hypower - voith · 2020. 3. 19. · will from now on generate 900 kw of energy from a 4.4 m head....

HyPowerCustomers magazine for Voith Siemens Hydro

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Summary Editorial

Generator modernizationFrequency conversion modifications andrewinds at Canadian generating station

Hydroelectric generator rewinds and modernization

Customer contactsEvents 2003

Milestones in historyOne hundred years of Niagara Fallsturbines

100 years of Pelton turbines from Voith

NHA Award for aerated runner development

EssayWhat is the origin of life?

EditorialEngineered reliability!

Focus on Small HydroWorldwide trend towards small hydro

Voith Siemens Hydro: big player in small hydro

Increasing demand for small hydro-power plants in Norway

Small hydro in Europe

Würmtal: 100 years of reliable operation

Small hydro in south and north America

Small hydro in south-east Asia

Efficient automation for small hydropower plants

Market splintersHydro power in the desert: successfulstart in Ghazi Barotha, Pakistan

Khopoli, India, connected to the grid

Kiskoere, Hungary: Model tested successfully

Rehabilitation of Bulgaria’s Orfeus andKrichim hydropower plant

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Dear clients and partners, dear readers,

Our new issue deals with small hydro as a market focusand I think that we do provide you with an extensiveoverview of where our activities take place: worldwide.

A newly-structured team in our company takes care of driving this focus on the basis of our new platform concept. Our message is, that especially in small hydro,innovative approaches and high-quality, high-tech solutions, do not automatically result in high-end prices.Our complete packaging concept does apply in smallhydro business at least as much as in large hydro. Excellent baseline designs together with short realizationtimes meet cost effectiveness. And still, this is done on the basis of our state-of-the-art research and deve-lopment experience, that can be considered leading in the industry.

Small hydro is again getting “fashionable”, also in termsof policital treatment, and can even help you to get greencertificates or can play a role in the Kyoto goals of indus-tries and nations.

The recognition of hydro power – small or large – as the most mature of all renewables in energy generation, is breaking ground again, these days: The World WaterForum in Kyoto, held in March this year, explicitelydeclared large hydro to be renewable. In our eyes it ishigh time for hydro to be acknowledged again for what it deserves to be. I congratulate International Hydro Asso-ciation’s tremendous efforts, to put forward their messagefor hydro in the context of this event!

Above this, our company’s technical contributions andefforts to even more environmentally friendly solutions arereflected in the award of NHA to our location in the USA: it was given to the common development of the U.S. ArmyCorps of Engineers’ and Voith Siemens Hydro’s aeratedrunner concept.

The optimization of components as well as completeplants, small or large, is our business, the handling of projects of any size in close and good cooperation with partners and customers as a project company is what we have to offer. We master this with well-estab-lished locations in the Americas and Asia, know-howbased on excellent staff and equipment, unique and unified standards and quality worldwide. We continue to offer what Voith and Voith Siemens Hydro havedeclared the company principle:

Engineered reliability!

Whatever your opinions and business interests are: please do not hesitate to let me have these!

Yours sincerely

My e-mail address is [email protected]

Engineered reliability!

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Dr. Hubert LienhardChairman of the Boardof Voith Siemens HydroPower Generation

Dr. Hubert Lienhard

Voith Siemens Hydro Power Generation


Focus on Small Hydro

Decentralized renewable energy cansolve numerous local problems relat-ing to energy supply. There are threemain drivers behind the global trendtowards small hydro:� The promotion of renewable power

is in full accordance with the latestnational legislation (green certifi-cates) in various countries.

� An increasing dependence onprimary energy sources could lead to serious economic threats. Powersupplies from alternative, decen-tralized sources are becomingmore and more attractive.

� Small hydro has the lowest envi-ronmental impact of all energysources, including other renewableenergies. It fully corresponds to environmental commitments,including the Kyoto protocol.

In line with the strategy of global hydro development, small hydro techno-logy is making a significant contribution to sustainable, clean energy policy.Small hydro is playing an increasingly important role in promoting socialand economic development, taking into account the fact that electricitysupply and availability is essential for developing rural areas as well as forindustrial growth.

Worldwide trend towards small hydro


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Technological edge and cost effectivenessBased upon such long-term experi-ence and state-of-the-art technology,a technological platform concept forsmall hydro has been established. It defines uniform technical standardson a modular design basis and stan-dardized components. Its develop-ment was possible only because of the extensive know-how derived from the huge number of contractsexecuted by Voith Siemens Hydro.Thus, seemingly conflicting smallhydro requirements have been united:cost-effectiveness, flexibility andsimplicity on one side, high perfor-mance, reliability and availability on the other side.

Voith Siemens Hydro: big player in small hydro

As a world leader in hydropower equipment and services with a product line covering project handling and technology for all types of hydraulic andelectrical machinery as well as a complete range of mechanical and electri-cal services, Voith Siemens Hydro has more than 135 years of tradition in small hydro worldwide. The most modern research and development centers in Germany, in north and south America provide the technologicalbackground for the international activities, thus profiting from research-based large hydro developments.

LocationsThe acquisition of a majority stake in the leading French small hydro spe-cialist Esac Energie at the beginning of last year further expanded VoithSiemens Hydro’s position in the smallhydro market. The technological edgeof a leading hydropower company hassince been combined with the focusand flexibility of a company fully andsolely dedicated to small hydro.

Worldwide activitiesVoith Siemens Hydro is involved innumerous successful small hydro projects in Europe, north and southAmerica, Asia and Africa.

For more information:[email protected]

Interested in our new Small-Hydrobrochure? Please contact: [email protected]



impression of the landscape. For this reason, the power house will bebuilt as a traditional timber log housewith a grass roof which blends intothe surrounding area. The highlyoptimized iron penstock will be laid in a trench covered by soil, and willthus be invisible to local trekkers.

