Bringing Untapped Hydropower to Reality
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1 voith.com Bringing Untapped Hydropower to Reality Whitepaper 2018 Voith Mini Hydro Solutions 1 Reducing Interfaces by Turnkey Solutions 2 Customized Solutions for Standard Applications 3 Water-to-Wire and Beyond: Voith as Your Partner The Hidden Potential of Mini Hydro There are many new and lasting trends in the energy market, including renewable projects with smaller production sites that are closer to the consumer. Energy conversion by utilizing remaining potential and offsetting part of the local consumption and electrification of rural areas by renewable projects go hand in hand with the environment or larger wind, solar or hydropower projects with a local footprint and close participation of the communities. The potential is still great, even for hydropower which generally provides a huge advantage over other renewables such as: long lifetime of equipment, favorable baseload characteristics and better predictability. These advantages give additional value to grid operators who struggle with the integration of smaller, fluctuating renewables. The graphs below show hydropower s share of more than 60 % within the renewable energy mix. Small and Mini Hydro contribute 7 % to that mix. A remarkable number which still has potential to grow considering that only 36 % has yet to be developed. But the success and future scalability, especially of Mini Hydro, is not definite. Smaller hydropower sites often face the challenges of project lead times and initial investment costs due to required water construction works. So the question is: how do we tap into the potential which is clearly there? This paper shall give a first answer the Voith Mini Hydro approach. Global share of renewable energy Bioenergy 5 % Solar power 11 % Wind power 22 % Small hydropower 7 % Geothermal power 1 % Large hydropower 54 % Global installed SHP* capacity Remaining 64 % Installed 36 % Source: World Small Hydropower Development Report 2016, World Bank, ICSHP * SHP = Small Hydropower Voith Hydro at a glance Since nearly 150 years Voith Hydro is a global leader in Small Hydro providing water-to-wire solutions from a few hundred Kilowatts up to 30 MW employees 25 locations 4 competence centers for Small Hydro in Austria, Spain, India and Japan 1 10
2 Voith Mini Hydro A Comprehensive Product Line The first principle is simple: reducing interfaces in the project. The complexity of larger hydropower projects is reduced by standardization of the entire concept. The product is not just the turbine or the generator the key is the right plant solution with the integrated and standardized components as part of it. The hydropower business is much more complex as one might think. Solar and wind power plants have relatively constant boundaries, the integration of a hydropower plant into the project site has often much more parameters to deal with. Therefore the first principle is to reduce the interfaces within the plant itself and have a fully integrated solution as a whole. The Mini Hydro site Alte Bleiche in Heidenheim, Germany The Voith Mini Hydro product line is designed and driven by this principle. The StreamDiver is an outstanding example of it. The picture above shows the Mini Hydro site Alte Bleiche in Heidenheim, Germany. The turbinegenerator unit is fully submerged into the existing water channel with an integrated trash rack and gate system. This provides fish friendliness, maintains the waterway s flood capacity and combines it with a high performance power plant which is 100 % oil-free. Voith and its project partners provided planning, design, manufacturing and supply of all plant components and supervised the construction. An outstanding example of the first key principle: reducing interfaces in both, the design and the execution. Mini Hydro key facts Complete water-to-wire solutions designed and manufactured by Voith Small Hydro Competence Center Kössler in Austria. Turbine-generator units from 50 to kw Head range from 2 to 200 m Flow range from 0.3 to 15 m³/s Compact, integrated auxiliary systems Standard low voltage protection & control system Mini Hydro application range Small Hydro MW 2 MW 1 MW 10 MW 15 MW 30 MW Mini Hydro StreamDiver Tubular eq Solutions Discharge [m 3 /s] kw 300 kw 100 kw 50 kw eq Kaplan eq Francis eq Pelton Head [m]
3 Mini Hydro Products The second principle is finding the link between the application and the solution. In many aspects Mini Hydro requires smart and innovative concepts to find the best solution for a specific site and save time and cost on all aspects of the project. eq Solutions The eq Solutions comprises simplified, highly standardized turbine-generator units and its auxiliary systems. The system is pre-assembled which allows fast and easy erection at site. With integrated controls and actuators, it provides a compact and reliable water-to-wire system. Kaplan Francis Pelton 2 to 10 m Up to 150 m Up to 200 m 2 to 20 m 3 /s 0.5 to 3 m 3 /s Up to 1 m 3 /s Up to kw Up to kw Up to kw Design features Vertical double-regulated Kaplan High efficient hydraulic design Short erection time due to pre- assembled parts Compact design to optimize civil structure Directly coupled generator or speed increaser option Maintenance-friendly due to modular design Runner diameter from 0.8 to 2 m Automation (see page 5) Design features Horizontal Francis unit Compact and pre-assembled Medium head up to 125 m Runner diameter from 400 to 790 mm Optimized inlet and draft-tube parts High-quality milled runner in-house in Austria Automation (see page 5) Design features Vertical or horizontal Pelton design with 1- to 6-nozzles Inner-regulated nozzles with hydraulic actuator Compact set with integrated generator Encased in concrete or free- standing Jet deflector for load rejection Automation (see page 5) 3 10
