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Mavel Kaplan BULB Turbine
Technical Specification

1.1.1 Turbine Basic Data

Turbine Type Mavel KA
Number of Runner Blades 4
Number of Wicket Gates (Guide Vanes) 16
Turbine Distributor Closing System Hydraulic

Type of Guide Bearing

Roller, (integrated in the gearbox)

Type of Thrust Bearing

Roller, (integrated in the gearbox)

Location of Runner Blade Servomotor End of Gearbox Shaft
1.1.2. Materials *
¢ EN
Name cuter Material Standard
Bulb $355J2/S355JR EN 10025-2
Runner Blades G-X4 CrNi 13-4 EN 10283
Runner Hub GJS 500-7 EN 1563E
Turbine Shaft 42CrMo4 EN 10083-3
Guide Vanes GJS 500-7 EN 1563E
Guide Vane Bearings bushes with liners from KU, DU, ZEDEX or equivalent
Housing for Guide Vane Bearings GJL-200 EN 1561
Guide Vane Distributor Chamber GJL 300 or $355J2/S355JR EN 1561 or EN 10025-2
Gate Operating Mechanism §355J2/S355JR EN 10025-2
Gate Operating Ring $355J2/S355JR EN 10025-2
Discharge Ring GJL 250 EN 1561
Draft tube §355J2/S355JR EN 10025-2

* Final material specification will be a part of detailed design.

1:2 Turbine Body

The turbine body consists of the turbine

intake and the turbine casing. The turbine intake is the first

part of the turbine body. It is made of steel plates forming a transient piece (from circle to rectangle)

and it is seated in the concrete.

The turbine casing is a welded steel plate fabrication functioning as the main supporting part of the
hydro-mechanical unit. The generator is fixed on the top of the turbine casing by means of a flange.

The upstream end of the turbine casing is connected to the turbine intake and forms the water passage
distributor. In the center, there is a pillar and inner bulb for location of bevel gearbox. Two ribs in the
interior are used to fix the gearbox. The downstream section is a machined ring that mates with the
turbine distributor. The centerline of the turbine body is coincidental with the turbine runner axis.

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Mavel Kaplan BULB Turbine
Technical Specification

www.mavel.com

GENERATOR

TURBINE [INLET DISTRIBUTOR

GUIDE VANES
GEARBOX
RUNNER BLADE

DRAFT TUBE

1.3 Turbine Distributor

The distributor is composed of inner and outer wicket gate ring. The inner wicket gate ring has spherical
shape that supports the sixteen wicket gates. The distributor will be bolted to the turbine body and is
coincidental with the runner axis.

The wicket gates are steel castings, machined in a CNC milling machine, and polished as the final
procedure. Their special prismatic shape will allow them to work both to regulate the turbine and to
shut it in the event of an emergency. They will be built as a single piece with integrated trunnions.

Each guide vane has have self-lubricated slide bearings to support the wicket gates trunnions. Each
wicket gate trunnion is connected to the regulation ring by levers. The regulation ring provides the
torque to turn the wicket gates for regulation and emergency closure. Each wicket gate has a friction
clutch, which allows slippage for overload conditions that protects the mechanism from damage due to
debris in the water passage. The wicket gate is adjusted back to its correct position by means of a special
tool (supplied with the turbine).

The wicket gates levers are connected to the regulation ring through two ball joints with a connecting
rod in between. The regulation ring turns on eight bronze supports placed close to the outer guide vane
plate. A single linear servomotor will provide the impulse for the rotation of this ring. The regulation ring
is also provided with a counterweight to close the wicket gates on loss of HPU oil pressure.

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Mavel Kaplan BULB Turbine
Technical Specification

1.4 Turbine Runner

The turbine runner is the driving element of the turbine, consisting on the runner hub, runner blades,
and regulation mechanism. The runner hub is assembled to the bevel gearbox shaft and holds the four
runner blades with self-lubricated bearings, and the inner regulation mechanism. This mechanism is
composed of a crosshead and lever sets. The linear displacement of the regulating crosshead produces a
rotation of the runner blades. The longitudinal displacement is transmitted to the crosshead by a
straight solid rod, placed along the longitudinal bore of the gearbox shaft. The hydraulic servomotor for
operating the runner blades is located at the end of the gearbox shaft in the turbine bulb and is
accessible through the pillar from the bottom of turbine body without need for de-watering the unit.
The runner blades are sealed both for loss of oil and from water contamination. The runner hub is
covered by a steel cone.

