Hydro News

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Hydronews

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Issue 14Oct. 2008

www.vatech-hydro.com

Acquisitionof GE HYDRO

New Opportunitiesfor Pumped Storage

KandilEnergy Projects


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ContentsIntroduction

Top story

Hydro business

Site report

Highlights

Events/Fairs

ImprintPublisher

VA TECH HYDRO GmbH

A-1141 Vienna

Penzinger Strasse 76, Austria

Phone +43/1 89100 2659

Responsible for the contentsAlexander Schwab

Editorial teamJens Putz, Peter Stettner,

Edwin Walch, Kurt Wolfartsberger

Copyright VA TECH HYDRO GmbH 2008

All rights reserved

Graphic designIdea: Gudrun Schaffer

Layout/Production: A3 Werbeservice

Edition: 20,500

New Opportunities

for Pumped Storage

Kandil

Edea I

Bemposta II

Healey Falls & Rochester II

Key projects

HIDROENERGIA 2008

ENERGY EFFICIENCYWORKSHOP

HYDRO AUTOMATION DAY2008

Markets Hydropowerin Southeast Asia

The Compact Hydro

Brazilian Market

Acquisition of GE HYDROAndritz VA TECH HYDROin CanadaAndritz HYDRO Ineparin Brazil

Islas

St.Martin

Schaffhausen

Kelenfld

NewPhone

Number:

VATECH

ESCHERW

YSSGmbH

Ravensburg,G

ermany

+49/75129511

-0

Andritz VA TECH HYDROsupports the category

WasserKOMMUNIKATIONof the Neptun Wasserpreis 2009

For more information seewww.wasserpreis.info


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Franz Strohmer

Introduction

Dear Business Partners

As part of the transaction we haveacquired GE Energys hydropower

technology and certain assets includingengineering and project managementresources, research and developmentfacilities, and a generator componentproduction centre in Canada. Moreover,a majority interest in GE Energys GEHI(General Electric Hydro Inepar) jointventure in Brazil has been obtained.

The other principal shareholder isthe Brazilian Inepar SA Group. Thenow renamed joint venture, AHI(Andritz Hydro Inepar), includes sales,engineering and project management

resources in Campinas/ Brazil,Tampere/ Finland and Kristinehamn/Sweden, as well as hydro laboratoriesin Finland and Brazil and a productioncentre in Araraquara/ Brazil. With

AHI Andritz VA TECH HYDRO alsohas access to the substantial manufac-turing resources of its Brazilian jointventure partner Inepar. With this acquisition, Andritz VA TECH HYDROnow employs approximately 4,800people worldwide and can refer toinstalled capacity of approximately400,000 MW, all of which adds upto highly significant corporate develop-ment.

I would also like to take the opportunityoffered by this edition of Hydro Newsto inform you that after more than 38years in Hydro, I shall be retiring bythe end of 2008. I had the honour ofbeing able to make a central contribu-tion to the development of todays

Andritz VA TECH HYDRO into one ofthe world's leading suppliers of electro-mechanical equipment for hydropower

After a very positive 2007,Andritz VA TECH HYDRO hasagain been able to successfullyfollow its growth path in 2008.By the end of June the acquisitionof GE Energys hydropowerbusiness was closed.

plants and to the success of the group.I see this as my life's work in the pro-fessional sphere. Accordingly, I wouldlike to offer my sincere thanks for theactive support during this journey toboth you as our business partner andto my staff. Alredy in mid-year, I trans-ferred my operational responsibilities tomy successors, although I will supportthem further in the transitional phase.

At the same time, I was nominated to theSupervisory Board of Andritz VA TECHHYDRO and I will remain on the super-visory boards at certain daughter com-panies. These Supervisory Board activi-ties will also continue after my retire-ment. My long-term, senior staff col-leagues, Wolfgang Semper and MichaelKombck, who formerly headed theLarge Hydro and Service & RehabBusiness Areas have now joined the

Management Board and in the nextissue of Hydro News we will introducethem in detail.

Dear business partners, please allowme to again thank you for our excellent,long-term cooperation and kindly askyou to continue to demonstrate yourconfidence towards Andritz VA TECHHYDRO and its new management inthe years to come. The further expan-sion of our range of competences andproducts, consistent technologicaldevelopment, the permanent growthin demand for electricity from renewableenergies and your trust in us allowme to leave in the sure knowledgeof a positive outlook for the future of

Andritz VA TECH HYDRO.

In gratitude,


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4 Hydronews

uated underneath the motor-generator,

which is designed to withstand the maxi-mum stresses caused by sudden loadchanges. In fact, up to 60 load cycles

are dealt with every day.With reversible Francis pump turbines,

the turbine and pump modes are real-ized in one hydraulic machine, wherebythe direction of rotation changes in linewith function thus reducing both thespace requirement and investment

costs. However, longer transfer timesalso result and it is necessary to useadditional equipment for pump operationstart-up.

New Opportunitiesfor Pumped StorageLeitartikel 3 Seiter...

factor in a secure and reliable energy

supply.The use of fossil fuels can be optimizedby a reduction in the partial load opera-

tions of thermal power stations.Maintaining a balance between demand

and electrical energy production createsideal electrical network conditions. Anyimbalance results in a frequency devia-tion, which has to be kept to a minimumand therefore the network needs energy

for fast balancing. This so-called regulat-ing energy can be quickly provided bypumped storage power. Finally, theemployment of pumped storage poweralso facilitates a reduction in bottlenecks,

a cut in over-capacity e.g. of nuclearpower plants, and energy resourcemanagement.

TechnologiesDiffering technologies are used in linewith project requirements and the follow-ing represents a description of the twomain groups.

In the three-machine group, one turbineand one pump are operated togetherwith a motor-generator using a commonshaft and are employed individually bymeans of clutches. The main advan-

tages derive from increased efficiencyand short transfer times betweenmodes, although the investment costsare somewhat higher. One referenceplant in this regard is the Kops II

pumped storage power plant, which isequipped with three 180 MW generatingsets. A special feature of this plant is thelocation of the Pelton turbine above themotor-generator and its operation with

counter-pressure. A 3-stage pump is sit-

What is pumped storage power andwhy is it gaining in importance?Basically, pumped storage powerserves the storage of electrical energy

through its transformation into potentialenergy using water as a storage medi-um. The network can be provided withadditional electricity at peak load timesand moreover, owing to the fact that this

kind of power can be made availablevery rapidly, it represents a substantial

Prominent examples of this type ofdesign in Austria include the two single-stage reversible pump turbines at theLimberg II pumped storage power plant,

which is an extension of the Kaprunpower station. Accommodated in a new

Top story

Factors such as liberalisation,rising electricity tariffs, increa-sing consumption and systemsecurity have become even more

important in todays electricity mar-ket. The unstable characteristics ofinnovative energy sources such aswind power and the higher demandfor regulating energy in expandingnetworks, make the operation ofstate-of-the-art pumped storagepower stations indispensable.Andritz VA TECH HYDRO hasrecognized the significant role ofpumped storage plants in systemstabilization and has responded tothis development by raising the

quality of its technology to thehighest level.

Limberg II, Austria

Kops II, Austria


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100

99

98

97

96

95

94

93

92

91

90

50 60 70 80 90 100

Hydronews 5

Upper limit

Lower limit

Upper limit

Lower limit

Variable Speed

Fix Speed

Variable Speed

Fix Speed

Variable Speed

Fix Speed

Turbine Efficiency Comparison

Pump Input Comparison

Turbine Output Comparison

Re

lative

Turb

ine

Efficiency-

%

Turbine Output - %

Turb

ine

Ou

tpu

t(MW)

Net Head

Pmax

Pmin

Hmin Hmax

Pump HeadHmin Hmax

Pump

Inpu

t(MW)

Pmax

Pmin

Top Story

underground power cavern, after com-

pletion the plant will reach rated outputof 480 MW and through the supply ofregulating energy will contribute greatly

to the reliability of the Austrian grid.

The Nestil pumped storage power plantin Switzerland provides a multi-stagereversible pump turbine reference.

A head of up to 1,060m necessitatedthe use of a four-stage pump turbine

unit, the rated speed of 600 rpm and theelectrical output of 175 MVA requiringmotor-generator design capable of with-standing extreme mechanical forces inthe rotor.

The variable speed principleConventional pumped storage powerstations usually have synchronousmotor-generators, whereby the generat-

ing set operates at a constant speed.However, the possibility of varying thespeed within certain limits brings majoradvantages. Speed variable technologywas first implemented on a large scale

in Europe at the Goldisthal PSPP. Two ofthe four electrical machines were imple-mented as double-fed, asynchronousmotor-generators (DASM).

The main advantages of variable speedpump turbines can be summarized asfollows: The speed variation in the turbine

mode results in greater partial load

operation efficiency. The shape of theefficiency curve is smoother.

The operational limits in the turbinemode are extended, which offers

higher output at low heads.

Technical data: Limberg IIOutput: 2 x 240 MW / 270 MVA

Voltage: 15 kV

Speed: 428.6 rpm

Technical data: NestilOutput: 1 x 141 MW / 180 MVA

Voltage: 13.8 kV

Head: 1,005 m

Speed: 600 rpm

Runner diameter: 2,260 mm

Stator diameter: 3,900 mm

Technical data: Kops IIOutput: 3 x 180 MW / 200 MVA

Voltage: 13 kVHead: 808 m

Speed: 500 rpm



Nestil, Switzerland

The speed variation in the pump mode

enables operation with adjustablepower input at each of the requiredpumping heads, thus providing regu-

lated pump operation. During fixedspeed operation, power input is direct-

ly dependent upon the pumping headand cannot be adjusted.

