Conversion of a Propeller Turbine

to Full Kaplan Operation at Michigamme Falls

By Gerard J. Russell, P.E., American Hydro Corp., York, Pennsylvania, USA,

Craig Peterson, P.E., American Hydro Corp., York, Pennsylvania, USA,
and Douglas T. Eberlein, P.E., We Energies, Milwaukee, Wisconsin, USA

ABSTRACT

FERC license renewal stipulations for We Energies Michigamme Falls plant included
new flow constraints that were outside the existing fixed-blade propeller turbines
efficiency range. One of the turbines was converted to fully adjustable Kaplan operation
to regain the lost generation.

Introduction

Renewal of the projects FERC license in October of 2001 required that the minimum
flow could be no less than 50% of the maximum flow during a given calendar day.
The existing generating units were typical fixed-blade propeller turbines with a very
narrow range of efficient operation, so they could not effectively meet this new
requirement. We Energies evaluated several options for addressing the new operating
regime including spilling the required low flow when necessary, installation of a
minimum flow turbine-generator unit, and conversion of one of the propeller units to full
adjustable blade Kaplan operation. The Kaplan conversion was chosen as the most
effective option to improve the operating efficiency and flexibility of the plant while
achieving the required low flow operating capability.

This paper describes the Owners planning process that resulted in the decision to
convert the unit from fixed to adjustable blade operation. The conversion not only
replaced the turbine runner but required the integration of a blade control system to
work with the existing governor. In addition, the mechanical and electrical capabilities of
the existing generator were evaluated to address the increased turbine output and
higher overspeeds. The hydraulic and mechanical design aspects of the conversion are
detailed and compared to actual performance. Guidelines for evaluating the feasibility
of performing this type of conversion for similar units are also offered.

Background and History

The Michigamme Falls Hydroelectric Plant is located on the Michigamme River 10 miles
northwest of Iron Mountain, Michigan just upstream of the confluence of the Brule and
Michigamme rivers. The project develops 65 feet of head and originally featured two
vertical propeller turbines rated at 6,500 horsepower driving 4800 kW synchronous
generators. The generating station is owned and operated by We Energies and was
first placed into commercial operation in 1953.

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The original operating regime for the plant was peaking mode. At times of the year
when river flows were not adequate for full power operation around the clock, the units
were shut down at night and operated only during the day for peaking power production.
The Owner began a negotiated process with the affected state and federal resource
agencies for renewing the projects license in 1998. This process concluded in 2001
with license renewal, which included new flow constraints to enhance the aquatic
environment downstream of the plant. The minimum flow downstream of the
confluence of the Michigamme and Brule rivers could be no less than 50% of the
maximum flow during a given calendar day. While the confluence is downstream of the
plant, the contribution of the Brule River to the total flow is not sufficient to allow the
existing turbine generators to effectively meet the new requirement at Michigamme
Falls.

This presented several problems. First, operating flexibility to dispatch the units when
needed for power production was severely limited. Secondly, given the narrow range of
efficient operation for these turbines, the owners analysis of the existing units operating
under the new flow requirements indicated that at least 7400 megawatt-hours of
electrical generation would be lost annually. Also, cavitation was a concern while
operating the units outside of their optimum range.

We Energies staff brainstormed possible solutions to these problems with assistance

from Black & Veatch Engineering of Kansas City, Missouri. Running the existing units
within the new flow constraints was undesirable for the reasons stated above. Spilling
the minimum flow through a tainter gate was considered but rejected due to winter icing
conditions and the associated lost generation with spilling. The addition of a small
turbine-generator set to accommodate peaking or low-flow operation was also
considered. However, space limitations and the cost for necessary civil modifications to
the plant made this option unfeasible. Converting one of the two existing turbines to
fully adjustable Kaplan operation was selected as the best option. While not the lowest-
cost option, it would regain the lost generation and preserve operating flexibility for the
owner.

