hypower - voith

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.

HyPowerCustomers magazine for Voith Siemens Hydro

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March 2003

Summary

Dear clients and partners, dear readers,

The late publication of our annual year’s results fromfiscal year 2001/2002 is the right moment to reflect onhow successful Voith Siemens Hydro has been in its thirdyear of the Joint Venture. Order intake as well as saleshave exceeded expectations by far. Our ambitious goalswere fully achieved. The new year running will be anotherchallenge to meet goals in a market situation whereinvestments financing and project development are evenmore under the influence of reluctance and delays.

However, we are trustful that our strategic orientationleads to the right results: as a well-positioned companythat sees itself as a project company and with the compe-tence of a full-liner in hydro we are focusing on strongmarkets with hydro potential that can add-up remarkablyto a country’s power generation mix. You can see thisespecially in India and China. And you can see in thisissue’s market highlight on India, that our activities arewell underway. The new company in New Delhi has startedworking close to the market and has an impressive num-ber of projects going on locally that are already in ourbooks. And we expect more to come!

The co-operation agreement with FKI’s Czech SEM Brushunit will very soon enable us to provide much betteropportunities for manufacture of and service for genera-tors up to medium-sized capacities, so especially clientsin Europe will profit from the location’s workshop vicinitywith their service needs on the electrical side of themachine. Our R&D acitivities for new insulation materialsare another effort in a series of programs to achieveoptimization and control through the whole operationprocess of a hydraulic machine. At the same time, we donot neglect sophisticated solutions for smaller plants, too,in automation and control.

Service on the whole is an ever increasing share of hydrobusiness where Voith Siemens Hydro has been developingits special concept on Integrated Solutions, with itsassessment and partnering approach. Customer relation-ship, where the bottom line counts at the end of not onlyassessments but also fulfilled contracts and shortestoutage time management, as well as operation and main-tenance of hydro power plants, are only self-understoodfacets of the complete range of our services and products.

With this in mind, the newly achieved ISO 9001:2000group certification was only another logical step towardsthe completion of these services: quality, services,processes, behavior and commitment from any VoithSiemens Hydro location, wherever you go.

Last, but not least, our participation in the record projectsof Itaipu, Tucuruí, Three Gorges, and Goldisthal, as well asour latest awards in Eastern Europe and China strengthenour confidence that we will – despite severed market con-ditions – again steer our hydro business with success onthe basis of a sound financial background, our high-endtechnology and in close, trustful and reliable relationshipwith you: our customers.

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

Yours sincerely

My e-mail address is [email protected]

On the way.

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Dr. Hubert LienhardChairman of the Boardof Voith Siemens HydroPower Generation

Dr. Hubert Lienhard

Voith Siemens Hydro Power GenerationEditorial

Solutions orientationNow rendering plant operation andmaintenance services

Delivery of giant runner for Tucuruíexpansion

Customer contacts12th International Seminar on HydroPower Plants, Vienna

Events 2003

China’s largest electricity and technologyexhibitions

LocationsFacility upgrade at North Americanheadquarters

York, PA location celebrates 125 years ofinnovations in hydro power in the U.S.

ActivitiesVoith Siemens Hydro and Czech BrushSEM decide to cooperate

Voith Siemens Hydro achieves interna-tional ISO 9001:2000 group certification

EssayIndia: With Tradition into the Modern Age

EditorialOn the way

Market highlightBoosting India’s hydro electric sector

Voith Siemens Hydro in India

Guest articleNHPC: Growth and Accomplishments

High ranking visitors at the constructionsite of Baglihar in India

Market splintersRecovering the Georgian hydro powersector

Modernization contract for the Bistricahydro power station

China: The world’s highest level of hydropower development activity

Technological leadershipNew high voltage insulation will makehydro generators more efficient

Sophisticated automation even for smallhydro power plants

First pump-turbine unit of Germany’sGoldisthal pumped storage plants con-nected to the grid

Records and moreThree Gorges: One of the largest turbinerunners in the world now being installed

Itaipu: Expansion of the world’s biggestoperating hydro power plant

More intense support and interestingfinancial terms and conditions in LatinAmerica

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Market highlight

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Priority for hydro projectsSix years ago, India celebrated 100 years of hydro power develop-ment. Then and now, the installedcapacity of India’s hydro power stations represented roughly onefourth of the Indian power mix. There is an estimated potential of150,000 MW of hydro electric powerin the country, of which only 17%have been harnessed so far. Since the government clearly sees theadvantages of hydro electricity as a non-polluting and secure form ofenergy that, contrary to thermalgeneration, is virtually unsusceptibleto price fluctuations, it has given highpriority to the development of hydropower projects. Plans have beendrafted to accelerate the exploitationof the vast untapped hydro potentialand expand the hydro share to 40%.

Electricity is the backbone of modern life in the industrialized world, a crucial ingredient for economic growth. A reliable and sufficient supply ofelectrical power is essential to guarantee India’s economic development.Today, India suffers from a 13% peak load shortage and projections foreseea dramatic increase in energy demand. To bridge the gap between demandand supply, total installed capacities will have to be doubled by 2012 toabout 210,000 MW. Boosting the hydro power capacities plays a prominentrole in the ambitious plan of the Indian government to achieve this goal.

Decisive role of public corporationsMajor hydro power projects targetedfor development are concentrated inthe Northern and Northeasternregions of the Indian subcontinent.Almost two thirds of India’s newhydro projects, totalling 21,000 MWof capacity addition, shall be under-taken by public corporations of theCentral Sector (federal government)until 2012. The remaining share ofplanned capacity addition will bedivided almost equally among privatecompanies and corporations of therespective state governments. Furthermore, the Ministry of Powerhas included 67 rehabilitation, mod-ernization and upgrade schemes with an aggregate capacity of over 10,000 MW in the 10th five-year plan (2002 to 2007).

Establishing a local unit, thus guaran-teeing easy access to local resourcesand know-how, has been consistentwith the continuous intensification ofVoith Siemens Hydro’s activities inIndia.

