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StreamDiver® for low head

hydropower plants
Curitiba, Brazil, June 14 to 15, 2016

1
Agenda

Motivation & Background


Introduction to StreamDiver
Innovative Plant Concepts
Service and Maintenance
Operational Experience

Voith Hydro | Curitiba 2016 | 14-15 June 2016 2


Agenda

Motivation & Background


Introduction to StreamDiver
Innovative Plant Concepts
Service and Maintenance
Operational Experience

Voith Hydro | Curitiba 2016 | 14-15 June 2016 3


Worldwide there is still tremendous potential for the use of low head
hydropower for power generation.
Decentralized hydropower generation is sustainable, renewable and
supports economic development of remote areas.
However, low head power plants have specific requirements
regarding commercial viability, availability and maintenance.

Voith Hydro | Curitiba 2016 | 14-15 June 2016 4


Specific Requirements for Low Head
Hydropower Plants
Reduce cost of ownership through entire
lifecycle and maximize production:
• Maximize standardization
• Reduce system complexity
• Ease of civil integration
• Environmental awareness
• Low maintenance in frequency and
duration
• Remote monitoring & operation

Voith Hydro | Curitiba 2016 | 14-15 June 2016 5


Agenda

Motivation & Background


Introduction to StreamDiver
Innovative Plant Concepts
Service and Maintenance
Operational Experience

Voith Hydro | Curitiba 2016 | 14-15 June 2016 6


StreamDiver is designed by simplicity for
maximum reliability
2 1 3 2 4 5 1 Permanent magnet generator
• Water-floated
2 Thrust and guide bearings
• Water-lubricated
3 Turbine bulb
• Water-filled
• No dynamic seals
4 Turbine housing with fixed guide
vanes
5 Propeller runner

Ensured low-maintenance due to


absence of dynamic seals & peripheral systems
Voith Hydro | Curitiba 2016 | 14-15 June 2016 7
Water-Lubricated Sleeve Bearings

• Process water-lubricated bearings,


100% oil-free design

• Bearing design based on hard-soft


pairing principle. Synthetic bearing pads
and shells with high-strength abrasion
surface

• Bearing concept has proven itself in


other Voith products, e. g. tidal flow
turbines, HyTide and Voith Inline
Thruster

• Wear resistance of bearings has been


tested and analyzed in bench tests
Voith Hydro | Curitiba 2016 | 14-15 June 2016 8
The Application range with 5 different sizes
and heads from 2m to 8m
A single unit generation ranges from below
50 kW up to above 750 kW depending on
the available head and flow.

The compact and


modular design allows to
build remote plants with
multiple units and higher
outputs up to several
MegaWatts
Voith Hydro | Curitiba 2016 | 14-15 June 2016 9
Plant layout with variant matrix: unit size and
number determines plant capacity

Optimized towards lower CAPEX Optimized towards energy yield

Q [m³/s] H [m] Q [m³/s] H [m]

unit 4 unit 6
unit 5
unit 3 unit 4
unit 2 unit 3
unit 2
unit 1 unit 1
duration (days per year) duration (days per year)

e.g. fewer, larger units e.g. more, smaller units

Voith Hydro | Curitiba 2016 | 14-15 June 2016 10


Agenda

Motivation & Background


Introduction to StreamDiver
Innovative Plant Concepts
Service and Maintenance
Operational Experience

Voith Hydro | Curitiba 2016 | 14-15 June 2016 11


Integration examples of StreamDiver
hydropower plants
RoR in diversion-type plants RoR as overflowed concept

Open canals for irrigation or cooling water Closed pipe systems

12
Diversion-type Power Plant:
3 vertical Kaplan turbines

Voith Hydro | Curitiba 2016 | 14-15 June 2016 13


Diversion-type Power Plant:
3 vertical Kaplan turbines

Voith Hydro | Curitiba 2016 | 14-15 June 2016 14


System limits:
3 vertical Kaplan turbines

Voith Hydro | Curitiba 2016 | 14-15 June 2016 15


Diversion-type Power Plant:
2 S-Kaplan turbines

Voith Hydro | Curitiba 2016 | 14-15 June 2016 16


Diversion-type Power Plant:
2 S-Kaplan turbines

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System limits:
2 S-Kaplan turbines

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Diversion-type Power Plant:
6 StreamDivers

Voith Hydro | Curitiba 2016 | 14-15 June 2016 19


Plant Layout with StreamDivers: top view

Voith Hydro | Curitiba 2016 | 14-15 June 2016 20


Diversion-type Power Plant:
6 StreamDivers

21
Diversion-type Power Plant:
6 StreamDivers

Voith Hydro | Curitiba 2016 | 14-15 June 2016 22


System limits:
6 StreamDivers

Voith Hydro | Curitiba 2016 | 14-15 June 2016 23


Comparison of Concrete Volumes of different
Powerplant Concepts within system limits
Layout Units Vertical Kaplan S-downstream StreamDiver®

