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ČEZ hydropower fleet – past, present and future VGB PowerTech 12 l 2017

ČEZ hydropower fleet – past, present and future

Authors

Kurzfassung

Die Wasserkraft bei ČEZ – Historie, Gegenwart und Zukunft

ČEZ ist ein erfahrenes Energieunternehmen mit einer langen Tradition, die bis ins das Jahr 1878 zurück reicht, als ein Textilunternehmen in Mähren einen ersten Generator installierte, der von einer Dampfmaschine angetrieben wurde und Strom für Bogenlampen zur Beleuchtung von Produktionsstätten lieferte. Weitere wichti-ge Meilensteine waren die Inbetriebnahmen ei-nes Kraftwerks zur Beleuchtung des Janacek-Theaters in Brünn im Jahr 1881 durch Thomas Alva Edison sowie die Lichtbogenbeleuchtung der Prager Stadthalle im Jahr 1882 durch František Janacek. Viele Anlagen der damaligen Zeit nutzten die Wasserkraft, indem einfache Wasserräder mit angeschlossenem Generatoren angetrieben wurden. Später wurde die Entwick-lung von Professor Viktor Kaplan und seiner gleichnamigen Turbine zum Standard in der Stromerzeugung. Zum Ende des Jahres 1919 er-reichte der Anteil der Wasserkraft 7,5 % an der gesamten Stromproduktion der damaligen Tschechoslowakei. In den Folgejahren nach den ersten Entwicklung hatte ein schnell wachsender Strombedarf dazu beigetragen, Ideen und tech-nische Entwicklungen von Wissenschaftlern, Technikern und lokalen Unternehmern zu bün-deln, um die Wasserkraft der Moldau zu nutzen. Die heutige ČEZ hat ihren Ursprung im Jahr 1946 mit der Integration mehrerer kleiner Un-ternehmen der Erzeugung, Übertragung und Verteilung von Strom. Im Jahr 1992 erhielt die ČEZ ihren neuen Namen mit neuer Struktur. Der heutige Stromerzeugungsmix des Unterneh-mens umfasst Kohle, Wasserkraft, Kernenergie sowie weitere Anlagen der erneuerbaren Erzeu-gung, die in den vergangenen Jahren neu hinzu gekommen sind. Die gesamte Erzeugungsleis-tung beträgt 21.856 MW l

ČEZ’s Hydropower Fleet – past, present and futureCurrent utilisation and prospective new projectsPetr Maralík, Roman Mašika and Václav Lagner

Petr Maralík, Eng.Managing Director of ČEZ HydroRoman Mašika, Eng.Maintenance Planning Manager of ČEZ HydroŠtěchovice, Czech RepublicVáclav Lagner, Eng.Specialist of ČEZ Engineering Štěchovice, Czech Republic

ČEZ belongs to experienced energy compa-nies with a deep tradition having a particu-lar historical log in the year of 1878 when one Moravian textile company installed a first electrical generator connected after steam engine to get power for arc lamps to illuminate its production facility. Huge pro-gress happened when Tomas Alva Edison installed his first power plant in order to provide illumination of Janacek’s Theater in Brno in 1881 and František Křižík suc-ceed to light – on an electric arc illumina-tion for Prague Municipal Hall in 1882. Many installations of those times used hy-dro energy by using water wheels driving electric generators at the beginning, then later when commercialised invention of professor Viktor Kaplan and his wheel came into „ routine use“ in power genera-tion. Shortly after the year 1919 the share of hydro power reached 7.5 % in the whole electricity production of the country. In the years after this initial period a fast growing electricity demand had helped to focus ideas and engineering inventions of scien-tists, technicians, politicians and local en-trepreneurs to utilise energy of the Vltava ( Moldau) river. The Vltava is delivering wa-ter from Šumava Mountains located on bor-der with Germany and getting further en-

richment from rivers Otava, Lužnice, Kocá-ba, Sázava and their smaller inflows formes a major energy utilising river. The river that passes through the Prague Capitol and heading to a town Melnik where under Ma-jestic Castle over a river junction contrib-utes by its flow to River Labe (Elbe) which is continuing through Saxony to the North Sea in Hamburg, Germany (F i g u r e 1 ).

