MAGAZINE FOR HYDROPOWER
HYDRO POWER TECHNOLOGYTECHNOLOGYHYPOWER
HyPower#22 | Spring 2013

SECURING THE FUTURE
WITH MODERNIZATION

MOVINGFORWARDINNOVATIVE SOLUTIONSA CLOSER LOOK AT SMALL HYDROGREEN ENERGY MIX

WHY HYDROPOWER LEADS THE WAYeditorial

Combining experienceand innovation
Imprint
Publisher:
Voith Hydro Holding GmbH & Co. KG
Alexanderstr. 1189522 Heidenheim, Germany
www.voith.com
Responsible for the publisher:
Ute Böhringer-Mai
Editor-in-chief: Lukas Nemela
Tel: +49 7321 37 0
Fax: +49 7321 37-7828
Email: info.voithhydro@voith.com
In cooperation with:
Burda Creative Group GmbHwww.burda-creative-group.de
Paper:
HyPower is printed on Respecta Silk. This
paper consists of 60% recycled fiber andwas produced on a Voith paper machine.
Photographs:
p. 5: gettyimages/Yuji Sakai; p. 8-10: Micha Wolfson (3);p. 11: gettyimages/Adam Gault; p. 27: laif/
Tobias Hauser; p. 28-29: unit/500gls; p. 30-31: EDP
Energias de Portugal; p. 32: Erich Meyer;
p. 40-41: Lifesaver (3); p. 43: gettyimages/Yuji Sakai.
All other photos from Voith Hydro.
All figures on installed hydropower capacity include
pumped storage. Figures on hydropower potentialrefer to technically feasible hydropower potential.
Copyright:
No part of this publication may be copied,
reproduced or otherwise disseminated,
nor may any of the content in it be used inpart or in whole in other works in any
form whatsoever, without express written
permission of the editor.

There is no substitute for experience. As the only manufacturer to have remained in the hydropower industry for morethan 140 years, Voith Hydro has experience in abundance.
Hydropower might be a mature, well-established technology,
but this does not mean there is no room for improvement.
Continuous enhancement and life-long learning are targets
we strive for, not only in terms of our products, but also with aview to our personnel.
The combination of long-standing experience and a hungry, forward-looking approach means that we are constantly
searching for technical innovations in order to improve efficiency and minimize the impact of hydropower on our natural
surrounding environment. This will enhance hydropower still
further as the main source of reliable green energy.
In recent years we have seen a growing trend towards
modernization of long-serving hydroelectric power plants.
Having trusted Voith’s expertise during the original construction phase decades ago, many of our partners are today once
again calling on our technical knowledge as they look into the
future.
And the future of hydropower is bright. The International
Energy Agency expects the amount of electricity generated
by hydropower to double by 2050. Having already experienced the successful development of hydropower over time,
we are confident that it will continue to contribute significantly
to climate-friendly power generation in the years to come.
In this issue, we hope that you will gain valuable insight
into our technical skills and project work around the globe,
and how to best pass on this knowledge and expertise to thenext generation.
Enjoy the read!

Yours sincerely,Your Feedback: If you have any
comments or questions on this issue of
HyPower, please contact us: hypower@voith.com

Ute Böhringer-Mai
Head of Communications

HyPower 2013 | 3

contents

contents

12

34

22

40

AGENDA SETTING

8

passing the baton
New CTO Dr. Norbert Riedel andpredecessor Dr. Siegbert Etter
discuss innovation at Voith Hydro

Discover more
about Voith in its
other insightful
publications.

22 hidden treasure
Bringing greater efficiency to
Italy’s Roncovalgrande plant

Boosting power output in Japan	global expertise

Creating a link between hydroelectricity past and present

12 resetting the clock

26 multinational milestone

An introduction to innovative
modernization work at Voith

Constructing a small hydro plantwith a large international reach18 extending life spans

4 | HyPower 2013

successful partnerships

37 new generation
Voith Hydro’s Swedish operating
unit provides cutting-edge
expertise in generators

38 safe passage

REGULARS

2 imprint
3 editorial
6 what’s new
39 world of voith
40 guest perspective
42 coffee break

34 maximizing potential
A closer look at the innovative
StreamDiver turbine

25 a culture of hydropower
full-line supplier

How key developments in pumped
storage are bringing flexibility andefficiency to our power grids

24 going vertical

11 knowledge is power
Knowledge expert Steve Trautman
on how to retain expertise

30 a higher plane

Modernization in the mature
Canadian market

green energy mix

Fulfilling potential with modernizationin China and South America

PROJECT DIRECTORY

43	around the world
28 hydropower leads the way

19 facing the future

A research project that improves
fish safety

An exclusive interview with
Dr. Paolo Frankl, head of the
IEA’s Renewable Energy Division

An easy-to-check reference of the Voith Hydro
projects mentioned in this edition of HyPower

HyPower 2013 | 5

Sectionwhat’s new

Voith at HYDRO2012 in Bilbao

exploring potential
in myanmar

Spain Voith Hydro took its place

myanmar January saw the first official
Myanmar Power Summit take place in thecity of Yangon, with Voith acting as cosponsor and the only hydro company tohave its own booth on site. Over 50 delegates from the local Ministry of ElectricPower attended to discuss development
and investment opportunities in the Myanmar energy sector. Only select parts ofthe country’s population have access toelectricity, while those who do are facedwith regular power outages. The potential
for hydropower in the region is considerable. Voith Hydro has already realized two
projects: at Yeywa, Myanmar’s largest
hydro plant, Voith Hydro supplied turbines,
generators and automation systems,
while at Kinda Dam the company delivered two units back in 1986. //alongside 1,300 participants from80 different countries at the
HYDRO 2012 conference in Bilbao. The annual hydropower
trade fair hosts an array of exhibitions and discussions on the
many concrete plans for globalhydropower and pumped-storage development. Voith Hydro experts from different operating units from allover Europe attended the fair, once again proving the company’s high technological expertise by contributing several conference papers on special
technical aspects as well as project case studies. During the gathering, Voith
hosted a conference dinner at the Museo Maritimo on the banks of the River
Nervio in the Basque city. In addition, the event was also the premiere for
Voith Hydro’s all new exhibition booth in the new design. //expanding aftermarket services
north america Voith has further strengthened its services portfolio for

The Voith pavilion at the Indo-German Urban Mela showcased
the company’s wide range of services on the subcontinent.

