DIVE Turbinen
- Offer Profile
- The DIVE Turbinen GmbH & Co. KG was founded in 2012. As a spin-off company of FELLA Maschinenbau GmbH the DIVE Turbinen GmbH & Co. KG has unique excess to the knowhow and experiences of the grown, renowned family owned company. The hydro power know how of the Fella Maschinenbau GmbH, including the development, design, manufacturing, assembling, erecting, start up and service of the DIVE-Turbine, is concentrated in the DIVE Turbinen GmbH & Co. KG. Due to the great success of the DIVE-Turbine on the market and the even greater outlook of the market potential, FELLA have decided to create a new company which will focus solely on the DIVE-Turbine, the DIVE Turbinen GmbH & Co. KG.
Product Portfolio
Technology
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DIVE-Turbine: Compact - Efficient - Reliable
The DIVE-Turbine is an innovative turbine concept for small hydropower plants. The concept fulfills all requirements for a modern hydropower plant with low head and an installed capacity of up to 2 MW per unit. The DIVE-Turbine is an efficient, reliable and cost-effective turbine solution. Based on the permanent magnet synchronous generator from OSWALD Elektromotoren GmbH an all-round conclusive concept was developed. A customized turbine design, in combination with the latest generation of power electronics guarantees high efficiency of the complete Turbine-Generator-Inverter-Unit, from water to wire. According to the singular requirements of each power plant, the DIVE Turbinen GmbH & Co. KG provides individual solutions, including the design, manufacturing, delivery, installation, start up, after sales service. An Innovative Concept
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Summary
The DIVE-Turbine is an innovative turbine- and generator concept for small hydropower plants. The concept fulfills all technical requirements of a modern hydropower plant with low head and an installed capacity of up to 2,000 kW per unit.
Integrated Turbine Solution
The innovative turbine solution DIVE-Turbine will be distributed by DIVE Turbinen GmbH & Co. KG, a spin-off of the Fella Maschinenbau GmbH. For more than 10 years FELLA Maschinenbau GmbH and OSWALD Elektromotoren GmbH have been developing and operating speed variable motors, this kind of motors will be used for the DIVE-Turbine as generators. During the design process of the DIVE-Turbine the one of the targets was to eliminate the pitching of the runner, due to maintenance and operational risks. Therefore the engineer’s developed a turbine with a fixed runner and an efficiency maximisation through speed variation.
A new turbine runner was designed together with the Institute of Fluid Mechanics and Hydraulic Machinery (IHS), Stuttgart University, especially for this application. The speed variable turbine operation from 10 up to 120 % of the nominal speed is provided by the high efficient and reliable inverters. The TF-Motor (Torque motor) from OSWALD Elektromotoren GmbH is a very compact Permanent Magnet Synchronous Generator (PMG). This generator can handle very high torques at low speeds. Due to this it is possible to realise a direct connection of the turbine runner and the generator runner (no gearbox or belt drive). Above all it has a very good efficiency between 95% and 98%.
Different and innovative possibilities for the turbine design are made possible by this compact design of the TF-Motor. Together the mechanical- and electric engineers of DIVE Turbinen GmbH & Co. KG, FELLA Maschinenbau GmbH and OSWALD Elektromotoren GmbH developed a compact turbine-/generator-unit with an integrated bearing unit and a free from wear and tear sealing system. This compact unit operates completely submerged. The only part reaching out of the water is the flexible connection to the Control Centre (Plant Control and Power Electronics). Range of Application of the DIVE-Turbine
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- Head between 2 m and 25 m
- Discharge from 0.6 m³/s up to 40 m³/s per turbine unit
- Rated power from 30 kW up to 2.000 kW per turbine unit
- New hydro power plants
- Refurbishment and reactivation of existing power plants
- Repowering of existing power plants
- Integration in existing weirs (residual flow/Dotierwater)
- Integration in already existing buildings and existing canal systems. (Reference: Hydro Power Plant Niederuntersberg)
- Save operation in flood prone sites
- Save operation in salt and drain water
Advantages of the DIVE-Turbine
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- Double regulated - speed variable
- Direct connected without a mechanical transmission (no gearbox or belt drive)
- Without the cost- and maintenance-intensive adjusting mechanism of a pitch able turbine runner
- Noiseless and Compact
- High overall efficiencies (water to wire)
- Cos φ -> 1; reactive power compensation not necessary (adjustable)
- Free of maintenance and virtually free from wear turbine-generator unit
- Very long durability
- Flexible integration in the power plant.
