Kevin Marshall
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Transcript Kevin Marshall
Grant County PUD
Plant Upgrades at Wanapum and
Priest Rapids Dams
Kevin Marshall, PE
GC PUD Hydro
Engineering Manager
NWHA Conference
February 18, 2014
Ongoing Upgrades for
Wanapum Dam
Turbine Replacement (Note: GCPUD took advantage of
CREB bonds and a DOE design/development grant) Work
is complete.
Generator replacements
New exciters
Digital Governors
Transformers
Reasons for Turbine Upgrades
Original turbine runners had
reached the end of their
useful life
Blade crack repairs
Trunnion seal issues
Operating linkage failures
Cavitation repair costs $75,000/unit/year (1987-1993
average costs)
Performance improvements
Improved fish passage
survival
Wanapum Turbine Upgrades
Design Features
Semi to fully spherical
Larger diameter: 20 inch increase
Deeper setting : 3.315 feet deeper
Increased capacity: 120khp to 150khp
Efficiency improvement: 3% average weighted
efficiency
Cavitation repair costs: $0
Performance Improvements
Reasons for Generator Upgrades
Replace components at
the end of their life.
Capture increased
output of new turbines
Wanapum Generator Upgrades
New Parts
Complete Rotor
Complete Stator
Generator Shaft
Ventilation System
Excitation System
Air-Gap Monitoring
Rotor spider arrives in 3
sections, stator frame in 4
Wanapum Governor/Unit Control
Upgrades
What
Mechanical governors
replaced with digital
Dynamic exciters
replaced with static
exciter and digital
controllers
Why
Spare parts no longer
available
Serviceman knowledge not
transferred with
retirements
Improved control/efficiency
Improved protection
More info/better trouble
shooting
Lower costs to maintain
Existing Wanapum Mechanical
Governors
New Wanapum Digital Governors
Current Wanapum Status
10th turbine, 4th generator, 4th exciter, and 3rd governor
complete and put into service October 2013
5th generator, 5th exciter, and 4th governor under
construction
10th generator and exciter to be completed in 2019
New turbines have a averaged, weighted efficiency gain of
3%
As tested new generators have an increased efficiency
from 98.0% to 98.5%
2 of 5 transformers replaced, 3rd transformer in process
Priest Rapids Dam
Upgrades
Planned Upgrades for
Priest Rapids Dam
Turbine Replacement
or life extension
Generator rewinds
New exciters
Digital Governors
Transformers already
replaced
Reason for Upgrades
Efficiency improvement
Life Extension
Aging equipment
First unit in service in 1959
Generators
Rotor pole problems including pole to
pole connection failures (as pictured)
Stator Winding age (oldest unit =
currently 27 years old)
Exciters are obsolete
Turbines starting to exhibit problems
Increased cycling of governor oil pumps
Wicket gate operating ring wear
Turbine Upgrade Process
Goals
Utilize lessons learned from Wanapum project
Obtain as many qualified bids as possible
Competitive turbine hydraulic model testing
Integrate biological considerations into design effort
Turbine Upgrade Process
Step 1: Hydraulic design contract
Professional Services Agreement
Prequalification process – three
contractors prequalified
All design solutions finalized by
contractors ahead of bidding
All design solutions verified by
independent hydraulic laboratory
Step 2: Manufacture and supply
contract
Bidders must participate in
hydraulic design contract to bid
Performance guarantees verified
prior to bidding
Status of Priest Rapids Upgrades
Turbines
Model testing was completed last week in Lausanne,
Switzerland for the 3 qualified vendors
Bids are due March 5th
Contract award this summer (if economics are
favorable)
Generators: Pre-qualification of Vendors in process
Controls: Governor specifications are in process
Field work for upgrades is scheduled for 8/1/2016
Priest Rapids and Wanapum
Upgrades
QUESTIONS