Hydro power - the design, use, and function of hydromechanical, hydraulic, and electrical еquipment

710 Pages·2016·26.63 MB·English

by  Raabe J.

HYDRO PO
The Design, Use, and Function
of Hydromechanical, Hydraulic,
and Electrical Equipment
Professor Dr.-Ing. Joachim Raabe
VDI-cVerlag GmbH
Mrlag desvereins Deulsd~cIrr lgenieure - Dlijseldorf
Raal~c,.J oachir~~: I
klydro poacr: tllc dcsign. usc. arid ftrnction of hy~lromcch;ln.,I iydraul., ;111dc lcctr. cqttipn~ctl/t I
Joacl~iniR aabc. Diisscldorf: VDI-Vcrlag, 1985.
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I
0
VDI-Verlag GmbH, Diisseldorf 1985
All rights rescrvcd. including the rights of reprinting extracts, partial or cvrnpletc photorne~hanical
reprodvction (photocopying, microfilming) and the translation into foreign languages.
Printed in Germany
Typ~sctting:D nten- und Lichtsatz-Service, Wiirzburg
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Printing and binding: Graphischer Betrieb, Konrad Triltsch, Wiirzburg
ISEN 3-18-400616-6
For Bert1
All my thoughts that 1 have.
they are with you . . .
(Old German folk-song)

Prefatory Note
The appearance of this new book is doubly welcome, firstly because, beins in English..it
is available to a very large number of readers and, secondly, because it is nn up to dale
and largely rewritten account of the subject on which the author has alread~m acie
;ill
international reputation. Professor Rntrbe's fcur previous books on liydraulic machinery
and installations published by the VDI-Verlag were available to readers of ihs German
language but are now out of print. Althouzh there has also been a translated Russirin
version his valuable account of hydroelectric practice have not therefore been easil!-
accessible to the vast number of potential readers familiar lvith Enzlish. This has bcen
particularly unfortunate recently because of the world-wide resurgence of the long estnb-
lished hydro power industry. Because of economic problems caused by risinz fuel cosrs
and expendable fossil fuels the interest in hydro power has greatl! increased in most
countries, not only for large schemes but also for mini and micro instilllntions where
power can be used locally for agricultural and industrial use. This new definiri\e ivork b!.
Professor Ratrbe will therefore meet with even ~vidcrr lcclrlin~i nternat:onall!. than hij
pseviocs publicatio~s.
The author is a distinguished hydraulic expert who has travelled widel!. and lccturcd in
many countries on hydraulic machines and hydro poiver equipment. He hi:> hat1 cxten-
give industrial. research and academic experience and is wzll kno11.n cn intrtrnat~or,;ii
technical committees for his valued contributions. This monograpl; rcprzsenis h ~rstc cu-
rnulated wisdom over many years together w~tha ccounts of recent recearchcs ant1 ad-
vanccd course lecture material. The result is a valuable trcailse \\~Ii~c\\.h11 1 help cnginrers.
teachcrs, advanced students, and many ot heis concerned wi th the creaLlon and mall-
agement of hydroelectric installations.
1 am most grateful for the opportunity to introduce this co~nprel-)ensilen en book and
wish both it and its reciders all success in helping to make the world a better place by the
skilf~ila pplication of hydro power.