Several challenges still remained, however. The original unit was set fairly deep in
relation to tailwater level and the configuration of the draft tube had always been in
question. Index testing performed after original unit commissioning found turbine
performance less than expected. The draft tube cross section was reduced and
reshaped to improve performance, with mixed results. The existing turbines had
experienced moderate to severe cavitation in the past; the draft tubes were suspect.
However, given a fixed project budget and difficult access to the draft tube, additional
modifications were out of the question. The new turbine would have to be designed to
perform satisfactorily with the existing draft tube configuration.

Generator overspeed during a runaway turbine event (loss of governor control) was
another concern. The overspeed of the proposed Kaplan turbine was significantly
higher than the existing propeller turbine. While a typical propeller turbine would have a
maximum runaway speed of 1.8 to 2.2 times the normal synchronous speed, a Kaplan

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turbine in this application could experience a maximum runaway speed of 2.5 times the
normal speed. Would the existing generator be able to withstand the higher speed, or
would modification or even replacement of the generator be necessary? An analysis of
the existing generator rotor was performed and, fortunately, showed that the robust
construction could satisfactorily accommodate the increased stress resulting from the
higher overspeed without modification.

Meeting the project schedule was also a concern. The license renewal was received
from FERC in January, 2001 and the new minimum flow requirements became effective
in November, 2001. Preliminary engineering had been initiated by We Energies in 2000
to allow the solicitation of proposals for the new turbine, but contract award was delayed
until June, 2001. Given the abbreviated schedule, the owner sought and received from
FERC and the resource agencies a waiver from the minimum flow requirements until
June, 2002. With license relief, the new turbine would still be needed to capture
generation from high spring runoff flows, so the completion deadline became April,
2002.

The Solution

American Hydros turbine engineers faced several design challenges when converting
the Michigamme Falls Unit 2 turbine to full Kaplan operation. The existing turbine and
generator were designed originally to operate as a fixed blade propeller, and therefore,
lacked the design features required for blade angle control. Conversion to full Kaplan
operation would require the design of an adjustable blade runner to fit the existing
turbine components with a minimum of modifications. The runner diameter, operating
speed and setting with respect to tailwater were essentially fixed. The requirement for a
very broad range of high efficiency operation made it necessary to design the runner
with a large range of blade angle adjustment. Also, to assure that the maximum power
of the turbine was not compromised, it was necessary to keep the hub size to a
minimum. Given the relatively small size of the hub, the large range of blade
adjustment, and the need to have the blade servomotor in the hub, as discussed later,
the design of the hub internal components had to be optimized to assure that no
components would be overstressed and that the assembled runner would operate as
desired. The existing cylindrical throat ring was not compatible with an adjustable blade
Kaplan runner, especially with the extremely large range of blade rotation, and therefore
a new semi-spherical throat liner was designed to retrofit into the unit.

Hydraulic Design and Analysis

The selection of the number of blades and the design of the blade shape were critical to
assure that the upgraded turbine would operate throughout the desired operating range
at high efficiency levels and without damaging cavitation. The design of new blades to
fit within an existing wheelcase and operate at predetermined operating conditions is
quite different from selecting a standard blade and runner design for operation at a
given site where the designer has the freedom to select the optimum runner diameter,
operating speed and setting. The blade shape for Michigamme Falls was carefully
custom designed and analyzed using American Hydros runner design system (AHRDS)
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 to suit the existing generator
speed of 276.92 RPM and plant
net head of 65 feet. Figure 1
shows the AHRDS blade shape
and calculated pressure pattern
on the low-pressure side of the
blade at the most severe
operating condition. The blade
design was tailored to optimize
efficiency across a wide
operating range while limiting
Figure 1 cavitation to acceptable levels.

