HİRFANLI
HEPP AS CONSTRUCTED 100% LOCAL
32
MW TURBINE - GENERATOR Story, in 1983
After
the 1974 Cyprus operation, Western countries imposed an embargo on
Turkey. Our country needed more electricity generation. Between years
1953- 1959, when the Hirfanlı Hydroelectric Power Plant was built on
Kızılırmak river, four Turbine generators were considered. Four
turbine generators were to be built, but our budget at that time was
enough to buy three Turbine-generators.
The
idea was that we would buy the fourth unit later. Fourth unit space
left empty. The fourth turbine water inlet was closed with a blind
cover. HEPP worked with three units, the foundation of the fourth
unit remained so empty until 1979.
In
1979, Electricity Authority decided to install a new 32 MWe HEPP
Turbine generator with available local facilities. The drawings of
the three existing units, and the original projects as found in the
archives, were brought together in the design departments. Within
next four years, local engineering, local purchasing, local site
installation were made. The first replica designs were very simple,
they were not clearly detailed. There were fatal errors in
fabrication and they were renewed. Modern quality control facilities
were introduced. The first steel castings were not suitable to the
desired quality. The difficulties of the first fabrication were
experienced. But in the end, the job was successfully completed, 32
MWe Hydro power plant turbine generator was fabricated, assembled
on-site, operated operated.
Within
four years, fabrication drawings, technical and administrative
specifications of this 32 MW turbine-generator unit and auxiliary
equipment were prepared, purchasing, manufacturing, quality controls
and transportation to Hirfanlı HEPP site, on-site installation and
testing works were completed. In mid-July 1983, the facility was
made ready for its trial operation. At the beginning of August 1983,
the job was completed.
In
order to realize the fabrication and site installation of the 32 MW
turbine-generator unit and auxiliary equipment, which was 100%
domestic completed in Hirfanlı HEPP, 40 different workplaces
belonging to 27 different local private-public institutions were
carried out as follows.
Turkey
Electricity Authority Headquarters, Department of Hydraulic Power
Plants, were responsible in preparation of technical and commercial
specifications and detailed manufacturing drawings. The realization
of the tender process and all kinds of control and co-ordination;
start-up of the unit was carried out here.
We,
Turkish Sugar Company, Ankara plant were responsible for fabrication
of Turbine draft tune, turbine spiral casing, turbine cover, turbine
guide bearing, turbine adjustment blades and transmission arms,
turbine adjustment blades and their servomotor, turbine butterfly
valve and its servomotor, turbine rotor, turbine shaft, generator
rotor body and generator, stator body, upper bridge, generator
housing, pressured and non-pressurized oil tanks and piping
equipment, pressure and non-pressurized water circuits pipe equipment
such as the main and auxiliary mechanical equipment manufacturing.
Karabük
Iron and Steel Factories, Foundry Directorate, were responsible for
casting Turbine and generator shafts, butterfly valve shaft and
carrier head, generator bearing bed shoes and white metal casting,
turbine rotor blades and upper and lower shells.
MKEK.
Kırıkkale Directorate: Steel Factory, produced Auxiliary shaft,
turbine and generator shafts couplings pouring and forging. They made
the forging of the turbine shaft and the generator shaft and the
butterfly valve shaft in their factories.
Ereğli
Iron and Steel Factories manufactured special sheet metal of
generator rotor core and special sheet metal of generator rotor pole.
DSi,
State Water Works. General Directorate, Department of Dams and
Hydroelectric Power Plants, were responsible for construction
projects, reinforced concrete and formwork projects, concrete casting
works during the consultancy and supervision tasks.
ESAŞ
Transformer Industry Co. has manufactured 40000 kV main power
transformer of 10.6 / 154 kV.
KAVEL
Kablo Sanayi AS has manufactured cables for protection, control and
control circuits.
KALEKALIP
Mak.San.A.Ş., manufactured special cutting molds of the generator
stator core lamination sheets, special cutting molds of lamination
sheets, generator rotor poles of lamination sheets and generator
stator core lamination sheets, lamination hair press printing cutting
operations.
RABAK
Electrolytic Copper Industry Co., has produced the generator rotor
poles special copper conductors.
SARKUYSAN
Electrolytic Copper Industry Co., Generator stator windings, and
special copper conductors.