celebrating indo-german relations
India As part of the celebrations for 60 years of diplomatic
ties between Germany and India, Voith was present as a city
partner at Delhi’s Indo-German Urban Mela in October 2012.
The fourth of five city visits across the subcontinent for themela (Sanskrit for ‘fair’), it showcased the best of Germany inall possible fields. Over 140,000 guests made their way
through the exhibition. In its company pavilion, Voith provided
insights into the firm’s portfolio of activities in India, focusing
on the challenges of rapid urbanization on the subcontinent.
India is a key market for Voith, which has successfully operated in the country since 1911. Services are diverse and include, among other things, solutions to provide efficient infrastructure (including components for the Delhi metro), clean
energy, safe water supply and resource-friendly factories.
At the Voith pavilion in Delhi, visitors could view the film
“Megacities of the World – Their Challenges” on a special large
6 | HyPower 2013

screen. The film was developed with the support of students
from the Indian Institute of Technology, with which Voith has
an ongoing cooperation. A highlight for visitors was the interactive iPad presentation of a hydropower project, including aquiz on hydropower and the environment. The quiz served as
the basis for a school competition, in which 19 top schools
from Delhi and its surroundings participated. Each schoolteam consisted of four members aged 14 to 17, and three top
teams were awarded with trophies and certificates.
Voith was also able to welcome a special delegation to
the company pavilion, consisting of Philipp Rösler, German
Federal Minister of Economics and Technology, Dr. Hubert
Lienhard, President & CEO of Voith GmbH, Dr. Roland Münch,Chairman of the Board of Voith Hydro, Siemens CEO Peter
Löscher and numerous other high-ranking representatives
from business and politics. //hydro plants and expanded existing aftermarket business activities by establishing a new operating unit in Canada. With the acquisition of Québecbased Vortex Hydro, Voith will benefit from the company’s expertise in new
auxiliary mechanical systems, specialized hydropower products and expert
consulting services. “Offering long-term comprehensive services is increasingly important as it is in demand by our customers,” states Kirsten Lange,
Member of the Board of Management and Chief Business Development
Officer of Voith Hydro Holding. Responsible also for aftermarket business,
Lange joined the management board in 2012. Aftermarket services include
preventive maintenance, repairs, quality spare parts and inspection. //Mission Success inSouth America
brazil Voith continues to succeed with

its hydropower business in the key
South American market. At the turn of
the year, the company received several
major orders for the modernization of hydropower stations in Brazil. The combined contract value is around €185 million and includes modernization of twoplants on behalf of Tractebel Energia
S.A., as well as one for operator Duke
Energy. In the 1,420-MW Salto Santiago,
the four turbines, generators, electromechanical equipment and automation
technology are all to be completely refurbished and renewed. At the 226-MW
Passo Fundo plant, Voith will modernize
the two generating units, automation
systems and the turbine governors, while
at Chavantes it will renew three generating units, including turbines and generators, and the electro-mechanical systems
in the 414-MW plant. //HyPower 2013 | 7

AGENDA SETTINGAGENDA SETTING

passing
the baton
After more than 30 years at Voith Hydro,
Chief Technology Officer Dr. Siegbert
Etter is retiring, with Dr. Norbert Riedel
taking over his responsibility. We sat
with both of them to discuss technicalinnovations at Voith and the importanceof effective knowledge transfer.

Dr. Norbert Riedel: after joining Voith in 1998, the engineer has
held numerous senior positions, most recently Managing
Director of the Voith Hydro Engineering Center.
8 | HyPower 2013

What have been the most important technological developments in the hydropower industry during your time atVoith Hydro?
Dr. Etter: As far as the basic principles are concerned, not much
has changed in the last 30 years. Hydropower is a very maturetechnology that we at Voith have been working with for morethan 140 years. However, there have been many changes on asmaller scale which have also altered the industry as a whole.
Driven through these developments, power, power density, sizeand efficiency have increased. Take material development, forexample. Today, steels are tougher, more flexible, sturdier, morecorrosion-resistant and the overall quality has improved enormously. We have reproduced and were actively involved in hugequality improvements in our laboratories and our foundry.
Dr. Riedel: A lot has happened in the field of automation, thedigitalization of control technology, and in instrumentationand sensor technology. This has opened up new possibilities
for external control and shorter response times, so the power
plant can earn more money through increased availability.
There has also been considerable progress with electricalequipment, for example in the insulation materials area. Ortake the air-cooled generator that has enabled higher efficiency rates.
Dr. Etter: Environmental aspects have also come into focus
more strongly: oil-free hubs, the aeration of process water using corresponding blade wheel designs or technologies tolower the risk of injury to fish.

Has the industry changed faster or more significantly thanyou expected?
Dr. Etter: Looking back, I think so, yes. There were manychanges as a result of the consolidation of the hydropowerindustry, starting in the late 1980s. The development into afull-line supplier that manufactures the entire product portfolio
for hydroelectric power plants occurred surprisingly quickly
and thoroughly. For Voith this came through the joint venturewith Siemens in 2000. Many major and established names
disappeared during the course of the industry consolidation,
but Voith maintained its excellent name and is the only manufacturer to remain in existence for more than 140 years.
Have there been any technical innovations that truly surprised you, or innovations that you expected but were
never realized?
Dr. Etter: Some innovations did not catch on, such as the‘Straflo’ principle or the high-voltage generator, often for economic reasons rather than technical ones. But we haven’t really seen any surprises. Not even the variable-speed turbine,which we certainly saw coming.
Dr. Riedel: What hasn’t happened yet is that the model tests
have become obsolete. This temporary assumption proved to
be unrealistic and I don’t expect it to happen in the future either. Despite developments in computer technology, model
tests will remain. Quite simply, they represent a unique form ofrisk minimization for our customers.
What have been the most notable changes at Voith Hydro
during your time with the company?
Dr. Riedel: The development into a true full-line supplier wasa gigantic step forward. We have seen technical expertise forgenerators, automation and the plant as a whole gradually
added to our knowledge of turbines.
Dr. Etter: Correct. And the knowledge that we at Voith wereable to benefit as a result of the integration of employees fromother companies.
Which technical innovation at Voith Hydro are you mostproud of and why?
Dr. Etter: Ocean energies. We have developed new, robust
technology in this field, such as water-lubricated and seawater-resistant components. In some cases we have even beenable to transfer this knowledge back into conventional hydropower, such as with the StreamDiver, a new development insmall hydropower plants [see page 34].
Which important technological developments do you expect to see for hydropower in the near future? What are
the current areas of research?
Dr. Riedel: We expect further new developments and applications in material research in the future. Environmental

Dr. Siegbert Etter: in 1982, Etter joined Voith as a constructionengineer for turbines, before going on to become Head ofCorporate Technology and later CTO.
HyPower 2013 | 9

