6.3.

Hydromechanics and Mechanics Equipment Introduction

Based on the data from the hydro-construction part of the project, to facilitate the production of the mechanical part of the project, the following startup data are derived: Installed flow of the power plant

Qinst =18 m 3/s Installed flow of the bigger aggregate m3/s

Installed flow of the smaller aggregate

14,5 3,5

m /s
3

Elevation of normal slow

194,50 mnm
Elevation of the lower water for the installed flow

191,75 2

mnm
Number of aggregates

(bigger and smaller)

Losses in the flow tract

Hg=0,2 m

(In consideration taken losses in siphons output, while the rest of losses are of inconsiderable size)

For the provided downfalls, of around 3 meters, the priority is given to the tube-axial- aggregates, comparing to the rest aggregates types. Into consideration are taken 3 types of tube aggregates:
Classical tube turbine has been discarded because of the small diameter of the impeller (not recommended if the impellers diameter is less than 3 meters)

S-turbine has been discarded because of the mechanicals construction size

BEVAL-GEAR tube turbine, which has been accepted as the best solution for both aggregates (see the picture below)

Picture 1: An example of the tube turbine BEVAL-GEAR construction

Axial turbines can be effectively used in the small hydro-electric plants, as per requests in the terms of flows (power) variation, they can be managed to have double regulation regulation by the blades of the rotating field and by the blades of pilot machine. As hydro-turbines for the small downfalls have small rotating frequency, in the most frequent use within the axial-turbines is the multiplicator, with a purpose of use a standard generator, with its economic justified rotating frequency. 2. Basic equipment in the mechanical construction Biserka, hydro-electric plants mechanical construction, is a dam type. Dimensions of the mechanicals construction base are defined: by the geometry of the turbines flow parts, by quantity of the equipment and by the areas, which is needed to set on the various appropriate elevations: turbines, generators, head covers, electric tables and cupboards, and supporting machines based on the adequate norms and rules. Outside dimensions of the mechanical hall are 12.25m x 20,17m. Inside the

mechanical building dimensions of 11,25m x 13,80m, there are two turbines aggregates situated, of the 4,70m axis spacing. Montage space has not been anticipated, yet the aggregates will be handled by the boom truck through the holes on the mechanical constructions roof.

2.1. Turbine The tube turbines have been chosen, with the conic multiplicator and dual regulation: regulation by the blades of impeller and by the blades of pilot machine. In such a way, a wide range of turbine work is covered with optimal range of usefulness, though turbine and turbines regulator are slightly more expensive.

Basic technical data of bigger turbine: the type of turbine (BEVEL-GEAR) type of generator (synchronus) nominal downfall maximal downfall nominal flow minimal flow number of the rotating frequency diameter of impeller 2,55 m 3,29 m 14,5 m 3/s 3,6 m 3/s 111,87min -1 cca. D1=2,10 m tube

nominal turbines power 334 kW expected level of the turbines efficiency in the normal working point 0,925

Basic technical data of smaller turbine:

the type of turbine (BEVEL-GEAR) type of generator

tube

(synchronus) nominal downfall maximal downfall nominal flow minimal flow number of the rotating frequency diameter of impeller 2,55 m 3,31 m 3,5 m 3/s 1 m3/s 250 min -1 cca. D1=1,0 m

nominal turbines power 80 kW expected level of the turbines efficiency in the normal working point 0,91

The main units of the both turbines types, smaller and the bigger are:

penstock valve stator with pilot machine impeller impeller housing with siphons cone turbine housing

The penstock valve is made of concrete, whose right angled pipe section is of dimensions: in the bigger 3.40m x 6.24m and 1,70m x 1,80m in the smaller aggregate and shift to the circuit, of the diameter 3,40m (bigger aggregate) i 1,70m (smaller aggregate). Intakes dimensions are defined in such a way, that the stream speed through the lattice, on the water well is of approximately 1 m/s. A cavity is done just in the vertical direction, by the hydraulic shaped grasp, yet the sideways are vertical. Stator of the turbine is joined with the penstock valve, and by the flanges, with the armature of the impeller.

On the upstream part of the stator are stairs for the leaning on the concrete panels implemented into bearer concrete pillars.

The impellers housing and cone of siphon are one complex, divided horizontally, because of the turbines montage of the impeller and joined with turbines stator on the upstream side, and with the siphon on the downfall side. It has been constructed of the stainless steel in the zone of runners blades. Upper leg of the siphon is ribbed, of the steel construction which can be divided horizontally as well. It leans on the concrete panels and pipes. On the lowest elevation of the siphon is a drainage sink-hole for the soaking-out.

