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HyPowerCustomers magazine for Voith Siemens Hydro

November 2004

Summary Editorial

News from the Far EastVoith Siemens Shanghai to equip Laxiwaon the Yellow River

Successful model acceptancefor China’s Shui Bu Ya

Miyashiro, Japan: 100 years of successful operation

News from EuropeEarly finishing of site rehab in Coopumped storage plant

Generator rehabilitation of theSchwarzach power plant in Austria

New turbines for Hauterive in Switzerland

Customer contactsHydroVision 2004 and Hydro 2004 Hydro technology with a political orientation

Hydro Facts: Did you know about…?Protecting the climate

EssayThe Madeira River

EditorialSuccessess and historical landmarks

Focus on BrazilBrazil: Hydro power to remain strong

Voith Siemens Hydro, São Paulo:40 years high-tech in hydro technology

40 years of Voith in São Paulo –a reason to celebrate

Technological leadershipMicalastic: outstanding performance facts and figures

South American market activitiesGreat expectations for small hydro

CIGRE: Expertise sought after in energy conferences

Modernization of Furnas, a Brazilianmilestone

Peruvian Callahuanca to be modernized

News from North AmericaContinued support – 13 units rehabilitation of NYPA’s Robert Moses Niagara power plant

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Dear readers,

With the end of the year approach-ing, Voith Siemens Hydro can lookback on a fascinating period, filledwith activity.

I am satisfied with the fact that theindustry increased its focus on political awareness inside-out and outside-in, which was evident from activities inthis year’s major international hydro events, HydroVision2004 in Montréal and Hydro 2004 in Porto. We are alsoproud to have contributed to the wonderful progressvarious hydro organizations and associations made thispast year. But in order to have hydro power of all sizesagain a “fuel” that is recognized for all its benefits in asensible ratio with some of its – undisputable – sideeffects, a lot still needs to be done. Our goal is to achievebetter reconciliation in processes involving all stakehold-ers, despite the limitations that the equipment suppliers’role usually has.

Voith Siemens Hydro has had a satisfying year in terms oforder intake and business development; as can be clearlyseen from the reports in this issue. Our success in China,North America and Europe, confirms our strategy ofcompensating changing business cycles in one region byother emerging markets throughout the world.

Our focus this time, however, clearly is on Latin America’slargest market: Brazil. Our operating unit in São Paulo hasrecently celebrated its 40th anniversary. We have enjoyeda long and rich period of local presence in a certainlyinterchanging market.

The celebration of this anniversary deserves the reflectionon Voith’s past activities in this country – including VoithPaper and Voith Turbo products as well – and acknowl-edges once more our corporate culture of being globaland acting local.

Even though the business in Brazil started almost 100 yearsago with the delivery of our first turbine, local engineeringand local manufacture was the right option in 1964 to beable to participate in market opportunities, which emergedfrom the country’s economic boost at the time.

Voith’s endurance to stay there, even with decreasingbusiness during the later economic slow-down has paidover and over again: Today, Voith Siemens Hydro in SãoPaulo is simply the Latin American hydroelectric equip-ment company with the deepest expertise for the largesthydro plants in the world.

The “Paulistas” can be proud of their history and proud of their business!

We are interested in your opinions and comments, please feel free to direct them to me personally [email protected].

Yours sincerely

Successess and historical landmarks

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Dr. Hubert LienhardChairman of the Boardof Voith Siemens HydroPower Generation

Dr. Hubert Lienhard

Voith Siemens Hydro Power Generation

However, the government successful-ly minimized the impact of the crisisby implementing a rationing program.

Since the end of the rationing period,an unprecedented decline in demand,some minor capacity growth andabundant rain have resulted in anestimated excess of up to sevengigawatts. It is important to note,however, that this surplus is onlytemporary. Unless new generatingcapacity is added to the system, anygrowth in demand could result in anew crisis. The new government,inaugurated in January 2003, hasacted quickly to evaluate the powersector policies and initiate programsto solve bureaucratic red tape andovercome investment problems in the sector.

With an installed capacity totalling almost 90 gigawatts, Brazil is one of theworld’s largest electricity markets. It is by far the largest in South America,with a total primary energy consumption twice as large as Argentina,Bolivia, Chile, Paraguay and Uruguay combined. Hydroelectric power is the most important primary source for generating electricity, occupying anoverwhelming share in the energy mix. There are approximately 50 millionconsumers in this country, and total consumption has more than quadrupledin the last 20 years. Currently, some 95% of Brazilian households haveaccess to electricity.