Numbers of units - 3 2 6

Width m 23.1 16.4 22.2

Length m 24.2 19.1 20.0

Depth+Height 1) m 12.4 13.2 14.5

Volume m³ 6,932 4,135 6,438

Concrete volume m³ 3,600 2,300 1,200

Concrete volume 100 % 64 % 33 %

1) civil structures without powerhouse

Voith Hydro | Curitiba 2016 | 14-15 June 2016 24


Delivery time

• The StreamDiver delivery time shorter than for conventional


customized turbines
• Due to the simplified civil structure the civil construction time
can be shortened as well
 Project execution time can be shorted
 approx. 3 months earlier grid connected!

Voith Hydro | Curitiba 2016 | 14-15 June 2016 25


Integration examples of StreamDiver
hydropower plants
RoR in diversion-type plants RoR as overflowed concept

Open canals for irrigation or cooling water Closed pipe systems

26
Overflowed Power Plant

The concept has been developed by the „Chair of Hydraulic and Water Resources Engineering“ at the
Technical University of Munich and is protected by various patents.

Voith Hydro | Curitiba 2016 | 14-15 June 2016 27


Overflowed Power Plant

Key of this concept is a completely submerged powerplant with


a horizontal trash rack arrangement.
The StreamDiver is the perfect turbine type for this powerplant

Voith Hydro | Curitiba 2016 | 14-15 June 2016 28


Overflowed Power Plant:
The Basic Principle

trash rack cleaner Water spilled against vortex


trash rack generation
(horizontal)
Head water gate with
head water upper and lower opening
for fish migration –
normal position
StreamDiver
Unit tail
water

Draft-tube

Voith Hydro | Curitiba 2016 | 14-15 June 2016 29


Agenda

Motivation & Background


Introduction to StreamDiver
Innovative Plant Concepts
Service and Maintenance
Operational Experience

Voith Hydro | Curitiba 2016 | 14-15 June 2016 30


Service and maintenance

The turbine can be


disassembled for service and
maintenance works without
de-watering of the water
chamber. 31
Maintenance Plan StreamDiver

Interval Location Scope Duration


once a week remote diagnosis review status of few minutes
sensors and check
alarm signals.
once a year on site Inspection of aux. one day total
components
once every 2-3 on site on site inspection after one day per unit
years dewatering chamber or
retrieving unit
after 5 years in workshop replacement of three days per
bearings and repair unit
painting, general
inspection (plus 1 day
on site for
retrieval/reinstallation
per unit)
Voith Hydro | Curitiba 2016 | 14-15 June 2016 32
Agenda

Motivation & Background


Introduction to StreamDiver
Innovative Plant Concepts
Service and Maintenance
Operational Experience

Voith Hydro | Curitiba 2016 | 14-15 June 2016 33


Feedback from Operations: Nussdorf, Austria –
Now 3,5 years of maintenance-free operation
Turbine Data: Project Status:
• Power Unit: 1x SD 13.10 (Ø 1310 mm) • In operation since August 2012
• Power Output: 314 kW / max.: 450 kW • Operating hours: > 28,000 hrs 1
• Net head: 3.58 m / max. 4.68 m • Exported electricity: > 7.4 GWh 1
• Flow: 9.96 cms • On-site inspections: 1 (downtime: 1 day)
• Generator speed: 333 rpm, 50 Hz • Maintenance services: 0

Voith Hydro | Curitiba 2016 | 14-15 June 2016 34


status: Jan. 2016
Nussdorf: Results of Feb. 2016 Inspection
after 3,5 years of operation
• general condition after
visual inspection:
excellent, only some biofilm
• lower wear of bearing parts
(shaft coating and pads) as
expected -> longer lifetime as
expected
• corrosion:
coating surface ok,
some minor damages
• blade condition: excellent
• generator leakage test: ok

Voith Hydro | Curitiba 2016 | 14-15 June 2016 35


Summary
The Key Values of the StreamDiver

StreamDiver Design
• high efficiency
• oil-free solution
• low maintenance
• cost savings due to modular concept
Operation & Maintenance
• highest availability
• fast & predictive maintenance (e.g. in
low water periods)
• standardized spare parts

Voith Hydro | Curitiba 2016 | 14-15 June 2016 36


Voith Hydro | Curitiba 2016 | 14-15 June 2016 37