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Seite 1

HyPower
10000

www.msw.deCustomers magazine for Voith Siemens Hydro

July 2003

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Seite 2

Summary

Editorial

3

Editorial
Engineered reliability!

22

4

Focus on Small Hydro
Worldwide trend towards small hydro24

5Voith Siemens Hydro:
big player in small hydro25

6Increasing demand for small hydropower plants in Norway

Generator modernization
Frequency conversion modifications andrewinds at Canadian generating station
Hydroelectric generator rewinds
and modernization
Customer contacts
Events 2003

26

Milestones in history
One hundred years of Niagara Falls
turbines

8

Small hydro in Europe

11

Würmtal: 100 years of reliable operation

28

100 years of Pelton turbines from Voith

12

Small hydro in south and north America

29

NHA Award for aerated runnerdevelopment

14

Small hydro in south-east Asia

16

Efficient automation for smallhydropower plants

18

Market splinters
Hydro power in the desert: successful
start in Ghazi Barotha, Pakistan

19

Khopoli, India, connected to the grid

20

Kiskoere, Hungary:
Model tested successfully

21

Rehabilitation of Bulgaria’s Orfeus andKrichim hydropower plant

30

Essay
What is the origin of life?

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Seite 3Voith Siemens Hydro Power Generation
Engineered reliability!

Our new issue deals with small hydro as a market focus
and I think that we do provide you with an extensive
overview of where our activities take place: worldwide.
A newly-structured team in our company takes careof driving this focus on the basis of our new platform
concept. Our message is, that especially in small hydro,
innovative approaches and high-quality, high-techsolutions, do not automatically result in high-end prices.
Our complete packaging concept does apply in smallhydro business at least as much as in large hydro.
Excellent baseline designs together with short realization
times meet cost effectiveness. And still, this is doneon the basis of our state-of-the-art research and development experience, that can be considered leading in
the industry.
Small hydro is again getting “fashionable”, also in termsof policital treatment, and can even help you to get green
certificates or can play a role in the Kyoto goals of industries and nations.
The recognition of hydro power – small or large – as
the most mature of all renewables in energy generation,is breaking ground again, these days: The World Water
Forum in Kyoto, held in March this year, explicitely
declared large hydro to be renewable. In our eyes it ishigh time for hydro to be acknowledged again for what
it deserves to be. I congratulate International Hydro Association’s tremendous efforts, to put forward their message
for hydro in the context of this event!

Above this, our company’s technical contributions andefforts to even more environmentally friendly solutions arereflected in the award of NHA to our location in the USA:it was given to the common development of the U.S. Army
Corps of Engineers’ and Voith Siemens Hydro’s aerated
runner concept.
The optimization of components as well as complete
plants, small or large, is our business, the handlingof projects of any size in close and good cooperation
with partners and customers as a project company iswhat we have to offer. We master this with well-established locations in the Americas and Asia, know-how
based on excellent staff and equipment, unique andunified standards and quality worldwide. We continue
to offer what Voith and Voith Siemens Hydro havedeclared the company principle:
Engineered reliability!
Whatever your opinions and business interests are:please do not hesitate to let me have these!
Yours sincerely

Dr. Hubert Lienhard

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

hypower 5/2003

Dear clients and partners,
dear readers,Dr. Hubert Lienhard
Chairman of the Boardof Voith Siemens Hydro
Power Generation

02
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Seite 4Focus on Small Hydro

Worldwide trend
towards small hydroIn line with the strategy of global hydro development, small hydro technology is making a significant contribution to sustainable, clean energy policy.
Small hydro is playing an increasingly important role in promoting socialand economic development, taking into account the fact that electricity
supply and availability is essential for developing rural areas as well as forindustrial growth.

Decentralized renewable energy cansolve numerous local problems relating to energy supply. There are threemain drivers behind the global trend
towards small hydro: The promotion of renewable power
is in full accordance with the latest
national legislation (green certificates) in various countries.
 An increasing dependence on
primary energy sources could leadto serious economic threats. Powersupplies from alternative, decentralized sources are becoming
more and more attractive.
 Small hydro has the lowest environmental impact of all energy
sources, including other renewableenergies. It fully corresponds
to environmental commitments,
including the Kyoto protocol.

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Seite 5Voith Siemens Hydro:
big player in small hydroAs a world leader in hydropower equipment and services with a productline covering project handling and technology for all types of hydraulic andelectrical machinery as well as a complete range of mechanical and electrical services, Voith Siemens Hydro has more than 135 years of tradition
in small hydro worldwide. The most modern research and development
centers in Germany, in north and south America provide the technologicalbackground for the international activities, thus profiting from researchbased large hydro developments.
Locations
The acquisition of a majority stakein the leading French small hydro specialist Esac Energie at the beginningof last year further expanded Voith
Siemens Hydro’s position in the smallhydro market. The technological edgeof a leading hydropower company has
since been combined with the focus
and flexibility of a company fully andsolely dedicated to small hydro.

Interested in our new Small-Hydro
brochure? Please contact:
Silke.Berger@vs-hydro.com

Worldwide activities
Voith Siemens Hydro is involved innumerous successful small hydroprojects in Europe, north and south
America, Asia and Africa.
For more information:
Anton.Mitteregger@vs-hydro.com

hypower 5/2003

Technological edge and costeffectivenessBased upon such long-term experience and state-of-the-art technology,
a technological platform concept forsmall hydro has been established.
It defines uniform technical standards
on a modular design basis and standardized components. Its development was possible only becauseof the extensive know-how derived
from the huge number of contracts
executed by Voith Siemens Hydro.
Thus, seemingly conflicting smallhydro requirements have been united:cost-effectiveness, flexibility andsimplicity on one side, high performance, reliability and availabilityon the other side.

