Objective
The renovation of the Buchenmuehle am Kocher Hydro Power Plant is intended to substitute the existing 2 old and uneconomic horizontal Francis open flume turbines, each with a 6 m3/s absorption capacity and a 6,45 m head by an innovative Kaplan S-reverse turbine incorporating combined double and frequency regulation and a particularly innovative, environmentally-friendly lubricant-free bearing technology. The first-time use of turbines of this size will also increase the power station's design water flow from 12 up to 14 m3/s, thereby increasing generation to 3,7 GWh in total.
The use of only one turbine assembly and improved runner geometry will significantly increase the economy of the proposed solution compared with a conventional turbine. This measure will enable the power station to generate environmentally-friendly, regenerative energy under economical conditions for other 50 years.
The project is currently in the planning phase. Initial result can be anticipated at the earliest after commissioning.
The existing turbine system contains two horizontal Francis open flume turbines with a vertical suction pipe into the underwater chamber. In future, one of the existing turbine chambers will serve as the inlet area, corresponding to the upper third of the S shape of the tubular turbine. The inlet pipe to the turbine is housed in the underwater chamber cover together with the connected elbow. Downstream of the inlet elbow, the turbine is positioned on the base of the current underwater chamber. The downstream concrete suction pipe cuts off the newly created machine chamber from the downstream works water. The suspended material occuring with the works water is moved by a screen cleaning machine. This functions on the same principle as an hydraulic dreger and removes the screenings automatically without the use of a screening transport unit.
The innovative part of the project is based on the followlng solutions:
- the annual power generation is optimized by the new double frequencyregulation (efficiency optimization)
- of all possible turbine types, it requires the lowest amount of conversion work
- the lowest underwater cavity is reached, thanks to horizontal installation of the turbine shaft
- the influences of the suction pipe are reduced compared to standard S tubular turbines
- the turbine type allows direct coupling of the turbine shaft to the generator, thus enabling the transmission unit to be omitted thereby reducing, sound emissions, omission of oil lubrication, omission of cooling, more economical design
- the turbine allows the installation of environmentally-friendly innovative bearing systems, resulting in it beeing impossible for lubricants to enter the water due to water lubricated underwater guide bearing water lubricated runner hub, self-lubricating lubricant free vane bearings
- combining all decentralized control units into a programmable logic controller with optimum processing, of all binary and analog, signals, comnbined with an all-in-all more economical design is possible
On the basis of an economy calculation, the energy generation costs are 0,1 17 DM/kWh. This figure is below the limit generation costs of 0,157 DM/kWh calculated for this location.
Programme(s)
Topic(s)
Data not availableCall for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
48950 Erandio
Spain