Voith Hydro

Hydro Power Plants

Dr. Jiri Koutnik, 2013-11-04 AGCS, Munich

1
Voith in figures

50 42,000 5
In over
countries Employees Markets

R&D ratio Family-owned since Sales

4.7 % 1867 €5.7 billion

Stand: 2011/12

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 2

 Energy
A quarter of all electricity generated
by hydro power worldwide is produced with
technologies and services from Voith.

Pumped Storage Plant

3
Run of River Plant Storage Plant
140 Years of Major Projects

1873 First Voith Francis turbine

1903 First Pelton turbine
1912 Niagara Falls, Canada
1934 Pedreira, Brazil
1938 Sungari, China
1964 Roenkhausen, Germany
1970 Raccoon Mountain, USA
1995 First fish-friendly turbine design
1997 Three Gorges, China
1998 Goldisthal, Germany
2000 Guangzhou II, China
2010 Frades II, Portugal
2011 Belo Monte, Brazil
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 4
 Flow Q and Head H are decisive for the power

P = Q × H × ρ × g ×η
IN

OUT

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 5

 Head H is mainly influencing the turbine type
Pelton:
10,000
~200m to 2.000m

2,000

1,000 Francis
~50m to ~700m

100
Kaplan
~2m to ~50m
10
Head (m)

Bulb
1
~2m to ~20m
10 100 1,000 10,000 100,000 1,000,000

Power (kW)
Pit ~2m to ~10m

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 6

Head H is mainly influencing the turbine type

Pelton
~200 m to 2,000 m

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 7

Head H is mainly influencing the turbine type

Francis (pump turbine)

~50 m to 700 m

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 8

Head H is mainly influencing the turbine type

Kaplan
~2 m to 50 m

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 9

 Head H is mainly influencing the turbine type

Bulb
~2 m to 20 m

Ohio River. Cannelton, USA

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 10

Complete Plant Systems
Pump Storage Powerhouse using full 3D CAD Capabilities

11
History of hydro power turbines and pump-turbines
BHT(China)
(in planning)
turbines
900

800
Itaipu Three Gorges
(Brazil/ Paraguay) (China)
700
Longtan (China)
600
Xiao Wan (China) Xi Luo Du (China)
500

storage sets
400

Bath County
300 (USA)
Gordon (Australia) Ingula
Guangzhou II
200 (S. Africa)
Paulo Afonso II (China) Goldisthal Limberg II
Palmiet
(Brazil) (Germany) (Austria)
100 (S. Africa)
IIha Solteira
Dworshak (Brazil)
Gokcekaya
50 (USA)
(Turkey)

0
1960 1970 1980 1990 2000 2010

Year

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 12

 History of hydro power generators
and motor-generators BHT(China)
(in planning)
1000
Itaipu (Brazil)
900
Water cooled
800 Air cooled GURI II (Venezuela)
Xi Luo Du (China)
700 Three Gorges (China)

600
Bath County (USA)
500 (2000)
Raccoon
400 (USA) Bath County (USA)
(1976)
300

200

100

0
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010
Year
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 |
13
Logistic Challenge:
400t Stainless Steel Runner

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 14

Rotor Assembly – Precision with > 2000t

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 15

 Pumped Storage
• Wind, Solar and Hydro Integration
– Reserves
– Frequency regulation

Wind Production in Denmark in 2009

MW
4000

3500

3000

2500

2000 actual

1500

1000

500 average
(765 MW)
0
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Energy Frequency Storage

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 16
Major pumped storage projects of Voith Hydro
Wehr

Castaic Wallace Dam Herdecke Saeckingen

Mount Elbert Goldisthal Malta Zhang He Wan

Waldeck I Tai An
Bath County Haeusling Shi San Ling
Coo II Guang Zhou II
Helms Venda Nova II Kops II Pan Jia Kou
Bad Creek Frades II Limberg II
Yang Zhou Yong Tedorigawa
Aguayo Rodund
Jocassee Velebit
Estangento Hong Ping
Fairfield San
Racoon Mingtan Cheongpyung
La Muela I Giacomo
Seneca Mountain
La Muela II Samrangjin
Muddy Ghatghar
Smith
Run
Mountain Siah Bishe
Flat Iron Ingula

Palmiet
Rio Grande

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 17

Possible Unit Configurations Depending on
Regulation Responsiveness and Grid Needs
Slower
• Conventional reversible unit Less Flexible

• Fast & frequent response reversible unit

• Conventional units in short circuit arrangement
• Variable Speed reversible unit
Faster
• Ternary unit arrangement More Flexible

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 18

Mode change times for various Unit concepts -
“Flexibility”
Pump Turbine time [seconds]
T Mode change A B C D E