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Seite 6Focus on Small Hydro

Increasing demand forsmall hydropower plants in Norway
Vedeld receives E+M-package andspecial outlet
Voith Siemens Hydro was awarded
the contract for the electro-mechanical package by Tussa Energi AS.
Extra attention must be paid to a
special outlet construction, as part ofthe discharged water from the turbine
goes to a salmon farm. Therefore,
Voith Siemens Hydro is installinga by-pass arrangement to secure
the water supply to the fish farmeven when the power plant is outof operation.
Data
Net head: 247 m
4 jet vertical Pelton turbines
3.4 MW turbine output
3.8 MVA generator output
Commissioning September 2003
Oyvind.Holm@vs-hydro.com

Riksheimdal to be visually integrated in Norwegian landscape
Riksheimdal is being built to utilize
the water between an existing water
reservoir and an old small hydropower plant. Voith Siemens Hydro
was awarded the turnkey contract,
including 3,000 m of penstock and apower house, by Sykkylven Energi AS.
Together with one of its best Norwegian customers, Nord-Trøndelag
Energiverk (NTE), Voith Siemens
Hydro will be installing a state-of-theart electro-mechanical package andan innovative power house. Bothsolutions have to be chosen very
carefully to preserve the original

impression of the landscape. For
this reason, the power house will bebuilt as a traditional timber log housewith a grass roof which blends into
the surrounding area. The highly
optimized iron penstock will be laid
in a trench covered by soil, and willthus be invisible to local trekkers.
Data
Net head: 380 m
2 jet horizontal Pelton turbines
4.6 MW turbine output
5.0 MVA generator output
Commissioning December 2003
Ovind.Holm@vs-hydro.com

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New equipment for Lovik
The Lovik hydropower plant is locatedin northern Norway. The plant had
been in operation for almost 50 years
when the machinery broke down. The
Lovik project is something special,
as Voith Siemens Hydro and the customer, Andøy Energi AS, entered intoa directly negotiated contract for the
replacement of the complete turbine,
the generator, the control systems,
and auxiliaries. The benefits of thisco-operation for the customer are
obvious: it will save delivery time andhence minimize the breakdown costs.
Data
Net head: 84 m
Horizontal Francis turbine
1.3 MW turbine output
1.45 MVA generator output
Re-commissioning February 2004
Oyvind.Holm@vs-hydro.com

Seite 7

Sagnfossen being uprated
Sagnofossen is an old hydropower
plant located in eastern Norway, nearto the border with Sweden. The customer, Hedmark Energi Kraft AS,
decided to rebuild the facility with anincreased output. From a variety ofpossible low head machine concepts,
Voith Siemens Hydro was awarded
the contract for a direct-driven vertical Kaplan turbine. The engineers will
install a turbine with a diameter ofapproximately 3.5 meters and an aircooled generator of 130 tons. Certainly not the type of equipment one
initially thinks of when talking about
small hydro plants. But running at a
speed of 136.3 rpm will ensure thatthe machinery is extremely reliable.
Data
Net head: 9.2 m
Vertical Kaplan
6.2 MW turbine output
6.85 MVA generator output
Commissioning August 2004

Turbine for New Bjölvo delivered
four months ahead of scheduleWith a head of 860 m, the 9.2 MW
horizontal Pelton machine for theextension of the Norwegian hydrostation New Bjölvo ranges among thehighest head small hydro turbines
built in recent years. Voith Siemens
Hydro delivered turbine and valvesfour months earlier than scheduled.
Data
Head: 860 m
Horizontal Pelton
9.2 MW turbine output
Discharge 1.2 m 3/s
Gerhard.Draxler@vs-hydro.com

Oyvind.Holm@vs-hydro.com
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Seite 8Focus on Small Hydro

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

Cargiaca, France
One Pelton unit of 4.6 MW was commissioned at the Cargiaca hydropower plant on Corsica. Voith Esac
Hydro was in charge of the mechanical part of the plant, including ahorizontal 2-jet Pelton machine.

Thomas.Roesch@vs-hydro.com

Christophe.Colnot@vs-hydro.com

Christophe.Colnot@vs-hydro.com

Stanley Mills, UK
Voith Esac Hydro supplied a complete
bulb unit rated 900 kW, for the
Scottish plant at Stanley Mills.

Work finished at Theodoriana
Voith Siemens Hydro has finishedwork on the small hydro project
Theodoriana in Greece. The contract
included two horizontal Francis turbines (2.6 MW and 1.3 MW), two
synchronous generators (3.0 MVA
and 1.5 MVA), three butterfly valves(diameters 1,100, 900, and 600 mm),and the installation of an automation
system including governor oil units.
Data
2 horizontal Francis turbines
2.6 MW/1.3 MW turbine output
3.0 MVA /1.5 MVA generator output
Gerhard.Draxler@vs-hydro.com

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Complete equipment for Gitani
The Gitani project is situated in thenorth-north-west of Greece on theKalamas river, near to Igoumensita,
the major port to Italy. Voith Siemens
Hydro received a letter of intent from
DIEKAT S. A. for the complete waterto-wire package, including two bevelgear pit turbines with an electrical
power output of approximately
2.1 MW each, generators, plant control system, electrical installations,and trashrack cleaning system.
Data
Head: 7.45 m
2 bevel-gear pit turbines
2.2 MW output per turbine
Commissioning early 2005

Seite 9New power station for Vorino
Voith Siemens Hydro will install a
new power station located in northwestern Greece approximately
150 -200 km from Thessaloniki.
Gener S.A. and Voith Siemens Hydrosigned a pre-contract for the supplyof the water-to-wire equipment package, containing one horizontal shaft
2-jet Pelton turbine, generator, plant
control system, and the electricalinstallations.