AGENDA SETTING

aspects will continue to push technical development, for example with oil-free hubs in Kaplan machines. With regard togenerators, we can expect continued optimization of insulating technology, cooling and even more robust machines forever-increasing output. We are monitoring the developments
in semiconductor and superconductor technology in order tointegrate the right elements at Voith Hydro at the right time.
Ultimately, all this helps us to better serve the needs of ourcustomers, such as with different operating modes, increased
flexibility, more frequent load changes and greater on-time
availability. Our skill as engineers and technicians must be tolisten carefully to the customers and anticipate where theywant to go in order to promote innovation based on thisinformation.
How has the transfer of knowledge and experience developed during your time at Voith Hydro?
Dr. Etter: Due to our global presence in all important hydropower markets and our range of services we have to gather,bundle and redistribute a lot of knowledge within the company. Our engineers in different regions have the local expertise,
which flows through the company, but they also need accessto the accumulated expertise that we have gathered at Voith.
This is our challenge and our goal: to be a local full-line supplier throughout the world.
Dr. Riedel: That will also be one of my aims as the new CTO;
to learn, retain and expand on Voith’s experience, and to continuously integrate this expertise into our products. My role
will also require me to manage knowledge transfer across all
the regions to ensure this know-how is close to the customers on a local level, throughout the world.

How important is a detailed transfer of know-how and expertise in order to achieve the best possible results?
Dr. Etter: Extremely important, which is why it is also vital that
we develop suitable successors within the company in thelong term – like Dr. Riedel. Trust, both internally and externally, and diverse experiences from different areas of the company are important in order to be able to do the job properly.
Also, actual plant experience is crucial for this.
Dr. Riedel: I agree, only once you have experienced a power
plant start-up in person can you understand the power involved, as well as gain the level of respect for the technology
and the force of nature, not to mention the risks.
What was the best advice your predecessor gave you andwhat advice do you want to give your successor?
Dr. Etter: Firstly, the human factor is crucial. Rely on the rightemployees in the right positions – trust on their abilities andallow them to rise to the challenge. The CTO’s job is also toattract younger talent to the company. I am always surprisedby the appeal of the label “German engineering” around theworld and it is important to make the best use of it. Secondly,
avoid being proud, because it prevents you from listening.
And listening – to both employees and customers – is themost important skill a CTO needs to have. Of course, I am
proud of the company’s market position, of its great development and the integration of new products and employees, but
one thing has definitely risen above all in my more than 30
years in the hydro industry: my love of and respect for hydroelectric power. //What other goals do you have as the new CTO?
Dr. Riedel: To be a challenger and partner – someone to challenge the company from the inside in order to drive performance and innovation. And a partner both internally and externally: to listen to our customers and staff in order to see therequirements of tomorrow and develop our technology accordingly. In doing so, we want to maintain the right balance
between innovation and risk. Hydropower must remain a safe
and secure renewable energy source.
Has the transfer of knowledge and expertise become easier,due to technological developments, or more difficult, because so much knowledge is available today?
Dr. Etter: Both. Computer technology has definitely madesome things easier. But at the same time the complexity has
increased heavily; the amount of know-how, interfaces, thedocumentation requirements and so on.
10 | HyPower 2013

“My role is to ensure that our
technological know-how is close
to customers throughout the world.”
Dr. Norbert Riedel, new Voith Hydro CTO

Agenda Setting

Transfer on the job
You cannot afford to have your experts
stop work to run formal classes. Knowledge transfer must be part of the fabricof regular work or it will never happen.
Since there are many nuances to whatmust be taught, transferring knowledge
on the job is the best environment.

Knowledge is
power
Knowledge-transfer expert Steve Trautman
explains how companies should go about
retaining expertise before it’s too late.

Succession planning – recruiting and developing employees to fill key roles – almost always focuses on top executives.
It should, however, include all experts
with critical and unique knowledge.
Knowledge-transfer programs reduce therisk of losing knowledge and experience.
Much more than on-the-job training, itmeans replicating the expertise, wisdom,and knowledge of critical professionals in
the heads and hands of co-workers.
Scientists and engineers needknowledge transfer to be practical. It
should start with a clear goal, such as:“Teach her how to analyze that data by
Tuesday. You’ll know she’s ready when
she can answer five questions and she
sounds like you when she’s talking.”
Technically oriented employees needhelp prioritizing knowledge-transfer relative to their regular tasks, as well as
tools to aid the communication of theirexperience and ideas. Step-by-step in-structions can be particularly useful.
Consider these steps concerning aneffective knowledge-transfer strategy:
Prioritize information
Long-time employees are tremendous
repositories of information, but not all of
it is equally important. Sort the highrisk/high-value expertise from knowledge that is out of date or already exists sufficiently within the organization.
Different types of knowledge
Knowledge transfer must move both explicit knowledge (how to follow a certain
procedure) and tacit knowledge, such as
what to look and listen for, which rules
must be followed and which ones canbe ignored under what circumstances,
who you have to know to get things
done, and so on. Tacit knowledge is the“secret sauce” that makes experienced
people so good at their jobs.

Understanding is key
Knowledge management (storing data)
does not solve the problem. Risk is not
reduced until critical knowledge is understood by the next generation. Use a
mix of knowledge-management tools
and knowledge transfer to achieve this.
Measurable approach
A clearly structured plan of what knowledge should be transferred and whenallows busy experts to schedule andprioritize knowledge transfer relative totheir other work. In terms of accountability, a measurable plan lets managers record progress, ensuring the risk ofknowledge loss is reduced.
Not long ago, an employee on thejob for five years was still “the new guy”
because many of his peers had been
there 20 or 30 years; taking five years to
get up to speed didn’t seem crazy. Today, employees entering the workforce
can expect to change jobs at least every seven years, so there is much greater urgency. Knowledge transfer mustbe fast and methodical to meet theneeds of today’s changing workforce. //Steve Trautman
With over two decades ofexperience advising clientssuch as Microsoft, Nikeand Boeing, Steve Trautman advises senior executives on practical ways tosecure effective knowledge transfer.

HyPower 2013 | 11

Full-line supplier

resettingthe clockAround the world, Voith Hydro is helping its customers to realize thetrue potential of their hydropower plants. Innovative modernization
work can increase efficiency, boost power output, make plants
more environmentally friendly and extend their lifetime by decades.
12 | HyPower 2013

HyPower 2013 | 13

Full-line supplier

Full-line supplier

Guide vane for the equipment of the completely rebuilt Rheinfelden plant at the Swiss-German border.

