Hydro power plants

Hydro power plants

Inlet gate Air inlet Surge shaft Penstock Tunnel Sand trap Trash rack Self closing valve Tail water Main valve Turbine Draft tube Draft tube gate

The principle the water conduits of a traditional high head power plant

Ulla- Frre

Original figur ved Statkraft Vestlandsverkene

Intake gate Intake trashrack Tunnel Inlet Tunnel Inlet trashrack

gate hoist

Surge tank Penstock inlet Valve

Desilting basin Anchor block

Headrace tunnel Anchor block

Shaddle Power house

Exp. joint

DT end gate IV G Tailrace SC IV -inlet valve R -turbine runner R SC -spiral case G -generator

DT

Typical Power House with Francis Turbine

Arrangement of a small hydropower plant

Ligga Power Plant, Norrbotten, Sweden

H = 39 m Q = 513 m3/s P = 182 MW Drunner=7,5 m

Borcha Power Plant, Turkey

H = 87,5 m P = 150 MW Drunner=5,5 m

Water intake
Dam Coarse trash rack Intake gate Sediment settling basement

Dams
Rockfill dams Pilar og platedammer Hvelvdammer

Rock-fill dams

1. 2. 3. 4.

Core Filter zone Transition zone Supporting shell

Moraine, crushed soft rock, concrete, asphalt Sandy gravel Fine blasted rock Blasted rock

Slab concrete dam

Arc dam

Gates in Hydro Power Plants

Types of Gates
Radial Gates Wheel Gates Slide Gates Flap Gates Rubber Gates

Radial Gates at lvkarleby, Sweden

Radial Gate
The forces acting on the arc will be transferred to the bearing

Slide Gate

Jhimruk Power Plant, Nepal

Flap Gate

Rubber gate
Reinforced rubber Open position Flow disturbance

Bracket

Reinforced rubber Closed position

Air inlet

Circular gate
End cover Hinge Ribs Pipe

Manhole

Bolt Fastening element Seal Frame

Ladder

Circular gate

Jhimruk Power Plant, Nepal

Trash Racks

Panauti Power Plant, Nepal

Theun Hinboun Power Plant

Laos

Gravfoss
Power Plant Norway Trash Rack size: Width: 12 meter Height: 13 meter Stainless Steel

CompRack
Trash Rack delivered by VA-Tech

Cleaning the trash rack

Pipes
Materials Calculation of the change of length due to the change of the temperature Calculation of the head loss Calculation of maximum pressure
Static pressure Water hammer

Calculation of the pipe thickness Calculation of the economical correct diameter Calculation of the forces acting on the anchors

Materials
Steel Polyethylene, PE Glass-fibre reinforced Unsaturated Polyesterplastic , GUP Wood Concrete

Materials
Material Max. Diameter [m] Steel, St.37 Steel, St.42 Steel, St.52 PE GUP Wood Concrete ~ 1,0 2,4
Max. p = 160 m.

Max. Pressure [m]

Max. Stresses [MPa] 150 190 206

160 320
Max. D: 1,4 m.

~5 ~5

80 ~ 400

Steel pipes in penstock

Nore Power Plant, Norway

GUP-Pipe
Raubergfossen Power Plant, Norway

Wood Pipes

Breivikbotn Power Plant, Norway

vre Porsa Power Plant, Norway

Calculation of the change of length due to the change of the temperature

L = T L
Where: L = L = = T = Change of length [m] Length [m] Coefficient of thermal expansion [m/oC m] Change of temperature [oC]

Calculation of the head loss

L c hf = f D 2g
Where: hf = f = L = D = c = g = Head loss Friction factor Length of pipe Diameter of the pipe Water velocity Gravity [m] [-] [m] [m] [m/s] [m/s2]

Example
Calculation of the head loss
Power Plant data: H = 100 m Head Q = 10 m3/s Flow Rate L = 1000 m Length of pipe D = 2,0 m Diameter of the pipe The pipe material is steel