For pumped storage projects operat-ing at synchronous speed, the ratio

of Hmax to Hmin is within a range ofapprox. 1.25. However, during opera-tions at variable speed, the said ratiocan be raised to 1.45, which isextremely important for projects sub-

ject to geological restrictions.

Substantial advantages can be realizedwith a variable speed motor-generatorconnected to the grid, as is evident from

the following details:

Simulations and operational experiencehave shown the ability of DASM toprovide immediate power injection into

the grid in the case of failure.Synchronous machines do not havethis capability and become unstable.

Therefore, DASMs improve transientstability performance during grid distur-

bances.

In particular, asynchronous machinesare characterised by their stabilizingeffect on other synchronous genera-

tors operating in the grid. Due to itsability to rapidly inject power into thegrid during failure, the system remainsstable and after fault clearance, healthyconditions can be restored within the

shortest possible time.


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6 Hydronews

-0.4

-0.2

0

0.2

0.4

0 0.1 0.2 0.3 0.4 0.5

-0.4

-0.2

0

0.2

0.4

0.6

0 0.1 0.2 0.3 0.4 0.5

0.4

0.6

0.8

1

1.2

0 2 4 6 8 10

0.4

0.6

0.8

1

1.2

1.4

0 2 4 6 8 10

t/s

t/s

Effect of asynchronous

operation of a distant

generator

Transient Behaviour of DASM during

Grid Disturbance

Positive Stabilizing Impact of DASM to remote

Generators during Grid Disturbance

pu

pu

Actice PowerPn

Voltage

Voltage

SM

DASM

Actice PowerPn Voltage

pu

pu

Actice PowerPn

Actice PowerPn

DASM

Voltage

SM

t/s

t/s

Source: 15. Triennial World Congress, I.Ehrlich, TU Duisburg,

U. Bachmann, VEAG

Source: 15. Triennial World Congress, I.Ehrlich, TU Duisburg,

U. Bachmann, VEAG

Top story

Variable speed pumped storage projects

are especially suitable for global applica-tions, due to their short-time regulatingfeatures. Goldisthal, which is the largesthydroelectric power plant in Germanyand the first speed-variable pumped

storage scheme in Europe, represents amilestone in technological developmentsof this type. Owing to its central locationin the UCTEs European interconnectednetwork, Goldisthal is an important sta-

bilization factor. In addition to the syn-chronous motor-generators, Andritz VA

TECH HYDRO supplied Goldisthals twodouble-fed, asynchronous motor-gener-ators (DASM), which with a unit capacity

of 351 MVA each, cover a speed rangeof minus 10% - plus 4%.

The festive opening of the plant tookplace in September 2003 in the pres-

ence of the then German FederalChancellor, Gerhard Schrder, and it hasbeen operating successfully ever since.

The interconnected power systemIn 1951, a decision was taken to coordi-nate the European electricity grid and in

1999, as a response to Europes movestowards electricity industry liberalization,the UCTE (Union for the Coordination of

Transmission of Electricity) was foundedwith the following main objectives:

Technical and operational co-ordina-tion in the synchronous area

The controlling of the short-term secu-rity of the system with regard of load,

frequency control and stability The monitoring of the medium- to

long-term adequacy of generation andload

Responsibility for the development of

the synchronous area.

At present, more than 450 million con-sumers are supplied and the UCTE has29 transmission system operators (TSO)

from 24 different countries as members.The total volume of installed capacity ofaround 625 GW produces annual outputof approximately 2,600 TWh.

A further aspect relating to improvedelectrical power system reliability is the

reduction of the inter-area oscillationphenomenon. In large electrical grids,hundreds or thousands of powerplants work together to supply theoverall network load. These power

plants are interconnected by

transmission lines and operating atsynchronous frequency.

Accordingly, should a rotationaldeviation occur between the genera-

tors, the necessary balance isprovided automatically by electricalenergy. This results in an oscillatingpower flow between the rotatingmasses of the generating units over

long-distance transmission lines.

If these inter-area oscillations are not

dampened, a loss of synchronism mayoccur and the whole system be destabi-lized. This can quickly lead to a blackout.

A further disadvantage is that inter-areaoscillations are visible as a fluctuation in

the power flow within the transmissionnetwork.

As a consequence, the transmissionlines cannot be loaded to their full

capacity. Therefore, sufficient dampingis indispensable. For local application,we recommend the use of a powersystem stabiliser as implemented in our

THYNE static excitation system along

with the targeted parameterization of ourTC 1703 integrated turbine governor.

Map of Europe showing the main North - South, East West oscillation modes


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Hydronews 7

Technical data: Goldisthal (asynchron)Output: 2 x 300 MW / 351 MVA

Voltage: 18 kV

Head: 339.2 m

Speed: 300 - 346.6 rpm



Conclusion

Technical data: Goldisthal (synchron)Output: 2 x 261 MW / 331 MVA

Voltage: 18 kVHead: 339.2 m

Speed: 333.3 rpm



Example of Windpower Production in E.ON - GridSource: E.ON-Net Windreport 2005

Windfarm

Energy Mix of the UCTE Grid 2006

energy balance must be providedand once again pumped storage plants

are the answer.

Wind

39 GW

6%Others

12 GW

2%

Hydro

135 GW

22%

Nuclear

112 GW

18%

Fossil

327 GW

52%

2004 between 0.2 to 38 % of the daily Grid Load

Jan. Feb. March April Mai June July Aug. Sept. Oct. Nov. Dec.

Windpowerproduction E.ON - Control Area

Rela

tiono

fWindpower

/Gri

dLoa

d(%)

Top story

Peter AmlerPhone +43/1 89100 [email protected]

The pumped storage scheme is the mosteconomic method of conserving large quan-tities of energy at a reasonable efficiencylevel. Key tasks involve providing an energybalance for the interconnected power sys-tem and improving system security.

The instable characteristics of innovativeenergy sources such as wind power make

pumped storage schemes indispensable.Consequently, owing to the increasingdemand for regulating energy in expandinginterconnected power systems and espe-cially in Europe, pumped storage schemesare experiencing a remarkable comeback.

Investment in pumped storage schemes isincreasing as a reaction to the forecastsconcerning future trends in the electricalenergy production and transmission field.In particular, new pumped storage powerstations profit from the technological achiev-

ments in the areas of hydraulic and electri-cal machines and the automation sector.

Due to the substantial expansion of theUCTE area, supply security and networkstability are gaining in significance andtherefore, pumped storage schemes willbecome an even more an important stabilityfactor in years to come and Europe willemerge as a global trendsetter.

View of the underground power cavern, Goldisthal, Germany

Ongoing studies are continuing withthe aim of creating the worlds largestelectrical interconnected power system.

This interconnection will finally lead to

synchronously interconnected powersystems with a total installed capacityof 800 GW, spanning 13 time zonesand serving some 800 million cus-tomers. Currently, there is no existing

example anywhere in the world of asystem of this size operating in a syn-chronous mode. It is therefore obviousthat the biggest challenge confrontingthe UCTE will be the maintenance

of the reliability of this largest-ever,interconnected electrical grid.

Wind powerA further major challenge facing theUCTE is the integration of the increasing

volumes of wind power into the intercon-nected network. Installed capacity hasreached approximately 39 GW, which isequal to 6% of total UCTE capacity andthe trend is upward. For example in

Denmark, wind power already consti-tutes 20% of nationwide installed capac-ity. According to European studies, by2020 wind power will represent some16% of total installed capacity in the

UCTE area.

The main problem with wind poweris its high volatility, low reliability andpredictability, which make it very difficult

to manage. Therefore, an appropriate


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8 Hydronews Adding up to approx. 400 GW of installed turbine capacity worldwide

The complementary nature of the combined globalfootprints will enhance our ability to serve your needs

Generators installed:VA TECH HYDRO: 51,000 MVA

GE HYDRO: 107,000 MVA

Turbines installed:

VA TECH HYDRO: 245,000 MW

GE HYDRO: 152,000 MW

HYDRO locations

Andritz locations

Hydro business

Acquisitionof GE HYDRO

These acquisitions further consolidate

Andritz VA TECH HYDROs position

as one of the worlds leading suppliers

W ith effect from July 1st 2008Andritz VA TECH HYDROhas included the hydropowerbusiness of GE with some 400 newcolleagues in Point Claire, Lachineand Peterborough in Canada,Campinas and Araraquara inBrazil, Kristinehamn in Sweden,Tampere in Finland, Doncasterin the UK and Hangzhou in China.An overview of the ongoingactivities in these countries canbe found on the following pages.

of hydropower equipment, and

strengthen its abilities to serve cus-

tomers in Brazil, China, North America

and Scandinavia.

In view of the rapidly rising demand

for renewable energies, the need for

hydropower, which is by far the most

important source of electricity produc-

tion from renewable energy sources, is

expected to show very strong growth

in the coming years. With these acqui-

sitions, Andritz VA TECH HYDRO is

now in a position to supply its cus-

tomers with a full range of hydropower

equipment on a global basis.


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Hydronews 9

Valves and Gates Turbines Generators

Newton Chambers

English Electric

1853Kvaerner Brug A/S

1922Sorumsand Mek Versted A/S

1981NOHAB Turbine AB

GE Hydro

1892General Electric Co.