W

hen you embark on modernization, you are essentiallyinvesting in the next generation,” says Lars Meier, Chief Engineer
at Voith Hydro York in the UnitedStates. He has no illusions about the financial imperatives that drive the company’s large refurbishment and modernization business. This business accounts
for a large portion of the company’s
overall hydro activity in the UnitedStates and significant proportions of its
business in other markets.
Voith Hydro’s portfolio of services
covers many aspects of hydropower,
providing solutions for every type of
turbine, generator and automation system, encompassing everything fromsmall hydro to the largest projects inthe world.
The balance of the company’s work
between new build and refurbishment
or modernization differs from region to
14 | HyPower 2013

region, reflecting the age and level ofmaturity of the hydro sector in each.
On average, automation systems are
refurbished after 20 years, generators
every 30 years and turbines every 40
years. The business comprises threebroad categories: what could be termed“after-care,” which can involve replacement of items prone to wear as well as
spare parts; refurbishment, which involves “setting the clock back to zero”
on an existing facility by extending its
lifetime for further decades; and modernization, which typically goes handin-hand with refurbishment, but seeks
to improve the original design andequipment in a variety of ways.
“The improvements in computational fluid dynamics, along with the focus on off-design operation in both thehead range and flow range, allowed significant improvements in operating
characteristics for all types of turbines,”

says Meier. Similarly, magnetic flux simulations have resulted in improvements
in generator design. These tools, used in
combination with scaled-down turbine
model testing for larger projects, ensurethat Voith supplies the most-modern
and, crucially, the most-reliable designs.
Employing a combination of moremodern design approaches and manufacturing techniques may deliver an increase in efficiency from an existing
unit, while installing new and improved
runners can capture a significant increase in flow, therefore boosting power
output. In addition, runner improvements may also reduce cavitation problems, reducing long-term turbine maintenance costs.
However, for most operators costbenefit analysis of a wide variety ofoptions is necessary to achieve the optimum balance in terms of expenditure

In Uglich, Russia, Voith Hydro carried out extensive modernization work, boosting the unit’s capacity by almost 20 percent.

“State-of-the-art technology is key tomaximizing the full benefits of hydropower plant modernizations.”
Lars Meier, Chief Engineer, Voith Hydro Yorkagainst returns. “Real teamwork withthe client is essential,” Meier points out.
“We have a reputation in the marketplace of bringing the best technical solutions to our customers. State-of-theart technology is key to maximizing thefull benefits of plant modernizations.”
One of the single biggest problems forservice-provider and customer alike are
the unknown challenges. Dismantling
inner workings that last saw the light of
day 40 years ago can be like opening a
Pandora’s box. From asbestos insulation

to hot spots in generator cores, you cannever be quite sure what you are going
to find, Meier says. “However, there is asolution to every problem.”Arguably the biggest challenge of
all is organizing the work to keep outage
times to the absolute minimum, keeping
the plant in operation while work isundertaken on individual units andquickly finding solutions as each newproblem is identified. It requires aunique blend of organization and technical expertise. But wherever there areoperators in need of Voith Hydro’s

technical expertise – from Conowingo
in the United States to Uglich in Russia– Voith is there, bringing with it provenproject management skills and worldwide manufacturing facilities.
The chosen results of a Voith
Hydro refurbishment in terms of performance may vary from project toproject, but for every one it means aguarantee of increased reliability andreduced maintenance outages for the
coming decades.
There are many examples from aroundthe globe where Voith has brought in its
long-term experience in modernization
and realized increases in efficiency andlife-time extensions, especially in established hydropower markets like North
America or Europe.
In the mature North American hydropower market, modernization and refurbishment has played a significant
HyPower 2013 | 15

Full-line supplier

Hydropower in
the USA
Installed capacity: 91 GW
Potential not
yet installed:
82 GW

Hydropower inGermany
Installed capacity: 10 GW
Potential not
yet installed:
6 GW

Hydropower in
RussiaInstalled capacity: 47 GW
Potential not
425 GWyet installed:
16 | HyPower 2013role in the hydro equipment business forover 30 years. Over the past 15 years it
has accounted for up to 70 percent ofVoith Hydro’s annual US turnover.
Examples of modernization projects Voith has recently carried out inthe United States include the refurbishment and upgrade of 10 56 MW turbines at Bonneville Lock and Dam FirstPowerhouse in Oregon, extensive renovation work at Conowingo Dam in
Maryland and the rehabilitation of 10
111 MW turbines at Wanapum Dam,located at the Columbia River in Washington state.
With its long-established presencein the North American market, Voith
frequently finds itself in a position toundertake refurbishment and modernization of equipment originally manufactured by either Voith or one of its integrated companies such as Allis
Chalmers or Westinghouse.
Since these plants were built, says
Marcel Bos, project manager at Voith
Hydro in York, there have been significant improvements in materials, offering potential benefits in terms of efficiency. In the heart of a turbine, forexample, tolerances on runners aredown to plus or minus one five thousandth of an inch, held over a part measuring several meters in diameter. To
put that in perspective, a sheet of paper
is about four one thousandths of an inch
thick – some 20 times thicker.
However, Bos is quick to pay tribute to his Voith predecessors who installed the plants several decades ago.
“There’s a lot we can do today in termsof design and computer simulations,but when you do a refurbishing job likethis it’s still amazing to me just how
good they were without today’s computer technology.”
Apart from the technological excellence, a good partnership with the customer is an important success factor,“It’s not just us doing the work
– it’s a real team effort. If you
don’t have a good relationshipwith the customer, you havenothing.” Marcel Bos, Voith Hydro engineer

Modernization work on generators can help extend a plant’s life span by decades.

Bos stresses. “It’s not just us doing thework,” he points out, “it’s a real joint
effort. If you don’t have a good relationship with the customer, you have nothing. Communication is vitally important; you have to understand their needs
and meet them.”
Several thousand kilometers away, on
the Swiss-German border, Björn Reeg,
project manager at Voith Hydro in
Heidenheim, confirms this statement
without hesitation. He worked on a rebuild at Rheinfelden, the largest single
investment in renewable energy in Germany at the time, for which Voith wascommissioned to supply a number ofcomponents. “A persistently trustful andreliable cooperation with the customer
throughout the entire duration of the
project was one of the key factors for the
successful modernization of Rheinfelden,” Reeg says in his agreement withhis colleague in the United States.
Originally built in 1898, Rheinfelden was the first large hydro plant to
be used for electricity generation in Europe. In what amounted to significantly
more than ‘mere’ modernization, theplant was largely dismantled and thenrebuilt with state-of-the-art, ecofriendly technology. “It’s quite amazing

what was achieved at Rheinfelden,”Reeg recalls. Thanks to four new Voith
bulb turbines, the plant now has a capacity of 100 MW, almost four times asmuch as the previous 26 MW. This alsomeans that the operator can now produce four times as much electricity
from the Rhine River, generating 600
million kWh per year.
Voith’s ability to significantly increase
power output through its modernization work has also been displayed in its
work at the Uglich hydropower planton the Volga River in Russia. By replacing one unit at the plant, consisting of avertical Kaplan turbine and generator
with 65 MW output, the electrical andmechanical equipment as well as the automation system, output of the modernized unit has increased by approximately
18 percent, raising the installed capacity
by 10 MW.
Also impressive were the dimensions, with the turbine runner alone
weighing 221 tons and measuring ninemeters in diameter. “This was the firsttime Voith delivered a complete turbine-generator set to a customer in Russia,” says Voith lead engineer SebastianPaul. “Given the all-round success, itcertainly won’t be the last.” //HyPower 2013 | 17

Full-line supplierI. extending
life spans
In the mature Canadian market,
modernization is improving performanceat the Gordon M. Shrum power plant.

