds

• Head: 50 to 1000 ft (15 to 300 m)

• Flow: 17.5 to 1250 cfs (0.5 to 35 cms)

• Power Output: Up to 25 MW


Production Technology


Kaplan Turbines



• Type: “S”, Bulb, Pit, and “Z”

• Power Output: 25 kW to 25 MW

• Head: 5 to 115 ft (1.5 to 35 m)

• Flow: 32 to 3200 cfs (0.9 to 90 cms)

• Innovation:

• CNC machined runners

• control of blades and gates

• gear box, belt drives

• wider head / flow range


Low Head Technologies

- Applications for low head sites

- Irrigation Systems

- Non Powered dams

- Water treatment plants

- “Conduit Exemption”

- Micro Turbine

- Kaplan Pit Turbine

- Vertical Kaplan


Micro Turbine: Overview

• Head: 5 to 20 ft (1.5 to 6 m)

• Power: up to 180 kW per Unit

• 3 different sizes

• MT3

• MT5

• MT10

• No need for a powerhouse

• Complete package

• Cost effective

• Easy to install

• Minimal civil work

• Siphon type turbine

• Propeller runner

• pitch can be manually adjusted

• Belt drive

• Very low maintenance costs

• Proven: 50 turbines, 30 locations,

since 1996


Siphon Turbine


Micro Turbine: Applications

• Existing Unpowered Dam

• Irrigation Canal

• Water Treatment Plant

• Low Flow Unit

Oomachishi, Japan

MT5


Micro TurbineOlawa Micro Hydroelectric Power Plant, Poland

• Head: 11.5 ft (3.5 m)

• Flow: 140 cfs (3.9 cms)

• Type: Three x MT10

• Power Output: 300 kW (100 kW each)

• Year Commissioned: 2006

• Runner diameter: 1000 mm


Mavel Kaplan Pit TurbineRunner Diameters 2000 mm to 4500 mm

Number of Runner Blades 3 or 4

Head 5 to 35 ft (1.5 to 10 m)

Flow 530 to 3200 cfs (15 to 90 cms)

Power Output 500 kW to 8,000 kW

Transmission Parallel Gearbox


Mavel Kaplan Pit Turbine: Applications

• Low Head Sites

• Alternative to Kaplan S Turbine for Larger Sites

• Powering Existing Lock and Dam Facilities

• Installation/Replacement in Existing Power Plants


Mavel Kaplan Pit Turbine

Lovosice Hydroelectric Power Plant, CZ

• Head: 6.2 ft (1.9 m)

• Flow: 5650 cfs (160 cms)

• 4 Kaplan Pit Turbines

• Runner Diameter: 3000 mm

• Total Installed Power: 2650 kW

• 662 kW each


• Innovation:

• number of turbines

• minimize civil work

• powerhouse can be

submerged


Lovosice Hydroelectric Power Plant, CZMavel Kaplan Pit Turbine

Interior of Powerhouse


Generator and Gearbox in Pit

Power Plant Spillway


Pit Turbine

• Bulkheads

• Gate actuator

• Runner

• Transition from pit to

draft tube


Mavel Vertical Kaplan Turbine

Runner Diameters 850 mm to 3400 mm

Number of Runner Blades 4 or 5

Head 5 to 100 ft (1.5 to 30 m)

Flow 32 to 3200 cfs (0.9 to 90 cms)

Power Output 10 kW to 24,000 kW

Transmission Direct Drive, Belt Drive or Parallel Gearbox

Infernos HPP, Portugal - 1019 kW Vertical Kaplan


Mavel Vertical Kaplan Turbine: Applications

• Francis/Original Turbine Replacement

• Wider Operating Range

• Double Regulated

• Minimal Civil Reconstruction

• Higher Turbine Efficiency

• Low Head Sites

• Existing Lock and Dam Facilities

• Custom design

Layout of Mavel Vertical Kaplan Turbine


Mavel Vertical Kaplan Turbine

Boatlock Hydroelectric Station, USA

• Replacement of Original Francis Turbine with New Mavel Vertical Kaplan

• Increased Power Output Threefold

• Increased capacity

• Output: 704 kW

• Head: 19.7 ft (6 m)

• Flow: 465 cfs (13.2 cms)

• Runner Diameter: 1600 mm



Kaplan Efficiency

• Flat efficiency curve over a wide flow range– 20% to 100%

of rated flow

• Francis has low efficiency at low flow; 35% minimum


Conclusions

• Continuous Innovation and Adaptation

• Modular Systems of Proven Equipment

• Adding New Sizes and Models to Existing Turbine Lines

• Efficiency Improvements

• Designs to Minimize Civil Costs

• Customized and Optimized Turbines for Each Site

• Use the 100 years of knowledge and improve


[email protected] www.mavel.cz

mailto:[email protected]

http://www.mavel.cz

technology - mavel

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