Benefícios de usinas reversíveis e aspectos técnicos do ... · motor-generator hydraulic torque converter pump ... 2013 Revin France 4 200 13,8 300 ... • Rotary valves and gate

Benefícios de usinas reversíveis e aspectos técnico s do equipo electromecânico

SEMINÁRIO TÉCNICO SOBRE USINAS HIDRELÉTRICAS REVERSÍVEIS NO SETOR ELÉTRICO BRASILEIRO, 12/11/2014

Alois LechnerMichael SchmidPeter Magauer

^ ANDRITZ HYDRO Austria / Alemania

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Benefícios de usinas reversíveis com controle de ve locidadeConteúdo

� Visão do sistema: velocidade fixa – velocidade variável

� Benefícios do controle de velocidade já implantados

� Carga variável no modo bomba

� Otimização da eficiência

� Transição rápida entre modo bomba para modo turbina

� Benefícios da velocidade variável a serem explorados

� Auxílio no controle instantâneo de potência

� Auxílio à inércia da rede

SEMINÁRIO TÉCNICO SOBRE USINAS HIDRELÉTRICAS, 12/11/2014 Alois Lechner

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Arranjo de vel. fixa (“Fixa ”)


• Rede

• Transformador elevador

• Motor/Gerador(+ Excitação CC)

Turbina-bomba “Fixa”

Benefícios de usinas reversíveis com controle de ve locidadeVisão do Sistema

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Arranjo de vel. variável com Gerador de Dupla Alimentação (“DFG”)


• Rede


• Trafo do conversor

• Conversor

• Motor/Gerador

Turbina-bomba “Var”


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Arranjo de vel. variável com Conversor Integral (“FSC”)


• Rede


• Conversor

• Motor/Gerador(+ Excitação CC)

Bomba-Turbina “Var”


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� Características do Conversor

� Consiste em dois inversores CA-CC

� Somente a potência ativa é comum a ambos os

inversores

� Independente em cada lado CA: Voltagem,

frequência, potência reativaSEMINÁRIO TÉCNICO SOBRE USINAS HIDRELÉTRICAS, 12/11/2014 Alois Lechner


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� Rendimento do sistema – operação como turbina


Benefícios de usinas reversíveis com controle de ve locidadeOtimização do rendimento

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� Rendimento do sistema – operação como bomba



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� Mudança do modo de operação


Fixa, DFG FSC

Benefícios de usinas reversíveis com controle de ve locidadeTransição rápida entre modo bomba e turbina

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� Dinâmica do FSC – variação instantânea de potencia (∆=15%)


Variação instantânea de potência de saída

Potência primária limitada pela pelo comprimento do conduto e velocidade da comporta

Benefícios de usinas reversíveis com controle de ve locidadeInjeção instantânea de potência

SEMINÁRIO TÉCNICO SOBRE USINAS HIDRELÉTRICAS, 12/11 /2014 Alois Lechner

Inércia virtual do sistema = múltiplas inércias físicas

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Benefícios de usinas reversíveis com controle de ve locidadeSustentação de inércia do sistema



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�Resultados das simulações de inércia do sistema

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�Resultados das simulações de inércia do sistema

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20 SEMINÁRIO TÉCNICO SOBRE USINAS HIDRELÉTRICAS, 12/11/2014 Alois Lechner

� O subsídio do governo a energia fotovoltaica na

Alemanha arruinou o retorno dos projetos de PSP,

sendo que a maioria dos projetos europeus de PSP

estão “on hold”.

� Os novos projetos pendentes buscam flexibilidade total

� Configuração FSC

� A Irlanda, vulnerável a problemas de estabilidade,

planeja recompensar o fornecimento de inércia ao

sistema.

