Refurbishment |
Transformative modernisation
Aging hydropower plants are undergoing transformative modernization and rehabilitation efforts, integrating cutting-edge technologies to enhance efficiency, safety, and environmental impact. Projects worldwide address challenges from corrosion to control systems, marking a crucial step towards a cleaner and more resilient energy future
HYDROPOWER MODERNIZATION AND REHABILITATION are essential tasks within ageing hydropower plants, essential for ensuring continued efficiency, sustainability, and resilience in our evolving energy landscape. As these plants age, the integration of cutting-edge technologies and updated engineering solutions becomes imperative to optimize energy output, enhance safety measures, and minimize environmental impact. Through meticulous modernization, we unlock the potential for increased energy generation, improved operational flexibility, and seamless integration with emerging renewable energy systems. Moreover, rehabilitation efforts address wear and tear, prolonging the lifespan of critical components and safeguarding against potential hazards. By investing in these transformative initiatives, we not only uphold the reliability of our energy infrastructure but also uphold our commitment to a cleaner and more robust energy future for generations to come. Across the world, an array of rehabilitation
projects are currently in progress, tackling a range of challenges that impact hydropower initiatives.
Overcoming corrosion In the US recently, when engineers at Hoover Dam
determined that the original cast iron lantern rings built into some of its turbines needed to be replaced, they were looking for a solution to help them overcome the corrosion issues they experienced with the cast iron. The maintenance team also faced another challenge.
Below: KONČAR has secured a contract with Verbund to work on the Egglfing – Obernberg and Braunau – Simbach projects
The Colorado River serves as a water source for the Hoover Dam hydropower station, and the water in this area is commonly referred to as “hard water” due to its high mineral content, specifically high levels of calcium
and magnesium ions. Aluminium lantern rings that were first tried as a replacement were corroded by chemical reactions with the minerals in the water. Having used Vesconite Hilube bearing material in other applications, such as guides on their pressure relief valves, the engineers were familiar with the no-swell, non-corrosive properties of the material and also with Vesconite Bearings’ capability to create large-diameter parts such as these 44-inch diameter lantern rings (Ø1,100mm). Vesconite Hilube also had the added advantage that it is not chemically attacked by the “hard water”. Two lantern rings were supplied, one of which was divided into two segments and another of which was divided into three segments. Like the lantern rings Vesconite Bearings makes for pumps, the large- diameter hydroelectric power plant lantern rings were easily machined and included the necessary flush holes that would cool the shaft on which they were located. “Our experienced staff in the machine shop can machine these large-diameter parts with the necessary accuracy,” noted Monique Potgieter, the application engineer who assisted the Hoover Dam team with the design and supply of the lantern rings. “Even though not all lantern rings are designed to run in close proximity to the shaft, it is important to know that our materials can be used with small clearances. This will result in better shaft support and stability, all the while you’ll have no worries of contact between the shaft and the lantern ring,” she said. “Vesconite’s low-friction materials are non-galling, and occasional contact with the shaft will not result in damage,” Potgieter added. The two lantern rings were supplied in early 2022,
and are the largest lantern rings Vesconite has produced to date.
New generators KONČAR – Generators and Motors recently
announced it has secured two significant contracts for substantial ventures in Germany and Austria, with the initial phase of these projects valued at over €10 million. Austrian electricity provider Verbund chose KONČAR’s proposal for the comprehensive revitalization of two hydropower plants situated on the German-Austrian border following a competitive tender process initiated in October 2022. In the Egglfing-Obernberg project, KONČAR – Generators and Motors will embark on the manufacturing of six entirely new generators for the German-side power plant. Meanwhile, as part of
26 | September 2023 |
www.waterpowermagazine.com
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