The Digital Twin
Development of the digital twin marks the start of hydropower project development. The entire electro-mechanical system, including automation and EPS, is digitally modelled and simulated. Major tools used during this phase are dynamic electrical and hydraulic network simulation, flow simulation (CFD) in pumps, turbines and generator ventilation, as well as simulation of heat transfer (CHT) in cooling systems, electromagnetic simulation and optimization of the structure by means of finite element analysis (FEA).
Development work continues based on interaction between the physical world and the digital world. High-end test rigs for turbines and pumps enable hydraulic development with the aim of achieving the most flexible operational characteristics across a broad range of operating conditions. The digital twin also supports the development of designs that are capable of delivering flexibility alongside a rapid response and stability – all while supporting to production of the necessary documentation needed to prove hydraulic and electrical performance targets according to IEC (Internatioal Electrotechnical Comission) standards.
Further measurements for design advancement are for example bearing optimization and high efficiency generator insulation development. Site measurements complete the development process and are a valuable source of information with regard to fulfillment of guarantees, feedback on designs and assessment of existing equipment. ANDRITZ uses world-leading measurement technology in order to cover the full range of site measurements needed for optimal designs and appropriate operational characteristics.
Subsequently, measurement data both from the test rig as well as from the site are systematically fed back to the digital twin for optimizing the products over the entire life cycle.