Benefícios de usinas reversíveis com controle de ve locidadeSumário e Conclusão

Motor-Generator – engineering highlightsSEMINÁRIO TÉCNICO SOBRE USINAS HIDRELÉTRICAS REVERSÍVEIS

NO SETOR ELÉTRICO BRASILEIRO

12/11/2014Michael Schmid, Dipl.Ing., MBA

Different Pump-Storage concepts

Variable speed Motor-Generator

MG-References

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Content

Motor-Generator Technology

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speed

pump storage power plants

fixed speed variable speedfixed speed


Fixed speed

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MG-Type

starting

mode

speed fixed speed

back to backstatic frequency converter (SFC) asynchron pony-motor ternary unit

synchronous machine


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Selected references:

2013: PSP Revin, 800 MVA2011: PSP Foz Tua, 300 MVA2010: PSP Reisseck II, 480 MVA2001: PSP Tong Bai, 1500 MVA

reversible pump turbine Ternary unit

Pelton

turbine

motor-generator

hydraulic torque

converter

pump

2011: PSP Hongrin Leman, 260MVA2004: PSP Kops II, 600 MVA1981: PSP Haeusling, 400 MVA

Fixed Speed Solutions


26 www.andritz.com

speed

pump storage power plants

fixed speed variable speedvariable speed


Variable speed

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MG-Type

starting

mode

speed variable speed

converter in the stator circuit –

Full size Converter (FSC)converter in the rotor circuit

all kinds of Motor Generators are possible

doubly fed asynchronous machine

(DFM)


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Rotor PSP Goldisthal

Link machine speed/grid frequency

)1(60

sp

fn −⋅⋅=

f stator voltage frequency in Hzn machine speed in rpmp number of pole pairss slip (zero for synchrounos machines)

⇒ two concepts:

• converter in rotor circuit (double fed motor-generator)

• converter in stator circuit (full size converter)

Electric system - Principle

www.andritz.com


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Doubly Fed Motor-Generator - dimension

Comparison of dimensions of Motor-Generator – example GOLDISTHAL

Synchronous Motor-Generator Variable Speed Motor-Generator

www.andritz.com


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Doubly Fed Motor-Generator – comparison

Comparison between FIX speed Synchronous and VARIABLE speed Double Fed Motor-Generators applied in Pumped Storage Plants

Synchronous Machine

� Rotor equipped with DC field windings and

2 slip rings

� Rotor field is fixed coupled with the rotor

position

� Rotor field can only be varied in magnitude

and not in position

� Simple DC excitation equipment

Double Fed Motor-Generator

� Rotor equipped with 3-phase winding system

and 3 slip rings

� Rotor field is decoupled from the rotor position

� Decoupled control of real and reactive power

is possible

� Converter for 4-Q operation connected

between rotor-circuit and generator bus duct


www.andritz.com

Doubly Fed Motor-Generator – Comparison


www.andritz.com

Doubly Fed Motor-Generator – Comparison

Shrink-on retaining ring design

+ approved (reference proj.: Goldisthal)

+ quick assembly

+ few parts of end winding support (approx. 2.300, incl. aluminum cooling profiles)

+ no radial compression forces on bars

+ low air friction losses

o indirect cooling of bars via aluminum profiles

- more costly solution

U-bolt design

+ less costly solution

+ easy assembly

+ simple parts, easy to manufacture

o cooling of bars due to direct convection

- high air friction losses

- radial compression forces on bars

- time-consuming assembly

- high number of parts of end winding support(approx. 19.000)


References

33 www.andritz.com


34 www.andritz.com

Selected references

Year Plant Country Unit Output Voltage Speed[MVA] [kV] [rpm]