Emek
Elektrik Sanayi A.Ş., were manufacturing 10.6 kV and 154 kV voltage
transformers;
ALCE
Industry Inc. Manufacture of some 10.6 kV current and voltage
transformers;
Boğaziçi
Döküm Sanayi A.Ş., Casting and processing of generator rotor poles
pressure flanges,
BUKA
Tire-Gasket Industry Inc., manufacturing all kinds of rubber-rubber,
gasket, seal, sealing elements
Çanakkale
Seramik Fabrikaları AS, domestic kits of 154 kV disconnectors and
insulators used in the production of current and voltage
transformers,
Teknim
Sanayi ve Ticaret Ltd.Şti., manufactured temperature probes and
indicators of generator stator windings and temperature control
probes and indicators of turbine and generator bearings;
Marshall
Paints, produced of special insulation voltage varnish;
ÇENAM
Çekmece Nuclear Research Center, All kinds of non-destructive
quality control inspections of casting parts by Gamagraphy method;
TUBITAK
Marmara Scientific and Industrial Research Center, Ultrasonic
inspection method for all kinds of shafts and steel construction
welding seams quality control inspection;
ITU
High Voltage Test Laboratory, High voltage insulation tests of 154 kV
disconnectors manufactured in Hirfanlı;
METU
Electrical Engineering Department Test Laboratory: Determination of
stator hair characteristics;
METU,
Metallurgical Engineering Laboratory, PMG generator for the
production of special permanent magnets;
MSB,
Ministry of Defense. R&D Laboratories, Non-destructive material
inspections by Gamagraphy method and qualitative and quantitative
chemical analyzes;
TSE
Turkish Standards Institute Laboratories, special chemical analysis
works;
MTA
Institute Laboratories, Performing some special chemical analysis
works;
Naval
Forces Gölcük Shipyard, Dynamic balancing of turbine rotor,
AEG
— ETİ. The provision of some special insulating materials was
accomplished.
This
project was not reported in the newspapers, no movies were made about
it, even the news were made very limited. Your writer wanted to tell
you about this project. In Ankara Sugar Machine Factory, your writer
has worked as machine shop manufacturing engineer responsible for
this project, he has always been proud to work actively in this
project. For Hirfanlı HEPP Hydroelectric Power Plant fourth unit,
there were 27 different public and the private sector organizations
in 40 different fabrication sites.
With
Turkish Electricity Authority's efforts in the workplace, with its
leadership, HEPP was constructed between 1979-1983 with 100%
indigenous local organization.
The
unit manufacturing price was calculated as US $ 80 / KWe based on the
currency value of 1983. Trial test work was completed in July 1983.
Electricity generation started in August 1983. The fourth
turbine-generator unit and its auxiliary plants with a nominal power
of 32 MW continue to operate and produce since then.
RESULTS,
Turkish
public sector together with privately owned Turkish Industry brought
together knowledge- technology- know-how, can now fabricate upto unit
capacity of 100 MW at 100% local.
Hirfanli
HEPP has nominal power of 32 MW with a water flow as small as 60
meters and a flow rate at 60 m3 per second. When the physical size
of the unit 4 is 150 mt, the unit can generate 100 MW.
2—
Although it is a trial and single unit, the time taken for the
design, purchasing, manufacturing, site installation, commissioning
tests of this unit were not much longer than the time taken for
foreign orders.
The
total amount of money spent on 100% domestic facility of the unit was
half of the money to be paid for the manufacturing, assembly and
testing of foreign manufacturers.
This
project is a repeat story of the "Devrim- Revolutionary Car"
in the energy markets. We worked on this project between 1979-1983.
We made the necessary projects, new designs were added, detailed,
manufacturing was produced better and more precise than the original
British HEPP equipment, on-site installation. We finished he job, and
the 4th unit was run, since 1983. It continues to run without any
major breakdown. The domestic manufacturing experience gained in this
project was transferred to other public and private institutions. We
have always been proud of working on this project.
Turkish
Source. Hidayet Basesme, TEK, EMO Article 1983
http://www.emo.org.tr/ekler/00d7c5998783ff3_ek.pdf?dergi=4
---
Haluk
Direskeneli, is a graduate of METU Mechanical Engineering department
(1973). He worked in public, private enterprises, USA Turkish JV
companies (B&W, CSWI, AEP), in fabrication, basic and detail
design, marketing, sales and project management of thermal power
plants. He is currently working as freelance consultant/ energy
analyst with thermal power plants basic/ detail design software
expertise for private engineering companies, investors, universities
and research institutions. He is a member of ODTÜ Alumni and Chamber
of Turkish Mechanical Engineers Energy Working Group.
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