Schweizerischer

W i t h ft b d Wasserwirtschaftsverband
Fachtagung Wasserkraft 2013 g g
Mittwoch, 6. November 2013
Hotel Arte, Olten
Auswirkungen des vermehrten Regelbetriebs auf
die Lebensdauer der el.-mech. Maschinen
Mirjam Sick, R&D / Engineering Methods, ANDRITZ HYDRO, Zrich
One rather sunny day in Italy
Rovigo 70 MW PV power plant
Electricity production by PV
Dark red: >450W/habitant
Bavaria: ~ 10% of consumption
Courtesy: IEA PVPS Task 14
2 www.andritz.com
Courtesy: IEA PVPS, Task 14
HYDRO as Grid Stabilizer
Moving from static to highly dynamic operation
The electrical grid is changing rapidly
Germany, Sept. 2011
Electricity production fromwind (green) and sun (yellow)
From coal, nuclear etc. to variable Renewable Energy Sources
(RES)
Hydro power technology integrates variable energy sources into
the electrical grid the electrical grid
Fast to dispatch and control
Significant storage capacity and high power output
(10 to 1000 MW)
Innovation needed in HYDRO technology
From pure power production (MWh) to ancillary services
(primary and secondary frequency control)
Balance of the electrical grid: stable frequency
(primary and secondary frequency control)
From hydraulic efficiency ($/MW) to operational flexibility
Key technological challenges
K h f E&M i t t id t bilit & ill Know-how from E&M equipment to grid stability&ancillary serv.
Wide operating range from spinning reserve to full load
Frequent operation and wear of control mechanisms
Fast and flexible pumped storage technology (variable speed!) Fast and flexible pumped storage technology (variable speed!)
3 www.andritz.com
Power plants for grid stability
Comparison Thermal plants Hydro plants
Thermal
plant
Gas
turbine
Hydro
(standard)
Hydro
(advanced) plant turbine (standard) (advanced)
Power gradient (%/min) 2 - 4 8 12 50 - 100 100% in <30s
Minimum load (% of P
N
) 40 40 40 (F), 20 (K,P) 0-5 (all types)
Start-up time 2 5 h < 15 min < 10 min < 5 min
Reduction of life time
(with more start-stops, part
load)
severe severe noticeable acceptable
> Hydro plants have the potential to react extremely fast to all kind of grid -> Hydro plants have the potential to react extremely fast to all kind of grid
disturbances / grid requirements
-> What about existing (older) Hydro plants ??
4 www.andritz.com
Pumped storage plants
Dynamic operation
Yesterday: load balance day night, winter - summer
Today: Primary and secondary control within minutes
y p
oday a y a d seco da y co t o t utes
Stand-by operation (speed - no - load)
Low load operation
Frequent load changes Frequent load changes
Frequent changes from pump to turbine mode and vice versa
n
e

m
o
d
e
Key questions
Additional costs of
o
d
e






t
u
r
b
i
Additional costs of
operation to deliver
ancillary services?
Additional income for
p
u
m
p

