Energy Projects

Energy Projects



Sainte-Catherine, Quebec

Refurbish Generating Units of COTE STE.CATHERINE POWER PLANT

Sainte-Catherine, Quebec

Client : Delom Services

Location : Sainte-Catherine, Quebec

Year : 2021

Delom Services was awarded a contract to refurbish the generating units #10 and #7 at the Côte Ste.Catherine power plant, and mandated LDV Consultants to provide the engineering for the following:

  • Disassembly and reassembly:
    • Provide work procedures and data sheets;
    • Prepare hoisting instructions;
    • Validate lifting equipment and specialized tooling.
  • Repair work to be done in the plant and on site:
    • Analyze data from inspection sheets and non-destructive test reports;
    • Write reports with recommendations and work instructions;
    • Size the parts to be replaced/manufactured; 
    • Draft the procedures for reassembling the Kaplan wheels in the workshop;
    • Resolve anomalies and non-conformities;
    • Ensure the presence of a contact person on site;
    • Provide engineering support.

Expertise for Embedded Parts, Air Gap and Model Test

Alma, Quebec

Client : Rio Tinto Alcan

Location : Alma, Quebec

Year : 2020

Rio Tinto Alcan mandated LDV Consultants to carry out analyses and make recommendations on several subjects pertaining to a generating unit at the Isle-Maligne power station:

  •  Analyze and produce a report on the embedded parts of the turbine by an expert in turbine mechanics:
    • Analyze the current condition of the parts;
    • Make recommendations for the refurbishment and repair of each of the embedded parts;
    • to extend their operating life;
    • Assess the impact of the increased turbine power on the embedded parts and make recommendations on the adjustments to be made to the turbine.
  • Analyze and produce a report on the evolution of the air gap by an expert in alternator mechanics:
    • Analyze the current condition of the alternator in an advanced state of wear;
    • Assess the impact of a breakdown on various components due to the state of degradation of the unit;
    • Assess repair options to ensure proper operation of the alternator until it is rebuilt;
    • Make recommendations on the monitoring and operation of the unit until it is refurbished.
  • Express an opinion and produce a report on the anticipated performance based on the digital simulations compared to a model test, by a turbine hydraulics expert:
    • Review the characteristics and guaranteed performance of the equipment;
    • Make recommendations on the need for a model test while taking into account guarantees, costs, and deadlines.
  • Propose a strategy for the upcoming major refurbishing of the 12 generating units to minimize the risks for the plant operator:
    • Use new or refurbished parts;
    • Plan the equipment downtime for refurbishment;
Alma, Quebec
Gatineau, Quebec

Bear Swamp rehabilitation

Gatineau, Quebec

Client : Brookfield Renewable

Location : Gatineau, Quebec

Year : 2019

Brookfield Renewable, is a world leader in alternative asset management. They are also one of the world's largest investors in renewable energy. They have assets located around the world which include a diverse technology base.

To monitor the Bear Swamp rehabilitation project, Brookfield Renewable mandated LDV Consultants during the design, manufacturing and implementation site phases to deliver the following engineering services:

  • Review of all technical documents issued by the manufacturers to validate conformance with the contractual requirements but also according to the industry’s best practices
  • Participate in design reviews as a Brookfield technical representative to review the proposed design, to identify potential design pitfalls or limitations
  • Review the technical aspects of the derogations, NCR and extra work occurring during the manufacturing process (and later during the site phase)
  • Review the manufacturing shops ITP to propose witness points
  • Act as the technical and quality representative of Brookfield for witness point during the manufacturing process.

 

Technical Support - Modification of Sill Seal

North America

Client : Major North American Company

Location : North America

Year : 2019

As part of a gate repair project, a major North American company commissioned LDV Consultants to design the modification of the existing intake gate in a hydroelectric facility. The repair work required the addition of a rubber sill seal to control the increasing leakage flow of the metallic seal. In addition, LDV Consultants provided support for the future refurbishing works of the intake gates.

As part of the technical assistance mandate for the intake gates, LDV Consultant has been mandated to perform the following tasks:

  • Design of an added rubber sill seal;
  • Drawings of new parts;
  • Assembly drawing of the new concept;
  • Validation of the wheel loads;
  • Validation of the operating loads;
  • Evaluation of the lifting system capacity;
  • Modification of the lifting system to remove the clutch;
  • Modification of the control system.
North America
North America

Engineering assessment of Wells Damn Hydroelectric Project

North America

Client : Toshiba America Energy Systems Corporation

Location : North America

Year : 2018

Toshiba America Energy Systems Corporation is a leader in the high-technology industry of engineering and construction that provides customer service for all energy platforms (hydro, nuclear, thermal…) like turbine sales, repairs, etc. Toshiba American Energy Systems mandated LDV Consultants to carry out the initial engineering assessment of Wells Dam Hydroelectric Project:

  • Review of equipment technical specifications, TAES’s refurbishment design drawings and procedure and units 1 & 2 refurbishment results with the objective of identifying the engineering potential improvement actions and priorities and put them in a report for TAES’s management;
  • Assisting Toshiba’s engineering to address the top 4 priorities for the Wells Dam Hydroelectric Project with the compilation of all the documentation pertaining the priority being addressed, in depth analysis of the information compiled, redaction of a proposed action plan and revision of it with the review of Toshiba and realization of the drawings, procedures and site record sheets necessary to reach the agreed upon goal;
  • Perform limited-scope mandates in support of Wells Dam refurbishment engineering, task details (deliverables, schedule, maximum hours) to be determined for each mandate.

