Project no.: 015286 CRESMED Cost Efficient and Reliable Rural Electrification Schemes for South Mediterranean Countries Based on Multi User Solar Hybrid Grids<br/><br/>STREP Integrating and Strengthening the European Research Area<br/><br/>D-15 Hydroelectric turbine presentation<br/>Due date of deliverable: December 2007 Actual submission date: February 2008 Start date of project: January 1, 2006 Duration: 42 Months<br/><br/>Organisation name of lead contractor for this deliverable: Trama TecnoAmbiental Revision 1<br/>Project co-funded by the European Commission within the Sixth Framework Programme (20022006) Dissemination Level PU Public PP Restricted to other programme participants (including the Commission Services) RE Restricted to a group specified by the consortium (including the Commission Services) RE CO Confidential, only for members of the consortium (including the Commission Services)<br/><br/><br/>Contract 015286 (INCO) - CRESMED Document: Deliverable 15 ­ Hidroelectric turbine presentation WP 3 Task 3.5 Final use- I Description: Hidroelectric turbines for system integration in MSGs Language English Responsible: Stefano Quaranta Revised by:<br/><br/>Date:08.01.08<br/><br/>Version:01 Level: WD Nš pages:15<br/><br/>Author: Stefano Quaranta Date Comments<br/><br/>WORK PACKAGE 3<br/><br/>DELIVERABLE 15: Hydroelectric turbines presentation<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 1/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>Content<br/>1 2 Executive summary ____________________________________________________ 3 Technical aspects ______________________________________________________ 4 2.1 Hydroelectric physics _______________________________________________ 4 2.2 Hydroelectric turbines: functioning and classification ______________________ 4 2.3 Technology ______________________________________________________ 5 3 Project feasibility ______________________________________________________ 7 3.1 Target countries___________________________________________________ 7 Overlook _____________________________________________________________ 7 Morocco _____________________________________________________________ 7 Algeria ______________________________________________________________ 8 3.2 Suitable hydroelectric turbines _______________________________________ 8 Turbines PT 06-H1 and PT 09-H1 _________________________________________ 9 Turbines PT 02 and PT 04 ______________________________________________ 11 Turbines KT 35 and KT 50 ______________________________________________ 13 4 Conclusions _________________________________________________________ 15<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 2/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>1<br/><br/>Executive summary<br/><br/>Hydroelectric field technologies are reckoned to be mature ones (meaning that no consistent innovations are expected). The industrial exploitation of hydro sources has almost reached its upmost in Europe thanks to the early start as far as two centuries ago. Looking further to other countries and extending the view to lower scale plants, many interesting uses can still be focused, especially out of the typical industrial use. This is the case of aqueduct falls or little turbines placed on water threads or mountain torrents, exploited for energy consumption by small villages, or even on irrigation canals and so on. The main objective of this document is to give decision makers, in the figure of public bodies, energy managers and environmental analysts a tool for evaluating the use of systems for decentralised as well as stand-alone energy production contributing to lower down other sources of energy such as fossil fuels and/or mitigating the scarcity of resources. The dossier is also voted to final users wanting to build their know-how on the best technologies that could be applied to domestic uses.<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 3/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>2<br/>2.1<br/><br/>Technical aspects<br/>Hydroelectric physics<br/><br/>Hydroelectric turbines make use of water mass potential energy contained in the difference of height, defined head, existing between a high watermark and a low watermark. The transformation from potential to mechanical water energy happens by mean of turbines, put in rotation by the water mass flowing in. This mechanical energy at the turbine axis can be used directly as mechanical work (e.g. watermills) or producing electric energy by connecting the turbine axis, through specific reductions, to an alternator. Power obtained by an hydroelectric turbine can be expressed with the following equation: P=gQH where: P  g Q H = = = = = electric power (kW) transformation process global efficiency (*) gravitational acceleration (m/s2) water flow (m3/s) net head (m)<br/><br/>(*) Global efficiency is intended as the percentage of power that can actually be obtained in comparison to the technical potential, keeping into account the losses due to the transformation process.