Hirfanlı HEPP

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

Ankara, 17 January 2020

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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.

To download in PDF, go to following link,

https://metu.academia.edu/HalukDireskeneli/