Current company roots of ČEZ have been formed in 1946 when during couple of next years smaller generating companies have been integrated to a one big corporation dedicated to generate, distribute and trans-mit the electric power. Then in 1992 ČEZ company has got its name and structure at the new era.

The actual power mix of ČEZ consists of coal, hydro and nuclear generation, last years also brought renewables into energy production mix; next to it, the company pro-vides energy distribution services, district heating, has its lignite mining company and provides further energy related services.

The company has an installed power capac-ity 21,856 MW, where 49 % is generated from coal (mainly lignite) and hydro in-cluding pump storage has 10 % of totanum-ber with an equal share (F i g u r e 2 ).

Fig. 1. Mělník – junction of Vltava and Labe rivers.

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VGB PowerTech 12 l 2017 ČEZ hydropower fleet – past, present and future

The company owns also hydro installations in Poland, Romania, and Turkey with a to-tal installed capacity of more than 314 MW. Small hydro power plants in the portfolio are owned by the specific company SPV and do not belong to the fleet of ČEZ Hy-dro. ČEZ’s domestic hydro power plant (HPP) installations are dominantly located as pre-viously mentioned at th Vltava River, pumped storage power plants ( PSPP) in-stallations are built in South Moravia – Dalešice PSPP and in North West Silesia – Dlouhé Stráně PSPP (F i g u r e 3 ). Hydro power plants located at the Vltava River are formed as a cascade. They have been constructed during a 56 years lasting period when Vrané HPP (currently 2 x 6.9 MW) has been put into operation in 1936 as a first installation, then in 1947 HPP Štechovice started its full commercial operation. Hydro power plant Štěchovice consists of 2 Kaplan units delivering 22.6  MWe of capacity and an additional pumped storage power plant installation which has been redesigned and refur-bished in 1996. This pumped storage pow-er plant provides 45 MWe with areversible Francis installation. Shortly after II. World War construction period of the Slapy hydro power plant started. The Sloppy rock mas-sive in the location near literally known Svatojánské Proudy (St.John Streams) mu-sically popularised in Bedřich Smetana Symphonical Poem Má Vlast ( My Home Country) - Part Vltava forms an impressive background for 3 Kaplan installations of 48 MW each. Self supply and distribution sub-stations are located inside a dam body, what helps to keep a nice scene of sur-rounding nature combined with a big hy-dropower installation. In 1960, on an op-posite end of the river, a new lake has been constructed to form an upper reservoir for

a dual Francis installation in Lipno hydro power plant. The machine hall is located in an artificially made cavern in 153 m depth of the right bank rock massive. The ar-rangement forms a huge head that pro-vides a double 65 MWe capacity. During the years of Lipno and Slapy hydro power plan construction, teams of planners and designers dealt with a project of two adja-cent ydro power plants to use a portion in the middle of Vltava River. The Orlik hydro power plant near the town of Solenice is a state of the art installation with a unique construction of its dam utilising four tur-bines with Kaplan Runners and a capacity of 91 MW each. This hydro power plant forms a unique example of technology-edge application of this runner technology. Down the river the hydro power plant Kamýk is located. It forms with its dam a lower reservoir of the Orlik hydro power plant. The Kamýk hydro power plant itself utilises a four Kaplan runner based instal-lation, by the size almost similar to those in

