Standardization in hydropower

projects: how, when and where?

Luxembourg, September 2017

Original topic:
Standardization of hydropower projects – Aiming
for further reduction of maintenance costs,
storage & grid balance, digitalizing in service &
maintenance of hydropower plants

2017 © Studio Frosio S.r.l.

Alternative titles proposed:
a)Standardization in hydropower projects: a
chimera?
b)Standardization in hydropower projects: the
pipe dream of off- the-shelf solutions

2017 © Studio Frosio S.r.l.

 How
How to standardize the hydropower projects?
What does Standardization mean?
Oxford Dictionary (OD) definition:
the process of making something conform to a standard
Wikipedia (WP) definition :
the process of implementing and developing technical standards based
on the consensus of different parties that include firms, users, interest
groups, standards organizations and governments..
Standardization can help to maximize compatibility, interoperability,
safety, repeatability, or quality
2017 © Studio Frosio S.r.l.
 How
Compliance with the OD definition

Technical standard: formal document that establishes uniform engineering or technical criteria,
methods, processes and practices

What a hydropower project is made of?

• Steps • Works and equipment

• Design • Civil works (dam, intake, forebay, channels, …)
• Construction • Hydraulic components (gates, valves, TRCMs…)
• Commissioning • Mechanical equipment (turbines)
• Operation • Electrical equipment (generators, LV, MV, HV
• Maintenance cubicles, breakers, lines…)
• Automation, control and monitoring (SCADA, PLCs…)

2017 © Studio Frosio S.r.l.

 Compliance with the OD definition How
IEC 60041:1991 Field acceptance tests to determine the hydraulic performance of hydraulic turbines, storage pumps and pump-turbines
IEC 60193:1999 Hydraulic turbines, storage pumps and pump-turbines - Model acceptance tests
IEC 60308:2005 Hydraulic turbines - Testing of control systems
IEC 60545:1976 Guide for commissioning, operation and maintenance of hydraulic turbines
IEC 60609-1:2004 Hydraulic turbines, storage pumps and pump-turbines - Cavitation pitting evaluation - Part 1: Evaluation in reaction turbines, storage pumps and pump-turbines

IEC 60609-2:1997 Cavitation pitting evaluation in hydraulic turbines, storage pumps and pump-turbines - Part 2: Evaluation in Pelton turbines
IEC 60805:1985 Guide for commissioning, operation and maintenance of storage pumps and of pump-turbines operating as pumps
IEC 60994:1991 Guide for field measurement of vibrations and pulsations in hydraulic machines (turbines, storage pumps and pump-turbines)
IEC 61116:1992 Electromechanical equipment guide for small hydroelectric installations
IEC 61362:2012 Guide to specification of hydraulic turbine governing systems
IEC TR 61364:1999 Nomenclature for hydroelectric powerplant machinery
IEC TR 61366-1:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering Documents - Part 1: General and annexes
IEC TR 61366-2:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering Documents - Part 2: Guidelines for technical specifications for Francis turbines

IEC TR 61366-3:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering documents - Part 3: Guidelines for technical specifications for Pelton turbines

IEC TR 61366-4:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering Documents - Part 4: Guidelines for technical specifications for Kaplan and propeller turbines

IEC TR 61366-5:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering Documents - Part 5: Guidelines for technical specifications for tubular turbines

IEC TR 61366-6:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering Documents - Part 6: Guidelines for technical specifications for pump-turbines

IEC TR 61366-7:1998 Hydraulic turbines, storage pumps and pump-turbines - Tendering Documents - Part 7: Guidelines for technical specifications for storage pumps

IEC 62006:2010 Hydraulic machines - Acceptance tests of small hydroelectric installations

IEC 62097:2009 Hydraulic machines, radial and axial - Performance conversion method from model to prototype
IEC 62256:2017 Hydraulic turbines, storage pumps and pump-turbines - Rehabilitation and performance improvement
IEC 62270:2013 Guide for computer-based control for hydroelectric power plant automation
IEC 62364:2013 Hydraulic machines - Guide for dealing with hydro-abrasive erosion in Kaplan, Francis and Pelton turbines

Hydropower projects (esp. large ones) are already OD standardized 2017 © Studio Frosio S.r.l.
 How
Compliance with the WP definition

OD definition: passive role (complying to a set of rules → cost)

WP definition : active role (implementing and developing → benefit)
Motives to standardize
Company level
• Pursuing specific company
interests
• Solving technical problems Hydropower project level?
• Knowledge seeking
• Influencing regulation
• Facilitating market access
2017 © Studio Frosio S.r.l.
 How
The Common Perception (CP) of what Standardization means
Standardization (technical)  Reduction to a single type or model
Standardization (economics)  production of a large quantity of goods
having identical characteristics and thus as the pure serial production
of an asset (through which it is preferable to produce the quantity
albeit a possible decrease in the production quality).
It promotes economies of scale.

