BULB UNITS

The complete solution for low heads

POWER

Model scale bulb runner

Alstom bulb units

for best performance

Alstom Hydro is the number one global
provider of clean power solutions accounting
for around 25% of the worlds installed hydro
base and offers the worlds most comprehensive range of hydropower generation
facilities and equipment.
It is not surprising then that Alstom bulb units
provide the most efficient solution when
faced with very low and low heads up to 30m.
Bulb units have now virtually replaced Kaplan
turbines for low head situations.

The name bulb comes from the shape of the

upstream watertight casing which contains a
generator located on a horizontal axis. Units
are submerged in the water passage and, as
the turbines are usually double regulated,
are able to handle significant discharge
variations.
The straight water passage in the draft tube
improves the hydraulic behaviour of the unit,
and also results in a low submergence. This,
in turn, allows for a reduction in size, cost

and civil works requirements of up to 25%.

There are hundreds of Alstom bulb units now
in operation around the world with more than
35 large units commissioned in China alone
during the last ten years.
The company has been an ardent pioneer in
the development of bulb units introducing
many outstanding innovations in size, design
and operational efficiency and will continue
the research and development programme to
extend the application range. Both standardised and customised solutions are offered.
Specific technologies have been developed to
adapt to customers needs and site surroundings such as the use of mobile or fixed guide
vanes and runner blades, shaft lines on 2 or
3 bearings, and pit turbine technology with a
speed increaser.

Alstom has gained outstanding knowledge

and experience in design, manufacturing,
installation, commissioning and management of complex bulb projects in a vast range
of environmental conditions, making Alstom
bulb units without doubt the worlds most
reliable solution.

Alstom bulb units application range

Customer value-driven

global optimisation
General design of a bulb unit

CONSTANT R&D to meet

environmental concerns

Alstom is also committed to helping customers balance commercial objectives with

environmental and social responsibilities.
Increasing environmental concerns are taken
into account resulting in fish-friendly turbines. In bulb turbines fewer but longer blades
decrease the fish mortality, while maintaining
efficiency levels.
Oil-free operations that prevent the pollution
of rivers have also been developed, resulting
for example in runners lubricated by water in
many bulb units.

PLANT INTEGRATOR

In the field of power generation, Alstom is

the plant integrator specialist, combining
skills in component design, auxiliary systems,
construction and plant optimisation. Alstoms
answer to the markets growing need for turnkey solutions is a unique combination of
in-house core components and customised
plant solutions based on the integration of
complementary packages.

This original combination creates more value

for customers than the simple addition of
individual packages by optimising:
Investment costs
Lead times
Performance and availability
Retrofit solutions
Plant life cycle

An Alstom bulb unit delivers maximum

customer value and return on investment.
Equipment investigation and design is carried
out by experienced interdisciplinary teams
as part of the total system optimisation.
Alstoms global geographical coverage and
the largest installed base allow the feedback
of experience to be taken into account
for each new project, whilst its local presence guarantees a perfect understanding of
regional variations.
Thanks to a global R&D organisation, the
main design parameters are defined by
hydraulic, mechanical and electrical engineers
working in close collaboration. This leads to
improved results for the bulb outer dimension
by considering and evaluating factors such
as productivity, global efficiency, civil work,
investment and reliability of the powergenerating unit.

 T he ability to offer the worlds broadest

scope of power generation equipment and
systems enables Alstom to deliver complete
optimised solutions, from turbines and generators to control systems and balance of
plant, including a full turnkey service.
The Alstom product range covers complete
electromechanical and hydro-mechanical
equipment for new hydropower plants, as well
as for the rehabilitation of existing plants.

DISTRIBUTED CONTROL SYSTEM

Alstom has a proven worldwide experience in

control systems for the power industry. Over
500 thermal, hydraulic and nuclear units
have been equipped in 25 years.
Taking advantage of its in-depth knowledge
of the hydro power plant processes, Alstom
has developed a comprehensive control and
instrumentation system, providing modern
operating control for hydro power plants.