A

nother well-established hydropower market is Canada, where
Voith is modernizing the Gordon M. Shrum hydropower plant.
Equipped with 10 turbine/generator
power units, the plant has a rated output
of 2,730 MW.
Units one to five were originally installed in the late 1960s with a nameplate capacity of 266 MW. In 2008, theoperator BC Hydro initiated a project
to upgrade the turbines. The aims wereto increase the rated power of each turbine from 266 MW to 310 MW, to realize the performance improvements associated with modern turbine designs(hydraulic efficiency, cavitation resistance, stability), and to eliminate thehistorical issue of runner blade cracking.
Model-development contracts wereawarded to Voith Hydro and to anotherworld-class turbine supplier, and eachcompany was given one year to design,
analyze and test the new components
being integrated with the existing turbine water passages.
At the end of the development period, each supplier’s design was independently tested at Swiss technology institute École Polytechnique Fédérale de18 | HyPower 2013

Lausanne, with Voith’s design selected
for implementation as it offered the better technical and economic benefits.
The lead operating unit is Voith Hydro
in Montreal and the hydraulic design
and tests were performed by Voith
Hydro Engineering Center in York.
Three different runner designs, alongwith various versions of wicket gate andstay vane, were tested in order to findthe best combination between the stayvanes, wicket gates and runner. Each iteration was first computed using computational fluid dynamics’ steady andunsteady numerical analysis and later
tested on the model.
At the beginning of the project, stayvanes had been identified as a great contributor to the losses in the distributor.
Various designs were tested, always
keeping in mind that the stay vanes areembedded in the concrete and cannot be
replaced. Each design kept most of thestay vane shape, with only leading andtrailing edges modified by the additionof steel extensions to better align waterflow with the wicket gates. Casting the
new wicket gate out of martensitic stainless steel means they can be thinner thanthe original ones. This helps further reduce distributor losses.
The final runner design features
longer blades to allow an output powerincrease and better cavitation protection. The runner band is also somewhat
longer that the original, which meant
embedded parts at the site needed modifying. The lower part of the discharge
ring has been extended in the upper partof the draft tube cone liner, involving
some minor civil work along with discharge ring and draft tube liner construction in the pit.
Modifications to the stay vane
proved a further challenge due to themachining, grinding, fitting and welding of steel extensions using templates
for proper alignment. For this particularturbine design, the bottom ring was embedded during the original power plant
construction, meaning any modifications had to be performed on site.
A limited number of weeks are available for site work, and given the extensive modifications needed on the embedded parts (discharge ring, draft tube
liner, bottom ring) the site crew is working around the clock to meet the contractual deadlines.
Besides the supply of new runner
and wicket gates, BC Hydro also required new components such as head
cover, turbine guide bearing, main shaft
seal and wicket gate mechanism. The
turbine shaft and gate operating ring are
refurbished.
The first refurbished unit had been
handed over to BC Hydro in late fall2012, while the commissioning under
the responsibility of BC Hydro wascompleted in late February 2013. //Hydropower in
CanadaInstalled capacity: 74 GW
Potential not
yet installed:
162 GWfull-line supplier

Turbine modernization at Venezuela’s Guri II hydroelectric plant
will see power output jump by 5.5% for each of its five turbines.

II. facing thefutureInnovative modernization work is helping
China and South America go some way tofulfilling their massive hydro potential.

Hydropower in
Venezuela
Installed capacity: 15 GW
Potential not
yet installed:
58 GW

F

or decades hydropower has offered some of the cheapest,
most ecological and reliable power to a number of
emerging countries in Asia, South America and beyond.
For some of these plants, the time has now come to undergo
modernization work.
Voith Hydro has developed a range of technologies toserve the modernization market and combat those challenges
where conventional engineering solutions are not sufficient.
Some of its latest innovations in hydro modernization and rehabilitation are also thanks to the insights it gained during a
joint Sino-German research project to develop sand-erosion
protection techniques for turbines.
The project was carried out for the silt-laden Yellow River,
one of the most extreme hydropower operating environments.
The first stage involved a comprehensive evaluation of likely
protection techniques in a ‘slurry pot’ test facility at the Max
Planck Institute in Stuttgart to compare the erosion-resisting
properties of a range of materials. The best of these were thenre-evaluated in a high-velocity test rig at China Institute of
HyPower 2013 | 19

full-line supplier

Water Resources and Hydropower Research, designed to replicate real-world conditions.
As a result of this combination of Voith Hydro’s extensive
manufacturing experience and its research and development
work, the company has created a toolkit of several surface protection technologies called the Wear Inert Surface Enhancement (WISE) system.
The toolkit consists of three main solutions: DIATURB, athermally sprayed hard coating technology based on tungsten
carbide materials; SOFTURB, a thick-film advanced polymer
coating; and TECTURB, replaceable wear elements that offer
life extensions for critical turbine components.
DIATURB coatings are high-velocity oxy fuel sprayedcermet coatings offering erosion-coating protection. The coatings consist of extremely dense layers with excellent bondstrength and abrasion resistance. Application is a technicallydemanding process, where the correct spray parameters are vital, including gun velocity and distance, and where application
using robotic methods is often required. These coatings canimprove wear resistance of turbine components by a factor ofthree to seven times with layer thicknesses of typically less than
0.4 millimeters, permitting its use where component dimension tolerances are tight.
SOFTURB coatings offer excellent abrasion resistance atcomparatively low cost, in part because they can be applied by
toweling, brushing or spraying in thicknesses of 1.5 to 2 millimeters. TECTURB wear elements, meanwhile, can be appliedto ‘hot spots’ on turbines that are exposed to more rapid wearing, thus, extending their lives.

unit output from 50 to 60 MW. In addition to ensuring improved resistance to erosion, the modernization will increase
the facility’s annual power output by just under 8 million
kWh per unit, says Mr. Xu Gang, Head of Sales for Voith
Hydro in China.
With less than a quarter of its technically feasible hydropower potential already installed, South America is understandably a popular market for new construction, althoughmodernization work is also ongoing at various key locations.
Voith Hydro is currently part of a consortium modernizing theGuri II hydroelectric plant in Venezuela, the country’s largest
hydro plant and the third-largest in the world (after China’s
Three Gorges and Itaipú, on the Brazil/Paraguay border).
Guri II is the first of these giant plants to be rehabilitated,which also makes it the largest such modernization hydro challenge ever taken on, says Telmo Gomes, project manager for
Voith Hydro at Guri II.
Voith Hydro’s part in the project includes rehabilitating
five turbines and 10 governors and accessories, installing new
Francis runners, head covers and five new sets of wicket gates.
The project additionally involves installing a new operator
ring and rehabilitating four others, installing 10 new sets ofscrew pumps for the hydraulic governor and 10 control panels
for the digital governor.
The overhaul will see the power output of the facility
greatly improved. “After concluding our job, the maximum
output power of the five machines of Guri II will rise from 730
MW to 770 MW each,” says Gomes.
Voith completed the rehabilitation of the first unit in May
2011 and has completed around 80 percent of the second, witha scheduled return into operation of late 2013. Following that
Gomes and his teams will start the rehabilitation of the otherthree turbines and eight governors.