Focus on Brazil

Brazil: Hydro power to remain strong

The prevalence of hydroelectric energymakes the Brazilian generating systemdiffer from that of any other countryin the world. Hydroelectric powermakes up almost 80% of the Brazilianelectricity market. Due to a severedrought, the hydro powered Brazilianenergy sector experienced a majorsupply crisis in 2001 when powerstations were left with shrinking ordry reservoirs.

São Paulo

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The Ministry of Mines and Energy(Ministério de Minas e Energia) isabout to issue licenses through anauction process for 2,800 MW of newhydroelectric projects expected to beoperated by 2009. The hydroelectricsite auction will award projects tobidders who offer the lowest electrici-ty prices rather than 20 year-contracts.

Iguaçu Falls

With average growth rates for Brazilexpected to be about 3% per year forthe next ten years, industrializationand development of the energy sectorwill continually increase. Providedthat there are no significant changes,this means an additional 37.6 gigawattof hydroelectric power is required tobe installed by 2014.

This can be traced back to 1964 andthe foundation of Voith S.A. Máquinase Equipamentos in the Jaraguá dis-trict. This plant was Voith’s firstproduction unit on the Americancontinent and was established onSeptember 22, 1966.

There is still an estimated 226 gigawatts of untapped hydroelectric potentialin Brazil. Due to this huge potential and to its economic attractiveness,hydroelectric power is the country’s most important primary source forgenerating electric energy. Moreover, it is a renewable source, not depen-dent on price increases or supply interruptions. Today, the technology for itsdevelopment is domestically available, with a very low import ratio.

Among them were three Francis tur-bines, supplied in 1912 for São PauloLight Co., with a capacity of 17,500HP each. In 1936, the company sup-plied a turbine for the Rio Light Co.,the biggest in the world at the time.Kaplan turbines were also brought toBrazil by Voith and installed in theTrês Marias hydropower plant inMinas Gerais, where they achievedthe record for the world’s highesthead for a Kaplan unit.

Focus on Brazil

Even before the creation of a facilityin Brazil, the name Voith was alreadyknown in the country, due to theGerman company’s supply of turbinesfor Brazilian plants. In 1905, Voithsupplied the turbines for the firsthydropower plant in Brazil, at ItatingaSantos. Since then, the name Voithhas been inseparably connected withhydroelectric power in the largestcountry in the southern hemisphere.

Voith Siemens Hydro, São Paulo:40 years high-tech in

Today’s main entrance of Voith Siemens Hydro São Paulo, Brazil

Location opening in 1966

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In 1964, Voith São Paulo started with295 employees and was able to supplyturbines to 62 projects over the nextfour years. Then, in the 1970s, thecontract for twelve units for Itaipu,the largest hydropower plant in theworld was awarded to Voith. Whenthe first turbine runner for Itaipu wasdelivered in 1982, it was the biggestin the world, weighing 300 tons witha height of 4.5 meters and a diameterof 8.6 meters. It was manufactured ofcarbon-steel and built entirely atVoith’s São Paulo facilities, during athree-year period.

Many important orders followed inthe subsequent decades. In the 1990s,the Brazilian factory started to manu-facture components for Chinese hydroprojects, including the world’s largestFrancis rotors for Wu Qiang Xi.

Competence center in generatormanufacturing

With the merger of the hydroelectricbusiness of Siemens and Voith Hydroin 2000, the plant in São Paulo beganto supply not only systems and equip-ment but also generators for com-plete plants.

By the turn of the millenium, the São Paulo facility had supplied a totalof 260 hydropower projects in thistropical country. Additionally, SãoPaulo delivered generator statorframes – the largest ever – and tur-bine buckets for the enormous ThreeGorges project on the Yangtze River.

São Paulo plays an important role inthe group’s overall development. This is the location of Voith SiemensHydro’s largest generator manufactur-ing plant worldwide. Know-how isregularly exchanged between Braziland Germany. International collabora-tion is a matter of course: employeesfrom Brazil work for a few months atthe headquarters in Heidenheim andemployees from Germany spend partof their project time in Brazil. Cross-training is essential to ourcommitment to excellence.

In the meantime, Voith employs over1,800 people at its plant in the city of 20 million. The Voith Siemens’plant is the largest metal-processingcompany in the city. In 2002, VoithSiemens Hydro Power Generationreceived an award from the Braziliantrade journal Exame as the mostrespected machinery manufacturingcompany in the country, an honor ofwhich we are very proud.

For more information:[email protected]

hydro technology

Xingó, Brazil Lapa, Brazil

And the Paulistas provided everythingworthy of such a success story. More than 700 people accepted theinvitation, and the festivities beganwith a splendid gala evening. Amongthe guests were many members of the Hanns Voith family, friends of the company, political and businessrepresentatives, as well as manycustomers from all around the world.