2013 Revin France 4 200 13,8 3002011 Foz Tua Portugal 2 150 11 187,52011 Hongrin Lemans Switzerland 2 130 15,5 5002010 Reisseck II Austria 2 240 15,5 7502010 Vianden 11 Luxembourg 1 230 15,75 333,32009 B.S. Montante Portugal 2 85 15 214,32006 Limberg II Austria 2 270 15 428,62006 Presenzano Italy 1 300 12 428,62005 Hintermuhr Austria 1 78 10,5 10002005 Nestil Switzerland 1 175 13,8 6002004 Kopswerk II Austria 3 200 13 5002003 Cheongsong Korea 2 333,3 18 3002003 Yixing China 4 278 15,75 3752002 Langyashan China 4 167 15,75 230,82001 Cruachan Great Britain 2 144,44 16 5002001 Tong Bai China 4 334 18 3001998 Goldisthal Germany 2 331 18 333,31998 Goldisthal (DFIM) Germany 2 340 18 333,3


www.andritz.com

New Pumped Storage Power Plant - extension to existi ng HPP

Scope of Supply:

• One reversible Pumpturbine, 70 MW

• Rotary valves and gate

• Reversible Motorgenerator(78 MVA, 10.5 kV, 1.000 rpm)

• Excitation Equipment

• MV-Switchgear incl. Busduct

• SFC 2.9 MW

• Automation, Protection and

Control Equipment

• Implementation of existing station service

Commissioning: 2007

Hintermuhr - Austria

Complete E&M Equipment


www.andritz.com

Main Equipment:� 1 x 142 MW 4-stage

reversible Pumpturbine,� 1 x 175 MVA Motorgenerator,

start up Pelton� Net Head 858..1066 m� 600 rpm

Project Highlights� Extreme pumping head requires use

of multi-stage pump

Commissioning: 2009

Tierfehd / Switzerland

Turnkey - Complete E&M Equipment


www.andritz.com

First speed variable Pumped Storage Plant

in Europe

Goldisthal / Germany

Customer:� Vattenfall

Motor Generator� 2x340 MVA DFIM and

2x331 MVA fixed speed M/G, AC Excitation and Starting - SFC

� 300..346 rpm and 333 rpm

Project Highlights� two sets of synchronous and

doubly fed asynchronous M/G� Central location in the UCTE grid

Commissioning: 2003

PSW Goldisthal 1060 MW


Reißeck II / Austria

14.11.2014 www.andritz.com

Main Technical Data

� 2 Units

� S = 240 MVA

� Un = 15,5 kV

� n = 750 r.p.m. (8 poles)

� Runaway speed = 1142 r.p.m.

� Overspeed test = 1200rpm

� currently under commissioning

Expected date of completion: 2014


Pole surface speed at rated speed 450 km/h

Pole surface speed at overspeed 724 km/h

Mass of one pole 9.100 kg

Centrifugal force of one pole at rated speed 7.800 t

Centrifugal force of one pole at overspeed 20.000 t

14.11.2014 39

www.andritz.com



� Geometrie of poles and pole fixing

ANSYS 12.1 and 13

Verification of fatigue strength with FKM method co nsidering

6 start / stops a day,

6 load rejections yearly,

Safety margin of 2 for stress level

Lifetime > 70 years

ComponentRe(MPa)

Lifetime (Years)

Rotor hub 800 > 100

Pole end plate 800 84

Pole sheet 550 > 100

Comb bolts 850 > 100

14.11.2014 www.andritz.com



41 The copyright of this document and all attachments remains with the company

Pump Turbine TechnologyContent

1) Changing requirementsfor equipment design

2) The classical concept: Fixed speed single stagereversible pump turbine

Design characteristics

Recent examples

3) Special configurations

Variable Speed

Ternary sets, Hydraulic short circuit

Multi Stage Pump Turbines

Sea Water Pumped Storage

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Increasing variety and complexity of requirements for equi pment:

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� Frequent load changes All Hydro Turbines

� Frequent start / stops Storage / Pumped storage plants

� Wide operation range Francis, Pump TurbinesStability over a wide range Pump Turbines

� Fast changeover times Pump Turbines

� Safe Operation, robust design All Hydro Turbines

� High efficiencies All Hydro Turbines

� Cost optimized dimensions/design All Hydro Turbines

� Environmental aspects All Hydro Turbines

Pump Turbine TechnologyChanging requirements for Hydroelectric equipment

The copyright of this document and all attachments remains with the company

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� Much more part load operation� Much more Start-Stop events� Dynamic stresses drastically

increased

CFD / FEM AnalysesVerification by prototype measurementsEstimation of lifetime for criticalcomponentsInvestigations currently for all 4 turbine types

Frequent Start – StopsOperation over full range

Measured blade stress

Startup/SNL full load SNL

Pump Turbine TechnologyEquipment Requirements


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Research on Unsteady Phenomena in Pump turbines

Pump stability at high head� Drop of head-flow characteristics at high

heads� Unstable operation or start-up possible ?

