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Derrick Boltt Southern Region Hydro Generation Eskom South Africa Hydro Power in the S/Region

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Derrick Boltt Southern Region Hydro Generation Eskom South Africa Hydro Power in the S/Region Derrick Boltt Southern Region Hydro Generation Eskom South Africa Hydro Power in the S/Region. History of Hydro in the S/Region. • In 1980 the former Transkei government financed the development of Hydro power schemes in the Eastern Cape . • Four Hydro Electric stations were built between 1980 and 1984 in the region. • The stations were allocated to the Transkei Electricity Supply Corporation. (Tescor) • The Four Facilities were handed over to Eskom Southern Region in April 1995. The Four Stations Are: • Collywobbles on the Mbashe river system approximately30kM east of Idutwya . • First Falls on the Mthatha river situated approximately 5kM east of Mthatha. • Second Falls on the same river about 15kM down stream from First Falls. • Ncora on the Tsomo river approximately 50kM west of Engcobo in the North. Mbashe Hydro Station. Mbashe From the Air 2nd Falls Hydro Station. 1st Falls Hydro Station Ncora Hydro Station. Southern Region 06/09/2004 10 SOUTHERN HYDRO INTERCONNECTION FLOW PLAN AND ELECTRICAL INTERCONNECTION Tsomo River Gauging weir LEGEND Mgwili River Umtata River Ncora Irrigation Xuka River ELECTRICAL SWITCH Ncora Dam Bypass RIVER WATER VALVE CONTROL Tsomo River Mbashe River Ncora Hydro ELECTRICAL Hydro TRANSMISSION LINE 3.3/22/66kV Ncora Load Municipal Gauging weir Qumbu/Dumasi Line First Falls Balancing Dam 132/66kV First Falls 132/66kV Hydro 11/66kV Butterworth Second Falls Load Port St. Johns Umtata Balancing Dam Butterworth Network Load 132/66kV S/S Mbashe Second Falls Weir Hydro 11/66kV Hydro Mbashe 132kV line River Umtata River from Pembroke Collywobbles Hydroelectric Scheme 11/66kV NCORA DAM 90 MCu capacity Over Flow from Ncora Dam MTHATHA DAM 250 MCu capacity Mbashe Buffer Dam Overview of Collywobbles/Mbashe • Mbashe has three 14MW units with the provision for a future fourth machine. • Penstock is 1.4kM long by 4.6m diameter dual lined tunnel operating at 14 bars. • Plant does not have SCO capability due to the design of the draft tube and tail race. • Siltation of the dam has significantly reduced the available water reserves. • Water consumed on full load is 38m3/sec. Mbashe Hydro Gens Salient Pole Rotor and Stator Mbashe Spare MIV and Penstock Mbashe Generator Floor Overview of Second Falls • The station has two 5.5MW units with the provision for a future third machine. • Penstock is 44m long by 3.5m diameter steel tunnel that operates at 4bars. • Water is discharged from 1ST Falls and reaches 2nd Falls about eight hours later. • Both units are modified for SCO mode. • Water consumed on full load is 25m3/sec. • Station was totally refurbished in 2000. 2nd Falls Hydro Generators 2nd Falls From the Road. Overview of First Falls • The station has two 3MW units with the provision for a future third machine. • Penstock is 27m long by 2.7m diameter steel pipe that operates at 2bars. • Water is discharged at 6m3/sec from Mthatha dam down the river to 1st Falls. • Both units are modified for SCO mode. • Water consumed on full load is 28m3/sec. • Discharged water flows down to 2nd Falls . 1st Falls Hydro Turbines 1st Falls Hydro Generators Overview of Ncora Hydro. • This station has a single 1.6MW unit and two 400kW slip ring machines. • The machines were removed from 1st and 2nd Falls when they were upgraded. • Penstock is 260m long by 1.6m diameter steel pipe that operates at 4 bars. • Water is released from the main Ncora dam via a canal to the holding dam. • The plant does not have SCO capabilities. • Water consumed on full load is 6m3/sec. Ncora Hydro Generators 400KW DC Excitation Machine. Ncora Hydro Splitter Weir Upgrading of Mbashe. • The tunnel was fitted with an extra 70m of steel lining to seal cracks in the concrete. • The three Boving turbines and the Main Inlet valves were refurbished in 2001. • The auto voltage regulators and generator protection controls were all upgraded. • The plant cooling was replaced with closed loop towers to minimized the down times. • Scada and Telemetry systems improved. Mbashe – Tremor. 1985 Cracks in the first 50m of concrete penstock. Water pressure in hillside results in landslides. Bore holes are established on the hillside to prevent pressure build-up but is only semi-successful. Access pit at station. To Hydro’s - To Weir - Concrete Steel section. section. 