There was much to celebrate in mid-September 2004: Voith’s facilities in São Paulo just received a prestigious award for beingthe largest metal-processing company in the city and it was designated asthe largest generator manufacture location within Voith Siemens HydroPower Generation worldwide.

40 years of Voith in São Paulo –a reason to celebrate

Geraldo Alckmin, Governor of theState of São Paulo, emphasized theimportance of Voith for the State ofSão Paulo in his address: “With itssuccessful history in Brazil, Voith iscontributing to the development ofthe country. Not least in our owninterest, we would like to wish Voithanother 40 successful years inBrazil!”

Focus on Brazil

40 years ago, Mr. Hugo Rupf inauguratesVoith facility in São Paulo and in September,2004 Mrs. Martina Mann inaugurates the Voith Siemens Hydro’s newest electriccomponent plant

Mrs. Martina Mann and her great-grand-daughter visit the school Friedrich von Voith

The commemoration starts with a press conference on September 16

Other highlights of the gala eveningwere speeches by Dr. MichaelRogowski, Chairman of the Supervi-sory Board and the Shareholders’Committee, and by Martina Mann, theeldest daughter of Hanns Voith.

The following day, the factory doorswere opened to customers, suppliersand employees and their families.During this day, Martina Mann inau-gurated the new Voith Siemens Hydrogenerator plant, which had beenmoved from the city’s Lapa district to the Voith location in Jaraguá. From now on, mechanical and elec-trical components of the project willbe built in these new workshops.

The visiting program also includedsome social and environmental pro-jects sponsored by Voith and anexhibition with photographs showingthe development of Jaraguá, thedistrict where the Voith plant hasbeen located over all its 40 years.

The last day of the anniversary saw acelebration with employees, friendsand relatives, with more than 10,000people taking part.

Johannes Hammacher, representingthe Hanns Voith family, said: “Alwaysremember that Voith cannot existwithout you. Brazil will always have aspecial place in the hearts of the Voithfamily.” Under the tropical sun of São Paulo, a barbecue with music and rhythms of the “Rosas de Ouro”(golden roses) samba school washeld.


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Mrs. Martina Mann talks tocustomers and employees in a very emotional speech

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10-1 100 101 102 103 104 105 ht

Years1 10 1001 10 60 min

Micalastic insulation is based on theuse of inorganic fine mica tape as abase and curing synthetic resins as abonding material, in conjunction witha sophisticated manufacturing tech-nique, including the VPI (VacuumPressure Impregnation) process toguarantee the complete removal ofany air or solvents in the insulation.

The main function of an insulationsystem is to separate the electricalcircuits of stator winding componentsat different voltages (high voltage)from each other and from metalliccomponents at earth potential inorder to assure high reliability andlong service life for the electricmachine.

Micalastic is the brand name of Voith Siemens Hydro’s successful insulationsystem for all kinds of hydro generators. It was introduced almost half acentury ago in 1957. Owing to an outstanding performance, the history ofMicalastic has become a success story that still continues today.

Micalastic: outstanding performance facts and figures

Micalastic effectively insulates thebars and coils of high voltagemachines. Based on VPI technology,it fulfills minimum Thermal Class Frequirements according to interna-tional standards (IEC 34). The maincomponents of this insulation systemare impregnated glass yarn for thestrand insulation, fine mica tape withaccelerator (Zinc-Naphthenat) for themain insulation, and an epoxy resinas impregnation resin.

Transposed conductor of a Roebel bar

Endurance curve of the Micalastic insulation

Technological leadership

The high reliability of the Micalasticinsulation system is shown byimpressive figures that underscore its flawless performance. Since 1957 it has been applied to over 400 hydro units worldwide(rated output higher than 5MVA). That equates to more than 275,000bars and coils adding up to over5,000 service years or an accumulat-ed service hours rate per unit of morethan 45,000,000. In all this time, nota single failure has been reported dueto the aging of the insulation.

Furthermore, since the early 1970s,the properties of the main insulationhave been proven by short- and long-term endurance tests. The short-termtest is the one-minute breakdowntest, in which the dielectric strengthis measured applying a voltage with a continuous increase rate until theinsulation fails. Typically, the break-down happens at a dielectric strengthhigher than 25 kV/mm.

The long-term endurance test is theVET (Voltage Endurance test). Typically, these tests are carried outat 3 x Un and 2 x Un. For these volt-age tests, respectively, the minimumlife time of a bar or coil is higher thanthe values specified by the KEMAstandard which is the internationalreference for this kind of test.Micalastic also fulfills the VET accord-ing to IEEE 1043 and IEEE 1553.