1980Kvaerner Boving

1910Boving

1962Dominion Engineering

Nohab Verstad AB Tampella

1984Kvaerner Hydro Power, Inc.

Boving-KMW Turbine AB

Axel JohnsonEngineering, Inc.

Kvaerner Hydro

JV GE Hydro Inepar

AndritzHydro Inepar

1900GE Canada Company

History 1892 - 1900

Canadian General Electric Company

Limited is incorporated in Canada

through the merger of Edison Light

Electric Company and the Thomson-

Houston Electric Light Company of

Canada. Manufacturing facilities in

Peterborough, Ontario are already in

operation. Generators, transformers,

motors, wire and cable, and lamps

are manufactured by 500 employees.

1962GE acquires the Dominion

Engineering Works in Montreal

1995GE Hydro in Montreal celebratesits 75th birthday

1999GE Hydro acquires the Kvaerner

Group hydroelectric turbine business.

TechnologyFrancis turbines suit the full range of

heads and specific speeds associated

with this type of machine and are

available for outputs over 800 MW,

runner diameters in excess of 9.00m

and heads of up to 800 m.

References

John H. Kerr, USAAndritz VA TECH HYDRO will refur-

bish/upgrade all seven vertical Francis

turbines and generators at the Kerrpowerhouse thus raising their

capacity from approximately 33.5 MW

to over 45 MW.

Following refurbishment, the rating

for generator 1 will remain the same,

while the ratings for the other six

generators will increase to 52 MVA.

Nam Theun, LaosThis project involves the design,

construction, and operation of a

1,070 MW trans-basin diversion

hydropower plant on the Nam Theun

River, a 450 km2 reservoir on the

Nakai Plateau, a 39-meter-high dam

northwest of the plateau, a powerhouse

350 meters below the plateau, a

regulating pond below the power-

house and a 27km channel from

the regulating pond to the basin of

the Xe Bang Fai River, a tributary

of the Mekong.

Andritz VA TECH HYDROin Canada

Hydro business

The newly formed companyAndritz VA TECH HYDRO inCanada comprising all the formerhydro activities of GE Hydro, is a

world leader in the supply of hydroturbines, generators and relatedelectro-mechanical equipment forthe hydropower industry. Capabilitiesinclude complete water-to-wiresolutions for new hydro powerplants as well as refurbishmentand service for existing plants.


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10 Hydronews

History

1962 1963 1977 1981 1982 1984 1985 1992 1997 1998 2007

GE Hydro started its activities in Brazil in 1962

GE (Schenectady -USA) technologytransfer.

GE Hydro(Peterborough Canada) technologytransfer.

EQUIPAMENTOSVILLARES S.A.acquired from GE Brasilall VIGESAs stock.

Beginning ofmanufactureby Villares in

Araraquara facility.

SADE VIGESAwas incorporatedby INEPAR Group.

GE Hydro transferits global hydrooperation to GEHydro Inepar.

The Joint VentureGE Hydro Ineparwas established.

VILLARES wasincorporatedby SADE

VIGESA S.A.

New investments,technology contractbetween GE Canadaand EQUIPAMENTOS

VILLARES S.A.was renewed.

Newly formedcompany, VIGESA,partnership betweenEQUIPAMENTOS

VILLARES andGeneral Electric do Brasil.

Beginning ofmanufacture inBrazil by GE Brasil Campinas (SP)

The acquisition represents growth,

strengthening Andritz VA TECH

HYDRO's position as a major global

supplier of hydropower equipment,

and underlines the Andritz Groupsgoal of achieving global leadership in

all its business areas. In addition, it

stresses the professionalism of the

employees, who will maintain team

working with their usual commitment

and competence.

The manufacturing facility is located

in Araraquara, SP and is one of the

largest heavy equipment plants in

Latin America having a strong presence

in the fields of power generation,

construction and assembly, oil and

gas, and integrated solutions on a turn-

key basis.

As of 2009, the Araraquara plant will

have a universal hydraulics laboratoryfor the testing of small-scale models

and simulation of all types of turbine.

This will be the only laboratory of its

kind in Brazil.

In addition to Brazil, AHI has facilities

in Tampere, Finland and Kristinehamn,

Sweden. In Tampere, AHI possesses

one of the worlds most advanced

turbine production plants, which

focuses on developing turbine solutions

for low head power plants. Established

in 1847, the Kristinehamn operation has

With July, Andritz HydroInepar do Brasil S/A (AHI)was established following Andritzsacquisition of GE Brasils stock, in

the GE HYDRO Inepar do Brasil S/Ajoint venture, which has facilitiesin Brazil, Sweden and Finland.The new corporate name and thenegotiations were included in thetransactions between the AndritzGroup and GE Energy.

Hydro business

Andritz HYDRO Ineparin Brazil

Aerial view of the facility in Araraquara

150 years of experience in the develop-

ment of technical solutions and has

provided most of the large hydropower

turbines installed in the country.

With its vast experience in equipment

manufacturing and hydropower plant

project design, Andritz Hydro Inepar

represents a benchmark in the energy

generation field, producing highly

efficient solutions on a global scale.

With its team of highly qualified

professionals and specialists, AHI

offers greater flexibility in terms of tech-

nical co-ordination, and produces the

most effective answers with regard tothe supply of customised equipment

and turn-key products.


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Hydronews 11

Hydro business

Alexander SchwabPhone +43/1 89100 [email protected]

Modernity and technology in

the service of customers

Ever attentive to changes in the

market and in anticipation of its

customers needs, Andritz

Hydro Inepar (AHI) stands out

due to its research and devel-

opment performance, a readi-

ness to undertake the most

complex assignments with cut-

ting-edge technology, and the

provision of creative solutions

implemented by highly qualified

professionals.

AHIs products include:

Hydraulic turbines

Hydro-generators

Turbine safety valves

Governor and excitation systems Project management

Services, installation and technical

assistance

Refurbishment, modernization and

the upgrading of existing equipment.

Technology highlightsAHI provides X-Blade technologyfor Francis runner blades. This profilewas developed in order to fulfil the

demands made on the new generationof hydraulic turbines through betterperformance over a broad rangeof heads and flows. In addition tohigh output level and stability,

X-Blade runners show excellentperformance in relation to cavitationand the X-Blade profile demonstratesimproved mechanical stress distributionand thus offers greater resistance to

fatigue.

The technology has also been used

with considerable success in turbine

upgrades as a means of enhancing

the level of runner performance and

eliminating the chronic problems

relating to cavitation and hydraulic

stability.

References: So Salvador, Brazil close to

Paran towns, Tocantins state,two generator units of 121.6 MW

each - AHIs largest current projectundergoing completion

Paulo Afonso III, Brazil, AHI wasresponsible for the refurbishing ofthe generator (209 MVA)

Campos Novos, Brazil - Canoas,

Santa Catarina state AHI provided98 per cent of the electromechanicalequipment, including the threegenerator units

Serra da Mesa, Brazil three

Francis turbines, 431 MW each,H =117.2 m, 120 rpm.


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12 Hydronews

Hacininoglu

Sarigzel

Kandil

tion supervision of six vertical Francis

turbine-generator units including the

inlet valves, transformers, switchyards,

excitation, control and protection

systems, as well as the relatedmechanical and electrical auxiliaries.

This adds up to a combined installed

capacity of about 460 MW and pro-

jected, average annual energy output

of some 1,200 GWh.

The implementation period has been

so defined as to ensure that the first

generating unit will already be con-

nected to the grid by the end of 2010.

The cascade arrangementThe waters of the Ceyhan River will be

used to feed the reservoir of the Kandil

dam, the flow for the Kandil power-

house being taken from the Kilimli weir

located at the north-western corner of

the reservoir. The water will then be

pushed south through a transmission

channel and penstock to the Kandil

Kandil Energy ProjectsHacininoglu Sarigzel Kandil460 MW for Turkish Power Plants

powerhouse. After being used to pro-

vide the plants designated output, the

water will then be directly discharged

into the Sarigzel dam reservoir. The

two generating units in Sarigzel will

be provided with water from the reser-voir via an approach tunnel system,

which will start at the dam and run

southwards to the powerhouse.

The water discharged for energy pro-

duction in Sarigzel will then be

employed to fill the Hacininoglu reser-

voir, the final and smallest reservoir in

the cascade scheme, from where it will

be returned to the Ceyhan River, hav-

ing been used to generate power for

the Turkish energy grid.

Optimized cascade scheme andstate-of-the-art equipmentDuring the entire pre-project phase,

special attention was allocated to a

joint approach to the optimization of

the cascade layout, in order to ensure

that Turkeys natural water resources

are used to the best possible effect.

Various studies were completed and

alternatives considered with the aim of

In course of the energy system

privatization process in Turkey,

Enerjisa, one of the emerging key

players in the Turkish energy market,

has applied for licences to build, own

and operate several power plants

throughout the country. Above all,

Enerjisa has acquired the licences

for projects on the Ceyhan River inKarhamanmaras province. Following

a tendering process, detailed negotia-

tions were subsequently held, which

ended with the contract signing cere-

mony at the Sabanci Center / Istanbul

in April 2008.

The contractual scope of works com-

prises the design, supply and installa-

Enerjisa has awarded acontract to a consortium ledby Andritz VA TECH HYDRO forthe supply of the complete electro-

mechanical equipment for a three-plant, hydropower cascade insouth-eastern Turkey.

