Pipelines and Penstocks Avoiding operational issues throughout the life of your project

Transcription

1 Pipelines and Penstocks Avoiding operational issues throughout the life of your project Presenter Dan Murrer, P.E. 322 East Front Street Suite 200 Boise, ID Tel NWHA 2014 Small Hydro Workshop September

2 Agenda Overview Design Considerations The Successful Penstock Project Examples Planning Phase: 75 kw Micro-Hydro Installation Fort Collins Water Treatment Plant, City of Fort Collins, CO Design Development Phase: 1.2 MW Granby Dam Hydroelectric Project, Northern Colorado Water Conservancy District Final Design Phase: 1.28 MW Head of the U Hydroelectric Project, North Side Canal Company, Idaho Construction Phase: 13 MW Jordanelle Dam Hydroelectric Project, Central Utah Water Conservancy District Project Commissioning Phase: 220 kw Dewitt Hydro, City of Logan UT Questions and answers 2

3 Overview: Conveyance - Essential Element of a Project Delivers Water to the Turbine Develops the Net Head Underpins Power Output and Energy Safe Conveyance of Water under all Conditions 3

4 Sample of Penstock Design Considerations Flow capacity, size, and Velocity Pressure Rating Materials of Construction Transient Conditions Air/Vacuum Release, Drain Valves Water Chemistry Joint type and constructability Maintenance Access Upstream screening/trash management 4

5 The Successful Penstock: A Proper start means long, trouble-free life Planning Careful attention to those design considerations means avoiding future surprises Design Turn your careful planning into reality Construction Build what you design Commissioning Don t overlook the need for a thorough shake-down 5

6 Project Examples: These are snapshots of actual projects Recent, firsthand information Domestic USA locations Various Types of Project Owners Each example highlights one of the phases of providing a successful penstock planning, design, construction, and commissioning. 6

7 EXAMPLE: Fort Collins WTP Hydropower Project City of Fort Collins, Colorado, USA Focus: Project Planning Phase SIZE SETTING FOCUS Single 75 kw horizontal Francis unit Off-the-shelf pump technology Rated head: 193 feet Maximum total flow: 6.6 cfs City of Fort Collins Utilities (owner) FERC Conduit Exemption Addition at existing raw water supply pressure dissipation valve station, in parallel with control valves. Operates on raw water supply flows. Flow Capacity Net Head Size: Length, Diameter, and Material Ability to withstand Normal and Emergency Conditions 7

8 EXAMPLE: Fort Collins WTP Hydropower Project City of Fort Collins, Colorado, USA Focus: Project Planning Phase Sampling of Project Specific Investigations 1. When and How Much Water is Available? 2. What does the pipeline and network look like to get to the turbine? 3. Can existing facilities adequately operate with a Turbine installed in parallel? 4. Can existing conveyance features withstand transient forces? 5. Can an installation be easily assembled, dissembled, isolated, and maintained within allotted space by maintenance capabilities at the Treatment Facility? 8

9 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA Focus: Design Development Phase SIZE SETTING FOCUS Twin 600 kw horizontal Francis units Rated head: 226 feet Maximum total flow: 76 cfs Northern Colorado Water Conservancy District (owner) Lease of Power Privilege Lake Granby is a 540,000 acre-feet (ac-ft) reservoir constructed on the Colorado River during the late 1940s as part of Reclamation s Colorado-Big Thompson (C-BT) project. Northern Water proposes to install a hydroelectric station that will use the minimum streamflow obligations and a portion of additional releases to generate power. Confirmation of what was planned Working through fatal flaws 9

10 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA Focus: Design Development Phase Sample of Project Investigations: 1. Relocation of Existing 1950s USBR Hollow Jet Valves and Retrofitting with electric actuators. 2. High Velocity Environment at the Gate Chamber 3. Cavitation and Transient Force Evaluations 4. Erosion and Corrosion of the Water Passage Coatings and Linings 5. Bifurcation Design 6. Drainage of the Ring Follower Gate 7. Air/Vacuum Release Locations 8. Vibration 9. Thermal Expansion and Contraction of the Pipeline 10. Weep Hole Maintenance/Pipe Support Locations 11. Rock Fall, Drainage, and Access 10

11 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA Relocation of Existing Hollow Jet Valves and Retrofitting with electric actuators 11

12 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA High Velocity Environment at the Gate Chamber, Cavitation and Transient Force Evaluations, Erosion and Corrosion of the Water Passage Coatings and Linings 12

13 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA Thermal Expansion and Contraction of the Pipeline Weep Hole Maintenance/Pipe Support Locations 13

14 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA Thermal Expansion and Contraction of the Pipeline, Weep Hole Maintenance/Pipe Support Locations 14