The hydraulic profile of the draft tube is as important as the blade shape when
determining the overall performance of a low head turbine. As mentioned previously,
the draft tubes at Michigamme Falls had long been a source of concern and were
suspected of causing certain poor performance characteristics. To confidently establish
expected performance levels with the
new adjustable blade runner, it was
essential to understand the loss
characteristics of the existing draft tubes.
American Hydro performed an extensive
hydraulic analysis of the Michigamme
Falls draft tube using a fully three-
dimensional viscous computational fluid
dynamics (CFD) computer program.
Figure 2 illustrates the CFD model and
calculated flow velocity profiles
throughout the draft tube. While some
areas of flow separation and reverse flow
can be observed, the hydraulic loss
calculations indicated that the draft tube,
with the new runner, would operate at
good efficiency levels throughout the
desired operating range. Figure 2

Blade Operating System

The main mechanical design hurdle was centered around actuation of the new
adjustable blades. Kaplan turbines typically utilize an oil operated servomotor located
either in the runner hub, or in an enlarged section of the turbine shaft, to adjust the
runner blade angle to suit the operating conditions. This configuration requires the use
of an oil piping system through the center of the turbine and generator shafts to deliver
high pressure oil to the blade servomotor. The oil piping must also provide a static head
of oil to lubricate the blade trunnion bushings and blade operating mechanism
components within the hub, as well as providing blade position feedback. An oil head is
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required to transfer pressurized oil into the rotating oil pipes from the stationary oil lines
originating at the hydraulic power unit. As the existing unit was originally designed as a
fixed blade propeller, the turbine and generator shafting system did not have the
features typically associated with Kaplan turbine oil pipes, oil head, and blade position
feedback. The turbine shaft was a solid forging without a center bored hole. The
generator shaft had a small central hole in the upper end used for exciter leads only.
The generator was also equipped with a brush type exciter and pilot exciter. The
possibilities of extending oil piping through this equipment, plus the addition of an oil
head on top of the entire assembly would not fit under the powerhouse roof.

The original design concept called for replacement of the turbine shaft with a new two
piece shaft set that included an integral blade servomotor. This concept would obviate
the need to replace the existing generator shaft. The blade mechanism in the hub
would be connected to the servomotor via an operating rod extending through the
turbine main shaft. Hydraulic oil would be delivered to the hub and servomotor through
an oil transfer / blade position feedback assembly surrounding the intermediate shaft
between the turbine and generator shafts. The complexity, and questionable reliability of
the over the shaft oil transfer box, soon ruled out this concept.

The remaining alternatives were to: 1) Replace both the turbine and generator shafts
and incorporate the blade servomotor into an enlarged upper end of the turbine shaft, or
2) Incorporate the blade servomotor into the runner hub and attempt to reuse the
existing turbine shaft and generator shaft if possible. Preliminary runner design
indicated that by using a 1000 psi oil pressure system, the blade servomotor could be
incorporated into the small hub. The second of the listed alternatives was therefore
selected as most desirable and cost effective.

Typically, three pipes are utilized to direct the oil to the opening and closing sides of the
blade servomotor as well as supplying pressurized oil to the runner hub cavity. Since
the diameter of the turbine shaft was rather small, it was determined that the only way
to reuse this shaft was to bore through the length of the shaft, and to use this bore as
one of the oil pipes. Increasing the diameter of the shaft would have entailed major
redesign of the turbine bearing, packing box and other related equipment in close
proximity to the shaft. Analysis of the shaft indicated that even with a 4.375 diameter
axial bore, stress levels under all operating conditions fell within normally accepted
limits.

The generator shaft, however, was another story. The diameters at the upper end of the
existing generator shaft were extremely small. The diameter at the root of the
circumferential groove for the thrust block collar was not much larger than that required
for the oil passage bore. It was decided, therefore, to replace the generator shaft. The
bore of the thrust block was increased to accommodate a larger shaft. Redesign of the
lock collar, along with the larger diameter at the thrust block permitted the addition of
the 4.375 diameter oil pipe bore, plus two axial holes, parallel to the center bore, for the
exciter leads. The shaft length was also increased to accept the new brushless exciter,
and to connect to the outer Kaplan pipe required at the oil head.