06/09/2004 32 Generator Protection Relay. Unitrol Auto Voltage Relay Closed Loop Cooling Towers Control Desk at Mbashe Upgrading of 2nd Falls • The station was flooded in 1998 when one of the Main Inlet Valve was damaged. • Renovations in 1999 has made the station the most modern facility in the region. • Most of the mechanical plant including the generators were salvaged and re-used after being refurbished on site . • Both the Turbines were recently rebuilt. • Fiber optic communications was installed. Damaged Main Inlet Valve . PLC controllers at 2nd Falls 2ND Falls Gen Control Panels Plant Capabilities . • Both 1st and 2nd Falls were modified for synchronous condenser operation. (SCO) • The new control relays allow for maximum reactive power support to the network. • The units produce real power during peak times and remain in SCO when off peak. • The change from MW to MVARs is a simple process and is done in a few minutes. • Protection is calibrated for Reverse Power. Plant Capabilities cont.. • Different modes of voltage regulation is available.(Voltage , Power Factor & MVar) • The most stable of these modes is to operate the machines in voltage control. • The large increase in network loading at Peak times has an effect on Plant stability. • A unique system of controls and settings have been applied to optimize all the network and plant conditions . Protection challenges • The control relay parameters are often revised to facilitate the dynamic network conditions to keep the plant on load. • The network generated negative phase sequence is high with low peak voltages. • Islanding of the plant does often occur. • Remote tripping of the three stations optimized the safe restoration of supply . Connecting to the Grid. • Second Falls is the only plant where the synchronization process is fully automated • The other stations have a manual close facility via a common synch check panel. • Keeping the plant synchronized to the grid under all conditions is still a challenge. • Local network conditions are dynamic with variations in network loading and Voltages Network Loading in the Region • The 70MVA of connected Hydro power was sufficient in the 90s to supply the 50MVA of loading in the region. (ex Tescor) • Electrification of the area soon changed that and by 1998 the load had doubled with an additional 132kV line from Natal. • The huge increase in power made the contribution by the Generators essential for network stability during peak times. Load in MVA 100 120 20 40 60 80 0 22/10/2001 00:00 22/10/2001 06:00 22/10/2001 12:00 22/10/2001 18:00 23/10/2001 00:00 23/10/2001 06:00 Evening 23/10/2001 12:00 23/10/2001 18:00 24/10/2001 00:00 24/10/2001 06:00 Date and time 24/10/2001 12:00 24/10/2001 18:00 Peaks 25/10/2001 00:00 25/10/2001 06:00 25/10/2001 12:00 25/10/2001 18:00 26/10/2001 00:00 26/10/2001 06:00 26/10/2001 12:00 26/10/2001 18:00 27/10/2001 00:00 27/10/2001 06:00 27/10/2001 12:00 46 27/10/2001 18:00 28/10/2001 00:00 MVA 100 120 140 20 40 60 80 0 06/09/2004 00:00 00:40 01:20 02:00 02:40 03:20 04:00 04:40 05:20 06:00 06:40 07:20 Load 08:00 08:40 2003 January 22 - Profile Load 09:20 UMTATA DISTRICT UMTATA 10:00 10:40 Profile 11:20 Time 12:00 12:40 13:20 14:00 14:40 15:20 16:00 16:40 17:20 18:00 18:40 19:20 20:00 20:40 21:20 LINES GENERATION LOAD TOTAL 22:00 22:40 47 23:20 Costing and Availability Data. • The average cost per MWH at the stations varies monthly and is rainfall dependant. • Plant utilization and availability in summer is high to maximize power production. • The cost per MWH has varied from R68 in 2007 to R153 per MWH in 2009 . • The present cost per MWH in July was low due to the recent high rainfall in the area. • The following graphs will provide detail. Year-On- Year Production in MWH: 49 Percentage Utilisation of Generators: 2011/09/23 50 Generators percentage Availability: Average Cost in Rand per MWH. Future long Term Planning. • A de-siltation study has recently been completed on the Mbashe dam system. • Refurbishment of the main inlet valves and the associated service seals. • Generator stator and winding repairs. • Maintenance to the Penstock and intake tunnel with all the sealing gates . • Repairs to the four Hydro dam walls. Mbashe Dam (Full) Mbashe Dam Siltation 55 Scouring at Mbashe Dam 06/09/2004 56 Strategic Value of Generation. • The Generators are needed in Peak times of the day to reduce the high demand which occurs twice a day in the region. • The Hydro generators ensure network stability for the regional grid in the area. • The stations provide emergency power on demand - when & If required in a few minutes. • The Hydro Stations have the ability to Black start and energize the 132kV Backbone. 57 Strategic Importance cont.. • Eliminates the need to Load shed large portions of the local network during the winter Peak. • Reduces the MVA max demand logged on the Transmission in feed to Distribution.
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