White Horse 2 central repair

North America

Client : Litostroj Hydro inc.

Location : North America

Year : 2018

Litostroj Hydro inc, is a leader in the hydroelectric industry with tailor-made solutions ranging from primary hydraulic design, model testing, production, assembly and commissioning.

‘‘ LDV - advanced engineering ’’, was able to support Litostroj Hydro inc during the evaluation of all of the current mechanical components for the planned power increase. LDV prepared all of the repair engineering to plan the actions on the components retained during the future repair. The engineering and evaluation were carried out in particular on the following parts:

  • Directors
  • Wheel coat
  • Vacuum shield
  • Lower and upper flange
  • Lower and upper cross
  • Carcass
  • Rotor spider
  • Alternator Shaft
  • Turbine Tree
  • Distributor mechanism
  • Spiral tarpaulin
North America
Campbellford, Ontario

Replace gates on Meyers Dam

Campbellford, Ontario

Client : Canada park

Location : Campbellford, Ontario

Year : 2018

Canada Park started a major refurbishment of the Trent Severn waterway in 2017. LDV was in partnership with Rouby Industries, a company specializes in the manufacturing of metal structures and structure parts, and more specifically hydraulic structures. During the refurbishing of the Meyers dam, Rouby-LDV was tasked with designing, manufacturing and delivering equipment used to control the water level of Trent River.

LDV Consultants task was to provide assistance during the design and manufacturing of various components, including the gate, embedded parts and hoisting device as well to ensure that the design and manufacturing comply with the client's requirements and Canadian standards (CSA S16). As part of its mandate, LDV Consultants carried out the following:     

  • Verify and validate the engineering, including the design notes for the components;
  • Check and certify the assembly and detail drawings;
  • Design and layout of the electrical control panels to heat the gate, embedded parts and gate control system;
  • Design and layout of the electrical control panels for the gate hoisting device

 

Technical Support - Gate Wheels Modification

Ontario, Canada

Client : Hydro Tech - OPG (Ontario Power Generation)

Location : Ontario, Canada

Year : 2018

As part of a gate repair project, Hydro Tech commissioned LDV Consultants to design the modification of the intake gate wheels at the Kipling hydroelectric facility. The repair work required the replacement of the bearing elements as the existing wheels were seized. In addition, the original design had to be modified in order to use commercial bearings instead of custom-made elements to limit the duration of the work.

As part of the technical assistance mandate for the design of the valve wheel modification at Kipling, LDV Consultant was mandated to perform the following tasks:

  • Selection of bearings;
  • Drawings for repairing and modifying preserved parts;
  • Drawings of new parts;
  • Assembly drawing of the new concept;
  • Supply of bearings;
  • Workshop assembly procedure;
  • Installation procedure for wheels at the site.
Ontario, Canada
USA

TURBINE SHAFT FEA ASSESSMENT

USA

Client : GE Renewable Energy Canada

Location : USA

Year : 2018

As part of a submittal requisite, the owner wanted to have a preliminary study of the turbine shaft structural integrity in order to assess if the component was robust enough to undergo another 40 years of service life in addition to a power increase.

LDV Mandate

  • Perform a FEA analysis of the turbine shaft to better understand its physical behavior under its normal and steady state load conditions.
  • Calculate by finite element analysis (FEA) the Von-Mises equivalent static stresses in the turbine shaft at full load in normal operating condition and compare the results against the criteria commonly used in the hydro business.
  • Calculate by FEA the Von-Mises equivalent static peak stresses in the turbine shaft for different fatigue cycles and compare the results against S-N fatigue curves commonly used in the hydro business to evaluate the cumulative fatigue damage.
  • Calculate by FEA the maximum allowable crack which is not propagated under the maximum load in normal operating condition using the methodology found in the API579-1/ASME FFS-1 Standard.

The preliminary finite element analysis showed that the base material of turbine shaft is robust enough to withstand an additional 40 years of service life and a maximum allowable crack size was identified.

 

Finite Element Analysis of the Pole and Rim

New Zealand

Client : New Zealand Operator

Location : New Zealand

Year : 2017

Following the inspection of the units of a New Zealand operator's hydroelectric power plant, LDV Consultants was mandated to conduct an analysis on the units of the hydroelectric power plant to draw up a series of recommendations and inspections for future unit shutdown. As part of the project, LDV Consultants was mandated to conduct a finite element analysis on the rotor trunnion pole and rim.

The purpose of this analysis was to determine the actual condition of the rotor's two main components given that the units, that are operational since 1967, have never undergone any major refurbishing.