1 Standstill TU-Mode 90 75 90 90 65
2 Standstill PU-Mode 340 160 230 85 80
5 SC-Mode TU-Mode 70 20 60 40 20
6 SC-Mode PU-Mode 70 50 70 30 25
8 TU-Mode PU-Mode 420 470 45 25
9 PU-Mode TU-Mode 190 90 280 60 25
Reversible PT
A – advanced conventional
B – extra fast response conventional
C – VarSpeed,
Ternary set
D – with hydraulic torque converter + hydr. short circuit, horiz, with Francis Turbine
E – same as E but vertical with Pelton Turbine
AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 19
 Fast control of var. speed units
Effect on water hammer
1.1
DC link voltage
1 230

220
0.9
rotor speed 210
0.8 active power 200
Spiral case pressure

[mwc]
[p.u.]

0.7
190

0.6 180

0.5 170

0.4 160
GVO
150
0.3

0 5 10 15 20
Time [sec]
TVA PSExpert
AGCS ForumDays
| 2011-09-13
| Voith - Dr.
| 34Jiri Koutnik | 2013-11-04 | 20
 Start up – Pump Turbine

1 min

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 21

Ancillary Services of Conventional and
Pumped Storage Power Plants
• Frequency regulation
• Voltage / Power Factor control
• Load Following
• Reduced system minimum loading (i.e. many base load
units run below minimum load; resulting inefficiency and
voltage & frequency problems)
• Black Start capability
• Regulation Up (in the generating direction)
• Fast Regulation Up & Down with variable speed pumped
storage power plants (in the generating and pumping
directions)

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 22

The Voith Hydro Policy for
Plant Operational Safety

23
Objective and goals

The Voith Hydro Safety Policy is deduced from the idea of

Engineered reliability.
The goal of this policy in Voith Hydro is to sustain highest protection of:
• Human lives
• Environment
• The capital investment of our customers

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 24

Basic philosophy

Start of the non-tolerable risk region One major failure tolerant in areas with
high energy flow or where the loss of
Safe region Unsafe / hazard region protection is not acceptable.

Voith Hydro requires for emergency

Risk situations and/or in case of failure of
one safety element a second
Tolerable risk region Non-tolerable
risk region
countermeasure.

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 25

Risk reduction process

Assess and Eliminate or Install Inform owner

document reduce risk by necessary about residual
all risks inherent safe protective risks
design systems
measures
Risks

Step 1
Step 2
Step 3
Step 4

Project life cycle

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 26

Hydro power plant – water ways

Plant safety – 1. Gate or roller stop log

water closing devices 2. Gate or butterfly valve

1
3. Butterfly valve or spherical
2
valve
4. Distributor or nozzles
G
5. Gate or stop log or
4
3 T
6 butterfly valve
5
6. Gate or stop log

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 27

 Hydro power plant

Example of 1 major failure tolerance in the water ways.

→ Minimum requirement of two closing devices.

Complete failure
of the distributor

Cutting the water flow

via inlet valve
(2nd measure)

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 28

 Hydro power plant
HV transmission line Example of 1 major failure
tolerance in the power train.

Grid breaker → Minimum requirement of two

opens
(2nd measure) circuit breaker levels, for
interrupting each current -even in
Generator
short circuit condition.
breaker failure

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 29

Example of penstock buckling

Safety Policy requires redundant aeration valves or natural

aeration for the penstock.
After a penstock pressure test the valve for the penstock
dewatering has been opened. Either the aeration valve was
not able to open or it was too small designed.
The same accident happens, if an emergency valve in the
upstream section closes and the aeration valve does not
open.

Source: From a publication of Vattenfall Europe (former HEW): „Strom vom

Strom – 40 Jahre Pumpspeicherwerk Geesthacht“.

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 30

Basic philosophy

VH requires in special cases also a mitigation system in order

to limit the damage extent. Penstock rupture and landslide in
Scotland.

no intake
gate

no emergency
butterfly valve

Source: International water power

and dam construction, Oct. 2006

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 31

Voith Hydro Safety Policy

Our Safety Policy is a crucial element in the supply of our products to owners and
operators. Highest reliability and safety of our equipment safeguard capital
investment of owners on a long-term basis and sustain the balance of state-of-the
art technological standards with highest demands in this area. Technological,
economical, environmental and social responsibility are incorporated in our
values of engineered reliability.

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 32

Contact:

Dr. Jiri Koutnik

Head of Basic Development,
Voith Hydro Holding, Heidenheim, Germany
jiri.koutnik@voith.com

AGCS Expert Days | Voith - Dr. Jiri Koutnik | 2013-11-04 | 33