The department of turbines design

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Activity

The beginnings of design and manufacture activity in U.C.M. Resita, took place on 1940, the systematic activity starting on 1960. Presently, the design activity in field of hydraulic machines covers the complete range of classic turbines (Pelton - P_max. = 174 MW, Francis - P_max. = 170 MW, Kaplan - P_max. = 178 MW, Bulb - P_max. = 28 MW) and of radial-axial pumps (P_max. = 10 MW); also in our own design have been manufactured axial pump-turbines (P_max. = 113 MW).

The design and manufacture of hydraulic machines was a real success for Resita Works and for the Romanian industry considering the fact that the output of the groups in service is about 6000 MW and their operation is still very good.

The experience achieved in the design and manufacture of hydraulic turbines, allowed us, starting with 1973 to perform export of Kaplan, Francis and Bulb turbines and electric generators for hydraulic power stations in China, Turkey, Yugoslavia.

The design of hydraulic machines is based on the existence of some performant models tested in our own lab. Also, we continuously aim to improve the efficiency of the turbines in service and to make them environment friendly in operation by adapting some new design concepts and optimizing their technical characteristics by means of CAD design and 3D modeling, finite element analysis and other specific procedures.

Also in refurbishment and rehabilitation of obsolete hydraulic turbines, we use the latest achievements in technology.

For the success of completing the activities to manufacture new hydraulic machines or to rehabilitate obsolete ones, the experts from he design department provide technical assistance in the manufacturing process, during assembling and at putting into operation.

The design in the field of hydraulic machines was developed in a long period of time, with prestigious achievements obtained by our own efforts and by collaboration with well known companies (L.M.Z.; Neyrpic), presently we give special attention to modernize this activity.

Main objectives

Hydraulic turbine for HPP Lotru. This power plant is provided with three vertical Pelton turbines, performed based on Neyrpic- France license, two of them manufactured by U.C.M. Resita SA and one by Neyrpic France. Main technical characteristics:

• maximum net head H_max = 788 m
• designed net head H_c = 730.5 m
• minimum net head H_min = 697 m
• rated speed 375 rpm
• design discharge = 26.66 m³/s
• design power calculation 174250 kW
• characteristic diameter of runner D₁ = 2950 mm
• number of nozzles: 6 pcs.

The turbine from HPP Lotru is Pelton type with highest output and head in the country and one of the largest in Europe.

Hydraulic turbine for HPP Mariselu. The hydraulic turbine Francis type manufactured by Resita Works, covers the range of net heads within 10 m and 600 m and unitary power between 1 MW- 170 MW. These turbines have been performed exclusively in Romanian design, continuously increasing the technical performances in a relative short period of assimilation (HPP Paltin - 1970, P = 5350 kW, H = 80 m; HPP Tarnita - 1974, P = 23200 kW, H = 78 m; HPP Mariselu - 1977, p = 85500 kW, H = 440 m; Hpp Retezat - 1986, P = 170500 kW, H = 526 m).

The manufacture of the hydraulic turbines FVM 85.5-440, for HPP Mariselu represents a special qualitative leap in design, with further implications in manufacture, assembly and putting into operation.

Main technical characteristics of the turbine:

• range of net head = 399-467 m
• rated speed 600 rpm
• characteristic diameter of runner D₁ = 2250 mm
• maximum output 85500 kW

The manufacture, assembly and putting into operation of the 3 (three) groups form HPP Mariselu also required special efforts of all personnel involved but these efforts were rewarded by the good operation of these groups from the date of their putting into operation till present.

The designs of these turbines represent one outstanding national premiere and a real success in design, manufacture and assembly, also due to a proper service of groups. These facts, made possible approaching of the design for highly performant Francis hydraulic turbines, 170 MW and 526 m, which have been performed by U.C.M. Resita SA, located since 1986 in HPP Retezat, where they are operating in proper conditions in the designed range of heads and outputs.

The experience gained by U.C.M. Resita SA, in the design and manufacture of Francis hydraulic turbines, made possible the export of these turbines, after 1980, to some power plants in Turkey.

The custom designed Francis turbines, were manufactured in 38 typo-dimensions, summing about 2760 MW, proving good behavior in service.

The hydraulic turbine KVB type, 178-27.16 from HPP Iron Gates I. The hydropower plant (HPP), on the Romanian side, pertaining to the Hydropower and Navigation System (SHEN) Iron Gates I, on Danube river, is fitted with 6 (six) vertical hydropower units with Kaplan turbines having the diameter of the turbine runner D = 9500 mm, directly coupled to the related synchronous generators. The design of each hydropower unit is "umbrella" type. Taking into consideration the dimensions and the unitary power, these hydropower units were a national premiere and even a world one, as concerns the unitary power installed on a hydropower unit with Kaplan turbines. Now and then, the HPP Iron Gates I, is the largest power plant on the Danube, both in respect of the installed power and the dimensions of hydropower units. The six hydropower units that fit the Romanian HPP of SHEN Iron Gates I, were put into operation within 1970-1972, three of them are Russian manufacture (L.M.Z. and Electrosila) and the other three are Romanian manufacture - U.C.M. Resita SA.