Gerhard.Draxler@vs-hydro.com

Data
Head: 550 m
Horizontal 2-jet Pelton turbine
3.9 MW turbine output
Commissioning early 2005

Turbines for the Turkish plant
Hacilar delivered six months earlier
Voith Siemens Hydro, responsible
for the entire electro-mechanicalequipment of the Hacilar smallhydropower station, manufactured
two horizontal shaft Pelton turbinesof 7 MW each in record time completely in its Heidenheim workshop.
The contractual manufacturing anddelivery schedule of the originalcontract had thus been reduced bymore than six months. Commissioning took place in June 2003.
Gerhard.Draxler@vs-hydro.com

Gerhard.Draxler@vs-hydro.com
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Seite 10Focus on Small Hydro

San Nicolo small hydro station will
yield profit in less than six years
The San Nicolo small hydro projectin Italy was carried out as a minimum
environmental impact project undera tight time schedule of roughly a year
from contract award to commissioning. In normal commercial operation
since January 2003, the power station
has been perfectly integrated in themountainous landscape of northeastern Italy. Its four-nozzle vertical
Pelton turbine, installed at a net headof 127.5 m, generates a maximum
power of 755 kW. The turbine wastested in the hydraulic laboratories
of Voith Siemens Hydro in Milan and
Heidenheim. Designed for a very flathigh-efficiency curve, it can be operated with one or more nozzles at thesame time. The unit produces morethan 3,000,000 kWh per year andrevenues are expected to reach about
300,000 Euro per year. Taking advantage of the so-called “green certificate” incentives (0.06 Euro/kWh),the plant will be completely repaid
in less than six years.
Roberto.Brivio@vs-hydro.com

Jerte commissioned in record time
In the extraordinarily short timeof just nine months, the Spanish unitof Voith Siemens Hydro manufactured
and delivered three horizontal Francis
turbines for the Jerte small hydroplant. With these units, the hydrostation, located in the famous valleyof the Jerte river in the provinceof Cáceres, can generate a total
power of almost 6 MW.

New contracts for Peneda and Arnoia
The good performance of the Peltonturbine at the Cierves hydro station,
which was supplied a few years ago
by Voith Siemens Hydro, is the reason
why the plant owner, Hidroeléctricadel Giesta, has now ordered two
vertical Kaplan turbines of 8.6 MW
and 2.4 MW for its Peneda smallhydro station and three vertical Francis turbines of 7.0 MW, 3.1 MW and
1.3 MW for its plant at Arnoia.

Carlos.Aguerre@vs-hydro.com
Carlos.Aguerre@vs-hydro.com

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Seite 11

Reliable operation: 100 years ofhydropower in Würmtal, Germany

After a general overhaul at the beginning of the 1960s, the machine operated continuously until 1970, when
the penstock was damaged. In 1980the station was recommissioned andthe electrical components and controls were replaced. In February 1982,
the plant was put back into operation.
The average energy production since
this reactivation is approximately
500,000 kWh per year.

The turbine has not been opened
for the last twenty years, merely
receiving minor servicing once a year.
With the exception of various bolts,
sleeves and bushings, the original
turbine parts are still in use. A newwater-cooled generator feeds its
excess heat directly into the heating
system of the building.
Today, the plant is used solely for
power supplies in parallel network
operation. Approximately 10 % of
the energy generated is supplied to asmall industrial estate which has been
built on the site of the sawmill in themeantime. Most of the energy generated is supplied to the public grid.
For more information:
Gerhard.Draxler@vs-hydro.com

hypower 5/2003

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

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Seite 12Focus on Small Hydro

Small hydro in south and north America

Paraíso, Brazil, commissioned now
Equipped with two horizontal Francis
turbines of 10.8 MW each, the Paraíso generating station almost escapes
the concept of small hydro: when infull operation, the two machines willproduce enough energy to supply
50,000 houses in the northeasternregion of the Brazilian state of Mato
Grosso do Sul. The commissioningof the units is scheduled for October
2003. As the consortium leader, Voith
Siemens Hydro is responsible forthe supply and supervision of theerection of all mechanical and electrical equipment.
Pedro.Fernandes@vs-hydro.com

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

two horizontal Francis turbines of
5.2 MW each and a brushless typegenerator of 5.6 MVA. It generates
electrical power for the nearby aluminum plant of the Brazilian company
Alcan Aluminío do Brasil Ltda. Voith
Siemens Hydro, as the consortium
leader, is responsible for all the electrical and mechanical equipment at
the plant.
Pedro.Fernandes@vs-hydro.com

São Bernardo
When commissioned at the endof 2005, the São Bernardo plant will
be supplying 15 MW to the grid.
Voith Siemens Hydro will contributethe turbines and governors to theproject, which is located on the
Bernardo José river in the Brazil
state of Rio Grande do Sul.
Pedro.Fernandes@vs-hydro.com

Furnas do SegredoThis small hydro power plant, locatedon the Jaguari river in Rio Grande doSul, is scheduled for commissioningin September. Voith Siemens Hydro
will deliver two low head Kaplan
S-turbines with 4.7 MW each.
Pedro.Fernandes@vs-hydro.com

Esmeralda
Like Paraíso, a high capacity smallhydro station that will generate
23 MW of electricity when in fulloperation. Commissioning is to takeplace at the end of 2005. Two Voith
Siemens Hydro-made Francis turbines
will produce 11.5 MW each. A Voith
Siemens Hydro governor system will
guarantee smooth operation.
Pedro.Fernandes@vs-hydro.com

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Seite 13

Rutherford Creek, Canada
Two vertical Pelton units of 25 MW
will be installed at Rutherford Creek
Hydropower plant, near the cityof Whistler, north of Vancouver,
British Columbia. Voith Esac Hydro
will supply the turbine-generator sets,with a commissioning date expectedin April 2004.
Pingston, Canada
Two Pelton units were commissioned
in early May, at the Pingston hydropower plant in Canada. Voith Esac
Hydro was in charge of the supply
and commissioning of the turbinegenerator sets, as well as the control
panels. This plant is located near
Revelstoke, British Columbia, andhas a total output exceeding 30 MW.