Voith Siemens Hydro India team

Voith Siemens Hydro in IndiaLast October, Voith Siemens Hydro’s Indian subsidiary started its businessoperations as a private limited company in New Delhi. This step has defi-nitely brought the company much closer to its customers. Moreover, it hasfacilitated the important transfer of Voith Siemens Hydro expertise consid-erably. Under the leadership of Vijaynagar Prahlada Rao, Managing Direc-tor, the Indian team can now follow up the different projects from the Indiancapital.

Vijaynagar PrahladaRao, ManagingDirector

Voith Siemens Hydro Office in Delhi

Boosting India’s hydro electric sector: Power on demand by 2012

Baglihar area

Market highlight

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GhatgarVoith Siemens Hydro is charged withthe electrical and mechanical worksfor the two Ghatgar 125 MW pumpedstorage units in Maharashtra state.

Nathpa JhakriThe 1,500 MW Nathpa Jhakri hydroelectric project is an undergroundpower station consisting of six unitsof 250 MW each. Voith SiemensHydro is a member of the EUCONAconsortium group, which is responsi-ble for the electrical and mechanicalworks of the project.

For more information: [email protected]

Baglihar area Hirakud contract signing Burla machine viewBhira site erection Bhivpuri inside view

The company has been involved in several key projects on the subcontinent:

BagliharThe first 450 MW stage of the 900 MWBaglihar hydro power plant is current-ly being set up in the Northern Indianstate of Jammu and Kashmir. VoithSiemens Hydro is the leader of theconsortium responsible for theturnkey execution of the electrical andmechanical works. Erection of embed-ded parts and development of theinfrastructure as well as civil worksare already under way. The first stageof the project, consisting of three 150 MW units, is due for commis-sioning by the end of December, 2004.The remaining units of the secondstage shall be put into operation twoyears thereafter.

HirakudTwo units of 24 MW each of theHirakud hydro power plant are nowbeing renovated and uprated to 32 MW each. Voith Siemens Hydro isthe turnkey contractor and has beenentrusted with the complete responsi-bility for all mechanical/electrical andassociated civil works for this project.Commissioning of the uprated units is planned for the end of October,2004.

Baspa Stage IIVoith Siemens Hydro has suppliedthe generators and the associatedelectrical equipment for the BaspaStage II 300 MW project. The projectis due for commissioning early in2003. Baspa II is a good example ofdeveloping a project together with aprivate promoter, Jaiprakash Indus-tries Ltd., who also executes all thecivil works.

Hirakud 48 MW (64 MW) R&M

Ghatgar 2 x125 MW

Bhira 150 MW

Baglihar I 450 MWBaglihar II 450 MW

Baspa 300 MWNathpa Jhakri 1500 MWSrinagar 330 MW

Bhivpuri /Khopoli72 MW/72 MW

Nepal

Bangladesh

Sri Lanka

China

Bhutan

Afghanistan

Pakistan

Myanmar(Burma)

Thailand

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Important steps during the last 5 years which have raised NHPC to the top of its field

Elimination of time and cost overrun: NHPC eliminates time & cost overrunin the implementation of hydro powerprojects through the use of effectivecontract management & project mon-itoring. As a result, all of NHPC’songoing projects are running onschedule or ahead of schedule. Expansion Plan: NHPC has undertaken a large numberof medium, large and mega size pro-jects for investigation & construction.During the Xth Plan (2002-2007) itplans to complete 11 projects with ayield of 4,357 MW, during the XIthPlan (2007-2012), 14 projects with ayield of 11,194 MW, and during XIIthplan (2012-2017), it plans to add13,000 MW.Aggressive project monitoring: A professionally managed MIS hasbeen put into place for the pro-active

To date, NHPC has added 2,175 MWof generating capacity to the coun-try’s power system, and is supplyingpower to 23 beneficiary federal statesand union territories, in addition toneighboring countries like Nepal andBhutan. During the years 2001-2002,NHPC achieved 96.86% machineavailability in the plants it operates:the highest level ever reached in thecorporation’s history.

In its over 27 years of existence, the National Hydroelectric Power Corpora-tion (NHPC) has become the single largest organization for hydro powerdevelopment in India, with the capacity to undertake all of the activitiesinvolved in administering hydro projects, from conceptualization to commis-sioning. NHPC, a public limited corporation, ranks among the top ten com-panies in the country in terms of investments. It has been granted ISO-9001and ISO-14000 certifications.

NHPC: Growth and accomplishmentsmonitoring of program implementa-tion, resulting in on-time decisionmaking.Emphasis on information, technology, and communication: Major emphasis has been placed on the use of state-of-the-art informa-tion technology solutions in NHPC’sprojects to achieve a smooth, uninter-rupted and faster flow of information.Since NHPC’s projects are situated inremote, hilly areas, this has donewonders for project implementationand crisis resolution.Human Resource Development:Special emphasis is being given to thefield of human resource development.The officers and staff of NHPC areregularly sent to various training pro-grams and seminars, both within thecountry and abroad, to keep them upto date on the latest technologies onthe market. Expansion through joint ventures:NHPC has started subsidiary compa-nies under its joint venture plan, incooperation with state governments,for the development of hydro &pumped storage projects in MadyaPradesh and West Bengal, which wereon hold due to a lack of availablefunds and of necessary expertisefrom state executive agencies.

Basin-centered development: In order to coordinate time & efforts,NHPC has been implementing basin-centered development in areas suchas the Ravi basin, the Parbati basin,the Chenab basin, the Teesta basinand the Siang & Subansiri basins.

The corporation currently has sixprojects under construction, with acapacity of 2,280 MW. In addition,two projects are being constructedas joint ventures, with a capacity of 1,520 MW, and two projects on adeposit/turnkey basis with a capacityof 65,25 MW.