1.5 Runner Chamber

The runner chamber is a cast steel construction. The inner surface of this chamber is spherical and
designed to minimize the distance between the outer extreme of the runner blades and the inner
surface of the chamber. The runner chamber is horizontally split into two parts. The upstream side of
the chamber will be bolted to the distributor, and the downstream side to the steel draft tube cone.

1.6 Guide Bearing
The guide bearing is part of the bevel gearbox and is a roller, oil lubricated bearing.
1.7 Shaft Seal

The shaft seal frictional rings are made of ceramic material with high hardness and high resistance
against wearing. The shaft seal maintenance requires regular cleaning, approximately once a year,
during the regular annual equipment inspection.

1.8 Turbine Draft Tube

The draft tube leads water out of the turbine. The first section is a steel cone bolted to the runner
chamber and is embedded in the concrete. This part of draft tube is assembled to the runner chamber
with an adjustable flange. The second part of draft tube is a transition from the draft tube cone exit
(circle) to rectangular section and the third part of draft tube is a straight diffuser. Mavel will provide
the hydraulic profile of sections two and three of the draft tube.

1.9 Gearbox

The gearbox is placed inside of the turbine bulb. It is composed of a steel casing, bevel gears, bearings
and minor parts. Both the input and the output shafts are placed on anti-friction bearings. The housing
of the gearbox will be steel plate made. Gears will be made out of high quality steel, and the teeth will
be case-hardened. The shafts will be made of high quality steel.

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In the event of a termination, abandonment, or suspension at will, Professional Engineer
shall receive all amounts due and not previously paid to Professional Engineer for work
satisfactorily completed in accordance with the contract prior to the date of the notice and
compensation for work thereafter completed as specified in the notice. No amount shall be
allowed or paid for anticipated profit on unperformed services or other unperformed work.

B. TERMINATION FOR CAUSE This agreement may be terminated by the City of Nashua on
10 calendar day’s written notice to Professional Engineer in the event of a failure by
Professional Engineer to adhere to any or all the terms and conditions of the contract or for
failure to satisfactorily, in the sole opinion of the City of Nashua, to complete or make
sufficient progress on the work in a timely and professional manner. Professional Engineer
shall be given an opportunity for consultation with the City of Nashua prior to the effective
date of the termination. Professional Engineer may terminate the contract on 10 calendar
days written notice if, through no fault of Professional Engineer, the City of Nashua fails
to pay Professional Engineer for 45 days after the date of approval by the City of Nashua
of any Application for Payment.

Upon receipt of notice of termination for cause, Professional Engineer shall:

1. Immediately discontinue work on the date and to the extent specified in the notice.

Provide the City of Nashua with a list of all unperformed services.

Place no further orders or sub-contracts for materials, services, or facilities, other

than as may be necessary or required for completion of such portion of work

under the contract that is not terminated.

4. Immediately make every reasonable effort to obtain cancellation upon terms
satisfactory to the City of Nashua of all orders or sub contracts to the extent they
relate to the performance of work terminated, abandoned, or suspended under the
notice, assign to the City of Nashua any orders or sub contracts specified in the
notice, and revoke agreements specified in the notice.

5. Not resume work after the effective date of a notice of termination unless and
until receipt of a written notice from the City of Nashua to resume performance.

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In the event of a termination for cause, Professional Engineer shall receive all amounts due
and not previously paid to Professional Engineer for work satisfactorily completed in
accordance with the contract prior to the date of the notice, less all previous payments. No
amount shall be allowed or paid for anticipated profit on unperformed services or other
unperformed work. Any such payment may be adjusted to the extent of any additional
costs occasioned to the City of Nashua by reasons of Professional Engineer's failure.
Professional Engineer shall not be relieved of liability to the City of Nashua for damages
sustained from the failure, and the City of Nashua may withhold any payment to the
Professional Engineer until such time as the exact amount of damages due to the City of
Nashua is determined. All claims for payment by the Professional Engineer must be
submitted to the City of Nashua within 30 days of the effective date of the notice of
termination.