m
o
Additional income for
ancillary services?
5 www.andritz.com
2 hours interval time
Ancillary Services
Balancing energy for frequency control
Technical specification is given in the grid code of the respective grid operator
Typical time constants
Primary control: 15 sec / 30 sec
Secondary control: 2 min
Tertiary reserve: 15 min
6 www.andritz.com
Overview: Technical challenges due to flexible operation
The entire system needs to be considered
1. Inspection, fitness check, reference
status of vibrations
2. Compliance with current grid code
3. Secondary equipment
4. Wide operating range (Francis turbines)
5. Life time assessment (F and PT runners)
6. Generator at frequent starts stops q p
7. Life time assessment Kaplan runner
mechanism
Aspects to be considered
Hydraulical aspects, waterways
Mechanical aspects turbine/generator set
St t l t ( i il t t )
8. Maintenance intervals
Structural aspects (civil structure)
Control aspects, governor
Electrical aspects, grid elements
Operational aspects, hydraulic stability,
id t bilit
7 www.andritz.com
grid stability
Fingerprint measurement of vibrations and noise
Identify technical risks, provide reference
Scope of fingerprint measurement
1st priority:
mechanical vibrations bearing housing
mechanical shaft displacement p
noise rating and dominating frequencies
2nd priority: 2nd priority:
pressure pulsation in draft tube and penstock
bearing temperatures
performance by index test performance by index test
noticeable observations at the main unit or
ancillary units
Positions
1: Upper generator bearing
2: Lower generator bearing
3: Thrust bearing
4: Turbine bearing
8 www.andritz.com
Grid Stability: Primary control existing HPP
New governor strategy for critical plants
Background
New ENTSO-E primary control regulations
requiring faster responses to frequency steps
(100% of power in 30s)
EDF wants ALL hydropower plants to participate EDF wants ALL hydropower plants to participate
to primary control and fulfill new regulations
Governor strategy must be adapted for plants
with critical waterway (long penstocks, small
t k t ) surge tanks, etc.)
Procedure
Case study: Hautefage (2x10MW Francis)
Response to -200mHz Frequency step (test measurements)
Guide vane opening / Mechanical power
Validate plant + governor model with
measurements
Improve governor algorithm, tests by simulation
Fulfill new European primary control regulations Fulfill new European primary control regulations
Benefit
Applicable to any plant with narrow surge tank
9 www.andritz.com
Frequency control
Life time analysis of Kaplan regulation mechanism
Background
Run-of-river plants switching from discharge control to
frequency control q y
Description
High cycle fatigue analysis of Kaplan runner regulation
mechanism
Adaptation of design in order to allow frequency control
Max. stress amplitudes below endurance limit: infinite
no. of load cycles allowed
Wear effects have to be considered: more wear of
bearings at frequency control -> higher friction ->
higher forces -> reduced life time
Benefit
Servomotor pressure for discharge control
(conventional operation mode, Melk, 5 days)
Kaplan machine delivering frequency control without
reduction of life time
References
Servomotor pressure for frequency
t l ( ti d M lk 5 d )
Melk
Altenwrth
Reckingen
Wildegg-Brugg
control (new operation mode, Melk, 5 days)
gg gg
10 www.andritz.com
Wide operating range
Francis 0 100% operation: push operating limits
Machines delivering ancillary services need flexible operation:
Spinning reserve
Francis turbine: operating limits
Low load operation
Issues to be solved
Mechanical issues
Francis turbine: operating limits
Full load vortex (draft tube)
Mechanical issues
High dynamic load in part load
conditions
Risk of fatigue
Hydraulic issues
Pressure pulsations and stability
Cavitation
Research projects active
Operation mode needs to be
specified during offer phase
11 www.andritz.com
Operation at low load
Low load dynamic pressure calculations
Background
Low load flow is
highly stochastic
Operation at such
operating condition
becomes more
common
Challenge
To calculate the
low flow conditions
with CFD
12 12 www.andritz.com
Fatigue analysis Francis runner
Strain gauge measurement hot spot
Linear regression analysis
Strain gauge
Rainflow counting method (Meas )
The calculated shape should give a good representation of
the strains from the measurement.
Strain gauge
The strain gauges are not located on the hot spot.
Rainflow counting method (Meas.)
Assumed peak stress matrix of measurement
C
y
c
l
e
s
13
Dynamic amplitude
www.andritz.com
Fatigue analysis
Damage factor based on peak stress
Miners Rule: Linear cumulative fatigue damage theory
If there are k different stress levels and the average number of cycles to failure at the i
th
stress (S
i
) is N
i
, then the damage factor C is:
n
n
i
: Number of cycles accumulated at i
th
stress level(S
i
).
Amplitude (stress level)
n
i
S
1
i
i
N
i
: Number of cycles to failure corresponding to the i
th
stress level(S
i
).
n
i
/N
i
: Damage ratio at the i
th
stress level(S
i
).
C C: The factor of life consumed by exposure to the cycles at the different stress
levels. In general, when the damage factor reaches 1, failure occurs.
14 www.andritz.com
Relative damage and life time dependent on operation
Example : Francis runner at speed no load
Rainflow
cycles count
Extrapolation
using Monte Carlo simulation
cycles count
SNL time
i l
1000
signal
100
S
t
r
e
s
s

a
m
p
l
i
t
u
d
e

i
n

M
P
a
Speed no load:
10
1.00E+03 1.00E+04 1.00E+05 1.00E+06 1.00E+07 1.00E+08 1.00E+09 1.00E+10 1.00E+11
Rainflow
Life time assessment based on 50sec data
Extrapolation to 1000 sec
Damage rate: 0.00011 per hour
Load cycles
Expected SNL life: 8000 hours
15 www.andritz.com
7 Life time assessment: calculation methodology
Ensure lifetime under new operating regime
Mechanical Calculation Procedure (present situation)
gy
New Engineering Approach
Start -
Stop
SNL Part Load
Full Load
/ RSI
dominant
Static
Load
M t i l
Fatigue Analysis
Operating
Regime
Material
Properties /
Condition
16 www.andritz.com
HPP delivering regulating power
Conclusion
Providing flexibility to the electrical grid is a key contribution of Hydro to stable
and secure electricity grid operation.
Flexible operation involves new technical challenges
D i t El t i l G id El t h i l E i t H d li S t Dynamic system: Electrical Grid Electromechanical Equipment Hydraulic System
Components of the electro-mechanical equipment
Auxiliary systems
Major issue: lifetime
Focus: Pump turbine and Francis runners
F ti d d ti i t Fatigue depends on operating point
Each operating point is related to specific damage factor and cost of operation
Design of robust plus hydraulically optimised runners requires new fatigue analysis method
More research needed to get the full picture of influence of type and design of runners on the specific More research needed to get the full picture of influence of type and design of runners on the specific
cost of operation
Operating range and hours of respective operation need to be specified in offer
phase before designing the electro mechanical equipment phase before designing the electro-mechanical equipment.
17 www.andritz.com