HyPower
Customers magazine for Voith Siemens Hydro

November 2004

Summary

03

04

Editorial
Successess and historical landmarks
Focus on Brazil
Brazil:Hydro power to remain strong

06

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

08

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

1012Technological leadership
Micalastic:
outstanding performance facts
and figures

CIGRE:
Expertise sought after in energy
conferences

14

Modernization of Furnas, a Brazilian
milestone

16

18

Successful model acceptancefor China’s Shui Bu Ya

20

Miyashiro, Japan:
100 years of successful operation

21

News from Europe
Early finishing of site rehab in Coo
pumped storage plant

22

Generator rehabilitation of the
Schwarzach power plant in Austria

23

New turbines for Hauterivein Switzerland

24

Customer contacts
HydroVision 2004 and Hydro 2004
Hydro technology with a politicalorientation

25

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

26

Essay
The Madeira River

Peruvian Callahuanca to be modernizedNews from North America
Continued support –13 units rehabilitation of NYPA’s
Robert Moses Niagara power plant

News from the Far East
Voith Siemens Shanghai to equip Laxiwa
on the Yellow River

19

South American market activities
Great expectations for small hydro1315EditorialVoith Siemens Hydro Power Generation
Successess and historical landmarks

Dear readers,With the end of the year approaching, Voith Siemens Hydro can lookback on a fascinating period, filledwith activity.

Dr. Hubert Lienhard
Chairman of the Boardof Voith Siemens Hydro
Power Generation

I am satisfied with the fact that theindustry increased its focus on political awareness insideout and outside-in, which was evident from activities inthis year’s major international hydro events, HydroVision
2004 in Montréal and Hydro 2004 in Porto. We are alsoproud to have contributed to the wonderful progress
various hydro organizations and associations made thispast year. But in order to have hydro power of all sizes
again a “fuel” that is recognized for all its benefits in asensible ratio with some of its – undisputable – side
effects, a lot still needs to be done. Our goal is to achieve
better reconciliation in processes involving all stakeholders, despite the limitations that the equipment suppliers’
role usually has.
Voith Siemens Hydro has had a satisfying year in terms oforder intake and business development; as can be clearlyseen from the reports in this issue. Our success in China,
North America and Europe, confirms our strategy ofcompensating changing business cycles in one region byother emerging markets throughout the world.

The celebration of this anniversary deserves the reflection
on Voith’s past activities in this country – including Voith
Paper and Voith Turbo products as well – and acknowledges once more our corporate culture of being global
and acting local.
Even though the business in Brazil started almost 100 years
ago with the delivery of our first turbine, local engineeringand local manufacture was the right option in 1964 to beable to participate in market opportunities, which emerged
from the country’s economic boost at the time.
Voith’s endurance to stay there, even with decreasing
business during the later economic slow-down has paid
over and over again: Today, Voith Siemens Hydro in São
Paulo is simply the Latin American hydroelectric equipment company with the deepest expertise for the largest
hydro plants in the world.
The “Paulistas” can be proud of their history and proudof their business!
We are interested in your opinions and comments,
please feel free to direct them to me personally at
Hubert.Lienhard@vs-hydro.com.

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

hypower 9/2004

Yours sincerely

Dr. Hubert Lienhard

02
03

Focus on Brazil

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

São Paulo

The prevalence of hydroelectric energy
makes the Brazilian generating systemdiffer from that of any other country
in the world. Hydroelectric power
makes up almost 80% of the Brazilian
electricity market. Due to a severe
drought, the hydro powered Brazilianenergy sector experienced a major
supply crisis in 2001 when power
stations were left with shrinking or
dry reservoirs.

However, the government successfully minimized the impact of the crisis
by implementing a rationing program.
Since the end of the rationing period,
an unprecedented decline in demand,some minor capacity growth andabundant rain have resulted in an
estimated excess of up to sevengigawatts. It is important to note,however, that this surplus is only
temporary. Unless new generating
capacity is added to the system, any
growth in demand could result in a
new crisis. The new government,
inaugurated in January 2003, hasacted quickly to evaluate the power
sector policies and initiate programs
to solve bureaucratic red tape andovercome investment problems inthe sector.