Christophe.Colnot@vs-hydro.com

Christophe.Colnot@vs-hydro.com

hypower 5/2003

Environmentally sound constructionof small hydro station in Chile
One will hardly find another smallhydro plant located in such an impressive region of stunning natural beauty
as the Lago Atravesado station insouthern Chile. The 12 MW plant,
owned by Empresa Electrica de Aysén
S.A., lies on the shore of the Atravesado lake surrounded by several millennial glaciers. Miles from anywhere,
there were no roads leading to theconstruction site. Due to the strict
environmental regulations of Chile’s
National Energy Commission (CNE),
a road could not be built. Consequently, the two 6 MW horizontal Francis
turbines, designed and manufactured
at Voith Siemens Hydro’s locationin Tolosa, Spain, like all the material
and equipment, had to be shipped
there on board of a transport barge.
Carlos.Aguerre@vs-hydro.com

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Seite 14Focus on Small Hydro

Small hydro in south-east Asia
Voith Fuji Hydro, the Japan based entity of Voith Siemens Hydro, has been
awarded several contracts for interesting hydro power projects in Japan,
in close cooperation with Fuji Electric, four of which are:Ohtaki generating station now
commissioned
The contract was awarded for installing a new hydro power station by
Kansai Electric Power Co., Inc. The
supply for Ohtaki hydro power plant,
located on the Kinokawa river, included a vertical Kaplan turbine, a generator with thrust bearing made out of
Teflon (PTFE), excitation, automation,
electrical BOP, erection, and commissioning.
Data
Head: 80.37 m
Vertical Kaplan turbine
10.8 MW turbine output
11 MVA generator output
Commissioning May 2003

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

Naoto.Yoneyama@vs-hydro.com

Naoto.Yoneyama@vs-hydro.com

New hydro station on
Surikamigawa Dam
The Ministry of Land, Infrastructure
and Transport awarded a contractfor installing a new hydro power
station on the Surikami river. The
supply includes turbine, generator,
automation, governor, excitation,
erection and commissioning.

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

New hydro station at Tomada
The Government of Okayama Prefecture awarded a contract for the
installation of a new hydro power
station on the Yoshii river. The supply
includes a vertical Francis turbine,
generator, excitation, automation,
electrical BOP, erection, and commissioning. Voith Siemens Hydro
installed an electric motor operating
servomotor for guide vane control,
replacing a pressure oil operating
servomotor which requires considerable maintenance work and costs.

Data
Head: 33.1 m
Vertical Francis turbine
4.83 MW turbine output
4.9 MVA generator output
Commissioning March 2005
Naoto.Yoneyama@vs-hydro.com

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Wainikasou-Vaturu, Fiji
Voith Esac started manufacturing ahorizontal Pelton turbine rated 3 MW
and 2 horizontal Francis machines
rated 3.4 MW each for two new power
plants located on the Fijian island of
Viti Levu. Generators are also partof the contract. The hydro plants will
replace diesel units presently in operation, and commissioning of bothprojects is foreseen in March 2004.
Data Wainikasou
Head: 115 m
2 horizontal Francis turbines
3.4 MW output per turbine
Commissioning March 2004
Data Vaturu
Head: 268 m
Horizontal Pelton turbine
3 MW output per turbine
Commissioning March 2004
Christophe.Colnot@vs-hydro.com

Seite 15

New power station for Erathne,
Sri Lanka
A new power station will be installed
for ZYREX Power Company Erathne,Ltd. located about 100 km south-eastof Colombo in the Ratnapura areaof Sri Lanka. The work order contains
a complete water-to-wire equipment
package including two horizontal
shaft 2-jet Pelton turbines withapproximately 5.15 MW electrical
power output each and a plant control
system, both of which will be manufactured at Voith Siemens Hydro
in Heidenheim, Germany.
Data
Head: 450 m
2 horizontal 2-jet Pelton turbines
5.15 MW output per turbine
Commissioning early 2004
Gerhard.Draxler@vs-hydro.com

Way Ganga: The largest privately
financed hydro project in Sri Lanka
DIDUL Pvt., Ltd. Is carrying out
the largest privately financed hydropower project in Sri Lanka. Way
Ganga powerhouse, located about
130 km south-east of Colombo,
will get its water via a long channel,
including a newly built aqueduct tocross the river valley. Voith Siemenshydro will install a complete electromechanical equipment package spanning three horizontal shaft Francis
spiral turbines with approximately
3 MW electrical power output each,generators, a plant control system,and the electrical switchgear.
Data
Head: 58 m
3 horizontal Francis spiral turbines
2.93 MW output per turbine
Commissioning end 2003/early 2004
Gerhard.Draxler@vs-hydro.com

