RE-05

Oct.26-28, 2011, Thailand
www.cigre-aorc.com
RE-05
CIGRE-AORC 2011
Introduction of Technologically Advanced Modular
Hydropower System for Pulangi IV Hydroelectric Plant
ENGR. RUDY P. BRIOSO
National Power Corporation-Pulangi IV Hydroelectric Plant
Philippines
SUMMARY
The Philippine Archipelago is consists of three (3) main island grids, namely; Luzon, Visayas
and Mindanao. The Department of Energy (DOE) have formulated methods to avert any
problem in the power supply specifically in Luzon and Mindanao and these are: locating and
making use of every capacity and energy available to the system; and revisiting the power
development plan modeling and process. Although it was projected that for 2011, Mindanao
Grid which basically comprise 50% hydro in the generation mix, would have a better
condition that in 2010 since the current water level in the region is favorable for hydro plants
but it still has thin reserve and short of 300MW.
The power situation in Mindanao Grid can be address through capacity addition and the
DOE is encouraging the participation of local and foreign investors, particularly those in the
Renewable Energy (RE) business to consider the market potential and opportunities in the
Philippines. For the Philippines’ National Power Corporation (NAPOCOR), a study was
recommended sometime on 2005 through the auspices of the so called capacity recovery
and improvement program in order to maximize the operational capability of its existing
hydropower plants. For Pulangi IV Hydroelectric Plant, there were studies undertaken to
further provide additional capacity, namely:
1. Uprating of the existing plant capacity by as much as 10%; and
2. Utilization of the existing potentials through the introduction of technologicallyadvance modular bulb turbine.
Installation of the technologically advanced modular hydropower system provides an option
for development of hydropower at low-head site condition with existing dam or gate
structures. The low head modular hydropower system design utilizes a factory assembled
grid or “matrix” of small propeller turbine-generators units. The system requires no major
excavations, foundations, channel modifications, or civil works and therefore enables small
hydroelectric power plants to be developed at investment levels below those normally
required in some conventional hydropower plants. Since the turbine-generator units are
shipped to site in pre-assembled condition, construction and start-up schedules can be
reduced significantly. By using existing civil structures, this low head modular hydropower
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system installation requires little or no additional land area and has the potential to minimize
environmental impact, particularly during construction phase.
CONCLUSION/RECOMMENDATION
Recent study by the Philippines’ Department of Energy (DOE) revealed that the island of
Mindanao has a thin power reserved for 2010 and will experience shortfall of capacity if
there will be no new power plants will be installed. Although there are two (2) hydro projects
committed for Mindanao for 2010, there is a need for the government to step up its effort and
encourage private investor in putting up the needed capacity. If the Philippine Government
through the Public Private Partnership (PPP) will push for the installation of state-of-the-art
technologically advanced modular hydro power system which is expected to provide an
incremental capacity of 16MW which could translate to all additional annual energy
generation of about 71.48 GWH of cheaper source of power to the Mindanao Grid.
CONTRIBUTION OF THE PROPOSED MODULAR TYPE HYDROPOWER TO MINDANAO
GRID
The modular type hydropower will provide an incremental capacity of 16 MW which could
translate to an additional annual energy generation of about 71.48 GWh of cheaper source
of power to the Mindanao Grid.
DOE’s Philippine Energy Plan (2007-2014)
TECHNICAL DESCRIPTION
The power generation of the existing Pulangi IV Hydropower Plant is conveyed through a 9km open channel which carries discharge capacity of 276 cms. Reservoir levels vary within
the range from 283.0 m and 285.0 m, while water level in the canal varies between 276.0 m
and 277.0 m. This gives rise to gross heads in the range of 6.0 m to 9.0 m. Using the flow
into the canal a new hydro generating capacity of up to about 16 MW could be considered.