The purpose of the finite element analysis was to determine the stresses and deformations of the rim and pole under various loading conditions so as to calculate their remaining useful life. Static stress and fatigue damage calculations were therefore performed as per the recommendations in the ASME Boiler and Pressure Vessel Code, Section VIII, Division 2. The analysis was conducted, using ANSYS Workbench r.18.2, on an assembly that included the rim and pole.

New Zealand
North America

FEA of a MIV

North America

Client : Major North American Company

Location : North America

Year : 2017

As part of a vast rehabilitation and certification project for its production units, a major North American compagny mandated LDV Consultants to perform a finite element analysis (FEA) of large main inlet valves (MIV) installed in a power house.

The purpose of the FEA was to determine the best solution, i.e. to replace or rehabilitate the MIV, from an economical point-of-view, but also from a safety perspective as the MIV plays an essential role in the safety and integrity of the turbine parts, generator parts and entire power house.

To achieve this objective, the stress fields and deformations under several load conditions were calculated by FEA. The different load conditions were then combined to evaluate the theoretical residual operating life of the MIV. The stress and cumulative fatigue damages were calculated and verified in accordance with the ASME Boiler & Pressure Vessel Code, Section VIII, Division 2 methodology and criteria. The FEA was performed using Ansys Workbench 17.2.

Technical support Côte Ste-Catherine Power Plant

Sainte-Catherine, Quebec

Client : Delstar Énergie

Location : Sainte-Catherine, Quebec

Year : 2017

The Delstar Énergie Company, a subsidiary of Groupe DELOM, is a well-known player in the world of energy, particularly in regard with generator poles and electrical conductors’ refurbishment or fabrication.

To get the support of hydro generator experts, Delstar Énergie contacted LDV which provided its engineering services for the refurbishment of one turbine-generator unit of 1,6 MW, that comprised a Kaplan runner with single regulation.

  • Site support for dismantling and reassembly of turbine and generator unit;
  • Dimensioning of new runner blade bushings;
  • New design of blade seals;
  • Shop support for machining of runner components;
  • Definition of technical requirements for pressure and balancing tests;
  • Recommendation on assembly tolerances and guide bearing clearance;
  • Writing of assembly/disassembly procedure of runner in a shop.

 In order to provide a high-quality service and to establish an effective collaboration and communication with Delstar’s personnel, LDV experts went either to the shop or the site many times during the project

Sainte-Catherine, Quebec
Latchford, Ontario

Gate Replacement of Latchford Dam

Latchford, Ontario

Client : Rouby Industries

Location : Latchford, Ontario

Year : 2016

Rouby Industries specializes in the manufacturing of metal structures and structure parts, and more specifically hydraulic structures. During the refurbishing of the Latchford dam, Rouby Industries was tasked with designing, manufacturing and delivering equipment used to control the water level of Bay Lake.

Rouby Industries mandated LDV Consultants to provide assistance during the design and manufacturing of various components, including the gate, embedded parts and hoisting device as well as the steel cofferdams, wood beams and steel guide rails to ensure that the design and manufacturing comply with the client's requirements and Canadian standards (CSA S16). As part of its mandate, LDV Consultants carried out the following:

  • Verify and validate the engineering, including the design notes for the components;
  • Check and certify the assembly and detail drawings;
  • Design and layout of the electrical control panels to heat the gate, embedded parts and gate
  • Control system;
  • Design and layout of the electrical control panels for the gate hoisting device.

Installation of Butterfly Valves at the Hydroelectric Power Plant

Romaine-2 Power Plant, Quebec

Client : Alstom-Power Canada

Location : Romaine-2 Power Plant, Quebec

Year : 2013

In 2010, Alstom-Power Canada was awarded a contract to design, manufacture and install two generating units for the Romaine-2 power plant. To validate the feasibility of the assembly sequence and the optimisation which the assembly of certain components represented, Alstom needed technical support to address the challenges posed by the assembly sequence.  

Alstom therefore mandated LDV Consultants to perform the design and engineering required to move and lift the butterfly valves at the Romaine-2 power plant. A structural analysis of the load cases and maximum strain calculations were also carried out. 

During installation, LDV was involved in the installation sequence modification process in order to make up for the one-month delay, due to late deliveries, in the planned schedule.   

Romaine-2 Power Plant, Quebec
Quebec

Design Towers for the Pointe du Bois Monorail | Pointe du Bois Power Plant

Quebec

Client : Alstom Renewable Energy

Location : Quebec

Year : 2013

Alstom Renewable Energy entrusted LDV Consultants with the mandate to design towers for the monorail used to move the beams of the main spillway at Manitoba Hydro’s hydroelectric power plant in Pointe du Bois. As part of the mandate, LDV carried out the following tasks:

  • Perform load calculations;
  • Design the monorail towers;
  • Produce a 3D model;
  • Provide assembly drawings;
  • Provide manufacturing drawings;
  • Ensure follow-up of subcontractors;
  • Address subcontractor non-compliances and derogations;
  • Draft engineering procedures.