- Flexible between turbine and Control Centre
- Easy to install
- Competitive
- Fast production time - fast operational availability
Product
Control Device
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Double Regulated Turbine - Pitch-Able Guide Vanes and Speed-Variable Turbine
The DIVE-Turbine is a double regulated turbine. The continual adjustment on the changing discharge and head is realised by the pitch-able guide vanes and the adaptation of revolutions per minute (rpm) of the turbine runner.
Pitch-Able Guide Vanes
The pitch-able guide vanes are ensuring a consistent headwater level or the maximal head by throttling the discharge. The guide-vanes have an optimal fluidic design.
All parts in contacted with water are produced out of stainless steel (1.4301 or 1.4313) and braze. The material of the slide faces is a specific synthetic material. This design guarantees a long durability and maintenance free operation of all parts.
The adjustment of the guide vanes is carried out by two double acting hydraulic cylinders. This cylinders are made especially for a submerged operation. The used materials, stainless steel, braze and chromed stainless steel, guarantee a long durability and maintenance free operation of the hydraulic system.
Permanent Magnet Synchronous Generator (PMG)
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Directly Connected Permanent-Magnet-Synchronous-Generator (PMG) from Oswald Elektromotoren GmbH
The TF-Motor/Generator from Oswald Elektromotoren GmbH is a so called Torque-Motor. This Torque-Generator is a very compact Permanent Magnet Synchronous Generator (PMG). This motor can handle very high torques at low speeds. Due to this it is possible to realize a direct connection between the turbine runner and the generator runner (no gearbox) therefore is it possible to realize a long lasting and cost-effective operation. Above all the TF-Motor has a very good efficiency between 95 % and 98 %.
The unique characteristic of the DIVE-Turbine is the direct connection of turbine and generator, due to this no mechanical transmission is necessary therefore not gearbox or belt drive is needed. This means that the parts with the highest maintenance effort and operational risk are eliminated as well as the efficiency losses occur in the mechanical transmission. Therefore with the DIVE-Turbine a maintenance free and reliable turbine operation with maximum efficiency can be realized.
The compact turbine and generator unit operates completely submerged. Due to this a good cooling of the generator is guaranteed by the surrounding water. This makes an active cooling system supersede and another part with maintenance and operational risk can be eliminated.
Advantages by Using a PMG:- Long durability
- Free of maintenance and virtually free from wear and tear
- Free of mechanical transmission
- Minimal numbers of moving parts
- Free of active cooling system
- Only one central DIVE-Bearing for the whole turbine/generator unit.
- Unique low noise-and vibration-level
- High efficiency > 95 %
- Unique compactness and low weight
- Permanent excitation of the generator runner - free of any kind of rotary feed through and no need of excitation energy which guarantees a high efficiency even in part load
Turbine Runner
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Turbine Runner - Propeller
A new turbine runner was designed together with the Institute of Fluid Mechanics and Hydraulic Machinery (IHS), Stuttgart University, especially for this application. This propeller blades are produced individually for each project. The propeller blades and the propeller hub are made out of stainless steel, both are welded together. For every single project the turbine runner is individually constructed and fluidic optimal designed to guarantee maximum efficiency.
The only set point for the fluidic design of the propeller is maximum efficiency of the DIVE-Turbine.
Material (freshwater configuration):- Propeller-blade: 1.4313
- Propeller-hub: 1.4301
Fluidic optimisation of the Propeller, Guide-Vanes and Draft-Tube will be done in cooperation with the experts of the Institute of Fluid Mechanics and Hydraulic Machinery (IHS), Stuttgart University.
Draft Tube
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To guarantee the maximum efficiency and the maximum discharge each DIVE-Turbine comes with a fluidic optimised draft tube. The design and fluidic optimisation of the draft tube is done in cooperation with the Institute of Fluid Mechanics and Hydraulic Machinery (IHS), Stuttgart University. In addition to the individuall draft tube design the scope of delivery comprises at least the draft tube cone.
- Material draft-tube-cone: stainless steel 1.4301 welded
- Material turbine-flange: stainless steel 1.4301 welded
In most of the projects the draft-tube-elbow and the -diffuser are realised with a wooden formwork on site. Optional we can deliver a fully finished steel draft tube.
DIVE-Bearing /DIVE-Sealing
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DIVE-Bearing
The only turning component is the direct connected unit of generator and turbine runner. This component is supported by a central bearing unit. The DIVE-Bearing ensures high working loads and maximum system rigidity. This assures a long durability and a maintenance free operation of the hydro power plant.
