Pump Hydro Turbines - Brochure

PUMPED STORAGEPOWER PLANTSPOWER HYDRO PROducT SOLuTIONSPumped storage solutions from the world leaderManaging the balance between energy production and consumption has become an issue of growing importance in order to guarantee the stability of electrical networks. Pumped storage hydroelectricity is the only economic and flexible means of storing grid scale amounts of excess energy, allowing power plants dispatchers to successfully manage that balancing act. This is becoming even more important as more and more countries are increasing their nuclear power generation capacities and ramping up their power generation from intermittent renewables such Wind and Solar.In pumped storage plants, Pump turbines transfer water to a high storage reservoir during off-peak hours, thereby levelling out the daily generated load. The energy used for pumping the water is derived from other energy sources, such as nuclear, fossil and renewable power plants, whose power output cannot be adjusted to follow load fluctuations. The stored water can then be used for hydroelectric power generation to cover temporary peaks in demand. The advantage of this technology is that it can come online very quickly, making it a useful tool to balance the varying electricity demand from consumers or unplanned outages of other power plants. Today there are over 130 GW of pumped storage in operation around the world, representing approximately 3% of instantaneous global generating capacity. In recent years, the profitability of pumped storage plants has increased as a consequence of increased price volatility on electricity spot markets. As the world leader in pumped storage Alstom provides a complete range of pumped storage electromechanical equipment. This includes Pump turbines, motor-generators, control systems and optimised hydro-mechanical and balance of plant equipment. Depending on the customer preference, these can be supplied either separately or as an integrated turnkey plant.In the latter case, specialised Alstom teams have developed specific skills for optimising the complete plant configuration so that the highest global water-to-wire performance is achieved.The largest portfolio for hydropower solutions:TURbinESGENERATORScONTROL SySTEmSHydRO-mEcHANIcAL EquIPmENTBALANcE Of PLANTSERvIcES25percent of the world‘s power production capacity depends on Alstom technology52,000 employees around the world in 70 countries100years of industry leading expertiseWith our recognised expertise all over the power generation market, we are able to find solutions to the challenges of today.CLEAN POWER TODAY™We recognise the need to improve the environ-mental balance of legacy plants while increas-ing adoption of new clean energy solutions.PLANT INTEGRATOR™Our solutions maximise performance by optimising the complex interactions between sub-systems from design to operation.LIFECYCLE MANAGEMENTAt all stages of the lifecycle we support owners to maximise their return on investment while minimising negative environmental effects.Alstom is a global leader in power generation with a portfolio of products covering all fuel types. From fossil and biomass to nuclear and renewables, close to 25% of the world’s power production capacity depends on Alstom Power technology and services. Whether in design, manufacture, procure-ment or servicing, Alstom Power is setting the benchmark for innovative technologies that provide clean, efficient, flexible and integrated power solu-tions. Alstom can supply anything from single components to complete turnkey power plants. Our Plant Integrator™ approach and power automation and control solutions ensure the optimisation of all elements to derive the maxi-mum lifetime value from all our customer’s investments. Alstom Power has more than 100 years of experience in engineering, pro-curement and construction (EPC) of new power plants. But our engineers are also experts in retrofitting, modernising and servicing existing plants. With operations in 70 countries, Alstom Power is close to customers all over the world, ensuring rapid responses and service excellence at all times. Welcome to Alstom PowerAlstom pumped storage power plants2 3Key benefitsEnERGY STORAGE FOR GRiD REGULATiOn As the only solution for efficiently storing large amounts of energy, pumped storage power plant act as a quick response for peak load energy supply.AnCiLLARY SERViCES Pumped storage technology provides network frequency and voltage regulation, reserve capacity, black start capabilities, as well as reactive power productioninCREASED PLAnT EFFiCiEnCY Pumped storage technology increases profitability for plant owners in volatile electricity spot markets and allows optimisation of global operations of power plant fleets and electrical network infrastructures.HiGHEST GLObAL CYCLE EFFiCiEnCY With approximately 80% efficiency pumped storage plants have the highest global cycle efficiency compared to other power plants.EnViROnMEnTALLY FRiEnDLY Pump turbines have a positive environmental impact by enabling increased use of renewable energy sources.Meeting all market needsAlstom has been providing Pump turbines for over 50 years and has supplied a total of 140 Pump turbine units to date. Between 1953 and 1960, orders were predominantly for low head units. More recent market trends indicate the need for high-speed Pump turbines at very high heads. In response to this, Alstom has invested heavily in Pump turbine R&D. In 2008, it extended its turbine hydraulic scale model test laboratory in Grenoble, France, to have two dedicated Pump turbine test-rigs, thus increasing the number of test-rigs in this facility to six and doubling its overall test capacity.