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Seite 16

Focus on Small Hydro

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

Since the relative costs of energy
production decrease while the overall
output of a power plant increases,
small hydropower plants are under
greater cost pressure than large
power plants. That applies particularly
to automation, as its cost percentage
decreases the larger the power plantis. Long pressure pipes, for example,
present significant control difficulties
for both large and small power plants.
These are even more difficult to overcome in small power plants than inlarge ones, due to the smaller massof the generating system, thus leading to a higher engineering effort andtherefore of course also to higher

costs. This basic disparity in costs
cannot be entirely eliminated – but it
can be reduced. Voith Siemens Hydro
has developed the Efficient automation system to solve this problem.
Voith Siemens Hydro’s Efficientsystem offers high performanceat low prices
In order to reconcile the demands
for high performance and high safety
standards on the one hand and for
low costs on the other, Voith andSiemens developed the Efficientsystem for smaller power plants inthe course of a reassessment of
the companies’ products conductedin Heidenheim. The goals of thedevelopment project could only beattained by means of standardization– but it had to be standardization ofa sort which does not compromise
on functionality or performance.
Efficient meets all of the criteria forfulfilling the greatest demands ofsmall hydropower plants: it is highly
performant, safe, easily accessible,
compact, inexpensive. Thanks to theVoith Siemens Hydro standards andto sophisticated simulator technology,
the automation system can now be“pre-commissioned”, thus reducing
time and risks involved when the

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Seite 17

VSHyCon: The Voith Siemens Hydro Control Family – Efficient

Two factors made it possible for Voith
Siemens Hydro to meet the highdemands for performance and safety
while maintaining low costs:
The company drew on its specialized knowledge of equipment andmachinery from its many years as
a hydropower plant specialist, andthoroughly integrated this knowledge
into the Efficient Standard Module.
This system was developed concurrently with the Excellent system
for large facilities, which created theopportunity for many synergy effects,
because many of the basic functional
blocks of the Excellent system canbe employed in the Efficient system
for small power plants as well.

Electrical equipment

governing systems– electrohydraulicconverters,
moving coil valves– control valves– emergency
shutdown valves– shut-off valves– relay valves

digital protection
systems

HMI

digital excitation
systemautomation
efficientexcellentpressure oil supply
systemmech./hydr. control
equipment for
butterfly andspherical valves
instrumentation

voltage regulator
reactive power
control
LV. switchgears
LV. distributions
power supply
batteries
UPS units
synchronizers
security system

For more information:
Wolfgang.Hoerger@vs-hydro.com

digital turbine
governorjoint control

river control
continuous
monitoring

Communication systems

VSHyCon System Family
ExcellentTechnical requirement

high

The system has meanwhile been
installed in several power plants
and tested successfully. The highquality modules designed to increase
the power plants’ rates of yield havereceived particularly high praise.

Unit automation& plant control

Mechanical equipment

PLC:
S7 400Efficient

PLC:
xx7

PLC:
S7 400/S7 300

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

PLC Basis
Software:
Step 7 (CFC/SFC)

HMI: WinCC
PC: Windows NT

hypower 5/2003

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

PLC Basis
Software:
Step 7low
small

plant size

large

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Market splinters

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

At the end of 1997, Voith Siemens
Hydro received a contract to provide
the hydro plant with 5 Francis turbines, 5 regulators, and cooling anddrainage systems. Now, 50,000
engineer hours, 120 shipments, and
800 drawings later, a new hydro plant
has been built: The assembly took
place in a desert landscape in heatreaching 50 degrees Celsius.

This project will surely not be thelast. Since Pakistan has the potential
to produce an estimated 40,000 MWof hydro power, but currently utilizes
only 6,500 MW of that capacity,
additional projects of this kind canbe expected in the future.
For more information:
Karsten.Horn@vs-hydro.com

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

Almost 90 years later end of 1999,
Siemens’ hydro power section, now
merged into Voith Siemens Hydro
Power Generation was awarded thecontract to built a new hydro power
station next to the old one whichshould be equipped with three units
with an output of 24 MW each.

The scope of supply for Voith Siemens
Hydro covers three generators, electrical auxiliaries, automation as wellas erection and commissioning. The
contract came from the private power
supply company TATA Power Company
Limited, Mumbai, Maharashtra.
The customer expressed his highsatisfaction on the efficient new units:
the plant now generates more thanseven per cent more electricity than
before.
For more information:
Markus.Thomczyk@vs-hydro.com

hypower 5/2003

At the beginning of this century,in 1911, a hydro power station with
the name Khopoli was already built in
the Indian Federal State of Maharashtra. At that time it was equipped with
six units with an output of 12 MW
each, which are still partially in operation today.

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Market splinters

Kiskoere hydro plant model
tested successfully

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

Experts after witnessing the model tests
in Heidenheim

Customer present at model test
The model was tested in the presenceof the customer, Tiszaviz Vezeroemue
KFT, Siemens Budapest as the consortium partner, and experts from
Miskolc University, in order to best
fulfill all of the guarantees as definedand agreed upon during the bidding
and selection process.

These measures will help to ensure
the reliability of electrical energy
supplies in the future, and will also
increase the annual production ofelectricity from its previous 90 GWh.

Reliable performance for the future
The Kiskoere hydro plant is equippedwith four bulb turbines (runner diameter: 4.3 m), which produce 7 MWof power each, at a head of around
6.3 m. In the course of the modernization project, the old runner blades andguide vanes of each machine were replaced with four newly-designed runner blades and 24 new guide vanes.

For more information:
Stefan.Riedelbauch@vs-hydro.com

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

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

Dam with spillway at Orfeus reservoir

The consortium is responsible for basic and detail engineering, supply andproject management, software, erection supervision and commissioning.
For more information:
Raimund.Gabriel@vs-hydro.com

Insight view of Orfeus power house

hypower 5/2003

The comprehensive renewal works
include delivery of new mechanical
key parts such as turbine runners,
wicket gates and regulating mechanism, the supply of new turbine
governors, control systems, mediumand low-voltage equipment, static
excitation and electrical protection
as well as rehabilitation works onworn parts and on the interfaces
between old and new equipment.