the Orlik hydro power plant, but with a much lower head it provides an output of 10 MW from each turbine. The choice for Kaplan runners in that time was influenced by a fact that hydro power had more sig-nificant share in a country base load supply due to lower capacity installations of coal fired power plants (6 x 50 MWe or 2 x 110 MWe installations). The wider output power control ability of Kaplan installation was a main favour in opposite to the Fran-cis runner technology, that can be applied in more steady operation. But skills of de-signers, metallurgists, workers and engi-neers of those times showed and still show the art of technology and skills. In the late 1960ies, the Government of for-mer Czechoslovakia decided to join a movement to nuclear power installations. In Slovakia started the construction of the Mochovce nuclear power plants after a suc-cessful pilot project at Slovakia’s Jaslovské Bohunice nuclear power plant. In Czechia the construction of the Dukovany nuclear power plant started. In those times energy (and energy safety) planners defined a definition that each big installation (nu-clear power plant) needs its secure back-up to prevent a possible black-out of the grid. In the early 1970ies the decision was taken to build the pumped storage power plant in Dalešice at the river Jihlava. The design documents included a capacity of 4 x 120 MW reversible (Francis) machines de-livering its output to the country’s trans-mission grid with the location proximity of the Dukovany nuclear power plant as a strategic advantage. This installation opened a new chapter in energy outlook of the Czech Republic (Czechoslovakia in that time). Technologi-cal abilities of local producers and local engineering teams gained an appetite of energy installation planners, also pros-pects of predicted industry and population grow established a demand to build a new big nuclear power plant installation in Te-melin with a high capacity. On parallel to the previously mentioned definition of the

100 % of PSPP installed power in CZ is operated by ČEZ a.s. (1,145 MW)

73 % of HPP installed power in CZ is operated by ČEZ a.s. (790 MW)

Hydropower plants of ČEZ a.s. (without PSPP) have a share of approx. 3.8 % of CZ installed capacity

Source of clean energy for approx. 800,000 households

Total installed power21,856 MW

Hydropower5 %

Pumpedstorage

5 %

Biogas4 %

Wind1 %

Gas6 %

Gas6 %

Nuclear20 %

Coal49 %

Fig. 2. ČEZ company hydropower fleet in Czech’s power energy mix.

Czech Republic

37 HPPIn total ca. 1,935 MW

3 x PSPP In total 1,145 MW

7 x HPPIn total 724 MW

27 small HPPIn total 66 MW

Vltava river cascade718 MW

Fig. 3. ČEZ group hydropower fleet.

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ČEZ hydropower fleet – past, present and future VGB PowerTech 12 l 2017

energy and energy safety concept, the planners requested to identify several new locations to install a new PSPP since the beginning of Temelin nuclear power plant early stages project (now called FEED stage). Due a several reasons as the most preferred or advantageous location has been choosen Dlouhé Stráně in Jeseníky Mountains. The construction started in first half of the 1980ies but due to country economy slow down and due to the politi-cal changes, both projects – Temelin nu-clear power plant as well as Dlouhé Stráně pumped storage power plant have been black-labeled by so-called environmen-tatlists and due to their political influence the projects have been temporarily termi-nated. After 1992 a new country govern-ment decided to resume the projects as an industry accelerator and put on a green light to restart the projects including a def-inition of new and sharp time schedules. Czech EPC companies have in that time fully fledged multi-profession teams of spe-cialists where majority of them enjoyed in-ternationally approved skills on several challenging projects abroad. In 1996 the installation of a couple of re-versible Francis turbines with 325 MWe (each) have been inaugurated and provid-ed firm message that also the Temelin nu-clear power plant will start operation soon. As a raw water source for the Temelin plant the Hněvkovice hydro power plant (2 x 4.8 MWe) and the Kořensko hydro power plant (2 x 1.9 MWe) at the Vltava River and as the final installation of Vltava River cas-cade were build (F i g u r e 4 ). The portfolio described forms the power fleet of ČEZ Hydro. Current role of ČEZ’s hydro division is de-scribed below.

– Fast backup in case of other company’s power plants failure

– ČEZ hydropower fleet provides impor-tant grid support services (grid ancillary services – ENTSO-E) for national grid operator (ČEPS) beside providing regu-lar “base laod”electricity supply.

The portfolio of available grid services cov-ers:

– Minute backup (QS5) – (PSPPs, Vltava river cascade) – ability to be initiated within 5 minutes from command receive as power demand and be kept in dura-tion of 4 hours.