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.Alstom’s complete pump turbine rangeAlstom provides Pump turbines adapted to the specific characteristics of each pumped storage plant. In order to cover the complete head range (from 10 m to 1200 m), axial, mixed or centrifugal flow runners are used. Alstom has built up an extensive Pump turbine hydraulic design portfolio, with more than 50 Pump turbine prototypes. Between 2000 and 2009 alone, Alstom commissioned 14 major Pump turbine projects, and since then has been working on an increasing number of new projects. This gives Alstom the strongest market base for designing optimised Pump turbines for new projects.For each project, a dedicated hydraulic team from the Alstom Global Technology Centre uses its state-of-the-art computa-tional fluid dynamics (CFD) tools and laboratory tests, to simulate how the life-size turbine will operate in order to optimise its hydraulic performance. Particular attention is given to power output, efficiency, stability, rotor-stator interactions and absence of cavitation. Mechanical constraints are taken into account by verifying all static and dynamic characteristics using Finite Element Method modelling (FEM) tools. After this, scale model tests are carried out on one of the two dedicated Pump turbine test-rigs in the scale model test laboratory. The high accuracy level of the laboratory tests (between 0.2% and 0.3%) ensures at an early project stage that the final Pump turbine will meet its performance requirements.Plant 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 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, specific 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.Alstom - the referencein pumped storage4 5to best suite site conditionsSingle-stage or double-stage regulated From 10 m head to 1200 m head Alstom has a solution to maximise overall plant performance.Recent developments have focused on enhancing the perfor-mance, economy and reliability of these pumped storage plants:• single-stage Pump turbine technology has been expanded to-ward double-stage and multi-stage Pump turbines for higher head units, while maintaining a compact design in all configu-rations.• in reply to specific maintenance requirements and to optimise the civil engineering costs, several Pumped storage plant configurations are possible, allowing runner dismantling from above, below or between the turbine and the generator thanks to the use of an intermediary dismountable shaft.• in addition to traditional oil lubricated white metal coated bearings, Alstom has developed several specific bearings, including self-pumping and water lubricated bearings.• different types of governing control system configurations are possible, either using an actuating ring to control all synchro-nized wicket gates, or using individually actuated wicket gates to optimise plant stability at start-up.• depending on the head and customer preferences, a selection of inlet valves are available including butterfly valves, spherical valves or ring gates. • in order to reduce costs and to limit power input at start-up in pumping mode, a Static Frequency Converter (SFC) or the back-to-back method are typically used, combined with dewa-tering of the runner.For projects with very high heads, between 700 m and 1200 m, multistage Pump turbines are needed in order to ensure good hydraulic efficiency and minimise stress and vibrations incurred by the turbine components. One typical limitation of these multi-stage Pump turbines is that their power output cannot be adjusted due to the absence of adjustable wicket gates on the lower stages. In order to overcome this limitation, Alstom has developed a unique solution consisting of a double-stage Pump turbine equipped with two adjustable distributors, one for each runner. These units can also be dewatered at start up to reduce the input power. These double-stage regulated Pump turbines combine the advantages of singleand multi-stage Pump turbines and are characterised by:• adjustable power output• better runner efficiency than with single-stage high heads, due to head sharing between runners• lower vibration than with single-stage high heads• lower pressure pulsations• higher mechanical stiffness• better stability than with single-stage high heads• the shaft crossing the draft tube improves part-load operation• smoother transients with better intrinsic stability at start-up• reduced civil engineering costs as the unit is more compact and its submergence can be reduced.In 2006, Alstom supplied the biggest ever double-stage Pump turbine built in the world, for the Yang Yang pumped storageplant in South Korea. The four units, which are equipped with two adjustable distributors, were built for a head of 798 m and a power level of 4 x 258 MW.Single-stage centrifugal units (< 700 m)As most of the Pump turbine projects concern sites with 60 m to 700 m heads, the majority of