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Generator modernization

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

The hydroelectric generators take advantage of the momentum generated
by the Exploits river as it flows to thesea from the immense watershed areaof the central Newfoundland plateau.
The plant has grown from its original
capacity of 1,500 kW in 1909 to a rating of 17 MW through several expansions. In the late 1990’s, the plantowner decided to upgrade the generating units by installing new turbines
in the existing flumes, while at thesame time converting the frequency
from 50 to 60 Hz. The new turbine
design resulted in a higher runaway
speed.

When doubts arose as to the suitability of the existing generators for
operation with this new runaway
speed, Voith Siemens Hydro was asked to perform an engineering study.
The new turbine design for the
Bishop’s Falls Generating Station
increased the runaway speed of theunits by almost 50 %, and the frequency change altered their normal
operating speed from 231 to 277 rpm.
Voith Siemens Hydro engineers
thoroughly investigated the impactsof these alterations and determinedthat the existing rotors were notsuitable for the new conditions:
Stress levels were found to be excessive in a number of areas of thegenerators. Due to the conclusionsof the runaway speed study, Voith
Siemens Hydro advised against recommissioning the units without
structural modifications. Excessive
stresses in the welds and rim could
possibly lead to a machine failure.
To solve the problem, modificationsin the rotor were found to be indispensable.
Following the stress analysis, Voith
Siemens Hydro received an order todesign and implement modifications
that would accommodate the speed
increase for the six 1950’s vintage
generators. From an engineering
standpoint, this was quite a challenging task. A non-weld retrofit was desired in order to avoid welding-related

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Stress- von Mises
Ibf//in^2

Stress- von Mises

Ibf//in^2
distortion issues, which could have led
35000
Overstressed rim
39375
30000
33750
25000
to increased modification costs and
20000
28125
15000
16875
10000
11250
5000
longer outages. The technical strategy
5625
00
was to reduce the load flow throughthe fillet welds as well as the bending
stresses in the rim. Voith Siemens
Hydro’s rehab specialists installed preOverstressed disk – Hub fillet welds
Rim
Fillet welds
Disk
Overstressed rim – Disk fillet welds
loaded radial ties to support the increased centrifugal loads that wouldHigh stress levels predicted in the original
High Rim – Spider Disk Weld Stress Levels
predicted in the original spider design at thebe produced by the increased runaway spider design at the new runaway speed
new runaway speed
speed. In addition, holes were machined in the rotor disks to reduce theto be reconnected from a Delta to a
stresses induced in the fillet welds.
stronger coil support stud assemblies
Wye configuration. Furthermore, thewere installed.
engineering analysis had determined
Working under a tight schedule, fourthat the original field coil interconof the units were equipped with new
While proper planning with experiennectors and coil support hardware
windings to adapt the units to the deced hydro equipment suppliers cansired uprate from 2,250 to 3,000 kVA. were unsuitable for the altered opercover most uncertainties, 50-year-old
The remaining two machines had been ating conditions. Therefore, redeunits can still present a few unplanrewound previously. However, they had signed field pole interconnectors andned challenges. Nevertheless, suchdifficulties are rather typical of thenature of modernization, and canbe effectively addressed by highlycqualified personnel applying state-ofa
the-art analytical methods and techb
nologies. At the Bishop’s Falls generdaating station, all six generators are
now operating and performing well.

a
b
c
d

New holes to reduce weld stresses
New radial ties
New field coil interconnectors
New coil support stud assemblies

a New holes to reduce weld stressesb New radial ties

For more information:
Jan.Seyler@vs-hydro.com

ahypower 5/2003

b

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Generator modernization

Hydroelectric generator rewinds
and modernization
Plant modernization can be an effective way to meet increasing demands
for energy without major capital investment. Particularly in older plants,
power generation capacity can often be significantly increased by rewinding
the generator with redesigned windings manufactured with modern insulation systems. Voith Siemens Hydro in Canada manufactures stator windings
and specializes in the uprate and modernization of Hydro Generators.
Uprating and modernizing a hydrogenerator requires a sound understanding of past and current generator technology. Voith Siemens Hydro
has been manufacturing generatorsfor over 135 years and is continuallydeveloping and applying improved
technologies for the design of new
generators. Significant synergies
exist in the development of new machine and modernization technologies.

Obtaining the optimal blend of new
and old technologies to maximize
the customer’s return on investment
requires specialized knowledge andexperience.
Voith Siemens modernization specialists can evaluate any manufacturer’s
generator to determine its uprate
capability. This evaluation requiresa review of both the electrical andCompleted stator rewind (Courtesy of Alcoa, Inc.)mechanical characteristics of themachine. By applying state of art
analysis and design technologies,
generators can typically be modified
to provide increased ratings withimproved efficiency and reliability.
For more information:
Jan.Seyler@vs-hydro.com

Stator bar manufacturing in Mississauga

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Customer contacts

Events 2003

The meeting gathered researchers andprofessionals from the energy sector,
NGOs and government organizations
with a broad spectrum of technological, political and environmental discussions. Voith Siemens Hydro not
only acted as a main sponsor, butalso presented its technology anddevelopment for small hydropower
plants.

SIMPASE (Simpósio de Automação
de Sistemas Elétricos), the Electric
Systems Automation Symposium,
one of the main forums for the discussion of problems and solutions
concerning the automation of electric power generation, transmission
and distribution systems in SouthAmerica. Held its biannual event for
the fifth time from May 11 to 14 in
the city of Recife, Brazil.
Voith Siemens Hydro presented 14
case studies, giving an insight into
their special solutions for the automation of hydroelectric power plants.