Micalastic Insulation – Characteristics and Test Voltages

Electrical characteristicsRelative dielectric constant, �r, 20 °C, 50 Hz ≈ 4Tang � at 0.2 UN, 20 °C, 50 Hz ≤ 2,0 %1/2 (Tang � /0.6 UN - Tang � / 0.2 UN), 20 °C, 50 Hz ≤ 0.5 %Max. � Tang � / step 0.2 UN (from 0.2 UN to UN) ≤ 0,5 %1 min. breakdown strength, 50 Hz, slot side ≥ 25 kV/mm

– Single stator bars (half coil) Up ≥ 4.5 UN at slot side kVUp ≥ 3 UN at front side kV

– Single stator coil (diamond coil) Up ≥ 2 . (2 UN + 1 kV) at slot side kV Up ≥ (2 UN + 1 kV) at front side kV

Surge voltage endurance along slot ≥ 50 (1.2/50 �s wave) kV/mmUs ≥ (4 UN + 5 kV) at slot side kV

Test voltages and permissible surge in operationTest voltage, 50 Hz, UpRMS, 1 min

– Single stator bars (half coil) Up ≤ 3 UN kV– Single stator coil (diamond coil) Up ≤ (2 UN + 5 kV) kV– finished winding assembly Up = (2 UN + 1 kV) kV

Ratio between test DC an AC voltage UpDC/UpAC 1.7Test voltage, conductor strands, 50 Hz 220 VPermissible surge voltage on windings in operation ≤ 3.5 UN at Uphase-core kV

≤ 5 UN at Uphase-phase kV 1011

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The Brazilian National DevelopmentBank can finance up to 70% of capitalcosts, excluding site acquisition andimported goods and services. Interestis not charged during construction,and amortization is set at ten years.Payments are due six months afterthe start of commercial operation.Furthermore, the Brazilian ElectricityRegulatory Agency (ANEEL) willdiscount as much as 50% of thetransmission and distribution ratescharged for power produced fromrenewable energy sources, includingsmall hydro electric plants.

Boosting Brazil’s renewables

The Brazilian Alternative EnergySources Incentive Program (PROIN-FA), originally launched in 2002 andrevised in November 2003, aims atsubstantially increasing the role ofalternative energy generation, includ-ing wind, biomass and small hydropower to 10% of the annual electricityconsumption, within 20 years.

To achieve this goal, the BrazilianGovernment has designated a federalstate-owned power utility, Eletrobrás,to act as the purchaser of electricenergy generated by alternativeenergy facilities in Brazil. Eletrobráswill buy energy at pre-set preferentialprices and then market the electricitygenerated from renewable sources.This guarantees a price of at least70% of the average energy supplytariff, charged to end consumers inBrazil. Contracts between Electrobrásand the renewable energy generatorswill be valid for a period of 15 yearsfrom the date of operation and applic-able to plants that begin productionbefore 2007.

Under PROINFA, 1,100 MW have been distributed for each alternativesource, totalling 3,300 MW.

Great expectations for small hydro

Power Future 2004

One of Brazil’s most important eventsof the year with regard to alternativeenergy, took place in April at theCeará Convention Center in Fortalezaand focused on renewable energysources and more specifically onPROINFA.

Voith Siemens Hydro São Paulopresented its small hydro technologyto a highly interested public, amongthem the state governor of Ceará andenergy secretary of São Paulo.


South American market activities

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Voith Siemens Hydro’s technicalcompetence is in great demand atCIGRE’s national committee events in Brazil, too. With 28 participantsand presentations on more than tendifferent technical topics, it was themost active private company in lastyear’s national seminar on electricenergy production and transmission (Seminário Nacional de Produção eTransmissão de Energia Elétrica). “For the next year, we have alreadysubmitted around 20 abstracts, which will be analyzed and evaluatedfor presentation,” stated ThomasHildinger.


Voith Siemens Hydro’s São Paulogroup participates in the technicalcommittee on rotating machines ofCIGRE (Conseil International desGrands Réseaux Électriques), theInternational Council on Large Elec-tric Systems, a non-governmental and non-profit organization, based in France.

At CIGRE’s biennial conference,various committees and work groupscome together to discuss reports onpredefined topics, submit papers, and define and publish new technicalrecommendations. This year, the conference took place from August 29to September 4 in Paris. HenriqueAlvarez and Thomas Hildinger of Voith Siemens Hydro, took part in the committee debates and plenarysessions.

Voith Siemens Hydro São Paulo, as the worldwide center of competence forgenerator technology gathers prolific manufacturing know-how and technicalexpertise. Brazilian experts also take an active role in the development andexchange of engineering knowledge and information at international eventson energy generation.