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

Iguaçu Falls

hypower 9/2004

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

0405

Focus on Brazil

Voith Siemens Hydro, São Paulo:
40 years high-tech in
There is still an estimated 226 gigawatts of untapped hydroelectric potential
in Brazil. Due to this huge potential and to its economic attractiveness,hydroelectric power is the country’s most important primary source forgenerating electric energy. Moreover, it is a renewable source, not dependent on price increases or supply interruptions. Today, the technology for its
development is domestically available, with a very low import ratio.

Today’s main entranceof Voith Siemens Hydro
São Paulo, Brazil

Location opening in 1966

This can be traced back to 1964 andthe foundation of Voith S.A. Máquinas
e Equipamentos in the Jaraguá district. This plant was Voith’s first
production unit on the American
continent and was established on
September 22, 1966.

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

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

hydro technology

Many important orders followed in
the subsequent decades. In the 1990s,
the Brazilian factory started to manufacture components for Chinese hydroprojects, including the world’s largest
Francis rotors for Wu Qiang Xi.

Xingó, Brazil

Competence center in generator
manufacturing
With the merger of the hydroelectricbusiness of Siemens and Voith Hydro
in 2000, the plant in São Paulo began
to supply not only systems and equipment but also generators for complete plants.
By the turn of the millenium, theSão Paulo facility had supplied a totalof 260 hydropower projects in thistropical country. Additionally, SãoPaulo delivered generator stator
frames – the largest ever – and turbine buckets for the enormous Three
Gorges project on the Yangtze River.

Lapa, Brazil

São Paulo plays an important role in
the group’s overall development.
This is the location of Voith Siemens
Hydro’s largest generator manufacturing plant worldwide. Know-how isregularly exchanged between Brazil
and Germany. International collaboration is a matter of course: employees
from Brazil work for a few months at
the headquarters in Heidenheim andemployees from Germany spend partof their project time in Brazil.
Cross-training is essential to ourcommitment to excellence.
In the meantime, Voith employs over
1,800 people at its plant in the cityof 20 million. The Voith Siemens’plant is the largest metal-processing
company in the city. In 2002, Voith
Siemens Hydro Power Generation
received an award from the Brazilian
trade journal Exame as the mostrespected machinery manufacturing
company in the country, an honor ofwhich we are very proud.
For more information:
Sergio.Parada@vs-hydro.com

hypower 9/2004

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

06
07

Focus on Brazil

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

There was much to celebrate in mid-September 2004:
Voith’s facilities in São Paulo just received a prestigious award for being
the largest metal-processing company in the city and it was designated as
the largest generator manufacture location within Voith Siemens Hydro
Power Generation worldwide.
And the Paulistas provided everythingworthy of such a success story.
More than 700 people accepted theinvitation, and the festivities beganwith a splendid gala evening. Amongthe guests were many members ofthe Hanns Voith family, friends ofthe company, political and business
representatives, as well as manycustomers from all around the world.
Mrs. Martina Mann and her great-granddaughter visit the school Friedrich von Voith

The commemoration starts with apress conference on September 16

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

Geraldo Alckmin, Governor of theState of São Paulo, emphasized theimportance of Voith for the State ofSão Paulo in his address: “With its
successful history in Brazil, Voith iscontributing to the development of
the country. Not least in our own
interest, we would like to wish Voith
another 40 successful years in
Brazil!”Other highlights of the gala evening
were speeches by Dr. Michael
Rogowski, Chairman of the Supervisory Board and the Shareholders’Committee, and by Martina Mann, theeldest daughter of Hanns Voith.

The visiting program also included
some social and environmental projects sponsored by Voith and an
exhibition with photographs showing
the development of Jaraguá, thedistrict where the Voith plant has
been located over all its 40 years.

