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BHARAT HEAVY ELECTRICALS LIMITED Cutting Edge Technologies for Renovation, Modernization and Uprating of Old Hydro Power Stations 16 th Dec 2016 National Workshop on Renovation, Modernization, Uprating & Life Extension of Hydro Power Plants – Diverse Issues & Handling Strategies

Transcript of µ ] v P P d Z v } o } P ] ( } Z v } À ] } v U D } v ] Ì...

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BHARAT HEAVY ELECTRICALS LIMITED

Cutting Edge Technologies for Renovation, Modernization and Uprating of Old Hydro Power Stations

16th Dec 2016

National Workshop on Renovation, Modernization, Uprating & Life Extension of Hydro Power Plants – Diverse Issues & Handling Strategies

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IntroductionRMU activities & methodologyAdvanced Technological tools for RMU (Numerical Simulation)Special Feature studiesConclusion

CONTENTS

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BHARAT HEAVY ELECTRICALS LIMITED

BHARAT HEAVY ELECTRICALS LTD

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BHARAT HEAVY ELECTRICALS LIMITED

BHEL: JOURNEY TILL DATE• FIRST Hydro Generating set -- 3x33 MW Obra HEP UP, 1970.• FIRST Hydro Generating set -- 3x33 MW Obra HEP UP, 1970.

• More than 50 years proven Expertise, Technology & Capability to manufacture, supply and commission.• More than 50 years proven Expertise, Technology & Capability to manufacture, supply and commission.• Supplied and commissioned 503 + sets having > 23100 MW including export of 49 sets totaling > 2730 MW.• Supplied and commissioned 503 + sets having > 23100 MW including export of 49 sets totaling > 2730 MW.• Augmented the annual manufacturing capacity for Hydro Sets to 2500 MW. • Augmented the annual manufacturing capacity for Hydro Sets to 2500 MW.

• State of art turbine model testing laboratory.• State of art turbine model testing laboratory.

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TOTAL: 43, 605 MW

MWAs on 31.03.16

• India has the potential of about 150 GW hydro power• Approx. 43 GW (upto 31.03.16) has already been installed

INSTALLED CAPACITY - HYDRO

R&M BusinessNumber of 454 Units totaling to 20,039 MW out of which more than 30% of the installed capacity are more than 30 years old .

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RMU & LE of Hydro Power Plants

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HYDRO POWER PLANT RMU & LE – WHY?

Life extension & performance restorationPlant safety improvementReliability and availability increaseOperating cost reduction

Modified hydrology conditionsPerformance improvement

Uprating

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RMU & LE PROJECTS: OBJECTIVESTo cater to change in operating parameters and up-gradation to new technology

To avoid unplanned outage & to replace damaged part due to silt erosion and cavitation

To reduce maintenance and operating cost.

To solve the existing problems(if any) such as cavitation.

To ensure greater availability of Power Houses especially during peaking hours

To enhance the life of power plant and performance restoration/improvement.

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RMU & LE: CHALLENGESNEW PROJECT RMU PROJECT

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RMU & LE Methodology

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RMU & LE: METHODOLOGY

• Efficient hydraulic passage• Design for minimizing losses at micro level

Performance Improvement

• High discharging runner to cater high discharge • Utilization of high available head

Capacity Uprating

• Replacement of worn out parts• Innovative design retarding damage due to silt erosion

Life Extension

• Oil leakage to be minimized• Efficient tapping of natural resource

Environmental Compliance

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RMU & LE: METHODOLOGY

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RANGE OF SOLUTIONS IN R&MTURBINES

• Model Testing/CFD Analysis• Restoring name plate rating• Uprating with upgraded Runner profiles• HVOF Coating/ Plasma Coating on underwater parts

GOVERNORS• High Pressure/ Microprocessor based Digital Governors• RGMO / FGMO features

GENERATORS• Re-winding with Class-F insulation• PTFE pads for Thrust bearings

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RANGE OF SOLUTIONS IN R&MC&I and PROTECTION SYSTEMS

• SCADA/ DCS System• Smart/Digital Instruments, High speed relays etc.