The behavior will be stable for a negative slope of the characteristic curve at the operating point, but for a positive slope the behavior will be unstable.

From P. Dörfler, M. Sick, A. Coutu. Flow-Induced Pulsation and Vibration in Hydroelectric Machinery. Springer Verlag (2013). Chapter 6.4.2



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Layout always is a compromise between several aspects� High efficiencies over a wide range� Safety against cavitation damage� Dimensions and geometry favourable for manufacturing and c ost� Impact on civil works (dimensions, setting level)� Stability� Robustness

Especially on Pump turbines, Robustness is crucial.



example: adjustablewicket gate bearings�� lower vibration level

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Pump Turbine TechnologyThe classical concept

Single stage, reversible,fixed speed Pump Turbine

Pump starting with SFC in dewatered condition

Often with Synchronouscondenser mode(Labyrinth cooling!)

Earlier NowDay / Night FrequentCycle part load

Changeover times 7-8 min 5-6 min(Fast changeover PUMP � TUR ~ 90 sec exeptional - very rough condition!)

Double peak test


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avoid:pit diameterreduction needsa split headcover(not valid for middledismantling)

include:prestressedbearings

include:partly concretearound drafttube cone

avoid:Shearpins

include:segment type radial bearing

include:access to lowerwicket gatebearing

include:axial hydrostaticshaft seal

Typical design features for a reversible Pump turbine

Prefer:Individual servomotors forGuide vanes

Pump Turbine TechnologyThe classical concept – Design features


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Pump Turbine TechnologyReversible Pump Turbine – Recent examples


Customer: SEO / RWE

1 Pump turbine 200 MW

D1 = 4400 mm H = 300 m

Contract year: 2010Second extension of the existingPumped storage plant

ANDRITZ Hydro Scope: Pump turbine, Motor generator

Vianden

Unit 11

Luxemburg

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Baixo Sabor MontantePortugal

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Customer: EDP

Runner Diameter 4112 mm

Head range H = 68.8 m – 104.6 m

Max power P = 76.9 MW

Speed n = 214.29 rpm

Scope of supply:

2 Pump Turbines

Motor/Generators

Auxiliary equipment

Wide head variation

Equipped with ring gate



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Baixo Sabor JusantePortugal

Customer: EDP

Runner Diameter D1 3948 mm

Head range H 26.2 m – 35.2 m

Max. power P 17.8 MW

Speed 150 rpm

Scope of supply:

2 Pump Turbines

Motor/Generator

Auxiliary equipment



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Large Hydro

Foz Tua

Portugal

2 Pump turbines 124 MWH = 96 mD = 3460 mmN = 187 rpm

Motor generators, Penstock, gates

Electrical power Systems

Cranes, Auxiliaries

Equipped with ring gate

Contract: November 2011

Model test,

adaptation to increased operating range

Portugal


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New concept for standardized solution

� Reduced project specific cost (engineering, assembly, …)

� No individual model test

� Standardized equipment

� Simple installation

� Variable Speed, Full size Converter

� Competitive W2W solution

High head applications:

Multi stage pump withseparate Pelton Turbine

Standardization

Range:

5 – 50 MW / unit

25 – 250 m Head


Pump Turbine TechnologyStandardized concept

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max. head

min. head

max. speed

min. speed

cavitation limit,high pressure side

cavitation limit,low pressure side

stability limit

Variable speed unitshave a substantiallywider operating rangeboth in Turbine andPump mode