<br/><br/>2.2<br/><br/>Hydroelectric turbines: functioning and classification<br/><br/>The hydro electric turbine is a motive machine providing water potential energy transformation to mechanical energy. It is made out of: a distributor with the function of driving and regulating of the water flow injected to the impeller and the hydraulic function of potential to kinetic energy transformation; an impeller moved by the water exiting the distributor, with the function of transmitting mechanical energy to the shaft on which it is mounted. Respect to their dynamic characteristics the turbines can be classified as follows: Action turbines in which the water energy coming out from the distributor is entirely kinetic (transformation from potential to kinetic energy is made by mean of a nozzle<br/>I1 Project: Internal document : Hydroelectric turbine presentation CRESMED Responsible: Stefano Quaranta Page 4/15 Date: 08.01.08<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>shrinking the diameter of the pressure pipe). Along the path through the impeller the flux is at atmospheric pressure. The only action turbine in practical use are PELTON turbines. Reaction turbines in which the water energy coming out from the distributor is partially kinetic and partially pressure (transformation from potential to kinetic energy is incomplete: water comes out with lower speed compared to action turbines, but with a pressure not null). Reaction turbines work wholly immersed into the water and are fitted with a diffuser. There are many type of such a turbine, the most renowned being FRANCIS or KAPLAN. Depending on head and water flow at disposal different types are installed: PELTON for high falls and small flows; FRANCIS for average values of head and flow; KAPLAN for short heads and big water flows;<br/><br/>Mini-hydro is the term UNIDO (United Nation Industrial Development Organization) uses to identify hydroelectric plants of power up to 1000 kW. Within this term a further classification is used for: pico: hydro power plants up to 5 kW micro: hydro power plants up to 100 kW mini: hydro power plants up to 1.000kW<br/><br/>Adding up to the possible classifications of hydroelectric plants another way to distinguish them is based on the way they work: fluent water plants which have regulation capabilities to make use of the flow of water during the year based on the regimen of the river regulated discharge plants which can regulate water amounts through daily, weekly or monthly regulating tanks. Regulating capabilities depend on tanks capacity.<br/><br/>2.3<br/><br/>Technology<br/><br/>Even if the same power can be obtained both by hydro plants using big water flows and short falls or by high heads and low water flow plants, the micro-hydro plants usually focus on very small flows as well as short net heads. The power one can get from a power plant, given the same head and water flow, depends on the transformation process global efficiency: approximating this efficiency it is suggested to choose an overall value lower then the one attributed to bigger power plants, usually choosing it in this range: 0,5 &lt;  &lt; 0,7<br/>I1 Project: Internal document : Hydroelectric turbine presentation CRESMED Responsible: Stefano Quaranta Page 5/15 Date: 08.01.08<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>The choice of the suitable turbine is made by mean of normograms in which the input of project data (net head and water flow) allow for extrapolation of the kind and size of the turbine that fit the most. Every such turbine is characterized by its own efficiency, depending on the use rate.<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 6/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>3<br/>3.1<br/><br/>Project feasibility<br/>Target countries<br/><br/>Overlook A growing number of countries, mainly developing countries in arid areas, encounter a range of water problems which have the potential to become much worse. Real water shortages are being experienced and water quality and environmental problems are becoming more widespread and complex. There is no need to elaborate more on these issues as a general consensus is well reached now on the global appreciation of the situation, its seriousness and the urgent need to act now. Countries like Morocco and Algeria have no choice. They must make a decisive break from past policies and management practices to embrace a holistic water sector approach that is economically, socially and environmentally sustainable. Morocco The emphasis in Moroccan development planning has been for the last three decades on maximizing the capture of the country's surface water resources and providing for their optimal use in irrigated agriculture, potable water supplies, industrialization and energy generation. Enormous capital resources have been invested in the essential infrastructure to control surface water flows. Infrastructure to capture and utilize about two-third of surface water potential is in place and a number of major infrastructure projects are in advanced stages of planning and/or construction to capture most of the remaining potential. Despite remarkable achievements, Morocco faces a growing challenge in the water sector. The main issues and constraints can be summarized as follows: Decline in available water resources Rapid degradation of water Inadequate maintenance of existing infrastructure and silting of reservoirs Low level of provision of potable water to rural population Low water use efficiency in irrigation<br/><br/>Morocco's water economy is now characterized by sharply rising costs of supplying additional water and more direct and intense competition among different kind of water users and uses. In this context, a better mix of increasing supply and demand management can be considered as the most rational response to water scarcity. Finally, there is a felt need to strengthen the institutional capacity and develop a more cohesive and integrated legal framework moving away from sector based legislation. Furthermore, it is necessary to develop a rational mechanism for intersectoral water allocation and to adopt a coherent water strategy and planning to guide its effective use<br/>I1 Project: Internal document : Hydroelectric turbine presentation CRESMED Responsible: Stefano Quaranta Page 7/15 Date: 08.01.08<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>and management. Algeria Algeria is one of a number of African nations predicted to have a ratio of water annually available per person at less than 1,000 cubic metres in 2025, a daunting figure when experts consider a country &quot;water-stressed&quot; at below 1,700 cubic metres available per person. Although government officials are working with international experts to increase water supplies to both rural and urban areas the task remains difficult. &quot;There are many construction sites that need to be opened in the water supply sector because our natural resources are not sufficient,&quot; says Water Resources Minister Abdelmadjid Attar. &quot;We are obliged to appeal to foreign companies as much for material needs as for a desire to master new technologies.