The Guide to Hydropower Mechanical Design

384 Pages·1996·32.593 MB·English

by  American Society of Mechanical Engineers

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What experts have to say abotk.. - . . .. ....1
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THE GUIDE TO
Hydrapower Mechanical Design
"The Guide will no doubt join the select group of basic reference
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books on hydro plant equipment design-the 'Bibles' familiarfto_c--
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"The Guide to Hydropower Mechanical Design stands out as a
modern and definitive text in this specialized field. The product
of some of the finest minds in the industry, this work broadly
covers hydroelectric plant and machinery for the benefit of
engineers, and operations and maintenance personnel. I highly
recommend this book."
-Edward 0. Groff, P.E.
President, 1997, American Society ofCivilEngineers
Principal Engineer, Northrop, Devine & Tarbell, Inc.
"The evolution of hydroelectric power engineering is marked
by milestones of achievement in recording the state of the art.
The Guide is an important new marker of progress .. lt achieves
particular quality from the comprehensive treatment it provides
of all mechanical aspects of a hydro development."
-J
Gavin Warnock, P.E., B.Sc.(Hons), D.I.C.(Hydro Power)
Managing Director, Monitor (International) Limjfed "',~_'(' - • , .•. - ., .. ~-..-''""''"- • ··"\
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"The Guide provides extensive and valuable technical infor
mation. It is a useful and practical tool found nowhere else,
which captures the experience and knowledge gained by the
authors through decades of designing hydropower projects."
--jean-Paul Rigg, Eng., M.Sc.
General Manager, Engineering and Services
Hydro-Quebec
Montreal (Quebec) Canada
More expert comments on back cover.
THIE: GUIDE: TO
power
Mechanical
Desiu11
PREPARED BY THE
AMERICAN SOCIETY OF
MECHANICAL ENGINEERS
HYDRO POWER TECHNICAL COMMITTEE
PUBLISHED BY
HCI PUBLICATIONS
. ,.,:,'··:·: .. :.· ... --·· ... · .. · ...
. _. ·--·. '.'.. . ..· .. __ . --- _. -- -·-----
Copyright ©1996 by HCI Publications, Inc.
All rights reserved
Printed in the United States of America
ISBN 0-9651765-0-9
NOTICE
This book was prepared as a project of the American
Society of Mechanical Engineers (ASME) Hydro Power
Technical Committee. Neither the ASME, individual
committee members, their employers, contributing
organizations, HCI Publications, nor any person acting
on behalf of them (a) makes any warranty, express or
implied, with respect to the use of any information,
apparatus, method, or process disclosed in this book or
that such use may not infringe privately owned rights; or
( b) assumes any liabilities with respect to the use of, or
for damages resulting from the use of, any information,
apparatus, method, or process disclosed in this book.
HCI Publications is the publisher of Hydro Review and
HRW-Hydro Review Worldwide magazines, Hydrowire
and Hydro World Alert newsletters, books, and other
materials useful to individuals and organizations having
interests in hydroelectricity. H CI also organizes hydro
related meetings and events, including the HydroVision
conferences.
HCI Publications
410 Archibald Street
Kansas City, MO 64111
Phone:[phone]
Fax: [phone]
- .
E-Mail: [email protected]
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Foreword
T
he technical information provided in this, The Guide to Hydropower
Mechanical Design, will be useful to any technical person involved with
the design of new hydroelectric plants or with the modernization of older
hydroelectric facilities.
With an installed base of nearly 700,000 megawatts of hydropower world
wide, and active construction programs underway throughout much of the world,
this Guide is especiallyt imely. Other books providing guidance relevant to hydro
project mechanical design are decades old, and virtually none capture the breadth
and depth of experience represented in this volume.
The publication of this guide is the culmination of more than a decade long
quest on the part of the American Society of Mechanical Engineers Hydro Power
Technical Committee. As authors of this guide, many committee members have
worked with passion and energy on the tasks leading to the Guide's completion.
Committee members, and their employers, have offered their valuable time and
resources to create a useful legacy to benefit future generations of hydroelectric
plant designers. This is also a legacy for society at large, which will reap the
rewards of safe, economical, and clean energy produced from hydroelectric plants.
The project to publish this Guide originated in 1984. It was suggested by
Bernard Eyden, who was then the committee's chairman. His vision was that a
mechanical design guide was needed for use by engineers who had about five years
of post-graduate working experience, but who were not experienced in hydro
design. In 1984, as today, there was concern that the knowledge of many very
capable and experienced hydro plant designers would be lost due to the
vicissitudes of reorganizations and the relentless march of Father Time. The imper I
ative was to take action to ensure that this knowledge and experience was not lost.