The last day of the anniversary saw acelebration with employees, friends
and relatives, with more than 10,000
people taking part.
Johannes Hammacher, representing
the Hanns Voith family, said: “Always
remember that Voith cannot exist
without you. Brazil will always have a
special place in the hearts of the Voith
family.” Under the tropical sun ofSão Paulo, a barbecue with music
and rhythms of the “Rosas de Ouro”(golden roses) samba school washeld.
For more information:
Renata.Presta@vs-hydro.com

hypower 9/2004

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

The following day, the factory doors
were opened to customers, suppliersand employees and their families.
During this day, Martina Mann inaugurated the new Voith Siemens Hydro
generator plant, which had been
moved from the city’s Lapa district
to the Voith location in Jaraguá.
From now on, mechanical and electrical components of the project will
be built in these new workshops.

08
09

Technological leadership

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

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

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

Micalastic effectively insulates thebars and coils of high voltage
machines. Based on VPI technology,
it fulfills minimum Thermal Class F
requirements according to international standards (IEC 34). The main
components of this insulation system
are impregnated glass yarn for the
strand insulation, fine mica tape withaccelerator (Zinc-Naphthenat) for themain insulation, and an epoxy resin
as impregnation resin.

40
kV
mm
20
15
Dielectric strength 50 Hz. 20 °C

Transposed conductor of a Roebel bar

10
8
6
4

2
10 -2

10 -1

1

10

10 0

60 min

10 1

10 2

10 3

10 4

10 5 h
t

1

10
Years

100
Endurance curve of the Micalastic insulation

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

Furthermore, since the early 1970s,
the properties of the main insulation
have been proven by short- and longterm endurance tests. The short-term
test is the one-minute breakdown
test, in which the dielectric strengthis measured applying a voltage witha continuous increase rate until the
insulation fails. Typically, the breakdown happens at a dielectric strength
higher than 25 kV/mm.

The long-term endurance test is theVET (Voltage Endurance test).
Typically, these tests are carried out
at 3 x Un and 2 x Un. For these voltage tests, respectively, the minimum
life time of a bar or coil is higher thanthe values specified by the KEMA
standard which is the internationalreference for this kind of test.
Micalastic also fulfills the VET according to IEEE 1043 and IEEE 1553.
For more information:
Caio.Kramer@vs-hydro.com

Micalastic Insulation – Characteristics and Test Voltages– Single stator coil (diamond coil)
Surge voltage endurance along slot

Test voltages and permissible surge in operation
Test voltage, 50 Hz, Up RMS , 1 min– Single stator bars (half coil)– Single stator coil (diamond coil)– finished winding assembly
Ratio between test DC an AC voltage Up DC /Up AC
Test voltage, conductor strands, 50 Hz
Permissible surge voltage on windings in operation≈4≤ 2,0 %
≤ 0.5 %
≤ 0,5 %
≥ 25
Up ≥ 4.5 U N at slot sideUp ≥ 3 U N at front sideUp ≥ 2 . (2 U N + 1 kV) at slot sideUp ≥ (2 U N + 1 kV) at front side
≥ 50 (1.2/50 s wave)
Us ≥ (4 U N + 5 kV) at slot sideUp ≤ 3 U N
Up ≤ (2 U N + 5 kV)
Up = (2 U N + 1 kV)
1.7
220≤ 3.5 U N at Uphase-core≤ 5 U N at Uphase-phase

kV/mm
kV
kV
kV
kV
kV/mm
kV

kV
kV
kV
V
kV
kV

hypower 9/2004

Electrical characteristics
Relative dielectric constant, r , 20 °C, 50 Hz
Tang  at 0.2 U N , 20 °C, 50 Hz
1/2 (Tang /0.6 U N - Tang / 0.2 U N ), 20 °C, 50 Hz
Max.  Tang / step 0.2 U N (from 0.2 U N to U N )1 min. breakdown strength, 50 Hz, slot side
– Single stator bars (half coil)

10
11

South American market activities

Great expectations
for small hydroBoosting Brazil’s renewables
The Brazilian Alternative Energy
Sources Incentive Program (PROINFA), originally launched in 2002 andrevised in November 2003, aims at
substantially increasing the role ofalternative energy generation, including wind, biomass and small hydropower to 10% of the annual electricity
consumption, within 20 years.
To achieve this goal, the Brazilian
Government has designated a federal
state-owned power utility, Eletrobrás,to act as the purchaser of electricenergy generated by alternative
energy facilities in Brazil. Eletrobrás
will buy energy at pre-set preferential
prices and then market the electricity
generated from renewable sources.
This guarantees a price of at least
70% of the average energy supply
tariff, charged to end consumers in
Brazil. Contracts between Electrobrás
and the renewable energy generators
will be valid for a period of 15 years
from the date of operation and applicable to plants that begin production
before 2007.
Under PROINFA, 1,100 MW havebeen distributed for each alternative
source, totalling 3,300 MW.