DataNet head: 380 m 2 jet horizontal Pelton turbines 4.6 MW turbine output 5.0 MVA generator output Commissioning December 2003

[email protected]

Riksheimdal to be visually integrat-ed in Norwegian landscapeRiksheimdal is being built to utilizethe water between an existing waterreservoir and an old small hydropower plant. Voith Siemens Hydrowas awarded the turnkey contract,including 3,000 m of penstock and apower house, by Sykkylven Energi AS.Together with one of its best Norwe-gian customers, Nord-TrøndelagEnergiverk (NTE), Voith SiemensHydro will be installing a state-of-the-art electro-mechanical package and an innovative power house. Bothsolutions have to be chosen verycarefully to preserve the original

Vedeld receives E+M-package andspecial outletVoith Siemens Hydro was awardedthe contract for the electro-mechani-cal package by Tussa Energi AS. Extra attention must be paid to aspecial outlet construction, as part ofthe discharged water from the turbinegoes to a salmon farm. Therefore,Voith Siemens Hydro is installing a by-pass arrangement to secure the water supply to the fish farm even when the power plant is out of operation.

DataNet head: 247 m 4 jet vertical Pelton turbines 3.4 MW turbine output 3.8 MVA generator output Commissioning September 2003

[email protected]

Increasing demand for small hydropower plants in Norway


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Sagnfossen being upratedSagnofossen is an old hydropowerplant located in eastern Norway, nearto the border with Sweden. The cus-tomer, Hedmark Energi Kraft AS,decided to rebuild the facility with anincreased output. From a variety ofpossible low head machine concepts,Voith Siemens Hydro was awardedthe contract for a direct-driven verti-cal Kaplan turbine. The engineers willinstall a turbine with a diameter ofapproximately 3.5 meters and an air-cooled generator of 130 tons. Certain-ly not the type of equipment oneinitially thinks of when talking aboutsmall hydro plants. But running at aspeed of 136.3 rpm will ensure thatthe machinery is extremely reliable.

DataNet head: 9.2 m Vertical Kaplan 6.2 MW turbine output 6.85 MVA generator output Commissioning August 2004

[email protected]

New equipment for Lovik The Lovik hydropower plant is locatedin northern Norway. The plant hadbeen in operation for almost 50 yearswhen the machinery broke down. TheLovik project is something special, as Voith Siemens Hydro and the cus-tomer, Andøy Energi AS, entered into a directly negotiated contract for thereplacement of the complete turbine,the generator, the control systems, and auxiliaries. The benefits of this co-operation for the customer areobvious: it will save delivery time andhence minimize the breakdown costs.

DataNet head: 84 m Horizontal Francis turbine 1.3 MW turbine output 1.45 MVA generator output Re-commissioning February 2004

[email protected]

Turbine for New Bjölvo delivered four months ahead of scheduleWith a head of 860 m, the 9.2 MWhorizontal Pelton machine for theextension of the Norwegian hydrostation New Bjölvo ranges among thehighest head small hydro turbinesbuilt in recent years. Voith SiemensHydro delivered turbine and valvesfour months earlier than scheduled.

DataHead: 860 m Horizontal Pelton 9.2 MW turbine output Discharge 1.2 m3/s

[email protected]


New hydropower plant in Hiltenfingen Voith Siemens Hydro recently con-cluded work on the turnkey project in Hiltenfingen on the Wertach inGermany. The new hydropower plant was committed to its intended usewithin the very short time frame of 2 1/2 years from planning, licensing,and commissioning to realization. The plant, which is equipped with an S-turbine (runner diameter 2 m)will from now on generate 900 kW of energy from a 4.4 m head.

[email protected]


Small hydro in EuropeCargiaca, FranceOne Pelton unit of 4.6 MW was com-missioned at the Cargiaca hydropower plant on Corsica. Voith EsacHydro was in charge of the mechani-cal part of the plant, including ahorizontal 2-jet Pelton machine.

[email protected]

Stanley Mills, UKVoith Esac Hydro supplied a completebulb unit rated 900 kW, for the Scottish plant at Stanley Mills.

[email protected]

Work finished at TheodorianaVoith Siemens Hydro has finishedwork on the small hydro projectTheodoriana in Greece. The contractincluded two horizontal Francis tur-bines (2.6 MW and 1.3 MW), twosynchronous generators (3.0 MVAand 1.5 MVA), three butterfly valves(diameters 1,100, 900, and 600 mm),and the installation of an automationsystem including governor oil units.

Data2 horizontal Francis turbines 2.6 MW/1.3 MW turbine output 3.0 MVA/1.5 MVA generator output

[email protected]


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Complete equipment for GitaniThe Gitani project is situated in thenorth-north-west of Greece on theKalamas river, near to Igoumensita,the major port to Italy. Voith SiemensHydro received a letter of intent fromDIEKAT S. A. for the complete water-to-wire package, including two bevel-gear pit turbines with an electricalpower output of approximately2.1 MW each, generators, plant con-trol system, electrical installations, and trashrack cleaning system.

DataHead: 7.45 m 2 bevel-gear pit turbines 2.2 MW output per turbine Commissioning early 2005

[email protected]

New power station for VorinoVoith Siemens Hydro will install anew power station located in north-western Greece approximately 150 -200 km from Thessaloniki. Gener S.A. and Voith Siemens Hydrosigned a pre-contract for the supplyof the water-to-wire equipment pack-age, containing one horizontal shaft2-jet Pelton turbine, generator, plantcontrol system, and the electricalinstallations.

DataHead: 550 mHorizontal 2-jet Pelton turbine 3.9 MW turbine output Commissioning early 2005

[email protected]

Turbines for the Turkish plantHacilar delivered six months earlierVoith Siemens Hydro, responsible for the entire electro-mechanicalequipment of the Hacilar small hydropower station, manufactured two horizontal shaft Pelton turbinesof 7 MW each in record time com-pletely in its Heidenheim workshop. The contractual manufacturing anddelivery schedule of the originalcontract had thus been reduced bymore than six months. Commission-ing took place in June 2003.