Nina Power station (China)

The system comprises three major parts:

Centralog provides the operator control interface and control room environment with
high availability and high performances
Controbloc automation cells execute the
control and protection functions of the
machines and connect to the process.
 The use of fieldbuses allows geographical
distribution of the equipment
Controcad provides a set of advanced engineering tools both for the design office and
the on-site high quality documentation
ALSPA P320 provides many features and
benefits for the plant owner and operator
including:
Hi-tech technologies: object oriented
engineering, internet, fieldbus
Intuitive, user friendly operator interface
Modular design concept
Adaptable multifunction controllers
Distributed control architecture
Open system architecture based on international standards
High performance, communication networks
Integrated comprehensive Plant Management System (integration of Alstom expert
software)
Hydroprocess
Centralised plant and dam management
software are embedded in the central supervision system, providing a set of functions
managing the active and reactive power
production of the power plant as well as the
dam and the reservoir water level.

Alstoms engineering depar tment has

acquired a vast experience in control and
instrumentation systems for all kinds of
hydro power plants. Its expertise in providing
tailor made solutions guarantees optimal
plant control implementation.

Alstoms automation product, commonly

known as AL SPA P320 system, is the
most suitable system to control and monitor
Alstom hydro power plant.

HYDrAULIc DeSIGN
state-of-the-art facilities and tools
for optimised designs

Downstream velocity field

Alstom has developed advanced technology

to optimise all hydraulic parameters. This
ensures that turbine designs perfectly match
the targeted characteristics of a given project, while taking into account any necessary
constraints.
during the hydraulic design phase, unit
p er f or mance s ar e pr e dic t e d t hr ough
theoretical investigation and experimental
developments.
Each component of the turbine is finely tuned,
from intake, stay vanes and distributor, to
runner and draft tube. alstoms objective is
to optimise efficiencies, minimise dimensions
and reduce downstream head losses.

THeoreTIcAL INveSTIGATIoN AND

ScIeNTIfIc cALcULATIoNS
Alstom has developed many software codes
to perfect shape design, from classical ones
to those based on full 3D surface generation
using global optimisation algorithms. these
permit the exploration of new design families
and allow the best shapes to be verified on a
test rig.
during the design process, deep numerical
investigations using the latest cfd codes
(computation fluid dynamics) are carried
out. These simulate the flow in the turbine
over the whole of the expected operating
range and help to determine the best adapted
turbine shape.
They allow the accurate determination of all
hydraulic parameters, such as load analysis,
efficiency and cavitation behaviour.

Turbine pressure field

Dedicated bulb test rig

MODEL AND SITE TESTING

Once a design has been defined theoretically,

its performance is validated by model tests in
an Alstom Global Technology Centre.
Two recent test rigs, one of which has been
in operation since 2003, are used for bulb
turbines, with up-to-date calibration tools
and automated acquisition systems.
T hese advanced facilities permit ver y
accurate measurements that are also a key
tool for performance improvement and act as
a further complete check of turbine behaviour, including efficiency, output, cavitation,
runaway and torque on blades.
Once all the investigations are completed, the
full scale turbine is manufactured and tested
on site if required. It is due to this continuous
process of research, design and testing that
Alstom remains the world leader in innovative
bulb unit technology.

governing system
Alstom has more than 100 years of experience in the expert analysis and production
of speed governing products.
The speed governor is the brain of hydraulic
turbines. It fulfils all the requirements and
needs of hydraulic turbine applications.

T.SLG governor with actuators

These systems fulfil various functions:

Speed governing in isolated or interconnected networks
Fast unit start and speed stability control
under no-load operating conditions
Automatic unit/network synchronisation
through runner blades, guide vanes or
downstream gate control
Flow or load regulation
Efficiency optimisation with respect to
head and load
Autonomous sluicing operation at variable
or steady flows
Blade/guide vane cam relationship
NEYRPIC T.SLG (Turbine Speed Load
Governor) is the latest product developed by
Alstom. It is interfaced with an automated
system to ensure flexibility of use.
Designed to operate in the most extreme
environments, the main benefits are its
high level of adaptability, robustness and
reliability.

