HYDRAULIC TURBINES PELTON FRANCIS KAPLAN

Transcription

1 HYDRAULIC TURBINES PELTON FRANCIS KAPLAN

2 THE COMPANY CENTURIES OF EXPERIENCE FRANCO TOSI MECCANICA - A COMPANY THAT HAS ALWAYS BEEN A REFERENCE STANDARD IN THE POW- ER GENERATION INDUSTRY - IS DEDICATED TO SERVE YOUR THERMAL AND HYDRO POWER GENERATION NEEDS WITH THE QUALITY AND ATTENTION YOU EXPECT AND DESERVE. SINCE THE BEGINNING OF THE INDUS- TRIAL AGE THE NAME FRANCO TOSI WAS CONSIDERED A LEADER FOR RELIABLE TECHNOLOGY AND LEADING EDGE DEVELOPMENT. After a period of significant work abroad, particularly in Germany, in 1876 the young engineer Franco Tosi was called to Legnano to manage Cantoni Krumm & C., a steam engine and boiler manufacturer, which thanks to Tosi s work remarkably expanded its operations. Franco Tosi, an industrial pioneer, devoted himself to study and build reciprocating steam engines that in a few years gained a reputation both in Italy and internationally. citizen who carried out outstanding philanthropic work through his health insurance, social security and professional training initiatives. An entrepreneurial style whose signs are still visible and present today in Legnano. The industrial development of the Company Franco Tosi followed the ups and downs of the European history in the early twentieth century, through two world wars, the post-war recovery and the 1960s economic boom including a strong internationalisation of the Company s markets. THE FIRST TOSI ENGINE, WITH A POWER OF 3 HP, DATES BACK TO 1877 AND IN 1881 THE FIRST 40 TO 50 HP RYDER STEAM ENGINE WAS PRODUCED. Tosi s entrepreneurial vision and undisputed design skills found their accomplishment with the advent of the first power plants. His steam engines definitely conquered both the domestic and the international markets. In a few years Franco Tosi became a shareholder and then, in 1884, the sole owner of a pioneer company in the energy sector that has borne his name since A name that still today is renowned all over the world. Besides having excellent technical skills and being an eminent industrialist, Franco Tosi was also a model 3

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4 GLOBAL POWER SALES AND MARKET APPLICATION SINCE IT WAS ESTABLISHED IN 1881, THE NAME OF FRANCO TOSI IS RECOGNIZED AND APPRECIATED IN THE WORLD OF POWER GENERATION AND IS SYNONYMOUS WITH HIGH QUALITY AND RELIABILITY. The results achieved by Franco Tosi and his technical excellence are well known to all of its customers. Franco Tosi Meccanica, through its experience and expertise, is willing to serve the needs of Power Generation with all the care its customers need and deserve. Our product portfolio includes steam turbines up to 850 MW, hydraulic turbines up to 500 MW and heat exchange apparatuses. FTM has been focused on a long lasting policy of investment in R&D, with important results in terms of products efficiency and reliability. In addition, Franco Tosi Meccanica has been very active in the field of Renewable Energy such as Hydraulic, Geothermal, Solar Thermal and Waste-To-Energy. As a dedicated and competent Company, our primary goal is Customers satisfaction. We want to achieve this objective through an entrepreneurial approach focused on international markets. We will be delighted to make our know-how and experience available to our clients. Franco Tosi Reference List has been realized through 130 years of experience on a global scale. The company accounts for 75,000 MW of installed capacity, 1,000 turbines in more than 40 countries. UTILITIES AND INDUSTRIAL POWER GENERATION FOSSIL COMBINED CYCLES HYDRO SOLAR-THERMAL GEOTHERMAL BIOMASS WASTE TO ENERGY NUCLEAR CHEMICAL FOOD PROCESSING PAPER MILLS PETROLCHEMICAL COGENERATION CHP OIL & GAS DISTRICT HEATING WE SINCERELY PLAN ON DEVELOPING FUTURE PROJECTS TOGETHER. 6

