FUTURE TECHNOLOGY Zek HYDRO 2014
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Verlagspostamt: 4820 Bad Ischl · P.b.b. „03Z035382 M“ – 12. Jahrgang 2014 INTERNATIONAL HYDRO FUTURE TECHNOLOGY zek HYDRO 2014 COMPACT HYDRO More than a small solution HYDRO Boot at h-N s o u : t . i S s i 3 V 2 y 1 e - k 2 r 3 u T M / a l y u 2 nb 014 • Ista ANDRITZ HYDRO supplies since 1980 units with a total output of 9,300 MW are small hydropower solutions branded installed globally. A high level of modu- as COMPACT HYDRO. The small hydro- larization allow the optimal mix between power business is an essential part of the standardization benefits, adaptation of de- ANDRITZ HYDRO product portfolio. Every sign criteria and customer requirements. month, another eleven COMPACT HYDRO units start producing clean energy some- We focus on the best solution – from where around the world. More than 3,000 water to wire. Photo credits: Kössler Photo credits: ANDRITZ HYDRO GmbH Lunzerstrasse 78, 4031 Linz, Austria Phone: +43 (732) 6986 3473, Fax: +43 (732) 6980 2554 [email protected] www.andritz.com 20_2014 ZEK-Intern_CH_Image_Sparte 216 x297.indd 1 2 HYDRO D R A N R E B : s t i d e r c o t o General view of weir and intake of the Karasu hydropower plant h p OPTIMISATION OF WATER INTAKES FOR EASTERN TURKISH CHAIN OF POWER PLANTS The eastern Turkish provinces of Erzurum and Erzincan are home to five power plants operated on the River Karasu by a German-based financial investor. The facilities are located along a 60 km stretch of the river. Dissatisfied with the overall per - formance of their quintet of power plants, the operators turned to renowned planning specialists BERNARD Ingenieure in Hall in Tirol for a solution. The main causes of the suboptimal performance were quickly identified as problems at the intake, and the surrounding geological conditions. Based on the improvement measures worked out by the Tyrolean engineers, the facilities are now being modified to raise them to the desired performance level. he adjacent provinces of Erzincan is 139.1 GWh. All five of the facilities were months later, however, it was obvious to the and Erzurum stretch across a moun - originally built by Turkish project developer new owners that the performance of the T tainous region that includes parts of Akfen Holding. plants was not quite up to scratch. Although eastern Anatolia and the Black Sea region. well equipped technically, they all suffered The entire landscape is characterised by its ANALYSIS AFTER ON-SITE INSPECTION clogging problems at the water intake struc - distinctive, high-towering mountains with It was in the year after the start-up of the tures, which caused a noticeable loss of pro - plenty of snow in the winter and some local fifth power station that the German-based duction. ski resorts to match. But high mountain tops financial investor acquired the entire chain of As a first reaction, the operators contacted are not the region’s only characteristic. It is facilities from Akfen Holding, along with Austrian planning specialists BERNARD also home to numerous lakes and rivers, several other hydropower stations. A few Ingenieure, which has a long list of successful - which account for its high hydropower D potential. This is one of the regions with the R A N R highest electro-hydrological utilisation poten - E B : s tial in all of Turkey. To leverage this potenti - t i d e al, a large number of new power stations have r c o t been built over the past few years. Among o h them were the five facilities on the River p Karasu, which flows through the two provin - ces of Erzurum and Erzincan. (Incidentally, the Karasu is considered to be the northern - most headstream of the Euphrates.) The Karasu power stations are all relatively new. The last of the power plant quintet to be opened was a 10-megawatt facility in the Erzincan province, in 2011. In total, this chain of power plants extends over 60 km along the river and has an installed capacity of Inlet screen with manual cleaning equipment (insufficient) 24.5 MW. The stated nominal annual output 28 May 2014 HYDRO General view of Channel comprising formed only on the Karasu 1 power station, the geological problems the results could be applied to the other four facilities accordingly. “At the intake of Karasu 1 we noticed that the four inlet openings were too small,” says Andergassen. “A lot of debris was carried along with the headwater and sucked into the desilting chambers. This would quickly cause a blockage at the intake.” This is a fundamental problem, especially since there are no trash racks, fine screens or trash rack cleaners installed. Also, there were no silt measuring devices installed in the desilting chambers, and the facilities were lak - king any equipment for automating or moni - D R toring the weir structures. A N R E B : s