Power Future 2004
The Brazilian National Development
Bank can finance up to 70% of capitalcosts, excluding site acquisition andimported goods and services. Interest
is not charged during construction,
and amortization is set at ten years.
Payments are due six months after
the start of commercial operation.
Furthermore, the Brazilian Electricity
Regulatory Agency (ANEEL) will
discount as much as 50% of thetransmission and distribution rates
charged for power produced fromrenewable energy sources, including
small hydro electric plants.

One of Brazil’s most important eventsof the year with regard to alternative
energy, took place in April at the
Ceará Convention Center in Fortaleza
and focused on renewable energy
sources and more specifically on
PROINFA.
Voith Siemens Hydro São Paulopresented its small hydro technology
to a highly interested public, among
them the state governor of Ceará andenergy secretary of São Paulo.
For more information:
Sergio.Parada@vs-hydro.com

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

At CIGRE’s biennial conference,various committees and work groups
come together to discuss reports on
predefined topics, submit papers,
and define and publish new technicalrecommendations. This year, theconference took place from August 29
to September 4 in Paris. Henrique
Alvarez and Thomas Hildinger ofVoith Siemens Hydro, took part inthe committee debates and plenary
sessions.

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

Thomas Hildinger

For more information:
Renata.Presta@vs-hydro.com

hypower 9/2004

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

12
13

South American market activities

Modernization of Furnas,a Brazilian milestone
Built in the late 1950s, the Furnas Dam was one of the first major modern
dams in Brazil. Its power stations marked the starting point of an accelerated
increase in installed capacity that went from around 5 gigawatts before
these plants began operating, to almost 90 gigawatts today. The Furnas
hydro plant, with an installed capacity of 1,216 MW, was a milestone in
the hydroelectric development of its time, noteworthy also for its ability
to regulate flow to important downstream installations. After more than
40 years of operation, it is now being modernized by a consortium of companies led by Voith Siemens Hydro.
120 meters high, the Furnas Dam
impounds the waters of the Rio Grandeand Sapucaí Rivers, forming a huge
reservoir spreading over 1,400 square
kilometers. Located in the southeastern state of Minas Gerais, thedam with its hydro power facilities
lies right in the center of an extensive
regional electrical grid serving theindustrial centers of São Paulo,
Rio de Janeiro, and Belo Horizonte.

The original design of the Furnas
plant included six machines – Nohab
Bardella Francis turbines and Siemens
generators – the first of which was
installed in July 1958. Five years later,in 1964, Furnas power station began
operation. In 1974 and 1975 anothertwo generating units were added, withthe same technical characteristics.

Voith Siemens Hydro is responsible
for the modernization of the older
units 1 to 6 that have now reachedthe limits of their life-span, after morethan four decades of excellent performance. The company will also deliver
supplementary items for units 7 and8, plus the plant substation.
Project duration is scheduled to be
62 months. The planning phase isalready completed, and constructionof the new relay house has alreadybegun.
The total modernization is expected
to be finished by March 2010.
For more information:
Jamil.Sallum@vs-hydro.com

Control room and substation

Peruvian Callahuanca
to be modernized

Callahuanca is located 60 km east of
the capital Lima and is situated in theAndes. With its four horizontal Pelton
unit, it is capable of generating a
total output of 73 MW. The first threemachines, equipped with Voith runners, were installed in 1938: a fourth
unit followed 20 years later. Now, thehydro specialists from São Paulo will
supply new runners with an optimized
hydraulic profile, thus increasing theturbine output of the three older units
by 25%.

New stator cores, speed and voltage
regulators, transformers and improved
turbine shut-off valves are part of themodernization work, too.
New auxiliary equipment will be provided for the newer unit and the entire
station will be automated and receive
a new control room.