5 HYDRAULIC TURBINES BULB up to 20 MW PUMPS AND PUMP TURBINES up to 250 MW SERVICE ACTIVITIES Training Rehabilitation Feasibility & Plant study Remote Equipment Operation PELTON AGGREGATE PLANT SUPPLY Repowering Buy-Back of Old Machineries Head from 200 to 1300 m Electro Mechanical for Hydro and Steam Turbines up to 300 MW Hydro Turbine and Generator Revamping & Retrofitting Electrical and Mechanical BOP Conventional Maintenance FRANCIS Instrumentation and Control Long Term Service Agreements Head from 30 to 600 m Hydro Mechanical 24/7 Support Hotline up to 500 MW Complete Hydro Electrical Monitoring Mechanical Package Diagnostic & Spare parts KAPLAN Plant Simulators Head from 5 to 70 m Field Erection and Commissioning Plant Management up to 150 MW PRODUCTS AND SERVICES OFFERED BY FTM STEAM TURBINES Power generation Cogeneration Condensing Back-Pressure Single or Double Reheat Single or Double Flow Single or Double Extraction AGGREGATE PLANT SUPPLY Steam Turbine Generator and Condenser Thermal Cycle Turbine Island Electrical and Mechanical BOP Instrumentation and Control Field Erection and Commissioning DESIGN FEATURES FTM philosophy is to organize its product line in different standard turbine modules arranged alone or together to tailor our solutions to customer specific needs. Dedicated design solutions are thought to give FTM steam turbines the best fitting to every market range, from industrial to pure power generation. (directly connected to cylinders or with pipe connections) High back pressure LSB families up to 5 m 2 annular exhaust area LSB up to 9 m 2 annular exhaust area (50 Hz). Fully 3D stator and rotor reaction blading for the highest level blade path efficiency Any kind of controlled extraction or induction / bleeding Skid supplied solutions (industrial), any Steam Induction SOME OF THEM: direction exhaust casings and high recovery and Upward, Downward, Lateral and Axial Exhaust efficiency axial ones Back Pressure or Condensing Configuration Rotor Welding technology for optimized shaft Integral steam chest / Separated valve assemblies material combination 8 9

6 HYDRAULIC TURBINES HYDRO MACHINERY Thanks to its long and diversified experience in hydro power machinery, today Franco Tosi Meccanica is able to cover a full range of market applications for the power generation industry. Advanced engineering and standardization methods are the strengths of our approach. Nature is the most important interface for hydroelectric power plants configuration and raises always new challenges for the engineering. TURBINES AND RANGE OF APPLICATION PELTON: Head from 300 to 1300 m up to 300 MW n q from 5 to 20 KAPLAN: Head from 5 to 70 m up to 150 MW n q from 100 to 250 FRANCIS: Head from 30 to 600 m up to 500 MW n q from 20 to 110 VALVES: BUTTERFLY up to DN 3000 and PN 30 SPHERICAL up to DN 2500 and PN

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8 MAXIMUM POWER [kw] Constant D, speed increase Constant speed, D increase HEAD [m] PELTON HYDRAULIC TURBINES EXAMPLE OF PELTON APPLICATION RANGE The above chart of a 2 jets Pelton shows the relation between head, speed, diameter and maximum reachable power for a typical 2 jets Pelton turbine. Moving along one of the red continuous lines, a rotational speed value is chosen and kept fixed, therefore the curve reflects the optimal ratio between head and Pelton runner impulse diameter. All the area below the chosen curve is the possible operational field, where the given power is proportional to the extracted flow. For higher or lower number of jets configurations, the above graph can be simply scaled up or down in maximum power according to the ratio between the actual number of jets and two. For example, at the same head and rotational speed, when a 2 jet Pelton produces a maximum power of kw, a 4 jet Pelton produces a maximum power of kw. APPLICATION RANGE Our Company has delivered important projects to the market through decades of international experience. We acquired specific experience in Pelton configuration and design with heads above 1000 meters. NET HEAD FROM 300 m TO 1300 m OUTPUT POWER UP TO 300 MW n q FROM 5 TO 20 Therefore, the curve represents the maximum power extractable for the given conditions of rotational speed and head. Moving along the dashed lines, which are in an infinite number, the runner impulse diameter is kept fixed, therefore they show the variation in maximum attainable power with the different combinations of rotational speed and head values