Hydro 2003
Dubrovnik, Croatia,
November 3-6, 2003
Booth 54-55
 Our papers presented in theconference:– Performance and economic benefits by integration of intelligent
supplementary functions into ahydroelectric plant control system– Precautions in the modernizationof hydrogenerators – how to eliminate old deficiences and avoid new
problems– Countermeasures to reduce hydroabrasive wear at hydro turbinesparts.
 Paper to be published in theconference proceedings:– First refurbishment of Kaplan bulb
turbines at the Kisköre HPP in
Hungary system.

Waterpower XIII in Buffalo, N.Y., USA
29-31 July, 2003, Booth 810
 Papers by Voith Siemens Hydro:– Exelon: Automation rehabilitation
program at the hydropower plant
Conowingo and the pump storage
plant Muddy Run.
– Apgi hydropower modernization –A partnered process approachto system optimization.
– Optimization of system operation.
– Wicket gate friction device
monitoring system.
 Paper by Avista Corporation,
co-authored by Acres International
and Voith Siemens Hydro:– Turbine upgrade for significant
capacity increase at Cabinet Gorge
hydro plant.

Deutsch-Chinesischer Wirtschaftskongress, October 22-24, 2003,
Grand Hyatt Hotel, Berlin, Germany Paper presented by Voith Siemens
Hydro, Dr. Konrad Roth, Shanghai– China. New opportunities for thecapital equipment business.

hypower 5/2003

ELPAH X (Encontro Latino Americano
e do Caribe em Pequenos Aproveitamentos Hidroenergéticos), the 10th
Latin American and Caribbean Small
Hydro meeting, took place from May
4 to 8 in Poços de Caldas, Brazil.

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Milestones in history

One hundred years of
Niagara Falls turbines

Voith historical poster (Power houses of the Canadian side)

Niagara turbines in 1911

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

This was an impressive machine forthe time and two additional units ofsimilar size and output were awarded
to Voith in 1910 and 1911 based on
the performance of the equipment
provided in the 1903 contract.

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

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

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are still operable. Ontario Power Generation explained that their future
status will be reviewed from time totime. Turbines that are still operable
after 100 years is an impressive record.
Another historic plant, the Decew Falls
Hydropower Station, was built in 1904.
This plant is close to Niagara Falls andis equipped with Voith turbines andgenerators from Westinghouse whose
technology is now merged into today’s joint venture of Voith Siemens
Hydro Power Generation.

This historical order for Voith provided the most powerful and largest
turbines in the world at that time andwas based on the trust in the German
company’s technology and performance. Voith’s engineers and workshops were motivated to insure thatthey would meet the challenges andcommitments of the project.
Four spiral twin turbines each with an
output of 8,826 kW were provided forthe contract. These were followed bythree more units from 1908 through1912 with an output of 9,047 kW at
53.4 m head.

Hanns Voith provided the following
personal memories of the Niagara
turbines: “As a trainee, I was allowed
to assemble the first of the Hamilton
turbines at the workshop in thewinter of 1903/1904. I also participated in the banquet that my father,
Friedrich Voith, gave to the Engineer
Commission of the Ontario Power Co.
in the Heidenheim dining hall.
My father gave a very good English
speech, which was difficult for him,
especially if one knew the he did notfavour holding speeches”. The Niagara turbines were decommissioned
in December of 1999 after 95 years
in operation. Even though they are
no longer connected to the grid, theyIn addition to these early historicalprojects, Voith Siemens Hydro Power
Generation later supplied the generators for the Sir Adam Beck 1 & 2stations between 1919 and 1955.
Another 13 generators were supplied
to a station on the US side of Niagara
Falls in 1950. The most recent award
for Voith Siemens Hydro in the Niagara Falls area is the contract to rehabilitate the first stator of 14 at theRobert Moses Niagara Hydropower
Station. The company is proud of thepast and current role it has played in
the history of hydropower development at the Niagara Falls.
For more information:
Barbara.Fischer-Aupperle@
vs-hydro.com

hypower 5/2003

Robert Moses Niagara Power Plant

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Milestones in history

100 years ofPelton turbines from Voith

Exactly 100 years ago, Voith built
the first Pelton turbines for the G.N.
Gaubitz mill construction company
in Mainbernheim, Germany. The
first export shipment of a Peltonturbine – to Japan – followed just
one year later.
The Pelton turbine is based on an1880 invention by the US citizen Lester Pelton. Pelton turbines are used
for particularly high heads – it is not
unusual for heads over 1,000 meters.
Water discharged from such a head
hits the runner at a speed of 500 km/h.

In the past 100 years, almost 2,000
Pelton turbines for more than 1,100
projects were built. These have beendelivered to 55 countries around theglobe.
The largest Pelton turbines manufactured by Voith Siemens Hydro were
supplied to Italy’s Cimego hydropower station in 1953 and the US stationof New Colgate with runner diametersof 4.48 and 5.44 meters. The mostpowerful Pelton turbine was built in1989 and is located in San Giacomo
sul Vomano, Italy, with a capacity of
282.5 MW. New Colgate and San Giacomo also hold the record in bucket
widths with 1,100 and 1,030 mm
respectively.

The highest head from a Voith
Siemens Pelton turbine is 1,404 m,
found in the San Fiorano power
plant in Italy.
For more information:
Barbara.Fischer-Aupperle@
vs-hydro.com

Italy breaks the records
Voith Riva Hydro, today a memberof the Voith Siemens Hydro group,
had already supplied 118 microand small Pelton turbines between
1896 and 1902.