4 StreamDiver Tubular Turbine The StreamDiver provides an industry-wide unique design which allows a simplification of the entire power house design. Lubrication and cooling water systems are not required, actuation systems for control and start-up are reduced to a minimum. A flexible and modular integration into the civil infrastructure, ease of installation and maintenance allow cost savings throughout the project phase. The Voith Tubular Turbine is designed to provide clean power from industrial water applications (e.g. sewage or drinking water treatment plants). Its focus is flexible integration, easy access and the use of standardized, off-the-shelf componets. Up to 8 m Up to 14 m 3 /s Up to 850 kw Up to 20 m Up to 4 m 3 /s Up to 250 kw Design features High-efficient propeller turbine Direct-driven permanent magnet generator River-water lubricated bearing design Completely oil- and grease-free operation Maintenance-friendly design for easy and fast service in the workshop Modular design for sites with high flow (parallel generation of multiple units) Runner regulation or variable speed as option for flow regulation Flexible integration and solution for low head run-of-river or energy recovery projects Automation (see page 5) Design features Fixed runner or runner regulation for variable flow Cost-efficient off-the-shelf generator Higher head through serial arrangement Higher flow through parallel arrangement Tubular design with high setting and easy access Special application in drinking or sewage water treatment plants Automation (see page 5) 4 10
5 1,000 h remaining Whitepaper 2018 Automation system Intelligent Hydropower Made by Voith 150 years of experience combined with in-depth digital expertise Voith brings intelligence into the digital hydropower plant. Step 1: Open up data securely in the cloud Step 2: Visualize processes detect variances Step 3: Analyze intelligently and extend service life Step 4: Run simulations and maintain proactively Step 5: Derive actions maximize revenue The Mini Hydro automation system yields as a standardized low-voltage platform for all Mini Hydro products. The design concept minimizes complexity by focusing on mandatory systems only. Additional functionality and systems can be added as options to account for local grid codes or customer preferences. Low voltage circuit breaker assembly Protection and synchronization Central plant control (common control functions) Automatic voltage regulator (AVR) Alarm and remote monitoring system House supply for support systems (motors and actuators) Uninterruptible power supply (UPS) Fully assembled stand-alone container system (option) Island operation system (option) Hydropower is already highly automated; now Voith is making it intelligent. We know the data that is important for hydropower plant operators to achieve greater efficiency, flexibility and security today and in the future. Together with our customers we are making available a pool of technical and system-related data for the power plant and its infrastructure securely in the cloud, visualize and analyze it, and develop self-learning models for well-substantiated and forward-looking decisions. Thanks to the intelligent hydropower plant, we are making the plants of our customers fit for the requirements of tomorrow. 5 10
6 Mini Hydro Applications Run-of-river Low head hydropower Energy recovery The most common application is the use of water resources in rivers with natural or man-made head and to turbinate a portion of this water. Depending on the head and flow range Kaplan, Francis, Pelton or Crossflow technologies are applicable. An important factor is the compact and flexible integration, to account for cost reductions on the civil and erection side. For many cases Voith eq Solutions will be the most suitable choice. As a special type of run-of-river, low head hydropower has a tremendous potential on waterways around the world. More than 85 % of the existing dams are not electrified yet and the majority of them have low heads. It is a question of an economic and ecological solution which makes these sites bankable. Voith s answer to it is the StreamDiver. Using non-utilized potential in existing power plants or industrial applications such as drinking or sewage water treatment plants has become more and more popular. It benefits from existing infrastructure or missing interfaces with natural flows which results in less requirements and plant components (e.g. fish protection). If it is for tubular or open-channel flows, the Tubular Turbine, StreamDiver or eq Solutions (Francis or Pelton for higher heads) cover a wide range of possible applications. Key requirements Cost-efficient concepts & products Compact, pre-assembled parts to shorten erection time High performance and flexible hydraulics Key requirements Low impact to civil structure Environmental-friendly solution Keep waterway management capabilities Key requirements Flexible integration into existing infrastructure (network, civil) Compliant with safety or usage requirements (e.g. drinking water treatment) Cost-efficient solution 6 10