[email protected]



San Nicolo small hydro station willyield profit in less than six yearsThe San Nicolo small hydro project in Italy was carried out as a minimumenvironmental impact project under a tight time schedule of roughly a yearfrom contract award to commission-ing. In normal commercial operationsince January 2003, the power stationhas been perfectly integrated in themountainous landscape of northeastern Italy. Its four-nozzle verticalPelton turbine, installed at a net headof 127.5 m, generates a maximumpower of 755 kW. The turbine wastested in the hydraulic laboratories of Voith Siemens Hydro in Milan andHeidenheim. Designed for a very flathigh-efficiency curve, it can be oper-ated with one or more nozzles at thesame time. The unit produces morethan 3,000,000 kWh per year andrevenues are expected to reach about300,000 Euro per year. Taking advan-tage of the so-called “green certifi-cate” incentives (0.06 Euro/kWh), the plant will be completely repaid in less than six years.

[email protected]

Jerte commissioned in record timeIn the extraordinarily short time of just nine months, the Spanish unitof Voith Siemens Hydro manufacturedand delivered three horizontal Francisturbines for the Jerte small hydroplant. With these units, the hydro station, located in the famous valleyof the Jerte river in the province of Cáceres, can generate a total power of almost 6 MW.

[email protected]

New contracts for Peneda and ArnoiaThe good performance of the Peltonturbine at the Cierves hydro station,which was supplied a few years agoby Voith Siemens Hydro, is the reasonwhy the plant owner, Hidroeléctricadel Giesta, has now ordered twovertical Kaplan turbines of 8.6 MWand 2.4 MW for its Peneda smallhydro station and three vertical Fran-cis turbines of 7.0 MW, 3.1 MW and1.3 MW for its plant at Arnoia.

[email protected]


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More than one hundred years ago,Voith turbine 492 was put into ser-vice in the Würmtal hydro powerplant near Stuttgart. After beingcommissioned in 1899, the plant wasused to supply power to a sawmill.

After a general overhaul at the begin-ning of the 1960s, the machine oper-ated continuously until 1970, when the penstock was damaged. In 1980 the station was recommissioned andthe electrical components and con-trols were replaced. In February 1982,the plant was put back into operation.The average energy production sincethis reactivation is approximately500,000 kWh per year.

The turbine has not been opened for the last twenty years, merely receiving minor servicing once a year. With the exception of various bolts,sleeves and bushings, the originalturbine parts are still in use. A newwater-cooled generator feeds itsexcess heat directly into the heatingsystem of the building.

Today, the plant is used solely forpower supplies in parallel networkoperation. Approximately 10 % of the energy generated is supplied to asmall industrial estate which has beenbuilt on the site of the sawmill in themeantime. Most of the energy gen-erated is supplied to the public grid.


Reliable operation: 100 years of hydropower in Würmtal, Germany



Paraíso, Brazil, commissioned now Equipped with two horizontal Francisturbines of 10.8 MW each, the Paraí-so generating station almost escapesthe concept of small hydro: when infull operation, the two machines willproduce enough energy to supply50,000 houses in the northeasternregion of the Brazilian state of MatoGrosso do Sul. The commissioning of the units is scheduled for October2003. As the consortium leader, VoithSiemens Hydro is responsible for the supply and supervision of theerection of all mechanical and elec-trical equipment.

[email protected]

Fumaça supplies aluminum plantThe last turbine-generator unit of theFumaça small hydro station has juststarted normal operation and hasattracted praise from the client. Theplant is located in the Brazilian stateof Minas Gerais and is equipped with

two horizontal Francis turbines of 5.2 MW each and a brushless typegenerator of 5.6 MVA. It generateselectrical power for the nearby alu-minum plant of the Brazilian companyAlcan Aluminío do Brasil Ltda. VoithSiemens Hydro, as the consortiumleader, is responsible for all the elec-trical and mechanical equipment atthe plant.

[email protected]

São BernardoWhen commissioned at the end of 2005, the São Bernardo plant will be supplying 15 MW to the grid. Voith Siemens Hydro will contributethe turbines and governors to theproject, which is located on theBernardo José river in the Brazil state of Rio Grande do Sul.

[email protected]

Furnas do Segredo This small hydro power plant, locatedon the Jaguari river in Rio Grande doSul, is scheduled for commissioningin September. Voith Siemens Hydrowill deliver two low head Kaplan S-turbines with 4.7 MW each.

[email protected]

Esmeralda Like Paraíso, a high capacity smallhydro station that will generate 23 MW of electricity when in fulloperation. Commissioning is to takeplace at the end of 2005. Two VoithSiemens Hydro-made Francis turbineswill produce 11.5 MW each. A VoithSiemens Hydro governor system willguarantee smooth operation.

[email protected]

Small hydro in south and north America


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Environmentally sound constructionof small hydro station in Chile One will hardly find another small hydro plant located in such an impres-sive region of stunning natural beautyas the Lago Atravesado station insouthern Chile. The 12 MW plant,owned by Empresa Electrica de AysénS.A., lies on the shore of the Atravesa-do lake surrounded by several millen-nial glaciers. Miles from anywhere,there were no roads leading to theconstruction site. Due to the strictenvironmental regulations of Chile’sNational Energy Commission (CNE), a road could not be built. Consequen-tly, the two 6 MW horizontal Francisturbines, designed and manufacturedat Voith Siemens Hydro’s location in Tolosa, Spain, like all the material and equipment, had to be shippedthere on board of a transport barge.

[email protected]

Pingston, CanadaTwo Pelton units were commissionedin early May, at the Pingston hydropower plant in Canada. Voith EsacHydro was in charge of the supplyand commissioning of the turbine-generator sets, as well as the controlpanels. This plant is located nearRevelstoke, British Columbia, and has a total output exceeding 30 MW.

