VA TECH HYDRO

A Complete electromechanical Upgrading Package for

the 1200 MW Kaplan Power Plant Portile De Fier I

Paper presented at
Hydro Vision 2000, August 8 – 11, Charlotte, N.C. USA

Hydro Vision 2000, Charlotte, N.C. USA 1

2 Hydro Vision 2000, Charlotte, N.C. USA
 A complete electromechanical Upgrading Package for
the 1200 MW Kaplan Power Plant Portile De Fier I

Ioan Bleier, S.H. Portile de Fier,

Ludwig Huser, Heinz Annen and Livio Ravicini, VATECH Escher Wyss Zurich,
Christian Niederer and Martin Zahler, VATECH Escher Wyss Kriens

ABSTRACT

After 25 years of operation, site investigations at the hydro power plant Portile De Fier I
showed that complete refurbishment of the turbine and generator would be necessary
within a short period of time for safety reasons. Cracks on important turbine parts were
increasing operational risks. The plant is operated in peak mode with frequent start and
stop sequences. To optimize day-to-day operation and fulfil the main requirements for
high plant availability, high reliability and just-in-time delivery, a new redundant
automation and control system was installed as well as a plant diagnostic system. A
number of effective and highly sensitive condition-monitoring tools were implemented for
supporting lean maintenance.

Introduction

The hydro power plant Portile De Fier I (HPP PdF I, also named „Iron Gate I“) on the
Danube was commissioned between 1970 and 1972 with six 178 MW Kaplan turbines
each on the Rumanian and Serbian sides. With these 12 units of 9.5 m runner diameter,
it is the largest river power station in Europe.
Several site investigations were made to analyse the status and condition of the power
plant. It was found that for safety reasons, complete refurbishment of the main turbine
and generator components would be necessary. In addition to this refurbishment, the
machines should also be modernized to increase their power output and improve energy
production with an enhanced degree of automation. The increase in output would be as
much as 132 MW for the 6 Rumanian turbines alone.
Sulzer Hydro, now VA TECH ESCHER WYSS (EW), has been working on this project
since 1993. Several site investigations and discussions were held in order to prepare an
optimally attractive proposal to the customer. In particular, EW put together a complete
upgrading and automation package, including generator modernization coordinated with
ABB.
After evaluating several tenders, the Rumanian government decided in August 1997 to
modernize the hydro power plant for safety and economy reasons. CONEL (the
Rumanian Electricity Company) were then instructed to ratify a contract with EW as
main contractor for works execution.

Hydro Vision 2000, Charlotte, N.C. USA 3

 The project will be financed in part by exporting electrical power from Rumania, in
partnership with the Swiss energy trading company Elektrizitätsgesellschaft Laufenburg
(EGL).
EW provides comprehensive support and services in all aspects of refurbishment,
ranging from project financing and coordination to design and realisation of the complete
automation and control system on a water-to-wire basis.

Figure 1: Hydro Power Plant Portile De Fier I

Turbine and Generator

Turbine type: Vertical Kaplan The six units of PdF I were

commissioned at the beginning of the
Original suppliers
seventies. Since this power plant was
– Turbine: LMZ Leningrad (St. Petersburg) designed and realised for peaking
UCM Resita purposes, the units have undergone a
– Generator: Elektrosila Leningrad large number of start and stop
UCM Resita sequences over the past thirty years.
Number of units: 6 Serious cavitation damage and cracks
Year of delivery: 1970, 1999 occurred on the runner blades, as well
as stay vane cracks [1]. Combined
Country: Romania
overhaul and upgrading will not only
Rated head: 26.5 m significantly improve the power output,
Head range: 15.4 – 31.4 m efficiency and cavitation behaviour, but
Rated output: 178 MW ® 194 (200) MW
also ensure the safety of main
components such as generator, turbine
Speed: 71.43 rpm shaft, stay vanes and runner blades.
Runner diameter: 9500 mm