Alstom ’s pumped storagereferences use reversible single-stage centrifugal units.Double- and multi-stage centrifugal units (> 700 m)6 7Our outstanding market recognition is the result of sustained R&D efforts that have led to continuous technology improvements. These constitute the cornerstones that over several decades guarantee the high availability and stability of Alstom’s motor-generators. These units are subjected to numerous thermal cycles and high centrifugal forces, and need to withstand potential fault disturbances such as short circuits. In reply to these design requirements, particularly important for peak-load units, Alstom’s motor-generator main features include structural design with oblique elements, state-of-the-art thrust bearings, permanently pre-stressed stator core, Vacuum Pressure Impregnation (VPI) insulation system, self-ventilated rotor rim (standard or high speed design) and bent pole coils (for easier assembly & better surface cooling).Advanced motor generator technologyfor highest reliabiliy In the last 50 years, Alstom has supplied more than 300 motor-generators for pumped storage plants worldwide.Thrust bearing pad membrane technologyThe thrust bearing is a critical component of large pumped storage plants because it supports heavy weights and operates at high speeds in two directions (pumping and generating mode). Hydrodynamic thrust bearings in pumped storage units operate with a very thin layer of lubricating oil. In order to ensure continuous lubrication of the thrust bearing pads, Alstom has developed the membrane technology, which acts as a self-regulating mechanism to carry the bearing pads. In fact, the bearing pads are positioned on oil-filled steel membranes that are hydraulically linked to one another to always guarantee equal oil pressure under each membrane. This enables the system to self adjust an equal load distribution on the thrust Oblique elementsOblique elements are designed to meet motor-generator requirements like roundness, concentricity and stability, in all operating conditions. The oblique element stator frame provides a rigid connection against eccentric displacement but allows free concentric thermal expansion. This arrangement also avoids buckling of stator laminations, which occurs in rigid frames with non-flexible foundation connections. In addition, the connection to the base plates is totally maintenance-free since no sliding pads are necessary with oblique elements.bearing pads. It does this in spite of deformations in the supporting frame or thrust loading conditions such as transient operation, shaft line deflection and shaft line misalignment. One of the main advantages of this unique membrane technology is that it helps to reduce friction losses in the thrust bearings. In fact it makes it possible to work at higher specific pressures on the pads, therefore minimising the bearing external diameter. A second advantage is that this system is faster to install on site as it is self-adjusting. Finally, by measuring the membrane oil pressure, it is possible to determine the hydraulic axial load on the shaft line and to carry out turbine condition monitoring.Permanently pre-stressed stator coreAlstom’s stator core lamination pressing system is specially designed for units with high load cycles such as pumped storage, which experience frequent starts and stops with high thermal expansion. The clamping bolts are positioned in the stator yoke and ensure high, constant distribution of the stator core pressing. Spring elements compensate any potential settling of the stator lamination inorder to maintain the pre-stress in the stator core over long service periods. Vacuum Pressure Insulation system The reliability of the stator winding is determined primarily by the quality of its insulation. Alstom has been using the Micadur® insulation system for more than 40 years. Additional research has led to further improvements to this system, providing excellent results on units even under severe conditions. To ensure permanent thermal and mechanical coupling between the stator bar surface and the stator core, the straight portions are supplied with “roundpacking”, consisting of a double-folded conductive polyester foil filled with a curable rubber compound. This system also ensures excellent grounding after installation due to the gap-free installation. Bent pole coilsIn bent pole coils, the centrifugal force of the field coil is perpendicular to the supporting surface of the insulation frame, between the pole coil and the pole shoe. This design concept, which eliminates the V-blocks between poles, makes the assembly easier and provides an increased pole coil cooling surface.8 9Variable speed PSPUnited Kingdom Cruachan – new: 4 x 106 MW , turbine/generator unitsSpainLa Muela – new: 3 x 230 MVA generators USADos Amigos - new 3 x 28 MW turbine/ generator unitsRacoon Mountain - refurb: 4x476MVA,300rpm water-cooled statorsBrazilPedreira - new: 1 x 20 MW turbine/gene-rator units, balance of lant, control systemSwitzerlandLimmern/Linthal 2015 – new: 4 x 250 MW variable speed turbine/generator units and VSINant de Drance – new: 6 x 157 MW variable speed turbine/generator units and VSIGrimsel – new: 4 x 90 MVA generators 750 rpmChinaHeimifeng – 4 x 300 MW turbine/generator units,electrical & mechanical