I.
Thus the Committee committed itself to the goal of capturing-in a practical, '
convenient, and useable form-the most useful information for guiding succeed
ing generations of hydro plant mechanical designers. This effort has brought the
earnest contributions of many individuals, and the stalwart support of their
employers. Many meetings and many thousands of hours have been devoted to
creating this Guide.
.r
The Guide to Hydropower Mech'!'nical Design iii
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In addition to the Committee member contributors and
their employers, others have provided meaningful assistance to
the Guide project. In particular, the Committee gratefully
acknowledges the financial support of the ASME Power Division
and the Factory Mutual Insurance Company. Also, the Commit
tee appreciates the efforts ofHCI Publications, especially of
managing editor Marla Barnes, first-draft editor Alia Michaels,
and editor-in-chief Carl Vansant, P.E.
Each chapter in the Guide is the product of multiple con
tributors and multiple reviews. Initial drafts of material were pre
pared by one or more authors; other individuals served to review
the material. The Committee as a whole reviewed each manu
script section on several occasions as the Guide evolved. While
the contributors listed at the front are the principal authors and
reviewers, materials were solicited from others as well and have
been incorporated where appropriate.
The Committee is pleased and proud to be able to provide
this Guide to our present.and future colleagues.
For the American Society of Mechanical Engineers
Hydro Power Technical Committee:
KERMIT PAUL, JR.
Chairman 1993-1997
iv The Guide to Hydropower Mechanical Design
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Contributors
Kermit Paul, Jr., P.E.-Consulting Mechanical/Electrical Engineer. Retired
Pacific Gas and Electric Company Supervising Mechanical Engineer and Project
Engineer for Helms Pumped Storage Project. Chairman, ASME Hydro Power
Technical Committee and past member of ASME Hydro Turbine Performance
Test Code Committee. [2, 4, 11, 12]
Donald R. Webb, P.E.-Manager, Applied Hydraulic Engineering, Voith
Hydro, Inc. with 27 years experience in hydraulic application, design, and testing
of turbines and pump-turbines. Has served in the ASME Fluids Engineering Divi
sion as Chairman of Fluids Machinery Committee, Honors Committee Chairman,
and Chairman of the Executive Committee. Vice Chairman, ASME Hydro Power
Technical Committee. Editor or co-editor of eight ASME symposium volumes.
[3, 12]
Glenn W. Brewer, P.E.-Engineering Manager for Raytheon Infrastructure Ser
vices in Bellevue, Washington. Formerly Project Engineer for Idaho Power Com
pany, responsible for overall hydro construction projects including permits, engi
neering, major equipment procurement, cost, schedule, construction coordination,
and documentation for severaln ew hydroelectric projects on the Snake and Payette
rivers in Idaho. Author or co-author of several papers for Waterpower conferences
and in Hydro ReJJiew magazine. Secretary, ASME Hydro Power Technical Com
mittee. [13, 14]
B.G. Ragsdale, P.B.-Mechanical Engineer/Manager of operations and mainte
nance of the Eastern Hydro Region power generating plants located in Tennessee
and North Carolina for the Tennessee ValleyA uthority. Twenty-five years design
experience in conventional and pumped-storage projects and design and imple
mentation of plant upgrades, hydro modernization, and development of aerating
methods to improve releases from power generating plants. Paper Review Coor
dinator, ASME Hydro Power Technical Committee. [13, 14]
Notes:
*-indicates retired.
**-indicates deceased.
Numbers in brackets ( []) indicate the numberrs) of chapters
to which the contributor has made a primary contribution.
The Guide to Hydropower Mechanical Design v
... ·. . •. . ~:.~ ..- :.· P-.-:~-.:. :. ': . .. ~ .. f·~· . ·.: ··. .:.:~~·,· ..- . -. ··.. · ." ..,
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Roger E.A. Arndt, PhD-Professor of Civil Engineering at the University of
Minnesota (since 1977); served as Director of the St. Anthony Falls Laboratory
until 1993. Taught Aerospace Engineering at Penn State; has worked in industry
in the areas of rocket design and high speed marine vehicles. He is the recipient of
several awards for teaching and research, including the Alexander von Humboldt
Senior Scientist Award, the ASME Fluids Engineering Award, and the Lorenz
Straub Award. He is a Fellow of the ASME. [2]
Hassine Benjannet, P.E.-Senior Project Manager, SNC-Lavalin Inc., Hydro
electric Consulting Company. Responsible for all aspects of hydroelectric develop
ments and is involved, at both the management and technical levels, in the design
of new plants and the rehabilitation of facilities built at the turn of the century,
including powerhouses, dams, substations, and transmission lines. [7]
Richard E. Bishop, P.E.-Senior Marketing Specialist, Oglethorpe Power
Corporation. Previously Senior Mechanical Engineer on the Rocky Mountain
Pumped Storage Project. Also, Plant Engineer at the Dayton Power & Light
Stuart Station, and Senior Operations Engineer for Oglethorpe Power at the
Hal B. Wansley and Robert W. Scherer fossil power stations. First chairman of
the Middle Georgia Group of the ASME.