– Island operation (OP) – ability of hydro power plants to operate in isolated grids

– Secondary frequency control (SR) – (Vl-tava river cascade) – not currently in use

– Black start – in case of a black-out, the ability to start without external sources of power from the grid

– Power source back-up for Czech nuclear power plants

– For Temelín nuclear power plants – provided from Lipno, Orlík, and Hněvkovice hydro power plants

– For Dukovany nuclear power plant – provided from Dalešice pumped stor-age power plant

A growing demand grow for a flexible pumped storage power plant services is shown in F i g u r e 5 , further utilisation of renewable power installations will keep necessity to have such massive and fast op-eration sources of peak power in order to keep national grid stable.

Main Areas of technical development

Maintenance activities of ČEZ’s hydro pow-er plant fleet are organised in periodical annual outages with a duration from 1 up to 3 weeks. Maintenance work focuses to correct minor negative observations on technical means and also to define neces-

sary information for maintenance activities and specific procedures to be planned and carried out (financially and technically) in further years. Maintenance activities are mostly considered as corrective, minor part of that can be found as preventive. All those activities are focused to achieve prolongation of the parts lifetime (water intake, turbine parts, outlets, bearings, hy-draulic control system, generator, I&C sys-tem).Overhaul periods are planned for each 25 to 30 years with a duration of several months. A general idea of overhauls is not only to replace matured components, but also to improve energy efficiency improve-ments (+3 % to +4 %). One further significant focus of ČEZ and its employees is dedicated to the topic of re-duction of environmental impacts resulting

Range in km

m a

.s.l.

Lipno I.2 x 65 MW

Štěchovice2 x 11,3 MW

1 x 45 MW PSPP

Slapy3 x 48 MW

Vrané2 x 6.9 MW

Hněvkovice2 x 4.8 MW

Kořensko2 x 1.9 MW

Orlík4 x 91 MW

Kamýk4 x 10 MW

900.00

800.00

700.00

600.00

500.00

400.00

300.00

200.00

100.00400 300 200 100 0

Fig. 4. ČEZ Hydro hydropower fleet – hydropower plants at the Vltava river cascade.

Year

Prod

uctio

n in

GW

h

1,400

1,200

1,000

800

600

400

200

02006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016

+177 %

EDS

EDA

EST

Suma

Fig. 5. Development of ČEZ´s pump storage hydropower fleet utilisation.

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VGB PowerTech 12 l 2017 ČEZ hydropower fleet – past, present and future

from hydro power plant operation. A de-crease of oil use, electrical consumption of hydraulic control systems have been achieved by a switch from low/mid pressure to high-pressure hydraulic regulation. Ac-tivities in the past years are shown below:

– Slapy hydro power plant (2011) control oil volume decreased from 3,000 l to 830 l

– Lipno hydro power plant (2013-2017) control oil volume decreased from 2 x 6,600 l to 2 x 500 l

– Kamýk hydro power plant (2008) con-trol oil volume decreased from 6,500 l to 450 l

– Vrané hydro power plant (2007-2009) control oil volume decreased 2 x 3,000 l to 2 x 450 l

Note: Original operating pressure ca. 20- 50 bar changed to cca150 to 200 bar

In total, he improvements resulted in sav-ing of ca. 25,000 l of oil at the 4 main hydro power plants and easier (as well less ex-

pensive) hydraulic control system mainte-nance shows the way for the future.ČEZ Hydro’s management and its team of employees has identified advantages of highest achievable level of process automa-tion very early after 1990. Since that year a massive implementation of highly unified solution of hydro power plant and pumped storage power plant automation supports maximum income from the installed oper-ation base, decreases time of outages, im-proves safety of operation, widens overall know-how that is shared among the opera-tion staff, and builds up own hydro power and pumped storage power plant control system knowledge management including the establishment of cyber-safety measures and procedures.

New PSPP projects

There are two examples of ČEZ’s future ac-tivities. The first requires a relatively mod-est budget, the second one is an example for a really challenging but strategical issue

A: Dlouhé Stráně PSPP Storage Capacity Increase ProjectYear to year higher utilisation of the Dlouhé Stráně pumped storage power plant is the trigger for the project to increase the Dlouhé Stráně pumped power plant stor-age capacity. The idea is to achieve it with-out huge civil works by larger utilszation of

Fig. 6. Orlik hydro power plant; current situation.