7 Mini Hydro Reference Examples Brukfors, Sweden Babino Polje, Montenegro Run-of-river modernization of existing power house (Usage of residual flow) Run-of-river high head application Mini Hydro technology: StreamDiver Plant output: 250 kw Head: 4.7 m Flow: 6 m³/s Units: 1 Mini Hydro technology: Pelton eq Solution Plant output: kw Head: 186 m and 174 m Flow: 1 m³/s and 0.4 m³/s Units: 2 Commissioning: March 2015 Commissioning: May 2017 Voith scope and features Water-to-wire supply Fixed-speed, non-regulated StreamDiver Cold climate operation (submerged power house) Fish-friendly power house concept Voith scope and features Supply of complete set of mechanical equipment Turbine-generator units with auxiliaries 3 and 6-nozzle vertical Pelton Pelton turbine without jet deflector Turbine inlet valve and hydraulic power unit Distribution pipe and drainage pipe Customer benefits Oil-free, environment friendly solution in sensitive region Fast delivery in 8 months Full integration into existing automation infrastructure Low maintenance solution Customer benefits Cost-efficient design Short delivery times Significant reduction of civil foundation cost by housing design High quality and performance 7 10
8 Egasaki, Japan The Tokyo Electric Generation Co., Ltd. Energy recovery drinking water treatment plant Mini Hydro technology: Tubular Turbine project Plant output: 80 kw Head: 14 m Flow: 0.7 m³/s Units: 2 (serial arrangement) Commissioning: 2003 Voith scope and features Complete electromechanical equipment Tubular Turbine-generator units Connection integration in existing system Propeller units (non-regulated) in serial arrangement Low voltage protection and control equipment Customer benefits Offset own load by 80 kw Integrated pipe system, easy to access Standardized, off-the-shelf components Short delivery and project execution time 8 10
9 Water-to-Wire and Beyond: Voith as your Partner The second driving principle was the link between the application and the solution. The third factor now refers to the first one reducing the interfaces. Projects on the lower end of the output scale hardly pencil off if the setup is not right from the start. Early involvement, transparent planning and a partner approach is key to bring more projects to realization. Project identification Project feasibility Project design Construction Operation Solution development Finding the best solution for a site is not straight forward. No matter if you are a project owner or a project engineer. Voith and its partners will support you by developing a comprehensive solution which considers your site-specific requirements. Planning support During the design phase of your project the interfaces to the equipment supplier are crucial. Voith s project design office will manage or assist you with these interfaces. Training You are interested in further training on plant operation or other special topics around hydropower. Ask us! Early project Pre-feasibility check You identified a site and want to know whether this can be a profitable opportunity? We can assist you or bring you in touch with the persons who do! Financing support You have a profitable project, but you are interested in further equity? Voith can support you finding equity and other financing options. W2W OEM We deliver what we ve promised. Voith can provide a comprehensive package from the hydropower resource up the grid connection point. Service We know our products and how to service them. We can provide service packages which suits your requirements and save operational costs, downtime and risks. 9 10
10 The importance of Hydropower Renewable energy is undoubtedly the most sustainable answer to the rise in energy demand. Hydropower plays a key role in sustainable and environmentally friendly power generation and is the leading renewable source of electricity generation globally. Worldwide it makes an indispensable contribution to a stable power supply which supports economic and social development in both industrialized countries and in high-growth regions. Since the early days of hydropower Voith has been and continues to be a leading supplier and innovator of hydropower technology. About the company For 150 years, Voith technologies have been inspiring its customers, business partners and employees all over the world. Founded in 1867, Voith today has around employees and earns 4.3 billion euros in sales. It has locations in more than 60 countries and is one of the largest family-owned companies in Europe. As a technology leader, Voith sets standards in the energy, oil & gas, paper, raw materials and transport & automotive markets. Editor Philipp Daus Global Product Manager Product Line Mini Hydro Voith Hydro GmbH Alexanderstr Heidenheim, Germany Philipp.Daus@Voith.com Tel Stay tuned and keep track of exciting news on Mini Voith in 2018: Visit our Website: VH 3416, en, vvk, Dimensions and illustrations without obligation. Subject to modifications. Voith Hydro Holding GmbH & Co. KG Alexanderstr Heidenheim, Germany 10 10
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