Universal turbine test rig

Mechanical Design
Safety and Reliability
WHAT IS DIFFERENT ABOUT ALSTOM HYDRO PELTON TURBINES?

To ensure the safety and reliability of all units,

Alstom carries out a continuous mechanical
R&D programme on all turbine parts.
During mechanical design, the complete
bulb structure is analysed by Finite-Element
calculations covering stresses, deflections
and eigenfrequencies to check the static and
dynamic behaviour of the entire unit.

Stay ring

The stay ring is the sole support structure of

the unit. This provides many advantages:
Weights and vertical loads are evenly
distributed in civil engineering structures
A xial forces carried to the anchor are
limited to hydraulic loads
Civil works are simplified
The two vertical arms of the stay ring are
hollow for generator bus bar outlet and piping.
This also allows easy access to the shaft seal
for adjustments.

Distributor

The conical distributor comprises 16 moving

guide vanes. They are guided on self lubricating bearings and controlled by an operating
ring.
To ensure continuous operational safety, the
distributor can be closed under both normal
and runaway conditions.
For units with a downstream gate, the
operating ring is actuated by two push-pull
servomotors. Shear pins are used as safety
devices for the guide vanes.
In the case of no downstream gate being
installed, the servomotors use a counter
weight to close the guide vanes safely.
A self-resetting device is then used instead of
a shear pin, to avoid the unit shutting down in
the event of a guide vane jamming.

Finite-Element dynamic analysis

erection time
opTImISATIoN
rUNNerS Up To 9m DIAmeTer

Thrust and counter-thrust bearing pads are

designed to handle the axial hydraulic force.
The counter-thrust bearing is stressed for a
few seconds in case of load rejection.
The thrust bearing pads are supported by
membranes to ensure even load distribution,
independent of the shaft movements.

since the draft tube is embedded into concrete

as a first stage, the stay ring is set into the
civil engineering structures. Then the shopassembled distributor is fitted. The shaft,
pre-fitted with bearings, thrust bearing and
counter-thrust bearing, is then inserted into
the assembly.

Runner hubs are normally filled with oil, but

for environmentally sensitive locations, water
may be used as a lubricant.

Bearing and thrust-bearing lubrication is

carried out by gravity from an oil tank located
above the unit. This very simple process has
proven to be extremely reliable.

The shaft line is adjusted on site so that the

generator rotor and the turbine runner are
centred on the theoretical axis of the unit.

SHAfT LINe AND BeArINGS

DoWNSTreAm GATe

runner design is one of the most important

tasks that alstom carries out when optimising
a unit for each project.
Blades can be directional, driven by a moving
servomotor cylinder located inside the runner
hub.

two radial bearings ensure the dynamic

stability of the horizontal shaft line during
operation.
The combined axial-radial bearing is located
next to the centre of gravity of the generator
rotor. it carries the weight of the rotor and the
force of the unbalanced magnetic pull when
the machine is in normal operation.
in case of double rotor earth fault, huge
rotating forces act not only on the bearing,
but also on the bearing and bracket supports.
The axial bearing is designed for steady-state
conditions of the turbine and also for dynamic
hydraulic transients.
The turbine guide bearing is supported by
a semicircular plate that allows it to follow
the shaft movements. Generator and turbine
bearings are both shell type bearings.

a draft tube gate provides a reliable protective

system for bulb units.
The downstream gate is sufficiently remote
from the runner to have a limited effect upon
the design of the draft tube. its shape is
designed to avoid the accumulation of solid
deposits on the side grooves.
downstream gate functions are:
Protection against runaway conditions
Downstream isolation during unit dewatering
Sluice operation
for units without control devices (fixed
distributor), the downstream gate also
initiates unit starting, coupling, progressive
loading and shutdown.