[email protected]

Rutherford Creek, CanadaTwo vertical Pelton units of 25 MWwill be installed at Rutherford CreekHydropower plant, near the city of Whistler, north of Vancouver,British Columbia. Voith Esac Hydrowill supply the turbine-generator sets,with a commissioning date expectedin April 2004.

[email protected]



Small hydro in south-east AsiaVoith Fuji Hydro, the Japan based entity of Voith Siemens Hydro, has beenawarded several contracts for interesting hydro power projects in Japan, in close cooperation with Fuji Electric, four of which are:

Shirahagi equipped with new hybrid actuator The contract was awarded for equip-ping the new Shirahagi hydro powerplant by Hokuriki Electric Power Co.The supply for the new plant, locatedon the Hayatsuki river, included ahorizontal Francis turbine, governor,generator, excitation, erection, andcommissioning. As a special feature,a newly developed hybrid actuatorwas provided for guide vane control.DataHead: 74.5 m Horizontal Francis turbine 3.29 MW turbine output 3.37 MVA generator output Commissioning December 2002

[email protected]

Ohtaki generating station now commissionedThe contract was awarded for instal-ling a new hydro power station byKansai Electric Power Co., Inc. Thesupply for Ohtaki hydro power plant,located on the Kinokawa river, includ-ed a vertical Kaplan turbine, a genera-tor with thrust bearing made out ofTeflon (PTFE), excitation, automation,electrical BOP, erection, and commis-sioning.DataHead: 80.37 m Vertical Kaplan turbine 10.8 MW turbine output 11 MVA generator output Commissioning May 2003

[email protected]

New hydro station at TomadaThe Government of Okayama Pre-fecture awarded a contract for theinstallation of a new hydro powerstation on the Yoshii river. The supplyincludes a vertical Francis turbine,generator, excitation, automation,electrical BOP, erection, and commis-sioning. Voith Siemens Hydroinstalled an electric motor operatingservomotor for guide vane control,replacing a pressure oil operatingservomotor which requires consider-able maintenance work and costs.

DataHead: 33.1 m Vertical Francis turbine 4.83 MW turbine output 4.9 MVA generator output Commissioning March 2005

[email protected]

New hydro station on Surikamigawa Dam The Ministry of Land, Infrastructureand Transport awarded a contract for installing a new hydro powerstation on the Surikami river. Thesupply includes turbine, generator,automation, governor, excitation,erection and commissioning.

DataHead: 51.1m Horizontal Turgo impulse turbine 1.21 MW turbine output 1.2 MVA generator output Commissioning April 2004


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New power station for Erathne, Sri LankaA new power station will be installedfor ZYREX Power Company Erathne,Ltd. located about 100 km south-eastof Colombo in the Ratnapura area of Sri Lanka. The work order contains a complete water-to-wire equipmentpackage including two horizontalshaft 2-jet Pelton turbines withapproximately 5.15 MW electricalpower output each and a plant controlsystem, both of which will be manu-factured at Voith Siemens Hydro in Heidenheim, Germany.

DataHead: 450 m 2 horizontal 2-jet Pelton turbines 5.15 MW output per turbine Commissioning early 2004

[email protected]

Way Ganga: The largest privatelyfinanced hydro project in Sri LankaDIDUL Pvt., Ltd. Is carrying out the largest privately financed hydropower project in Sri Lanka. WayGanga powerhouse, located about 130 km south-east of Colombo, will get its water via a long channel,including a newly built aqueduct tocross the river valley. Voith Siemenshydro will install a complete electro-mechanical equipment package span-ning three horizontal shaft Francisspiral turbines with approximately 3 MW electrical power output each,generators, a plant control system,and the electrical switchgear.

DataHead: 58 m 3 horizontal Francis spiral turbines 2.93 MW output per turbine Commissioning end 2003/early 2004

[email protected]

Wainikasou-Vaturu, FijiVoith Esac started manufacturing ahorizontal Pelton turbine rated 3 MWand 2 horizontal Francis machinesrated 3.4 MW each for two new powerplants located on the Fijian island ofViti Levu. Generators are also part of the contract. The hydro plants willreplace diesel units presently in oper-ation, and commissioning of bothprojects is foreseen in March 2004.

Data WainikasouHead: 115 m 2 horizontal Francis turbines 3.4 MW output per turbine Commissioning March 2004

Data VaturuHead: 268 m Horizontal Pelton turbine3 MW output per turbine Commissioning March 2004

[email protected]



in Heidenheim. The goals of the development project could only beattained by means of standardization– but it had to be standardization of a sort which does not compromise on functionality or performance.

Efficient meets all of the criteria forfulfilling the greatest demands ofsmall hydropower plants: it is highlyperformant, safe, easily accessible,compact, inexpensive. Thanks to theVoith Siemens Hydro standards andto sophisticated simulator technology,the automation system can now be“pre-commissioned”, thus reducingtime and risks involved when the

costs. This basic disparity in costscannot be entirely eliminated – but itcan be reduced. Voith Siemens Hydrohas developed the Efficient auto-mation system to solve this problem.

Voith Siemens Hydro’s Efficientsystem offers high performance at low pricesIn order to reconcile the demands for high performance and high safetystandards on the one hand and forlow costs on the other, Voith andSiemens developed the Efficient system for smaller power plants inthe course of a reassessment of the companies’ products conducted

Efficient automation forsmall hydropower plants

No power plant can today be operated without at least a minimum degree of automation. The basic goals of automation are the same as they were a century ago. But automation systems today are much more efficient. In addition, remote control and remote operation now play a significant role in the design of power plant automation.

Since the relative costs of energyproduction decrease while the overalloutput of a power plant increases,small hydropower plants are undergreater cost pressure than largepower plants. That applies particularlyto automation, as its cost percentagedecreases the larger the power plantis. Long pressure pipes, for example,present significant control difficultiesfor both large and small power plants.These are even more difficult to over-come in small power plants than inlarge ones, due to the smaller massof the generating system, thus lead-ing to a higher engineering effort andtherefore of course also to higher


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equipment is actually put into service.This does not only bring benefit to the new equipment, it also reducesthe amount of working time lostduring the modernization process.