BOPs• Retrofitting

ONLINE MONITORING DEVICES• Vibration monitoring• Measurement of silt content in water• Air Gap Monitoring system• Partial Discharge Measurement system

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Advanced Technological Tools for RMU

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BHARAT HEAVY ELECTRICALS LIMITED

The behavior of each component of a turbine can be studied in a better way & fine tuned to get better performance parameters and higher Efficiency.Investigate into different facets of the problem and explore possible solutions in a faster & inexpensive way to improve the reliability of the Hydro ProductHydro Turbine is capable of operating in a wider operating range by virtue of smarter design.Lesser downtime of machine since the micro phenomenon of cavitation and erosion can be studied & mitigated at the design stage

Product cycle time is reduced significantly

IMPACT OF MODERN TECHNOLOGY ON RMU&LE PROJECTS

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BHARAT HEAVY ELECTRICALS LIMITED

CFD ANALYSIS Computational Fluid Dynamics (CFD) is one of the branches of fluidmechanics that uses numerical methods and algorithms to solve andanalyze problems that involve fluid flows. Computers are used to performthe millions of calculations required to simulate the interaction of fluidsused in engineering.

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BHARAT HEAVY ELECTRICALS LIMITED

WHY CFD ?

Advent of high capability computer resources.

Advancement in mathematical modeling of real life physical phenomenon.

Using the modern CFD Techniques, the designer can analyze the behavior of each component of a turbine in a better way and fine tune them to get better performance parameters.Cycle time of design optimization using CFD is extremely less as compared to the experimental methods.

Only the best variant is experimentally tested for the validation of results.

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PROCESS OF CFD ANALYSIS

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BHARAT HEAVY ELECTRICALS LIMITED

CFD ANALYSIS AT BHELBHEL Bhopal uses one of the most powerful & popular CFD packages for turbo-machinery applications (Ansys-CFX).It is based on full 3-D Navier-Stokes equations.Multiple frames of reference for simultaneously solving rotating and stationary components.Turbulence effects are taken care using a variety of turbulence models.Grid generation is done using ICEM-CFD, Ansys Turbogrid & blade geometry synthesis is done by Ansys Bladegen.Structured grid is generally used in all the components for more accurate simulation.Using suitable macros validated by experiments, various performance parameters are evaluated.

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NUMERICAL SIMULATION OF REACTION TURBINES

GOVERNING EQUATIONS

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TYPICAL COMPUTATIONAL DOMAIN & RESULTS

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CFD Analysis of Francis turbine

NUMERICAL SIMULATION BY CFD ANALYSIS

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NUMERICAL SIMULATION BY CFD ANALYSIS

CFD Analysis of Kaplan turbine

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OPTIMIZATION USING CFD ANALYSIS

Mismatch between Runner Blade & Guide Vane :- Entry Shock Loss- Secondary Flow LossesOptimized Geometry:Minimized Losses

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OPTIMIZATION USING CFD ANALYSIS

• Hydraulic Losses• Flow Induced Vibrations

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BHARAT HEAVY ELECTRICALS LIMITED

OPTIMIZATION USING CFD ANALYSIS

• Von Karman vortex-shedding• Flow Induced Vibrations

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NUMERICAL SIMULATION OF IMPULSE TURBINES

• Simulating Free water jet, Water sheet over buckets still poses a challenge

• Extension of CFD analysis to Pelton Turbine poses a complex set of problems in regard with numerical stability and accuracy.

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CFD ANALYSIS RESULTS

CFD MODEL

CFD Analysis of Pelton turbine

NUMERICAL SIMULATION OF IMPULSE TURBINES

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NUMERICAL SIMULATION OF IMPULSE TURBINES

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BHARAT HEAVY ELECTRICALS LIMITED

NUMERICAL SIMULATION OF IMPULSE TURBINES

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RUNNER BLADE STRUCTURAL ANALYSIS

Applied Pressure Profile on Suction-side Applied Pressure Profile on Pressure-side

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BHARAT HEAVY ELECTRICALS LIMITED Stress Plot (Max 108 MPa)

RUNNER BLADE DESIGN

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FEA OF RUNNER BLADE & HUB FOR KAPLAN TURBINE

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Special Feature Studies

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BHARAT HEAVY ELECTRICALS LIMITED

SPECIAL FEATURE STUDIES

Special studies like erosion of water wetted areas can be conducted using CFD.

Using numerical tool more insights can be thrown into the mechanism of erosion of under water components by silt.This erosion causes losses in terms of power generation, equipment damage and machine down time.Using Lagrangian particle tracking module, the flow of silt particles in the turbine passage can be simulated.Exact location where a silt particle of a typical size will hit the surface and the damage done by it can be assessed by this numerical tool.