COMPREHENSIVE CORRECTIVE MEASURES t i d e r To improve the situation, the team from c o t o BERNARD Ingenieure suggested a whole set h p of measures: This included the implementati - on of a trash rack with a clear spacing of 250 ly implemented projects, primarily in hydro - a problem with the open headrace channels. mm. The individual removable round steel power construction. The main tasks for the Gravel, pebbles and sand keep sliding into the bars are to be put in place directly in front of Tyrolean engineers were to identify the parti - channels, reducing the flow velocity of the the intake. A second suggestion calls for con - cular problems and to work out ways of sol - water and restricting the overall flow capacity. struction of a skimming wall to guide floating ving them. “To be able to do that, it was All that leads to a loss of power generating materials towards the sluice gate essential for us to get there and take a look at capacity. Another weak point of the existing Another measure consists in the implementa - the situation on-site,” recalls BERNARD structures was a poor drainage system along tion of two fine screens with 40 mm clear Ingenieure project leader Ernst Andergassen. the headrace channel. As Andergassen spacing, as well as a trash rack cleaner with A dedicated specialist for water intakes, he set explains, “The concrete structures at the flushing capability. Further items on the list off for eastern Turkey, together with his col - headponds looked a little worn-out, and there of measures include the installation of silt league, certified geologist Maike Weissflog. were sediment deposits in some parts. But,” gauging devices at all desilting chambers and This project was to prove yet again how useful he adds, “at least we didn’t notice any leaks.” implementation of an automatic flushing it is for BERNARD Ingenieure staff to be able The power house and its electromechanical routine. Also, the two existing narrow sluice to rely on in-house experts for cooperation. equipment gave the engineers no cause for constructions are to be replaced by a single complaint either. All hydro-mechanical and one with a radial gate on top for flushing floa - RESTRICTED FLOW RATE AT THE INTAKES electrical equipment was working. ting materials downstream. Also on the list of “Our work consisted primarily in identifying improvement measures is the implementation the problems with the intake structures and MISSING TRASH RACK CLEANERS of a data circuit for remote-controlling the the headrace channels. We were able to dis - Although the hydraulic problem analysis and water intake structures, along with water level cuss the problematic influencing factors with development of corrective measures were per - measuring equipment and surveillance came - the operators directly on-site,” says Andergassen. Based on their proposals, BER - NARD Ingenieure was assigned the task of working out detailed solutions for the neces - sary structural modifications. This required close cooperation with the contracted hydraulic steelwork engineering firm, Southern Tyrolean specialist Wild Metal. There are only slight differences in design between the five intake structures. As a result, they all suffered from almost identical hydraulic and structural problems. “The main problem was that the intakes are arran - ged in a hydraulically unfavourable way, and D to make things worse, there is a total lack of R A N R cleaning devices. This causes the intake to E B : s block up rather quickly with bedload gravel t i d e r and floating debris, which reduces the flow of c o t water to the turbines,” as Andergassen o Inside powerhouse, machinery h explains. But that was not all: There was also p May 2014 29 HYDRO l a t Typical view of a channel e M d l i W : s c i h p a r g Planned installation of trash rack cleaning system ras. Rounding off the package of improvement measures is the instal - lation of groins in the backwater area as guiding device for the river D channel. R A N R Next, the team from BERNARD Ingenieure ZT-GmbH went on to E B : s work out in detail all the civil drawings, statical calculations and rein - t i d e forcement drawings required for the modification of the Karasu 1 r c o t power station. The design of the modifications was tailored to the o h requirements of the hydro-steelwork supplier. By now, all plans and p blueprints have been sent to Turkey, where the contracted constructi - Technical Characteristics on firm will soon begin implementing the required measures. This w Karasu 1: Design flow 2 x 7.5 m 3/s, Net head 29 m, Power output 2 x 1.9 MW, 2 Francis turbines means everything is set for the five Karasu facilities reaching their pro - w Karasu 2: Design flow 2 x 7.5 m 3/s, Net head 23 m, Power output 2 x 1.45 MW, 2 Francis turbines jected performance level in the near future.