Two factors made it possible for VoithSiemens Hydro to meet the high demands for performance and safetywhile maintaining low costs: The company drew on its speciali-zed knowledge of equipment andmachinery from its many years as a hydropower plant specialist, andthoroughly integrated this knowledgeinto the Efficient Standard Module.This system was developed concur-rently with the Excellent system for large facilities, which created theopportunity for many synergy effects,because many of the basic functionalblocks of the Excellent system can be employed in the Efficient systemfor small power plants as well.

The system has meanwhile beeninstalled in several power plants and tested successfully. The high-quality modules designed to increasethe power plants’ rates of yield havereceived particularly high praise.


Excellent HMI: WinCC (OS)CS7 (Server)PC: Windows NT

PLC BasisSoftware:Step 7 (CFC/SFC)

PLC:S7 400

Efficient PLC:S7 400/S7 300

HMI: WinCCPC: Windows NT

PLC BasisSoftware:Step 7

PLC:xx7

low

high

small largeplant size

Tech

nica

l req

uire

men

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Communication systems

continuous monitoring

river control

joint control

digital turbine governor

automationefficientexcellent

HMI

Unit automation& plant control

security system

synchronizers

power supply batteriesUPS units

LV. switchgearsLV. distributions

voltage regulator

digital excitation system

reactive power control

digital protection systems

Electrical equipment

instrumentation

mech./hydr. control equipment for butterfly and spherical valves

pressure oil supply system

governing systems– electrohydraulic

converters,moving coil valves

– control valves– emergency

shutdown valves– shut-off valves– relay valves

Mechanical equipment

VSHyCon: The Voith Siemens Hydro Control Family – Efficient

VSHyCon System Family


Market splinters

At the end of 1997, Voith SiemensHydro received a contract to providethe hydro plant with 5 Francis tur-bines, 5 regulators, and cooling anddrainage systems. Now, 50,000engineer hours, 120 shipments, and800 drawings later, a new hydro planthas been built: The assembly tookplace in a desert landscape in heatreaching 50 degrees Celsius.

After more than five years of construction, the first 300 MW turbine for the Pakistani hydro plant GhaziBarotha was put into service in the presence of thecustomer, the Water and Power Development Authority(WAPDA). The WAPDA Chairman reported a successfulwet test and a smooth start to operations. Ghazi Barotha,located on the Indus River in north-western Pakistan,will provide a total of 1,500 MW once it is completed in June 2004, thus providing for one tenth of Pakistan’selectricity needs.

Hydro power in the desert:successful beginning

to operations in Pakistan

This project will surely not be thelast. Since Pakistan has the potentialto produce an estimated 40,000 MWof hydro power, but currently utilizesonly 6,500 MW of that capacity, additional projects of this kind can be expected in the future.



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At the beginning of this century, in 1911, a hydro power station with the name Khopoli was already built inthe Indian Federal State of Maharash-tra. At that time it was equipped withsix units with an output of 12 MWeach, which are still partially in opera-tion today.

Almost 90 years later end of 1999,Siemens’ hydro power section, nowmerged into Voith Siemens HydroPower Generation was awarded thecontract to built a new hydro powerstation next to the old one which should be equipped with three unitswith an output of 24 MW each.

Khopoli connected to the grid

After four years of construction and installation works the last unit of the new Khopoli hydropower station was connected to the grid. With a total output of 72 MW Khopoli equals the electricity supply of a city with around 87,000 inhabitants.

The scope of supply for Voith SiemensHydro covers three generators, elec-trical auxiliaries, automation as well as erection and commissioning. Thecontract came from the private powersupply company TATA Power CompanyLimited, Mumbai, Maharashtra.

The customer expressed his highsatisfaction on the efficient new units:the plant now generates more than seven per cent more electricity thanbefore.



Market splinters

Customer present at model testThe model was tested in the presenceof the customer, Tiszaviz VezeroemueKFT, Siemens Budapest as the con-sortium partner, and experts fromMiskolc University, in order to bestfulfill all of the guarantees as definedand agreed upon during the biddingand selection process.

The model of the modernized hydraulic systems planned for the Kiskoere hydro plant in Hungary was successfully tested at the testing facilities of Voith Siemens Hydro Corporate Technology Center “Brunnenmühle” inHeidenheim at the end of March 2003. The power plant, located on theTisza River, around 130 km east of Budapest, is currently being modern-ized after almost 30 years of service.

Kiskoere hydro plant model tested successfully

Experts after witnessing the model tests in Heidenheim

Reliable performance for the futureThe Kiskoere hydro plant is equippedwith four bulb turbines (runner dia-meter: 4.3 m), which produce 7 MW of power each, at a head of around 6.3 m. In the course of the moderniza-tion project, the old runner blades andguide vanes of each machine were re-placed with four newly-designed run-ner blades and 24 new guide vanes.

These measures will help to ensurethe reliability of electrical energysupplies in the future, and will alsoincrease the annual production ofelectricity from its previous 90 GWh.



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Bulgaria covers 70 % of its energyrequirements with nuclear power andimported fossil fuels. The renovationof the hydropower plants, locatednear Plovidiv, Bulgaria’s secondlargest city, therefore represents animportant contribution to increase theshare of environmentally friendlyenergy in the country’s energy mix.Work on the 15 million Euro projectbegan in April 2003 and is to becompleted within 36 months.

The comprehensive renewal worksinclude delivery of new mechanicalkey parts such as turbine runners,wicket gates and regulating mecha-nism, the supply of new turbinegovernors, control systems, medium-and low-voltage equipment, staticexcitation and electrical protection as well as rehabilitation works onworn parts and on the interfacesbetween old and new equipment.