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A new three pipe conventional oil head was designed and fabricated. The inner oil
pipe serves as the mechanical feedback from the blade servomotor in the runner and
also provides the static oil pressure supply to the hub. The intermediate oil pipe
transmits the closing oil pressure from the oil head to the blade servomotor. The outer
pipe, (the bore of the turbine and generator shafts) transmits the opening oil pressure
to the blade servomotor. The oil head base was designed to mount directly to the new
static exciter housing, appropriately insulated for electrical isolation. The existing
Woodward PMG mounts directly to the top of the new oil head. A new splined PMG
drive shaft was designed to accommodate the axial motion of the inner pipe. Figure 3
illustrates the oil head design.

A dedicated hydraulic power unit

with a PLC based control system
was specified for control of the
new adjustable blade runner. The
system was purchased from The
Hope Group / Sorensen Governor.
The blade control system operates
as a slave to the existing
governor that controls the turbine
operation and position of the
wicket gates. The optimum runner
blade angle is set by the blade
control system based on the
position of the wicket gates for any
point of operation.

The Kaplan Runner

The adjustable blade runner

presented its own design
challenges. Even though the
configuration is more or less
typical of vertical Kaplan runners,
the small physical dimensions of
the hub, combined with the large
Figure 3 angular rotation of the five blades,
the servomotor located in the hub
and the relatively long servo stroke severely taxed the available space. As runner
dimensions become smaller, the need for assembly space for a workers hands and
tools does not decrease and had to be kept in mind during the design phase.

The blade tip diameter was increased to 84, 2 larger than the original propeller runner.
The hub ratio is 42% for a spherical diameter of 35.25. The cylindrical portions of the
hub immediately above and below the sphere are only 30 in diameter, smaller than
the original propeller hub. The centerline of the runner was also lowered 5 to improve

6
the cavitation performance. All of these factors resulted in a rather long runner
assembly, considerably longer than the fixed blade runner. The increased length
contributed to field assembly challenges as the clearance under the outdoor gantry
crane was not adequate for the increased length of runner and shaft. Refer to Figure 3

Typically, American Hydro prefers plate steel fabrications over steel castings, however,
the design configuration of the hub and the servomotor/crosshead did not readily lend
themselves to fabrications. These two components were made as castings of ASTM
A216 grade WCC. All other components within the hub with the exception of the blades
were either forgings, or steel or alloy steel plate. The extremely tight space within the
hub necessitated the use of higher strength carbon or alloy steels to minimize the
physical dimensions of the parts. Self aligning spherical bearings were selected for use
in the link ends, both for their high load carrying capacity and to eliminate any bending
loads in the mechanism.

The stainless steel blades are ASTM A744 CA6NM castings. The blade leaf was cast to
near net shape, only requiring grinding to attain the required finish, fairness and edge
shape. The trunnion and disc areas were machined on a five-axis CNC horizontal
boring machine.

The Kaplan runner was completely assembled in the American Hydro facility, pressure
and stroke tested using the blade servomotor to verify oil tightness and correct
operation of the blade mechanism. The runner was shipped to the field completely
assembled with the exception of the inner oil pipe.

Turbine Rehabilitation

During the early 1990s, both propeller turbines at Michigamme Falls were overhauled
and new runners installed, therefore it was anticipated that minimal refurbishment would
be required. The main shaft bearing parts, the inner and outer head covers, the wicket
gates and mechanism parts, the gate operating ring and the turbine main shaft were
shipped to the American Hydro facility for inspection and evaluation. All bearing
surfaces on the gates, outer head cover and gate operating ring were re-machined
removing minimal material to establish new uniform sizes and finishes. Extensive
corrosion on the lower wicket gate stems necessitated the removal of considerable
material so the diameters were restored by the addition of stainless steel sleeves. Minor
rework of the adjustable water bearing shoes and installation of new rubber staves was
performed. New bronze gate stem bushings, thrust washers and new operating ring
pads were installed. The turbine main shaft was dimensionally inspected, the center
was bored through the entire length to 4.375 diameter, and the runner end face and
spigot were re-machined to restore surface finish and flatness tolerances. The existing
embedded throat ring was deteriorated due to cavitation and other wear and tear. To
assure close running clearances with the blades at all operating blade positions, a new
semi-spherical stainless steel throat liner was fabricated and installed as illustrated by
Figure 4. Figure 5 illustrates the final configuration of the Michigamme Falls turbine
following conversion to full Kaplan operation.