NHPC has drawn up a massive capac-ity addition plan for the hydro sector,extending up to 2017:

Guest article

Yogendra Prasad,Chairman of National HydroPower Corporation (NHPC)Faridabad, Haryana, India

Projects to be completed in X plan (2002 - 2007)Sl. Project (state) Total No Capacity

(MW)1 Dulhasti (J & K) 3902 Chamera – II (HP) 3003 Dhauliganga – I (UP) 2804 Teesta – V (Sikkim) 5105 Sewa – II (J & K) 1206 Bav – II (Maharashtra) 377 Indira sagar (NHDC) (M.P.)* 1,0008 Teesta low dam stage – III (WB) 1329 Omkareshwar (NHDC) (M.P.)* 520

10 Purulia pss (W.B.)* 90011 Teesta low dam stage – IV (WB) 168

Total 4,357* Joint Venture

Initiatives & SuggestionsSome of the initiatives taken by NHPCfor hydropower development in thecountry:

NHPC has taken advance action tocreate a range of bankable DPR’s fora number of viable hydro projects,which will help in the projects’ earlyphases.Conducting a survey & investigationof mega projects in Dihang & Suban-siri Basin in Arunachal Pradesh,which will have an installed capacityof more than 20,000 MW.

NHPC has started subsidiary compa-nies under its joint venture plan incooperation with state governmentsfor the development of hydro &pumped storage projects in M.P andWest Bengal, which were on hold dueto a lack of available funds and ofnecessary expertise from state execu-tive agencies.

NHPC has taken up projects whichhad long been pending due to inter-state disputes. These include fourprojects in the Cauvery basin with acapacity of 1,150 MW, and the UpperKrishna projects with a capacity of810 MW in Karnataka.NHPC commissioned the first hydro-electric project in the A & N Islands inAugust 2001.

NHPC is eliminating time & cost over-run in the implementation of hydropower projects through the use ofeffective contract management & pro-ject monitoring. This sends a positive signal to policy-& decision-makers that hydro pro-jects can be completed within a fixedtime frame.Professionally-managed MIS has beeninstituted for the pro-active monitor-ing of program implementation.The general atmosphere of the corpo-ration has been made conducive tofaster decision-making, with a profes-sional approach which will movethings in right direction. Empoweringemployees with latest technologies intheir respective fields has also helpedin dealing with the unique problemsassociated with hydro projects.

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Guest article

In order to ensure that the maximumcapacity of hydro power is added tothe national power system, NHPCsuggests:

Fixing a strict time frame for variousagencies involved in grantingapproval/clearance, and at the sametime reducing the time limit for allsuch approvals.Adopting a three-stage clearanceprocedure for hydro project clear-ance.Making dedicated funding available inagreed-upon installments.Implementing a national policy for thesettlement of R&R plans.Shifting security costs, especially inultra-infested areas, to central andstate governments, rather than addingthem to the project costs and ulti-mately to the tariff.Simplifying land acquisition proce-dures.

Challenges facing India’s hydro sector‘State of the art’ technology is nowrequired in place of conventional tech-nology in order to accomplish bettersite investigation & to deal with geo-logical surprises.

Better desilting arrangements areneeded, as well as erosion-resistantmaterial for the underwater portionsof turbines.A high voltage network connected tothe national grid to bring emergencypower to power-starved regions is tobe taken up on priority basis.Standardization of features & equip-ment for hydro projects is not possi-ble.The young Himalayas are very unsta-ble mountains. Underground facilitiesin these mountains require the high-est level of expertise and the courageto face all challenges. Silt-laden river water flows out ofyoung Himalayan rivers.Transmission problems occur fromthe northeastern region due to Chicken Neck.

In spite of the above challenges, thedevelopment of hydro power is a tech-nical necessity for attaining the idealhydro : thermal mix of 40:60 for pro-viding quality power. Now, with theshift in focus towards hydro power,NHPC is prepared to harness the vastuntapped hydro potential of India.

Projects to be completed in XI plan (2007 - 2012)Sl. Project (state) Total No Capacity

(MW)1 Parbati – II (H.P) 8002 Parbati – III (H.P) 5203 Chamera – III 2314 Siang middle site 1,000

(Arunachal Pradesh)5 Siang lower site 1,700

(Arunachal Pradesh)6 Subansiri middle 1,600

(Arunachal Pradesh)7 Pakal dul (J & K) 1,0008 Bursur (J & K) 1,0209 Subansiri lower 2,000

(Arunachal Pradesh)10 Loktak D/S (Manipur) 9011 Uri – II (J & K) 28012 Bav – I (Maharashtra) 1813 Farakka Barrage (WB) 12514 Upper Krishna projects 810

(Karnataka)Total 11,194

Projects to be completed in XII plan (2012 - 2017) TentativeSl. NoProject (state) Total

Capacity (MW)

1 Siang upper site 11,000(Arunachal Pradesh)

2 Subansiri upper site 2,000(Arunachal Pradesh)Total 13,000

High ranking visitors at the construction site of Baglihar in IndiaRecently the Chief Minister of Jammu and Kashmir, Mufti MohammedSayeed and the Chairman, Coordination Committee Ghulam Nabi Azad, paida visit to the construction site of India’s Baglihar hydro power station. Hewas accompanied by the Deputy Chief Minster Mangat Ram Sharma and theMinister for Power Development Mohammed Sharief Niaz as well as furthergovernmental representatives. Voith Siemens Hydro participated withJuergen Sehnbruch, Member of the Board of Management, and Karl-HeinzSchmidt, Project Manager for Baglihar.

The Chief Minister, while inspectingthe execution of work, expressed hissatisfaction over the pace of execu-tion. This 900 MW hydro powerstation will be built in two stages:450 MW should be commissioned byend of 2005, while the second phasewill be completed by end of 2007. Theconstruction site also provides jobs inthe region: nearly 4000 employees arelocals.

After the commissioning of Baglihar,the State of Jammu and Kashmir willbe self sufficient in power and becomean ideal place for setting up indus-tries as the State has an attractivepackage of incentives, both from theState and the Central Governments.The Indian State of Jammu andKashmir has a hydro power potentialof 20,000 MW out of which only1,500 MW have been tapped.

Dignitaries visiting Baglihar hydro electric project

Voith Siemens Hydro Power Genera-tion, as consortium leader, signedcontracts on 17th of July 2002, forsupply of the electro-mechanicalworks for the second stage. Oncecommissioned this will be the largestpower station set up in the IndianState of Jammu and Kashmir andtherefore gives a considerably contri-bution to the power generation forthe total State of India.