4 Hydro Vision 2000, Charlotte, N.C. USA

The modernisation process started in 1995 with preliminary studies. In October 1998 the
diagnosis phase was completed by the successful conclusion of model acceptance tests
in the independent laboratory. In summer 1999 dismantling of the first unit started, and
currently work is proceeding both in the machine shops and on site.
Target of the first study was to determine the hydraulic improvement potential. The
existing runner was analysed by means of numerical flow simulation at all important
operating points. Weak points were detected with regard to the existing runner blade
profile, and comparison with a new, numerically designed runner blade revealed the
existing improvement potential in efficiency, cavitation behaviour and maximum
discharge flow rate accordingly.
These activities were followed by site investigations of the plant conditions. On behalf of
the supplier and the owner, engineers well-experienced in upgrading and refurbishment
inspected the plant and established its condition in close cooperation with the plant
personnel.
Determination of the plant condition was possible without dismantling the plant
components, based on:
· the owner’s operating and maintenance experience,
· the design (as-built) drawings of the plant components
· the extensive experience of EW with numerous upgrading and refurbishment jobs in
the past.
A list of potential improvements, risks, necessary rehabilitation work and additional
studies was worked out. The main conclusion was that in order to clarify several key
issues, further studies and site measurements would have to be carried out.
Measurements of the wicket gate servomotor pressure were performed to define the
specific hydraulic loads. This provided a basis for designing the wicket gate mechanism
of the upgraded unit to handle all operating conditions (with its higher full-load discharge
values), in order to ensure safe operation with the existing servomotors and hydraulic
governor. After thorough analysis based on strain-gauge load measurements on the
rotating shaft, replacement of the turbine shaft was recommended. Extensive analysis of
the stay vanes was carried out to clarify and optimally solve the crack formation problem
as economically as possible. Analysis of the stress readings and values of
eigenfrequency clearly showed that cracks were induced by vibrations. However, this
problem can be eliminated by appropriate modification of the stay vanes trailing edges.
The generator site investigations including online diagnostic measurements (partial
discharge, air gap, vibration), indicated that rehabilitation of the generator stator is a very
urgent matter.
Development of the new runner blade profile was carried out in very close cooperation
between our hydraulic and mechanical engineers. Since the existing runner hubs on
next 5 units are to be reutilized, including blade trunnions with bolt holes, links, levers
and servomotors, numerous additional boundary conditions have to be met by the
hydraulic design. Apart from standard measurements such as efficiency, cavitation,

Hydro Vision 2000, Charlotte, N.C. USA 5

 runaway speed, etc. the model tests included torque measurements on guide vanes and
runner blades as well. Due to the planned recommissioning and the large size of the
runner blades – about 20 tons per blade – the runner blade profile had to be established
at a very early stage.
To meet all requirements, the model tests were divided into semi-homologous and fully
homologous phases. The runner blade design by CFD, combined with the mechanical
analysis and correspondingly admissible runner blade torque values, helped to develop
and identify the final runner blade shape at a very early (semi-homologous) stage. The
fully homologous tests incorporated all contractual data measurements. Especially the
runner blade torque measurements at the end of these tests confirmed the computed
runner blade torque values with good correspondence between calculation and
measurement. The results of the torque computations, combined with the experience
gained from previously measured runner blade torque curves, enabled mechanical
design of the runner for safe operation. Thanks to the above-mentioned procedure, EW
were able to deliver all technical data on time. Compliance with the hydraulic
performance guarantees was demonstrated to the client by model acceptance tests at
an independent laboratory [2].

Figure 2: Dismantling of the unit

The main work involved, both on site and in several shops (mainly at UCM Resita, IMGB
Bucuresti and VA TECH Escher Wyss), can be summarized as follows:
· Manufacturing of one complete new runner and six sets of new runner blades (five
hubs will be overhauled)
· Manufacturing of six new turbine shafts
· Manufacturing of new main generator stators and pole windings (by ABB as
subcontractor)
· Manufacturing of new stator cores
· Manufacturing of new stator core for the auxiliary generator (part of the excitation
system)
· Manufacturing of new generator stator windings and new poles for the auxiliary
generator

6 Hydro Vision 2000, Charlotte, N.C. USA

· Refurbishment and overhaul of the powerhouse cranes (by CONEL)
· Complete dismantling of the units (with Energomontaj as subcontractor)
· Inspection of all main turbine and generator components
· On-site machining and coating of discharge rings
· Substantial crack repair work on stay vanes and turbine covers
· Installation of a high pressure jacking device on the thrust bearings for unit startup
and shutdown
· Refurbishment and overhaul of all remaining turbine components such as guide
vanes, servomotors, hubs; reconditioning of all other remaining components,
including conversion to grease-free bushings
· Refurbishment and overhaul of all remaining generator components
· Complete corrosion protection
· Complete reinstallation of all turbine-generator units
· Recommissioning and testing of all units