In the parallel processing of the hydro-electric plant and the network, the upper water level is kept on the 194,50 mnm elevation, yet the water energy has been transformed to electricity which has been placed into distribution. The excess water which inflows to the hydro-electric plant and cant be transformed to the power, overflows through spillways.

Productive aggregates in the parallel processing with the network, work automatically without permanent human input. Beside that, turbine i.e. generator could be conducted locally and from the turbine i.e. generator control apparatus.

Fast blocking (shutdown) of aggregates is needed:

if the cyclic shift goes excessively which is a protection of runaways if a hydrodinamic lubrication stops, and a water flows stops in the supporting machines and if the pressure in the hydrodinamic lubrication declines to some point.

2.2. Equipment of turbine regulation

Based on the feature of a small hydro-electric plant in the electrical network, the level of automation, turbine category and system flow, as well as the consumers characteristics, the most profitable choice of the control equipment has been made.

a) Mode and type of regulation Within the parallel functioning of aggregates with a large electrical network, a regulator performs to the turbines regulatory organs. Regulatory quantities are: level of the upper water potency of aggregate the flow through turbine b) Basic technical requirements for the turbines control apparatus Regulation system of the hydro-aggregates with the tube turbine (i.e. when the blades of directed apparatus and impellers are regulated) is based on the combinatorial conjunction. Equipment of the turbines regulation has to fulfill the following main functions: startups sequences and shutdowns of the turbine and supporting machines setting and descent of the regulatory loading aggregate shutdown following the security measures signals

Control apparatus must have a facility of the manual conduction on the mechanism for startup and mechanism for shifting aggregates power. Apparatus for the rotation frequency speed control must to provide a stable regulation within the functioning of aggregate namely: in the idle motion when the generator is disconnected from the network

without loading or with loading up to 10%, for the supply of private consumption consumers in the idle motion parallel with the network Within load changes

Rotating frequency regulator is acting by hydraulic system within oillubrication under pressure. Regulatory system of turbine must have enough standby energy within all working strokes, to ensure expected regulation and turbines shutdown in the emergency case. Regulation speed response, which determinates quality of regulation, is needed to adjust with characteristics of water flow system and impetus aggregates volumes. This process will ensure required safety and operation reliability of small hydro-electric plant. System of turbine regulation is made of device for the rotating frequency speed, programmable logic controllers (PLC), hydroelectric governor system and unit for the turbine pump oil-lubrication.

Programmable logic controller is situated in the cupboard of hydro-electric power and its delivery is included in the equipment supply. Sensors for the level measuring in the accumulation, outflow, rotation frequency and the placement of servo motors pistons, are included as well in the shipment of the controller. Electro hydraulic-managing unit of the regulator, accommodate the elements; they operate servo motor of the pilot machine and impeller, in the accordance with orders from digital regulator; pilot dividing valves (commensurable valves) are involved for automatic-continual operating with servo motors, and electro-magnetic and hydraulic commanded valves, for common average shutdown. Device for the oil-lubrication under pressure is anticipated, for both aggregates, and is made of steel reservoir for oil, two operating and one spare oil-pump fitted on the reservoir, oil-hydraulic accumulator, pipeline and pipe fittings. Pressure level of oil-installation would be accordingly maintained to a standardized technical solution of equipment distributor, for the pressure of 100 bar or more.

Mechanism of pilot machine is equipped with contra-weight which acts in the case of trapped blades (one or more) of pilot machine.

2.3. Multiplicator To increase a number of the rotating frequency turbine to a number of synchronic generator, it is anticipated conic one-level multiplication. a )Bigger aggregate: Inlet number of rotation Outlet number of rotation Expected level of efficiency Multiplicator number a) Smaller aggregate 111,87min -1 750 min -1 0.96 1

Inlet number of rotation Outlet number of rotation Expected level of efficiency Multiplicator number

250 min -1 1000 min -1 0.96 1

2.4. Supporting equipment in mechanical construction 2.4.1 Drainage and discharge Equipment for drainage of mechanical construction and equipment for discharge of water flow are implemented to one complex. Oozed waters through the walls of hydro-electric plants and turbines are collected by gravitational drainage watercourses, and carried on into drain hole; the hole that is situated on the lowest elevation of mechanical construction. From this drain hole, by the pipeline, water goes to the cumulative drain outflow of mechanical construction. Drainage of pre-turbine chamber is done by grasp on the penstock valve and the concrete part of concrete pipeline; on the spot where pipeline penetrates into hydro-electric plant, is flat gate valve, operated manually. Siphons

drainage is done through grasp on the lowest point of the siphon, by steel concrete pipe. On this pipe is flat gate valve. Via pipeline system, water goes gravitationally to the cumulative drain outflow and by pumps, there, is soaking-out of the outflow turbines tract. Drainage and soaking-out of the outflow of the turbine tract, is done by one or two pumps for each of aggregates. Each pump has separated pipeline with back circuit. Soaking-out of back-circuit is to the tailwater, downfall of the siphon head-cover, above the reservoirs elevation. (hundred years high water) 2.4.2. Hitting and aeration