Fig. 7. Project Orlík. Convert the power plant to a pumped storage power plants (artist view).

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ČEZ hydropower fleet – past, present and future VGB PowerTech 12 l 2017

current basins with minimal investment costs. Main reason are:

– Increasing of basins capacity by 150,000 m3 with the advantage of further 23 minutes of operation (+189 MWh). Main activities:

a) Upper basin – Decreasing of minimum operational wa-

ter level about ca. 0.5 m (to 1325.8 masl.) – Increasing of maximum operational wa-

ter level about ca. 0.7 m (to 1348.7 masl.)b) Lower basin

– Decreasing of minimum operational wa-ter level about ca. 0.3 m (to 800.5 masl.)

– Increasing of maximum operational wa-ter level about ca. 0.3 m (to 822.7 masl.)

– Excavations of sediments and material (ca. 40,000 – 70,000 m3)

B: PSPP Orlík – REVAMP project of HPP Orlík, change of runner technologyA strategical discussion among ČEZ´s plan-ners and strategist comes into venue near a life-time period end of main hydro technol-ogy at Orlik hydro power plant. Higher uti-lisation of the company’s pumped storage power plant fleet during last year is also an idea behind.What is current situation of Orlik hydro power plant (F i g u r e 6 )?

– 4 units – 4 x 91 MW – peak operation – Kaplan – 8 runner blades (150 m3/s) – 364 MW available in 128 seconds – Runner diameter: 3,700 mm – Maximum head: 75 m – Commissioning: 1961 to 1962

There are 3 superlatives to notice about that location:

– It is the largest-capacity reservoir in the Czech Republic (720 mil. m3 )

– It is the highest head for this type of tur-bines and

– It is, last but not least, with 364 MW the most powerful power plant at the Vltava river cascade.

The Company plans for years after 2021 are to replace two existing Kaplan turbine sets with reversible Francis turbines. Such change will result in a new utilisation of the Orlík and Kamýk basins. There are some main reasons for this project. First is a ne-cessity to prepare an overhaul of two units in 2021 to 2024 (Orlík hydro power plant). Business wise ideas related to overhaul are influenced with a new movement in area of grid support services for CEPS (national grid operator) what is also complementary to the optimisation of CEZ Group energy sources portfolio. It comes into account to increase the pumped storage power plant installed capcity of 1,145 MW by 2 x 90 MW (F i g u r e 7 ). Set of expectations is as follows:

– Daily operation except failures and planned outages

– Annual availability 92 % – Time of turbine operation at maximum

power of both units 4.5 hours – Time of pump operation at maximum

power of both units 5.6 hours – Installed capacity of the turbine / pump

90 MW / 89 MW – The efficiency of the pumping cycle

≥ 79 % – Production per one cycle

761 MWh – Consumption per one pump mode cycle

964 MWh – Estimated time of works 50 - 60 months

(downtime is about 30 - 48 months) – The project evaluation activities prior to

a final decision to start the project covers

a wide spectrum of topics and will be prolonged in coming months/year to identify known or still yet hidden risks and uncertainties.

– Before final statement of this article showing ČEZ’s past, present and future, there are some rather philosophical as-pects about the future of the pumped storage power plant branch.

– The economy of ROI in pumped storage plants is influenced by the price volatility of electricity/possibly related to the de-mand for ancillary services

– Despite the increase in renewable ener-gy  price volatility declines in the last 5 years, the future development may be influenced by many factors (continued growth in the share of renewable energy sources, conventional sources flexibility – flexibility of demand, market coupling with ancillary etc. ...)

– Economy of pumped-storage power plants is affected by a considerable un-certainty.

– However, due to the expected needs of flexibility we consider it is appropriate to prepare projects having potential com-petitive advantage.

– The expected investment costs of the Or-lik pumped storage power plant is ap-proximately 400 € /kW.

– Planned and/or realised projects in neighbouring countries have an average investment cost of 1,200 €/kW.

– Another advantage of this project should be shorter construction time and easier permitting process.

Energy from hydro power plants and pumped storage hydro power plants is and will remain environmental friendly. l

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