Baglihar site view

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Voith Siemens Hydro modernizesGeorgia’s largest hydro plant The Enguri hydro power plant willnow undergo extensive modernizationwork in three of its five units, whichhave an output of 306 MVA each.Modernization work includes design,supervision, erection and commis-sioning of electro-mechanical equip-ment, such as new water-cooledgenerator stator windings, statorcore, re-insulation and cooler, as wellas digital and hydraulic governors andthe inlet valve control systems. Thevoltage regulator and excitation, thegenerator circuit breaker and discon-

As a result, Georgia’s hydro powergeneration facilities invariably requirerehabilitation. The five largest plantsaccount for more than two thirds ofthe country’s total hydro powercapacity. The largest of them is locat-ed in the western province of Abk-hazia on the Enguri River, which isfed by the glaciers of the southernCaucasus. This underground hydropower station has the world’s largestarch concrete dam.

Until the mid 1990s, Georgia had one of the fastest growing economiesamong the former Soviet Republics and nearly 5,000 MW of installed powergeneration capacity, about 60% of it hydro electric. However, politicaldisturbances in the Caucasian state have led to serious economic problems.Due to these difficulties, fuel for thermal power plants has become increas-ingly hard to afford and hydro power stations have started to produce aneven larger share of the total electric energy. The CIA World Factbook forthe year 2000 indicates an annual gross generation of 7,404 GWh, whereby21% is thermal and 79% hydro. Regardless, service and maintenance havebeen neglected for years.

Recovering the Georgian hydro power sector

nector, as well as the systems formedium and low voltage switchgear,the battery, and the compressed airand drainage systems will also beupgraded. Furthermore, plant employ-ees will be trained “on the job” foroptimized operation and control of theunits. Unit 3, which was dismantled in1991 and has been out of order eversince, will be the first unit to be com-pleted. Its completion is scheduledfor early in the second half of 2004.

Within a period of 26 months thescope of supply for Voith SiemensHydro Power Generation covers themodernization of the equipment ofBistrica 1, including hydraulic steelstructure, penstocks with butterflyvalves, three Francis turbines withan output of 8 MW each, generators,turbine governors, automation andcontrol as well as mechanical andelectrical auxiliary equipment.

Voith Siemens Hydro is the consor-tium leader. Apart from the modern-ization, the establishment of a 110 kVtransmission line, substations in the

Voith Siemens Hydro Power Generation, St. Poelten,Austria, in consortium with Siemens, Greece, recentlyreceived a modernization contract for the hydro powerstations Bistrica 1 and 2. The total volume of order is18 million Euro.

Modernization contract for the Bistrica hydro power station

Market splinters

David Mirtskhulava, Minister of Energy, in TV interview

Levan Mebonia, Director ofEngurihesi Ltd. signing contract

Levan Mebonia handing overthe signed contract to ClausSchmitt, Voith SiemensHydro, under applause ofDavid Mirtskhulava

The modernization of the Georgianplant by order of the state-run com-pany Engurihesi Ltd. is financed bythe European Bank for Reconstructionand Development, with co-financingfrom the European Union. The execu-tion will be managed by the EnguriRehabilitation Project ImplementationUnit (PIU), established by the Bank,and supervised by the French Elec-tricité de France as the IndependentEngineer. It will essentially contributeto the stability of the electricity sup-ply in Georgia.


South Albanian cities Sarande andGjirokaster, as well as modernizationof the distribution network in Sarandewere assigned to the consortium. Theplants are operated by the Albanianpower supplier Korporata Elektroen-ergjetike Shqiptare.

The modernization of the hydropower station enables future reliableelectricity supply to approximately300,000 inhabitants in the sourround-ing area of Sarande.


Inside view of power housecavern with unit 3 alreadydismantled

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with its foreseen world record outputof 18,200 MW. When fully commis-sioned in 2009, it will supply morethan 100 million people and industryin the coastal areas of South-eastChina.

Voith Siemens Hydro deeply involvedThrough its Chinese joint venturecompany Shanghai Hydro-PowerEquipment Company Ltd. (SHEC),Voith Siemens Hydro is deeplyinvolved in this project, delivering thelargest turbine runners and statorframes ever manufactured. ThreeGorges will spare the environment100 million tons of carbon dioxideand 2 million tons of sulphur dioxide,which would be released annually ifthe corresponding energy were to beproduced from coal.

Considering this breathtaking pace,hardly any country has increased itshydro power generation capacityfaster. Still today, only one fifth ofChina’s vast feasible hydro powerpotential is being utilized. As airpollution worsens due to the tradi-tionally overwhelming share of coal-fired power plants in the electricityproduction, environmental awarenessis on the rise. The Chinese govern-ment therefore plans to increase thehydro power sector by 8% annually.

Efforts to significantly expand thegeneration of emission-free hydroelectricity are already under way.There are several major hydro electricprojects presently under construction.The biggest of them is the ThreeGorges plant on the Yangtze River

With a total installed capacity that reached 319 GW in 2000 andan electricity production of 1350 TWh, the Chinese power sectoris the second largest in the world, right after the United States.Currently, hydro power in China accounts for roughly 16% of thegenerated electricity. This share of the total power mix may seemsmall when compared to the prominent role hydro power is playingin countries like Brazil, Canada or Norway. And actually, the por-tion of hydro electric power in China was as high as 20% in 1980.But the Chinese power sector has more than quadrupled its capacity since then.

The Taian pumped storage plantVoith Siemens Hydro’s most recentproject in China is the Taian pumped-storage plant in the province of Shan-dong in cooperation with Japan’sMarubeni Corporation. This plant willbe equipped with four Francis-typereversible units, each with a capacityof 250 MW. Voith Siemens Hydro willsupply the pump-turbines, motor-generators and a computer superviso-ry and control system.

With financing provided by the JapanBank for International Cooperation,and following a public bidding open-ing on June 12, 2002, the contractwas awarded to Marubeni Corporationof Japan as prime contractor andVoith Siemens Hydro Power Genera-tion as the manufacturer of the foursets of complete units for this impor-tant project.

At the official contract signing cere-mony on Nov. 29, 2002, in Beijing,Voith Siemens Hydro was representedby Voith Fuji Hydro of Kawasaki, Japan– supplier of the electrical portion –,Voith Siemens Hydro of Shanghai,China, – supplier of the mechanicalportion – and the company’s Germanbusiness unit – supplier of the Com-puter Supervisory Control System.

The first unit is planned to be com-missioned in the beginning of 2007.

This most recent cooperation between Voith Siemens Hydro andMarubeni Corporation confirms theimportance of the company’s Japan-ese unit, Voith Fuji Hydro in Kawasa-ki, Japan and follows a number ofearlier successes of Voith SiemensHydro in large international hydroprojects in Asia.

Market splinters

Voith Siemens Hydro turbines for 4,900 MW Hydro Project Longtanin ChinaVoith Siemens Hydro Power Genera-tion, in a consortium led by DongFang Electrical Machinery Company,has been selected to supply the seven700 MW, 140 m head Francis turbinesfor the Longtan hydro-electric projectin Guangxi Province, China.

The turbine contract, which wassigned on January 22, 2003 by repre-sentatives of Voith Siemens Hydro –Shanghai and Dong Fang, has anorder volume of US$ 81 million, withthe two consortium partners havingapproximately equal shares.

Voith Siemens Hydro as part of itsscope in this project will provide thedesign, supply part of the turbinesfrom its Shanghai facility, and willmanage the site-manufacture of five

of the seven runners. Since the sizeof these 8 m turbine runners exceedsthe transport limitations to the projectlocation, they will be manufactured ina specially erected facility at the pro-ject site.

Dong Fang will manufacture thebalance of the equipment.

The Longtan project, located onHongshui River, a tributary of thePearl River, will be among the world’slargest hydro-power projects. Theproject is internally financed in China.

Following start of generation at Long-tan in 2007 the energy from thisproject will be transmitted to Guang-dong, Hong Kong and to Guangxi.


The Longtan project team of VoithSiemens Hydro: Huang Qing, Fu Huawei,Goetz Pfaefflin and Tang Xu.Longtan areaNegotiations Longtan

Contract signing Taian

China: The world’s highest level ofhydro power development activity

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New high voltage insulation will make hydro generators

more efficient

The most important insulated compo-nent of a high voltage machine is thestator winding, particularly its barsand coils. Even under normal operat-ing conditions, the mechanical andthermal stress on the insulated partsis quite high. Vibrations and disparateexpansion rates of the copper and theinsulating material due to poweroutput changes require an insulationsystem with high resistance qualities.This is especially true for combinedmotor-generators in pumped storageplants where turbine and pump modeschange frequently. Moreover, theintra-winding current during failurescan cause extraordinarily high mag-netic forces, and possible machineoverloads place high demands onthermal resistance.

Technological leadership

Bildlegende

Effective insulation is of vital impor-tance for the stator bars and coils,and for the functioning of the wholegenerator unit. For decades, MICA-LASTIC, a bubble-free and homoge-neous insulation system, has guaran-teed a long life to the winding compo-nents with its high 1-minute break-down voltage of about 30 kV/mm.After 2 years of development work,Voith Siemens Hydro engineers haveimproved the MICALASTIC productionprocess and optimized the materialsused, thus significantly increasing thesupportable dielectric strength. As aresult, the ground wall thickness ofthis new MICALASTIC Advanced insu-lation can be reduced by 15% whilemaintaining the high breakdownstrength of the traditional system.

The other outstanding characteristicsof MICALASTIC, such as a lifeexpectancy of about 40 years underreal operating conditions, a low dissi-pation factor, and thermal resistancemeeting the standards of IEC 34class F, remain unchanged as well.

New MICALASTIC Advanced hasalready proven to be a key factor inthe production of smaller and moreefficient machines. In a case study,Voith Siemens Hydro engineers com-pared the performance of two basical-ly identical generators, one equippedwith the traditional system, one withMICALASTIC Advanced. The findingswere more than promising: While allperformance parameters, includingefficiency and power output, proved

to be the same, the generator de-signed using the new insulation isabout 8% lighter. Furthermore, therespective costs have been reducedby 7% compared to the traditionallyequipped machine.

MICALASTIC Advanced is the firststep towards a whole new generationof high tech insulation systems. Theprospects for this high performanceinsulator are bright. Combined withmodern basic designs for hydro gen-erators, it will make possible the pro-duction of smaller and more efficientmachines. MICALASTIC Advancedwill be officially released soon.


When it comes to high voltage hydro generators, there is a constantlygrowing demand for higher power outputs. At the same time, machinesof reduced weight and size are increasingly called for. Developingsmaller and lighter generators that nevertheless offer the same or evena higher power output is quite an engineering challenge. With thedevelopment of an advanced high performance insulation system basedon the highly-rated MICALASTIC standard, Voith Siemens Hydro hasfound a way to substantially enhance the power-per-weight and thepower-per-size ratio while leaving the total power output unchanged.

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Modern technology for smallerpower plantsThe SWU Energie contract includesthe installation of a new controlsystem in one further hydro powerplant as well as the option for twofurther plants on the Danube and theIller canal. A contract of this sort isalmost unprecedented. Up to now itwas thought unprofitable to fit smalland medium sized hydro power plantswith sophisticated automation sys-tems that include modules for opti-mized operation and interfacing toremote control systems. The VoithSiemens Hydro Control System nowmakes it possible to operate even

small plants in a fully automated wayincluding optimization modules likethey are known for large hydro powerplants only. Furthermore, VoithSiemens Hydro through a close co-operation in partnership with SWUEnergie GmbH, has found a way toreduce the installation costs effective-ly. After a joint, precise planningphase the complete installation of thecontrol system was carried out byqualified power plant staff. Moreover,under the guidance of the VoithSiemens engineers the staff memberscould gain profound knowledge ofthe system.


Power house Donaustetten

A challenge for the specialists The pre-requisites for this project atthe Donaustetten power plant wereanything but ideal. The technicalequipment for instance the rollerpump was not immediately suitablefor conversion to a modern, digitalcontrol system. They had to be fittedwith two Voith Siemens moving coilswith integrated servomotors. Theexisting governor system also causedproblems in speed control mode sincethe time needed from unit start upuntil closing of the circuit breakerwas quite long. Furthermore, thecurves for the gate blade relationshipwere not available and had to beinitially measured from the runningmachinery using a special measuringmethod.

Using Voith Siemens Hydro know-how to reach a solutionTo control the existing machineryeach machine was equipped with anautomation system including a digitalgovernor. The automation system isconstantly exchanging data with acommon control unit. This unit con-trols the common functions of theplant: for instance the interfacing to atelecontrol center which provides thecommon control unit of the powerplant with required setpoints for thelevel and the flow. This information isprocessed in the common unit withthe joint control function whichcalculates the number of machines

necessary to realize the demandedflow or level. The output of start andstop commands to each machine isalso carried out by the joint controlmodule. Moreover, a new monitoringsystem is installed. All analoguevalues are stored and their behaviouras a function of time can be dis-played. All event and alarm messagesare stored, can be displayed andreports can be generated. Further-more this monitoring system enablesfaster reactions in the event of prob-lems because remote diagnosis andoperation can be carried out bymodem via this unit.

The successful modernization of the German hydro powerplant at Donaustetten marks the first result of the cooperationbetween SWU Energie GmbH and Voith Siemens Hydro. Thepartners are thus taking a new path in project planning andrealization: engineering is done by the contractor; installationwork is carried out by the customer. This also allows to equipsmaller power plants with modern control system technologyfor an optimized and cost-efficient operation.

Results and future prospectsEven shortly after the initial start-upof the new control system in Donau-stetten positive results can be seen.The common control system not onlyprocesses the instructions of thetelecontrol center but also calculatesboth the most favorable load parti-tioning among the automated unitsand the most efficient relationshipbetween blade and gate using itsoptimization modules. These opti-mization measures enable constantoperation within the optimum effi-ciency range and thus result in asignificantly increased annual output.


Sophisticated automation even for small hydro power plants

Georg Schneider, Head ofSection Power Plants of SWU Energie in front of newautomation unit

Regulating unit after renovation


A consortium, in which Voith SiemensHydro Power Generation is responsi-ble particularly for the hydraulicdesign and the complete control sys-tem, including the technology ofvariable-speed turbine regulation intwo of four machines, supplied thehydro-electric machines. Technologi-cally speaking, Goldisthal sets newinternational state-of-the-art stan-dards in several aspects. The giganticmachines can be synchronized to thegrid from standstill to full power inrecord time in world comparison.

A novelty for European pumped-stor-age plants: Two of the four machinesaccomplish so-called “variable-speed”operation and for this reason varia-tions in the electrical grid are by farbetter to balance than with formerpump-turbine units.

The first of four pump-turbine units with an output of 265 MW each of theGoldisthal pumped-storage plant in Thuringia has started commercial opera-tion. Numerous guests from public authorities and from industry witnessedThuringia’s Minister of Economy, Franz Schuster, starting the 600 tonmachine with a push of button. After five years of manufacture and installa-tion and a series of function tests during commissioning, the most efficientand most modern pumped-storage plant in Europe was activated.

First pump-turbine unit of one of the most modern European pumped storage plants

connected to the grid

Voith Siemens Hydro is more thanpleased with the operation: “Ourmachine runs as quietly as a sewingmachine” said Managing DirectorArno Hoepner, “certain operatingmode conditions are so quietly passedthrough that you can hardly hear thechange”. Voith Siemens Hydro alsoprovides latest state-of-the-art tech-nology in control and automation: The Goldisthal control centre is themost modern one in the world’s hydropower stations.


Goldisthal installation

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Records and more

Three Gorges runner

One of the largest turbine runners in the world now being installed

A giant turbine runner manufactured at SHEC, the jointventure of Voith Siemens Hydro in China, is currentlybeing installed at the Three Gorges construction site onthe Chinese Yangtze River. After a 10-day trek that start-ed at the manufacturing facility in Shanghai, the runnerarrived at the site on December 11th. It has a maximumdiameter of 10.07 meters and weighs 416 tons – thesame weight as 381 Volkswagen Golf cars. The energythat the Three Gorges hydro power plant will produceafter completion in 2009 will equal the output of approx-imately 15 nuclear power stations.

Revealing ceremony

The runner in all itsmagnificence together withSHEC employees

Distinguished guests attendingthe ceremony

Dr. Roth, President of SHEC speakingat the runner delivery ceremony

For more information:[email protected]

When the two new generator unitsenter operation, in February and May2004, the power plant will have suffi-cient energy available to supply acity of three million inhabitants.Though, when fully erected in 2009,the Chinese Three Gorges project onthe Yangtze will surpass Itaipu interms of total installed capacity, the

The new turbine runners are currentlybeing manufactured at Voith SiemensHydro in Brazil. They will be deliveredin the first half of this year and havethe same characteristics as thoseinstalled at the beginning of the plant’sconstruction. The Voith-manufacturedmachines already installed at theplant have made an essential contri-bution to the plant’s outstandingoperational performance. Itaipu’sindexes of availability, forced unavail-ability and the low failure rates of itsgenerator units are international ref-erence points. It didn’t come as a sur-prise that the bi-national plant ownerdemanded similar machines not onlyfor reasons of standardization.

Records and more

Almost 19 years ago, on May 5th, 1984, the first of the 18 initially plannedgeneration units was synchronized: Itaipu hydro power plant, located on theParaná river on the Brazilian-Paraguayan border, started operation. Whenthe 18th unit was commissioned in April 1991, Itaipu’s installed capacitytotalled 12,600 MW, which made it the largest hydroelectric power plant inthe world. It still is today. Nevertheless, expansion works are under way toinstall another two turbines and raise the total capacity to 14,000 MW.Voith Siemens Hydro, which already supplied more than 50% of the originalequipment, will also supply these two additional 700 MW machines.

Expansion of the world’s biggest operating hydro power plant

South American power station willremain unrivaled in its annual energyproduction. Expectations are that,with all 20 machines in operation andfavorable hydrological conditions,Itaipu can attain an annual productionof almost 100 million MWh comparedto the estimated 84 million MWhconsidered possible for Three Gorges.

Consulting and support Already in the pre-project phases, thecustomers will profit from distinctlymore comprehensive project consult-ing and support. Seminars, work-shops, and presentations can thus bespecifically tailored to the existingdemands. Also in smaller countries,where Voith Siemens Hydro does notyet have a local branch, this newstandard is to be guaranteed throughcooperation with the individualSiemens companies in each country.

During the past fiscal year, Voith Siemens Hydro remained themarket leader in Brazil, the largest South American water-powermarket. Now, the company will be increasing its activities in theother Latin American countries, too.

More intense support and interesting financial terms

and conditions in Latin America

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Excellent financial terms and conditionsIn addition, it was possible to gainsupport for Voith Siemens Hydro pro-jects throughout all of Latin Americafrom the Brazilian state developmentbank BNDES (Banco Nacional deDesenvolvimento Econômico e Social),and from the credit insurer SBCE(Seguradora Brasileira de Crédito àExportação). Specifically for the LatinAmerican customers, the financialpossibilities are thus extremely

Voith Siemens Hydro representatives of Latin America

Voith Siemens Hydro in São Paulo, Brazil

attractive. Voith Siemens Hydro wasable to announce this piece of goodnews last November in São Paulo,during a 4-day conference of its re-presentatives from all Latin Americancountries. The conference served toreflect on the progress of customersupport and analyze the specific needsof clients in Latin America. It will nowtake place annually.


Itaipu runnertransportation

Excellent teamwork and new tech-nologies used in the manufacturingprocess insured the runner’s extraor-dinary quality. The fully milled buck-ets guarantee perfect erection andhomology between the model and theprototype. A porosity index of virtual-ly zero was achieved through theremoval of the surface region that isalways more susceptible to pores.In addition to the superior quality,the application of these new manu-facturing technologies resulted inshorter manufacturing cycles andlower costs.

The 4,240 MW Tucuruí hydro powerplant is currently being expanded.Located on the Tocantins River in theBrazilian state of Pará, the powerstation utilizes a reservoir 80% biggerthan that of the world’s biggest oper-ating plant, Itaipu. In this phase,Voith Siemens Hydro is responsiblefor the supply of three runner/shaftsets. The other two sets will be deliv-ered in November 2003 and 2004,respectively.


Tucuruí hydropower plant

Delivery of giant runner for Tucuruí expansion

At the end of 2002, Voith Siemens Hydro delivered therunner of Unit 15 for the Brazilian Tucuruí power station.With its impressive weight of 250 tons, it is the secondheaviest runner ever manufactured by the company.

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With the outsourcing of the operationand maintenance services, the plantowner directly benefits from thevaluable know how and the techno-logical expertise of Voith SiemensHydro, the company that has devel-oped and manufactured the respectivemachines. There is no one else whoknows the plant as intimately. VoithSiemens Hydro’s operation and ser-vice team consists of highly experi-enced personnel. The service teamlocated in the power plant, will con-stantly be in contact with the engi-neering staff in São Paulo that will

The first plant operation and maintenance contract has just been signed forthe Jauru hydro power plant, located in the Brazilian state of Mato Grosso.The plant, equipped with Voith Siemens Hydro technology, has three generat-ing units with a total capacity of 118 MW.

Voith Siemens Hydro São Paulo now rendering plant operation

and maintenance services

support them in determining theplant’s ideal operation parametersand optimizing maintenance.

The client can be completely sure ofoptimum operation and ideal machinemaintenance, which will keep thecosts for unscheduled service repairslow and the plant’s life expectancyhigh.

Solutions orientation

Jauru hydro power plant

Tucuruís runner transportation

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Along with the increasing significanceof environmentally-relevant subjectsin recent times, interest in corre-sponding solutions has been growingas well. Consequently, Voith SiemensHydro’s information regarding theThree Gorges Project attracted theinterest of several hundred delegates,including the senior executives ofState Power, one of the major spon-sors of the exhibition. All told, theVoith Siemens Hydro booth in theGerman pavilion offered an excellentplatform for the exchange of technicalknowledge.


In November 2002, China hosted twolarge electrical apparatus and exper-tise exhibitions – the 9th InternationalExhibition of Electrical Power Equip-ment and Technology (EP China 2002)and the 2nd International Exhibitionof Electrical Engineering, ElectricalEquipment and Contractors’ Supplies(Electrical China 2002). Voith SiemensHydro presented its newest develop-ments and projects alongside otherinternationally leading companies inBeijing’s China International Exhibi-tion Center.

Night scenery of the entrance to Beijing’s forbidden city SHEC booth view

The 12th International Seminar onHydro Power Plants took place at theTechnische Universität in Vienna onNovember 27-29 of this past year.The event’s coordinators welcomed atotal of 150 delegates from 14 nationsto the conference, which offered atwo-day forum for exchanging infor-mation and ideas in various fields ofhydro power.

In his paper, Helmut Buchmaier ofVoith Siemens Hydro presented thelatest developments relating to theconference’s main theme, “Safety andRisks of Hydro Power Plants”. Hehighlighted considerations relating tothe typical run-away speed behaviorof Kaplan turbines. Based on theinformation which he provided, it ispossible to apply more differentiatedcriteria to the dimensioning of therotating parts of generator-turbineunits, rather than simply using themaximum possible speed withouttaking its influence on the total loadinto consideration.

Customer contacts

Events 2003

Waterpower in Buffalo, N.Y., USA29-31 July, 2003Booth 810

2003 Annual Conference 6-9 April, 2003 National HydroAssociationWashington, USA

Montreal 2003,ICOLD16-20 June, 2003Montreal, CanadaPeninsula 213/312

Hydro 2003 Dubrovnik,Croatia3-6 November, 2003Booth 54-55

A focal point of interest at China’s largest electricity

and technology exhibitions

12th International Seminar on Hydro Power Plants, Vienna: Voith Siemens Hydro

presents new developments

Locations

Upgrade work on the facilities at theNorth American headquarters in York,Pennsylvania, USA are well underway.Voith Siemens Hydro’s commitmentto the North American market isreflected in the continuation of theupgrade and renovation project whichbegan when the Voith company pur-chased the facilities in 1986. Thecurrent modernization of the build-ings will not only improve their over-all appearance, it will also create amore energy-efficient environmentfor the almost 400 employees whowork there.

As an environmentally sensitive com-pany, Voith Siemens Hydro wants tosubstantially increase the insulationof the factory walls, which will greatlyreduce the amount of natural gas con-sumed in heating the factory, andconserve natural resources. The finalphase will be completed soon. Onyour next visit to York, please stop inand provide your comments on ourproject.

Facility upgrade at North American headquarters

Building site 1952 Building frame 1952 Building 1953

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York, PA

In October 2002, Voith SiemensHydro celebrated the 125th anniver-sary of its York-based U.S. subsidiarywith a open house for its employeesand invited guests. For more than acentury, this company based in Penn-sylvania has stood for ground break-ing developments in turbine and gen-erator design. This drive for innova-tion has helped it to become one ofNorth America’s largest engineeringand manufacturing centers devotedto the production of hydroelectricequipment.

York, PA location celebrates 125 years of innovations

in hydro power in the U.S.

The York facility, which serves asVoith Siemens Hydro’s North Ameri-can headquarters, is the only turbinespecialist in the U.S. with a centerfor continued hydroelectric research.It has spearheaded hydro powerprojects around the world and NorthAmerica, including work with theRobert Moses /Niagara Project andthe Bonneville Dam Project on theColumbia River.


At the end of last year Voith SiemensHydro and FKI Energy Technologydecided to cooperate in the hydro-generation sector. The contract bringstogether the top-level competence ofVoith Siemens Hydro in Engineeringand Design with the experience ofBrush SEM in the production of hydro-generators. Brush SEM is a Czechcompany of international FKI Group.Thus Voith Siemens Hydro’s medium-sized hydro generators will be pro-duced together with the Czech com-pany up to maximum output of 150 MVA.

The production of competitive gen-erators, both in terms of price andquality, will form the focus of thecooperation. This development is,however, only the starting point forfurther projects. Besides the foundingof a Voith Siemens Hydro companyin the Czech Republic emphasis willalso be put on modernization projectsand high-quality after-sales services.


Activities

Voith Siemens Hydro and Czech Brush SEM

decide to cooperate

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“I know, preparation for the simulta-neous group certification was definite-ly a challenge to the local managementin the operating units, but in today’smarket situation, it is exactly what weowe our customers.”

Dr. Lienhard, President and CEO ofVoith Siemens Hydro Power Gen-eration and Member of the Board ofVoith AG, where he holds the respon-sibility for the corporation’s qualitymanagement, highlights the excellentcooperation with the TÜV auditors:

Voith Siemens Hydro’s current plansaim at including the newly foundedlocations in India and the CzechRepublic into this system in thecourse of this year.


Signing of cooperationagreement

Identical quality standards of allproducts and services throughoutthe worldwide organization of afull-lining supplier are an essentialaspect in customer relationships andpart of customers’ expectations allover the globe.

Voith Siemens Hydro managementhas, therefore, implemented an in-ternal management system thatguarantees the control of identicalquality standards and their certifica-tion worldwide at all locations. Repre-sentatives of TÜV (Technischer Über-wachungsverein, the major auditingenterprise in Germany) of SouthGermany and Rhineland, Berlin andBrandenburg, had audited the head-quarters and each of 15 Voith SiemensHydro locations around the world inNovember and December of last year.

TÜV has now come up with theresults: the Voith Siemens Hydroheadquarters as well as all operatingunits of the group have been certifiedaccording to the new ISO 9001:2000standard.

Voith Siemens Hydro achieves international ISO 9001:2000 group certification

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sensitive to the many parasites thatlive in the folds of their skin. A dailybath and an extensive washing ritualby the elephants’ keepers are there-fore among the most important mea-sures in elephant care.

The elephants repay the Mahouts’kindness by offering them a copiousshower later on! Elephants have aproverbial good memory and aredefinitely able to register and recallkindly or threatening gestures.Regardless of the more modernmethods that prevail in many regionsof India, they work hard and withoutcomplaining.

India’s main trading partners. Ger-many alone imports goods valued atabout 3 billion Euro every year.

The agricultural sector, which ac-counts for one third of India’s grossdomestic product, has of course beenindustrialized in many areas too.Otherwise it would not be possibleto satisfy the immensely high dailydemand for food. More than 100million people earn their living in theagricultural sector. India’s farmersmainly grow rice, wheat, corn, pota-toes, sugar cane, cotton and tea.

All those activities would not functionwithout an efficient energy supply.This industrial sector is therefore ofgreat importance with regard to thecountry’s modernization. The respon-

sible people in India have long sincediscovered the advantages of hydro-electric systems.

Four large religions shape the coun-try’s spiritual world. Hinduism,Buddhism, Jainism and Sikhism alsoinfluence India’s everyday life, day-to-day culture and the fine arts. Ele-phants have a major part to play hereas well. These gigantic animals areworshipped here – the god Ganeshhad appeared in this guise and is stillrespected in modern India. And aswe have seen, in many regions ofIndia these giants are still essentialto cultivate this fertile country.

India has many faces. On the one hand this hugesubcontinent is on the threshold of becomingan industrialized nation. But on the other, thecountry has been shaped by numerous ancientcivilizations with different religious roots.

Hardly a city or town – even the verysmallest – is without its temple. Suchtemples influence many aspects ofthe country’s day-to-day life andculture. Animals that are among theoldest on Earth play an importantpart: one cannot imagine a templefestival – these are noted for highspirituality and genuine joie de vivre –without lavishly adorned elephants.

The dutiful Mahouts who look afterand guide the elephants treat themin a profoundly kind, gentle way.Elephants, contrary to the generalassumption and despite their prover-bial thick skin, are in fact distinctly

India – with Tradition into the Modern Age

This situation is related to the coun-try’s difficult climatic and geographi-cal conditions. Since heavy machineryis difficult to maintain because of thehigh temperatures and extremehumidity, elephants can still ensuretheir owners a profitable income, forexample in the timber industry.

Despite all its traditions, this multi-cultural country is on the verge ofbecoming a highly industrializedeconomic zone. 3,287,263 squarekilometers in size, India is the world’sfifth largest country. With approxi-mately one and a half billion inhabi-tants –over 7 million people live inthe capital city of New Delhi alone –it has long since caught up with theWestern World in many industrialsectors. Whether in software pro-gramming, telecommunications, thetextile industry or the mining ofnatural resources, modern India hasestablished itself as a competent andefficient partner. This applies to mem-ber states of the European Commu-nity in particular, which are among

Essay

hypower - voith

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