Thomas Hildinger

CIGRE: Expertise sought after in energy conferences

South American market activities

Voith Siemens Hydro is responsiblefor the modernization of the olderunits 1 to 6 that have now reachedthe limits of their life-span, after morethan four decades of excellent perfor-mance. The company will also deliversupplementary items for units 7 and8, plus the plant substation.

Project duration is scheduled to be 62 months. The planning phase isalready completed, and constructionof the new relay house has alreadybegun.

The total modernization is expected to be finished by March 2010.


Modernization of Furnas, a Brazilian milestone

The original design of the Furnasplant included six machines – NohabBardella Francis turbines and Siemensgenerators – the first of which wasinstalled in July 1958. Five years later,in 1964, Furnas power station beganoperation. In 1974 and 1975 anothertwo generating units were added, withthe same technical characteristics.

120 meters high, the Furnas Damimpounds the waters of the Rio Grandeand Sapucaí Rivers, forming a hugereservoir spreading over 1,400 squarekilometers. Located in the south-eastern state of Minas Gerais, thedam with its hydro power facilitieslies right in the center of an extensiveregional electrical grid serving theindustrial centers of São Paulo, Rio de Janeiro, and Belo Horizonte.

Built in the late 1950s, the Furnas Dam was one of the first major moderndams in Brazil. Its power stations marked the starting point of an acceleratedincrease in installed capacity that went from around 5 gigawatts beforethese plants began operating, to almost 90 gigawatts today. The Furnashydro plant, with an installed capacity of 1,216 MW, was a milestone in the hydroelectric development of its time, noteworthy also for its ability to regulate flow to important downstream installations. After more than 40 years of operation, it is now being modernized by a consortium of com-panies led by Voith Siemens Hydro.

Control room and substation

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Callahuanca is located 60 km east ofthe capital Lima and is situated in theAndes. With its four horizontal Peltonunit, it is capable of generating a total output of 73 MW. The first threemachines, equipped with Voith run-ners, were installed in 1938: a fourthunit followed 20 years later. Now, thehydro specialists from São Paulo willsupply new runners with an optimizedhydraulic profile, thus increasing theturbine output of the three older unitsby 25%.

Voith Siemens Hydro São Paulo is pleased to announce that it will modern-ize the Peruvian hydropower plant Callahuanca. The contract with plantowner Edegel S.A.A., a company of the Spanish Endesa group, has alreadybeen signed. It is the first time that the Brazilian unit will carry out a mod-ernization of this importance in Peru.

New stator cores, speed and voltageregulators, transformers and improvedturbine shut-off valves are part of themodernization work, too. New auxiliary equipment will be pro-vided for the newer unit and the entirestation will be automated and receivea new control room.

An innovative runner productionmethod will result in superior qualityand allow for reduced manufacturingtime. Under a tight project schedule,limiting unit outage to a challengingmaximum of 90 days per unit, thisgain of manufacturing time is muchappreciated.


Peruvian Callahuanca to be modernized

Voith Siemens Hydro’s involvement in the rehabilitation of the power plantstarted in 1992 after a successfulcompetitive model test resulted in acontract award for 14 uprated 213”(5.4 m) Francis runners rated at 200 MW.

The Robert Moses power plant was constructed between 1958 and 1962 withthirteen Francis units rated at 175 MW. In the late 1980’s, the New YorkPower Authority made the decision to rehabilitate the existing units ratherthan expand the power plant.

The contract included the hydraulicdesign, model manufacture, test andshafting analysis for uprate as well as the additional scope for variousparts and services that result fromthe evaluation of each unit and dis-assembly.

News from North America

Continued support – 13 units rehabilitation of NYPA’s Robert Moses Niagara power plant

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Installation, transportation, fieldmachining and a spare runner are alsoincluded in Voith Siemens Hydro’sworkscope. The project rehabilitationschedule of one unit per year accom-modates having the maximum avail-ability of units for power generation.

In 2002, Voith Siemens Hydro wasgiven the additional opportunity to continue the relationship with theNew York Power Authority and in the improvements of the RobertMoses plant. The contract to perform the stator repair and rewind of the 13 generator units and one spare wasawarded to the Voith Siemens Hydrofacility in Mississauga, Canada.

To date, eleven units have been com-pleted with runner uprates and turbinerehabilitations with scheduled com-pletion of all units for 2006. Two unitshave been completed with statorrepairs and rewinds with scheduledcompletion of all units slated for 2010.


Before and after repair

Voith Siemens Hydro’s work in progress on the stator repair and rewind at the Robert Moses Plant

News from the Far East

In August 2004, Voith Siemens HydroPower Generation Shanghai Ltd. wasofficially awarded the contract forsupplying five 711 MW Francis tur-bines by Yellow River Upper StreamHydropower Development Co., whichbelongs to China Power InvestmentCorporation. It is the largest contractVoith Siemens Hydro Shanghai hasever received since it has been estab-lished.