An innovative runner production
method will result in superior quality
and allow for reduced manufacturing
time. Under a tight project schedule,
limiting unit outage to a challenging
maximum of 90 days per unit, thisgain of manufacturing time is muchappreciated.
For more information:
Antonio.Canina@vs-hydro.com

hypower 9/2004

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

14
15

News from North America

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

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

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

The contract included the hydraulicdesign, model manufacture, test andshafting analysis for uprate as wellas the additional scope for various
parts and services that result fromthe evaluation of each unit and disassembly.

Installation, transportation, fieldmachining and a spare runner are also
included in Voith Siemens Hydro’s
workscope. The project rehabilitation
schedule of one unit per year accommodates having the maximum availability of units for power generation.
Before and after repair

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

For more information:
Carol.Rose@vs-hydro.com

Voith Siemens Hydro’s work inprogress on the stator repair andrewind at the Robert Moses Plant

hypower 9/2004

To date, eleven units have been completed with runner uprates and turbine
rehabilitations with scheduled completion of all units for 2006. Two units
have been completed with stator
repairs and rewinds with scheduled
completion of all units slated for 2010.

16
17

News from the Far East

Voith Siemens Shanghai to equip Laxiwa
on the Yellow River

Laxiwa project site

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

Laxiwa dam

In August 2004, Voith Siemens Hydro
Power Generation Shanghai Ltd. wasofficially awarded the contract for
supplying five 711 MW Francis turbines by Yellow River Upper Stream
Hydropower Development Co., which
belongs to China Power Investment
Corporation. It is the largest contract
Voith Siemens Hydro Shanghai hasever received since it has been established.

Laxiwa is the biggest hydro project
along the Yellow River, and is part of
the Chinese National Hydro Power
Development Program to utilize thehydropower resources in the westernregion. It transmits the energy to theeastern areas. The first unit is scheduled to be put into operation in 2008.
The plant will help meet the continuously increasing Chinese power
demand.
For more information:
Xiaping.Shen@vs-hydro.com

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

Voith Siemens Hydro will supply fourFrancis turbines with a capacity of
466.3 MW plus auxiliary equipment.
The first unit is planned to be commissioned in July 2007. The project isscheduled for completion in 2009.

The power station will play an important role in the regulation of flow on
the Yangtze during summer flood
season and will help balance peaking
power demand in Central China’s
power grid, thereby enhancing safeand reliable operation of local power
grids.
For more information:
Wolfgang.Rudolf@vs-hydro.com

hypower 9/2004

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

18
19

News from the Far East

Miyashiro, Japan:
100 years of successful operation
It was a good 100 years ago when a caravan of heavily loaded horse-drawn
carts made its arduous way through the central mountains of Japan.
In big wooden boxes they carried a turbine and a generator destined forone of the early hydro power stations there, Miyashiro No. 1 Power Station,
not far away from the famous city of Matsumoto located in the Northern
Japanese Alps.
The equipment had made a long
journey, all the way from Germany,
since the turbine was designed andmanufactured by J.M.Voith in Heidenheim and the generator by Siemens
Schuckert Werke in Berlin.
For 100 years, to the delight of theowner, Chubu Electric Power Co.,
Inc., the machines have run smoothly
and without major failure or breakdown.

On September 11, 2004, Chubu
Electric Power Co. Inc. commemorated 100 years of flawless operation at
the power station. After a religious
Shinto ceremony held at the site, acheerful party was given, attended bymany former employees, engineers
and city officials. Representatives ofthe owner, the operators and Voith
Siemens Hydro expressed their greatsatisfaction and pride in making andsuccessfully maintaining a power
station over such a long period oftime.

