Operations and Maintenance – classroom presentations

Presentations are:

Benefits of Corrosion Prevention and Coatings/Linings Programs in Hydroelectric Power Generation Facilities, presented by Max Fulton-Manders, Salt River Project (SRP), and Daniel Toft, Duromar Repair & Maintenance Coatings

Evaluating Environmentally Acceptable Oils for Hydropower: Study Findings and Utility Applications, presented by Alexandra Sammons, CEATI

Leveraging FEA to Fortify Mechanical Seals, presented by NAME TO COME, Bureau of Reclamation

When to Replace our Turbine Shaft? Analysis and Considerations Regarding the Lifetime of Turbine Shafts Immersed in River Water, presented by Andrew Wodoslawsky, P.E., M.Eng., MBA, Hydro Mechanical Engineer, Hydropower & Hydraulic Structures, Black & Veatch

Details about each presentation and the speakers are below:

Benefits of Corrosion Prevention and Coatings/Linings Programs in Hydroelectric Power Generation Facilities
Presented by Max Fulton-Manders, Salt River Project (SRP), and Daniel Toft, Duromar Repair & Maintenance Coatings

By safeguarding equipment from corrosion, coatings and linings enhance the long-term operational life of hydroelectric facilities, ensuring continuous power generation for the grid. This abstract highlights how the selection and installation of high-quality coatings and linings substantially outweigh the financial burden of equipment replacement, offering long-term cost savings and operational resilience to owners and energy producers.

Evaluating Environmentally Acceptable Oils for Hydropower: Study Findings and Utility Applications
Presented by Alexandra Sammons, CEATI

Hydropower owner-operators are considering Environmentally Acceptable Lubricants (EALs) as alternatives to conventional oils to align with environmental regulations, but have concerns about maintaining reliability. Comprehensive testing of commercially available EALs in hydroelectric applications, using labs which are independent from lubricant manufacturers, will assist in evaluating risks to reliability. To address this need, CEATI’s Hydropower Plant Equipment Interest Group conducted a study assessing EAL performance using standardized ASTM testing.

This session will cover key findings from the first phase of testing, which evaluated oxidation stability, wear prevention, and water separability across multiple EALs. Some results confirmed expectations, while others raised important considerations for utilities:

• Oxidation stability varied significantly, with one EAL maintaining performance for 1,864 minutes, while others degraded much faster.
• Water separation challenges were observed in certain samples, where emulsions persisted for over 30 minutes, which could be a factor in hydro plant operations.
• Wear resistance differences across products indicate that selection should be based on specific application needs.

As a member of CEATI’s Hydropower Plant Equipment Interest Group, USACE (Catherine Campbell, Hydropower Mechanical Systems SME, Hydroelectric Design Center) will share how they are considering these results in their approach to lubricant selection and maintenance planning. Catherine Campbell will provide insights into how USACE evaluates oil performance and what factors are influencing their next steps.

The scope of this study focused on test results that could be applied broadly across hydropower operations. Compatibility between EALs and in-service oils was not included since it is highly specific to individual powerhouses and their in-service lubricants. Instead, the goal was to generate results that would be useful to all members by providing comparative data on performance characteristics.

The second phase of this project will commence in 2025, and will evaluate the top-performing EALs in their biodegradability, toxicity, and bioaccumulation performance. This step will complete the lab testing requested by participating CEATI members. Because independent verification of properties and performance of commercially available EALs has been limited, these results will offer valuable data to hydropower operators making decisions about lubricant transitions, helping to fill a critical knowledge gap on how EALs perform beyond laboratory testing. We expect to have additional findings to share by October 2025.

This presentation will provide practical insights for utilities evaluating EALs, with a focus on test results and experience-based considerations.

Leveraging FEA to Fortify Mechanical Seals
Presented by "Name to Come", Bureau of Reclamation

Overview
In this presentation, we will explore a finite element analysis (FEA) study conducted on the mechanical seal of a vertical Francis hydroelectric generator, which experienced critical flaws in early 2024. Our focus will center on how FEA aided in identifying root causes of structural cracking and in developing actionable solutions to enhance design integrity and operational safety.

Objectives
1. Root Cause Analysis: We will detail our methodology for uncovering the fundamental reasons behind the observed cracking in the mechanical seal housings, specifically in areas affected near the bolted connections.
2. Collaborative Engineering Efforts: We will highlight the collaborative approach between the USBR TSC and field service engineers, demonstrating how this partnership leveraged diverse engineering expertise to mitigate cracking risks.
3. Potential Solutions: Present designs of four FEA models aimed at reducing flange deflection. Key metrics will include displacement and von Mises equivalent stress, allowing us to estimate the safety factors and fatigue life of each design.
4. Operational Insights: We will share lessons learned from operational measurements taken during the assessment, emphasizing the importance of routine maintenance and integrating advanced technologies to enhance system reliability.

Key Takeaways
• Understanding the value of finite element analysis in diagnosing structural issues can significantly improve the reliability of critical hydropower components.
• Collaboration among various engineering teams ensures that innovative, effective solutions are developed to address complex concerns swiftly.
• Effective communication of technical findings can lead to enhanced operational protocols and better risk management strategies in hydroelectric generation.

Conclusion
This presentation will provide valuable insights from an owner/operator perspective, showcasing the intersection of advanced engineering analysis and practical application in hydropower systems. Attendees will come to appreciate the role of FEA in creating solutions to reduce failures, ensure public safety, and promote the sustainable operation of hydroelectric facilities. We aim to instill a deeper understanding of how proactive measures can extend the life and performance of key infrastructure components.

When to Replace our Turbine Shaft? Analysis and Considerations Regarding the Lifetime of Turbine Shafts Immersed in River Water
Presented by Andrew Wodoslawsky, P.E., M.Eng., MBA, Hydro Mechanical Engineer, Hydropower & Hydraulic Structures, Black & Veatch

A prominent hydro power producer in the Midwestern United States experienced a 2X overload in one powerhouse, followed in two months by a discovery of a broken runner, followed in a month by a dramatic failure of a shaft and its thrust and guide bearing at a sister powerhouse in the same vicinity.

he twin events, and given two shaft failures in the distant past, and the heavy corrosion and visible linear defects along the full lengths of the shafts fully immersed in river water, prompted the owner to revisit the design, fitness-for-service, and failure modes of both shaft systems, and to consider the relative merits of run-to-failure, periodic inspection, or phased replacement strategies going forward.

Attendees will benefit from our qualitative considerations, numerical analysis, and conclusions for two separate powerhouses with a similar question: when should we replace our turbine shaft?

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