Alexander Sozinov
Project Management Department Head, OJSC “ VNIIG Vedeneev “
Today’s global hydropower development trends are based on principles of energy-efficient and environmentally friendly power facilities. Russia, being a major player in the global fuel and energy market, pays special attention to renewable energy sources, including hydroelectric power generation.
In current market conditions, the construction of new hydroelectric power plants is challenging due to the requirement of large investments, and is often only economically viable with a partnership of the state and the private sector. That being said, the majority of hydroelectric facilities currently in operation have been in service for over 50 years. The main buildings and structures are generally in an operable state and, after some repair work, could serve for another 50 years. As for the equipment, the situation is not so good. It could be said that the majority of equipment has reached the end of its operable life and is in desperate need of modernization.
The above mentioned factors forced Rushydro, the largest hydro power company in Russia, to commence a modernization program for all facilities that have been in operation for over 50 years.
The following major objectives need to be resolved as part of the reconstruction process:
» extending the facilities’ lifetime;
» increasing energy efficiency;
» improving the safety standards for the facilities in service;
» Implementation of modern technologies aimed at mitigating the influence of human error by creating automated process management systems (ASM TP), automated control systems for hydrotechnical facilities (SAK HTF), and introducing single center asset management technology.
As part of the program, the North Ossetia branch of OJSC “RusHydro” and its assets are to be reconstructed. Key facilities to undergo the reconstruction include: Ezminskaya HEPS, Gizeldonskaya HEPS, Dzaujikauskaya HEPS, Bekanskaya HEPS.
Ezminskaya HEPS (Photo 1). Location: Republic of North Ossetia-Alania, Chmi settlement, Terek river; distance from embouchement – 561 km. Mean annual runoff at power site – 0,860 km3/year. Installed capacity of HEPS – 45 MW. Mean energy capability – 231000 thousand kWh/year. Launch date for the first pump storage genset –24.11.1954. Major equipment:
Gizeldonskaya HEPS (photo 2). Location: Republic of North Ossetia-Alania, Vladikavkaz, Prigorodniy district, Koban settlement, Gizeldon river. Mean annual runoff at power site – 0,106 km3/year. Installed capacity of the power site – 22,94 MW. Mean energy capability – 53400 thousand kWh/year. Launch date for the first pump storage genset– 29.06.1934. Major equipment:
Dzaujikauskaya HPP (Photo 3). Location: Republic of North Ossetia-Alania, Vladikavkaz. Mean annual runoff at power site – 0,85 km3/year. Installed capacity of HEPS – 9,2 MW. Mean energy capability – 39800 thousand kWh/year. Launch date for the first pump storage genset– 01.08.1948.
Major equipment:
Bekanskaya HEPS (photo 4). Location: Republic of North Ossetia-Alania, Ardonsky district, Bekan settlement. Installed capacity of HEPS – 0,504 MW. Launch date for the first pump storage genset– 25.12.45.
Major equipment:
The reconstruction is planned in three stages:
» A review of all structures and equipment to determine the remaining life expectancy and volume of reconstruction required
» Development of design and what expertise is required
» Project realization
The most important stage is the review, which will entail the:
» Which objects require demolition and what new building/facilities will be required
» Which objects require reconstruction
» Which objects requiring repair and restoration
During the review of mechanical and electric equipment, its remaining life expectancy will be assessed and it will then be classified as follows:
» Equipment to be completely replaced;
» Equipment that needs partial replacement;
» Installation of new modern systems.
Based on the preliminary evaluations that are made, the following can be concluded in relation to the condition of objects in need of reconstruction:
Hydrotechnical structures (HTS), including dams, dikes, intake chambers, discharge sluices, channels and penstock conduits – their overall condition can be deemed as satisfactory, with few units requiring repair and restoration work, including any reinforcement of the main structures. Also, all of the structures require additional retrofitting with measuring and control equipment and a relevant automation system.
The proposed instrumental revision will apply modern ultrasound flaw detection survey technology (a non-destructive control method), as well as sample taking (destructive control method); the technical condition of the structures will be assessed, including their sub water parts so that hidden defects will be revealed. During the revision for subsequent design work, 3D laser scanning will be used and its results will be applied to create a 3D model of the structure’s actual condition.
Equipment:
» Hydropower and electrical equipment – preliminary estimates show that the equipment is to be completely replaced, as it’s worn out and outdated. Apart from this, the latest equipment is required to improve overall performance and automation
» The hydromechanical equipment is severely worn out, and needs complete replacement
It should also be noted that the complex revision stage for the plants will include a revision of the equipment with participation of the original manufacturers.
During the reconstruction project, it is planned to implement pilot (for Russia) 3D modeling technologies. Development of the project will be done using three dimensional models which will be created at the revision stage using laser scanning.
Using 3D modeling technologies at the development stage will reduce time and save design documentation, save costs and decrease the likelyhood of any errors.
The 3D model, designed and updated during the construction period, will then be passed on to the operating company and be used as an instrument for managing the operating the asset. It will also be able to carry out additional functions, such as being a drill simulator for plant staff.
In order for the project to be undertaken successfully, with the latest equipment and best available project management, we plan to use the expertise of foreign equipment manufacturers. In this specific case, we are looking to potentially work with Andritz Hydro, with the design and construction work being carried out by Russian companies with the RusHydro group.
Conclusions
» The recent economic crisis has demonstrated the sad fact that Russia is now unable to use resources from the Soviet period and the time has come for global restructuring and modernization. Nothing but modern technologies implemented at hydropower facilities together with increased attention paid to secondary (and using the accepted terminology, basic) structures will enable us to reach sufficient levels of energy efficiency for hydropower facilities, and more imprtantly allow them to become fully capable of participating in the energy market.
» The first step is for sure modernization the facilities, however it is also important to streamline the opration of the assets through automation and control, mitigating the risk of emergencies and environmental damage.
» This program of innovation and modernization by RusHydro will see an implementation of new technologies and ideas which will be unparalleled any where in the world.