To mark the opportunity, the responsible Chubu Electric General Managerof the Power Station, Mr. Norio
Yamanoi, received from Dr. Martin
Kuechle, President of Voith Fuji Hydro
K.K., the entity of Voith Siemens
Hydro in Japan, a large acrylic panel
displaying the etched copy of theVoith original order sheet for theturbine. The document reads, among
other things, “Turbine No. 1433…
Spiralturbine Gr. 5 B 3%”, order
received on July 13, 1903, to bedelivered on October 1, 1903 (!) and,remarkably, among other technicaldata, the machine output was given
as “Nutzeffekt PS 371” (output 371
horse power).
For more information:
Naoto.Yoneyama@vs-hydro.com

News from Europe

Early finishing of site rehab
in Coo pumped storage plant

The plant is equipped with six Voith
Siemens Hydro Francis pump-turbines, three in the Coo 1 and three in
the Coo 2 power houses. The overall
installed capacity of Coo exceeds
1,100 MW. The partial on-site overhauling of Coo 2 was tightly scheduled for six weeks and three days.

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

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

Besides a rather limited working area
Voith Siemens Hydro had to deal withsome unexpected damages on single
parts of the valves during the refurbishment. Nevertheless, the teamfinished its task ahead of schedule.
Before Coo 2, Voith Siemens Hydro
had already successfully completed
the overhauling of three sphericalvalves in Coo 1 within a comparablychallenging timeframe.
For more information:
Luciano.Lorenzini@vs-hydro.com

hypower 9/2004

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

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News from Europe

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

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

This enables the power station to
generate peak power. Voith Siemens
Hydro has already rehabilited – from1987 to 1991 – the Francis turbines ofthe four units in existence since 1959,
when the output was raised to 34.41
MW. The present generators, however, are not capable of fully reaching
this capacity.

View of the hydro power plantMoreover, the existing stator windings, including stator cores, havearrived at the end of their service lifeand have to be renewed.
Through modernization, losses can be
reduced by around 20%, even with a
7% increase in output. Furthermore,
the present auxiliary equipment forthe oil bearings will be renewed.
For more information:
Kurt.Dienstleder@vs-hydro.com

Generator hallNew turbines for Hauterive in Switzerland

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

In the spring of 2006 the new machine
will relieve the older models from1919 and 1925. At a head of 94 meters,
24.7 MW will be generated from the
new unit in addition to three existing
units with Francis turbines at 15 MW
each.
For more information:
Jean-Pierre.Fouilloux@vs-hydro.com

hypower 9/2004

The small hydro operating unit ofVoith Siemens Hydro at St. Loup in
France has signed the contract with
the Swiss plant owner, Entreprises
Eléctriques Fribourgeoises near
Fribourg. Scheduled to be renovatedby means of a new, vertical Francis
turbine are two old units, each withan output of 7.5 MW.

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Customer contacts

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

As a keynote speaker, Gregg Easterbrook, editor-in-chief of the “The New
Republic”, attracted particular attention. Easterbrook explained his mostimportant argument for hydro power:“As long as the world produces more
people, they will need more dams tobring water, irrigation and clean
power to displace polluting powersources.” Not only the Western world,but developing countries in particular
could be substantially benefiting fromhydro power, according to Easterbrook. On one hand, energy generation through hydro power is economically profitable, emissions-free, andrenewable. On the other hand, alternatives like wind, solar, geothermic
power and biomasses can never cover
the increasing need for primaryenergy production.

He backed his speech with a call tonational governments: “There are
failings of governments, not of hydropower… The root problem is the needfor all governments to treat theimpoverished better.”
The hydro industry – convinced that
it is providing power in the best way,
but while the public image of hydropower is often tarnished – has founda platform for action: joining forces
for the second time at HydroVision,
the Joint Organizations Meeting, called
for by International Hydro Association(IHA) and National Hydro Associationof USA (NHA) saw an increasing movetowards activating the disseminationof IHA guidelines.
Another increase in focus on environmental and social issues of hydroand a turn-around in the public image
could also be felt in Hydro 2004 in
Porto, Portugal.

Not only was the keynote speech of
Dr. Hans P. Schiffer, Chairman of Hydro
Equipment Association, looking at thehistory of development in mankind's
history from a very different angle.
The attendance of representatives ofNGOs, such as IRN (International
Rivers Networks) showed, that dialogue among the sometimes mostcritical stakeholders has started to
evolve.
As a sponsor and member of the
IHA and NHA, Voith Siemens Hydro
fully supports this. Additionally,
through Hydro Equipment Association,
the suppliers’ association of Voith
Siemens Hydro, Alstom Power Hydro
and VA Tech Hydro, it will continue
to work in this field.
For more information:
Barbara.Fischer-Aupperle@vs-hydro.
comHydro Facts: Did you know about…?