auxiliariesPushihe – 4 x 300 MW turbine/generator units,electrical & mechanical auxiliariesHohhot – 4 x 300 MW turbine/generator units,electrical & mechanical auxiliariesHuizhou – 8 x 306 MW turbine/generator units,balance of plant, control systemBailianhe – 4 x 306 MW turbine/generator units,balance of plant, control systemBaoquan – 8 x 306 MW turbine/generator units,balance of plant, control systemZanghewan – new: 4 x 255 MW turbines, control systemShahe – new: 2 x 51 MW turbine/generator units,electrical & mechanical auxiliaries, gatesGuangzhou – new: 4 x 306 MW turbine/air cooled generator units 500 rpm, electrical & mechanical auxiliaries, control systemPortugalAlqueva I – new: 2 x 129 MW turbine/ge-nerator units, hydromechanical equipmentAlqueva II – new 2 x 134 MW turbine/ge-nerator units, hydromechanical equipmentFranceGrand Maison – new: 8 x 150 MW multi-stage turbine/generator units, 4 x 150 MW Pelton turbine/genera-tor units, control systemMoroccoAfourer I&II - new: 2 x 176 MW turbine/generator units, 2 x 60 MW turbine/generator units, electrical & mechanical auxiliaries, hydro-mechanical equipment, control systemAlgeriaBeni Haroun – new: 2 x 90 MW double-stage pump/motor units, electrical & mechanical auxiliaries, control systemThailandLam Ta Khong – new: 2 x 260 MW turbine/ge-nerator units, electrical & mechanical auxiliariesSouth KoreaYecheon – new: 2 x 408 MW turbine/generator units, turnkey power plantYang Yang – new: 4 x 250 MW double-stage regulated turbine/generator units, electrical & mechanical auxiliaries, control systemProject highlights worldwideAlstom has installed pumped storage plants all over the world. No wonder then the most prestigious, biggest and complex projects in the world rely on Alstom technology.Alstom has a strong position in the field of variable speed pumped storage, gained through early R&D initiatives. This key expertise has resulted in the signing of significant contracts such as Linthal 2015 for 4 x 250 MW units and Nant de Drance for 6 x 157 MW units, both in Switzerland.nAnT DE DRAnCESwitzerlandManaged by nant de Drance SA, with partners Alpiq, the national railway company Swiss Federal Railways (Sbb) and the FMV (Forces Motrices Valaisannes), the nant de Drance hydropower station is expected to generate 942 MW of elec-tricity upon completion, corresponding to the total peak power demand of the Swiss Federal Railways. Kraftwerk Linth-Limmern AG (KLL) is a partnership between the Glarus cantonal authority and Axpo AG. in 2009, KLL decided to extend its power station and has granted Alstom a contract to provide four new 250 MW variable speed pump turbine and motor generator units, boosting the output of the plant from 450 MW to 1450 MW. This will help meeting the peak power demand and helping to further develop the low carbon power generation of Switzerland. LinTHAL 2015SwitzerlandLatest innovation for highest flexibilityUnlike conventional hydropower plants, variable speed pumped storage plants use asynchronous motor-generators that allow the Pump turbine rotation speed to be adjusted.As a result, Alstom’s variable speed pumped storage plants benefit from high levels of additional flexibility including:• regulation of the amount of energy absorbed in pumping mode. This facilitates energy storage when power levels avail-able on the network are low, reduces the number of starts and stops, and allows the sell of grid regulation service (network frequency and voltage) while in pumping mode.• operating closer to the turbines optimal efficiency point, which results in a significant increase in global plant efficiency.• smoother operation (for example at partial load), elimination of operation modes prone to hydraulic instability or cavitation. This results in improved reliability, reduced maintenance and increased lifetime. It also results in a reduction in the Pump turbine submergence level, reducing civil engineering costs.• operating over a wider head range, increasing the availability of the plant. Installation of pumped storage plants on sites characterised by wide head variations, increases the partial load operation range to 33% of rated power in turbine mode and thus increases the generation flexibility.• instantaneous power output adjustment help to rectify sudden voltage disruptions/variations caused by network problems. These benefits result in improved profitability for pumped storage plant owners, and allow network operators to improve the reliability of the grid as well as the quality of the power supplied to end consumers.10 11PWER/bPROb/PPSTRG11/eng/HYD/05.11/FR/7414 © ALSTOM 2011. 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. Alstom PowerBrown Boveri Str. 75401 BadenSwitzerlandwww.alstom.com/powerAlstom Hydro EMEAAlstom Hydro4, avenue André Malraux 92309 Levallois-Perret Cedex France Alstom Hydro North AmericaAlstom Hydro Canada Inc. 1350 chemin St-Roch J3R 5P9 Sorel-Tracy, Québec Canada Alstom Hydro Latin AmericaAlstom Hydro Energia Brasil Ltda Av. Charles Schneider 12040-001 Taubaté Brazil Alstom Hydro ChinaTianjin Alstom Hydro Co., Ltd Gaofeng Road, Beichen District Tianjin 300400 China Alstom Hydro AsiaAlstom Projects India Ltd Hydro Maneja Vadodara - 390 013 IndiaAlstom contributes to the protection of the environment.This brochure is printed on environmentally-friendly paper.