The Yellow River is one of the earth’s ten longest rivers. It starts in theBayankale Mountains which divide it from the Yangtze in the south. From these mountains, whose highest peaks reach over 5,000 meters, theriver flows eastward, passing through a number of narrow gorges. It is here,at the upper stream of the Yellow River in the province of Qinghai, where theriver falls 140 m every 100 km, that a new generating facility with a capacityof well over 3 gigawatts will be built: the Laxiwa hydro power plant.

Voith Siemens Shanghai to equip Laxiwaon the Yellow River

Laxiwa is the biggest hydro projectalong the Yellow River, and is part ofthe Chinese National Hydro PowerDevelopment Program to utilize thehydropower resources in the westernregion. It transmits the energy to theeastern areas. The first unit is sched-uled to be put into operation in 2008. The plant will help meet the continu-ously increasing Chinese powerdemand.


Laxiwa dam

Laxiwa project site

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Voith Siemens Hydro will supply fourFrancis turbines with a capacity of466.3 MW plus auxiliary equipment.The first unit is planned to be com-missioned in July 2007. The project isscheduled for completion in 2009.

The 1,840 MW Shui Bu Ya project will be the third hydropower stationconstructed on the Qingjiang River,one of the major affluents to theYangtze. The annual energy output ofthe power plant is 3.92 billion kWh,with a head range of 145 to 203 m.

A successful model acceptance test for the Chinese hydropower station ShuiBu Ya took place at the “Brunnenmühle”, Voith Siemens Hydro’s CorporateTechnology facilities in Heidenheim, in September 2004. The model turbine,designed and optimized for the requirements and boundary conditions of theChinese hydro project, was tested in the presence of representatives of thecustomer, Hubei Qingjiang Hydroelectric Development Co., Ltd. Much to thecustomer’s satisfaction, the operating performances fulfilled, and in somecases even exceeded the contractual guarantees. Thus, the final step of thehydraulic development phase has been taken.

The power station will play an impor-tant role in the regulation of flow onthe Yangtze during summer floodseason and will help balance peakingpower demand in Central China’spower grid, thereby enhancing safeand reliable operation of local powergrids.


Successful model acceptance for China’s Shui Bu Ya

News from the Far East

The equipment had made a longjourney, all the way from Germany,since the turbine was designed andmanufactured by J.M.Voith in Heiden-heim and the generator by SiemensSchuckert Werke in Berlin.

For 100 years, to the delight of theowner, Chubu Electric Power Co.,Inc., the machines have run smoothlyand without major failure or break-down.

It was a good 100 years ago when a caravan of heavily loaded horse-drawncarts made its arduous way through the central mountains of Japan. In big wooden boxes they carried a turbine and a generator destined for one of the early hydro power stations there, Miyashiro No. 1 Power Station,not far away from the famous city of Matsumoto located in the NorthernJapanese Alps.

On September 11, 2004, Chubu Electric Power Co. Inc. commemorat-ed 100 years of flawless operation atthe power station. After a religiousShinto ceremony held at the site, acheerful party was given, attended bymany former employees, engineersand city officials. Representatives ofthe owner, the operators and VoithSiemens Hydro expressed their greatsatisfaction and pride in making andsuccessfully maintaining a powerstation over such a long period oftime.

To mark the opportunity, the respon-sible Chubu Electric General Managerof the Power Station, Mr. NorioYamanoi, received from Dr. MartinKuechle, President of Voith Fuji HydroK.K., the entity of Voith SiemensHydro in Japan, a large acrylic paneldisplaying the etched copy of theVoith original order sheet for theturbine. The document reads, amongother things, “Turbine No. 1433…Spiralturbine Gr. 5 B 3%”, orderreceived on July 13, 1903, to bedelivered on October 1, 1903 (!) and,remarkably, among other technicaldata, the machine output was givenas “Nutzeffekt PS 371” (output 371horse power).


Miyashiro, Japan: 100 years of successful operation

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News from Europe

The main scope of work comprisedthe disassembly and overhaul of theupstream and downstream movableand fixed seal rings in addition to thedisassembly of the downstream half-body and the non-destructive testing(in this case an ultrasonic test) of allbolts.

The plant is equipped with six VoithSiemens Hydro Francis pump-tur-bines, three in the Coo 1 and three inthe Coo 2 power houses. The overallinstalled capacity of Coo exceeds1,100 MW. The partial on-site over-hauling of Coo 2 was tightly sched-uled for six weeks and three days.