Preface
Water is one of nature's gifts. The mere chance of creation has made water vapour lighter
than the surrounding atmosphere. so that sunshine can raise it from the ocean, while
sun-born winds carry it to those regions where it condenses again and then kills down
to the earth, from which gravity makes it flow downhill back towards the ocean, thus
closing its earthly cycle.
Ancient civilizations were fluvial and their members already managed to lift water for
irrigation by machines equipped with pails and driven by water mills of the undershot
t Y Pee
In 1831 when the French engineer B. Fourneyron had already built the first reliable water
turbine, the famous German poet Goethe finished the second part oi his tragedy Fatrsr.
At death's door Faust wins his wager with the devil (to be redeemed if there came a
moment of which he could say, "linger you now you are that fair"), when he has the
following vision of the harnessing of the tidal powers of the ocean.
"A paradise our closed-in land provides,
Though to its margin rage the blustering tides;
When they eat through, in fierce devouring flood,
All swiftly join to make the dammage good.
Ay, in this thought I pledge my faith unswerving.
Here wisdom speaks its final word and true,
None is of freedom or of life deserving,
Unless he daily conquers it anew.
With dangers thus begirt, defying fears,
Childhood, youth, age shall strive through strenuous years.
Such busy, teeming throngs I long to see,
Standing on freedom's soil, a people free.
Then to the moment could I say:
Linger you now, you are that fair!"
The hard Stachar~oviteh and labour of Goethe's vision of liberty would today be thought
of as an unbelievable slavery in the face of a graceless nature to which men were delivered
up when they had not the powerful tools of today's electrotechnology.
The inventions of engineers in the last century and a half since the death of our famous
Goethe are the main factors which have relieved the average man from laborious slave-
like work.
This has been done by harnessing the energy resources offered by nature in the form of
fuel and, last but not least, in the form of hydro power. Even if hydro power covers at
present in West Germany only a modest portion of the electric energy demand, hydro-
electricity has made in our country, and especially in its more waterpower blessed
southern part, a decisive contributiorl to the momentum that electrification brought into
our daily economical life during the last century.
2-0 ur~clcl-standth is nianifcstation, a glntlcc tlic historicill tlcvclopnicnt of clcctrification
.it
should bc niadc. 7'wo kcy events have stin1ul;lted the consumption and pratll~ctiono f
elcctrici ty.
One was the invcti~iono f the self-exciting dynatno (1869) by IV: \*oti Sicittors in Bcrlin and
thc induction motor by h.1. rlo:l Dolivo Dohrol~olskyi n IS90 also in Rcrlin. 'Tlic other was
thc inven tiori of the light bulb by the Gertiir~n-AmericanG 6hcl 1859 in Ncw York. Erfisotl
made the vital contribution of reinventing this 25 years later and illumitlating a quartcr
of New York by these means with the aid of the first thcrmo-clcctric power plant erccted
1882 in New York.
With the invention of electric illuminatiori a large consumer market was stimulated to
install electricity in homes. These consumers were concentrated in big towns whereas the
usable waterpower was in far remote areas. Therefore power transmission of hydro power
from sites io the consumer became an urgent need.
In 1891 the crucial step forward was made by the Germans 0. votr ,%filler,t he promoter,
and 1Vl. yon Dolivo Dobro)lolsky, the construcior, by the transmission of 300 hp over
175 km betv:een Heilbronn and Frankfurt using a 15 000 Volt three phase AC power line.
Aftcr this breakthrough experiment, which was successful, the USA started with the
erection of the first huge power station on the Niagara Falls with 10 5000 hp in 1892.
Anothcr advance for harnessing waterpower was achieved by the German professor Fiitk
in Berlin, who obtained a patent on adjustable wicket gates. In 1873 the German manu-
facturer K~itlte quipped for the first time a Francis turbine with these gatcs. O~ilyth is
combination made the Francis turbine an effective tool for harnessing waterpower.
Thc way was shcwn for the development of low head river power plants by the patent
of the Germ:~n-Atlstrian 1/: Knplan in 1913 for axial turbines with adjustable runner
vanes. To harness river poivet of the lowest head, the Gernian A. Fischer together with
the Escher Wyss firm have built, since 1936, tubular turbines with rim generators after
Harza's patent from 1919, and the tirst bulb turbine. In the compact design of a rim
generator plant, all the ccimponents have to be adapted to each other with respect to their
G
purpose and the small space available. In this context the pioneer work of the German
H. FerttzloJ must be mentioned. Pumped storage plants have been developed by the
Slviss firm Sulzer and Escher Wyss and the German firm Voith since the turn of the
-
century, culminating in 1928 in the Herdecke plant with 4 27 MW tandem sets. In 1932
and 1936 Escher Wyss and Voith built the first axial and radial pump turbines in the
German Baldeney plant and the Brazilian Pedreira plant.
Recent corner stones in 'the West German development of hydro power are as follows.
Firstly the African plant Cabora Bassa in hqozambiq:ie: There 5 415 h4W \yere installed
for power transmission over 1400 km by 1 million volt DC using dry thyristor technique;
the turbines were manufac:ured by a consortium of the West German firm Voith and the