Automation and Control System Upgrading

With the liberalization of energy markets, power plant business is coming under
increasing price pressure. This trend is also having a significant effect on control system
and automation technology.
Whether migrating to a newer technology, integrating a new system or adding
functionality, a strong partner familiar with the complete turbine, generator, governor,
protection, diagnosis and auxiliary processes is indispensable. Such partner must also
be able to provide the necessary products, expertise and support services for meeting
all the requirements of fast project handling, as well as homogenous overall plant control
system design.
Modernisation and refurbishment of the PdF I plant control system started in October
1997. After analysis and investigation of the general status and condition of the existing
plant control system, the refurbishing solution was mainly established prior to contract
signing. Besides complete replacement of the control room equipment, the unit control
boards (UCB), the temperature measuring system, the unit low-voltage distribution
(LVD), related sensors and actuators, and the electrical field wiring, it was decided to
also replace the speed governor including mechanical cam and related governor head,
the excitation and voltage regulation system, and the electrical protection system.
The main goal of refurbishment was to increase system availability, stability and self-
diagnosis capability while retaining a clear and simple human-machine interface (HMI).
To keep the entire system as robust, fail-safe and manageable as possible, it is based
on control and protection redundancy for maximum safety and availability.

Hydro Vision 2000, Charlotte, N.C. USA 7

 Plant Control System
The new system incorporates completely decentralised control, with network
interconnection via a duplicated multi-core optical Industrial Ethernet H1 data
communication link, which is based on a SIMATIC S7 and WinCC process control
system. The main configuration is shown as a block diagram including the main parts
and connections of the redundant numerical control system (Fig. 3). The control system
design is based on 4 main operation and communication levels.
– Operation level: Joint Control Control Room Unit Control Local Process
– Communication level: Remote Link Terminal Bus System Bus Field Bus

Terminal Bus Level (Control Room)

The terminal bus level incorporates the HMI operation and visualisation data flow
between the designated clients and the two redundant servers, which are separated
from the main process data flow (system bus). The two operator stations, the video
mimic board, the engineering station, the two servers, the machine hall supervision
terminals, the diagnostic system, the net printers and the connections to the electrical
management system are linked with the terminal bus. Connection to the main process
data is via the two hot standby servers, which are permanently synchronised and ensure
safe data storage handling. This configuration allows complete operation, supervision,
maintenance and teleservice at high availability.

Mimic Board Diagnostic

Operator Operator Energy Managment Diagnostic
Terminal 1 Terminal 2 System (existing) Terminal 1 Terminal 2
Control Room

Terminal Bus (Ethernet TCP/IP)

Engineering
Station

PLC DTL Flow Diagnostic

Joint Control Measurement Server

Plant Control Plant Control

MOD
Server A Server B

Operator GPS Operator

Terminal 3 Terminal 4

Redundant System Bus (Industrial Ethernet H1 Ring, 1500m)

Unit 1 - 6
Machine Hall

Operator Mimic PLC

Electrical Plant Auxiliary
Panel Board Diagnostic
Auto Main Protection A Flow
System
Synchronis Excitation & Measurem
ation AVR ent
PLC PLC Air Gap
Unit Control A Unit Control B Electrical
Protection B Vibration

Decentralized Periphery Temperature Decentralized

Manual Aux. Periphery
Partial Discharge Unit
Synchronis Excitation &
Mechanical Auxiliaries
ation AVR
DTL Turbine DTL Turbine Protection Cavitation
Governor A Governor B
Process

Process Process

Figure 3: Overview of Plant Control System

8 Hydro Vision 2000, Charlotte, N.C. USA

System Bus Level
The system bus level incorporates the main control and process data flow from the 6
redundant numerical unit control systems, the plant auxiliary system, the joint control,
the diagnostic system and the flow monitoring system. The main bus is based on a 12-
feeder fibre optic ring, which is separately used by the redundant Simatic system bus,
the diagnostic system bus, and the flow monitoring system bus. This structure ensures a
high speed data link from the machine hall to the control room. The connected system
bus provides full block time synchronisation of the connected systems by a GPS based
system.

Unit Control Level

The new UCB includes the redundant numerical Simatic S7 PLC system, which is linked
to the redundant system bus and to the redundant field bus. The UCB further includes
the high voltage and main voltage synchronisation equipment, the main operator panel,
and a small classical mimic board for manual synchronisation and emergency operation.
Besides the numerical control section, a mechanical and electrical protection system is
also included. In case of communication failure to the control room, the unit control level
remains steady, thus allowing complete operation via the operator panel.
The new digital turbine governor system is based on the DTL 595 family, structured in
well-standardised and completely redundant philosophy for double-regulated turbines
(Fig. 4).