Neither narrow working areas nor unexpected difficulties are obstacles tocompleting a successful refurbishment. Voith Siemens Hydro completedoverhauling three 2,650 mm diameter spherical valves at the Coo 2 pumpedstorage plant in Belgium, operated by Electrabel, two days earlier thanscheduled.

Early finishing of site rehab in Coo pumped storage plant

Besides a rather limited working areaVoith Siemens Hydro had to deal withsome unexpected damages on singleparts of the valves during the refur-bishment. Nevertheless, the teamfinished its task ahead of schedule.Before Coo 2, Voith Siemens Hydrohad already successfully completedthe overhauling of three sphericalvalves in Coo 1 within a comparablychallenging timeframe.


From left to right:Found condition of valve insideLiftout of seal ringExamination of the bolts

This enables the power station togenerate peak power. Voith SiemensHydro has already rehabilited – from1987 to 1991 – the Francis turbines ofthe four units in existence since 1959,when the output was raised to 34.41MW. The present generators, how-ever, are not capable of fully reachingthis capacity.

The Schwarzach power plant, situatedon the Salzach River, is not a typicalrun-of-river power station. The waterfor generating power is drawn fromthe Högmoos weir facility, 17 kilome-ters away, led to the Brandstatt stor-age reservoir and from there throughthe penstock into the power house.

An award to renovate a generator of the Schwarzach power plant was granted to Voith Siemens Hydro Power St. Pölten by Verbund-AHP (AustrianHydro Power). In November 2005, a completely new stator will be delivered,resulting in an increase of rated output from 35 MVA to 37.5 MVA.

Generator rehabilitation of the Schwarzach power plant in Austria

Moreover, the existing stator wind-ings, including stator cores, havearrived at the end of their service lifeand have to be renewed. Through modernization, losses can bereduced by around 20%, even with a7% increase in output. Furthermore,the present auxiliary equipment forthe oil bearings will be renewed.


View of the hydro power plant

Generator hall

News from Europe

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Hauterive, located in the Canton of Fribourg in Switzerland on the GruyèreLake and fed by the Sarine river houses, is one of the oldest swiss hydro-electric plants. The people know it especially for the Hauterive-Rossenspower plant which was put into operation in 1902 with six turbines. This historical plant is still running, and, when modernized by Voith SiemensHydro Power Generation, will soon have a substantially increased output.

The small hydro operating unit ofVoith Siemens Hydro at St. Loup inFrance has signed the contract withthe Swiss plant owner, EntreprisesEléctriques Fribourgeoises nearFribourg. Scheduled to be renovatedby means of a new, vertical Francisturbine are two old units, each withan output of 7.5 MW.

New turbines for Hauterive in Switzerland

In the spring of 2006 the new machinewill relieve the older models from1919 and 1925. At a head of 94 meters,24.7 MW will be generated from thenew unit in addition to three existingunits with Francis turbines at 15 MWeach.


As a keynote speaker, Gregg Easter-brook, editor-in-chief of the “The NewRepublic”, attracted particular atten-tion. Easterbrook explained his mostimportant argument for hydro power:“As long as the world produces morepeople, they will need more dams tobring water, irrigation and cleanpower to displace polluting powersources.” Not only the Western world,but developing countries in particularcould be substantially benefiting fromhydro power, according to Easter-brook. On one hand, energy genera-tion through hydro power is economi-cally profitable, emissions-free, andrenewable. On the other hand, alter-natives like wind, solar, geothermicpower and biomasses can never coverthe increasing need for primaryenergy production.

In mid August, more than 1900 delegates from 56 countries met for one ofthe most important conferences in the hydropower sector: HydroVision 2004in Montréal, Canada. In this year’s program – besides technical lectures onsubjects such as state-of-the-art technologies and equipment, distributionstrategies, etc. – a clear emphasis was additionally put on social, environ-mental and political aspects.

Not only was the keynote speech ofDr. Hans P. Schiffer, Chairman of HydroEquipment Association, looking at thehistory of development in mankind'shistory from a very different angle.The attendance of representatives ofNGOs, such as IRN (InternationalRivers Networks) showed, that dialo-gue among the sometimes mostcritical stakeholders has started toevolve.

As a sponsor and member of the IHA and NHA, Voith Siemens Hydrofully supports this. Additionally,through Hydro Equipment Association,the suppliers’ association of VoithSiemens Hydro, Alstom Power Hydroand VA Tech Hydro, it will continue to work in this field.


Customer contacts

He backed his speech with a call tonational governments: “There arefailings of governments, not of hydropower… The root problem is the needfor all governments to treat theimpoverished better.”