French firm Neyrpic.
Both firms are now erecting the turbines for the 18. 715 MW Francis turbine sets of
Itaipu in Bra~il,a t the moment the hydro power station with the largcst i~lstalled
capacity. In this context it may also be mentioned, that the West German firm Ossberger
has logicaily developed from the Michell type turbine the most reliable and simple small
turbine of the Ossberger type, especially for developing countries.
Crintera., the founder of the author's institute, fonilulated in 1905 the specific speed as the
generally adopted most important criterion to distinguish typcs of hydroturbines. In 1922
my predccessor Tltonrtr introduced the now interfiationally used cavitation index a.
In the past decade I have had the privilege of holdins lecture courses on hydro power for
advanced post-graduate students in the following centres of reccnt water power develop-
ment: The Indian Institute of Technology Madras, India; The University of Siio Paulo.
Brazil; The Laval University, Quebec and Hydro Quebec, Montreal, Canada: The Cen-
tral University Caracas, Venezuela; The Polytechnic Institute Timisoara, Rumania; The
Huazhong Institute of Technology, Wuhan, People's Republic of China.
This has stimulated me to publish this book, which can be considered as the outcome of
these lectures, some rewritten chapters of a former book of mine in German, and the
many papers and findings made over the past 15 years in the Teaching Chair and
Laboratory headed by me at The Technical University of Munich, Federal Republic of
Germany.
In this context the names of Dr.-Ing. W Kiihnel, Dr.-Ing. D. Castorph, Dr.-Ing. E. Bar,
Dr.-Ing. M. V-dtter, Dr.-Ing. G. Schlemmer, Dr.-Ing. G. Mollenkoyj; Dr.-Ing. R. Gerich,
Dr.-Ing. M. Lotz (deceased), Dr.-Ing. R. Kirmse, Dr.-Ing. J. Korcian, Dr.-Ing. N. Fttrtner,
Prof. Dr.-Ing. R. Jahn, Dr.-Ing. E. Hartrter, Dip].-Ing. H. Pfoertner, Dr.-Ing. E. Walter.
Dr.-Ing. J. Klein, Prof. Dr.-Ing. F. El Refiie, Professor Dr. Engng Ravinn'rall, and Mr.
D. Lauria may be mentioned for their valuable help, their suggestions, and contributions
in connection with scientific papers presented at international or national congresses, or
in connection with work for theses made at the Lehrstuhl und Laborato~iumfu r Hydrau-
lische Maschinen und Anlagen der Technischen Hochschule Miinchen.
For many neatly drawn figures my thanks are due to Mr. M. Ring. In connection with
the erection of reliable test stands but mainly for his valuable contribution of building
quick response vector probes, the name of Mr. H. Kriegl, head of our lab's workshop
should be mentioned.
Many firms have supported the publication of this book monetarily in a liberal manner.
They are
Allis Chalmers, Milwaukee, Wisconsin, USA
1ng.-Buro Freisl, Garmisch-Partenkirchen, F. R. Germany
Hydroart, Milano, Italy
KaMeWa, Kristineham, Sweden
Kvaerner Brugg, A. S., Oslo, Norway
Neyrpic, Grenoble, France
Ossberger, Weissenburg, F. R. Germany
Sulzer Escher Wyss, Ziirich, Switzerland
Tampella, Tampere, Finland
Vevey-Charmilles Engineering Works, Vevey, Switzerland
Voest Alpine, Linz, Austria
Zahnradfabrik Friedrichshafen, Friedrichshafen, F. R. Germany
The library of the Technical University Munich an organization of the Bavarian State
Ministry of Education and Kultus headed by Dr. Schweigler contributed in a similar
manner.
Moreover thanks should be given to the VDI-Verlag as the publisher, who undertook the
venture of publishing a book directed to all the specialists and students in the world
engaged in the development of hydro power.
The work would not have been succeeded if Mr. T. B. Ferguson, Senior Lecturer at the'
Department of Mechanical Engineering of the University of Sheffield. a well-known
author of a book on turbomachinery, versed in treating technical terms and also versed
in colloqitinl E:~glisl~h,a d not revicwed thc wholc manuscript twicc very carcfi~lly.F or
[hat I gre;~llyi r~clcbtcdt o hirn.
ill11
In this contcsi also two Inclinn hydro turbine speci;tlists Professor Dr. Rlltrrltr Kr.islrtrtr,
head of the t1ydro-turbomachines labor;ltory, 11T Matlras, and l'rofessor Dr.-Ing.
K Vtr.scu~cltrtlih, cad of Dep;irtmcnt at Punjitb Collcgc of Engineering, may bc grc;itfully
mentioned. Thc same holds also for Professor 111K- r11 Alei, Departlnent of IlyJraulic
Engineering at Quinghua University Beijing (Peking), China.
For advice and help in their special fields, I am also indcbted to Prof. Dr. Erhtrrtl
F. Joerrs. Uni\.crsity of Wisconsin, Madison, USA; [email protected] rofessor. Dr., Dr., Dr., Dr. h.c.,
Dr.-Ing. E.h. E. ,\losotlj.i, University of Karlsruhe, F. R. Gcrniriny, o. Prof. Dr.-Ing.
G. Sclt~l~iclPtr, ofessor Dr.-Ing. If. Stei~thic~glebro, th at the Technical University Munich,
and Mr. K. !L bl4lli. deputy director of Siemens, El-langcn, F. R. Germany.
Although care has been taken to make the E~~glisrhen dering as clear as possible, it is
hoped that any reader who may detect Faults would kinclly bring them to my attention.
My thanks are also due to Mr. Braitsclr and Mr. Olbricl~f os carefully reading the
manuscript and the proofs7 and for making valuable suggestions.
Last but not least my thanks are due to my secretary .Mrs. A. Fltllr- for having typed parts
of the final copy of the manuscript.
This book may show how scientific work can bridge the frontiers between countries of
different cultures. May Hydro Power, which to date is used only by about ten percent of
its potential, flourish also in future under the motto: vivat, floreat, crescat!
Munich, autumn 1954 Joncllitn Ratrhe