Francis Hydro Turbines - Brochure

FRANCIS HYDRO pOweR plantsThe most efficient turbineFrancis turbines have the highest efficiencies of all hydro electric turbines – typically over 95 per cent. In addition to this high efficiency, they can cover a wide range of heads—between 30 m and 800 m, and have the widest and highest range of power outputs. This is why Francis turbines drive all the world’s highest rated power stations. Recognised expertiseAlstom has a long and successful history of building, installing, refurbishing and replacing Francis power units and can offer plants with unit outputs up to 1000 MW. The world’s biggest hydropower stations use Francis turbines designed by Alstom. All Francis hydropower plants benefit directly from our ongoing efforts to increase production, output and safety. In refurbishment applications, the improved performance offers the potential for increased profits.World-leading experienceWe have the largest technology portfolio and reference list on the market. Alstom is the only company able to provide choices for the entire value chain of a hydropower plant, from electro-mechanical equipment to sub-stations to services. Our project management competence, whether as part of a consortium or as a turnkey supplier, is widely recongised in the industry. With the largest worldwide installed base, representing more than 25 percent of the global hydropower capacity, Alstom brings decades of experience in the design and installation of hydropower plants of all types all over the world.High performance from the hydropower world leaderClean Power, Clear Solutions 04How alstom is helping you meet the challenges of energy sustainabilityContinuous improvements 10For a long-standing relationshipGlobal presence and local expertise 16For hydro power plants that stand the test of timeAn integrated approach 18plant control systemsHigh performance for high revenues 06with alstom’s Francis turbinesProven solutions 12Backed by innovation03REDUCING COST OF ELECTRICITYINCREASINGFLEXIBILITY & RELIABILITYLOWERINGENVIRONMENTAL FOOTPRINTOur Power generation offering is based on a deep understanding of power markets and our customers’ needs. It is organised around three levers to maximise the return of assets over their entire lifecycle.It takes competitive assets to keep electricity affordable. We enable power companies to compete successfully in the marketplace and provide affordable electricity to consumers. We help you reduce the cost of electricity through:•?Efficiency?improvements•?CAPEX?reduction?/?scaling?up•?Capacity?Factor?increase? (renewable)•?Lead?time?reduction•?Competitive?O&M•?Competitive?financingClean?generation?is?one?way?of?demonstrating environmental responsibility. Another is lowering resource usage, visual impact and noise pollution. In both cases, we can help you meet or exceed regulations and environmental standards. That is why Alstom innovates in the following areas:• Renewable portfolio•?Natural?resource?optimisation•?Pollutants?control???(SOx,?NOx,?PM,?mercury)•?CO2?emission?reduction?&?CCS•?Land?use,?visual?impact?and?noise•?Water?intensity?reduction???&?recyclabilityIntermittent power generation is a growing challenge of energy security, as is maintaining an aging installed base and adapting it to changing market conditions. We help you tackle both issues so that you can enjoy dependable operations with:•?Maintainability?and?outage? time reduction•?Operational?and?fuel??flexibility•?Lifetime?extension? and power uplift•?Designs?and?service?for?improved? availability and reliability•?Climate?packages•?Energy?storage04How alstom is helping you meet the challenges of energy sustainability Clean Power, Clear SolutionsREDUCINGCOST OFELECTRICITYFOOTPRINTENVIRONMENTALENVIRONMENTAL RESPONSIBILITYCLEAN GENERATION DEPENDABLE OPERATI ONSENERGY SECURITYCO M P E T IT IV E A S S E T SAFFORDABLE ELECTRICITYLOWERING& RELIABILITYFLEXIBILITYINCREASINGENERGY SUSTAINABILITY : A GLOBAL ChALLENGEpeople globally lacks electricity.1 in 5of renewable energies in global electricity generation.Only 20%rise of the global energy-related carbon dioxide emissions could happen by 2035.A 20%05How alstom is helping you meet the challenges of energy sustainability Clean Power, Clear SolutionsINlet vAlveS For high heads, alstom supplies a wide range of spherical valves, as well as butterfly valves with single discs or lattice plugs for medium to low heads. alstom’s range of butterfly valves with lattice plugs is particularly strong in wide diameters, appropriate for installations with high water discharges. For example, the 2,000 Mw lower subansiri project in India will use alstom butterfly valves measuring 7m in diameter. there are three types of spherical valves with diameters of up to 3.5 m within the alstom range, including a spherical valve with a single welded body, which has bearings and seals which are easier to maintain. RING GAteSalstom has specialised in ring gates for