&quot; Government officials are in a race against time to maximize the already scant water resources. Building new dams, reducing dam silting, used-water treatments, preventing water loss and waste and desalinization projects are some the efforts underway. To repair the estimated 30 per cent of water pipes in Algeria that leak, the government has earmarked 53 billion dinars. Projects are underway in Algiers and Oran, with an additional 16 of the 40 cities slated for repairs targeted in the next phase. On the coasts, about 50 desalinization facilities are under construction to supply water. Attar says the process is one of the major alternative technologies being utilized by Algeria because dams are only sufficient to keep shortages at current levels. As many as 50 dams and other water-containing structures are also under construction to meet the Ministry of Water's goal of 12 billion cubic metres of water collected annually by Algeria. Currently, only 5 billion cubic metres are collected annually. Years of drought have depleted ground water supplies and dam reserves. Additionally, Algeria suffers from substandard management of water utilities and other existing networks. In order to manage all this hydraulic sector construction, two government agencies were created. Goals of the agencies include fostering annual and multi-annual investment programmes and undertaking projects through concessions or any form of partnership. A December 2004 meeting in Tipaza of Mediterranean countries under the auspices of the 1971 Ramsar Convention on Wetlands announced that 16 new Algerian areas are officially classified as wetlands of international importance, a designation that protects them from destruction and overuse. Conservationists are excited about the decision. Involvement in Algerian water management is not just restricted to international corporations and global conservation organizations, individuals are also making a positive impact.<br/><br/>3.2<br/><br/>Suitable hydroelectric turbines<br/><br/>A bunch of hydroelectric turbines is shown below, describing their technical features and covering up most of the possible scenarios focused in the previous paragraphs.<br/>I1 Project: Internal document : Hydroelectric turbine presentation CRESMED Responsible: Stefano Quaranta Page 8/15 Date: 08.01.08<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>Turbines PT 06-H1 and PT 09-H1 Compact hydro electric unit for mobile or stationary application with Pelton turbine (one nozzle), synchronous generator, switchboard and governor for isolated operation or to be fed into existing bigger grids. Applicable for the following ranges: Net heads: Discharges: Turbine outputs: Generator outputs: Turbine speeds: Runaway speeds: Generator speed (50/60 Hz): Hn QA PT PG n1 nd n2 = = = = = = = 5 - 200 1 - 40 l/s 1,5 - 35 1,0 - 30 290 - 2300 520 - 4140 1500 - 3000 m kW kW min-1 min-1 min-1<br/><br/>Turbine housing Aluminium-Titanium alloy, founded; consisting of bipartite housing, shaft feed-through openings on both sides sealed by means of labyrinth seal; all connecting and sealing surfaces are mechanically worked. Foundation frame Steel St 360 C, welded, hot galvanised; common base frame for the incorporation of the<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 9/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>turbine casing and the generator. Turbine shaft Stainless Steel 1.4301. Turbine shaft bearing Well dimensioned roller bearing in plummer block; prepared for grease lubrication. Shaft sealing Labyrinth sealings and splash proof centrifugal rings are mounted on the turbine shaft. Runner One piece Pelton runner made of Aluminium, fine grinded; runner dynamically balanced and attached on the turbine shaft by means of fit-in key. Nozzle elbow Aluminium-Titanium alloy, founded; connecting and sealing surfaces are mechanically worked; one-sided longitudinally arranged needle bar guide bush, therefore no possibility for plugging; tested for 1,5 - fold nominal pressure, incl. pressure gauge (3/8&quot;-65 mm). Nozzle end Chrome-nickel steel 1.4301, hardened, changeable. Needle Chrome-nickel steel 1.4301, hardened, changeable. Needle bar Rust and acid resisting steel 1.4301; sealed twice by means of sealing rings; beared in maintenance-free slide bearing bushes. Needle adjustment Threaded spindle with handwheel, position indicator with scale in mm and pointer. Belt transmission: Pulley made of Aluminium; long-living plastics flat belt with contact surface made of leather and belt guard. Connecting tubes: All connecting and fixing tubes are made of rustless material. Corrosion protection: Surfaces in contact with water: no corrosion protection, because made of Aluminium or stainless steel, surfaces in contact with air: 1 priming coat Friazink R 40 my, 1 finishing coat 40 my, surfaces to be embedded in concrete: no treatment.