For the initial parameters of the power plant SHEN Iron Gates I, the designer and the supplier of three of the six turbines, L.M.Z. - Sankt Petersburg, provided following characteristics of turbines:

• range of net heads H = 17.50 - 35.46 m
• rated power at turbine coupling P_n = 178 MW
• characteristic diameter of the runner D = 9500 mm
• rated speed n = 71.43 rpm
• optimum net head H_opt. = 29.95 m
• maximum efficiency n_max. = 94 %

In over 25 years of operation, from the date of putting into operation of groups, until 1998, when the contract for hydropower units refurbishment was signed, each of them recorded over 170,000 hours of operation, meaning 6,800 hours/ year.

After the tests performed in 1976, in order to check the guaranteed parameters and the possibility to increase the power at the turbine coupling, the designer and the supplier - L.M.Z. Sankt Petersburg increased the power in the whole range of net heads and changed the parameters of the turbine, reaching the maximum output of 194 MW at H = 26.5 m.

Beginning with 1998, U.C.M. Resita SA is the partner of Sulzer Hydro (VA TECH) in the refurbishment of the six hydraulic turbines.

Hydraulic turbine KVB 28-7.45 at HPP Iron Gates II. The hydropower plant (HPP), on the Romanian side, pertaining to the Hydropower and Navigation System (SHEN) Iron Gates II, on Danube river, is fitted with 8 (eight) horizontal bulb hydropower units with Kaplan turbines, with horizontal shaft in hollow shape line, having the diameter of the turbine runner D = 7500 mm, directly coupled to the related synchronous generators. The design of each hydropower unit is on 3 (three) bearings, having the runner in bracket. Taking into consideration the dimensions and the unitary power, these hydropower units were a national premiere and even a world one, except the Russian Federation, as concerns the unitary power installed on a hydropower unit. The HPP Iron Gates II, is the largest European power plant fitted with bulb hydropower units, both in respect of the installed power and the dimensions of hydropower units. The eight hydropower units that fit the Romanian HPP of SHEN Iron Gates II, were put into operation within 1985- 1986, two of them are Russian manufacture (L.M.Z. and Electrosila) and the other six are Romanian manufacture - U.C.M. Resita SA.

For the initial parameters of the power plant SHEN Iron Gates II, the designer and the supplier of two of the eight turbines, L.M.Z. - Sankt Petersburg, provided following characteristics of turbines:

• range of net heads H = 5.0 - 12.75 m
• rated power at turbine coupling P_n = 28 MW
• characteristic diameter of the runner D = 7500 mm
• rated speed n = 62.50 rpm
• optimum net head H_opt. = 9.60 m
• maximum efficiency n_max. = 94.0 %

Based on the experience recorded in the design and manufacture of Bulb hydropower units, U.C.M. Resita performed the manufacture of 2 (two) bulb hydropower units, intended to fit the HPP Djerdap II, on Danube river, for former Yugoslavia.

Standard EOS turbines. This type of turbines, are used in the range of heads from 2.5 to 20 m and discharges from 0.2 to 9 m³/s.
They are delivered in a range of five dimensions having the diameter of the runner within 350 and 1100 mm and output from 15 to 1200 kW.
The turbine is eolian type, horizontal, having the hydraulic circuit in "S" shape, the runner being provided with 4 (four) stainless steel fixed blades and the wicket gate with adjustable guide vanes. The turbine is coupled directly with the hydro generator by means of a flexible coupling.
The method of fitting allows complete automation operation of micro hydropower units, not requiring service personnel.
U.C.M. Resita SA produced and delivered approx. 233 EOS micro turbines with a total installed power of 60 MW.

Standard FO turbines. This type of turbines, are used in the range of heads from 10 to 110 m and discharges from 0.1 to 4 m³/s.
They are delivered in a range of five dimensions having the diameter of the runner within 390 and 720 mm and output from 30 to 1200 kW.
The turbine is of Francis horizontal type, metallic spiral case, the runner of carbon steel (it can be provided from stainless steel, at request) and taper metallic exhaustor. The turbine is coupled directly with the hydro generator by means of a flexible coupling.
Depending on the power plant, the turbine can be fitted/ or not with flywheel, the bearings being self-lubricated slide bearings, respectively rolling bearings.
The method of fitting allows complete automation operation of micro hydropower units, not requiring service personnel.
U.C.M. Resita SA produced and delivered approx. 234 FO micro turbines with a total installed power of 112 MW.

Products designed for the first time

The hydraulic turbine for HPP Kapulukaya. This is the first Francis turbine, of own design for export Turkey, performed 80 % by U.C.M. Resita and the remaining by the Guris, Turkey. The power plant is fitted with three turbines having the following main technical characteristics:

• maximum/minimum net head = 38.25 m/32.25 m
• rated speed n = 166.7 rpm
• design discharge Q = 55.2 m³/s
• design power P = 18.2 MW
• characteristic diameter of runner D₁ = 2850 mm

The turbines were put into operation in 1988 and they have a good behavior in service. The technical performances of these turbines made possible the development of the export in Turkey for this type of machines. Presently, being in operation other three power plants (Kilickaya, Gezende, Dicle) and others in progress of design and contract.

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