Francis turbines ever since its first patent in 1947. this protecting device turns the water supply to the turbine off or on by closing or opening a metal cylinder placed around the outside of the wicket gates. Ring gates provide additional powerhouse safety, reduce leakage losses when implemented in a project without main inlet valves and may be used to protect wicket gates from silt. also, when replacing other types of inlet valves, they reduce civil works costs, particularly in underground power stations. The most efficient turbineOptimising hill charts according to unique project parameters requires?a?great?deal?of?skill?and?experience.?Conflicting?variables, critical operating points and machine behaviour often have to be reconciled. Alstom’s knowledge from extensive references and continuous research is key to designing machines which combine high performance with high stability and long lifetimes.A complete product range – built with careIn addition to the turbine itself, Alstom also supplies associated equipment such as main inlet valves, ring gates and other hydro-mechanical equipment like penstocks and dam gates. All of this equipment features strong, proven in-house designs and is built to the same high standards throughout the world, ensuring long, reliable operation.Best efficiency pointOperating rangeInlet cavitation limit suction sideIncipient partial loadinterblade vortex limitPartial?load?interblade?vortex limitInlet cavitation limit pressure sideOutPut?(MW)HEAD?(m)No?rope?zone06with alstom’sHigh performanceBirecik, Turkey 2 x 112 MW, 45 m headKey benefitsHIGH PeRFORMANCe for high revenues: The turbine, shaft-line and generator are key to the cash flow and profitability of hydroelectric power plants. Alstom uses its extensive experience and the latest technology to offer equipment capable of meeting the most demanding customer specifications.RelIAble COMPONeNtS for dependable electricity generation: Alstom’s Francis turbines and generators are driving many of the world’s biggest hydropower plants. Similar design parameters are used throughout the product range, ensuring high levels of plant availability.Wide product range covering All CONFIGURAtIONS: Alstom’s range of Francis hydropower plants comprehensively covers all heads and outputs, for both new plants and upgrades to existing plants.Built throughout the world to the SAMe DeMANDING StANDARDS: With facilities and offices worldwide and the ability to work with local suppliers and contractors, Alstom is close to the customer. All plants are built to the same high standards, regardless of location.A wide range of configurationsFrancis units can be arranged in a variety of configurations, according to customer needs. typically, the key criteria are the position of the bearings and the method of dismantling.Thrust bearings carry axial loads. For vertical machines, these loads are the weight of the rotating parts and the hydraulic thrust. The thrust bearing is generally placed on the upper generator bracket, the lower generator bracket or Alstom’s recommended solution — the turbine head-cover.Dismantling?the?runner?depends?on?local?conditions?such?as?water?quality. Runners can be removed through the stator bore or from below but they can also be dismantled between the turbine and the generator but then the shaft line is longer.whether plant owners require a new facility, or are simply looking to upgrade or renew an existing installation, Alstom has the experience, know-how and mix of technologies to provide the right solution.07Francis turbinesfor high revenuesthe?320MW?Yedigoze?hydropower?plant generates sufficient power to provide electricity to around 640,000 homes. Yedigoze,?turkey,?2?x?159?MW, 91 m head.Reliability and ease of maintenanceAlstom’s membrane thrust bearing system has long been renowned for its reliable operation. Thrust and guide bearings support high axial and radial loads and are critical devices in a hydropower plant to ensure trouble-free operation. Since it was first patented, the membrane thrust bearing system has been continuosly improved based on customer feedback, bringing new features and making the concept even more maintenance friendly. Today, the bearing can be dismantled with minimum disassembly of other accessories as the base plates are in two pieces.?Parts?have?been?made?more?compact,?which?means?that?they can be easily serviced on-site or in a nearby workshop. Alstom’s hydrostatic water guide bearing also acts as a shaft seal. Eliminating?the?separate?shaft?seal?reduces?maintenance?cost and decreases the likelihood of plant outages. This robust design, which also removes mineral oil from close to the water passage, is being increasingly adopted to reduce maintenance whilst also being of benefit to the environment. the?Francis?power?plants?of?Nytt?Funna?and?Jøssang?in?Scandinavia are among the many references for this product in the last ten years. Hydrostatic water guide bearings10For