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 Figure 4 Figure 5

Results

The design and manufacture of the Kaplan runner and other new components began in
June 2001 and field disassembly commenced in August 2001. Given the need to have
the unit running in time for the spring runoff in 2002 it was necessary to have the
design, manufacture and field work proceed in parallel. Critical dimensions for some of
the new components could not be determined prior to disassembly due to lack of
detailed generator component drawings. This resulted in several new components
including the new runner, new generator shaft and new oil head, appearing as critical
path items on the project schedule. Good communication between American Hydros
designers, field service personnel and We Energies was necessary to keep the project
moving toward a timely and successful completion.

Following disassembly of the turbine and generator, the turbine components were
shipped to American Hydros shop for modification and refurbishment as required.
Figure 6 is a photograph of the old propeller runner during removal from the unit. Figure
7 shows the new Kaplan runner following pressure testing on the shop floor. In parallel
with the shop work, the new stainless steel throat liner was installed in the field as
illustrated by Figure 8. The new and refurbished turbine components were delivered to
site and installation began in mid-January 2002. Figure 9 shows the new runner being
lowered into position. The unit reassembly and commissioning were completed in time
for the spring runoff in mid-April 2002.

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 Figure 6 Figure 8

Figure 7 Figure 9

An index test was

performed in June Michigamme Falls Kaplan Conversion
2002 to verify 100
performance Index Test After
Relative Efficiency (%)

95 Conversion
guarantees and refine
90
the shape of the Expected

blade-gate cam curve. 85 Performance

Curve
Figure 10 shows the 80
results of the index 75
Index Test
test plotted as relative 70 Before
efficiency versus 65 Conversion

turbine output. Also 60

shown on this graph 0 1000 2000 3000 4000 5000 6000
are the expected
Turbine Ouptut (KW)
performance curve
and the results of an
Figure 10

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index test performed
prior to the conversion. Michigamme Falls Kaplan Conversion
Figure 11 shows the 100

Relative Efficiency (%)

pre and post 90 Index Test
conversion index tests 80 After
Conversion
plotted as relative 70
efficiency versus 60 Index Test
turbine discharge. As 50 Before
Conversion
these curves clearly 40
indicate, the project 30
goal of improving 20
operating efficiency 0 200 400 600 800 1000 1200
and flexibility while Turbine Discharge (cfs)
meeting the FERC
mandated low flow Figure 11
operating capability
was achieved.

Conclusion

For low head hydroelectric sites with propeller turbines, conversion of an existing
propeller unit to full Kaplan operation may be the best alternative when considering
options for meeting low flow requirements. As the Michigamme Falls project
demonstrates, with careful planning by the owner and due consideration by an
experienced turbine designer, conversion from propeller to full Kaplan operation is
technically feasible and may be economically justified. The following checklist includes
some important items to address when evaluating or implementing a Kaplan
conversion:

Desired Operating Range is capacity or efficiency more important?

Site Hydraulic Conditions

Generator Overspeed Capability

Thrust Bearing Capacity

Existing Governor Capacity

Turbine and Generator Shafting Features

Detailed Drawings of Existing Components are they available?

Powerhouse Headroom Above the Generator

Available Budget (Ecomomic Justification)

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Authors

Gerard J. Russell, P.E., is Marketing Manager at American Hydro Corporation. He is

responsible for sales and marketing of American Hydros products and services in North
America as well as hydraulic engineering for many of their projects including
Michigamme Falls.

Craig Peterson, P.E., is the Chief Design Engineer at American Hydro Corporation. He
is responsible for mechanical design and analysis for American Hydro and performed
the detailed engineering for the Michigamme Falls project.

Douglas T. Eberlein, P.E., is a Project Manager at We Energies. He is responsible for

various improvement projects at the public utility, including the Kaplan Conversion at
Michigamme Falls.

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