Standardization of a whole hydropower project is almost impossible

2017 © Studio Frosio S.r.l.

 When & Where
The magic word is: REDUCTION OF COSTS

Reduction of costs in any phase of the project

When Where
• Steps • Works and equipment
• Design • Civil works (dam, intake, forebay, channels, …)
• Construction • Hydraulic components (gates, valves, TRCMs…)
• Commissioning • Mechanical equipment (turbines)
• Operation • Electrical equipment (generators, LV, MV, HV
• Maintenance cubicles, breakers, lines…)
• Automation, control and monitoring (SCADA,
PLCs…)
2017 © Studio Frosio S.r.l.
 When & Where
Where put our attention?
SMALL HYDRO LARGE HYDRO

10% 5%
15%

35% 55%

80%
Percentage of total
cost of a HPP
EM Civil Works ENG EM Civil Works ENG

2017 © Studio Frosio S.r.l.

 When & Where
CIVIL AND HYDRAULIC WORKS
Main barrier: SITE SPECIFICITY No “copy and paste”
• Geology
• Type of foundations (shallow, deep,….)
• Type of retaining systems (sheet piles, continuous
diaphragms, jet grouting columns,…)
• Topography:
• Optimized position of plant components
• Boundary conditions (access, use of land, ….)

IT’S DIFFICULT TO STANDARDIZE LARGE HYDRO

2017 © Studio Frosio S.r.l.
DESIGN PLANTS LAYOUT When

The copy and paste dream: ~ 1990

River stretch: 28 km
production of a large quantity of goods
Total head: 105 m
Total installed capacity: 41 MW
Nr. of plants: 7 equal plants ~ 6 MW each
2017 © Studio Frosio S.r.l.
DESIGN PLANTS LAYOUT When

The river stretch of given total head divided in seven parts of similar head

production of a large quantity of goods

The same EM equipment solutions replicated seven times

The same civil works solutions replicated seven times
The same gates, TRCMs works solutions replicated seven times
….

2017 © Studio Frosio S.r.l.

DESIGN AND COSTRUCTION When & Where
The copy and paste dream comes true: 2016 update
Cascade of three equal plants

2017 © Studio Frosio S.r.l.

DESIGN AND COSTRUCTION When & Where
The copy and paste dream comes true: 2016 update
HPP Sarezzo 1 Sarezzo 2 Sarezzo 3
Maximum diverted flow rate 20 20 20 m3/s
Average diverted flow rate 6,79 6,79 6,79 m3/s
Average gross head 3,20 3,20 3,20 m
Nominal power of the plant 213,02 213,02 213,02 kW
Turbine installed capacity 500 500 500 kW
Generator installed capacity 625 625 625 kVA
Expected yearly average
1,49 1,49 1,49 GWh
energy production
Cost of design and realisation 1.920.000 1.950.000 2.050.000 €
Cost/capacity ratio 3.840 3.900 4.100 €/kW
Cost/energy ratio 1,29 1,31 1,38 €/kWh
Incentivised tariff 210 210 210 €/MWh
Expected yearly income 313.000 313.000 313.000 €
2017 © Studio Frosio S.r.l.
DESIGN AND COSTRUCTION When & Where
The copy and paste dream comes true: 2016 update
3 equal flap gates
6 equal units
3 equal TRCMs
3 equal unit gates
3…..
3….
3…

2017 © Studio Frosio S.r.l.

The copy and paste dream comes true: 2017 update When & Where
Cascade of six small hydro plants in Northern Italy
Cost reduction: the second pillar of profitability assurance
• Plants of this size may be expected to
have a higher feed-in tariff
• But construction costs are also higher in
relation to performance
The realization of several similar projects
represents an opportunity to reduce the
overall investment
By standardizing the technical solutions,
the construction, planning and operating
costs can be reduced:
• the layout is basically the same for each The boundary conditions are almost identical:
hydroelectric power station Accesses, morphology, geology, etc….
• the building of the powerhouse is
particularly compact 2017 © Studio Frosio S.r.l.
 When & Where
Reduction of construction and operating costs
The choice of the machines has fallen
on the belt-driven pit turbine:
• Cheaper than a Kaplan turbine
• Requires a narrower substructure
• The efficiency is nevertheless good
In cooperation with the
manufacturers, we also uniformize WKA Badia –Längsschnitt des Krafthauses

the delivery as far as possible with

In this way we reduce:
regard to the size of the units • The cost of delivery (in comparison with a single order)
• The operating and maintenance costs

2017 © Studio Frosio S.r.l.

