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- GMR/GBHPL/ICB/LOT/05
PROJECT: - ALAKNANDA HYDROELECTRIC PROJECT (3X100MW) OWNER: - GMR (BADRINATH) HYDRO POWER GENERATION PVT. LTD.
Rev. A B C D
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Description
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
TABLE OF CONTENTS
1 Introduction............................................................................................................................................. 3 2 Design Data............................................................................................................................................. 3 2.1 Main Dimensions................................................................................................................................... 3 3 Hydraulic Dimensioning and Model Testing......................................................................................... 4 4 Codes and Standards............................................................................................................................. 4 5 Scope of Supply...................................................................................................................................... 5 6 Pelton Turbine........................................................................................................................................ 6 6.1 Introduction............................................................................................................................................ 6 6.2 Turbine Runner...................................................................................................................................... 6 6.3 Turbine Shaft......................................................................................................................................... 6 6.4 Nozzles and Jet Deflector Assembly...................................................................................................... 6 6.5 Brake Jet................................................................................................................................................ 7 6.6 Distribution Pipe..................................................................................................................................... 7 6.7 Housing and Pit Liner............................................................................................................................ 8 6.8 Turbine Bearing..................................................................................................................................... 8 6.9 Tool and Devices.................................................................................................................................. 11 6.10 Runner Removal................................................................................................................................ 11 7 Shop Assembly and Pressure Tests................................................................................................... 12
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
Introduction
This proposal document provides an overview and introduction to Voith Hydro Pelton Turbine and Technologies. Particular emphasis is given to those aspects of the product scope which demonstrate the superiority of many of the special features incorporated into todays designs. This proposal is based on the typical or standard methods normally used for this class of machine. Many years of experience have been accumulated in the area of Hydro Turbines. In particular, including the following significant achievements: More than 40,000 hydraulic machines have been supplied world-wide since the beginning of manufacturing in 1870. Experience with both cast and fabricated runner manufacturing techniques. The turbine will be of the Pelton, vertical type with a distributor pipe embedded on concrete, nozzle assembly and turbine housing. Dismantling of runner will take place from turbine bottom side. Typical cross sectional views / arrangements are provided in this document. However, exact details / arrangements will be provided specific to the project during detailed engineering.
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2.1
Design Data
Main Dimensions
Nominal diameter Rated Output Rated Head Rated Speed Elevation Runner
D1 P H N CL
mm MW m RPM masl
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
The following national / international standards are normally adopted : ISO IEC DIN EN IS ASTM BS VDE AD-specifications: VH Mechanical Equipment Standards - Model Acceptance Tests - Field Acceptance Tests IEC 60193 IEC 60041 International Standards Organization International Electro-technical Commission German Institute of Standardization European Standard Indian Standard American Society for testing and materials British Standard Association of German Electro-technicians working group on pressure vessels VOITH HYDRO standard
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
- Standard for Turbine - Generator Shaft couplings and runout - Guide for Commissioning, Operation and Maintenance of Hydraulic Turbines - Standard for allowable stresses - Standard for Cavitation Guarantee - Standard Forged shafts and General use - Martensitic Stainless Steel Casting - Martensitic Corrosion Resistant Steel Casting
IEC 60545
Voith Standard IEC 60609 ASTM A 668 Gr. D ASTM A743 GradeCA-6NM G - X 4 CrNi 13 4
X 3 CrNiMo 13-4
Scope of Supply
- Vertical shaft Pelton turbine consists of the following main components : - Fixed/ embedded components including, Turbine Housing and discharge pit liner, Distributor pipe, nozzles and deflector assembly, Inspection platform with rail arrangement. - Rotating components including runner and turbine shaft etc for each unit; - Guide bearing and necessary instrumentation for each unit; - Coupling parts between Runner/turbine shaft and turbine shaft/generator shaft - Necessary handling / lifting devices such as runner trolley, runner lifting device, nozzle trolley, nozzle alignment fixture etc. shall be provided. - Necessary fittings / piping / accessories etc. for each unit; - set of mandatory spare as per offer
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
Pelton Turbine
6.1 Introduction
Pelton machines are preferred turbine for hydro-power when the available water sources are in relatively high head at a low flow rate. The water flows along the tangent to the path of the runner bucket profile. Nozzles direct streams of water against a series of hydraulically shaped buckets mounted around the edge of a wheel. As water flows into the bucket, the direction of the water velocity changes to follow the contour of the bucket. When the water-jet contacts the bucket, the water exerts pressure on the bucket and the water is decelerated as it does a "u-turn" and flows out the other side of the bucket at low velocity. In the process, the water's momentum is transferred to the runner.
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
pipe. The needle will move axially by an integrated hydraulic cylinder, which will be operated with pressure oil by the governor high pressure unit. This axial movement results in increasing or decreasing the discharge area of the jet and thus controls the water flow. The hydraulic forces at the needle and piston are balanced with a differential piston arrangement and spring force such that in all possible needle positions closing tendency of the needle will result. If the oil pressure drops below a critical value, then the needle will automatically close. The compensation piston will seal the water side using a wiper and a special seal. The oil side has a separate seal. Between both seals, a circumferential groove will collect any leakage developed by the seal on both sides, which will be discharged by a leakage tap. All nozzles are controlled by the governor. The position of the needle will be restored by a linear transducer which is incorporated in the needle. The necessary transducer will be installed in the control cabinet. Each nozzle is equipped with a jet deflector, which will be applied at load rejections. It will deflect the jets as a whole from the runner quickly, while simultaneously the nozzles are slowly closing. Thus the pressure rise in the penstock and the speed rise of the unit are limited below the admissible values. Each jet deflector has an individual oil operated servomotor below the nozzle. Opening and closing of deflector servomotor is by oil pressure only. In case of oil failure from oil pressure unit, oil will be available from accumulator to close the deflector. The deflectors will enter the jets only during load throw off and unit trip command. All bearings used for this application are maintenance-free. Drainage of pressurized water of penstock shall be done mainly through opening one of the nozzles with deflector in closed position. Rest of water left at bottom of horizontal part of penstock will drained via penstock drainage provided in upstream pipe of main inlet valve.
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
The distributor will also be provided with a sufficient number of leveling screws or jacks, lugs and anchor rods with turn buckles for supporting and holding the case during checking and concreting. The complete distributor will be firmly embedded in concrete. No flexible wrapping will be used to cover the distributor to avoid any small movement of the distributor under working load (internal pressure), thus keeping the alignment of the nozzle in respect of the turbine runner as precise as possible. Distributor pipe will be pressure tested at site with turnbuckle arrangement at its center to hold the distributor pipe in its position.
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
The oil is led into chambers between each segment and is flooding the segments. The heat generated by the bearing due to friction loss is removed by oil cooling system equipped with an internal cooler which is connected to the cooling water piping system. The bearing oil supply system will also be equipped with all necessary piping, valves, controls and instrumentation.
1 2 3 4 5 6 7 8
Turbine Shaft Bearing Segment Adjusting Wedge Bearing Housing Oil Reservoir Oil Outlet Oil Inlet Level Indicator
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
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Typical Turbine Bearing Arrangement
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05
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