15 EXAMPLE: Granby Dam Hydroelectric Project Northern Colorado Water Conservancy District, Colorado, USA Rockfall, Drainage, and Access 15

16 EXAMPLE: Head of the U Hydroelectric Project North Side Canal Company, Idaho, USA Focus: Final Design Phase SIZE Eight 160 kw Siphon Type Units Rated head: 20 feet Maximum total flow: 1200 cfs SETTING Northern Side Canal Company (Owner) Located outside of Jerome, Idaho FERC Conduit Exemption Planned hydro installation was integrated with the replacement of an aging diversion structure. Structure Design occurred summer and fall Structure Construction occurred between 2013 & 2014 Irrigation Seasons Turbine Contract Awarded to Mavel in January 2014 Final Hydropower Project Features Currently in Final Design Planned Commissioning March/April 2015 FOCUS Making what was designed, happen. 16

17 EXAMPLE: Head of the U Hydroelectric Project North Side Canal Company, Idaho, USA Focus: Final Design Phase Sample of Operation and Maintenance Considerations 1. Approach Velocity and Flow Patterns within the Forebay 2. Debris Management 3. Isolation of the Forebay 4. Accessing the Forebay 5. Cleaning of the Forebay 6. Drainage of the Forebay 7. Integrating your Turbines with your Control Gates and System Operation 17

18 EXAMPLE: Head of the U Hydroelectric Project North Side Canal Company, Idaho, USA Approach Velocity to the Structure and flow patterns within the Forebay 18

19 EXAMPLE: Head of the U Hydroelectric Project North Side Canal Company, Idaho, USA Debris Management in the Forebay 19

20 EXAMPLE: Head of the U Hydroelectric Project North Side Canal Company, Idaho, USA Isolation, Draining, Accessing and Cleaning of the Forebay 20

21 EXAMPLE: Head of the U Hydroelectric Project North Side Canal Company, Idaho, USA Making your Turbines work with your Control Gates and System Operation 21

22 EXAMPLE: Jordanelle Dam Hydroelectric Project Central Utah Water Conservancy District, Utah, USA Focus: Construction Phase SIZE Twin 6.5 MW horizontal Francis units Rated head: 270 feet Maximum total flow: 600 cfs SETTING Central Utah Water Conservancy District (Owner) Lease of Power Privilege Addition at existing federal dam. Stringent operating constraints and design review by Reclamation. Operates on programmed releases. FOCUS Construction supervision to confirm what was designed is installed 22

23 EXAMPLE: Jordanelle Dam Hydroelectric Project Central Utah Water Conservancy District, Utah, USA Focus: Construction Phase Sampling of Construction Inspection 1. Shop Drawing Review 2. Lining Inspection 3. Trench Inspection 4. Connection Inspection 5. Shoring Inspection 6. Field Protection 23

24 EXAMPLE: Jordanelle Dam Hydroelectric Project Central Utah Water Conservancy District, Utah, USA Shop Drawing Review and Lining Inspection 24

25 EXAMPLE: Jordanelle Dam Hydroelectric Project Central Utah Water Conservancy District, Utah, USA Penstock Trench and Connection Inspection 25

26 EXAMPLE: Jordanelle Dam Hydroelectric Project Central Utah Water Conservancy District, Utah, USA Erection, Shoring, Field Protection 26

27 EXAMPLE: Dewitt Pipeline Hydroelectric Project City of Logan, Utah, USA Focus: Commissioning Phase SIZE Single 220 kw horizontal Francis unit Rated head: 146 feet Maximum total flow: 22 cfs SETTING City of Logan, UT (Owner) FERC Conduit Exemption Pipeline upgrade. Addition at existing flow control vault in parallel with control valve. Critical surge control on long pipeline. Operates on raw water supply flows. FOCUS Commissioning Expect the Unexpected 27

28 EXAMPLE: Dewitt Pipeline Hydroelectric Project City of Logan, Utah, USA Focus: Commissioning Phase Sample of Commissioning Considerations 1. Everything is Tested Real-Time 2. Net Head will Dictate Equipment Performance and Its Confirmation 3. Full-Load Rejections are often the Acid Test of the Penstock 4. Careful and Systematic Testing are Essential to Safely Running Plant and Penstock Through its Paces 28

29 EXAMPLE: Dewitt Pipeline Hydroelectric Project City of Logan, Utah, USA Focus: Commissioning Phase ADDITION OF FLYWHEEEEL TO MANAGE UNIT OVERSPEED SURGE EFFECT BURIED SURGE STANDPIPE EXTENDED UP HILLSIDE 29

30 EXAMPLE: Dewitt Pipeline Hydroelectric Project City of Logan, Utah, USA The Unexpected 30

31 Questions? Presenter Dan Murrer, P.E. 322 East Front Street Suite 200 Boise, ID Tel NWHA 2014 Small Hydro Workshop September