Redundant System Bus Operator Panel Mimic Board

(Industrial Ethernet H1) Frequency

HZ HZ
Synchronisation Voltage

kV kV
SIHydro

Active Power Reactive Power IGEN U GEN

Opening Wicket Gate Runner Speed IEXC

Control Room

Unit Conditions
Rev. Local

Standstill

Ready Operation Mode

Idle Running

MPI
Auto
Excitation

Grid Test Hand

Synchronisati on

ESD
Lamps ON

G Lamps Test

S7-400 A S7-400 B Periphery DTL595 A DTL595 B Electrical Electrical

Protection A Protection B

L T P

Mechanical
Protection
Profibus DP1 / DP2

TRIP TRIP
Low Voltage RELAIS A RELAIS B
Governor Turbine Generator Excitation /
Hydraulic Instrumentation Instrumentation Breaker Distribution

P L T T T T P

Figure 4: Unit Control Level

Hydro Vision 2000, Charlotte, N.C. USA 9

 Field Bus Level
The entire field bus is based on a Profibus DP link with completely decentralised I/O
modules. These I/O modules are distributed to local terminal cubicles or mounted in the
distributed system cubicles. This decentralised structure allows complete works testing
of the data links, thus enabling fast installation and commissioning at site. The
redundant digital turbine governor system as well as the main/auxiliary excitation
system, the redundant electrical protection system and generator circuit breaker, are
parallel or serial linked to the decentralised I/O modules.

Process Control Level

Apart from full numerical control, specific auxiliary systems can be operated locally for
maintenance or troubleshooting purposes.

Unit Control Redundancy

The redundant numerical control system is designed for high availability and
manageability. In view of the 1600 field signals per unit, including nearly 200 RTD's, the
redundant numerical system was executed as a decentralised redundant field bus
system. At sensor level, only the most important signals are kept redundant and
distributed to various I/O modules. Since both PLC's recognize both redundant signals,
these signals can be monitored online. Consequently, loss of a signal does not provoke
a switchover to the standby numerical system. Switchover between the two numerical
systems is performed by the switching communication card in the decentralised I/O
modules.
Since only the numerical master system is write-enabled, a mechanical protection
system is added to the UCB. With selected direct sensors and an integrated emergency
stop sequence, this ensures redundant safety of the unit.
Additionally, each digital turbine governor is separately linked to the decentralised I/O
modules by a distributed communication card. This also allows each PLC to work with
both governors. Consequently, loss of a digital governor does not provoke a switchover
to the standby numerical system.

Control System Advantages

The clearly structured and allocated communication duties of the overall plant control
system allow clear and easy supervision and maintenance of all systems. Failed
systems or components can be isolated without interrupting the other control and
supervising systems.
The decentralised I/O modules enable local commissioning and troubleshooting by the
operation engineers using the process sensors.
The redundant numerical system supervises the redundant sensors permanently, since
their failure or deviation constitutes the main risk in a hydropower station.
With this size of plant control system, the decentralised redundant I/O modules enable a
redundant system without interposing relays.

10 Hydro Vision 2000, Charlotte, N.C. USA

Total Single-Source Plant Design
This also means comprehensive single-source data management — one of the main
design tasks for a complete water-to-wire project. In the PdF I project, complete data
management, from the initial list of signals up to visualisation, was realised with the
latest tools for automatic data transmission (see Fig. 5: List of signals - instrumentation
scheme, electrical engineering scheme - graphical software designer - graphical
sequence designer – HMI screen).

Figure 5: Engineering tools for integrated data management

Hydro Vision 2000, Charlotte, N.C. USA 11

 Plant Diagnostic System
The main duty of the machine condition monitoring and diagnostic system (SUDIS) is
permanent supervision of the overall condition of the machine and components, thus
enabling early detection of overloaded and/or worn components.
To this purpose, all available characteristics are displayed as trends. The vibration
measurements provide extensive data on vibrational characteristics, from which
additional information on unit operating conditions is derived. The turbine-specific
module (operating point visualisation and cavitation monitoring) enables optimisation
of turbine operation. The system is furthermore extended with generator-specific
modules (air gap and partial discharge monitoring). Based on long-term data storage,
our procedure termed smartALARM for simplified trend analysis (patent pending),
enables pre-fault diagnostics before warnings or alarms are triggered by the control
system.
System-supported assessment of all this data by the operator or specialists enables
preventive (condition based) maintenance for enhanced availability. This enables on
the one hand early detection of potential serious damage, thus saving respective
repair outlay, and on the other hand well-founded assessment of individual component
condition (development prognosis of damage and wear).