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NHA Award to Voith Siemens Hydro
control system, levels of dissolved
oxygen have significantly increased
and even exceeded expectations.
Voith Siemens Hydro in York, Pennsylvania developed and patented
the aerating runner design that also
results in an increase in the rated
capacity for the units.
The J. Strom Thurmond Powerhouse
is located on the Savannah River inSouth Carolina, 22 miles north ofAugusta, Georgia and houses 7 hydrounits originally installed in 1953.
Completion of the current rehabilitation is scheduled for 2006. The
powerhouse is owned and operated
by the U.S. Army Corps of Engineers.

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

hypower 5/2003

In April 2003 the National Hydro
Association in the United States presented its Technical Achievement
Award to Voith Siemens Hydro Power
Generation and the U.S. Army
Corps of Engineers for the J. Strom
Thurmond Project.

The award is presented by NHA torecognize projects that demonstratesignificant technical contributions
to the hydropower industry. Colonel
Roger A. Gerber, Commander, Savannah District accepted the award for
the U.S. Corp of Engineers and Gregory Snyder, Project Manager accepted for Voith Siemens Hydro Power
Generation. The NHA awards committee saluted the Corps of Engineers
for tackling an issue of great importto the region with a solution of equal
technological enormity. Insufficientdissolved oxygen in southeast rivers
is a serious problem at many hydroelectric projects, adversely affecting
aquatic life. By employing the latest
technology from Voith Siemens Hydro,
remarkable results have been realized.
Since the installation of the first new
aerating runner and a new turbine

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Essay

What is the origin of life?
This is – admittedly – a loaded question, but it can be answeredin a reasonably entertaining and colourful way. Life cannot exist
without water. Let’s look for a reason to this phenomenon first.

Snakes are often essential parts of myths
in many cultures

From a scientific point of view thesolution is complex but logical.
Hydrogen is the most abundant element in our Universe. When it encounters oxygen, it reacts with it toform water. The cloud of primevalmineral material out of which our
Earth was formed was cold and contained a lot of ice. This cloud wascompressed by gravity and thus became very hot. The water containedin the cloud was diffused and formed
gigantic clouds of vapour in theatmosphere.
After our planet had reached its final
size and temperatures had fallen
below 100 degrees as a result of
reduced gravitational force, water
was also available in liquid form.
Part of it evaporates into space andleaves our atmosphere entirely, butsince the interior of our Earth contains a lot of water in crystallized
form, as springs or as constitutedhydroxide water, this loss is compensated for – the total amount of wateris actually growing slightly. So muchfor the technical side of the question.
But how did human beings explain life
and the world to themselves before
the advent of science? Myths help us
to throw light on this question. Myths
exist in every culture and are an attempt to paint a complete picture ofthings we cannot understand. Theirapproach is a personal one, basedon the characters and moods of Gods
and Goddesses, to whom humanbeings are mere playthings.
The oldest and most primordial conceptions are based on the assumptionthat a snake demon living in andclosely linked to the water was theorigin of all things.
In Mesopotamia this demon was
called Tiamat, the Early Chaos snakethat was defeated by Marduk. Marduk
cut the snake into pieces, which thenformed a division between the watersof heaven and water of lower depths.
He then created human beings.
In ancient Egypt a hill emerged fromthe primeval water Nun and the holy
bird Ibis laid an egg that was hatchedby the heat of the sun, with the Sun
God Re emerging from it.
In China, during the Han Dynasty(206 to 220 AC), people believed thateverything had been created fromwater and that everything lived andVS_HP5_S30_31_RZ.qxd

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For the papuas a giant tortoise
created the first land

One of India’s Hymns of Creation, theRigveda, puts it this way: “In the beginning everything was unmistakably
floods of water.” In this primevalwater a golden egg began to develop,
containing the spirit – Brahma or
Purusha. From the two halves of theegg, this spirit stepped out andformed Heaven and Earth.
In the Hindu myth, the God, Vishnu,
descended into the watery depths andemerged with the Earth. Even today,
Buddhists and Hindus worship water
as the primeval substance.

The Papua people in New Guinea
believed that in the beginning thesurface of the Earth was covered
with water. A giant tortoise swimmingin this water rested on the water’sbottom. With its powerful flippers
it shovelled sand upwards from theseabed, and created land.
According to a North American Indian
tribe it was a crayfish that pulled
the Earth up from the bottom of theocean and thus created land. For
the Algonquians it was the muskrat.
In the Bible, the Book of Genesis saysthat there was darkness above theprimeval flood and the Spirit of God
moved upon the face of the waters.
The process of the world’s creation
started by separating the water into
Heaven and Earth.

The interesting fact common to allthese myths is that our world originates from watery chaos, and only
had to be snatched from it. Cosmogony is the doctrine of creation,– the story of a process of transformation accompanied by enormous
conflict. An uncontrolled primitive
state is transformed into a world oforder. In mythological philosophiesof life, water has absolute priority
above all other elements – it is purely
and simply the essence of life.
The fact that we use it to develop
our civilizations also goes back tothe beginning of time. The intelligent
use of the power in water enables
us to generate energy, which in turnprovides us with all the amenities
that make our life safer and more
comfortable.

hypower 5/2003

developed through water. Water was
omnipresent; there was nothing that
could not be filled with water. Water
accumulates in the sky and on the
ground, it is hidden in every object
and gives birth to living creatures.

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31

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.voithsiemenshydropower.com

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Editorial coordination:
Barbara Fischer-Aupperle
Copyright 2003
Reproduction permitted,
provided source is given.

www.msw.de

11.08.2003

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