L c hf = f D 2g

cD Re =
Where: c = 3,2 m/s Water velocity = 1,30810-6 m2/s Kinetic viscosity Reynolds number Re = 4,9 106

Where: Re = 4,9 106 Reynolds number = 0,045 mm Roughness D = 2,0 m Diameter of the pipe /D = 2,25 10-5 Relative roughness f = 0,013 Friction factor The pipe material is steel

0,013

Example
Calculation of the head loss
Power Plant data: H = 100 m Head Q = 10 m3/s Flow Rate L = 1000 m Length of pipe D = 2,0 m Diameter of the pipe The pipe material is steel

L c 1000 3,2 hf = f = 0,013 = 3,4 m D 2g 2 2 9,82

Where: f = 0,013 c = 3,2 m/s g = 9,82 m/s2 Friction factor Water velocity Gravity

Calculation of maximum pressure

Static head, Hgr (Gross Head) Water hammer, hwh Deflection between pipe supports Friction in the axial direction

Hgr

Maximum pressure rise due to the Water Hammer

h wh
hwh a cmax g = = = =

a c max = g

2L IF TC << a

Jowkowsky

Pressure rise due to water hammer Speed of sound in the penstock maximum velocity gravity

[mWC] [m/s] [m/s] [m/s2]

Example
Jowkowsky
a = 1000 [m/s] cmax = 10 [m/s] g = 9,81 [m/s2]
TC << 2L a

h wh

a c max = = 1020 m g

c=10

m/s

Maximum pressure rise due to the Water Hammer

h wh a c max a = c max 2 L = TC g TC g
= = = = = = Pressure rise due to water hammer Speed of sound in the penstock maximum velocity gravity Length Time to close the main valve or guide vanes

2L

IF TC
[mWC] [m/s] [m/s] [m/s2] [m] [s]

2L a

Where: hwh a cmax g L TC

C
L

Example
L TC cmax g = = = = 300 10 10 9,81 [m] [s] [m/s] [m/s2]

h wh

c max 2 L = = 61 m g TC

C =1 0
L

m/s

Calculation of the pipe thickness

L Di p Cs = 2 t L t t = p ri Cs t

Based on:
Material properties Pressure from:
Water hammer Static head

p = g (H gr + h wh )
Where:

L
Di p t t Cs Hgr hwh

= Length of the pipe

= Inner diameter of the pipe = Pressure inside the pipe = Stresses in the pipe material = Thickness of the pipe = Coefficient of safety = Density of the water = Gross Head = Pressure rise due to water hammer

[m] [m]
[Pa] [Pa] [m] [-] [kg/m3] [m] [m]

ri
t

Example
Calculation of the pipe thickness

L Di p Cs = 2 t L t p ri Cs t= = 0,009 m t
p = g (H gr + h wh ) = 1,57 MPa
Where:

Based on:
Material properties Pressure from:
Water hammer Static head

t
L
Di t Cs Hgr hwh

= 0,001 m
= = = = = = 2,0 m 206 MPa 1000 kg/m3 1,2 100 m 61 m

Length of the pipe

Inner diameter of the pipe Stresses in the pipe material Density of the water t Coefficient of safety Gross Head Pressure rise due to water hammer

ri

Calculation of the economical correct diameter of the pipe

dK tot d(K f + K t ) = =0 dD dD
Cost [$]
T
tot ts, K s l co ota

ost Installation c

s, Kt

Costs for h ydraulic lo sses, K

Diameter [m]

Example
Calculation of the economical correct diameter of the pipe Hydraulic Losses
Power Plant data: H = 100 m Q = 10 m3/s plant = 85 % L = 1000 m Head Flow Rate Plant efficiency Length of pipe

PLoss

L Q2 C2 = g Q hf = g Q f = 5 2 4 2r 2g r r
Loss of power due to the head loss Density of the water gravity Flow rate Head loss Friction factor Length of pipe Radius of the pipe Calculation coefficient [W] [kg/m3] [m/s2] [m3/s] [m] [-] [m] [m]