aContinuous From research to maintenance, our customers’ needs drive our decisions so that we can find the right choices that correspond to each plant’s situation.Total customer focusAlstom is always focused on the customer’s needs. While some requirements such as the need for robust, reliable equipment may be common, others may be specific to a particular project. For example, plant owners may need the plant to come on line in a very short time or there may be specific issues relating to the environment, water quality or operating parameters such as large discharge and head variations. Global project management skillsWhatever the requirements, customers are accompanied by expert Alstom personnel in all stages of the process – from tendering to project sign-off, from site installation to plant commissioning – whether it is a turnkey project or one being executed in individual lots. Alstom’s extensive project management skills and worldwide presence bring knowledge and solutions to mitigate potential project risks resulting from various on-site challenges. Its technical experience and long history in project management means that Alstom?can?execute?and?manage?projects?of?any?size?in?any?part?of?the world, as its references demonstrate. Customer-driven solutionsWe help customers achieve the optimum plant configuration for increased performance and profit and, in some cases, reduced plant construction and commissioning times, improving customers’ cash-flow. For example, Alstom, as the consortium head?of?the?major?turcurui?project?in?Brazil,?ensured?that?it?took?only 33 months after the contract was signed to commission the first unit.11long-standing relationshipimprovementsHigh-quality generatorsGenerators are critical in ensuring high availability and stability of the power generating unit. Alstom’s decades of experience in providing hydro generators for all kinds of plants have been the basis for innovations that since have become state-of-the art technologies. Alstom’s generators main features include self-ventilated rotor rim air-cooling (standard or high speed design) or water-cooling, high structural integrity and advanced stator windings, as well as long-lasting and high quality insulation, ensuring high operating availability and low maintenance.CoolingAlstom is at the forefront of developing robust and ingenious cooling systems. Recent developments have focused on customer requirements for self-cooling technologies that eliminate the need for auxiliaries, reduce maintenance and lower costs. Of particular interest to large Francis units, is Alstom’s extension of air cooling to high-power, low-speed generators previously covered by water-cooling only. Air-cooling has been used in generators with outputs as high as 890 MVA. In cases where higher speeds are required or where the output per pole is high, Alstom also offers leading water-cooling systems.high structural integrityBoth rotors and stators are designed with high structural integrity to eliminate the possibility of damage from vibrating or loose components, ensure full contact insulation properties for efficiency and long-life and optimise other parameters such as the air-gap to achieve the best possible performance.Eastmain,?Canada,?3?x?184?MVA,?120?rpmPhoto:?Hydro-Québec12BackedProvenStator windingsAll of Alstom’s stator windings are factory tested up to four times the rated voltage to ensure the highest quality and guarantee long, trouble-free electricity generation. Alstom provides either bar or coil stator windings that are insulated?with?class?F?main?insulation?(155ºC).?Alstom’s stator core pressing system uses bolts through the stator core that ensure high, uniform distribution of the stator core pressing. Spring elements compensate for any potential settling of the stator lamination to maintain the pre-stress in the stator core over time. To ensure permanent thermal and mechanical coupling between the stator bar surface and the stator core, the straight portions are supplied with unique “round-packing”. Round packing allows the bars to be removed if necessary, during a major overhaul for example, and is a conductive system as well. The fixing system, together with “roundpacking”, guarantees permanent electrical and mechanical coupling of the bar to the slot.all of alstom’s stator windings are factory tested up to four times the rated voltage to guarantee long, trouble-free electricity generation. 