Key projects

The contract signing


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14 Hydronews

The Eda power plant

Key projects

south of Doualas harbor. The dam siteand the hydropower plant were builtnear a rock bed break, that createsspectacular waterfalls some of which

reach a height of twenty meters. It israre to find such waterfalls on a river ofthis scale and with such massive sea-sonal flow variations, which range from250 m3/s during the dry season inMarch to more than 6,500 m3/s in thehigh water season in October.

These condit ions justified the choice ofthis site and construction work beganin 1949. Two units, each with an out-put of 11 MW, were commissioned in1953 to meet the energy needs of theDouala region. However, this initial

power plant only used a minimalamount of the hydropower available.

The nearby installation of a large alu-minium production plant offered furtheruses and justified the enlargement ofcapacity, which was carried outbetween 1954 and 1958. This upgradeended with the creation of a secondplant, thus bringing the number of gen-erating units to nine and the totalinstalled power output to 159 MW.In order to properly supply the tur-

bines, an entire network of structureswas created. In particular, this consist-ed of several dikes to concentrate thewaters passing through the turbine in alarge phase loading chamber, whichowing to its shape, is called a glovefinger. At this stage, the equipment onthe river could not be operated withthe water flow during the dry season.Nevertheless, an increase in produc-tion proved necessary in order to satis-fy rising consumer demand and toensure sufficient power supplies to thealuminium plant during the low water

period. Edas hydropower plant oper-ates on a flow basis and any tempo-rary drop in the output of the equip-ment set creates an immediate fall in

the power available.River regulation, which was alreadyconsidered necessary after the installa-tion of the first nine units became vitalto ensuring the proper operation ofthe five newly planned units of the alu-minium production plant, which wereneeded to expand its operations andmeet the requirements of the publicsector.

The aim of the work, which began asearly as 1967, was to increase thetotal number of production units from

9 to 14 by improving the phase loadingstructures and by building in a furtherstage, two large regulation reservoirs inthe La Sanaga basin, consisting of theMBakaou dam on the Djerem River(2.6 billion m3) and the Bamendjin damon the Noun River (1.8 million m3). Theintention was to create the essentialreserves required for optimum plantoperation during low water periods.In June 2006, we received the docu-mentation for the invitation to tender

for the rehabilitation of the 14 units atthe Eda Plant. It should be noted thatamong these units, twelve numberedfrom 3 to 14, were built by the Ateliersde Constructions Mcaniques de

Vevey (today Andritz VA TECHHYDRO). For this reason, we had theadvantage of being largely very familiarwith the original equipment.In order to enquire as to the exactscope of the services to be provided,an interdisciplinary delegation, incorpo-rating engineers from French Cegelecand the Austrian and Swiss units of

Eda IAES Sonel renovates its Capacityin Cameroon

On May 9, 2008, i.e. two yearsafter submission of the firsttender and after four days ofintense negotiations, AES-Sonel

General Manager Mr. Jean DavidBile and Mr. Christian Dubois,VA TECH HYDRO SA Vice Director,Vevey signed the ContractAgreement for the rehabilitationof the first section of the EdaHydroelectric Power Plant inCameroon.

The project falls under the scope ofan agreement signed in 2007 betweenthe European Investment Bank and

AES Sonel involving a sum of EUR65 million, which is intended topartially finance a capacity renovationprogramme. Our project comprisesthe replacement of the three generator- propeller turbine units (Kaplan withnon-adjustable blades) at the Edapower plant, which have been inoperation for more than 50 years.

The Eda plant is located on the LaSanaga, the countrys largest river,around 60 kilometers from Douala,the economic capital of Cameroon.

With its source in the eastern part ofCameroon at around 2,000 metersabove sea level, the La Sanaga drainsthe waters from a vast 135,000 km2

reservoir near Eda to the south-westand flows into the Atlantic Ocean


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Hydronews 15

The overjoyed negotiating team Eda I signing ceremony in CameroonThe contract signing in Paris

Michel BorlozPhone +41/21 925 [email protected]

Left: Christian Dubois (Vice Director Andritz VA TECH HYDRO, Switzerland)Right: Jean David Bile (General Manager AES Sonel, Cameroon)

Key projects

tion between AES Sonel and AndritzVA TECH HYDRO. As a reminder, thelast project to date was the renovationfollowing the concrete warping of the

Francis turbines at the Song Louloupower plant, around 40 km away onthe same La Sanaga River. With thesupport of our representative and theSwiss Embassy, this site was entirelyfinanced with funds, which with theagreement of the World Bank, wereallocated by the Swiss governmentto a project of general interest.For the Eda I project, the teamsinvolved in Vevey, Vienna, Linz andNanterre will employ all the meansat their disposal to meet this new

challenge, which represents part of thepolicy of close collaboration at everynew stage with our client, AES Sonel.

As a result of its experience in Africa,our Group remains very interested incontributing to the development ofprodigious natural sites in order toadvance hydropower, which is one ofthe best alternative solutions to theglobal energy crisis.

Andritz VA TECH HYDRO and headedby of Andritz VA TECH HYDRO, Vevey,visited the plant in July and submitteda tender in September 2006.

In November, a working session heldat our client's premises in Doualabrought together the project ownersdecision-makers and the members ofthe bidding consortium for a detailedpresentation of both the technical andcommercial aspects of our tender.However, although we followed thefate of our offer very closely, during theensuing period, the situation barelychanged. Indeed, after several monthsduring which the project seemed tohave faded into background, our

client, AES Sonel, decided to reissuean invitation to tender for the Eda Isection only, i.e. for the three oldestsets commissioned between 1953and 1955. We thus received a newinvitation to tender in August 2007 andwith our representative's support,began a fresh phase of negotiationswhich took place in various stagesfrom September 2007 to April 2008,partly in Douala at AES-Sonels head-quarters and partly in Paris. At the end

of April 2008, all the technical aspectshad been finalized, although the com-mercial and legal aspects of the con-tract still had to be negotiated. Thisfinal round took place from May 5-9,initially bringing together the salesmanagers and the financial and legalexperts and, on the last day, the man-agers of both companies.

All the documents pertaining to thefinal contract were edited and initialledafter have been bound. The contractwas thus complete and the consor-tium, made up of Cegelec and the

Andritz VA TECH HYDRO group ofcompanies in Linz, Vienna, Weiz and

Vevey, with the latter acting as theleader of the consortium, will provide

the following equipment and services: New gantry and swivelling cranes Refurbishment of the powerhouse

cranes Refurbishment of the draft tube stop

logs, intake bulkheads and intakeradial gates

New propeller turbines, wicket gate,covers and runners, with an outputof 16.4 MW. The power increase ofthe units is around 44 % for units 1and 2 and more than 31 % for unit 3

Replacement of the generators

with next generation generatorsoffering a power output of 18.9 MVA,i.e. an increase of 33 %

New turbine governor systemsincluding oil hydraulic units anddigital regulators

Control system and electricalequipment

20 MVA power transformers,95 kV / 10.3 kV

Mechanical and electrical auxiliaries.The project execution period is 40.5

months from the coming into force ofthe contract. This new rehabilitationproject is part of long-term collabora-

Technical data:Output (old): 11.4/ 14.2 and 12.2 MW/ 14.3 MVA

Output (new): 16.4 MW / 18.9 MVAHead: 24 m

Speed: 187.5 rpm



The waterfalls on the La Sanaga River at Edaand a CAD model of a modern propeller turbine


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16 Hydronews

Key projects

By adding the new Andritz VA TECHHYDRO turbine generator set the totaloutput of the power plant will be raisedby approximately 80%. The substantial

increase in the numbers of wind andsolar power installations in Portugalrequires additional output fromhydropower stations in order to securethe necessary stability in the electricalgrid. Bemposta II and several otherhydropower projects, as well as windand solar power generation, are beingdeveloped as part ofan ambitious programme aimed atincreasing the share of renewableenergy and thus a contribution to areduction in greenhouse gases as

defined in Kyoto and the provision ofa secure and environmentally soundelectricity supply for the country as awhole. The scope of supply and servic-es of the consortium, which consistsof the three partners Andritz VA TECHEscher Wyss Ravensburg, Andritz

VA TECH HYDRO Austria and ENSULMECI, Lissabon, includes the supplyand installation of one Francis turbinewith governing system and homologousmodel testing, the synchronous

generator, the entire control system,the hydraulic steel structures, cranes,elevators, transformers and variousauxiliary systems. Our local partner,

Manfred MotzPhone +49/751 29 511 [email protected]

The project is located in the middlesection of the Rio Douro, where thisfamous river forms the border betweenSpain and Portugal. The existing dam

and the Bemposta I powerhouse werebuilt in the early 1960s, since whenthey have remained basically unaltered.

The old powerhouse contains threeFrancis turbines with an output of72 MW each, which were suppliedby ACM Vevey, one of the Andritz

VA TECH HYDRO Groupspredecessor companies. The newunit will be installed in a 60 m deeppit on the right river bank, not farfrom the existing powerhouse.

A local civil engineering companywill provide the new powerhouse pit,as well as tunnels and other civilworks, under a separate contract.

On March 17, 2008, aconsortium consisting ofAndritz VA TECH HYDRO andENSUL MECI signed a contract

with the Portuguese public utility,Gesto da Produo de EnergiaS.A. (EDP), for the supply andinstallation of the completeelectromechanical equipmentfor the Bemposta II power station.Commissioning is planned forthe second half of 2011.