One of the new technologies being developed is an integrated turbine generator to produce
electricity economically in a free flow environment that operates at lower speeds and does
not require high head or pressure. These turbines can use the flow of water coming from the
existing facilities of Pulangi IV HEP, thus generating additional electricity. The low head
turbine technology makes it possible to utilize existing dam structures without making major
changes to the surrounding structures. See Figure 5.1: Figure 5.1: Modular Hydropower
Plant Application Range and Figure 5.2: Cross Section of a Modular Hydropower Plant
(Sample).
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Figure 5.1
Modular Hydropower Plant Application Range
Figure 5.2
Cross Section of a Modular Hydropower Plant (Sample)
The installation of modular low-head turbine will inquire no major excavations, foundations,
channel modifications, or civil works. This technology may therefore enable small
hydroelectric power plants to be developed at investment levels below those normally
required in conventional hydropower plant. Also, construction and start-up schedules can be
reduced significantly. In addition, this type of hydropower development requires little or no
additional land area and has the potential to minimize environmental impact, particularly
during the construction phase.
1. PROJECT LAYOUT AND DESIGN
1.1 General
The existing Pulangi IV power station has a long-term average plant factor of about 55%, but
the proposed low-head modular power facility, which will essentially utilize the same flows as
the main plant, is expected to have lower plant factor due to the variation in head under
which it will operate. Assuming an average head of 8.0 m and an installed capacity of 16
MW, the plant factor would be around 51% and the annual energy production should be
around 71.48% GWh per year.
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1.2 Access Road
The proposed modular project shall similarly use the existing road access to the dam site
and water diversion facilities.
1.3 River Diversion Construction
No major river diversion works will be required for this construction. A simple half-circular
steel caisson, both at upstream and downstream side of the intake site, will be needed to
keep water from the specific construction area.
1.4 Generating Units
Given the range of heads and flows under which the scheme will operate, the most suitable
and least-costly four (4) units turbine-generator per module (per intake) is considered. For
the purpose of this assessment, a total of four (4) modules turbine-generator sets will be
installed in four (4) intakes utilizing some 8.6 m net head.
1.5 Transmission Line and Interconnection
Generation output will be conveyed via a new 9.5 km long x 69 KV transmission line to the
existing sub-station adjacent to Pulangi IV powerhouse. The transmission line will follow the
existing headrace canal over most of its length. The sub0station will be extended to
accommodate the new incoming transmission line.
2. ENVIRONMENT AND SOCIAL IMPACTS
The Pulangi IV Headrace Canal Intake hydropower facility is an efficiency enhancement
rather than a typical greenfield construction project. The works could therefore be contained
within the existing premises of the Pulangi IV property boundaries and the development can
occur within the context of the environmental management plan of Pulangi IV HEP.
Social impacts will also be minimal with a relatively small amount of workforce required for a
limited duration. Since the total power production capacity is greater than 5 MW but less
than 30 MW, an Initial Environmental Examination (IEE) Report is required to support the
Environmental Compliance Certificate (ECC) application and the processing will be
performed by the concerned Department of Environment and Natural Resources
(DENR)/Environmental Management Bureau (EMB) regional office.
PROJECT COST
The estimated total project cost is equivalent to P 1,404.99 million (exclusive of price
contingency & interest during construction) or equivalent of US$ 28.67 million in foreign
currencies.
The cost includes the supply and installation of major electro-mechanical equipments and
auxiliary equipment; civil works; transportation; insurance; engineering and supervision; and
physical contingencies.
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All costs are expressed in August 2009 level at an exchange rate of P 49.0/US$.
The project cost is further broken down as follows:
Table 7.1
Cost Estimate
Forex
US$
A. Preliminary and General Items
(Includes Mobilization and Pre-Con Cost)
B. Civil Works
(Includes Intake, Control Station, Tailrace and
Tailrace Bridge)
C. Electro-Mechanical (E/M) Equipment
(Includes Power Station Equipment, Intake, Draft
Tube and Transmission Facilities)
0.90
In Millions
Local
PM
0.00
.