runner erection

an initial adjustment is made by eccentration

of the guide bearings following the shaft line
calculation. The final process is completed on
site, centring the stator on the rotor and the
runner chamber on runner blades.
The following operations are carried out
simultaneously:
Erection of rotor, stator and bulb nose in
the upstream pit
Erection of the runner hub, blades, turbine
cone and runner discharge in the downstream pit
Erection of accessories

Bulb shaft line and bearings assembly

ADvAnceD

GeNerATor DeSIGN

Alstom design concepts ensure reliability in

all operating circumstances taking account
of the bulb units sensitivity to instability
and vibrations due to the horizontal position
of the generator. They have been developed
to handle conditions such as roundness and
air gap concentricity, and have been successfully applied in bulb units up to 60 mvA.

STATor DeSIGN

alstom stator designs incorporate special

V- s h ap e d e l e m e n t s w i t h s i gni f i c an t
operational advantages. They guarantee the
necessary stiffness required of the structure,
with less radial height compared with traditional design concepts. They also ensure the
necessary space between stator core and
casing required for efficient air circulation
through the cooling slots.

roTor
With the introduction of oblique elements
for hydroelectric generators two decades
a g o , A l s t o m l a un c h e d a n e w e r a in
large generator design, offering outstanding
mechanical performance.
oblique arms connect two concentric annular
parts, the rotor hub and the rotor rim, allowing
them to turn in relation to each other.
The application of oblique elements on the
rotor provides improved radial precision and
a uniform air gap under all load conditions.

The alstom stator key bar design, in combination with the spring effect of V-elements and
stator core pressing system, provides vital
protection against stator core buckling.

Bulb generator rotor with oblique arms

oblique elements are used in the rotor spider

to provide optimum resilience regarding
thermal expansion, centrifugal force and
operational torques.

Compared to classical designs with radial

arms, oblique arms offer many advantages.
machine torque only stresses the arms
in the tensile direction while oblique arms
absorb rim expansion due to centrifugal force
and thermal dilatation by allowing rotation
of the rim in relation to the hub. Alstom
rotor design also permits stacked rotor rims
without shrink fit to the rotor spider.

vpI INSULATIoN SYSTem

The reliabilit y of the stator winding is

determined primarily by the quality of its
insulation. a generator is heavily stressed
thermally, electrically and mechanically
during operation. This makes the heaviest
demands on insulation.

the MIcADuR vacuum pressure impregnation system (vPI) has been used by
Alstom for more than 40 years.
t he s y s t em has b e en cont inuousl y
researched and further developed and has
produced excellent results on all machines
even under severe conditions.

The uniform Vpi production process ensures

a high insulation quality with the following
properties:
The requirements of temperature class F
are met
High dielectric strength and voltage endurance values with low loss factors
Proven system for all types of electrical
machines up to 30 kV
Excellent corona-resistance
Very good resistance to oil, water and other
coolants
Excellent mechanical properties
other Vpi insulation systems can also be
provided.

AIr cooLING SYSTem

The closed air ventilation system is designed

for safe operation at maximum output and
maximum river water temperature.
To guarantee high unit availability, the cooling
system is generally installed with a redundant
complete cooling device.
in order to provide maximum value to
customers, alstom offers integrated solutions
in combination with the secondary cooling
circuit. Thanks to its vast experience in bulb
generator design, alstom always delivers
maintenance-free and reliable solutions.
wedging of the stator bar in stator core

Field
excITATIoN
A reliable excitation system is the key
to trouble-free generator operation. It
ensures fast and efficient reactive power
and voltage control, and the best possible
generator performance overall.
alstom automatic voltage regulators and
excitation systems have been produced for
more than 35 years with the installation of
2,850 systems controlling 315,000 mVa in
130 countries.
To guarantee optimal results, all alstom generators come with a high quality excitation
system as a standard.
for medium and high speed machines,
brushless excitation systems are provided.
synchronous machines are supplied with
rotating diodes. This supplies dc-current to
the rotor without any brushes or slip rings,
which are commonly subject to wear and tear.
Both solutions are equipped with the latest
automatic voltage regulation (p 320 aVr)
technology.
all alstom static excitation systems incorporate state-of-the-art technology and
the required redundancy provision.