Technical data:Output: 193 MW / 212 MVA

Voltage: 15 kVHead: 65 m

Speed: 115.4 rpm



Bemposta IIKisuaheli Lorem

View of the dam and reservoir

Contract signing in Lissabon on March 17, 2008

ENSUL MECI, is responsible forcertain local components, as wellas for the installation work on site.With a runner weight of almost 100 tons

and a large generator diameter thisturbine generator set will be one ofthe largest of its type in Europe.

As a result of this important contract,Andritz VA TECH HYDRO is set tocontinue a long tradition as a supplierof first class hydropower equipmentto Portugal. As early as 1914, a hydro-power plant with an output of 2.5 MWwas commissioned for the TamegaRiver using turbines from Andritz

VA TECH HYDRO. Since then, over175 units have been delivered to

Portugal. Although there have beenvirtually no new projects in recent years,

continuing attention has been paid tothe Portuguese market and under theleadership of Andritz VA TECH EscherWyss Spain, Andritz VA TECH HYDROhas nevertheless been highly successfulin the fields of compact hydro equip-ment and turbine and governor rehabili-tation and servicing. In these sectors,

Andritz VA TECH HYDROs marketshare exceeds 40%.


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Hydronews 17

Site of the new hydropower plant

The contract administration and projectmanagement functions for this job willbe performed via VA TECH HYDROCanada, Inc.s offices in Stoney Creek,Ontario Canada.

In 2007, two customers werelooking to install added capacityat existing sites. Similar solutions,using Kaplan turbines where Francis

had been previously employed, arenow being implemented.

Healey Falls Expansion / CanadaIn January 2008, Ontario PowerGeneration (OPG) awarded VA TECHHYDRO Canada, Inc. a contract forthe design, manufacture, supply andinstallation of a compact axial turbine(CAT) generator unit for the Healey Fallhydropower project. The EvergreenEnergy Group, the small hydro division

of OPG, operates the Healey Fallshydroelectric facility on the TrentSevern waterway. The Healey Falls G Scurrently has three machines inoperation. These machines consistingof horizontal axis, pressure case,double runner Francis turbines, werebuilt in 1913-1914. The facility islocated near the town of Campbellfordabout a 2-hour drive northeast of

Toronto. The new turbine will be fedby a dedicated penstock, there being

only limited space between the top ofthe existing machines and the cranehook. In spite of this restriction, thecustomer required a minimum genera-tion capacity of 6 MW. The turbinewill be designed and manufactured atthe Andritz VA TECH HYDRO facilitiesin Ravensburg, Germany.

Healey Falls &Rochester II

Mark BarandyPhone +1/973 403 [email protected]

Key projects

Technical data: Rochester IIOutput: 6.6 MW

Head: 25.9 m

Speed: 327 rpm


Rochester II / USAIn February 2008, Rochester Gas& Electric Corp. (RG&E) awarded

VA TECH HYDRO Canada, Inc. acontract for the design, manufactureand supply of a new compact axialturbine (CAT) generator unit includingcontrols and switchgear for the

Rochester II hydropower project.RG&E, a subsidiary of Energy EastCorp., is increasing its hydroelectricgeneration capacity through theaddition of a new powerhouse tobe built adjacent to its existinghydropower facility on the GeneseeRiver.

This addition effectively doubles thesites capacity. The project is locatedat the base of the High Falls in ascenic and historic area of downtownRochester, New York. The expansionof the Rochester Station II facilities is ofsignificance as RG&E is implementingthe retirement of its existing fossil fuelpower plants.

The scope of supply being provided byAndritz VA TECH HYDRO includes avertical CAT turbine, a synchronous

Sudhir SarinPhone +1/905 643 5881 [email protected]

Rochester II

Healey Falls Expansion

generator, a hydraulic pressure systemand the electrical control systems.Both the new and existing power-houses will be fed by a new penstockand bifurcation. The new unit will haveadjustable blades and wicket gates,giving it a wide operating flow rangefor optimum annual energy production.

A six-blade runner design was selectedto avoid cavitation during operationsunder a relatively high operating net

head.In order to minimize on-site equipmentinstallation time and effort, the turbinewill be shipped as a complete assemblyfrom Ravensburg in Germany, ready formounting onto the embedded drafttube liner. Similarly, the generator willalso be shipped as a single assembly.Equipment installation is planned forSeptember 2009.

Technical data: Healey FallsOutput: 6.3 MW

Head: 21.5 mSpeed: 276 rpm



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18 Hydronews

HydropowerDevelopments in Southeast Asia

Southeast Asia is a sub-regionof Asia, comprised of thecountries that are geographicallysouth of China, east of India and

north of Australia.

Markets

of the Magat (360 MW), Tamugan(2 x 10 MW) and Panigan (1 x 7.5 MW)HEPPs.

VIETNAMAfter gas (40 %), hydropower plants(36.5 %) constitute the main meansof national power generation.

Total electricity production in 2005amounted to 53.3 GWh and isprojected to rise to 294 GWh/year by2020. Hydropower is playing a majorrole in current development activities,with numerous projects under waythroughout the country and nearly5,000 MW of new capacity planned.

The potential for small hydro in Vietnam

is estimated at around 1,000 MW,and this will play a significant part inrural electrification. Many multipurposeschemes will provide a water supply,irrigation and recreational benefits forthe population. Andritz VA TECHHYDRO recently won contracts for the

Tra Xom HEPP (2 x 10 MW), the DakpsiHEPP (3 x 10 MW) and the Xe KamenIII HEPP (250 MW).

LAOS

With a third of the Mekong Riverflowing through the country, Laoshas immense hydropower potential.Of the some 18,000 MW, which istechnically feasible potential, atpresent 672.6 MW of hydro capacityis in operation. Small hydro plants areplanned for the electrification of remoteareas where the main grid cannot beconnected at the moment. The govern-ment plans to develop some 7,000 MWof hydro capacity by 2020 and Andritz

VA TECH HYDRO is actively monitoringthis market.

All of the countries described are mem-bers of the Association of Southeast

Asian Nations (ASEAN), with theexception of East Timor, which is an

ASEAN candidate state. Southeast Asiahas an area of approx 4,000,000 km2.In 2004, the regional populationexceeded 593 million people withmore than a fifth of these inhabitants(125 million) living on the IndonesianIsland of Java, the worlds most densely

populated large island.

RENEWABLESIncreasing oil, gas and coal pricesmake hydropower sites economicallyviable and as a lot of its feasiblehydropower resources are underdevel-oped, within the next 10 yearsSoutheast Asia is set to become ahotspot for investors and contractorscompeting for a share of the market.

INDONESIAIn 2006, energy sales in Southeast

Asias most populous country totallednearly 114,000 GWh and installed

capacity was about 21,000 MW. Atpresent, some 4,300 MW of hydrocapacity are in operation and as thegovernment intends to increase ruralelectrification to 45 %, micro to smallhydropower plants will be required inthe years to come. Owing to the factthat only about 6 % of Indonesias tech-nically feasible potential has been devel-oped thus far, hydropower plants willplay a significant role in the countrysdevelopment schemes. Indonesia is alsoplanning to build its first pumped stor-

age power plant (1,000 MW UpperCisokan) in the near future and recently,

Andritz VA TECH HYDRO capturedcontracts for the upgrade of the CirataHEPP control system, the KarebbeHEPP (132 MW) and a refurbishmentcontract for the Larona HEPP (136 MW).

PHILIPPINESThe capacity of all the power plantsconnected to the main grid totals15,619 MW, of which approximately

2,450 MW are contributed by hydroplants. Some 17 % of the technicallyfeasible potential in the hydropowersector has been already developed andcurrently there are 18 small hydroplants in planning, although in 2007none were under construction.Moreover, various peaking, mid-rangeand base load power plants areplanned for commissioning by 2013.

Andritz VA TECH HYDRO was recentlyawarded contracts for the rehabilitationand upgrading of the PantapanganHEPP (112 MW), the refurbishment


19/32

Hydronews 19

Josef M. UllmerPhone +62/21 390 [email protected]

MALAYSIADuring the last 10 years, around USD3.2 billion have been invested in gener-ation projects and this has led to animprovement in both the efficiency andavailability of the power supply. Thegovernment has also carried out astudy regarding the restructuring andfurther liberalization of the power sector.While the potential on the Malaysianpeninsula is relatively small, as about

25% of feasible hydropower potentialhas already been developed, in Sabahand Sarawak vast amounts remain tobe exploited. In overall terms, there iscurrently installed hydro capacity ofabout 2,078 MW in operation, while107 MW is generated in small hydroplants. Malaysia is presently preparingfeasibility studies for the followingprojects. Limbang HEPP - 150 MW;Belaga HEPP - 70 MW; Batang AiHEPP 60-80 MW; Metjawah HEPP -

300 MW; Baram HEPP -1,000 MW.

MYANMARMyanmars hydro plant capacity hastripled since1990 from 253 to 745 MWand supplies nearly half of the countryspower generation. Moreover, immensepotential of up to 39,000 MW ofhydropower remains available forexploitation. With eight schemes underconstruction and some 16 planned, thecountry is moving ahead with a majorprogramme of hydropower develop-ment.

THAILANDIn 2006, oil provided 43.3 % ofnational energy consumption, naturalgas 37.3 %, coal 9.3 %, lignite 7 %and hydro/imported electricity 3%.Some 31.2 % of the countrys techni-cally feasible potential for hydropowerplants has been developed. In thenear future Thailand is to focus onsmall-/medium-scale hydro developmentand the upgrading of existing plants.