13by innovationsolutionsalstom’s range of Francis hydropower plants comprehensively covers all heads, outputs and speeds, for all scopes of supply anywhere in the world.Itaipu, Brazil 10 x 740 Mw , 118 m headSpecialist production sites embedded in the global Alstom networkTurbine research for continuous improvementAlstom’s team of highly qualified technicians make constant use of state-of-the-art technology to make continuing advances in equipment and project design. The use of computerised modelling has brought significant gains in efficiency over the last decade and Alstom has been at the forefront of these efficiency increases, knowing that it brings higher output and revenues. More fundamental research is also continuously being undertaken at the state-of-the-art?scale?model?test?laboratory?at?Alstom’s?Global?technology?Centres.?These high-tech laboratories contain a number of test rigs capable of simulating conditions identical to those in a hydropower plant. This emphasis on research and development enables Alstom to better understand some of the more complex hydraulic phenomena in order to find imaginative solutions and push back the frontiers of current knowledge.GtC?–?Global?technology?Centre?At?Alstom’s?Global?technology?Centres?we?carry?out?fundamental?research?and/or?run?state-of-the-art?hydraulic?scale?model?testing. Our test rigs are capable of simulating operating conditions identical to those in a hydropower plant. We can study and verify complex hydraulic phenomena that are still beyond the scope of even the most advanced computer simulations. The benefits are intergrated into our standard modular designs and custom engineering projects. The use of universal platforms for?product?development?across?all?GtCs?enables?effective?international collaboration for our customers’ benefit.Grenoble (France)Global?technology?CentreManufacturingVadodara (India)Global?technology?CentreManufacturingBirr (Switzerland)Global?technology?CentreManufacturingSorel-Tracy (Canada)Global?technology?CentreManufacturingTaubaté (Brazil)Manufacturing Bilbao (Spain)ManufacturingLevallois-Perret (France)HeadquartersTianjin (China)Global?technology?CentreManufacturing16For hydro power plantsGlobal presenceProject?highlights?worldwide?Alstom has installed Francis turbines all over the world totalling over 115 GW of power output and has upgraded or retrofitted?hundreds?of?turbines.?No?wonder?then?the?most?prestigious,?biggest?and?complex?projects?in?the?world?rely?on?Alstom technology for efficient turbine output.SON lA (vIetNAM)turnkey plant, 6 x 400 MW Francis turbine/generator units, balance of plant and training (head: 78 m)located on the Da river, the 2,400 Mw son la plant is the biggest hyropower plant in south-east asia. this is the ninth project for alstom in Vietnam.tHRee GORGeS (CHINA)14 x 710 MW Francis turbine/generator units, control systems, governors (head: 85 m)the three Gorges project is the world’s largest electricity-generating plant, containing 32 main turbine/generator units at over 700 Mw each, totalling 22,700 Mw.ItAIPU (bRAzIl)Consortium leader, 10 x 740 MW Francis turbine/generator units, control systems, hydromechanical equipment (head: 118 m)located on the parana River on the border between Brazil and paraguay, the Itaipu power plant is the world’s second largest plant in terms of generation capacity (14,800 Mw). alstom’s hydraulic design was used by the other members of the consortium.SHAStA (USA)Refurbishment of 5 x 142 MW Francis turbines and 2 generators (head: 130 m)alstom’s rehabilitation significantly increased the 60-year old shasta plant’s efficiency rating. Unit output increased from 133 to 142 Mw even though the head was lower after the refurbishment — a significant hydraulic engineering achievement.SUbANSIRI (INDIA)8 x 250 MW vertical Francis turbine/generator units, governing system, balance of plant (head: 86 m)located in assam, India, the 2,000 Mw subansiri project is the largest hydroelectric plant in India. It includes India’s largest Francis runner which was manufactured by alstom’s Vadodara unit. subansiri will provide much need electricity for the northern and western regions of India. bAkUN (MAlAySIA)turnkey plant, 4 x 300 MW vertical Francis turbine/generator units, control systems, hydromechanical equipment and balance of plant (head: 173 m)located in sarawak, Malaysia, the 2,400 Mw Bakun hydroelectric plant is the largest rock-filled dam in asia outside China. sarawak Hidro Bhd, a wholly-owned subsidiary of the Ministry of Finance, is the project developer.17that stand the test of timeand local expertisePlant?Integrator™?–?optimising?the?value?chainthe?Plant?Integrator™?approach?creates?real?value?for?our?customers?by?optimising?the?entire?value?chain?and?the?overall?plant?performance.?this?approach?goes?beyond?the?typical?product?compilation?simply?aimed?at?reducing?costs.?As?an?OEM,?EPC?and?O&M?provider, Alstom has a unique perspective that allows the analysis of the whole plant and the full lifecycle as an integrated system. using?proven?models?and?established?benchmarks,?speci?c?investment?costs?can?be?understood?in?their?true?context.?Customers?benefit from a greater range of options to determine the solutions that are best-suited to their needs. These help them achieve their business objectives and consequently, better serve their markets.Governing systemA crucial part of the overall plant control system, the governing system regulates the flow of water passing through