Technologies for Hydro Development in the Pacific Northwest

9/24/2011

Innovation and Adaptation

Contents
* Introduction * Mavel Overview * Pelton * Francis * Micro Turbine

* Kaplan Pit Turbine * Vertical Kaplan Turbine * Conclusion

Hydro Technology by Mavel

Introduction
-

Technology is an enabler
-

Improve efficiency Improve reliability Reduce cost

Design
-

CFD Controls

Manufacturing Optimize / customize for each site Proven Technology + Innovation + Adaptation = Success

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Mavel Overview
Focus: Product Expertise: Small Hydro up to 30 MW Turbines: Kaplan, Francis, Pelton and Micro

Experience:
Ownership: Production Capability: Sales/Service Territory:

400+ turbines installed in 18 years

50% American / 50% Czech Two European Facilities; 200 employees Americas, Europe, Africa and Parts of Asia

Quality:
Technical Capacity:

ISO 9001:2008 Certified

40 Engineers, 85 Proprietary Designs, In-house R&D Czech Technical University hydraulic lab

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Mavel Turbines
Kaplan Turbines
PIT Turbine Bulb Turbine Vertical Turbine Z Turbine S Turbine Pelton Turbines Horizontal Vertical
Micro Turbines

3 kW 30 MW

Francis Turbines
Horizontal Vertical
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Mavel Manufacturing Headquarters

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Mavels Final Assembly Hall

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Pelton Turbines
Runners: 300 mm to 2000 mm 1 to 6 Jets Vertical or Horizontal Head: 160 to 3300 ft (50 to 1000 m)

Flow: 3.5 to 350 cfs (0.1 to 10 cms) Power Output: Up to 30 MW

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Pelton Turbines
Innovation:
external distributor compact powerhouse reduced civil cost improved runner design CNC machined runners optimal runner size optimal jets match the site

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Francis Turbines
Runners: 400 mm to 2000 mm Vertical or Horizontal 6 specific speeds

Head: 50 to 1000 ft (15 to 300 m)

Flow: 17.5 to 1250 cfs (0.5 to 35 cms) Power Output: Up to 25 MW

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Production Technology

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Kaplan Turbines
Runners: 500 mm to 4500 mm

Vertical or Horizontal Type: S, Bulb, Pit, and Z

Power Output: 25 kW to 25 MW Head: 5 to 115 ft (1.5 to 35 m) Flow: 32 to 3200 cfs (0.9 to 90 cms) Innovation: CNC machined runners control of blades and gates gear box, belt drives wider head / flow range

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Low Head Technologies

- Applications for low head sites - Irrigation Systems - Non Powered dams - Water treatment plants - Conduit Exemption - Micro Turbine - Kaplan Pit Turbine - Vertical Kaplan

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Micro Turbine: Overview

Head: 5 to 20 ft (1.5 to 6 m) Power: up to 180 kW per Unit 3 different sizes MT3 MT5 MT10 No need for a powerhouse Complete package Cost effective Easy to install Minimal civil work Siphon type turbine Propeller runner pitch can be manually adjusted Belt drive Very low maintenance costs Proven: 50 turbines, 30 locations, since 1996

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Siphon Turbine

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Micro Turbine: Applications

Existing Unpowered Dam Irrigation Canal Water Treatment Plant Low Flow Unit

Oomachishi, Japan MT5

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Micro Turbine
Olawa Micro Hydroelectric Power Plant, Poland

Head: 11.5 ft (3.5 m) Flow: 140 cfs (3.9 cms) Type: Three x MT10

Power Output: 300 kW (100 kW each) Year Commissioned: 2006 Runner diameter: 1000 mm

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Mavel Kaplan Pit Turbine

Runner Diameters
Number of Runner Blades Head Flow Power Output Transmission

2000 mm to 4500 mm
3 or 4 5 to 35 ft (1.5 to 10 m) 530 to 3200 cfs (15 to 90 cms) 500 kW to 8,000 kW Parallel Gearbox

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Mavel Kaplan Pit Turbine: Applications

Low Head Sites Alternative to Kaplan S Turbine for Larger Sites Powering Existing Lock and Dam Facilities Installation/Replacement in Existing Power Plants

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Mavel Kaplan Pit Turbine Lovosice Hydroelectric Power Plant, CZ

Head: 6.2 ft (1.9 m) Flow: 5650 cfs (160 cms) 4 Kaplan Pit Turbines Runner Diameter: 3000 mm Total Installed Power: 2650 kW 662 kW each Year Commissioned: 2010 Innovation: number of turbines minimize civil work powerhouse can be submerged

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Lovosice Hydroelectric Power Plant, CZ

Mavel Kaplan Pit Turbine

Interior of Powerhouse

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Generator and Gearbox in Pit

Power Plant Spillway

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Pit Turbine
Bulkheads Gate actuator
Runner Transition from pit to

draft tube

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Mavel Vertical Kaplan Turbine

Runner Diameters Number of Runner Blades Head Flow Power Output Transmission 850 mm to 3400 mm 4 or 5 5 to 100 ft (1.5 to 30 m) 32 to 3200 cfs (0.9 to 90 cms) 10 kW to 24,000 kW Direct Drive, Belt Drive or Parallel Gearbox

Infernos HPP, Portugal - 1019 kW Vertical Kaplan

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Mavel Vertical Kaplan Turbine: Applications

Francis/Original Turbine Replacement

Wider Operating Range Double Regulated

Minimal Civil Reconstruction Higher Turbine Efficiency Low Head Sites

Existing Lock and Dam Facilities Custom design

Layout of Mavel Vertical Kaplan Turbine

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Mavel Vertical Kaplan Turbine Boatlock Hydroelectric Station, USA

Replacement of Original Francis Turbine with New Mavel Vertical Kaplan Increased Power Output Threefold

Increased capacity
Output: 704 kW Head: 19.7 ft (6 m)

Flow: 465 cfs (13.2 cms)

Runner Diameter: 1600 mm

Year Commissioned: 2010

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Kaplan Efficiency

Flat efficiency curve over a wide flow range 20% to 100% of rated flow Francis has low efficiency at low flow; 35% minimum

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Conclusions
Continuous Innovation and Adaptation Modular Systems of Proven Equipment
Adding New Sizes and Models to Existing Turbine Lines Efficiency Improvements

Designs to Minimize Civil Costs Customized and Optimized Turbines for Each Site Use the 100 years of knowledge and improve

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sellars@mavel.cz www.mavel.cz

Hydro Technology by Mavel