Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No.

- GMR/GBHPL/ICB/LOT/05

PROJECT: - ALAKNANDA HYDROELECTRIC PROJECT (3X100MW) OWNER: - GMR (BADRINATH) HYDRO POWER GENERATION PVT. LTD.

System Description Pelton Turbine

Rev. A B C D

Page

Description

Executed by

Approved by

Date

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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.

2
2.1

Design Data
Main Dimensions

Nominal diameter Rated Output Rated Head Rated Speed Elevation Runner

D1 P H N CL

2656 103 587.59 375 2295.50

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

3 Hydraulic Dimensioning and Model Testing

Numerous existing model tests, which are used as a basis to calculate prototype performance and component dimensions of the various machine components, are supplemented by advanced numerical design and flow simulation tools in optimizing the design of the turbine. Conversion of data from model to prototype including scale effects are done according to IEC standards.

Codes and Standards

National (Indian Standard), International standard (DIN, ASTM, BS, IEC, VH) are the basis for design / engineering of materials, manufacturing, and testing.

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

ANSI / IEEE 810

IEC 60545

Voith Standard IEC 60609 ASTM A 668 Gr. D ASTM A743 GradeCA-6NM G - X 4 CrNi 13 4

- Corrosion Resisting Steel Forgings

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.

6.2 Turbine Runner

The Pelton runner will be of the integrally cast and made of stainless steel ASTM A743 CA6NM Cr-Ni 13-4 or equivalent material. The disc shall be machined and bored to centre on a male projection at the end of the main shaft ensuring proper centering and alignment of runner. After the runner is completely machined and finished, it will be statically balanced.

6.3 Turbine Shaft

Each unit is equipped with one main turbine shaft which transmits the torque, created by Pelton runner to the generator. The shaft is connected to the runner at lower end and to generator shaft at upper end via integral flange and bolts. Type of Coupling between shaft and runner & shaft and generator shaft is friction coupling. Shaft will have center bore of suitable size throughout its length to facilitate assembly and dismantling of runner. The turbine shaft will be made of forged steel, properly heat-treated. It shall be designed to operate safely in combination with the generator shaft at any speed up to the maximum runaway speed without detrimental vibration or distortion.

6.4 Nozzles and Jet Deflector Assembly

The Pelton turbine is equipped with five sets of nozzle & five sets of deflector which are arranged inside the turbine housing. All five nozzles are bolted to outlet flange of distribution

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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.

6.5 Brake Jet

One brake jet will be supplied for each unit to stop the unit from full speed down to approx. 30% of rated speed before the generator brakes are applied to bring the unit to rest. The supply of water to the brake jet shall be taken from the upstream of the main inlet valve. Brake nozzle shall be straight, made of stainless steel without needle. An automatic shut-off valve will be supplied, complete with all necessary instrumentation, piping, attachments, etc.

6.6 Distribution Pipe

The distribution pipe will be constructed from welded high strength plate steel properly stress relieved, suitably sectionalized for transportation and handling. The segments will be properly prepared for field welding. The first segment of spiral distributor will be prepared for field welding to the inlet pipe. However final dimensions of segments of the distributor pipe will be decided during detail engineering. The spiral distributor plate thicknesses of the individual sections will be designed to safely carry the maximum admissible loads under all operating conditions.

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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.

6.7 Housing and Pit Liner

The turbine housing and discharge/runner pit liner will be made of fabricated steel plates. It will be sectionalized into suitable sections for easy transportation. The turbine housing and pit liner assembly will be field welded at site. Labyrinth sealing arrangement is provided in inner housing to prevent water going on top of housing. The turbine housing will support the bearing and also support the shaft and runner when the generator shaft is uncoupled. While the turbine is operating, loads are transferred to concrete through embedded part of housing. The housing / pit liner is equipped with air ventilation ducts and holes to assure proper discharge of the water below the runner in the tail water channel. The housing / pit liner will be equipped with a runner removal hatch of appropriate size to allow access to the turbine runner and nozzles to facilitate their assembly and dismantling. An inspection platform is provided in pit liner for inspection / repair to runner, nozzles & deflectors etc... Pit liner is further extended upto tail race floor. The lower side of the pit liner is provided with levelling pads for the purpose of levelling during erection. All necessary brackets, adjustable tie rods, turn buckles and anchors is supplied for securing the housing while embedding in concrete.

6.8 Turbine Bearing

The turbine guide bearing will consist of segmented steel plates with a babbited bearing surface. Lubricating oil will be supplied by the rotating turbine shaft (i.e. self pumping type). The bearing housing, of fabricated steel plate, supports the bearing segments and will transfer the bearing load to the bearing support and turbine foundation.

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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

7
Typical Turbine Bearing Arrangement

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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05

6.9 Tool and Devices

Special tools and devices necessary for normal operation and maintenance will be supplied (some of the devices may be jointly used with the inlet valve).

6.10 Runner Removal

The runner removal and assembly will be performed with the help of runner removal equipment. The unit shaft will be equipped with a central bore, which allows an erection rod to be linked from the powerhouse crane to the turbine runner flange. The runner flange will be disengaged and the runner will be lowered onto the runner cart and firmly attached hereto. The runner cart will be moved on rails firmly attached to the inspection platform. The cart will be moved horizontally through the runner removal door in the turbine housing underneath the turbine distributor up to the vertical runner removal duct. Here, the runner with the cart will be attached to the powerhouse crane, will be rotated into vertical position and pulled out of the access duct The re-assembly will be performed in reverse order.

Typical Runner removal arrangement

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Alaknanda Hydro Electric Project (300 MW) Techno-Commercial Document ICB No. - GMR/GBHPL/ICB/LOT/05

Shop Assembly and Pressure Tests

Turbine parts to be assembled as per details given below : - Turbine Housing - Assembly at site - Distributor Pipe - Final assembly at site - Nozzle & Deflector Assembly - Assembly at works - Turbine Guide Bearing - Mock up assembly at works and final Assembly at site All oil systems (servomotors, oil coolers etc.) will be pressure tested as applicable. The distributor without nozzles will be pressure tested in the field and embedded with 50% design pressure.

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