CAMBODIACambodia has a population of over14.1 million, but has only developedabout 0.1 % of its technically feasiblehydropower potential thus far. Up tonow, about 97 % of its electricity needshave been imported. Of Cambodiastotal installed capacity of 214 MW,approximately 12 MW are generated byhydropower plants. By 2015, powerdemand is expected to reach 740 MW.

EAST TIMORWith about 85 % of the total installedcapacity of 30 MW being consumed inthe area around the capital of Dili, thenewest nation in the world has electrici-ty supply shortages in its rural areas. By2009, energy demand is projected toreach approximately 153 MW. Currently,there are no hydro plants in operationbut with an estimated electricitydemand growth rate of 7-8 per centover the next ten years they are certainto play a significant role in future.

Main hall of Cirata Unterground power station, Indonesia

SINGAPOREWith an area of only 648 km2,Singapore has total installed capacityof over 10,000 MW. The electricitymarket is designed to promote theefficient supply of competitively pricedelectricity. However due to the lack ofwater, Singapore is a purely thermalpower market. Nevertheless, we areseeing Singaporean investors pouringmoney into renewable development

throughout the region.

Andritz VA TECH HYDROThe Group has been active in South-east Asia for more than 20 yearswith companies/offices in Indonesiaand Vietnam. Consequently, as aninexpensive supplier of Indonesia-basedqualified turbine, generator and BoPexperts for the entire Andritz VA TECHHYDRO Group on a worldwide basis,and with long-term experience in

the outsourcing and supervision ofcost-effective manufacturing ofgenerator and turbine components,PT VA TECH Indonesia has thereferences and experience to position

Andritz VA TECH HYDRO as theleading electromechanical equipmentsupplier to the SEA Region.


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20 Hydronews

Joel de AlmeidaPhone +55/114 13 3000 8

[email protected]

Markets

The Brazilian CompactHydro Market

Eighty-two CH plants, which add up to

1,358 MW, are currently under con-struction and the necessary authoriza-

tions for over 3,700 MW from other CH

projects are undergoing issuing proce-

dures by the Brazilian authorities. In

fact, due to the incentives granted by

the Brazilian government, which include

a discount of 50% on the transmission

tariffs and several tax and duty exemp-

tions, investment in CH projects has

come into fashion. In addition, the

obtainment of environmental licences is

less complex and the period neededprior to becoming operational is rela-

tively short (only 20 months).

Selling CH-energy in the free contract-

ing ambience is easier, as prices are

higher and contracts longer than the

ones used in the regulated contracting

area. All the above factors have attract-

ed most of the large investment groups,

such as ERSA, which is controlled by

Patria Investments, Eton Park (USA)

and DEG (Germany), who at present

are investing EUR 270 million in 12 CH

If large and compact hydro, wind,solar, nuclear and thermal powersources are taken into considera-tion, today Brazil has 1,713 power

plants in operation, with totalinstalled capacity of 101,300 MW.

Internationally, a five per cent energy

shortage risk is commonly accepted.

However, according to the latest

research in Brazil, in view of increasing

demand this risk may reach 28% in

2011, if major investments are not

made in enlarged, national energy

supply capacity. Spending of about

EUR 500 billion is needed in the

next 25 years in order to raise hydroand thermal energy production to

217,000 MW.

Today, of the aforementioned 101,300

MW, hydropower plants provide

installed capacity of 77,265 MW, which

represents nearly 30 per cent of Brazils

total potential hydro capacity of

260,000 MW. One hundred and forty

five projects are currently under con-

struction involving a total of 7,881 MW

and together with another 469 already

awarded projects these will representan addition of 34,720 MW to Brazils

installed capacity within the coming

years. Compact hydro (PCH

Pequenas Centrais Hidreltricas in

Portuguese) is used in Brazil in the

form of projects involving outputs of up

to 30 MW and total permitted flooded

areas not exceeding 3 km2. Of the total

hydro installed capacity mentioned

above, 2.7 per cent derives from com-

pact hydropower (CH) plants with an

overall output of 2,086 MW.

Compact powerhouse and penstock, units installed at the Salto Jauru HPP

projects with a total output of 167 MW.

Tarpon Investments also has put itsfaith in this business and has just

entered into a partnership with Winbros

and Poente Engenharia to create the

company Omega Energias Renovveis,

which has acquired CH projects with a

volume of 240 MW, which are sched-

uled to go into commercial operation

not later than 2012. Concrete plans are

also on the table at Omega for the part-

nering of other investment groups, in

order to complete 1,100 MW of green

field projects in the near future in addi-

tion to the plants already in operation.

Investment groups, electro-intensive

consumers and private entrepreneurs,

such as Suez (Belgium), AES (USA) and

other smaller enterprises are all very

keen on participating in this business,

thus making Brazil one of the most

promising CH markets in the world.


21/32

Hydronews 21

Site report

IslasSwitzerland

The Islas power plant has been running

since 1932 with three Francis turbines

from Escher Wyss. The refurbishing

project envisaged an increase in the

flow rate from 8.0 to 10.4 m3/s.

In summer, the plant is used to

produce base load, while in the winter,

it generates peak load energy using

water from the St. Moritz lake.However, owing to the international

WHITE TURF horse race on the

frozen lake, power generation is

strictly limited.

The order for the delivery of the

electromechanical equipment was

allocated to a consortium headed byVA TECH HYDRO AG Switzerland and

the Spanish enterprise INDAR as the

generator supplier.

VA TECH HYDRO AG Switzerlands

scope of supply consisted of the

inlet pipe between the penstock and

the turbine inlet butterfly valves, three

butterfly valves, three Francis turbines

including auxiliary equipment, the

turbine governor and the control,

command and communication system.Due to the excellent collaboration with

the client, the consultant, the construc-

Islas-new (and old) units

In August 2006, Andritz VA TECHHYDRO Switzerland receivedan order from E-Werk St. Moritzfor the delivery of three Francis

turbines as part of the update ofthe Islas hydropower plant.

Urs RupperPhone +41/71 950 [email protected]

Transportation and delivery of the bifurcation pipe

Technical data: Islas Turbine 1Output: 508 kW

Head: 50.95 m

Speed: 750 rpm

Runner diameter: 518 mm

tion company and within the consor-tium, the very short timetable for the

demolition of the existing plant, the

modification of the existing buildings

and the erection and commissioning of

the electro-mechanical equipment wasadhered to and the plant was handed

over just before Christmas 2007.

Technical data: Islas Turbine 2Output: 1,287 kW

Head: 50.35 m

Speed: 750 rpm


Technical data: Islas Turbine 3Output: 2,895 kW

Head: 48.71 m

Speed: 500 rpm



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22 Hydronews

Site report

Michael HeubergerPhone +43/3172 606 3357

[email protected]

St. MartinOverhaul of theAsynchronous Generator

the rotor was transported to theWeiz plant for close examination andCO2 cleaning and fortunately, due toits positive general condition, only

minimal repairs were required.

The aim of the renewal and overhaulmeasures was the securing ofcontinual operation for the years tocome and the main obstacle to besurmounted during project realisationwas the very brief completion periodof just nine months.

Therefore, Andritz VA TECH HYDROcarried out the engineering, materialsourcing and production at the Weiz

plant, as well as the on-site assemblywork, in something approachingrecord time.

This was not only possible due tothe outstanding co-ordination andteamwork among all those involvedfrom both Verbund AHP and Andritz

VA TECH HYDRO.Support from the extremelycompetent specialists secondedfrom Verbund AHP for the work at theplant also greatly eased the burden on

our installation team.

In the period from August 2007to April 2008, Andritz VA TECHHYDRO completed the replacementof the stator and the overhaul of

the rotor from the St. Martin powerplant. Verbund AHP had decidedto undertake this general refurbish-ment of the generator due to factthat it had been operationalsince 1965.

The St.Martin power plant is one offour units belonging to the Teigitschauf der Pack group, which is locatedin the border area between the

Austrian federal provinces of Styriaand Carinthia. The Teigitsch group ischaracterised by the optimum useof the energy potential stored in thePack and Hierzmann annual reservoirsby the Arnstein, Teigitschmhle, Packand St. Martin power plants, which canonly be used in joint operation.

Accordingly, in order to keep the stand-still of the entire power plant group to aminimum, it was decided to exchange

the entire stator. Following disassembly,

This project is a typical example ofthe potential lying dormant in old plant.As a result of the use of the latestcalculation methods, state-of-the-arttechnology and the newest materials,a reduction of over 25% has beenachieved with regard to stator ironand copper losses.

New stator ready for stacking Stator and rotor before assembly

Technical data:Output: 11 MVA

Voltage: 6.3 kV

Speed: 602.5 rpm

Power factor: 0.85

Transportation of the old stator

Generator after commissioning


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Hydronews 23

SchaffhausenTurbine Overhaul completedSuccessfully

to carry out the order from KWS/ NOK

for the complete overhaul of both

machines. Due to their size, the

work on the runners and shafts was

allocated to Andritz VA TECH HYDROin Ravensburg, while parts of the

shafting, tracking and distributor were

dealt with by the facility in Kriens.

Some components had to be newly

manufactured and the old shaft

sealings were exchanged for modern

synthetic replacements. Moreover,

a maintenance-free concept was

implemented for the distributor.

The dimensions and quantity of

the components involved posed anenormous challenge, especially as

these had to be finished within a very

short period of just a few months

against the background of a marked

economic boom. Nonetheless, due to

the close co-operation with the shops

and the engineers in Ravensburg,

every requirement was met to the

complete satisfaction of the customer.

Following refurbishing, the first

machine went back online in mid-2007.