If after termination for the failure of Professional Engineer to adhere to any of the terms
and conditions of the contract or for failure to satisfactorily, in the sole opinion of the City
of Nashua, to complete or make sufficient progress on the work in a timely and professional
manner, it is determined that Professional Engineer had not so failed, the termination shall
be deemed to have been a termination at will. In that event, the City of Nashua shall, if

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Mavel Kaplan BULB Turbine
Technical Specification

The gears and bearings are designed for more than 100,000 hours of service life under full load
continuous operation. The bearings are equipped with Pt100 temperature sensors. The gearbox design
considers a 2.0 operational factor.

1.9.1 Lubrication and Cooling System of the Gearbox

This system ensures the lubrication and cooling of the bearings and gears of the gearbox. This system is
placed on the turbine floor. The heat generated by the gearbox is removed by means of oil/air heat
exchanger. The system ensures the following functions:

- Cooling and lubrication of the gears and bearings of the gearbox.
- Filtration of the lubrication oil.
- Cooling of the heated lubrication oil.

The lubrication and cooling system is closed loop. There is a oil/air heat exchanger, which part of
lubrication unit.

1.10 Shaft Couplings

Couplings between the turbine and gearbox shaft, and the gearbox generator shaft will be friction clutch
type. This will allow slippage of one shaft with respect to the other in the event of overload of design
torque (short circuit load).

1.11 Brake

The unit is supplied with a single hydraulically controlled disk brake. The braking disk is placed on the
generator shaft, being firmly attached to the shaft with the necessary bolts and screws.

2 GUARANTEED PARAMETERS
2.1 Guaranteed power

MAVEL guarantees that the maximum power on turbine shaft shall not be lower than that one specified
in the List of Guaranteed parameters, corresponding to its given net head and discharge taking into
account p-g value. If necessary, corrections in the power for variations in head or discharge will be
performed in accordance with the IEC 60041.

The guaranteed power can be verified in tests performed on the unit to be supplied in accordance with
recommendations of IEC Code, Publication 62006, Class A. “Hydraulic machines — acceptance tests of
Small Hydroelectric Installation”.

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Technical Specification

2.2 Cavitation

MAVEL guarantees that the weight of the lost material caused solely by cavitation during the warranty
period for cavitation specified below will not be greater than the value defined by the IEC code —
60609/2004, provided however, that the turbine operates within the operating range (zone) determined
in the operating instructions provided by MAVEL. The warranty for cavitation is provided for the period
of 8000 hours of effective operation, but not longer than two (2) years from the date of the startup of
the turbine.

If not otherwise specified in the Contract, the turbine must not be operated (i) longer than 500
operation hours per year (in aggregate) at working points below 60% of the load (between 0% and 60%
of output) at minimum and nominal net head; (ii) at working points below minimum discharge at
maximum net head; (iii) if the position of the centerline of the runner in relation to the tail water level
does not observe (meet) the values stipulated by MAVEL; (iv) if during operation rumbling, detonation
or excessive noises occur in the draft tube.

Any damage caused directly or indirectly by aggressive chemical substances, galvanic or electrolytic
reaction or caused by bacteriological aggression, erosion or damages caused by solid particles in
suspension in the water are expressly excluded from the warranty.

Slight marks and/or normal wearing and/or corrosion shall not be considered defects.
2.3 Vibration

Vibration is evaluated in compliance with ISO 10816 and the vibration level should be zone B (the
machines with vibrations within this zone are normally considered as acceptable for unlimited long time
operation).

3 QUALITY CONTROL

All parts manufactured by MAVEL will be inspected according to internal inspection and testing
programs. The standard manufacturing program includes certificates of chemical analysis, material
tests, testing of non-destructive parts such as castings and welds, visual and dimensional inspection,
static and dynamic balancing of all rotating parts and leakage and pressure tests of all parts exposed to
fluid pressure.

4 COMMISSIONING PROCEDURE

The commissioning procedure consists of the following:
e Tests without water
e Tests with water (wet tests)
e Tests without turbine loading
e Tests with unit loading

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Mavel Kaplan BULB Turbine
Technical Specification

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The test program is based on requirements of the norm CSN EN 61116 — Principles for installation of the
technologic equipment of small water power plants, in publication IEC 545 — Directives for

commissioning, exploitation and maintenance of small water turbines and on the internal practices of
MAVEL.