BUT: Even with FullSize Converter,- Hydraulic limits

must be con-sidered (cavitation, stability)

- High flexibility effectonly with regulatedturbines (guidevanes, speed)


Pump Turbine TechnologyVariable Speed Units

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Maximum flexibility byHydraulic Short Circuit

to tailwater

Hydraulic short circuitPartly to tailwater, partly to pump

To and from headwater

Hydraulic short circuitPartly to headwater, partly to turbine

from tailwater

Example: Kops II / Austria


Vertical or horizontal shaft

Pump Turbine TechnologyTernary Units

Obervermunt II (2x180 MW)

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Client: Vorarlberger IllwerkeUnique Ternary concept

Pressurized downstream chamber

In operation since 2009

3 x 180 MW Tu / 150 MW Pu / 826 m

Full load in 20-30 s (Tu and Pu mode)

> 8000 operating hours / year!

Pump Turbine TechnologyTernary Units

Typical operation curve over 12hoursPUMP

TUR

Hydraulic TorqueConverter allows maximum flexibility


Source: P. Matt, Vorarlberger Illwerke, Sep 2014, Porto

Kops II Austria

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Two stage reversible units: 2 regulateddistributors ��flexibilityin turbine modeFor heads < 1000m Smaller dimensions thanternary sets


Pump Turbine TechnologyMulti Stage Pump Turbines

Shop assembly in Ravensburg

Tierfehd (Nestil), Switzerland

Customer: AXPO

1 four stagereversible

Pump turbine, MIV,motor generator

P = 130 MW

H = 1062 m

n = 600 rpm

Contract year: 2005

For high headsNo part load operationFlexibility only ifcombined in a ternaryset

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Projects are promoted with sea water PSP. One pilot plant in Japan exists.

PRO CONTRA

Saving of Downstream Reservoir Stainless steel for turbin e partsAustenitic steel - Lower blade

Additional sites possible strength �� bigger unitsCorrosion resistant penstock

No evaporation problem Gates subject to high corrosion

Projects in dry hot , areas will Salt water in headpon d may createanyway need desalination environmental problemsor salt content grows Marine life in water circuit (cooling…)

Increased maintenance & repairCathodic protection system

Possible to build, BUT: Substantial additional cost !

We consider the economic benefit of sea water PSPs question able


Pump Turbine TechnologySea water applications

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Comparison for more than one unit

58 www.andritz.com

Fixed speed Variable speed

ReverisblePump-Turbine

Ternary unit

DFM(Doubly fed

asynchronousMG)

FSC (salient pole MG with a full size

converter)system efficiency T: P: T: P: T: P:control range (Power +/-100% output)mode change times

Grid

stab

ility

reaction time on failure(frequency changes)power factor adoption(voltage changes in the

grid)

synchronous condensermode

rotatinghydraulicmachine

rotatinghydraulicmachine

rotating hydraulicmachine

in standstill

space requirements(Volume)

100% 150%-200% 115%-125% 130%-140%

world wide references >300 only a few >101 in hydrobusiness

costs of the E&Mequipment

100% 120%-140% 115% - 130% 150-170%

worseMiddleAlmost bestbest

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Obrigadopara su

atenção !

59 www.andritz.com

Alois Lechner

ANDRITZ HYDRO GmbHEibesbrunnergasse 201120 Vienna, AUSTRIA

[email protected]: +43 664 8330948

Michael Schmid

ANDRITZ HYDRO GmbHEibesbrunnergasse 201120 Vienna, AUSTRIA

[email protected]:+43 664 9614516

Peter Magauer

ANDRITZ HYDRO GmbHEscher-Wyss-Weg 1

Ravensburg, [email protected]

Mobile: +49 173 5623522

Documents

Benefícios de usinas reversíveis e aspectos técnicos do ... · motor-generator hydraulic torque converter pump ... 2013 Revin France 4 200 13,8 300 ... • Rotary valves and gate