Not far from the Rheinfall, Europes

largest waterfalls, lies the no less

impressive Schaffhausen power plant.

This low-pressure, run-of-river plant

exploits the energy provided by the

Rhine along a 13.6 km stretch of

river between Diessenhofen and

Neuhausen. The plant, which numbersamong the largest of its type in

Switzerland, is fitted with two vertical

Kaplan turbines, both of which have

5.9 m-diameter runners.

It is of note that, with the exception

of a governor update completed by

Bell Escher Wyss in the mid-1990s,

since their start-up the turbines have

been in constant operation without

any major overhauls.

Between 2006 and 2008, Andritz

VA TECH HYDRO, Kriens was able

By order of KraftwerkSchaffhausen AG (KWS) andthe NordostschweizerischeKraftwerke AG (NOK), AndritzVA TECH HYDRO has completelyoverhauled the turbines at theSchaffhausen power plant, whichwere supplied by Escher Wyss inthe 1960s.

Davide PirasPhone +41/41 329 52 30

[email protected]

Technical data:Output: 14.4 MW

Head: 9.25 m

Speed: 71.42 rpm


Processing of wicket gates for unit 1 in Kriens

The second unit was handed over to

the customers for power production

in mid-June 2008, thus providing a

successful conclusion to the project.

The Schaffhausen hydropower plant

Preassembly of cone and thrust bearing

Site report

Runner lifting at unit 1


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24 Hydronews

Technical data:

Output: 156.5 MVA Voltage: 15.75 kV

Speed: 3,000 rpm

Power factor: 0.8

Site report

tract was first allocated in January2008, which left a pre-project period of

just five months for the manufacture ofthe winding components and made

exact logistical planning vital.The unit was shutdown on June 16and work on the disassembly of therotor started without delay. The sensi-tive transport of the 42 tons rotor tothe Weiz plant and back was complet-ed in teamwork with the experiencedtransport company Felber. The dam-ageable stator components had to besupplied and returned on a just-in-timebasis, as the storage space availableat the power plant and in the machinehall were extremely limited. In addition,

GE was also completing a parallelmajor overhaul of the gas turbine.Immediately after the disassembly ofthe rotor, work commenced on provid-ing the stator with new windings andat the same time, Weiz carried out thedesign upgrade of the rotor, as wellas the individual overhauls of the pro-tection, excitation and start-up inverter.

The existing online monitoring systemwas also upgraded and brought upto the state-of-the-art. The completion

of these extensive activities in suchan extremely short time posed anenormous challenge to the entire team.Material sourcing, production at theWeiz plant and the precise schedulingof the various assembly steps was only

From June 16 - July 31, 2008,Andritz VA TECH HYDRO carriedout a major overhaul of the gasturbine generator no. 2 at theKelenfld power plant in Hungary.This contract included the replace-ment of the entire stator winding,the repair of the rotor and balanc-ing at the Weiz plant, the overhaulof all the auxiliary systems such asprotection, excitation and startingfrequency converter, and theupgrade of the existing DIA TECHOnline Monitoring System.

Budapesti Eromu ZRt. is part of theEDF Group and operates three gas-

fired combined cycle power plants inBudapest (Kelenfld, Ujpest, Kisbest),which supply the city with electricityand district heating. In recent years, thepower plants have been fully updatedand represent the state-of-the-artin both an ecological and technicalregard.Modifications, scheduled maintenanceand repairs are only possible at theKelenfld plant during a short summershutdown. Accordingly, Andritz VA

TECH HYDRO only captured the orderfor a complete overhaul after thepresentation of stringent scheduleinvolving 2-shift working, which envis-aged the completion of the work in just45 calendar days. Moreover, the con-

KelenfldMajor Overhaul ofa Turbo Generator

Engelbert AblasserPhone +43/3172 606 [email protected]

Loading of the rotor onto a truck

possible due to the outstandingco-ordination among the engineersinvolved. Moreover, the site work wasfinished on time thanks to the effortsof highly experienced personnel fromwithin Andritz VA TECH Hydro. OnJuly 30, 2008 plant operation wasreinitiated in teamwork with engineersfrom Budapesti Eromu , who providedour team with excellent support, and allthe commissioning tests were completed.

On August 1, the plant was then handedback to the customer for full operation.

The Kelenfld power plant

Installation of the new stator windingRotor disassembly


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Hydronews 25

Technical data: Harsprnget/KilforsenOutput: 117 / 100 MW

Head: 105 / 95 m

Speed: 166.7 rpm


SWEDENHARSPRNGET &

KILFORSENSwedish Vattenfall AB Vattenkrafthas awarded Andritz VA TECHHYDRO an order for the upgradingof two Francis turbines for theHarsprnget and Kilforsenhydropower plants.

Jrgen Tyrebo

Phone +46/640 17731

[email protected]

NORWAYSYLLING &

KRISTIANSANDAndritz VA TECH HYDRO, Jevnakerhas been awarded with an order forthe modernization of the start andcontrol equipment for two StatnettSF rotating phase compensatorplants in Sylling and Kristiansand.

Andritz VA TECH HYDRO Norway andVienna successfully modernized thephase compensators in Frogner andBalsfjord in 2005 and in early 2008. Allfour compensators play an essentialrole in the operation of Statnetts 400 kVgrid with its long transmission dis-tances. Therefore, short outage andreliability after modernization was ofmajor importance to the client. ForSylling and Kristiansand the Norwegianand Austrian units of Andritz VA TECHHYDRO are to supply static frequencyconverters for unit start-up, THYNE 5static excitation systems, DRS electricalprotection equipment, synchronization,

NEPTUN unit control, SCADA, andcooling gas surveillance for the hydro-gen-cooled rotating machines. In addi-tion, Syllings 13 kV switchgear is toreceive new controls. Re-commission-ing of the plants is scheduled for mid-2009 and early 2010 after respectiveoutages of 6 months.

Ole Andreas Gundersen

Phone +47/61315 257

[email protected]

Both stations went on-line in the earlyfifties and at that time, Harsprnget wasthe world's largest hydropower plant.

The new order encompasses the

hydraulic design and manufactureof two new Francis runners (weight32,000 kg). Model testing and theCFD calculations will be completed at

Andritz VA TECH HYDROs laboratoryin Linz, Austria. Andritz WAPLANS,Sweden, which became a fully owned

Andritz subsidiary in January 2008, willbe responsible for the dismantling andmodification of the turbines for the newrunners, the regulation systems and thegeneral turbine upgrading, including

refurbishment, as well as the installationand commissioning work. Following theupgrade, the power output at the ratednet head of both power stations will beincreased by approximately 20% overcurrent levels, by means of a flow andefficiency increase. Commissioningfinalization is expected in February2011 for Harsprnget and in November2011 for Kilforsen.

Technical data: Sylling/ KristiansandOutput: 160 / 140 MVAr

Voltage : 13 / 16 kV

Speed: 750 rpm

Technical data:Output: 43 MW

Head: 704 m

Speed: 428.6 rpm


SWITZERLANDSOAZZAAt the end of 2007, AndritzVA TECH HYDRO, Kriens receivedan order from Officine Idroelettrichedi Mesolcins SA (OIM) andNordostschweizerische KraftwerkeAG (NOK) for two new Peltonrunners and casing inserts. Theaim of the replacement is toachieve confirmed high efficiencywith a minimum of investment.

The Soazza hydropower plant wasbuilt in the late 1950s and apart fromthe exchange of two runners, suppliedby Escher Wyss in 1988, in the mean-time the plant has not seen any major

changes. The runners have beenregularly serviced and replacementwas not vital, but the customerrecognized the positive ROI to beobtained through the efficiency gainoffered by new runners. To ensureits investment, the customer adopteda new approach during bidding,accepting no measurement turbineefficiency tolerances with regard toeither the model or the prototype.

At the end of July 2008, we exceededthe model efficiency expectation andsuccessfully completed the customersacceptance test, which gives us greatconfidence for the prototype accept-ance test in March 2009.

Pascal Haas

Phone +41/41 329 53 14

[email protected]

Highlights


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26 Hydronews

Highlights

BELGIUMNISRAMONT

Andritz VA TECH HYDRO, Germanyhas received a contract in Nadrin,Belgium for the modernization ofthe Barrage de Nisramont hydro.power plant with two new compactFrancis turbines.

Dieter Krompholz

Phone +49/751 29 511 483

[email protected]

Technical data:Output: 2 x 611 kW

Head: 13 m

Speed: 300 / 1,000 rpm


AUSTRIAGSTATTERBODENAt the beginning of November 2007,Verbund-Austrian Hydro Powerawarded a contract to a consortiumconsisting of Andritz VATECH HYDRO,Germany and ELIN EBG MotorenLtd. for the delivery of a compactbulb unit for the Gstatterboden weirpower plant. The new hydropowerplant will be built in the immediatevicinity of the existing weir.

Edwin Walch

Phone +43/732 6986 3437

[email protected]

Technical data:Output: 1,995 kW

Voltage: 6.3 kVHead: 9.5 mSpeed: 250 rpm



Head: 235.9 m

Speed: 1,000 rpm


CHILELICANIn April 2008, Andritz VA TECHHYDRO received an order for twohorizontal Francis turbines from theChilean company ELISA S. A.

