REFURBISHMENT OF SMALL HYDRO PLANTS

REFURBISHMENT OF SMALL HYDRO PLANTS Hugo Carle, Eng. General Manager Innovative small hydro technologies Waterpower XIII July 29, 2003

CONTENTS • INTRODUCTION • ASSETS OF OLD SMALL HYDRO PLANT • INNOVATIVE TECHNOLOGIES • CIVIL WORKS • MECHANICAL EQUIPMENT • ELECTRICAL EQUIPMENT • END RESULTS • CONCLUSION

INTRODUCTION Most of the hydro plants and mills built in the late 1800s and the early 1900s to power the industrial era are now considered obsolete. • Need full time staff on site • Regulated by massive hydraulic systems • Protected by massive and unsafe electrical switchgears • Controlled by large panels of levers, switches and gauges • Civil structures are too old to be refurbished • Electromechanical equipment is too expensive to maintain • Power plant is uneconomical to operate This usually leads to a permanent shutdown decision by the owner. However, these once large hydro plants could be now opportunities for small hydro refurbishments.

ASSETS OF OLD SMALL HYDRO PLANTS Old small hydro plants still have very attractive assets which strongly support their refurbishment and potentially their upgrade. • Existing access road • Existing civil structures • Existing electromechanical equipment • Well known upstream and downstream water levels • Well known river flow conditions • Proximity to an existing transmission line or substation • Water usage, environmental and ownership rights • Historical building architecture The evaluation of these assets is necessary to determine what is the potential of success of an old small hydro plant refurbishment.

INNOVATIVE TECHNOLOGIES All the electronics and the latest of high tech can be used to refurbish and to interface with the old structures and equipment. Innovative technologies will used in the design, the manufacturing and the implementation of almost all items of the project. • Civil works • Mechanical equipment • Electrical equipment They will also be used for the operation and for the maintenance after the project implementation.

INNOVATIVE TECHNOLOGIES CIVIL WORKS • Laser level (survey, dimension control) • GPS coordinates (survey) • GIS system (3D modelisation of powerplants on computer) • Concrete additives (grouting, injection, curing) • Self-levelling concrete for complex forms • Geotechnical membranes • NDT development on earth and concrete dams • Protective coatings (water leakage, mussels, erosion) • Structure design, water infiltration and flood simulation softwares • Etc.

INNOVATIVE TECHNOLOGIES

INNOVATIVE TECHNOLOGIES MECHANICAL EQUIPMENT • Finite element analysis of components (static, dynamic) • Computer fluid dynamics of water passages (design, performance) • Laser survey of existing turbine runner • Cutting processes (water, laser and others) • Welding processes (electroslag and others) • Numerically controlled machining (just about any shape) • Material (stainless steel, al-bronze, cavitation protection, self-lub) • Turbine performance tests (equipment and methods) • Fish friendly turbines • Etc.

INNOVATIVE TECHNOLOGIES ELECTRICAL EQUIPMENT • Protection relays (multifunctions, event recording) • Automation system (HMI, communication links, remote control) • PLC applications for control mode (speed, voltage, level, pf) • Electronic servo-valves (HPU, governing systems) • Excitation systems (AVR, DVR) • Winding insulation processes (VPI, tapes) • Material (winding copper strands, stator lamination, rotor field poles) • Monitoring transducers (temperature, vibration, pressure, speed) • Direct drive generator for small bulb unit • Etc.

END RESULTS The end results are numerous and sometimes astonishing. • The old structures are still standing. • The historical building architecture has been saved. • The old machinery is still working after being cleaned and refurbished. • New equipment has been installed where necessary. • Modern electronic equipment has been hooked to the old and new equipment to properly monitor them. • The old small hydro plant is now remotely controlled by computer rather than by an on site staff.

CONCLUSION There are hundreds of old small hydro plants. Most of them have very interesting assets which are still in fairly good condition to properly refurbish them. Innovative technologies greatly contribute to the refurbishment process. This is not limited to the electronics clearly showed in the end results, especially the protection and the automation systems. It is also deeply involved in the design and the manufacturing of the electromechanical equipment and the implementation of the civil works. It is now up to some of you to initiate new projects and to some others to find new innovative ways to successfully implement them.

ACKNOWLEDGEMENT THANK YOU ! Hugo Carle, Eng. General Manager Gestion Conseil SCP inc. Tel.: (819) 562-7266 Fax: (819) 562-7210 hugo.carle@gcscp.qc.ca

REFURBISHMENT OF SMALL HYDRO PLANTS