Hydraulic design for R&M projects

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EROSION PATTERNS

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EROSION PATTERNS

Basic Runner Blade Improved Runner Blade

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BHARAT HEAVY ELECTRICALS LIMITED

CAVITATION STUDY

Cavitation prediction through CFD tools ,i.e. Extreme low-pressure areas

Runner improvements reduce cavitation problems, reducing long-term turbine maintenance costs

Distribution of static pressure and dynamic pressure inside draft tube are related to operation stability

Influence of cavitation on pressure pulsation

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CAVITATION STUDY

Cavitation Curve from CFD analysis Cavitation results from CFD

Analysis

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CFD ANALYSIS INFRASTRUCTURE AT BHEL BHOPAL

Established in 1989, and accredited by NABL

Recognized by the Department of Scientific & Industrial Research (DSIR), Government of India as in-house R & D group for Hydraulic Design & Development of Hydro TurbinesState-of-the-art Hydro turbine development and model testing facility

Sophisticated model testing laboratory

Hydraulic design & development of all types of hydro turbines

CENTRE OF EXCELLENCE – HYDRO MACHINES

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MODEL TESTING FACILITY

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BHARAT HEAVY ELECTRICALS LIMITED

STATE-OF-THE- ART TESTING FACILITIES

More than 150 Development Tests & 50 Contractual Witness Tests conducted till date.

More than 150 Development Tests & 50 Contractual Witness Tests conducted till date.All types of Hydro turbinesAll types of Hydro turbines Pumps & ValvesPumps & Valves In-situ calibration of all measuring devicesIn-situ calibration of all measuring devices

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BHARAT HEAVY ELECTRICALS LIMITED

Latest parallel processing technology is being usedLatest parallel processing technology is being used

High performance Cluster (HPC) dedicated for CFD analysisHigh performance Cluster (HPC) dedicated for CFD analysis

State of the art Hardware & software facility for CFD AnalysisState of the art Hardware & software facility for CFD Analysis

CFD ANALYSIS OF HYDRO TURBINES

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ADVANTAGE - BHEL

HBG single window facility to meet all the requirements

Concept to Commissioning solutions for Uprating/R&M of Hydro plants

First hand knowledge of O&M practices with Excellent Lab Facilities

Availability of original design data and performance test results

Make in India – In house Manufacturing facilities

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BHARAT HEAVY ELECTRICALS LIMITED

HYDRO R&M POTENTIAL

No. of Sets MWBHEL Make 90 4748.35Non-BHEL Make 81 2463.70Total 171 7212.05

Sets identified for R&M

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RMU PROJECTS CURRENTLY BEING EXECUTED BY BHEL

Ganguwal Kotla HEP (BBMB), 2 x 24.2 MW• Renovation, modernization & Life Extension of Propeller turbines.

Balimela HEP (OHPC), 6 x 60 MW• Renovation, modernization & Life Extension of Francis turbines

Bairasiul HEP (OHPC), 3 x 60 MW• Renovation, modernization & Uprating of Francis turbines

Keban HEP (Turkey), 8 x 183 MW• Renovation, modernization & Uprating of Francis turbines

Rihand HEP (UPJVNL), 3 x 50 MW• Renovation, modernization & uprating of Francis turbines

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RMU PROJECTS EXECUTED BY BHEL

SN Customer Project Rating(No. of Units x MW)

1 NEEPCO Khandong 1x25 2 NEEPCO Kopili 2x50 3 GSECL Ukai 2x75 4 OHPC Rengali 2x50 5 UPJVNL Rihand 3x50 6 KESB Idamalayar 2x37.5 7 KPCL Nagjhari 1x150 8 DGPC, Bhutan Chukha 2x84 9 NEA, Nepal Devighat 3x5

10 Barki Tojik, Tajikistan Varzob 2x4.75

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RMU PROJECTS : BHEL OBSERVATIONSNo. of years of operation should be clearly defined in the guidelines for Hydro projects, after which R&M to be made mandatory.

To bring down the frequency of Unplanned outage, replacement should be made mandatory for the machines that are above 35 years.

Sharing of firm Hydrological & Petrographic data for better design.

History card of the Units should be shared with R&M bidders.

Civil structure drawings/ data should also be shared.

Complete scope to be defined clearly during tender stage.

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BHARAT HEAVY ELECTRICALS LIMITED

CONCLUSION

R&M, uprating & life enhancement of Hydro Power Plants is very important in order to ensure the full utilization of nation’s precious natural resource

Advanced Numerical Simulation techniques like CFD Analysis offer very potent solutions to the challenges associated with Hydro power plant R&M

CFD has an added advantage in terms of cost as well as flexibility to simulate complex phenomenon

BHEL is fully equipped with the latest technologies to offer the best R&M solutions

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BHARAT HEAVY ELECTRICALS LIMITED

THANK YOU


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