The scope of supply will be incorporat-ed in the hydraulic system of the Licanproject (approximately 65 km far fromthe city of Osorno). The projectinvolves intake structures, a first waterchannel, a surge tank, a second waterchannel, a load chamber, a steel pen-

stock, the powerhouse with adjacent

Paolo Nardello

Phone +39/44 56 78 356

[email protected]

This hydropower plant is part of alarger complex built in the 1950s. Italso includes a buttress dam, awater pumping station and a drinkingwater treatment plant. Two double

Francis turbines will produce electric-ity for the pumping station and thetreatment plant. The plant is ownedby Socit Wallonne des Eaux(SWDE) and our client, AndrLemaire S.A., has received a con-tract from SWDE for the completemodernization of the electrical andmechanical equipment based onCompact Hydros proposed solution.Finding an answer for the specialboundary conditions of this plant,especially in view of the fact that the

existing building was to be affectedas little as possible, represented achallenging task for Compact Hydro,together with the consultant VALID

Technologies from Sr l (VT) inSwitzerland. The consultants originalidea involved Kaplan turbines, butfinally an unorthodox solution wasfound using two Francis turbines incombination with gearboxes. Thiswas evaluated as the best and onlyfeasible idea and was finally ordered.

The scope of supply consists of two

completely new compact Francisturbines each with gearbox, a genera-tor, oil supply and the main inletvalve. The commissioning of turbine Iwill take place in May 2009.

In addition to the compact turbine,the scope of supply includes the

corresponding drainage equipment, asynchronous generator with brushlessexcitation, an automation system forthe machine and the existing secondary

equipment, as well as spare parts.

Furthermore, the consortium isresponsible for the installation andcommissioning of supply. Trial operationis scheduled for the end of 2009.

The Hieflau power plant was put intooperation in1956. It was designed asa diversion canal scheme with a dailystorage capacity. Hence the fact that,in terms of the current state-of-the-art,the rated discharge of the existingscheme was too low. The upgradingof the Hieflau power plant schemeincludes a new pressure tunnel

built parallel to the existing one anda new small hydropower plant inGstatterboden, which will generatean ecological flow of energy of approxi-mately 8 million kWh annually.

tail water channel, and a reservoir.The scope of supply for Andritz VATECH HYDRO consists of two hori-zontal Francis turbines with genera-tors, inlet valves, units automation,

joint control and remote SCADA. The

plant will be delivered and installed byVA TECH ESCHER WYSS S.r.l., Schio,Italy and start-up is scheduled to takeplace in November-December 2009.


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Hydronews 27


Head: 82.3 m

Speed: 360 rpm


USAJORDANELLE DAMThe turbine generator units providedby Andritz VA TECH HYDRO Canadafor the Jordanelle Project were suc-cessfully started-up and commis-sioned during June 2008.

Mark Barandy

Phone +1/973 403 8210

[email protected]

In late 2005, the Central Utah WaterConservancy District awarded Andritz

VA TECH HYDRO Canada an order forthe design and supply of water towire equipment, including two hori-zontal Francis turbines, synchronousgenerators, inlet valves, and a controlsystem for a new powerhouse for itsJordanelle Dam. Andritz VA TECHHYDRO equipment was specificallychosen due to its high efficiency and

energy production. The Francis turbineswere designed and manufactured by

Andritz VA TECH HYDRO France. TheJordanelle dam is part of the complexwater supply and distribution systemfor the Salt Lake City region in Utah.

The new powerhouse will now use thewater discharge for the production ofapproximately 44 GW/h. The high alti-tude project site is located approxi-mately 16 km from Park City, Utah, thevenue for the 2002 Winter Olympics.

The Central Utah Water ConservancyDistrict plans to use the facility as aneducational showcase exemplifying thedevelopment of a renewable resourcefor energy production.

Site report


Head: 400 m

Speed: 750 rpm


SWITZERLANDSCHATTENHALB IIIIn early 2008, EWR ENERGIE AG(EWR), a company of the BKWGroup, placed an order with AndritzVA TECH HYDRO for the electro-mechanical equipment at itsSchattenhalb III hydropower plant.

Markus Eisenring

Phone +41/71 9500 166

[email protected]

EWR uses the River Reichenbachin two stages, comprised by theSchattenhalb I and II stations (commis-sioned in 1901 and 1926). The catch-ment area of the Reichenbach meas-

ures 48 km2

and extends from theEngelhrnern to the Grindelgrat, via theWetterhorn, the Grosse Scheidegg andthe Schwarzhorn. With the newSchattenhalb III power plant the upperstage, Schattenhalb II, can be replaced.

Andritz VA TECH HYDRO is leading aconsortium that also includes ELIN EBGMotoren and ESATATEC. The scope ofsupply of the consortium includes theturbine, a turbine governor, agenerator, a voltage regulator, protec-tion and synchronisation, control andcommunication systems, a coolingsystem, auxiliary power and earthing,a turbine shut-off valve (ball valve), apowerhouse crane, equipment forthe positioning of the generator, andmedium - voltage equipment.

CANADACLOUDWORKSThis project in British Columbiainvolves the design and deliveryof 14 turbines, generators and inletvalves and is moving at top speed.

In 2007, Andritz VA TECH HYDRO Canadawas awarded a contract to design andsupply turbine, generator and auxiliaryequipment for the Kwalsa and UpperStave hydropower projects. Commercialoperation for Kwalsa and Upper Staveis scheduled for November 2009 and

November 2010 respectively. For theexecution of these run-of-river projects,which in total consist of 14 units and havea combined output of 165 MW, four

Andritz VA TECH HYDRO locations areinvolved, in addition to key external partnersin France for the generator and inlet valves.

At this stage the engineering for all projectsand production is complete and is movingfast in Europe and in Canada. Site progresshas been unfolding at an impressive paceand all the embedded components havebeen installed at the four Kwalsa sites.

The first generator and runner deliveriesare expected in November 2008, andeverything is in place to have the first twounits commissioned this year, thus beatingthe schedule by several months!

Javier Esparza-Baena

Phone +1/905 643 5881 207

[email protected]


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28 Hydronews

Events

Mr. Dr. E. Doujak (Vienna University of Technology) visiting Andritz VA TECH HYDRO booth

HIDROENERGIA 2008New Impetus for Small Hydro Power,a Significant Factor in the EU Energy Mix

Edwin WalchPhone +43/732 6986 [email protected]

Co-organized by the European Small

Hydropower Association (ESHA) and

the Slovenian Small Hydropower

Association (SSHA), the conference

brought together over 250 leading,

small hydropower sector experts

from 36 countries in the beautifulcity of Bled.

This years programme focused on

the two crucial issues of the role

of small hydropower within the EU

energy and climate package and

sustainability. The conference

included more than 50 presentations

in 12 sessions from distinguished

speakers representing the views of

industry, research institutes, the

European Commission, NGOs andgovernments with a key focus on:

Policy framework

New opportunities and image

Environmental and technical

solutions

Planning, engineering and innova-

tions.

ESHA, the European Small

Hydropower Association (ESHA), is

an international non-profit making

The Hidroenergia 2008 washeld in Bled/Slovenia fromJune 11-13, 2008. This was thefirst time that the fair had taken

place in one of the new EUmember states and appropriately,Slovenia chaired the EuropeanCouncil Presidency in the firsthalf of 2008.

association representing the small

hydropower sector.

ESHA is a founding member of the

EREC (European Renewable Energy

Council), which groups together all

of Europes main renewable energy

industry and research associations.ESHA is located in Europes head-

quarters for renewable energy, the

Renewable Energy House in Brussels.

With more than 17,800 small

hydropower schemes and total

installed capacity of 12,333 MW in

the EU-27, the small hydropower sec-

tor plays an important part in meeting

todays urgent need for clean energy.

The straightforward concept of

generating electricity using the energy

of water to turn the blades of a

turbine has been developed and

refined so that hydro schemes are

able to immediately respond to

fluctuations in electricity demand.

Hydropowers main advantage is

that it provides a steady and securesource of electricity supply and can

thus counter the intermittency of

other renewable energy technologies

such as solar electricity and wind.

In addition, small hydropower

also offers a long lifespan (up to

100 years) and a very high pay-back

ratio.


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Hydronews 29

Walter SchwarzPhone +43/1 89100 [email protected]

Events

The ENERGY EFFICIENCY WORK-SHOP was designed to bring togetheruniversity students and representa-tives of the power industry. About 115students from the UCT (University ofCape Town) and the CPUT (Cape

Peninsular University of Technology)attended the Energy EfficiencyWorkshop. This participation wasextraordinary high in view of the factthat the event was held on a Fridayafternoon. Each of the various pre-sentations was followed by a paneldiscussion, which demonstrated thestudents high levels of interest andinvolvement. South Africa is facinga tense energy supply situation withrepeated blackouts. Therefore, issues

such as demand side managementand load shedding met with a specialresponse. The event received generalapproval, the questionnaire debriefingshowing very positive feedback fromthe students. The information content,organization, presentation quality andpanel discussions were given an 8 out

The ENERGY EFFICIENCYINITIATIVE goes live. In thecourse of the Energy Efficiencyfor Power Plants in South Africa

B2B project, an Energy EfficiencyWorkshop was held at theUniversity of Cape Town (UCT)on March 14, 2008. The workshopwas initiated and organized by theENERGY EFFICIENCY INITIATIVE.

ENERGY EFFICIENCYWORKSHOPin Cape Town

of 10 rating. During the concludingworkshop dinner, further key pointssuch as initial contacts relating to theissues of training, education,

advanced courses for students,energy efficiency research projectsand the establishing of a personaldatabase for interested students wereall discussed. It was generally agreed,that the preparation of

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