Rehabilitation of Bulgaria’s Orfeus and Krichim

At the end of last year Voith Siemens Hydro was granted the contract torehabilitate the Bulgarian hydropower plants Orfeus and Krichim. The contract, awarded by Natsionalna Elektricheska Kompania EAD (NEK) in Sofia,will be carried out in a consortium with Alstom Power Austria AG.

Insight view of Orfeus power houseDam with spillway at Orfeus reservoir

The consortium is responsible for ba-sic and detail engineering, supply andproject management, software, erec-tion supervision and commissioning.



Generator modernization

The small Canadian town of Bishop’s Falls, founded in the early 20th century, is situated in a strategically unique location, with access to the vast woodland and water resources of central Newfoundland. Since the turn of the last century, the Bishop’s Falls generating station has been accommodating the energy demands of the town’s paper mill.

When doubts arose as to the suit-ability of the existing generators foroperation with this new runawayspeed, Voith Siemens Hydro was ask-ed to perform an engineering study. The new turbine design for theBishop’s Falls Generating Stationincreased the runaway speed of theunits by almost 50 %, and the fre-quency change altered their normaloperating speed from 231 to 277 rpm.Voith Siemens Hydro engineersthoroughly investigated the impactsof these alterations and determinedthat the existing rotors were notsuitable for the new conditions:Stress levels were found to be ex-cessive in a number of areas of thegenerators. Due to the conclusions

The hydroelectric generators take ad-vantage of the momentum generatedby the Exploits river as it flows to thesea from the immense watershed areaof the central Newfoundland plateau.The plant has grown from its originalcapacity of 1,500 kW in 1909 to a ra-ting of 17 MW through several expan-sions. In the late 1990’s, the plantowner decided to upgrade the gener-ating units by installing new turbinesin the existing flumes, while at thesame time converting the frequencyfrom 50 to 60 Hz. The new turbinedesign resulted in a higher runawayspeed.

of the runaway speed study, VoithSiemens Hydro advised against re-commissioning the units withoutstructural modifications. Excessivestresses in the welds and rim couldpossibly lead to a machine failure. To solve the problem, modificationsin the rotor were found to be indis-pensable.

Following the stress analysis, VoithSiemens Hydro received an order todesign and implement modificationsthat would accommodate the speedincrease for the six 1950’s vintagegenerators. From an engineeringstandpoint, this was quite a challeng-ing task. A non-weld retrofit was de-sired in order to avoid welding-related

Successful frequency conversion modifications and rewinds

at Canadian generating station


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distortion issues, which could have ledto increased modification costs andlonger outages. The technical strategywas to reduce the load flow throughthe fillet welds as well as the bendingstresses in the rim. Voith SiemensHydro’s rehab specialists installed pre-loaded radial ties to support the in-creased centrifugal loads that would be produced by the increased runawayspeed. In addition, holes were ma-chined in the rotor disks to reduce thestresses induced in the fillet welds.

Working under a tight schedule, four of the units were equipped with newwindings to adapt the units to the de-sired uprate from 2,250 to 3,000 kVA.The remaining two machines had beenrewound previously. However, they had

to be reconnected from a Delta to aWye configuration. Furthermore, theengineering analysis had determinedthat the original field coil intercon-nectors and coil support hardwarewere unsuitable for the altered oper-ating conditions. Therefore, rede-signed field pole interconnectors and

Stress- von MisesIbf//in^2

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Fillet weldsRim Disk

stronger coil support stud assemblieswere installed.

While proper planning with experien-ced hydro equipment suppliers cancover most uncertainties, 50-year-oldunits can still present a few unplan-ned challenges. Nevertheless, suchdifficulties are rather typical of thenature of modernization, and can be effectively addressed by highlyqualified personnel applying state-of-the-art analytical methods and tech-nologies. At the Bishop’s Falls gener-ating station, all six generators arenow operating and performing well.


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Overstressed rim

Overstressed rim – Disk fillet weldsOverstressed disk – Hub fillet welds

High stress levels predicted in the originalspider design at the new runaway speed

High Rim – Spider Disk Weld Stress Levelspredicted in the original spider design at thenew runaway speed

a New holes to reduce weld stressesb New radial ties

a New holes to reduce weld stressesb New radial tiesc New field coil interconnectorsd New coil support stud assemblies

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Plant modernization can be an effective way to meet increasing demands for energy without major capital investment. Particularly in older plants,power generation capacity can often be significantly increased by rewindingthe generator with redesigned windings manufactured with modern insula-tion systems. Voith Siemens Hydro in Canada manufactures stator windingsand specializes in the uprate and modernization of Hydro Generators.

Hydroelectric generator rewinds and modernization

mechanical characteristics of themachine. By applying state of artanalysis and design technologies,generators can typically be modifiedto provide increased ratings withimproved efficiency and reliability.


Stator bar manufacturing in MississaugaCompleted stator rewind (Courtesy of Alcoa, Inc.)

Obtaining the optimal blend of newand old technologies to maximize the customer’s return on investmentrequires specialized knowledge andexperience.

Voith Siemens modernization special-ists can evaluate any manufacturer’sgenerator to determine its upratecapability. This evaluation requires a review of both the electrical and

Uprating and modernizing a hydrogenerator requires a sound under-standing of past and current genera-tor technology. Voith Siemens Hydrohas been manufacturing generatorsfor over 135 years and is continuallydeveloping and applying improvedtechnologies for the design of newgenerators. Significant synergiesexist in the development of new ma-chine and modernization technologies.

Generator modernization


Events 2003ELPAH X (Encontro Latino Americanoe do Caribe em Pequenos Aproveita-mentos Hidroenergéticos), the 10thLatin American and Caribbean SmallHydro meeting, took place from May4 to 8 in Poços de Caldas, Brazil.

The meeting gathered researchers andprofessionals from the energy sector,NGOs and government organizations with a broad spectrum of technologi-cal, political and environmental dis-cussions. Voith Siemens Hydro notonly acted as a main sponsor, butalso presented its technology anddevelopment for small hydropowerplants.