DIVE- Sealing
To guarantee the durable completely submerged operation of the DIVE-Turbine the engineers developed a special wear and tear free sealing system. The wear and tear free DIVE-Sealing ensures that the inside of the turbine-generator-unit is protected against any moisture infiltration.
This ensures that the DIVE-Bearing will reach or exceed the nominal lifetime of the bearings. The wear and tear free DIVE-Sealing enables the DIVE-Turbine to operate durable completely submerged, due to this any kind of high water or flood will not damage/harm the hydro power plant.
Due to the wear and tear free sealing system an absolutely reliable operation of the DIVE-Turbine can be ensured even in saltwater.
DIVE-Power Electronics Including Inverters
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An increase of efficiency through variation of the speed of the turbine can only be realised by inverter technology. Beside the efficiency increase, the use of IGBT Inverters for the energy feed-in brings additional advantages. These Inverters ensure a completely automation of the power plant operation including grid synchronisation, plant protection and cos φ-control by microcomputer control.
As a matter of principles we deliver a turn key electromechanical hydro power turbine solution including the power electronics and plant control.
DIVE-Plant Control
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The DIVE-Plant Control is an up do date control system of a speed-variable hydro power plant for a system-parallel operating hydro power plant according to the parallel operating regulations of the German electricity association (VDEW).
The DIVE-Plant Control Comprises the Following Functions:- Automatic operation and water head water level control
- Automatic operation starts and stops according to the water level
- Automatic speed variation / torque control according to the changing discharge and head
- Grid monitoring
- Fault monitoring and logging
- Monitoring of the hydraulic aggregate
Automatic Shut-Down (Emergency Shut-Down) of the Turbine:- Monitoring of mains contactor signals
- Monitoring temperature limits
- Currentasymmetry of generator
- Monitoring of inverter signals
Monitoring System for the Whole Hydro Power Plant:
The monitoring system comprises the main measuring systems to realize a fully automatic operation and is designed to ensure a durable and failure-free operation of the whole power plant.- Monitoring and logging of all relevant signals
- Fault- and confirmation report
- Direct and live data connection to the DIVE-Service of the DIVE Turbinen GmbH & Co. KG
- Generator protection (Voltage, Current, frequency)
- Cos φ-control (cosφ →1, adjustable) no need of a reactive power compensation system.
- Grid synchronisation
- Monitoring electrical power output
- Monitoring temperatures generator (PT100- thermometer / redundant)
- Monitoring temperatures bearings (PT100-thermometer / redundant)
- Monitoring water level before and after inlet rack
- Monitoring operation start procedure
- Digital controller integrated in SPS
- Water-level sensor (pressure sensor)
- Touch Panel, up to 19'', color
- Additional data-logging
References
Hydro Power Plant Kroatien01, Croatia
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Customer Ekotok d.o.o. Start of operation January 2015 Head 2,80 m Runner diameter 1080 mm Nominal Power 105 kW (effective/net output, grid side)
Hydro Power Plant Crampagna, France
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Customer Ondulia Start of operation January 2015 Head 5,50 m Runner diameter 1600 mm Nominal Power 540 kW (effective/net output, grid side)
Hydro Power Plant Guilhot, France
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Customer Ondulia Start of operation January 2014 Head 10,50 m Runner diameter 1450 mm Nominal Power 3x900 kW (effective/net output, grid side)
Hydro Power Plant Korea 1, South Korea (saltwater-resistent)
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Customer DSK Engineering Co., Ltd Start of operation October 2013 Head 6,25 m Runner diameter 1450 mm Nominal Power 400 kW (effective/net output, grid side)
Hydro Power Plant Chile02, Chile
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Customer Donguil Energia S.A. Start of operation May 2011 Head 4,70 - 4,90 m Runner diameter 1310 mm Nominal Power 250 kW (effective/net output, grid side)
Hydro Power Plant Purisima, Chile
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Customer B. Bosch
Start of operation February 2012 Head 9,50 - 10,50 m Runner diameter 1150 mm Nominal Power 444 kW (effective/net output, grid side)
Hydro Power Plant Chatel Chehery, France
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Customer SHEMA France Start of operation February 2012 Head 5,50 - 5,80 m Runner diameter 1080 mm Nominal Power 200 kW (effective/net output, grid side)
Hydro Power Plant Niederuntersberg, Austria
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Customer Energie AG Oberösterreich Kraftwerke GmbH Start of operation December 2007 Head 2,50 - 2,80 m Runner diameter 1280 mm Nominal Power 105 kW (effective/net output, grid side)