1. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Reconstruction of the Small Hydro Power Plant Les Království, Czech Republic Miloslav Šlesinger Karel Kyzlink Hidroenergia 2008 13 th June 2008 – Bled, Slovenia

2. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Introduction In December 2003 ČKD Blansko Engineering, a.s., obtained a turkney contract for reconstructions of SHPP Les Království in Czech Republic. The goal of the reconstructions of this power plant was the replacement of an existing hydromechanical equipment produced in 1923. Supplies for the reconstruction included the technological part, the electrical part, and civil works.

3. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Dam crest

4. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Dam architecture

5. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia History of the dam and the small power station Dam construction1910–1919 Power plant1923 Major overhaul1952–1959 Technical monument1964 Reconstruction2005

6. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Original technological equipment of the SHPP Two horizontal-shaft twin Francis turbines (each was designed for a 4.5m 3 s -1 discharge, 600kW power and 428 rpm speed), produced by Českomoravská-Kolben in Prague Two horizontal synchronous generators, produced by Fr. Křižík, Prague Two hydraulic turbine governors, produced by PRAGA, Prague

7. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Horizontal-shaft twin Francis turbine (cross section)

8. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Horizontal-shaft twin Francis turbine (cross section)

9. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Overall scope of the reconstruction Technological equipment: Major overhaul of the intake structure emergency closing gate Sealing of the penstock Turbines and generators Power house ventilation Electrical part: Control system Low voltage switch room, accumulator battery 1600kVA and 250kVA transformers 6.3kV and 35kV switch room Civil part: Demolition works Concrete structures

10. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Solution of technological part reconstruction The supply of new technological equipment consisted of: 2 butterfly valves 2 horizontal Francis turbines 2 horizontal synchronous generators 2 hydraulic control set major overhaul of the intake structure emergency closing gate

11. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Solution of hydraulics The flow in the discharge canal was simulated numerically in Fluent CFD software by two-phase flow simulation with free water level. Outlet canal capacity was evaluated because of the total discharge gain from 9 to 12 m 3 s -1 Height position of the draft tube discharge profile compared to outlet canal ground was analyzed Draft tube shape was optimized using CFD computations

12. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Contour of velocity magnitude

13. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Water flow in the outlet canal

14. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Main technical parameters of the technological equipment Turbine: Horizontal Francis turbine with turbine runner overhung on the generator shaft Runner diameter1040 mm Discharge6 m 3 s -1 Speed375 rpm Head22.5 m Maximum power1180 kW The distributor servomotor is controlled by pressure oil from a hydraulic control set with 12MPa operational pressure

15. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Horizontal Francis turbine (cross section)

16. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Turbine and hydraulic control set

17. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Generator: Horizontal 3-phase synchronous generator Apperent power1300 kVA Watt power1108 kW Nominal voltage6300 V Speed375 rpm Sliding generator bearing (one radial axial and one radial bearing) The generator is air-cooled

18. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Horizontal 3-phase synchronous generator

19. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Butterfly valve (in front of each turbine): Diameter 1400 mm Opened by pressure oil from the hydraulic control set and closed by weight

20. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Irrigation discharge pipe: Diameter500 mm Capacity1,9 m 3 s -1 To ensure an automatic outlet of minimal discharge to the river when both turbines are shut down at the same time (butterfly valve opened by weight)

21. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Process of operations on site: Machines shut-down1. 5. 2005 Reconstruction started2. 5. 2005 Work progress: Sealing of the penstock and dammimg and emptying the outlet canal under the power house Disassembly of existing equipment Civil works Installation of new technology Major overhaul of the emergency closing gate Repair of outlet canal concrete construction under the power house Disassembly of the steel plug Perfoming tests Works finished30. 11. 2005

22. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Intake sealing Steel plug diameter2400 mm Design pressure27m water column Installation on the penstock inner sheath by divers in the depth of about 16m

23. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Disassembly of existing turbines, generators and governors According to office of conservation project

24. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Transport – incline lift

25. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Transport of the spiral case

26. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Civil works on draft tube unit 1

27. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Spiral case unit 1

28. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Turbine house after the reconstruction Unit 2Unit 1

29. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Environmental precautions Use of two-circuit cooling system of generator bearing lubrication aggregate with stainless steel cooling coil placed in the SHPP outlet canal Installation of retaining tanks under hydraulic aggregates Self-lubricating fit of guide vane stems Self-lubricating wheel track stems and connecting rod stems of the emergency closing gate

30. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Technical conditions (restrictions) of the reconstruction Disassembly of existing turbines, generators and hydraulic governors according to office of conservation project (now being an exhibit of the National Technical Museum in Prague) Major overhaul of the emergency closing gate – the intake structure could not be temporarily dammed, so the dimensions had to be located by divers In order to disassembly the existing butterfly valves and turbines and to install new ones, intake sealing by the steel plug was necessary Transport conditions – all building material and equipment were transported using a incline lift with 8t load capacity An expertise of the existing engineering constructions built between 1919 and 1923 was made in order to resolve transmission of load forces from the technology to existing concrete supporting structures. Its correct evaluation was needed to determine the rescue works procedure and facture and to install new technological equipment

31. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia Conclusion Current operation of the machines has proved that projected power specifications have been achieved All guaranteed parameters like power output and efficiency of new turbine-generator units and transformers were met The benefit of the reconstruction was a complete renewal of the obsolete mechanical and electrical equipment A higher utilization of present water resources potential during the year by as much as 40% was achieved thanks to the gain of flow rate through new turbines from 2 x 4.5m 3 s -1 to 2 x 6m 3 s -1 and the gain of maximum installed turbine power from 2 x 600kW to 2 x 1180kW

32. Reconstruction of the SHPP Les Království HIDROENERGIA 2008, Bled, Slovenia ČKD Blansko Engineering, a. s. Čapkova 2357/7 678 01 Blansko Czech Republic www.cbeas.com We do all for the future without polluted environment