John R. Chappel, P.B. *-Mechanical Engineer, Idaho National Engineering
Laboratory, Idaho Falls, Idaho. Senior Engineering Specialist involved in moni
toring engineering development activities of the U.S. Department of Energy
National Hydropower Program. Formerly Research Supervisor at Newport
News Shipbuilding Hydraulic Laboratory involved in research on and testing of
hydraulic turbines, pumps, and other fluid equipment. Intermittently involved
with hydropower for 41 years.
Rick J. Christensen-Mechanical Engineer, Bureau of Reclamation. Responsible
for designs, specifications, and construction support for the following types of
equipment: trashrakes, conveyors, selective withdrawal structures, screening
equipment, screen cleaning systems, and fish-related equipment and structures.
Team member of the Reclamation's research program on the Development for
Better Trash Screening and Cleaning Devices. Co-author of the technical paper
"Interaction of Technical and Economic Factors in Pumped Storage Evaluation."
John B. Codrington, P.E.-Senior Staff Engineer, Acres International Limited,
Niagara Falls, Canada. Thirty years experience in an engineering consultancy that
specializes in hydroelectric design for projects in Canada and overseas. Special
interests include computer modeling of hydraulic transients and their interaction
with the electrical system. Recent experience includes design for high-head hydro-
vi The Guide to Hydropower Mechanical Design
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electric plants for sediment-bearing rivers in Latin America, and resolution of
unusual operating problems involving penstock and water column behavior. Co
author of Canadian Electricity Association research report on draft tube surges.
William H. Colwill, PhD-Vice President, Marketing, American Hydro Corpo
ration. Responsible for marketing and sales of American Hydro's products and all
hydraulic engineering including turbine and pump-turbine application, design,
and quality assurance. Dr. Colwill has developed advanced application procedures
for turbines and pump-turbines. Previously,D r. Colwill has developed three
dimensional flow analysisc odes for centrifugal compressors and new aerodynamic
designs for compressors and new hydraulic designs for pumps and turbines. [ 3]
Marcus E. Crahan III, P.E.-Founder and Director of Power Engineering.
Managed repair and overhaul oflarge hydroelectric pumped-storage and conven
tional turbine-generators. Proficient in the areas of system modeling, numerical
analysis,f ield testing, and performance data acquisition. Expert in the area of
rotating machinery dynamics. Authored many papers on vibration analysiso f elec
tric power generating apparatus. Member of the ASME Hydro Power Technical
Committee from 1990 to present. Registered Mechanical Engineer, Member of
ASME. [13]
Percy B. Dawson, P.E.-Consulting Mechanical Engineer. Formerly Chief
Engineer, Pelton Division of Baldwin Lima Hamilton Corp. Senior Mechanical
Engineer, Pacific Gas and Electric Company and International Engineering
Company; and Project Mechanical Engineer for Morrison Knudsen Engineers.
William H. Duncan,Jr., P.E.-Mechanical Engineer, Bureau of Reclamation
Hydroelectric Research and Technical Services. Leading technical expert and
team leader in the operation and maintenance of hydroelectric turbines, pumps,
and related mechanical equipment. Services are provided for 56 hydroelectric
power plants with more than 12,000 MW of power capacity.A uthor or co-author
of numerous USBR publications. ASME member and Vice Chairman of PTC 29
( Governor Test Code) Committee.
\
Bernard Eyden-P.E. (U.S.), P.Eng. (Canada), E.Eng (U.K.), Fellow ASME,
I
Member American Society of Civil Engineers, MIMechE. Engineering Consul I:
I
tant. Experienced in design, procurement of equipment, construction, and testing I
!
of all types of hydropower and pumping installations, including pumped storage, f
i
in capacitiesr anging from 1.5 MW to 1,136 MW in the U.S., Brazil, and Korea.
I
l
Served as Chief Mechanical Engineer and in other senior positions with Brown &
Root, TAMS, Stone & Webster, and Brazilian L&P. Has authored several papers
I
and articles. [8, 13]
!·
The Guide to Hydropower Mechanical Design vii