At San Men Xia, Voith Hydro is now applying some of these
innovations at the location where it originally tested them.
The company is modernizing two 50-MW turbines at San
Men Xia, as well as other components, and is also carrying out
automation work.
Such large projects offer a range of challenges, in this case
The scope of work to Units 2 and 4 of the facility includes
the problems posed by transporting equipment to the remote
modernizing the entire runner, the wicket gates and the wearsite and the fact that Voith Hydro has to work with legacy
ing plates for the head cover and bottom ring, as well as autoequipment that it did not make. The greatest challenge of all,mating the turbine elements. Voith will apply tungsten carbide
though – as with all modernization projects – is time, somecoatings for the flow-through surfaces
thing Gomes says he and his team neverand convert the discharge ring from semiforget. “Considering the importance ofHydropower in
spherical to fully spherical.
Guri to Venezuela, the greatest chalChina
The works will increase prototype
lenge was, and will continue to be, toInstalled capacity:249 GW find the fastest solutions to bring theturbine optimum efficiency from 91.5 toPotential not
94.35 percent, increase the rated effiunits back into operation in the shortest
yet
installed:
466
GW
ciency from 89 to 93.8 percent and boost
possible time.” //20 | HyPower 2013

Modernization at San Men Xia• Increase prototype turbine optimum
efficiency from 91.5 to 94.35 percent• Increase the rated efficiency from89 to 93.8 percent• Improve unit output from 50 to 60 MW

12

3

1& 2 The SOFTURB polymer coating offers excellent resistance against abrasion. It can be applied byconventional means, such as brushing or spraying.
3 Improvements to the San Men Xia plant will increase efficiency, output and erosion resistance.
HyPower 2013 | 21

Full-line supplier

Pelton runner with modified Tosi injector, fully assembled after revision and ready for commissioning.

III. Hidden Treasure
Located underground at the foot of the Alps, theRoncovalgrande hydroelectric plant is oneof Europe’s largest, and now, thanks to Voith
Hydro, one of its most modern and efficient.

22 | HyPower 2013

F

rom its underground position by
the picturesque Lake Maggiore in
northern Italy to the combinationof its technological and ecological innovation, the Roncovalgrande hydroelectric plant is truly unique. Originallyconstructed in the 1960s, the plant recently underwent a major modernization, updating what was a smorgasbordof the finest available engineering at thetime into one of Europe’s most efficienthydroelectric plants with an installed
power output of 1,000 MW. Together
with the international Musignano-Livargo link, Roncovalgrande is one of themain power restoration lines in theevent of a power blackout in Italy.
“The modernization demanded
very high standards in performance andA view of the different power units inside the Roncovalgrande cavern.

reliability,” explains Vincenzo Marino,
Technical Director at Voith Hydro in Italy. “Regulators of the main groups
were replaced to increase operating capacity, while the volumes of lubricantsand hydraulic fluids were also addressed.
The grease that once lubricated the 44
Pelton injectors was eliminated by redesigning the needle shaft slide mechanism, to now use a self-lubricating system, coupled with stainless-steel casingson the original carbon steel shafts.”
While rather simple in itself, this modification was complicated by a complete
overhaul of the hydraulic system, which
now operates at four times the original
pressure (80 bars instead of 20) and required a redesign of the force-balancing
system for the needle mechanism.
Given the original pump generators
were supplied by different manufacturers, a uniform approach was not possible. As Marino explains, it was a relatively simple task for the 24 injectors in

the units supplied by Riva Calzoni,
Considering the high number of injecwhich were already set up with an oil
tors, this is a large saving, in terms ofand spring system, where the overallboth provisioning and storage costs.
closure thrust was generated by the“But we mustn’t forget the other bencombined action of the water and theefits at Roncovalgrande,” Marino says.
spring. Here, the only necessary modifi“The new hydraulic system also achieves
cation was to reduce the thrust surface
energy savings. Overlapped proportionof the internal servomotor.
al valves significantly reduce oil loss and“However, it was more complicatedpump engagement times without comfor the 20 Franco Tosi injectors, wherepromising the response speed of the sysreducing the thrust surface of the intertem to the regulanal servomotor retor controls. An
quired modification
Hydropower in Italy
algorithm in theof the equilibration
Installed
capacity:
23
GW
regulator recovers
system so that waPotential not
the deadband arister alone could be
yet installed:
12 GW ing from the overused to provide thelap in the proporclosure
thrust,tional valve. What’s
since the original
more, the hydraulic oil controlling themechanism used hydraulic oil for both
operation of the machinery, while more
opening and closing.” Having overcome
costly than mineral oil, is now biodethese difficulties, the new high-pressure
gradable; an environmentally friendly
hydraulic system allows a significant resolution that befits a plant overlooking
duction in oil required for operation
Lake Maggiore.” //thanks to the reduced thrust surface.
HyPower 2013 | 23

full-line supplier

B

IV. Going
Verticaloosting efficiency without excessive financial outlay is
the goal in all hydropower modernization projects.
Voith Hydro is at the forefront of achieving this by theuse of vertical bulb turbines, and the upgrade of a major plantin Japan illustrates just how such a balance can be achieved. At
Toyomi, which was originally built in 1929, the six existingvertical Francis turbine units (installed capacity of 56.4 MW)
are being exchanged in favor of two high-efficiency, verticalbulb turbines (installed capacity 61.8 MW).
The project will increase Toyomi’s existing power output
by 10 percent, reinforcing Voith Hydro’s market-leading operation in Japan. This is crucial in a country in which hydroelectricity is the main renewable energy source.
A particular highlight is the use of the largest vertical bulb
turbine and generator in the world at 32 MW and with a runner diameter of 4.4 meters. “One of the technical features
is the application of a couple of cooling methods in order
to eliminate auxiliaries,” explains Toyomi plant engineer
Masahide Masuo. “The heat created in the generator statorand rotor is transmitted to the equipment’s outer cover andthen discharged to river water. The heat generated in the bearing is cooled in a double-walled oil chamber arranged in thebulb bracket,” he adds.

