Referat Sick Auswirkungen Regelbetrieb Auf Lebensdauer
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Transcript of Referat Sick Auswirkungen Regelbetrieb Auf Lebensdauer
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Schweizerischer
asserw r sc a sver an
Fachta un Wasserkraft 2013Mittwoch, 6. November 2013
Hotel Arte, Olten
Auswirkungen des vermehrten Regelbetriebs auf
die Lebensdauer der el.-mech. Maschinen
Mirjam Sick, R&D / Engineering Methods, ANDRITZ HYDRO, Zrich
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HYDRO as Grid Stabilizer
Moving from static to highly dynamic operation
The electrical grid is changing rapidly
Germany, Sept. 2011Electricity production from wind (green) and sun (yellow)
From coal, nuclear etc. to variable Renewable Energy Sources(RES)
Hydro power technology integrates variable energy sources into
Fast to dispatch and control
Significant storage capacity and high power output(10 to 1000 MW)
Innovation needed in HYDRO technology From pure power production (MWh) to ancillary services
rimar and secondar fre uenc controlBalance of the electrical grid: stable frequency
From hydraulic efficiency ($/MW) to operational flexibility
Key technological challenges Know-how from E&M equipment to grid stability&ancillary serv.
Wide operating range from spinning reserve to full load
Frequent operation and wear of control mechanisms
3 www.andritz.com
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Power plants for grid stability
Comparison Thermal plants Hydro plants
Thermal Gas Hydro Hydro
Power gradient (%/min) 2 - 4 8 12 50 - 100 100% in What about existing (older) Hydro plants ??
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Pumped storage plants
D namic o eration
Yesterday: load balance day night, winter - summer
Toda : Primar and secondar control within minutes
Stand-by operation (speed - no - load)
Low load operation
Frequent changes from pump to turbine mode and vice versa
nemode
Key questions
de
turbi
operation to deliver
ancillary services?
pumpmo
ancillary services?
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2 hours interval time
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Overview: Technical challenges due to flexible operation
The entire system needs to be considered
1. Inspection, fitness check, referencestatus of vibrations
2. Compliance with current grid code
3. Secondary equipment
4. Wide operating range (Francis turbines)
5. Life time assessment (F and PT runners)
6. Generator at fre uent starts sto s
7. Life time assessment Kaplan runner
mechanism
Aspects to be considered Hydraulical aspects, waterways
Mechanical aspects turbine/generator set
8. Maintenance intervals ruc ura aspec s c v s ruc ure
Control aspects, governor
Electrical aspects, grid elements
Operational aspects, hydraulic stability,
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gr s a y
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Grid Stability: Primary control existing HPP
New governor strategy for critical plants
Background New ENTSO-E primary control regulations
requiring faster responses to frequency steps
(100% of power in 30s)
to primary control and fulfill new regulations
Governor strategy must be adapted for plantswith critical waterway (long penstocks, smallsurge an s, e c.
Procedure Case study: Hautefage (2x10MW Francis)
Response to -200mHz Frequency step (test measurements)
Guide vane opening / Mechanical power
Validate plant + governor model withmeasurements
Improve governor algorithm, tests by simulation
Benefit Applicable to any plant with narrow surge tank
9 www.andritz.com
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Wide operating range
Francis 0 100% operation: push operating limits
Machines delivering ancillary services need flexible operation: Spinning reserve
Low load operation
Issues to be solved
Full load vortex (draft tube)
High dynamic load in part loadconditions
Risk of fatigue
Hydraulic issues Pressure pulsations and stability
Cavitation
Research projects active
Operation mode needs to bespecified during offer phase
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Fatigue analysis Francis runner
Strain gauge measurement hot spot
Linear regression analysis
The calculated shape should give a good representation ofthe strains from the measurement.
The strain gauges are not located on the hot spot.
.
Assumed peak stress matrix of measurement
Cycles
13 Dynamic amplitudewww.andritz.com
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Fatigue analysis
Damage factor based on peak stress
Miners Rule: Linear cumulative fatigue damage theory
If there are k different stress levels and the average number of cycles to failure at the ith
stress (Si) is Ni, then the damage factor C is:
n
n : Number of cycles accumulated at ith stress level(S ).
Amplitude (stress level)
niS1
Ni: Number of cycles to failure corresponding to the ith stress level(S
i).
ni/Ni: Damage ratio at the ith stress level(Si).
: The factor of life consumed by exposure to the cycles at the different stress
levels. In general, when the damage factor reaches 1, failure occurs.14 www.andritz.com
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Relative damage and life time dependent on operation
Example : Francis runner at speed no load
Rainflow Extrapolationusing Monte Carlo simulation
SNL time
1000
s gna
100
Str
essamplitudeinMPa
Speed no load:
10
1 .0 0E+0 3 1 .0 0E+0 4 1 .0 0E+0 5 1 .0 0E+0 6 1 .0 0E+0 7 1 .0 0E+0 8 1 .0 0E+0 9 1 .0 0E+1 0 1 .0 0E+1 1
Rainflow
Life time assessment based on 50sec data
Extrapolation to 1000 sec
Damage rate: 0.00011 per hourLoad cycles
Expected SNL life: 8000 hours
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7 Life time assessment: calculation methodology
Ensure lifetime under new operating regime
Mechanical Calculation Procedure (present situation)
New Engineering Approach
Start -Stop
SNL Part Load
Full Load/ RSIdominant
StaticLoad
Fatigue AnalysisOperatingRegime
a er aProperties /Condition
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