The verification of the parameters done during the start of operation is made both by the value reading

from operating instruments and by post evaluation in according with norms IEC 42 and IEC 41,
respectively.

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Technical Specification

WwW

5 PAINT SYSTEM
NUMBER
E NCE OF LAYER
TYPE OF COAT SHADE 5 oe = 2 OF nN NOTE
coats |
Surfaces in permanent contact with the water - inner surfaces of the equipment
Sand blasting on the grade Sa 27/2
Interzone 954 black P —in factory 1 200 epoxy
Interzone 954 RAL 7038 light grey V—in factory 1 200 epoxy
Visible external surfaces of the turbine in the machine hall — stationary
Sand blasting on the grade Sa 2?/,
Interseal 670HS | sand yellow Z —in factory 1 120 epoxy
Interseal 670HS | grey P —in factory 1 120 epoxy
Interthane 990 | RAL 5005 blue V —in factory 1 60 polyurethane
Non-visible surfaces of the turbine in the machine hall — stationary
Sand blasting on the grade Sa 27/2
Interseal 670HS | sand yellow Z—in factory 1 150 epoxy
Interseal 670HS | RAL 7038 grey P — in factory 1 150 epoxy
Visible external surfaces of the turbine in the machine hall — movable
Sand blasting on the grade Sa 27/2
Interseal 670HS | sand yellow Z-—in factory 1 120 epoxy
Interseal 670HS | grey P —in factory 1 120 epoxy
Interthane 990 | RAL 1012 yellow V —in factory 1 60 polyurethane

Generator, HPU

Acc. To Subcontractor

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Appendix D
Generator Information
Generator Drawing

G&Em Brochure and References

Offer No. P1903076
Project: 29029

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1 unit of vertical synchronous generator type SG198WL10U41,6

Apparent output power

Active output power

Received power

1 306 kVA 1175 kW) 1226 kW
Voltage Current Frequency
Y 4160 V 181 A 60 Hz
Nominal speed |Maximum speed Time of max. speed
720 rpm 2 160 rpm 10 min
Direction of rotation Mounting Nominal power factor
on request IM 3011 2 0,90 -
Ambient temperature A.A.S.L. Efficiency cos @
+40 °C 1 000 m Sn % 0,90 | 0,95 dl
Protection / cooling lInsulation / Utilization class 100 95,9 | 96,1 | 96,4
IP 23/1C01 F/B 75 95,7 | 96,0 | 96,2
Standards Duty 50 95,1 | 95,4} 95,6
EN 60034 $1 25 92,5 | 92,9 | 93,3
Moment of inertia Weight Lagging/leading power factor
J=154 kgm’ |} approx. 8 000 kell 0,9/ 0,9
Reactances
Direct axis synchronous reactance Xq 1,34 [p.u.]
Direct axis transient reactance Xq" 0,24 = [p.u.]
Direct axis subtransient reactance Xq" 0,20 = [p.u.]
Quadrature axis synchronous reactance Xq 1,22 = [p.u.]
Quadrature axis transient reactance Xq" 1,22 [p.u.]
Quadrature axis subtransient reactance Xq"" 0,40 = [p.u.]
Armature resistance Vy 0,01 = [p.u.]
Leakage reactance x 0,09 = [p.u.]
Time constants
Direct axis open-circuit transient time constant Tao’ 1,28 {s]
Direct axis open-circuit subtransient time constant Tyo" 0,05 {s]
Quadrature axis open-circuit transient time constant Tao’ 1,28 [s]
Quadrature axis open-circuit subtransient time constant Tgo" 0,05 [s]
Direct axis short-circuit transient time constant Ty 0,23 [s]
Direct axis short-circuit subtransient time constant T," 0,05 [s]
Quadrature axis short-circuit transient time constant Ta 1,28 [s]
Quadrature axis short-circuit subtransient time constant Ty" 0,02 [s]
Other parameters
Inertia constant (only rotor of the main generator) H 0,33 [s]
Zero sequence reactance Xo 0,00 = [p.u.]
Negative sequence reactance Xo 0,29 = [p.u]

G&Em s.r.o.

email: info@gaem.cz

tel: +420 773 338 013