The world’s largest vertical bulb turbine
and generator will increase power output
by 10 percent at Japan’s Toyomi plant.

Hydropower inJapan
Installed capacity: 50 GW
Potential not
yet installed:
16 GW

24 | HyPower 2013

1

Voith Hydro has proved that this modernization work can be
carried out efficiently using a technique that allows the runnerto be dislodged without taking apart the generator and turbine
itself – thus reducing construction time. Installing a bulb turbine remains the most obvious solution for high outputs at
low-head sites, enabling elimination of the linear water channel required for horizontal units. “This reduces the powerhouse plane area, making the powerhouse building itself compact and significantly cutting construction costs,” says Masuo.
Scaling down this area also means vertical turbines can beused in sites which have severe geographical limitations, suchas where there is a dam upstream. “Selection of the most suitable powerhouse location and type of turbine is indispensable
in constructing new power plants and redeveloping existingones,” concludes Masuo.
This bulb turbine technology has been supplied by Voith
since the 1950s, with new designs approaching high outputs
in excess of 80 MVA. For those companies with older plants,
vertical bulb turbines provide an ideal way of upgrading, withhigher full-load efficiency and higher flow capacities offering
many advantages. And when it comes to low-head projects,
the equation becomes simple: turbines, such as the ones recently installed at Toyomi, offer higher annual energy output
and lower building costs. //Global Expertise1

2
1 The new small hydro plant will generatearound 9 GWh of clean energy a year.

A culture of hydropower

2 The special Kaplan turbine featuring
integrated generator.

In southern Finland, a modest new construction
houses a link between hydroelectric power of thepast and the very latest in cutting-edge technology.

When the Finnish utility Suur-Savon
Sähkö put out a call for bids on a newhydropower plant to be installed at the
Kissakoski dam, southern Finland, it
presented a project with cultural andtechnical challenges. The new plant was
to replace the two hydroelectric power
plants built in 1932 and 1940 that had
played a major role in the history of electrification of the region. In order to gain
approval from the authorities to develop
the site, one of the key requirements
was the historical preservation of the oldplants, machinery and intake structures,
as well as the creation of an industrial
museum with a focus on hydropower.
The main technological challenge
was installing a modern turbine into theexisting dam structure. The old weirpresented extremely wide variations inoperation and unusual hydraulic conditions: a typical water supply of 40 m³/s
that might sink at times to 6 m³/s and afall rate that could vary between twoand six meters. In addition, Suur-Savon
Sähkö was looking for a sensibly packaged and economic solution to keep
costs manageable. Further requirements included interruption- and vibration-free operation, while also preventing cavitation.
Unlike any of its competitors, the offer from Voith Hydro subsidiary Kössler
included a specially designed Kaplan
bulb turbine. These turbines are widelyused throughout the world for electrical
power production, though typically onlarger installations. Karl Henninger, Offer Project Manager for Scandinavian
countries at Kössler, says: “Once weinvited Suur-Savon Sähkö to see a similar installation on Munich's Isar River,they were convinced.”
But meeting the parameters was
not easy, explains Gerald Hochleitner,
Head of Design at Kössler: “Integrating
the turbine housing, bulb and 20-ton

generator while coming up with the entire cooling system was an incredible
challenge. The end result was a synchronous generator flanged on the extended shaft of the turbine.” Austrianbased Kössler provided both theturbine and generator, and all necessary auxiliary equipment as well as accessories and spare parts. The company
wasalso
responsiblefortransportation, installation, supervisionand commissioning.
Despite the arctic weather conditions
that accompanied the January 2012
start, the project ran like clockwork andthe hydropower plant entered operation
barely five months later. And although
this signaled the beginning of a new era
in hydropower on the Kissakoski dam,the Kissakoski Power Plant and Electricity Exhibition housed in the oldgroundwood mill ensures it will neverforget its past. //HyPower 2013 | 25

Global Expertise

Multinational
milestone
Voith Hydro’s Cubujuquí project in
Costa Rica is a small hydro plantwith big international reach.

Global effort: the turbine runners were designed in
Brazil and India, and manufactured in India.
26 | HyPower 2013

It may have been installed in Costa Rica, but Cubujuquí is theresult of equipment made in Brazil, Italy, Colombia and India.
Commissioned by Voith and one of the largest local cooperatives, Coopelesca, Cubujuquí was launched into service in December 2012. The plant is equipped with two 11.4 MW horizontal Francis turbines designed by Voith Hydro Brazil andVoith Hydro Noida (India), and manufactured by Voith Hydro
Vadodara (India); two 13.8 MVA generators and butterfly
valves, supplied by partner companies in India and Italy, withthe valves supervised by Voith Hydro in Milan; hydromechanical parts supplied from partners in Costa Rica; substationequipment from Siemens Colombia and Siemens Costa Rica;and lastly, mechanical and electrical balance-of-plant and automation systems from Voith Hydro Brazil.
Why this multinational involvement in one small hydroplant? Leonardo Penteado, Voith Hydro Brazil’s project manager for Cubujuquí, explains: “In the increasingly competitive
global small hydro market, you have to be creative to achieve
the best possible quality-to-price ratio. Bringing in equipmentfrom these different sources allowed us to minimize our costs
and maximize our supply chain while keeping quality high.”
Cubujuquí is Voith Hydro’s first project in Latin America
to employ a power unit designed, manufactured, tested and delivered from India, but it will certainly not be the last. Not
only did the products meet Voith Hydro’s quality standards,
but the Indian team also had a firm handle on costs. Sumeet
Mazumdar, Head of Communications and Project Management & Field Services, Large Hydro, for Voith Hydro India,
notes that the company benefits from tax breaks, low laborcosts and incentives from the Indian government for hydroplants when producing for export, all of which means considerable savings for customers.
Rohit Uberoi, Head of Small Hydro Engineering at Voith
Hydro Noida, points out that the Cubujuquí project was asteep learning curve in a number of ways. “Our plant in Vadodara opened in 2010 and at that time did not have many workers with experience in this kind of project. In addition, wewere set up to implement standard solutions, but for Cubujuquí, the generator was a type that we had just developed. We

Dense forest at the Cubujuquí site. Terrain prevented the use of surge tanks, so an innovative solution had to be found.