 When & Where
Main data of the projects
• The rated flows were
reduced to improve the
efficiency of the SHPP Qold Qnew H PTUR E
(m3/s) (m3/s) (m) (kW) (MWh/yr)
projects
• MAIN DRIVER OF THE #1 26,00 9,00 3,70 300 1.560
STANDARDISATION: #2 26,00 15,00 2,30 310 1.190
#3 24,00 15,00 1,60 220 800
Direct access to feed-in
#4 24,00 15,00 3,40 460 1.660
tariffs (plants with an #5 24,00 13,00 3,50 410 1.680
average output up to #6 17,00 15,00 2,00 270 750
250 kW) TOTAL - - 1.970 7.640

2017 © Studio Frosio S.r.l.

 When & Where
ELECTRO-MECHANICAL EQUIPMENT DESIGN
Standardization of hydro turbines
Process started between ‘70s and ‘80s XX century
Range of power 100  5.000 kW
• Choice of the typical machine
• Choice of the acceptable simplifications
Reduction of design time → Reduction of delivery time
→ Reduction of investment costs
Use of off-the-shelf components:
→ Reduction of the O&M costs
2017 © Studio Frosio S.r.l.
 When & Where
ELECTRO-MECHANICAL EQUIPMENT
1987
H (m) Type Nr. Features Axis Speed Speed
models increaser
2,510 4 blades KT 1 Single regulated V-Incl. 158-625 Y

7,520 5 blades KT 1 Single regulated V-Incl. 158-625 Y

1320 Francis 1 Distr. 12/12 blades V-H 200/1500 Y/N

or 12/6 blades

85400 1-2-3-4 jets 1 Single type of runner V-H 750/1500 N

Pelton

2017 © Studio Frosio S.r.l.

 When & Where
ELECTRO-MECHANICAL EQUIPMENT
2017

2017 © Studio Frosio S.r.l.

 When & Where

ELECTROMECHANICAL EQUIPMENT DESIGN AND MANUFACTURING

Chinese approach:
Development of a limited sets of machines from each prototype model
– chosen from the smallest possible number of models

• Off-the shelf products

• Pre-fabrication and storage of large amounts of units
• Oriented to markets where the attention to efficiency is low

2017 © Studio Frosio S.r.l.

 When & Where
ELECTROMECHANICAL EQUIPMENT DESIGN AND MANUFACTURING
European approach:
Development of a large sets of machines from each prototype model –
chosen from the smallest possible number of models. Each
standardized machine covers a narrow area of the hill chart

• Customized products
• Set of construction drawings already done for each model in each of
the installation versions
• Oriented to markets where the attention to efficiency is high
2017 © Studio Frosio S.r.l.
 When & Where
PLANT AUTOMATION AND CONTROL
Sector where the standardization is easier thanks to the large set of
International Standard (ISO, CEN, IEC, IEEE, etc.) available:
• IEEE Std 1010-2006: Guide for Control of Hydroelectric Power
Plants
• IEEE 1249-1996: Guide for Computer-Based Control for
Hydroelectric Power Plant Automation
• IEEE Guide for Control of Small Hydroelectric Power Plants
• EN 61850-7-410:2013-01: Communication networks and systems
for power utility automation Part 7-410: Basic communication
structure - Hydroelectric power plants
2017 © Studio Frosio S.r.l.
 When & Where
PLANT AUTOMATION AND CONTROL
Low cost of collecting data from the field

Predictive maintenance: what would have been "unplanned stops"

are transformed to shorter and fewer "planned stops", thus increasing
plant availability
Model Based Condition Monitoring
• temperatures monitoring
• vibration analysis
• sound level measurements
• oil analysis
2017 © Studio Frosio S.r.l.
 When & Where
OPERATION AND MAINTENANCE
Some common sense remarks:
Hydropower plants are made of many off-the-shelf components
Standardization can help to maximize compatibility and interoperability
That’s particularly true if a single operator manages many different
powerplants or a single plant with many units. Costs reduction for:
• Spare parts costs
• Maintenance contracts of special components
• Training of personnel for ordinary maintenance activities

2017 © Studio Frosio S.r.l.

 CONCLUSIONS
• Site specificity makes difficult to get technical standardization
(Reduction to a single type or model) of hydropower projects,
especially large ones (and it doesn’t make much sense, too)
• Standardization (technical and economics related) can be got in
single components of a hydropower project as for any other
industrial process
• Small hydro cascade systems can benefit from standardization at
each stage of the project

2017 © Studio Frosio S.r.l.

Thanks for your attention.