Local
THB M
0.00
1.98
291.68
16.80
0.00
0.00
0.00
35.00
0.00
24.63
326.68
229.96
28.67
D. Engineering and Administration
0.91
E. Physical Contingencies
1.41
(Civil Works 12% and E/M equipment 7%)
TOTAL
22.00
TOTAL IN US$
205.28
Forex Rate
1 US$ = 49
KEYWORDS
Modular Bulb Turbine for Renewable Energy. State of the Art Technology Utilizing
Hydromatrix
Short Bio-data of Main Author
Rudy P. Brioso received his master in Management from Asian
Institute of Management in 1990. He also attended the Energy
Management Program from Australia International Development
Bureau in Australia, 1994. He is a Professional Electrical Engineer by
profession and a Career Executive Service Officer. He joined the
National Power Corporation in 1977 and was holding several key
positions in its power transmission and the power generation
functions of the Corporation. From 1991 to present he was tasked to
managed Pulangi IV Hydroelectric Plant where he gained various
expertise in the field of operations and maintenance of large hydro power complex.
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INTRODUCTION OF TECHNOLOGICALLYADVANCED MODULAR HYDRO POWER
SYSTEM FOR PULANGI IV HYDROELECTRIC POWER PLANT
AORC Technical Meeting 2011–Chiang Mai, Thailand
RUDY P. BRIOSO
PLANT MANAGER,
PULANGI IV HE PLANT
INTRODUCTION OF TECHNOLOGICALLY ADVANCED MODULAR
HYDRO POWER SYSTEM FOR PULANGI IV HYDROELECTRIC
POWER PLANT, PHILIPPINES
•Philippine Power Profile
•Pulangi IV HE Plant Profile
•The Concept of Modular Hydropower System
•Advantages of Modular Bulb Turbine
•Application Criteria
•Design Criteria
•Peak Efficiencies of Modular Bulb Turbine
•Operational Features
•Impacts of Modular Hydropower System
•Project Layout and Design
•Environmental and Social Impact
•Project Cost
PHILIPPINE POWER PROFILE
• Hydroelectric plants make up about 20% of the total installed generating
capacity in the Philippines.
Oil-Based
Hydro
Geothermal
Coal
Renewable
Natural Gas
* Dept of Energy Philippine Power Statistics 2005
• In 2005, Hydroelectric plants contributed about 15% of the total power
generation in the Philippines.
Oil-Based
Hydro
Geothermal
Coal
Nonconventional
Natural Gas
* Dept of Energy Philippine Power Statistics 2005
Agus & Pulangi Capacity
Enhancements
* The Philippine Energy Sector: “Three Years of Reforms”, Oct 2004
“Pulangi IV HEP is expected to deliver through plant
enhancement programs.”
LARGE HYDROELECTRIC
PLANTS IN THE PHILIPPINES
Bakun A/C Hydro
70 MW
Binga Hydro
100 MW
San Roque Hydro
345 MW
Magat Hydro
360 MW
Casecnan Hydro
140 MW
Angat Hydro
245 MW
Pantabangan Hydro
100 MW
Agus 1 (Units 1&2) Hydro
80 MW
Agus 2 Hydro
180 MW
Agus 5 Hydro
55 MW
Agus 7 Hydro
54 MW
Kalayaan Hydro
300 MW
Kalayaan 3&4 Hydro
350 MW
Agus 4 Hydro
158 MW
Pulangi 4 Hydro
255 MW
Agus 6 Hydro
200 MW
PULANGI IV HE PLANT PROFILE
• A 255-MW Hydroelectric Plant and the 4th largest
Hydroelectric Plant in the Philippines
• The largest single-operated HE plant in Mindanao in terms of
Dependable Rated Capacity.
• The first Hydroelectric Plant in the country to be IMS
Certified, certifiable on ISO 9001 (Quality), ISO 14001
(Environment) and OHSAS 18001(Safety and Health).
• Pulangi 4 contributes roughly 20% of Hydro
Generation Mix for Mindanao Grid.
• In 2005-2010 data, it generated a total of
5,106.189 GWH to the System.
• Average Production Cost for 2005-2010 was
PhP 0.358/kwh.