<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 10/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>Turbines PT 02 and PT 04 Compact small scale hydroelectric power plants for the generation of power to charge batteries (12/24 V) or supply power consumers (110V/220V/380V) for isolated operation or to be fed into existing bigger grids. Range of capacity: 50 Watt to 5 kW. Net heads: Discharges: Turbine outputs: Hn QA PT = = = 5 ­ 200 1­5 50 ­ 5000 m l/s W<br/><br/>Turbine with Pelton runner; optionally equipped with one to four fixed or adjustable nozzles. The casing can either be mounted over an open flume or fixed on a pipe outlet. A screw neck is provided on the casing for the connection of the penstock. A pressure gauge is screwed in the upper side of the casing. Generator with extended shaft. Turbine runner is mounted on the generator. Optionally the following types of generators can be employed: D.C. generator, single or three-phase<br/>I1 Project: Internal document : Hydroelectric turbine presentation CRESMED Responsible: Stefano Quaranta Page 11/15 Date: 08.01.08<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>generator. The generator is fixed in vertical shaft position directly on the turbine casing. Switchboard consisting of voltmeter, ammeter, generator fuse, optionally either to choice electronic load governor or speed regulator as well as connecting terminals.<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 12/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>Turbines KT 35 and KT 50 Split turbine with a three blade Kaplan runner, runner diameter 355 mm, un-adjustable runner blades, fixed wicket gates. KT 35 1-6m 100 - 750 l/s 2,5 - 40 kW 1,8 - 35 kW 520 - 1280 rpm 1665 - 4100 rpm 1500 - 1800 rpm KT 50 1-6m 300 - 1500 l/s 2,5 - 60 kW 1,8 - 50 kW 350 - 1000 rpm 1200 - 3200 rpm 1500 - 1800 rpm<br/><br/>Net heads: Discharges: Turbine outputs: Generator outputs: Turbine speeds: Runaway speeds: Generator speed (50/60 Hz):<br/><br/>Hn QA PT PG n1 nd n2<br/><br/>Butterfly valve Spherical iron casting GGG 50 or steel, installed for the closing of the water discharge on the turbine intake flange; including hand lever Turbine housing Steel St 360 C, welded, hot galvanised; consisting of intake tube with connecting flange and cleaning opening, driving pit with bearing brackets and generator base frame with belt tensioning device, external intake cone with guide vanes, internal guide vane cone with bearing housing; all-connecting flanges are machine-faced Draft tube cone<br/>I1 Project: Internal document : Hydroelectric turbine presentation CRESMED Responsible: Stefano Quaranta Page 13/15 Date: 08.01.08<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>Steel St 360 C, welded, hot galvanised; bi-partite, straight, with dismantling flange and inspection eye Turbine shaft Steel Ck 45 Turbine shaft bearing Low-maintenance grease lubricated roller bearings, the main bearing on pulley side consists of axial and radial bearing, guide bearing on the runner side; including all lubricating conduits Bearing sealing Guide bearing sealed by means of a sliding ring seal Runner blades Aluminium Nickel bronze CuAl10 Ni; fixed on the runner hub by means of attachment screws Runner hub Aluminium Nickel bronze CuAl10 Ni Runner adjustment Adjustment of the runner blades within the range of 15 - 100 % is possible during closed down condition. This can be done by loosening the attachment screws Discharge ring Spherodical iron casting GGG 50 Guide vans Three-dimensionally bent, made of spherodical iron casting GGG 50 Belt drive Siegling Polyamide flat belt with leather-coated running surface; pulley made of steel, welded Corrosion protection All the connecting elements in contact with water are made of rustproof material. As far as steel parts are not hot galvanised, the following corrosion protection is provided: All the surfaces will be de-rusted by sandblasting (SA 21/2). All the steel parts in contact with water are provided with two priming coats of zinc dust (2 x 40 my) and with three antifouling top coats based on Epoxy-pitch (2 x 50 my). The surfaces in contact with air are provided with two priming coats of zinc dust (2 x 40 my) and one top coat with Epoxytwo components lacquer (1 x 30 my).<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 14/15<br/><br/>Work Package : 3 ­ Power technologies<br/><br/><br/>4<br/><br/>Conclusions<br/><br/>Perhaps European sites eligible for hydroelectric exploitation have been found out and used for years at the time of writing. With a delay of few decades knowledge and technologic advancements done in these sector can focus on new areas and get the most out of them. Mediterranean countries taking part to the CRESMED project can take great advantages from the use of such technologies and know-how. The path through out technical and economical aspects, as well as the presentation of some real solution out of the several ones on the market has been proposed to promote a first step in this direction. Particular emphasis has been put on the use of very small size hydroelectric installations in order to extend as much as possible the use of this source or energy and suggest the investigation of most of the water sources, despite the attitude to think only about rivers for energy production. Hydropower generation in Algeria and Marocco can be undoubtedly a way important for economy development and social aspects comprised into it and, has shown, it is finally only a question of choices.<br/><br/>I1 Project:<br/><br/>Internal document : Hydroelectric turbine presentation CRESMED<br/><br/>Date: 08.01.08 Responsible: Stefano Quaranta Page 15/15<br/><br/>Work Package : 3 ­ Power technologies