SIMPASE (Simpósio de Automaçãode Sistemas Elétricos), the ElectricSystems Automation Symposium,one of the main forums for the dis-cussion of problems and solutionsconcerning the automation of elec-tric power generation, transmissionand distribution systems in SouthAmerica. Held its biannual event forthe fifth time from May 11 to 14 inthe city of Recife, Brazil.

Voith Siemens Hydro presented 14case studies, giving an insight intotheir special solutions for the automa-tion of hydroelectric power plants.

Hydro 2003 Dubrovnik, Croatia, November 3-6, 2003Booth 54-55

� Our papers presented in the conference:

– Performance and economic bene-fits by integration of intelligent supplementary functions into a hydroelectric plant control system

– Precautions in the modernization of hydrogenerators – how to elimi-nate old deficiences and avoid new problems

– Countermeasures to reduce hydro abrasive wear at hydro turbines parts.

� Paper to be published in the conference proceedings:

– First refurbishment of Kaplan bulb turbines at the Kisköre HPP in Hungary system.

Deutsch-Chinesischer Wirtschafts-kongress, October 22-24, 2003,Grand Hyatt Hotel, Berlin, Germany� Paper presented by Voith Siemens

Hydro, Dr. Konrad Roth, Shanghai– China. New opportunities for the

capital equipment business.

Waterpower XIII in Buffalo, N.Y., USA29-31 July, 2003, Booth 810� Papers by Voith Siemens Hydro: – Exelon: Automation rehabilitation

program at the hydropower plant Conowingo and the pump storage plant Muddy Run.

– Apgi hydropower modernization –A partnered process approach to system optimization.

– Optimization of system operation. – Wicket gate friction device

monitoring system. � Paper by Avista Corporation,

co-authored by Acres International and Voith Siemens Hydro:

– Turbine upgrade for significant capacity increase at Cabinet Gorge hydro plant.

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Customer contacts


Milestones in history

Niagara turbines in 1911Voith historical poster (Power houses of the Canadian side)

One hundred years of Niagara Falls turbines

In 1903, the City of Hamilton provided the opportunity for Voith to supplyturbines for a new hydro station. Prior to this time, some smaller stations in the area were equipped with machines from Switzerland and Italy.

Walter Voith met with the EngineeringCommittee that was visiting Europe insearch of equipment and technologi-cal solutions for the hydro equipment.The committee was impressed withthe turbines and technical solutionsthat he offered and the contract wasawarded to Voith in April of 1903. The four Francis spiral turbines thatwere supplied to Dominion Power andTransmission Ltd. Hamilton had anoutput of 515 kW at a head of 79.5 m.

This was an impressive machine forthe time and two additional units ofsimilar size and output were awardedto Voith in 1910 and 1911 based onthe performance of the equipmentprovided in the 1903 contract.

Additional units were ordered byOntario Power Company for their newhydropower station located at the baseof Niagara Falls on October 1st, 1903.This award was made as a result ofthe superior work performed at Hamilton even before the units therewere commissioned.


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Robert Moses Niagara Power Plant

This historical order for Voith provid-ed the most powerful and largestturbines in the world at that time andwas based on the trust in the Germancompany’s technology and perfor-mance. Voith’s engineers and work-shops were motivated to insure thatthey would meet the challenges andcommitments of the project.

Four spiral twin turbines each with anoutput of 8,826 kW were provided forthe contract. These were followed bythree more units from 1908 through1912 with an output of 9,047 kW at53.4 m head.

Hanns Voith provided the followingpersonal memories of the Niagaraturbines: “As a trainee, I was allowedto assemble the first of the Hamiltonturbines at the workshop in the winter of 1903/1904. I also partici-pated in the banquet that my father,Friedrich Voith, gave to the EngineerCommission of the Ontario Power Co.in the Heidenheim dining hall. My father gave a very good Englishspeech, which was difficult for him,especially if one knew the he did notfavour holding speeches”. The Nia-gara turbines were decommissionedin December of 1999 after 95 years in operation. Even though they are no longer connected to the grid, they

are still operable. Ontario Power Ge-neration explained that their futurestatus will be reviewed from time totime. Turbines that are still operableafter 100 years is an impressive record.Another historic plant, the Decew FallsHydropower Station, was built in 1904.This plant is close to Niagara Falls andis equipped with Voith turbines andgenerators from Westinghouse whosetechnology is now merged into to-day’s joint venture of Voith SiemensHydro Power Generation.

In addition to these early historicalprojects, Voith Siemens Hydro PowerGeneration later supplied the genera-tors for the Sir Adam Beck 1 & 2stations between 1919 and 1955.Another 13 generators were suppliedto a station on the US side of NiagaraFalls in 1950. The most recent awardfor Voith Siemens Hydro in the Nia-gara Falls area is the contract to reha-bilitate the first stator of 14 at theRobert Moses Niagara HydropowerStation. The company is proud of thepast and current role it has played inthe history of hydropower develop-ment at the Niagara Falls.



Exactly 100 years ago, Voith built the first Pelton turbines for the G.N.Gaubitz mill construction company in Mainbernheim, Germany. The first export shipment of a Peltonturbine – to Japan – followed just one year later.

The Pelton turbine is based on an 1880 invention by the US citizen Les-ter Pelton. Pelton turbines are used for particularly high heads – it is notunusual for heads over 1,000 meters.Water discharged from such a head hits the runner at a speed of 500 km/h.

The highest head from a VoithSiemens Pelton turbine is 1,404 m,found in the San Fiorano power plant in Italy.


Milestones in history

In the past 100 years, almost 2,000Pelton turbines for more than 1,100projects were built. These have beendelivered to 55 countries around theglobe.