9 DESIGN Our engineering department can ensure the best practices and solutions to our customers since we have developed a large range of projects and delivered Pelton Turbines up to six jets. 3D standardization of main turbine components is used for quick modular and parametric design. NUMERICAL SIMULATION Completely CFD unsteady biphase simulation is performed to study the jet impact on the bucket, in order to maximize the turbine efficiency. Finite Element Mechanical simulation and fatigue analysis are performed to find the most critical regions and to reduce the stress. TOTAL PRESSURE (contour) 5.643e e e e e e e e e e e+005 [Pa] 16

10 LOW Ns FRANCIS: HEAD VS. RUNNER DIAMETER GIVEN A MAXIMUM INSTALLATION DEPTH HEAD [m] rpm 250 rpm DIAMETER [m] LOW Ns FRANCIS: POWER VS. RUNNER DIAMETER GIVEN A MAXIMUM INSTALLATION DEPTH POWER [kw] rpm rpm DIAMETER [m] FRANCIS HYDRAULIC TURBINES EXAMPLE: LOW SPECIFIC SPEED FRANCIS APPLICATION RANGE One of the most important parameter to fit a turbine model into a given plant configuration is the maximum installation depth. An example of typical Francis configuration can be defined by the charts above which clearly express the relationship among head, diameter, revolutions per minute and power of our turbines. speeds all generator number of poles configuration are feasible. For example, with a head of approximately 160 m and 250 rpm, the diameter of the turbine is approximately 3,4 meters with a corresponding maximum power greater than 45 MW. APPLICATION RANGE Natural conditions are never the same. Thanks to our wide experience, we have developed a set of solutions for the configuration of the most challenging environmental conditions. The application range for our Francis Turbines could be best defined as follows: NET HEAD FROM 30 m TO 600 m OUTPUT POWER UP TO 500 MW n q FROM 20 TO 110 The first chart describes the application range from 40 m to 160 m. Diameters change in relationship to the head and the desired configuration in terms of revolutions per minute. The second chart describes the power in terms of kw at the change of diameter and revolutions per minute. In between the two limits at lower and upper rotational 18 19

11 DESIGN FTM is able to design the entire turbine and to study new components to fit existing installed parts. In case of lack of original drawings, FTM can perform reverse engineering in order to get the 3D model of the turbine components. This gives the possibility to estimate the efficiency improvement due to the replacement of the hydraulic active parts. CFD ANALYSIS Complete hydraulic channel is simulated in order to estimate the turbine performances depending on the wicket gates opening. Specific analysis is performed to identify the regions which can be affected by cavitation problems. Complete unsteady simulation is performed to detect and reduce instability phenomena at partial load. VOLUME FRACTION ABSOLUTE PRESSURE [Pa] 20

12 blades vertical 5 blades vertical or horizontal (S-type) 4 blades vertical or 3 blades horizontal (bulb, open pit) 60 TYPICAL KAPLAN TURBINES APPLICATION RANGE NET HEAD [m] SPECIFIC SPEED [nq] KAPLAN HYDRAULIC TURBINES KAPLAN TURBINE MODELS APPLICATION RANGE The most characteristic feature of a Kaplan turbine, which immediately permits to identify a standard model, is the number of runner blades. Due to the limited load carrying capability of each runner blade, the more the turbine head increases, the greater number of blades is needed to convert the water pressure into mechanical energy. The close correlation between the turbine head H and the specific speed nq permits to reflect the just explained function into a relationship between the specific speed and the number of turbine blades, which is expressed in the chart above. diate central zone with 5 blades solutions and the high specific speed (above 200) zone on the right, with few blades (3-4) and typically horizontal applications. It is clear also from the number of applications that the 5 blades type is the most flexible design in terms of different environmental conditions coverage capacity. For example a turbine with H = 20 m, Q = 50 m 3 /s will be very likely to rotate at rpm (if with direct connection to the generator) and have a specific speed n q of 140, leading to a 5 blades solution. APPLICATION RANGE Our Company has delivered important projects to the market through decades of international experience. We acquired specific experience in configuration and design both for Vertical and Horizontal Kaplan. VERTICAL SHAFT NET HEAD OUTPUT POWER HORIZONTAL SHAFT NET HEAD OUTPUT POWER FROM 5 m TO 70 m UP TO 150 MW FROM 5 m TO 15 m UP TO 15 MW In the graph are reported real-case application data of FTM turbines, which lay on the chart space with a typical hyperbolic shape, as the specific speed nq grows with the turbine flow and decreases with the turbine head. Three typical zones are identifiable: the high head zone on the left, typically corresponding to relatively low specific speed Kaplan turbines (below 100) and great number of blades (7-8), the interme