WORLDWIDE
Project Highlights
La Rance, France 1966

Canada
Bromptonville 1997 - 1 unit, 11MW, run. dia.: 3.75m.
Saint Lambert 1995 - 1 unit, 6.2MW, run. dia.: 4.50m.
USA
Worumbo 1989 - 2 units, 10 MW, run. dia.: 4.25m.
Greenup 1982 - 3 units, 25 MW, run. dia.: 6.10m.
Rock Island 1978 - 8 units, 58 MW, run. dia.: 7.40m.
Brazil
Ourhinos 2004 - 3 units, 15MW, run. dia.: 4.25m.
Canoas 1999 - 6 units, 27MW, run. dia.: 4.70m.
Igarapava 1999 - 5 units, gen.: 44 MVA.
Austria
Pfarrwerfen 1995 - 2 units, gen.: 11 MVA.
Croatia
Cakovec 1982 - 2 units, 42 MW, run. dia.: 5.40m.
France
Saint Egreve 1990 - 2 units, 23.4 MW, run. dia.:
5.60m.
Argentat 1989 - 1 unit, 17 MW, run. dia.: 4.10m.
Sault Brenaz 1986 - 2 units, 23 MW, run. dia.: 6.25m.
Chautagne/Belley 1980 - 4 units, 46 MW, run. dia.:
6.40m.
Caderousse 1975 - 6 units, 32 MW, run. dia.: 6.90m.
Sauveterre 1973 - 2 units, 33 MW, run. dia.: 6.90m.
La Rance 1966 - 24 units, 10 MW, run. dia.: 5.35m.
Germany
Heidelberg 1997 - 2 units, 2 MW, run. dia.: 3.35m.
Guttenbach 1992 - 1 unit, 3 MW, run. dia.: 3.16m.
Hungary
Tisza 1973 - 4 units, 7 MW, run. dia.: 4.30m.

Luxembourg
Schengen 1995 - 2 units, 2.4 MW, run. dia.: 3.50m.
Portugal
Crestuma 1987 - 3 units, 43 MW, run. dia.: 6.80m.
Turkey
Seyan 2 1992 - 3 units, 3 MW, run. dia.: 3.50m.
Switzerland
Rheinfelden 2007 - 4 units, gen.: 25 MVA.
Ruppoldingen 2000 - 2 units, gen.: 12 MVA.

10

Rock Island, USA 1976

Wu Jin Xia, China 2005

Alstom has equipped more than 250 bulb

units in the world for a total output of
approximately 5,000 MW.

SOUTH Korea
Nam Gang 2000 - 2 units, 7 MW, run. dia.: 3.00m.
Paldang 1999 - 4 units, 31.5 MW, run. dia.: 5.20m.
China
Chang Zhou 20 07 - 3 units, 42.9 MW, run. dia.:
7.50m.
Tong Wan 2007 - 4 units, 46.2 MW, run. dia.: 7.10m.
Qiao Gong 2007 - 4 units, 58.5 MW, run. dia.: 7.45m.
Wu Jin Xia 2007 - 4 units, 36.1 MW, run. dia.: 7.00m.
Zhi Gang La Ka 2005 - 4 units, 39.0 MW, run. dia.:
6.10m.
Ni Na 2003 - 4 units, 41.0 MW, run. dia.: 6.00m.
Hongjiang 2003 - 5 units, gen.: 47 MVA.
Gong Chuan 20 01 - 2 units, 22.2 MW, run. dia.:
5.50m.
Sha Xian 1999 - 3 units, 16.5 MW, run. dia.: 4.90m.
I ndia
Sone Link Canal 1986 - 6 units, 2 MW, run. dia.:
3.22m.

11

PWS/BPROB/BLBNTS09/eng/HYD/01.09/FR/6786 ALSTOM 2009. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the
completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. - Photo credits: Alstom 2009 - Design & Layout: www.kineka.com.

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