It is not required to warm up mechanical construction with extra energy sources, for the minimal positive temperature in nominal working conditions, considering that generators release heat in the working phase, by dissipation. To maintain hitting in the winter period which is needed for equipment service in the mechanical building (screenings, repairs, breakups, etc.) while generators are not in drive, it is anticipated to have plug box for an electric hitter. While summer, mechanical building is aerated naturally via gateways of waste heat, in the generators working phase. For that purpose, is lattice maintained on the outside wall, above the entrance of mechanical construction. 2.5. Hydro-mechanical equipment of mechanical construction 2.5.1. Inlet lattice Lattice prevents penetration of floating objects (traversals, wood, plastic bottles, etc.) inside the turbine. It is consisted of two panels, whereas each of them has strips, in the brazing process mutually, solidly coupled with transversed girders. Basic technical data of lattice of bigger aggregate: Lattice width Lattice height Elevation sill lattice The upper elevation in front of lattice 3.9 m 6.5 m 187.47 mnm 194.50

Bevel of lattice toward horizontal level Number of segment Gaps between strips Dimensions of strips mm Number of lattice 2 80 mm

85

80 mm x 10 1

Basic technical data of lattice of smaller aggregate: Lattice width Lattice height Elevation sill lattice The upper elevation in front of lattice Bevel of lattice toward horizontal level Number of segment Gaps between strips Dimensions of strips Number of lattice 1.97 m 3.2 m 188.60 mnm 194.50 85 2 50 mm 70 mm x 8 mm 1

2.5.2. Upstream multi-pieced head-cover On the entry of penstock valve, beside the inlet lattice in the upstream direction, is recess situated, for the rigging of head-cover. Its feature is to prevent water inflow into the turbines flow tract, if turbine is under screening or repair. The head-cover is multi-pieced, paneled shape (stop-log). It can be lifted and lowered by boom-truck of adequate capacity.

Basic technical data of head-cover of bigger aggregate:

Type of head-cover

Multi-pieced paneled

 Width of light hole Height of light hole Elevation of head-covers sill Elevation of platform for maintaining head-cover covercover Manipulation Number of head-cover

3.91 m 6.10 m 187.50 mnm 197.00 mnm Boom truck 1

Basic technical data of head-cover of smaller aggregate:

Type of head-cover Width of light hole Height of light hole Elevation of head-covers sill Elevation of platform for maintaining head-cover Manipulation Number of head-cover 2.5.3 Siphons head-cover

Multi-pieced paneled 1.96 m 3.0 m 188.60 mnm 197.00 mnm Boom truck 1

For the purpose of water isolation from the downfall side of hydro-electric plant, in cases of screening and repair of turbine flow tract, siphons headcover is anticipated. Head-cover has been lifted and lowered by bridge crane. While the normal turbines work, head-cover is always in complete open degree, and is situated in concrete slideways. A siphons head-cover is without an automatic shutdown possibility and the protection of turbines move off, as the lower price and considering the type of hydro-electric plant, of relatively small power. To provide intervention in emergency cases (in the case of canceled shutdown by pilot machine), the head-cover needs an access capability into waters power by its own weight, under all levels of upper water. In this sense, stopping plate of head-cover would be from the downfall side, while the head-cover itself, would be hard with needed overweight. Basic technical data of head-cover of bigger aggregate:

Type of head-cover Width of light hole Height of light hole

Paneled with wheels 2.7 m 2.74 m

Elevation of head-covers still Elevation of platform for maintaining head-cover lower water with Qinst =18 Elevation of Nominal flow through head-cover m3/s Number of head-cover

188.01 mnm 197.00 mnm 191.75 mnm 14,5 m 3/s 1

Basic technical data of head-cover of smaller aggregate: Type of head-cover Width of light hole Height of light hole Elevation of head-covers still Elevation of platform for maintaininglower water with Qinst =18 Elevation of headhead-cover m3/s Nominal flow through head-cover Number of head-cover Paneled with wheels 1.35 m 1.30 m 188.01 mnm 197.00 mnm 191.75 mnm 3,5 m 3/s 1