Diagnostic System Components

The diagnostic system consists of 2 diagnostic client stations, 1 SUDIS master server
station and 6 unit diagnostic systems linked by the diagnostic system bus (Fig. 6).

Functions of the Diagnostic modules

The following list contains the main functions implemented in the diagnostic system for
general, turbine and generator-specific modules.

§ Vibration module § Visualisation of trend data

§ Air Gap & Partial Discharge module
§ Cavitation module
§ Temperature Monitoring
§ Status Monitoring of Auxiliaries
§ User-friendly HMI
§ Operating Point Visualisation
§ Pre-fault diagnosis, smartALARM
§ Performance Monitoring
§ Data Storage, Backup
§ Remote access

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 Plant Control System Plant Diagnostic System
HMI-Clients SUDIS Clients Programs:
- Air Gap Client
- PD Client
- Vibration Client
- HPM Alarm Client
- Sudis Client
(Diagnosis, Pictures, Trends)
- Characteristic operating diagrammes
Hub Hub Temp, Events, PV,
Management Infos
overall alarms, informations

Switch

smartMONITOR of
- Air Gap Characteristics
Hub - PD Characteristics
- Vibration Characteristics
WinCC WinCC - Cavitation Characteristics
Local DB Local DB SUDIS - Temperatures
Global DB - Diagnosis of events and alarms

GPS Joint

Vibration Characteristics
PD Characteristics
AG Characteristics
Cavitation Characteristics
Redundant System Bus
(Industrial Ethernet H1)

Unit 1-6

HPM (local DB) Hub

spare

UNIT Air Gap PD Vibration smartCAVIT

Control Process Variables,
Status

Safety monitor
Alarm / Protection

Sensors and Air Gap PD Vibration Cavitation

Actors Sensors Sensors Sensors Sensors
HPM Cabinet

Figure 6: Overview of Plant Diagnostic System

Diagnostic System Advantages

After a detail fingerprint period and increasingly added operator knowledge, the system
grows into an expert system.
Splitting the system into a local signal acquisition and fast signal analysing diagnostic
system on the one hand, and an overall diagnostic supervision and managing system on
the other hand, keeps the total data flow and system demands within an economic and
manageable range. With remote visualisation of the local acquisition system the
operator is not aware of this splitting.

Conclusion
Extensive site investigations in close cooperation with the owner, proven engineering
experience in upgrading and refurbishment and new, higly optimised new runners are
fundamental for a safe and profitable plant operation in the next 30 years.

Hydro Vision 2000, Charlotte, N.C. USA 13

 Single-source refurbishment of the PdF I HPP enabled fast and homogeneous project
realization. By handling all data management, turn-key project implementation was
possible with minimal on-site modifications. Since operation and visualisation is also
strongly related to the turbine, governor and auxiliaries, EW turbine engineering
experience could be fully integrated in the control and operation philosophies.
With realisation on the Simatic platform, EW was able to base the plant control project
on a system family already installed in the customer’s electrical management concept.
Comprehensive process knowledge, with open hardware and system families, is an EW
strength which was applied in a professional manner throughout the realisation of this
project.

References

[1] I. Eugeniu, N. Paunescu and D. Pantelimon

“Modernisation and refurbishment of the HPP Portile De Fier 1, Rumania“
urhp, Berlin, Germany, May 1999, pages 295 - 307

[2] Rolf Grunder and Heinz Annen

„Iron Gate 1 and Birsfelden – Case Studies of Large Kaplan Rehabilitation – Safe
and Profitable into the Next Century,“ Hydropower Conference, Gmunden, 1999,
pages 669 - 678

Authors

14 Hydro Vision 2000, Charlotte, N.C. USA

Hydro Vision 2000, Charlotte, N.C. USA 15
VA TECH HYDRO
VA TECH ELIN GmbH & Co
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Telephone (+43) 1/89 100
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E-Mail: contact@vatech.elin.at
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Telephone (+41) 1 278 23 23
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E-Mail: contact@vatew.ch
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Hydro Vision 2000, Charlotte, N.C. USA