ECCO — cam curve optimizer for Kaplan and bulb turbines with vibration monitoring
ECCO (Efficiency & Cam Curve Optimizer) is a device for automatic and continuous optimization of the combinator (cam) relationship between runner blade angle and wicket gate opening of Kaplan and bulb turbines. It raises the hydraulic efficiency of the unit across the whole range of operating points and reduces mechanical wear of the turbine. The device works with a turbine governor of any model and any manufacturer.
- Turbines
- Kaplan, Bulb
- Functions
- local real-time search, automatic index tests, configurable optimization zone, cam curve algorithm
- Compatibility
- governors of any models and manufacturers
- Vibration monitoring
- 4 proximity probes + 2 accelerometers
Price, availability and lead time on request. We help with analogue selection, customs clearance and delivery.
Description
The cam curve links the runner blade angle to the wicket gate opening of a Kaplan-type turbine. Unit efficiency, vibration and cavitation depend on how accurately it is selected. The task of the device is the highest hydraulic efficiency across the whole range of operating points with less mechanical wear of the turbine. ECCO exchanges data with the speed governor. Through this channel it slightly changes the positions of the guide vanes and runner blades, evaluates efficiency and repeats the step until it finds the best ratio. The device can load the calculated cam curves into the governor itself if a communication channel exists between them.
There are several functions. Local search optimizes the curve in real time during normal operation, without shutting the unit down. Automated index tests safely run through the whole operating range, so third-party testing organizations need not be invited for such measurements. The working optimization zone is set in the settings so that the search does not take the unit outside safe modes. A separate algorithm generates the cam curve, and the SCADA interface allows unit operation to be monitored.
The built-in vibration monitoring system has 4 proximity probes and 2 accelerometers. It performs continuous diagnostics of turbine condition and shows whether the unit has gone outside the guarantee limits set by the turbine manufacturer. The brochure presents vibration monitoring as a function that can be added to the package.
According to the manufacturer, continuous optimization gives the highest power at the lowest water consumption. The best curve is maintained throughout the hydrological cycle, for all headwater and tailwater levels, and is refined after turbine reconstruction or with the passage of time. Wear from uncoordinated operation of blades and wicket gates, that is vibration and cavitation, is reduced. ECCO belongs to the Vision line, which includes tools for advanced plant monitoring and optimization.
The device is used at run-of-river and dam-toe hydropower plants and at small hydropower plants with Kaplan and bulb turbines. In particular, it is installed after runner replacement, during governor modernization and where the head varies noticeably during the year. Vibration monitoring and the SCADA interface also serve for permanent monitoring of unit condition.
Technical specifications
| Turbines | Kaplan, Bulb |
|---|---|
| Functions | local real-time search, automatic index tests, configurable optimization zone, cam curve algorithm |
| Compatibility | governors of any models and manufacturers |
| Vibration monitoring | 4 proximity probes + 2 accelerometers |
| Communication | SCADA interface; loading of curves into the governor when a communication channel exists |
Request a price and lead time
ECCO — cam curve optimizer for Kaplan and bulb turbines with vibration monitoring. We reply within one business day.
Or email sales@usk.ua or call 044 339-50-20.
Questions and answers
Which turbines is ECCO intended for?
For Kaplan-type turbines and bulb turbines. The device works with a governor of any model and any manufacturer.
Does the unit need to be stopped to optimize the curve?
No, local search runs in real time during normal turbine operation. Automated index tests safely run through the whole operating range without involving third-party testing organizations.
Which sensors are included in the vibration monitoring system?
The system has 4 proximity probes and 2 accelerometers. It performs continuous diagnostics and checks that the unit does not go outside the guarantee limits of the turbine manufacturer.
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