The hydro industry – convinced that it is providing power in the best way,but while the public image of hydropower is often tarnished – has founda platform for action: joining forcesfor the second time at HydroVision,the Joint Organizations Meeting, calledfor by International Hydro Association(IHA) and National Hydro Associationof USA (NHA) saw an increasing movetowards activating the disseminationof IHA guidelines.

Another increase in focus on environ-mental and social issues of hydro and a turn-around in the public imagecould also be felt in Hydro 2004 inPorto, Portugal.

HydroVision 2004 and Hydro 2004Hydro technology with a political orientation

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Hydro Facts: Did you know about…?

Each kWh produced with hydro powerreduces CO2 emissions by 1 kg.

The energy generated annually byhydro power is free of emissions anddoes not use up natural resources.


Hydro power helps to keep emissions as low as possible.

1 kg of coal

fossil energy3 kWh

3 kg CO2

Protecting the climate

The incredibly large Amazon Riversystem – if source rivers are included– is the longest river in the world.One of its tributaries is the RioMadeira, and with 1,450 km, is amighty river in its own right so there-fore, worth a closer look.

The river owes its name to the factthat on the journey to the Amazondelta from its source, at the conflu-ence of the Guapore and the MamoreoRivers, it carries a great deal oftimber – countless trees that it hastorn down. Since the Portugueseword for wood is “madeira”, it istoday known as the “river of wood”.

Most people, if asked about the greatrivers in the world, think immediatelyof the Amazon.

When its water levels are at theirpeak, this river can flood an area upto 100 kilometers wide in the forestsalong its banks. The delta on theSouth Atlantic coast is also severalhundred kilometres wide and encom-passes the huge river island Marajó,and, with approximately 4,900 squarekilometres, is the largest delta islandin the world.

In the interests of three countries

The Madeira River

With a navigable section of 1,100 kmbetween Porto Velho and Itacoatiara,the Rio Madeira is one of the mostimportant waterways in South Ameri-ca. It is the main transport route formost of the soy, produced in the stateof Mato Grosso, and also for exportedgoods transferred to large ocean-going freightships at the tradingcentre of Itacoatiara.

The Rio Madeira has an importantpart to play in the development of thetransport infrastructure in three majorSouth American countries – Brazil,Bolivia and Peru.

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Together with the other rivers, it formsa navigable waterway of 4,225 km,giving access to the Atlantic Oceanand thus to international markets foragricultural products and industrialgoods.

The cultural history of the Rio Madeirais closely linked with the creation ofthe federal state today known asRondônia and its capital Porto Velho,which is also the most important porton the river.

The Amazon delta was discovered in1499 or 1500. The sailing ships of theItalian Amerigo Vespucci and theseafarer Vicente Yanez Pinzon reachedit at almost the same time, butVespucci is often credited as the firstto arrive. His voyage was commis-

sioned by the Portuguese, who thenbegan to colonize the Amazon regionand made the land fit for agriculture.

Marshal Cândido Mariano Da SilvaRondon, who was born on May 5th

1865 in Mimoso, Mato Grosso, isconsidered to be a trailblazer of themodern era in terms of nationaldevelopment policy. A great humanist,he served in the new republicangovernment of Brazil and was respon-sible for opening up the vast regionaround Rondônia. Rondon and histeam built roads, erected hundreds oftelegraph poles and with many kilo-meters of wire, recorded the topogra-phy of the areas, discovered unknownrivers, studied the flora and fauna andwere the first to build up a relationshipof respect with the native inhabitants.

Any description of the flora and fauna of the vast riverscape aroundthe Rio Madeira calls for the use ofmany superlatives. The rainforest isextremely rich in species.

Exotic plants, ancient trees that growto unimaginable heights, and count-less wild creatures, all enjoy virtuallyperfect living conditions here. A particular feature is that the MadeiraRiver is home to the largest freshwaterspecies of dolphin. These friendlymammals – known as boto – are thesubject of many legends still told bythe region’s inhabitants.

The area around the Rio Madeira is,of course, still developing. High levelsof investment are improving the livingconditions of many people in Brazil,Bolivia and Peru. The carefully con-trolled use of hydroelectric powerplays a large part in this. The statesof Rondônia, Acre and Mato Grosso,for instance, are to be connected tothe Brazilian electricity grid and theamount of hydroelectric power pro-duced is to be increased by some 18,000 megawatts.

Voith Siemens HydroPower Generation GmbH & Co. KGAlexanderstraße 1189522 Heidenheim/GermanyTel. +49 7321 37 68 48Fax +49 7321 37 78 28www.voithsiemens.com

Editorial coordination:Barbara Fischer-Aupperle

Copyright 2004 Reproduction permitted,provided source is given.

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