13 DESIGN FTM product range covers axial turbines both in horizontal and vertical layout, S-Type, steel and concrete spiral case. The machining capability goes up to 10 m of external runner diameter. NUMERICAL ANALYSIS CFD analysis are performed to study the flow in the hydraulic channel, in order to optimize the profile and to get the best conjugation law between wicket gates and runner blades opening. The hydraulic pressure is imported from CFD to Mechanical Finite Element simulation, to study the localized stresses and to design the local relief grooves and the fillet radius of the runner blades. VELOCITY (LINE) 3.332e e e e e-003 [m s^-1] 24

14 6 4,5 FLUID TORQUE COEFFICIENT ON THE ROTOR cc [-] 3 1, VALVE OPENING [deg] 80 cq=2 cq=1 cq=0.5 cq=0.2 VALVES BUTTERFLY - SPHERICAL PRESSURE RELIEF VALVES The chart above can be used for a rapid evaluation of the hydraulic torque acting on the rotor and therefore for the design of the rotating system, starting from a non-dimensional parameter obtained from the ratio between the current and the reference flow. The reference valve characterization is obtained through a series of CFD simulations. APPLICATION RANGE Thanks to a well proven experience, FTM is able to design and produce customized main shut-off and penstock valves as well as pressure relief valves. BUTTERFLY UP TO DN 3000 UP TO PN 30 SPHERICAL UP TO DN 2500 UP TO PN

15 DESIGN The selection of the valve typology is based on the operating characteristics of the turbine. Advanced design tool permits to find the solution to fit any operational requirement VELOCITY [m s^-1] NUMERICAL ANALYSIS Plant hydraulic transient analysis is performed in order to optimize water column dynamic response in terms of over-pressure and over speed. CFD and mechanical finite element analysis are performed to study the flow into the valve and to verify the structural integrity. 28

16 ALBANIA ARGENTINA AUSTRIA BAHRAIN BELGIUM BOPHUTHATSWANA BRAZIL BULGARIA CHILE CONGO COSTARICA EQUADOR ETHIOPIA FRANCE GERMANY GHANA GREECE GUADALUPE GUATEMALA INDIA INDONESIA IRAN IRAQ ITALY JAMAICA JORDAN KOREA LEBANON LIBYA MALTA OUR JOB FOR YOUR POWER IN THE WORLD MEXICO NETHERLANDS NICARAGUA PAKISTAN PANAMA PERÙ PHILIPPINES POLAND PORTUGAL QATAR RUSSIA SAUDI ARABIA SOUTH AFRICA SERBIA SPAIN TAIWAN THAILAND TURKEY UAE - ABU DHABI UAE - DUBAI UNITED KINGDOM UKRAINA URUGUAY U.S.A. UZBEKISTAN VENEZUELA All rights reserved. Subjects to change without prior notice. Information in this document contains general descriptions which are not legally binding for Franco Tosi Meccanica. Each turbine produced by Franco Tosi Meccanica is specifically tailored to the needs and requests of our client. Each request shall be discussed with our Marketing & Sales Department.

17 FRANCO TOSI MECCANICA SPA Piazza Monumento, Legnano (Mi) ITALY U.S.A. Office Franco Tosi/Energy Allied 5847 San Felipe, Suite 4150 Houston, TX 77057, U.S.A. Phone: Fax: