HyPowerThe magazine for: More. Powerful. Solutions.

Issue three
November 2002

Summary

03

Editorial
Voith Siemens Hydro Power Generation
Expertise for growth24

Higher reliability with improved
Pelton turbine nozzle design04

100 years of hydro electricity in Turkey –100 years of Voith Siemens Hydro in Turkey

25

Kaplan turbine rehabilitation –San Men Xia anti-erosion research project08

Sharp growth in the Iranianhydro power market

26

Numerical calculationof unsteady flow in draft tubes

10

Voith Siemens Hydro
continues to be the world leader
in pump-turbine technology

28

Hydrovision 2002, Portland, Oregon, USA –a review

30

Succsessful IAHR symposium

Streamlining project management
and completing 450 MW project in record
time

31

SHEC to participate in EP China 2002

31

Upcoming: international seminar in Vienna

15

Change in the managementof Voith Siemens Hydro, Brazil

32

Recent contract awards

34
16

Advanced governor technology
for Cornetu and Kühtai

Essay
The invigorating power of water18

Grosio, Italy – fourth unit successfully
supplied in 28 months

19

Successful model acceptance tests
for Middle Marsyangdi and Peixe Angical

20

Modernization of the turbines andgenerators in the Dychow hydroelectric
power plant

22

Solina power plant – maximum client
satisfaction after modernization

23

Mechanical and electrical modernization
for Kiskoere, Hungary

14

EditorialVoith Siemens Hydro Power Generation
Expertise for growth.

First of all I would like to thank allof you who have sent me comments, Dr. Hubert Lienhard
Chairman of the Board
information, also critical letters andof Voith Siemens Hydro
encouraging e-mails. It was interPower Generation
esting for me to receive all yourfeedback which we will integrate in our plans and which
will help us to grow further. Once more, you will find mye-mail for further feedback at the end of this editorial.
As of September 30, 2002 we ended our fiscal year 2001/
2002. We will report the highlights during the coming
months. Let me say it has been a rewarding year, but wecannot rest on our laurels; now we must focus on the newyear. In November, we will participate in the Hydro 2002 in
Kiris, Turkey. As you will see, Turkey is well-known to us;
we have installed numerous hydro power plants there
as well as in neighboring Iran and in the entire region
surrounding Turkey.
This area has shown and will show – we believe – large
growth in the coming years. In these countries, hydropower still enjoys the reputation as renewable, green
power, matching ecology with economy. I sometimes
wonder why we have lost this basic understanding inEurope, an understanding our forefathers had when theyutilized hydro resources which in today’s modern worldof liberalization help to keep our grids stable.

Perhaps it is time to learn from the countries surrounding
Turkey, learn from their capability to harvest this clean
energy and make use of the natural resources these countries have, eliminating the need to import prime energy forthese Megawatthours generated in these hydro power plants.
It is our goal to continue to bring to this important region
our know-how and our expertise which Voith Siemens
Hydro has acquired during the 135 years of operation inthis field. As you will read in this issue we can base ouroffers on a vast number of contracts in this region but also
in other parts of the world. Among those is our contribution to the newest and largest pumped storage plant for
VEAG in Germany, a marvel of technology of which we areproud to be given the chance to participate.
As you will agree, this industry has unbelievable chancesand opportunities to serve our society. We will use theHydro 2002 event in Kiris to focus on this region and tobring its expertise to the world.
I hope you will enjoy reading this magazine and we can inspire you in your areas of activity to make things even better.
Sincerely yours,

Dr. Hubert Lienhard

My e-mail address is Hubert.Lienhard@vs-hydro.com.

hypower 3/2002

Dear clients and partners,
dear readers,

0203

100 years of hydro electricity in Turkey –100 years of Voith Siemens Hydro in Turkey
Turkey can look back on a century-long tradition in
generating electricity from water. In 1902 the very firstpower plant was built in the Turkish town of Tarsus:
a small hydro power plant equipped with an 60 kW
Voith Siemens Hydro turbine installed to supply a
privately owned textile factory. The beginning of hydropower generation in this small plant in Tarsus also
marked the beginning of Voith Siemens Hydro’s presencein the Turkish market – a presence which has continued
successfully for 100 years of partnership.

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Solutions.

Situated at the meeting point of two
continents, Turkey stands as a bridge
between Asia and Europe. The socialand economic development throughout the last decades has been considerable. Turkey today is an emerging
nation with a massive increase inenergy demand. Having installed a
total of more than 28000 MW ofgeneration capacity (producing over
122000 GWh), of which nearly 12000
MW are hydro installations (producing over 24000 GWh), Turkey’s future
electricity demand is predicted to
grow by 4% per year.

The main objective of Turkey’s energy
policy is to meet these increasing
demands in line with economic development targets, population growth,industrialization and social changes,
in a reliable manner and environmentally compatible. Hydropower development has extensively contributed tomeet these demands, and an ambitious development program of hydropower for the years coming is under
execution.

Borçka:signing of model acceptance test protocol.

BorçkaThe 306 MW hydro power project islocated on the Çoruh river in northeastern Turkey, close to the borderwith Georgia. Construction work has
begun in September 1999 and isscheduled to be completed within
69 months. Voith Siemens Hydro
manufactures and delivers two
Francis turbine units including thegovernor system and turbine inlet
valves and is also responsible forthe installation and commissioningof the two 153 MW machines.
The respective model acceptancetest was successfully performed inJune 2000 in Voith Siemens Hydro’s
hydraulic research laboratory in
Heidenheim, Germany. Commercial
operation of the first unit is scheduled
for April 2005. The contracting authority is the Ministry of Energy and Natural Resources, General Directorate ofState Hydraulic Works (DSI).

Ermenek
The 306 MW hydro power project
is located on the Göksu river at theErmenek canyon in mid-southernTurkey and includes the Ermenek dam
with the main power station and an
auxiliary hydroelectric power plant,
Erik. The ground breaking ceremony
at the Ermenek site took place in
May 2002. Voith Siemens Hydro, asa member of the supplier group forelectrical and mechanical equipment
is responsible for the mechanicaldesign and delivery of the two
153 MW Francis turbines and spherical inlet valves for the main power
station. It is also responsible for thehydraulic and mechanical equipmentof the auxiliary power station of Erik.
Commercial operation is scheduled
to start in April 2007. The contracting
authority is also DSI.

Ermenek ground breaking ceremony.

Suat Ugurlu hydro power station.

hypower 3/2002

Voith Siemens Hydro has been
involved in a number of recent hydropower projects in the country.
Here’s a brief outline:

04
05

Alpaslan I
The 167 MW hydro power project
is located in eastern Anatolia.
This contract is the most recent one
realized in cooporation with Temsan
for the contracting authority DSI,
as where the hydro power projects
Kürtün and Suat Ugurlu, and others.
For Alpaslan I, Voith Siemens Hydro
designs, manufactures and will deliver the four 41.75 MW Francis turbines
including governor systems andbutterfly valves, and will supervise
the installation on site and be responsible for the commissioning.
Kürtün dam site.

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Solutions.
Karkamis: final acceptance.

KarkamisThe 213 MW hydroelectric power
plant is located on the Euphrates
river, close to the Syrian border.
The Karkamis plant comprises six
35.5 MW bulb turbine units, theturbines manufactured, delivered,installed and commissioned byVoith Siemens Hydro.
Commercial operation of the firstunit started on December 20, 1999,
11 days earlier than planned.
All other Karkamis units were handed
over to the contracting authority DSI
at least one month ahead of schedule.
On February 7, 2002 the final acceptance protocol was signed.

KürtünThe 80 MW hydroelectric power plant
is situated in northeastern Anatolia on
the Harsit river. Voith Siemens Hydro
delivers the two 40 MW Francis
turbines, adapted for synchronous
condensor operation, including governor systems and butterfly valves,
will supervise the installation on siteand be responsible for the commissioning. Main installation has begunin spring 2002 and commissioningof the first turbine is expected to takeplace soon.

SucatiThis small hydroelectric power plant
was erected in 1998/1999. It is operated by the Turkish private company
ERE, Elektrik Üretim ve Dagitim
Sanayi ve Ticaret A.S. on BOT basis,and equipped with two double-regulated Kaplan bulb turbines and two
generators with a maximum output
capacity of 5,100 kVA each. It is
located near Kadirli, approximately
50 km southeast of Kayseri.
Voith Siemens Hydro was the turnkey
contractor and has delivered the entire
mechanical and electrical equipment
including the control and protection
system and the medium-low voltage
equipment.

Sucati hydro power station.

Dinar
Commissioned in November 2000,
the small hydro power station Dinar
is located about 200 km north ofAntalya. Operated by the Turkish
private company METAK Enerji VE
Ticaret A.S. on BOT basis, the plant
is equipped with Francis bulb turbines
and two generators with a maximum
output capacity of 1,950 kVA each.
Voith Siemens Hydro was the turnkey
contractor and has delivered theentire mechanical and electrical equipment including the control and protection system and the medium-low
voltage equipment.

Hacilar
The plant with an installed capacityof 13.34 MW is currently under construction, commissioning is scheduled mid of 2003. Hacilar is locatedin Darende-Malatya with two units.
Voith Siemens Hydro is the turnkey
contractor and delivers the entire
mechanical and electrical equipment
including control and protection
system and medium voltage equipment. Hacilar will be operated on
auto-producer basis for 49 years.
The owner of the plant is Bilgin
Elektrik which already operates
Hazar I and II hydro power plants.
Those plants were taken over from
DSI under the TOR (Transfer of Rights)
model and were equipped with Voith
Siemens Hydro turbines and shut-off
valves in the fifties and sixties.
For more information:
Leopold.Heninger@vs-hydro.com
Adil.Tekin@siemens.com.tr

Dinar penstock view.

Hazar: inside power house.

hypower 3/2002

Voith Siemens Hydro also successfully serves the emerging private
market in Turkey.
A brief record of recent projects:

06
07

With over 31,000 MW installed nominal capacity, the Islamic Republicof Iran has a leading position on the energy sector in its region.
In 1998, the Energy Ministry unveiled its long-term plans to nearly quadruple the capacity of the national grid by 2022. Several hydro power plants
are currently under construction and will be completed in due time.

The Islamic Republic of Iran is still
forging ahead with its ambitious
energy program. Considering thecountry’s feasible hydro power potential, estimated at about 50,000 GWh/year, and a current utilization of lessthan 15%, the hydroelectric field willcertainly be developed extensively.

For hydro power generation government plans foresee an additional
11,700 MW of generation capacity by
the year 2022. Voith Siemens Hydro
has a remarkable share in this development program.

More.
Powerful.
Sharp growth in the Iranian
Solutions.
Shop assembly ofhigh-pressure oil units
and digital governors.

hydro power market

Construction site
Masjed-e-Soleyman extension.

Digital governor
inside view.

Masjed-e-Soleyman Extension
The dam with a height of 180 m andthe hydroelectric power plant islocated on the Karun river, about
25 km north-east of the city of Masjedin the Khuzestan Province.
The 1,000 MW project, equipped withfour 254 MW vertical Francis turbine
units, is scheduled to become operational by 2004.
Upper Gotvand
The hydroelectric power plant at thefoot of the Gotvand-e-Olia dam will beequipped with four 254 MW vertical
Francis turbines. The plant is locatedon the Karun river, 90 km south of thecity of Godarlandar, and its commissioning is planned for 2006.

Karun IV
Also located on the Karun river in the
country’s south-western province ofKhuzestan, Karun IV is yet another
1,000 MW project. The hydroelectric
power plant will receive four vertical
Francis turbines with an output of
255 MW each. It is scheduled forcommissioning in 2006.
Ostour
The 170 MW project is located on
the Ghezel Ozan river, near the cityof Mianeh in Iran’s north-western
province of Azerbaijan.
Contracts foresee equipment comprising four 41 MW vertical Francis
units.
For more information:
Ernst.Bruckner@vs-hydro.com

hypower 3/2002

Major contracts awarded toVoith Siemens Hydro
FARAB, an Iranian contracting company set up in 1992, was awarded
with several contracts for hydropower projects in Iran. To date, FARAB
has awarded various major contracts
to Voith Siemens Hydro, comprising
design, manufacture, installation andcommissioning of turbines, generators and governor systems.

08
09

Voith Siemens Hydro
continues to be the world leader
in pump-turbine technology
With almost a century of experience in the design and manufacture ofpump-turbines and motor-generators, Voith Siemens Hydro is indisputably
the leader in this field of hydro technology. Since the first pumped storage
plant was developed in Voith’s hydraulic research laboratory in Germany
in 1908, Voith Siemens Hydro has been supplying the world’s largest andmost powerful units, continually breaking through existing barriers.
The latest developments, already utilized in current projects, include
variable speed technology and wide head range applications.

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Solutions.
Guangzhou II, China.
Pumped storage
power station.

Pumped storage plants have beendeveloped as “energy storage systems” capable of quickly responding
to fluctuations in power demand.
In times of reduced energy demand,excess electric capacity in the grid isused to pump water, previously used
to generate power, back into an upper
reservoir. This water can then be used
to generate electricity when needed.

Though all pumped storage plants are
based on this main principle, there
are no two facilities in the world thatare alike. Each plant has its own
unique hydrology and physical constraints. Pumped storage plants
operate on daily or weekly cycles thatvary based on the time of the year
and the plant’s location. Operating
conditions may require a reversible
pump-turbine or an optimally designed combination of turbine andpump. In some cases, optimum
results may be achieved through apump-turbine equipped with a fixed
distributor, in other cases an adjustable distributor may be necessary.
Depending on the required changeover speed, separate turbine andpump units may best be equippedwith synchronizing torque converters
or a clutch operable at standstill.

Guangzhou II, China.
Pumped storage power station.

Guangzhou, China
The Guangzhou pumped-storage plant
is located about 100 km northeast of
the provincial capital of Guangzhou(Canton), and about 200 km north of
Hongkong. It is the first high-head,large-capacity pumped storage facility
in China. With a total output of
2,400 MW, it ranks among the largest
in the world. Guangzhou comprises
two groups, each with four 300 MW
reversible pump-turbines with a headof 535 m.

Voith Siemens Hydro supplied thecomplete electrical and mechanicalequipment for the second group,
including pump-turbines and motorgenerators, high voltage starting frequency, PROKON LSX control system.
Since commercial operation began
two years ago, these units have been
operating very reliably for more than
35,000 hours.

hypower 3/2002

Having installed more than 200 pumpturbines worldwide with a combined
output of well over 24,000 MW, Voith
Siemens Hydro can offer the rightmachines for the most variable conditions and pump-turbine technology
which has proved to be extremely
reliable. Consequently, it does notcome as a surprise that Voith Siemens
Hydro is involved in today’s mostimportant pumped storage projects:

1011

Pumped storage station:spiral casing.
Goldisthal, Germany.

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Solutions.
GoldisthalGoldisthal, Germany
Goldisthal pumped storage power
station is located in southern
Thuringia, Germany, on the upper
Schwarza river. With a total capacityof more than 1000 MW, it is one of
the biggest pumped storage plants in
Europe. Voith Siemens Hydro supplied two 270 MW pump-turbine units
capable of operating at variable
speeds ranging from 300 to 346 rpm.
The adjustable speed control of thepumped storage units makes it possible to control input during pumping
operations and increase the electricity
yield in turbine mode.

Bath County, USA
Situated in a mountainous region in
Virginia, USA, Bath County pumped
storage plant is currently being modernized by Voith Siemens Hydro
specialists. The station consists of
two large reservoirs – one 385 meters
higher than the other, a massive
power house and the huge tunnels
that connect them. The upgrading
covers the combined turbine/generator scope of supply.
The refurbishment of the stator windings and new runners will push thesix 350 MW units installed to an
astonishing 480 MW/530 MVA each.
After completing the modernization,
Bath County will again become theworld’s most powerful pumped storage generating station.
For more information:hydrocontact@vs-hydro.com

hypower 3/2002

Goldisthal, upper reservoir.

1213Streamlining project management
and completing

When the go-ahead was given at the end of May 1999 for the constructionof the Brazilian hydro power plant Cana Brava in the north of the federal
state of Goiás, expectations were high. The work was to be completed ina record time of 37.5 months, commissioning was planned for August 2002.
From the very beginning, Voith Siemens Hydro, responsible for the engineering, the complete electrical and mechanical equipment, installation,
tests and commissioning, brought everything to bear on safeguarding theambitious time goal with its streamlined project management.
With overwhelming success.
In the late Brazilian summer of 2001,
an increasing number of power cuts
throughout the country documented
an acute energy shortage. Brazil began
to suffer from a serious energy crisis.
Additional capacities for electricity
production were urgently needed.
In view of the extremely tense situation on the Brazilian energy market,
the Voith Siemens Hydro project
Cana Brava hydro power station.
managers responsible for Cana Brava
streamlined their planning to the limit.
The deadlines for all work packages
were brought a long way forward,
critical paths in the part-projects wereshortened and optimally adapted to
the work of the partners, which for its
part was also accelerated.

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Solutions.

Cana Brava hydro power station.

Optimum interface management
Optimum interface management andunconditional support from the client,
Tractebel Energia, for the increased
efforts finally set tremendous synergies free. In this way, the first rotor
blade of the first of the three 150 MW
turbines for Cana Brava was delivered
considerably earlier than accounted
for in the already very ambitious
original plans. With the early deliveryof the runners, the overall progress ofthe hydroelectric project speeded up
significantly. At the handover of thefirst turbine, Sérgio Parada, Directorof Voith Siemens Hydro’s São Paulolocation, promised to save at least
two months of time.

450 MW project in record time
Cana Brava in operation four months
ahead of scheduleSérgio Parada was proved to be right.
The other two turbine units were alsodelivered with a considerable timesaving. His prognosis even turned out
to be quite modest. The Cana Bravahydro power plant, situated on theriver Tocantins, went into operation
as early as April this year – a full fourmonths before the contractuallyagreed date. The time gain which had
been fought for so hard exceeded all
expectations.

The finished power plant will produce
more than 2700 GWh per year, enoughto supply 1.5 million households inthe central-west and north-east of
Brazil, chiefly in the federal state of
Bahia, and to make a valuable contribution to checking the Brazilianenergy crisis.

Contract Manager Amiro de Sousa
looks on this achievement with pride:“Everybody remembers the difficulties
we had to overcome, but the memory
is of a positive result. It is a feeling of
personal satisfaction, everyone saw
the effort rewarded with success.”
For more information:
Camilla.Varussa@vs-hydro.com

Change in the managementof Voith Siemens Hydro, Brazil
Edgar Horny, President of the Boardof Management for Voith Siemens
Hydro Power Generation Ltda., SãoPaulo, Brazil, resigned from the company management on September 30,
2002.
Julio Fenner

He will continue as an advisor to Voith
Siemens Hydro Power Generation Ltda.,
Voith Paper Máquinas e Equipamentos
Ltda. and to Voith Turbo Ltda.

Sergio Parada

On October 1, 2002, Julio Fenner
became Edgar Horny’s successor as
President of the Board and, together
with Sergio Parada, now constitutes
the Board of Management of Voith
Siemens Hydro Power Generation Ltda.

hypower 3/2002

Edgar Horny

14
15

Advanced governor technology
for Cornetu
The Cornetu hydro power plant in Romania and Kühtai hydro power stationin Austria have several things in common. This year, Hidroelectrica, theoperator of Cornetu and TIWAG, operator of Kühtai, both awarded contracts
to Voith Siemens Hydro to replace the existing analog governors by modern
digital governor systems. Moreover, manufacturing, installation and commissioning deadlines meant that the time scheduling for both projects was
extremely tight, which posed a major challenge for the respective project
teams. Nevertheless, through the unique partnership and cooperation
between Voith Siemens Hydro specialists and the clients’ staffs, both projects were completed successfully and on time.
Kühtai pumped storage plants.

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Voith Siemens Hydro digital governor
in Romania:
When the Romanian Prime Minister
Adrian Nastase together with Ministerof Industry and Resources, Dan Ioan
Popescu and General Director of
Hidroelectrica, Eugen Pena, opened
the Cornetu power plant in a ceremony this year, just 15 weeks had
passed since award of the governor
contract to Voith Siemens Hydro.

After manufacturing and delivery,
installation of the governors andcommissioning was executed in anenormous effort and excellent cooperation between Hidroelectrica, theerection company and Voith Siemens
Hydro staff within two weeks.
The scope of supply and services also
covered the supply of governor valves,electrical feedback and speed measuring system for the two Kaplan units.

Cornetu hydro power station.
Inauguration of Cornetu.
The unit was started by
Dan Ioan Popescu, Ministerof Industry and Resources,
Adrian Nastase, Prime Minister,
Eugen Pena, General Director,
Hidroelectrica.

and Kühtai

Satisfied faces
The successful works’ acceptance byboth clients confirmed the quality andefficiency of the Voith Siemens Hydro
digital governor systems.
Within a few weeks, both hydro power
plants had been successfully updated
to advanced technology.
For more information:
Robert.Doppler@vs-hydro.com
Engelbert.Knoll@vs-hydro.com
Wilhelm.Gruber@vs-hydro.com

Kühtai pumped storage scheme:
aerial view.
Kühtai pump-turbine.

hypower 3/2002

New digital governors forpump turbines in Kühtai
The turbines of Kühtai pumped storage plant are equipped with single
wicket gate blade control.
The replacement schedule for the
analog turbine governors with engineering and installation works wasagain quite tight. As part of thisproject, the previous main functionsof the governor, such as opening,
speed and power control were to besupplemented by a range of new
functions through the upgrade todigital governor technology.
For service and maintenance reasons,data acquisition and storage functionalities were implemented.
Data can be read and displayed ona direct or modem-connected PC.
Drift compensation was anotherfeature to be newly implemented.
Safe behavior, during different modesof operation, was a main requirement
also. Therefore, new functions were
installed, such as:- feedback of turbine inlet pressure
for damping of pressure oscillations- blocking of the actual wicket gate
opening in case of unallowed
pressure oscillations- redundant speed measuring
and speed direction detection

16
17

Grosio, Italy –fourth unit successfully supplied in 28 months
Erection of the newrunner.

The Italian operator Azienda Elettrica Municipale (AEM)
di Milano has awarded Voith Siemens Hydro a contractfor increasing the power of their most important hydropower plant. One part of the contract comprised the
supply and installation of a new Pelton turbine.
Once this new turbine, in a total of four, was commissioned in September this year, the plant’s overall capacity increased to 450 MW.

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Solutions.

Further to the vertical Pelton turbinewith a diameter of 3750 mm, Voith
Siemens Hydro’s activities comprised
the installation of a new control
system. Above this, the runners in
the existing turbine units were replaced by runners weighing 20 tons
each. This replacement allowed theperformance of each unit to increase
considerably.

The importance of the Grosio project
is not only due to the fact that it is
the main operative center as far as
the electrical production and output
of all hydroelectric power plants ofAzienda Elettrica Municipale di Milano
is concerned, but also because it is
the central site of the remote telecontrol of all AEM plants in the Lombardian region of Italy.
For more information:
Gianfranco.Vodopivec@vs-hydro.it

Front view ofGrosio hydropower plant.

New runner with deflectors.

Successful model acceptance tests
for Middle Marsyangdi and Peixe Angical
In July 2002, successful model acceptance tests were again held in theCentral Technology facilities of Voith Siemens Hydro. The model turbines
for the hydroelectric power plants of Middle Marsyangdi in Nepal and Peixe
Angical in Brazil were on the test stand in Heidenheim, Germany.

Successful model tests and their teams:
Middle Marsyangdi and Peixe Angical.

The performance of the Peixe Angicalunit was particularly gratifying:
the guarantee of the highest performance in an ambitiously short periodof just 2.5 years until commissioning
was a real challenge of planning anddesign, construction and manufacture
including installation. The successful
test run means that the first major
milestone has been reached.
Peixe Angical, located in the Brazilian
state of Tocantis on the river of that
name, will be equipped with three
Kaplan turbines, each of which willproduce 169 MW with a runner diameter of 8.6 m and a head of 29 m.

The Nepalese hydroelectric power
plant uses the water of the Marsyangdi
river and is located approx. 160 km
west of Kathmandu. This will be servedby two Francis turbines, which will
each produce 40 MW with a runnerdiameter of 2.2 m and a head of
approximately 100 m.
For more information:
Martin.Giese@vs-hydro.com
Thomas.Kaechele@vs-hydro.com

hypower 3/2002

In the presence of the clients, Nepal
Electricity Authority for the Nepaleseand Enerpeixe for the Brazilian hydroelectric power plant, the model systems were tested under all relevant
operating conditions. The guarantees
of performance made during thetender process and contract awards
were fulfilled in full.

18
19

Modernization of the turbines and generatorsin the Dychow hydroelectric power plant
Punctually to the 50-year celebrations in September 2002, the official
go-ahead was given for the beginning of extensive modernization workin the Dychow power plant in Poland. Built in the 30s, the plant was
re-equipped in 1951 and had been in continuous operation since then.
Due to this long operation period, wear and tear deteriorated the units
to an extent that jeopardized reliable operation. Elektrownie SzczytowoPompowe (ESP) entrusted Voith Siemens Hydro with the modernizationof the units. Thus, peak power provision and increased annual generated
energy are secured.

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Powerful.
Solutions.

Dychow hydro power plant.

Two contracts from Warsaw
ESP in Warsaw awarded two contracts
to Voith Siemens Hydro to carry out
the modernization of three Kaplan
turbines and generators, four storage
pumps, and one motor including
ancillary equipment in Dychow hydropower station in the last two years.

All supplies and services for thisproject are being provided byVoith Siemens Hydro in cooperation
with local partners. The challenging
implementation time table is basedon the strong commitment of a successful team between ESP and Voith
Siemens Hydro which has alreadyproven successful in earlier projects
with ESP.

Customized solutions for increased
performance
Even though one part of the contract
is to renew turbine components,
simply replacing old parts with newones is not enough to increase efficiency. An improved customized
hydraulic layout was developed forthe given hydraulic profile of thehydraulic machines by application of
CFD (Computational Fluid Dynamics).

Extensive tests are carried out toassess the condition of parts to be
renewed. Residual life time calculation is executed for the units.

Results
The consequence of this optimization
process is that once the modernization is completed, the parameters
guaranteed in the contract will evenbe exceeded partially: turbine performance will increase from 26.1 MW
to 31.6 MW (12% increase) and discharge from 110 m 3/s to 122.7 m 3/s.
Pump discharge will increase from
17.5 m 3/s to 19.2 m 3/s.
All in all, thanks to a customized
Voith Siemens Hydro solution, andproven close cooperation between
ESP and Voith Siemens Hydro, theDychow hydroelectric power plant
will in future not only use 100% of
its newly installed capacity, but also
have a significant increase in operational reliability. Recommissioning for
the whole plant is scheduled for 2004.
For more information:
Josef.Gaschl@vs-hydro.com

hypower 3/2002

Dychow inside view.

20
21

Solina power plant –maximum client satisfaction
after modernization
When Voith Siemens Hydro was awarded the contract for the modernizationof the units of the Polish hydroelectric power station Solina, the owner,
Elektrownie Szczytowo-Pompowe (ESP), was assured of significant improvements in part-load behavior and remarkable increase in performance.
Most advanced Voith Siemens Hydro IT technology and special in-house
software, helped to provide extremely precise statements on results, timelines, cost and extent of the modernization work before the project wasstarted. Once, modernization work had been completed, the contractually
guaranteed parameters were subject to verification, carried out by anindependent consulting engineer.
These tests, were carried out by therenowned Institute of Fluid-Flow
Machinery at the Polish Academy of
Science in Gdansk. Data on runnerperformance had been awaited withparticular interest, as Voith Siemens
Hydro had based their hydraulicoptimization of the runner design on
Computational Fluid Dynamics (CFD)
solely.

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Solutions.

The extensive tests done by theInstitute covered efficiencies, dynamic operating behavior and turbine
loudness reduction. Results were convincing with all parameters guaranteed in the contract being verified
in all areas. ESP now operates twoquiet turbine units with remarkably
improved performance at their disposal for unlimited operation.
As part of the official opening celebration, Elektrownie Szczytowo-Pompowe
expressed their great satisfaction withthe hand-over of a letter of appreciation to Voith Siemens Hydro.

PressureHigh

For more information:
Josef.Gaschl@vs-hydro.com
Low

Solina CFD runner.

Letter of appreciation from ESP.

Mechanical and electrical modernization
for Kiskoere, Hungary
Voith Siemens Hydro in consortium with Siemens RT, Budapest, recently
received a modernization contract from Tiszaviz Vizeroemue, KFT, Hungary,for the modernization of mechanical and electrical equipment of Kiskoerehydro power station in Tiszaloek in Hungary.

Kiskoere hydro power plant.

Kiskoere is equipped with four bulb
turbine units. Modernization works
will start in summer 2003, including
modernization of all mechanical andelectrical components of the units,
such as new runner blades, rehabilitation of runner discharge rings, redesign and parts renewal of distributors, including new wicket gates, newshaft seals, re-wind of generators,
installation of new excitation equipment and re-design and renewal of
hydraulic, governor, automation andcontrol equipment. The units will be
re-worked and re-commissioned at
one-year intervals. Completion of recommissioning is planned at the endof 2006.

Kiskoere is located on the Tisza river
and was originally put in operation
1974. The power plant generates
around 90 GWh per year. The modernization works thus not only ensure
electricity to the public grid of Hungary, but also help the plant to continue to serve its primary purpose forwater supply and irrigation.
Technial data:
Runner diameter
Head range
Discharge per unit
Speed
Generator output per unit

4.3 m
2 - 10 m
140 m 3/s
107.1 rpm
7 MW

For more information:
Anton.Huber@vs-hydro.com

hypower 3/2002

Kiskoere hydro power plant.

22
23

Higher reliability with improved
Pelton turbine nozzle design
After a service life of almost 30 years, the reliability ofthe two Bulgarian hydroelectric power plants Belmeken
und Sestrimo had dropped tremendously. The source ofthe defect was found to be the dramatically short lifespanof the springs in the nozzle system of the Pelton turbines.
Within a short contractual period of just six months forthe modernization of the first turbine, Voith Siemens
Hydro specialists adapted highly sophisticated Pelton
nozzle design to ensure highest operational reliability.

More.
Powerful.
Solutions.

Nozzles in workshop.

When the state electricity company NEK(Natsionalna Elektricheska Kompania
EAD) entrusted the project for themodernization of a total of 32 turbine
nozzles to Voith Siemens Hydro, thetask was obvious: a re-design of theactuating mechanism inside the nozzles had to be carried out with theconstraint of the given dimensions of
the unchanged nozzle body in orderto achieve significant improvementsof the force transmitting system byreducing the load on the springs.

Belmeken hydro power plant.

By application of simultaneous engineering, time and mechanical constraints could be met and evenexceeded. In this way, the criticalparameter – the too high load on thesprings – was reduced to a level,
enabling significant increase of lifespan and reliability of the units.
Excellent cooperation between NEK
and Voith Siemens Hydro ensured
that all targets set could be achieved.
For more information:
Rupert.Emsenhuber@vs-hydro.com

Kaplan turbine rehabilitation –San Men Xia anti-erosion research project
The San Men Xia Hydropower
Station is located on the middle
reaches of the Yellow River inHenan Province, China.

Layout comparison
between original andmodernized design

In order to solve the above problems,
San Men Xia awarded the rehabilitation contract for the No. 1 unit toVoith Siemens Hydro in 1997.
This rehabilitation was combinedwith a research project addressing
the problem of sand erosion of theturbines. Following the contract
award in 1997, Voith Siemens Hydro
optimized the hydraulic design, confirmed in a model test carried out in
1998. The runner blades with coatings(tungsten carbide hard coating andpolyurethane soft coating) were madein Voith Siemens Hydro Heidenheim
and the other equipment with coatings was manufactured at the Shanghai Hydro-Power Equipment Company(SHEC) – Voith Siemens Hydro’s
operation in China. The unit was recommissioned in December 2000.

OutputBlade No.
Runner diameter
Hub ratio

Old
50 MW
8
6000 mm
0.55

New
60 MW
7
6100 mm0.53

After returning the modified unit tooperation, Voith Siemens Hydro/SHEC
and San Men Xia made three joint
inspections on May 29, 2001,
November 6,2001 and May 8, 2002
respectively.
The inspections show that the unit
operates stable at all heads andmeets the design output. The actual
efficiency is improved significantly.
No cracks appear on the blades.
The rehabilitation has reached the
expected goals. With regard to theanti-erosion program, after one anda half years of operating experience,
it is confirmed that both coatings
have helped to significantly reducesand erosion. The tungsten carbide
has shown particularly good antiabrasion performance. The long-term
comprehensive effect of the coating
will be further verified during the next
two years of operation.
For more information:
Michael.Liu@vs-hydro.com

hypower 3/2002

There have been two major problems
in this power station:
1. The sandy water (max. sand content over 100 kg/m 3 ) passing
through the turbines during theflood season cause serious erosion
damage to the wet components ofthe turbines.
2. Runner blade cracks – 80% of theblades in this station have developed cracks, and one blade evenbroke during operation.

24
25

Numerical calculationof unsteady flow in draft tubes

t = 1/8*T

t = 2/8*T

t = 3/8*T

t = 4/8*T

t = 5/8*T

t = 6/8*T

t = 7/8*T

t = 8/8*T

Calculated vortex rope at different times.

The numerical calculation of the flow in the components of hydraulic turbo
machines has become a standard during the past decades. The implementation of this approach in the hydraulic turbine design process has led to thedevelopment of powerful machines. One weak point of the traditional process previously used was the purely steady calculation. In particular, theflow conditions under part load could not be adequately described in thisway. This meant that under unfavourable circumstances, pressure pulsations
could arise with serious consequences. Voith Siemens Hydro has now developed an improved calculation process.

More.
Powerful.
Solutions.
Draft tube mesh and pressure pulsations.

20000
16000

p [Pa]

10000
5000
0

4

5

-5000
-10000-16000-20000t [s]Deficits in the conventional
calculation process
The entire turbine is conventionallyseparated into single components –spiral casing, tandem cascade, runner, and draft tube – and each component is then calculated in steadymode, thus neglecting pressure
pulsations, i.e. time-dependent variations in the flow. As a result, partload operation of Francis and pumpturbines – in turbine mode – isfrequently accompanied by suchmeasuredpredicted
incalculable pressure pulsations.
Especially within the range of thenatural frequency of the mechanicalcomponents or the water circuit,these pulsations can cause severe
damage to the machines and lead to
6 fluctuations in the rotational speed
and the torque of the runner.
Worst case, a destabilizing effect on
the electrical grid could be the consequence.

The need for a holistic approach
When applying the conventional analytical method, the fluid and gaseous
phase in the draft tube, responsible
for pressure pulsations, is incalculable. Voith Siemens Hydro specialists
realized that the synergetic complexity of the whole system with various
components interacting could not be
broken down to separate elements:
under conditions of part-load operation, the flow regimes of both components can never be separated properly. Instead, a holistic approach considering the runner and the draft tube
together was needed.

Breakthrough in Heidenheim
Throughout the past year, an extensive research program has been
conducted at Voith Siemens Hydro
in Heidenheim covering theoreticalfoundations, numerical calculations
and experimental measurements.
Researchers have developed sophisticated physical models, fundamental
for the explanation of the decisive
fluid-gaseous phenomena.
Comparisons of the numerical resultswith experiments performed at our
test stands revealed excellent agreement with regard to both, visuallyobserved flow phenomena and quantitative data.

Outlook
The research project provided a
detailed insight into the complex
flow situation and the far-reachingcomprehension of the formerly
incalculable pressure pulsations.
This will enable Voith Siemens Hydro
specialists to improve the part-load
behavior of Francis and pump-turbines, with regard to both, rehabilitation projects and the developmentof new hydraulic turbines.
For more information:Thomas.Scherer@vs-hydro.com

hypower 3/2002

Bifurcating cavitating vortex ropein the model test stand.

26
27

Hydrovision 2002, Portland,
View of the Portland
cityscape from theWillamette River.

Over 2000 participants from 51 countries attended theHydrovision 2002 conference held at the Oregon convention center in Portland, Oregon. The conference presented
opportunities to learn, network and share with those in
the hydropower industry.

More.
Powerful.
Solutions.
Winfried Stach, Director,
Hydro Automation, York,
explaining automation
concepts as the moderatorof the interactive session
on automation.

Individual presentation sessions
Voith Siemens Hydro’s exhibitionbooth focused on the individual
products and technology that are
involved in the Integrated Services
solution for project evaluation,planning and implementation.
These products and services weredepicted in photos and descriptionsof some of the projects currently
under way in the North American
market. As a highlight for thosecustomers interested in the details ofVoith Siemens Hydro’s most recent
technological developments andservice approach, presentations wereavailable in a separate room at theconference center. These individual
presentation sessions provided thevenue necessary to discuss andexplore the Integrated Services Tool
Box, Automation and Waterview.
Alan Roth (right), Vice President Marketingand Sales, Mississauga, during booth duty.

Expertise shared
The conference offered 8 sessions
each day in 9 different tracks focusing on every aspect of hydropower.
Voith Siemens Hydro specialists presented a technical paper “Applicationof Fish-Injuring Shear Criteria andComputational Fluid Dynamics toInvestigate Fish Survival in Kaplan
Turbines” and served as moderator
for the interactive session on automation entitled “Automation/Remote
Control: How much is enough?”Voith Siemens Hydro's boothin the exhibition hall.

Oregon, USA – a review

Celebrate Science Party
The sponsorship of events at theconferences provided a chance for all
attendees to socialize and experience
the conference city. Voith Siemens
Hydro’s sponsorship of the Thursday
evening event “Celebrate Science
Party” held at the Oregon Museum of
Science and Industry provided an
enjoyable evening of relaxation andlearning. Complete with an Omnimax
theatre and interactive displays
including a submarine, the museum
allowed time to socialize during thedinner provided and to explore theadvances in science and industry.
The event proved to be so popularthat it was difficult for everyone toleave at the end of the evening.
For more information:
Carol.Rose@vs-hydro.com

View of the Columbia River
at the Bonneville Power Plant.
Bonneville Power Plant –Powerhouse No. 1.
A tour guide from the US Park
Service provides answers
during the tour of Bonneville.

The OMSI Museum, site of
the Celebrate Science Party.

hypower 3/2002

Historic tour
Voith Siemens Hydro provided a picnic
lunch for participants during the tourof the historic Bonneville Power Plant
organized by the U.S. Army Corps ofEngineers. Approximately 100 attendees spent a beautiful sunny day in
the Columbia Gorge, learning about
the history of the project along withthe technical and environmental
enhancements that have been madeto produce electricity with respect
and reverence to the needs of theriver system. Voith Siemens Hydro
and its predecessor companies in
the United States have been a partof the Bonneville Hydro projects fromthe first 518 MW powerhouse completed in 1938 to the second 558 MW
powerhouse completed in 1982 andthe current rehabilitation of the firstpowerhouse.

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29

Succsessful IAHR symposium
For the 21st Symposium of the International Association of HydraulicResearch (IAHR) in Lausanne, Switzerland, from September 9 -12, around
170 participants could share progress in hydraulic research in the hydroindustry in a relaxed engineers’ atmosphere. In a round of technicalsessions, Voith Siemens Hydro’s international set of speakers presented
latest inside view on:
Numerical Investigation of the Flowin a Pelton Turbine
Reiner Mack, Winfried Moser(Heidenheim)

More.
Powerful.
Solutions.

Experimental Analysis andNumerical Calculation of the
Rotating Vortex Rope in a Draft Tube
Operating at Part LoadThomas Scherer, Peter Faigle,
Thomas Aschenbrenner (Heidenheim)
The Importance of the UnsteadyFriction Term of the Momentum
Equation for Hydraulic TransientsHans Günther Poll (Sao Paulo, Brazil)

IAHR opening ceremony.

Development of New Generationof High Speed Reversible PumpTurbines
Hidetoshi Yamanaka, Yutaka Kimoto(Kawasaki, Japan),Armin Schuh, Martin Giese,
Gilbert Grosse (Heidenheim)
Development of a Broad-Band Micro
Hydraulic Turbine
Morihito Inagaki, Akira Suzuki,
Mitsuhiro Ishiguro,
Tadashi Tsukamoto, Shoichi Yamato,
Kengo Izutsu, Michihiro Nishi(Kawasaki, Japan)
A Case Study in Resonant Hydroelastic Vibration: The Causes of Runner
Cracks and the Solutions Implemented for the Xiaolangdi Hydroelectric
Project
Richard K. Fisher, Werner Gfeller(York, PA; USA)
Ulrich Seidel, Gilbert Grosse,
Roland Klinger (Heidenheim)

Succsessful symposium:
the IAHR participants.

Co-authored papers were:

Design Optimization of Hydraulic
Machinery Bladings by Multi Level
CFD-Technique
R. Schilling, S. Thum, N. Müller,
S. Krämer,Voith Siemens Hydro:
N. Riedel, W. Moser

Simulation of Vortex Rope in a
Turbine Draft Tube
Albert Ruprecht, Thomas Helmrich,
Voith Siemens Hydro:
Thomas Aschenbrenner,
Thomas Scherer
For more information:
Stefan.Riedelbauch@vs-hydro.co

SHEC to participate in EP China 2002
From Nov. 13 to 16, 2002,
Voith Siemens Hydro’s Joint-Venturecompany SHEC of Shanghai will bepresenting itself at Electric Power
China 2002.

The booth will be located within theGerman Pavilion in the Beijing China
International Exhibition Centre.
The event is organized by the China
Electricity Council International.

For more information:
Clare.Chen@vs-hydro.com

Upcoming: international seminar in Vienna
Within the three days programfrom November 27-29, 2002,
Voith Siemens Hydro will present
a paper on “Runaway speed of double
regulated Kaplan turbines – aspects
of different safety philosophies andsolutions” (authors are A. Oeguenc,
H. Buchmaier, J. Klein of Voith
Siemens Hydro in Heidenheim,
Germany).

More information on the event canbe found under
www.tuwien.ac.at/wup/tagung2002

hypower 3/2002

The bi-annual event of the Vienna
University of Technology’s Institutefor Waterpower and Pumps willfeature a series of paper presentations under the theme of “Hydro
power plants – safety and/or risk?”

30
31

Accounting for one third of the world’s hydroelectric power with its turbinesand generators, Voith Siemens Hydro Power Generation is a true global
player. Recent contracts awarded to Voith Siemens Hydro operating units allaround the globe underline its position as a worldwide leading company forhydropower equipment:
Pedra do Cavalo, Brazil
The hydro power station Pedra do
Cavalo, located on the Paraguaçú
river in Brazil’s north-eastern federal
state of Bahia, will be supplied in fullby Voith Siemens Hydro’s Brazilian
unit in São Paulo. The 165 MW projectwill be equipped with two Francis turbines, designed to generate 82.5 MW
each at a head of 105 m, and two
generators with an output of 90 MVA.
Both units are scheduled for commissioning in August and October 2004
respectively and will be able to cover
the complete annual electricity demands of about 290,000 households.

More.
Powerful.
Solutions.

Baglihar, India
The 900 MW Baglihar project islocated in the north of India.
Voith Siemens Hydro, as a consortium leader, will supply three verticalgenerators with an output of 168 MVA
each, excitation systems, bus ducts,
phase transformers, switchgear andcables. The contracting authority is
the Jammu & Kashmir State Power
Development Corporation.

Recent contract awards
Site assembly of the draft
tube liner at the Tomada
hydro power station.

Final assembly of thedraft tube liner before
embedment at Tomada
hydro power station.

Tomada, Japan
Tomada hydro power station will bepart of a multi-purpose dam projectin the Okayama prefecture.
Besides being responsible for erection and supervision, Voith Fuji Hydro
will provide all electrical and mechanical equipment, including a 4.8 MW
vertical Francis turbine and the generator. The commissioning is scheduledfor February 2005.

Shin-Taishaku, Japan
Shin-Taishaku Power Station is partof a re-development project of anaging dam in the Hiroshima prefecture and will include the utilization of
a 10.08 MW vertical Francis turbine.
Most of the power station equipment
such as turbine and generator will be
supplied by Voith Fuji Hydro. Commissioning is planned for June 2006.

hypower 3/2002

Shin-Asaka, JapanThe small Shin-Asaka hydro plant,
located in the Fukushima prefecture
in central Japan, will be the heart ofan irrigation project. Voith Siemens
Hydro’s Japanese unit, Voith Fuji
Hydro K.K., Kawasaki, will supply theentire electrical and mechanicalequipment, including a 2.4 MW horizontal Francis turbine and the generator. Voith Fuji Hydro is responsible
for the balance of plant, erection andsupervision of the power station,scheduled for commissioning in July
2003.

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33

The invigorating power of water
Modern people tend to begin and end their day in the bathroom. This was
not always the case: until well toward the middle of the nineteenth century,even intellectuals and the aristocracy were not convinced of the value ofa daily bath. Water was regarded as a carrier of disease and excessive
hygiene was considered to be a health risk. Yet for thousands of years
before the cleansing, relaxing and invigorating properties of water had been
known throughout the ancient world.
People have enjoyed bathing in every
era of the world’s history. All cultural
regions built their own bathing facilities, but long before that people wereusing natural rivers, ponds and pools
for ritual bathing or on account of
their healing properties.

Essay
Pamukkale terraces in Turkey.

One of the best-known examples isin Turkey; the snow-white sintered
terraces of Pamukkale. These cascades,
consisting of sparkling limestone
deposits, located deep in the countryside bordering the southern AegeanSea, have been celebrated since time
immemorial for the regenerative
powers of their waters, which containcalcium and are slightly radioactive.

The water emerges from the groundat a temperature of 35 degrees Centigrade and cools as it flows over the
cascades, so that the calcium is precipitated and forms these wonderfulnatural basins as the deposits build up.
In the Islamic cultural regions, thedevelopment of bathing had a primarily religious significance. For thisreason, there were baths in themosques. The true believer visitedthem mainly as ritual, with the pleasure of bathing a secondary consideration. Cleansing of the soul and the
body are closely linked in Islam.
The prophet called for believers topray five times a day and to washthemselves each time before prayer.
If no water is available, for instancein the desert, the use of sand ispermitted.

Turkish hamam bath.

Today’s Turkish baths are more secular in character, but a cultural experience none the less. Whoever has
relaxed in the “hamam” will havelearned to value this pleasant for of
total physical and mental relaxation.
The alternation of rooms heated tovarious temperatures, refreshment in
ice-cold water, resting in dimly lit
rooms and the deep penetration of
the pleasantly scented soapy water
massaged with a brush into the poresof the skin by the bath attendant –all this restores the well-being of theguest to a most remarkable degree.
Japanese onsen.

Now let us turn to Hindu culture in
India. Every year, millions of people
make the pilgrimage to the holy cityof Varanasi (Benares) on the Ganges
river. To bathe in the river, whichis considered holy at this point, is
to be cleansed of the sins one hascommitted and granted absolution.
The bells ring, the priests chant hymns
and the hypnotic scent of the innumerable flowers scattered on the wateraccompany this age-old spiritual rite,
which is still practised with great awe
and respect.
In Japan people have for several
millennia bathed communally every
day in exceptionally hot water, forreasons of hygiene and also social
contact. In many cases thermal
springs (onsen), of which there aremany in Japan, supply the water.

The traditional Japanese bathtub ismade of wood, the temperature being
maintained at a constant level by ametal boiler located inside, regardlessof how many bathers at a time are
seeking relaxation from the day’s
hectic stress.
As we can see, despite all the culturaland ritual differences that have grown
up between the peoples of this world,
they have always remained aware of
the healing and purifying power ofwater and have also learned, in themost prosaic way, to use this naturalelement purely for their own pleasureand delight.

hypower 3/2002

Ganges riverin India.

It is either piped into the buildings, orthe bathing and regeneration process
is enjoyed in the open air. The bather
cleanses his or her body prior to,
before the actual ceremony. One sitson a small stool and soaps one’s bodythoroughly with the onsen cloth fromone’s own small vat. After rinsing
down, one plunges into the actual
bath, which is usually at a temperature that the average European finds
unbearably hot.

34
35

Copyright 2002
Reproduction permitted,
provided source is given.

www.msw.de

Editorial coordination:
Barbara Fischer-Aupperle

10000

Voith Siemens Hydro
Power Generation GmbH & Co. KG
Alexanderstraße 1189522 Heidenheim/Germany
Tel. +49 7321 376848
Fax +49 7321 377828
www.more-powerful-solutions.com