• On 2005, a study was made for the capacity
recovery and improvement program:
•Uprating proposals to attain 10% increase in the existing capacity;
•Introduction of technologically advanced modular bulb turbine.
Concepts of Modular Bulb Turbine
Advantages
• Clean and environmentally friendly energy (KYOTO-protocol)
• Use of existing weir structures
 no major civil construction
 no geological risk
 no additional land usage
•
•
•
•
•
Standardize modular concept
Compressed project schedule
Modules removable at flood conditions
Keep existing river flow pattern
High availability
Concept of Modular Bulb Turbine
Application criteria
•
•
•
•
•
•
Available plant discharge from – 100 m3/s (3,500 cfs)
Available head from 3 m up to 30 m (10 – 100 feet)
Minimum submergence 1.5 m (5 feet) below tailwater
Unit output from 200 kW up to – 800kW
Close grid connection
Structure available & suitable for HYDROMATRIX®
Application range
Cross Section of a Modular Hydropower Plant
Concept of Modular Bulb Turbine
Design Criteria
•
•
•
•
•
•
•
•
Unregulated propeller turbine
Direct driven induction generator
Traditional hydraulic steel structure
Mechanical face seal
Roller type bearings
Modular switchgear
Flexible concept
Minimum maintenance
Kaplan-type turbine with horizontal
shaft, fixed guide vanes, fixed
runner blades and a submerged
generator
Test Installation of TG - unit
Installation of TG units at Verona, Italy
Modular bulb
turbines installed
in matrix – top
view
Installation of TG units at Verona, Italy
Trash rack
Inlet structure
showing the
modular bulb
turbine installed
in matrix
Diversion
canal
Installation of TG units at Verona, Italy
Peak Efficiencies of Modular Bulb
Turbines
Type
Turbine
Generator
Total
Conventional Bulb
95%
98%
93%
Bulb Turbines
90%
95%
85.5%
Difference:
7.5%
Potential Applications
Concept of Modular Bulb Turbine
Influences on Dam Structure
 Horizontal dam loads
• Statical loads less than without HYDROMATRIX®
• Dynamical load identical
 Vertical dam loads
• Additional weight through modules
• Additional weight through new crane and trash rack
cleaning machine
 Civil works
• Anchors for guiding rails, supports and platforms
• Protection pipes, cable trays
Concept of Modular Bulb Turbine
Operational Features
 Maintenance intervals
• According to maintenance schedule
 Accessibility
• Easy access to all components without disturbance of
overall plant operation
 Expected life time
• Identical to conventional hydropower concepts
Layout and Design of Modular Bulb Turbine
Based on a study, assuming with average head of 8.0m and an
installed capacity of 16MW:
•Plant factor would be around 51%;
•Annual energy production should be around
71.48% GWH per year;
Environmental Impact
•Proposed introduction of modular bulb turbine for Pulangi IV HE
Plant is an efficiency enhancement;
•Proposed bulb turbine installed in matrix is not a typical greenfield
construction project;
•Installation works is contained within the existing headworks weir
structure;
•Development is within the context of environmental
management plan of Pulangi IV HE Plant;
•Social impacts will also be minimal with a relatively small
amount of workforce;
Project Cost
• The cost includes the supply and installation of major electro-mechanical equipments
and auxiliary equipment; civil works; transportation; insurance; engineering and
supervision; and physical contingencies.
• All costs are expressed in August 2009 level at an exchange rate of Php 49.0/US$.
• The project cost is further broken down as follows:
Conclusion and Recommendation
•Based on a study conducted by NPC, the proposed installation of
modular bulb turbine is technically, economically and financially
viable hence, the implementation is worth undertaking.
•Financial sensitivity analysis was also conducted which also shows
that proposed installation of bulb turbine will be viable even if
subjected to 20% increase in cost or loss in energy generation.
•Modular bulb turbine is a feasible hydropower system,
investment cost approx. 800 - 1,200 USD/kw.
“Diversifying our power mix with
renewable energy is not only good for the
environment – it makes perfect business
sense as well as mitigates climate change.”
-World Wide Fund on
climate change
Thank you…