Where: PLoss = = g = Q = = hf f = L = r = C2 =

Example
Calculation of the economical correct diameter of the pipe Cost of the Hydraulic Losses per year

K f = PLoss T kWh price

Where: = Kf PLoss = T = kWhprice = r = C2 =

C2 = 5 T kWh price r
[] [W] [h/year] [/kWh] [m]

Cost for the hydraulic losses Loss of power due to the head loss Energy production time Energy price Radius of the pipe Calculation coefficient

Example
Calculation of the economical correct diameter of the pipe Present value of the Hydraulic Losses per year

Where: = Kf T = kWhprice = r = C2 =

C2 K f = 5 T kWh price r
Cost for the hydraulic losses Energy production time Energy price Radius of the pipe Calculation coefficient [] [h/year] [/kWh] [m]

Present value for 20 year of operation:

K f pv
Where: Kf pv n I

Kf = (1 + I )i i =1
[] [-] [-]

= Present value of the hydraulic losses = Lifetime, (Number of year ) = Interest rate

Example
Calculation of the economical correct diameter of the pipe Cost for the Pipe Material

pr m = m V = m 2 r t L = m 2 r L = C1 r 2

K t = M m = M C1 r
Where: m = m = V = r = L = p = = C1 = Kt = M = Mass of the pipe Density of the material Volume of material Radius of pipe Length of pipe Pressure in the pipe Maximum stress Calculation coefficient Installation costs Cost for the material

[kg] [kg/m3] [m3] [m] [m] [MPa] [MPa] [] [/kg]

NB: This is a simplification because no other component then the pipe is calculated

Example
Calculation of the economical correct diameter of the pipe

Installation Costs:
Pipes Maintenance Interests Etc.

Example
Calculation of the economical correct diameter of the pipe
C2 T kWh price n 5 = r (1 + I )i i =1 K f pv

K t = M C1 r 2

d (K t + K f ) 5 n C 2 T kWh price = 2MCr 6 =0 i r i =1 dr (1 + I )

Where: Kf = = Kt T = kWhprice = r = C1 = = C2 M = n = I = Cost for the hydraulic losses Installation costs Energy production time Energy price Radius of the pipe Calculation coefficient Calculation coefficient Cost for the material Lifetime, (Number of year ) Interest rate [] [] [h/year] [/kWh] [m]

[/kg] [-] [-]

Example
Calculation of the economical correct diameter of the pipe

d(K t + K f ) = 2M Cr dr

C 2 T kWh price 5 =0 i 6 r i =1 (1 + I )
n

5 n C 2 T kWh price r = 7 2 i =1 M C (1 + I )i

Calculation of the forces acting on the anchors

Calculation of the forces acting on the anchors

F5 F1 F F2 F3 F4

F1 = Force due to the water pressure [N] F2 = Force due to the water pressure [N] F3 = Friction force due to the pillars upstream the anchor F4 = Friction force due to the expansion joint upstream the anchor F5 = Friction force due to the expansion joint downstream the anchor

[N] [N] [N]

Calculation of the forces acting on the anchors

F

R G

Valves

Principle drawings of valves

Open position Closed position

Spherical valve

Gate valve

Hollow-jet valve

Butterfly valve

Spherical valve

Bypass system

Butterfly valve

Butterfly valve

Butterfly valve disk types

Hollow-jet Valve

Pelton turbines
Large heads (from 100 meter to 1800 meter) Relatively small flow rate Maximum of 6 nozzles Good efficiency over a vide range

Jostedal, Norway
*Q = 28,5 m3/s *H = 1130 m *P = 288 MW

Kvrner

Francis turbines
Heads between 15 and 700 meter Medium Flow Rates Good efficiency =0.96 for modern machines

SVARTISEN

P = 350 MW H = 543 m Q* = 71,5 m3/S D0 = 4,86 m D1 = 4,31m D2 = 2,35 m B0 = 0,28 m n = 333 rpm

Kaplan turbines
Low head (from 70 meter and down to 5 meter) Large flow rates The runner vanes can be governed Good efficiency over a vide range