The largest Pelton turbines manufac-tured by Voith Siemens Hydro weresupplied to Italy’s Cimego hydropow-er station in 1953 and the US stationof New Colgate with runner diameters of 4.48 and 5.44 meters. The most powerful Pelton turbine was built in1989 and is located in San Giacomo sul Vomano, Italy, with a capacity of282.5 MW. New Colgate and San Gia-como also hold the record in bucketwidths with 1,100 and 1,030 mmrespectively.

100 years of Pelton turbines from Voith

Italy breaks the recordsVoith Riva Hydro, today a member of the Voith Siemens Hydro group, had already supplied 118 micro and small Pelton turbines between1896 and 1902.


In April 2003 the National HydroAssociation in the United States pre-sented its Technical AchievementAward to Voith Siemens Hydro Power Generation and the U.S. ArmyCorps of Engineers for the J. StromThurmond Project.

The award is presented by NHA torecognize projects that demonstratesignificant technical contributions to the hydropower industry. ColonelRoger A. Gerber, Commander, Savan-nah District accepted the award forthe U.S. Corp of Engineers and Gre-gory Snyder, Project Manager accept-ed for Voith Siemens Hydro PowerGeneration. The NHA awards com-mittee saluted the Corps of Engineersfor tackling an issue of great importto the region with a solution of equaltechnological enormity. Insufficientdissolved oxygen in southeast riversis a serious problem at many hydro-electric projects, adversely affectingaquatic life. By employing the latesttechnology from Voith Siemens Hydro,remarkable results have been realized.Since the installation of the first newaerating runner and a new turbine

control system, levels of dissolvedoxygen have significantly increasedand even exceeded expectations.Voith Siemens Hydro in York, Penn-sylvania developed and patented the aerating runner design that alsoresults in an increase in the ratedcapacity for the units.

The J. Strom Thurmond Powerhouseis located on the Savannah River inSouth Carolina, 22 miles north ofAugusta, Georgia and houses 7 hydrounits originally installed in 1953.Completion of the current rehabilita-tion is scheduled for 2006. Thepowerhouse is owned and operatedby the U.S. Army Corps of Engineers.


NHA Award to Voith Siemens Hydro

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since the interior of our Earth con-tains a lot of water in crystallizedform, as springs or as constitutedhydroxide water, this loss is compen-sated for – the total amount of wateris actually growing slightly. So muchfor the technical side of the question.

But how did human beings explain lifeand the world to themselves beforethe advent of science? Myths help usto throw light on this question. Mythsexist in every culture and are an at-tempt to paint a complete picture ofthings we cannot understand. Theirapproach is a personal one, based on the characters and moods of Godsand Goddesses, to whom humanbeings are mere playthings.

The oldest and most primordial con-ceptions are based on the assumption

From a scientific point of view thesolution is complex but logical.Hydrogen is the most abundant ele-ment in our Universe. When it en-counters oxygen, it reacts with it toform water. The cloud of primevalmineral material out of which ourEarth was formed was cold and con-tained a lot of ice. This cloud wascompressed by gravity and thus be-came very hot. The water contained in the cloud was diffused and formedgigantic clouds of vapour in theatmosphere.

After our planet had reached its finalsize and temperatures had fallenbelow 100 degrees as a result ofreduced gravitational force, water was also available in liquid form. Part of it evaporates into space andleaves our atmosphere entirely, but

This is – admittedly – a loaded question, but it can be answered in a reasonably entertaining and colourful way. Life cannot existwithout water. Let’s look for a reason to this phenomenon first.

that a snake demon living in and closely linked to the water was theorigin of all things.

In Mesopotamia this demon was called Tiamat, the Early Chaos snakethat was defeated by Marduk. Mardukcut the snake into pieces, which thenformed a division between the watersof heaven and water of lower depths.He then created human beings.

In ancient Egypt a hill emerged fromthe primeval water Nun and the holybird Ibis laid an egg that was hatchedby the heat of the sun, with the SunGod Re emerging from it.

In China, during the Han Dynasty(206 to 220 AC), people believed thateverything had been created fromwater and that everything lived and

Essay

Snakes are often essential parts of myths in many cultures

What is the origin of life?


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developed through water. Water wasomnipresent; there was nothing thatcould not be filled with water. Wateraccumulates in the sky and on theground, it is hidden in every objectand gives birth to living creatures.

One of India’s Hymns of Creation, theRigveda, puts it this way: “In the be-ginning everything was unmistakablyfloods of water.” In this primevalwater a golden egg began to develop,containing the spirit – Brahma orPurusha. From the two halves of theegg, this spirit stepped out andformed Heaven and Earth.

In the Hindu myth, the God, Vishnu,descended into the watery depths andemerged with the Earth. Even today,Buddhists and Hindus worship wateras the primeval substance.

The Papua people in New Guineabelieved that in the beginning thesurface of the Earth was covered with water. A giant tortoise swimming in this water rested on the water’sbottom. With its powerful flippers it shovelled sand upwards from theseabed, and created land.

According to a North American Indiantribe it was a crayfish that pulled the Earth up from the bottom of theocean and thus created land. For the Algonquians it was the muskrat.

In the Bible, the Book of Genesis saysthat there was darkness above theprimeval flood and the Spirit of Godmoved upon the face of the waters.The process of the world’s creationstarted by separating the water intoHeaven and Earth.

The interesting fact common to allthese myths is that our world origi-nates from watery chaos, and onlyhad to be snatched from it. Cosmo-gony is the doctrine of creation, – the story of a process of transfor-mation accompanied by enormousconflict. An uncontrolled primitivestate is transformed into a world oforder. In mythological philosophies of life, water has absolute priorityabove all other elements – it is purelyand simply the essence of life.

The fact that we use it to develop our civilizations also goes back to the beginning of time. The intelligentuse of the power in water enables us to generate energy, which in turnprovides us with all the amenities that make our life safer and morecomfortable.

For the papuas a giant tortoise created the first land


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

Editorial coordination:Barbara Fischer-Aupperle

Copyright 2003 Reproduction permitted,provided source is given.

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