Protecting the climate
3 kg CO2

fossil energy
3 kWh
1 kg of coalHydro power helps to keep emissions as low as possible.
The energy generated annually byhydro power is free of emissions anddoes not use up natural resources.
For more information:
Barbara.Fischer-Aupperle@vs-hydro.
com

hypower 9/2004

Each kWh produced with hydro power
reduces CO 2 emissions by 1 kg.

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EssayThe Madeira River

In the interests of three countries
Most people, if asked about the greatrivers in the world, think immediatelyof the Amazon.
When its water levels are at theirpeak, this river can flood an area up
to 100 kilometers wide in the forests
along its banks. The delta on theSouth Atlantic coast is also several
hundred kilometres wide and encompasses the huge river island Marajó,
and, with approximately 4,900 square
kilometres, is the largest delta islandin the world.

The incredibly large Amazon Riversystem – if source rivers are included– is the longest river in the world.
One of its tributaries is the Rio
Madeira, and with 1,450 km, is amighty river in its own right so therefore, worth a closer look.
The river owes its name to the factthat on the journey to the Amazon
delta from its source, at the confluence of the Guapore and the Mamoreo
Rivers, it carries a great deal oftimber – countless trees that it has
torn down. Since the Portuguese
word for wood is “madeira”, it istoday known as the “river of wood”.

With a navigable section of 1,100 km
between Porto Velho and Itacoatiara,
the Rio Madeira is one of the mostimportant waterways in South America. It is the main transport route formost of the soy, produced in the stateof Mato Grosso, and also for exported
goods transferred to large oceangoing freightships at the trading
centre of Itacoatiara.
The Rio Madeira has an importantpart to play in the development of thetransport infrastructure in three major
South American countries – Brazil,
Bolivia and Peru.

The cultural history of the Rio Madeirais closely linked with the creation of
the federal state today known as
Rondônia and its capital Porto Velho,
which is also the most important porton the river.
The Amazon delta was discovered in
1499 or 1500. The sailing ships of the
Italian Amerigo Vespucci and theseafarer Vicente Yanez Pinzon reached
it at almost the same time, but
Vespucci is often credited as the firstto arrive. His voyage was commis-

sioned by the Portuguese, who thenbegan to colonize the Amazon region
and made the land fit for agriculture.
Marshal Cândido Mariano Da Silva
Rondon, who was born on May 5 th1865 in Mimoso, Mato Grosso, isconsidered to be a trailblazer of themodern era in terms of national
development policy. A great humanist,he served in the new republican
government of Brazil and was responsible for opening up the vast region
around Rondônia. Rondon and his
team built roads, erected hundreds oftelegraph poles and with many kilometers of wire, recorded the topography of the areas, discovered unknown
rivers, studied the flora and fauna andwere the first to build up a relationshipof respect with the native inhabitants.

Any description of the flora andfauna of the vast riverscape aroundthe Rio Madeira calls for the use ofmany superlatives. The rainforest is
extremely rich in species.
Exotic plants, ancient trees that growto unimaginable heights, and countless wild creatures, all enjoy virtuallyperfect living conditions here.
A particular feature is that the MadeiraRiver is home to the largest freshwater
species of dolphin. These friendly
mammals – known as boto – are thesubject of many legends still told by
the region’s inhabitants.
The area around the Rio Madeira is,of course, still developing. High levels
of investment are improving the living
conditions of many people in Brazil,
Bolivia and Peru. The carefully controlled use of hydroelectric powerplays a large part in this. The statesof Rondônia, Acre and Mato Grosso,
for instance, are to be connected to
the Brazilian electricity grid and theamount of hydroelectric power produced is to be increased by some
18,000 megawatts.

hypower 9/2004

Together with the other rivers, it forms
a navigable waterway of 4,225 km,
giving access to the Atlantic Ocean
and thus to international markets for
agricultural products and industrial
goods.

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Copyright 2004
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 37 68 48
Fax +49 7321 37 78 28
www.voithsiemens.com