the turbine to adjust the power output to the grid as well as ensuring turbine, generator and penstock protection against over-speed in the event of load rejection.With more than 100 years in the field of turbine speed regulation, Alstom has developed and qualified a universal turbine governing system that offers customers a cost-effective, reliable solution for all types of turbines. Alstom’s governing system is:•?extremely reliable and robust•?a?modular?design?for?best?cost/function?configuration,•?easy to install, operate and serviceNeyrpic® t.SlG – This state-of the-art controller can perform far?more?functions?than?standard?systems.?Proven?at?plants?around the world, the system includes two dedicated, optimised modules – the unit processing controller and the servo positioning controller. When combined, the two modules meet the governing application requirements for all types of turbines.Oil pressure unit – the complete solution for the oleo-hydraulic part of the governing system. Actuators are safety critical and must have guaranteed availability. Alstom’s actuators are extremely durable and have a proven lifetime of over 40 years, requiring little or no maintenance during this period. Plant?control?systemsLike?the?nervous?system?in?the?human?body,?the?control?system?is the intelligence of any power plant. In order to guarantee safe, reliable and optimised power plant operation, Alstom has developed and qualified a full range of advanced control systems for hydropower plants. From distributed control systems (DCS)?adapted?to?the?size?of?a?plant,?to?turbine?speed?governing?systems, generator excitation, protection, condition monitoring and process application software, our solutions cover all plant control needs.Alstom has a range of control systems to best fit customer needs. these systems are dedicated to power generation, providing operators with the ability to:•?control and protect equipment to ensure the plant is operating correctly •?monitor the condition of equipment •?optimise the use of the individual asset or fleetAs well as providing automation and plant management systems, Alstom also supplies power electronics for generator excitation as well as grid connection and substation engineering. Such a wide scope of supply allows Alstom to manage turnkey projects, providing the customer with a single point of contact, which simplifies and speeds project development and execution.18An integrated approachRail transportElectrical gridPower generationAlstom is a global leader in the world of power generation, power transmission and rail infrastructure and sets the benchmark for innovative and environmentally friendly technologies. Alstom builds the fastest train and the highest capacity automated metro in the world, provides turnkey integrated power plant solutions and associated services for a wide variety of energy sources, including hydro, nuclear, gas, coal, wind, solar thermal, geothermal and ocean energies. Alstom offers a wide range of solutions for power transmission, with a focus on smart grids. AlstomAlstom Power offers solutions which allow their customers to generate reliable, competitive and eco-friendly power.Alstom has the industry’s most comprehensive portfolio of thermal technologies – coal, gas, oil and nuclear – and holds leading positions in turnkey power plants, power generation services and air quality control systems. It is also a pioneer in carbon capture technologies.Alstom offers the most comprehensive range of renewable power generation solutions today: hydro power, wind power, geothermal, biomass and solar. With ocean energies, we are developing solutions for tomorrow. Alstom is one of the world leaders in hydro power, the largest source of renewable energy on the planet.Power?generationRPWR/BRCH/FRCSPP13/EN/6.2013/FRA/1536?©?ALStOM?2013.?All?rights?reserved.?Information?contained?in?this?document?is?indicative?only.?No?representation?or?warranty?is?given?or?should?be?relied?on?that?it?is?complete?or?correct?or?will?apply?to?any?particular?project.?this?will?depend?on?the?technical?and?commercial?circumstances.?It?is?provided?without?liability?and?is?subject?to?change?without?notice.?Reproduction,?use?or?disclosure?to?third?parties,?without?express?written?authority,?is?strictly?prohibited.?Photo?credits:?ALStOM.?Printed on environmentally friendly paper. A PDF version of this brochure is available at: www.alstom.comEurope, Middle East and Africa Alstom Hydro 4,?avenue?André?Malraux? 92309?Levallois-Perret?Cedex? FranceNorth America Alstom?Hydro?Canada?Inc.? 1350 chemin St-Roch J3R?5P9?Sorel-tracy,?Québec? CanadaLatin America Alstom?Hydro?Energia?Brasil?Ltda? Av.?Charles?Schneider? 12040-001?taubaté? BrazilChinatianjin?Alstom?Hydro?Co.,?Ltd? Gaofeng?Road,?Beichen?District? Tianjin 300400 ChinaAsia Alstom?Projects?India?Ltd??Hydro?Maneja Vadodara – 390 013 IndiaAlstom?Renewable?Power4,?avenue?André?Malraux92309?Levallois-Perret?CedexFrancewww.alstom.com