also discovered that we needed to improve our sourcing network to avoid delays.”
In spite of the challenges, the Vadodara plant managed tosatisfy Voith Hydro Brazil’s criteria with the help of teams
worldwide. “A quality manager from Brazil came to our plantand helped train the workers to ensure we would meet Voith
standards,” Uberoi explains. “We also had regular design reviews with Voith Hydro in Brazil and Germany to ensure that
we were all on the same page. Our team learned a lot of lessons from Cubujuquí that we have already been able to carryover into other projects, including producing turbines for ahydro plant in Canada, which we managed to deliver aheadof schedule.”
Partnering with colleagues on the other side of the globe presented several challenges, including linguistic and cultural differences as well as distance, although as Penteado explains, thetime-zone gap actually turned out to be a plus in some ways forthe project. “We would e-mail the team in India in the middleof their night, and by the time we got back to work the nextday, they had answered our questions. It was as though wewere working on the project 24 hours a day.”In addition to coordinating input from all over the world, theproject had to overcome a number of daunting constraints.
Terrain at the site prevented the use of surge tanks, and relief
valves would have been prohibitively expensive. So, the teamin Brazil got innovative: they designed a hydraulic solution inwhich the turbine functions as a relief valve.
“There were very few references for something like
this, so the Brazilian team had to carry out a number ofcomputer simulations to test the feasibility, with Voith engineers in Germany verifying their proposals,” Penteado explains. “The system is working very well at Cubujuquí. In
fact, this plant is now a benchmark in Costa Rica’s energy
sector.” Extensive testing may have proved time-consuming, but the project was still completed less than two years
after it had begun.
Another first at Cubujuquí was the “basic” automation
solution developed by Voith Hydro Brazil. “This is a simplified automation solution that focuses on the customer’s specific needs,” says Penteado. “It is much more cost-effective
than traditional systems.” Such is its success, Voith is already
implementing the automation in another Latin American
project. The reach of Cubujuquí continues to expand. //HyPower 2013 | 27

green energy mix

green energy mix

hydropower leads the way
Dr. Paolo Frankl, head of the International
Energy Agency’s Renewable Energy
Division, discusses the role of hydropowerin green energy on a global scale.

What are some of the new technologies that you feel will
be most important in green energy development?
While renewable energy in general is becoming more mature,
we are eagerly looking forward to second- and third-generation technologies for specific types of renewable energy.
These include third-generation photovoltaic devices based on
ultra-high-efficiency cells or ultra-low-cost organic cells; second-generation biofuels that can convert biomass waste directly into ethanol; enhanced geothermal systems that use
geothermal heat at much lower temperatures, which would
significantly expand the potential of geothermal energy; marine energy; and more. Technological developments for somerenewables will move forward more quickly than for others,
but I am confident that with a good policy framework that focuses not only on the most advanced technologies but alsostresses research and development, technological innovation
for all renewables will be achieved in a reasonable time.

Enabling technologies are crucial to all of this. There are twomain types of these for renewables: storage and smart grids.
They both contribute to flexibility and this is the key to making
viable renewable energy more readily available. Power systems of the future will need the flexibility to adapt to a varietyof energy supplies, including ones that can be ramped up andramped down very quickly, such as hydropower and gas.
Power systems will also need storage systems that give themflexibility, such as pumped storage and new technologies thatconcentrate solar power. Power systems will also need access to smart grids that efficiently and cost-effectively connect demand with supply, including wide-grid systems involving cross-border energy trading.
What role does pumped storage play in the renewableenergy mix?
Pumped storage is currently the cheapest way to store large
quantities of electricity. The International Energy Agency [IEA]
is bullish on pumped storage – not only because of its importance in hydropower, but also because this type of storage
can help to integrate much larger quantities of wind and solar

Paolo Frankl
Currently head of theRenewable Energy
Division, Frankl
joined the IEA in
2007. He has a
PhD in energy andenvironmental technologies from the
University of Rome.

energy to the global power system in the future. Totally new
pumped storage systems can be expensive, but some types
will remain economically attractive, for example ones using
cascading lines between energy systems.
A recent IEA report says that hydropower is now the leading renewable energy in use worldwide. Will it maintainthis dominant role?
Hydropower will remain the leading single renewable energy
employed globally at least until 2050, although other types ofrenewables, especially solar and wind power, will steadily gain
larger shares of the green-energy market. Hydropower is infact a special case among renewables because the technology is already mature. Technological advances in hydropowerin the future will improve the sustainability of hydro systems,
limit environmental impact, such as through fish-friendly turbines, and eventually expand pumped-storage options, forexample through developing storage systems that can use
seawater. New technologies for small hydro plants, which arevery important in many parts of the developing world, will help
enhance energy security in those countries.
What are some of the key current global trends in renewable energy?
One striking recent development is the rapid growth in thenumber of countries that are developing renewable energies– some of them for the first time. We are also seeing a significant increase in the number of countries that are setting ambitious renewable energy targets, such as China. Emerging
economies are playing a more and more important role ingreen energy development, particularly China and Brazil, butalso South Africa, Mexico and others. One sign of the growing
focus on renewables worldwide is that the International Renewable Energy Agency, founded in 2009, already has 160
members, including the EU.
What are your own priorities as the head of the IEA’s
Renewable Energy Division?
The IEA is committed to providing a factual, reliable and neutral picture of the status, progress and potential of all types ofrenewable energy. We want to make sure that green energies
are fully integrated into the global energy system, that they arecompetitive and that energy markets provide a level playing
field for them. The IEA is currently calling attention to the factthat subsidies for fossil-fuel development vastly outweighthose for renewable energy development. In the global energy
market, we need to change the current rules of the game tofocus more on policies aimed at developing secure, clean andaffordable energies for the future. The IEA will continue toidentify and promote global best practices in green energy. //28 | HyPower 2013

HyPower 2013 | 29

Green Energy Mix

A Higher Plane
With energy demand on the rise, three key developmentsin pumped-storage technology are helping provide
greater flexibility and efficiency to our grids.

A

Harmonizing wind and water energy: Frades II
30 | HyPower 2013s the mix of renewable energies
in the world’s electricity supply
grows, so does the need for reliable, high-efficiency short-term storageof energy to reduce fluctuations in thegrid. According to a 2011 study by Germany’s Federal Ministry for the Environment, Nature Conservation and Nuclear Safety, the German grid will needmore energy in the coming years forhourly and daily balancing of load fluctuations than it will for balancing overlonger intervals, such as weekly, monthly
and yearly (see chart on following page).
“Over the long run, a minimum of 70 to
80 percent of the storage business will
be short-term,” explains Alexander
Schechner, Head of After-Market Business at Voith Hydro in Germany.
Fortunately, hydropower pumped
storage is already helping to meet theneed for cost-effective grid-scale energy
storage the world over. The design ofthe plants allows energy to be stored aswater and then generate electricity: first,
water is pumped up to an elevated reservoir; when electricity is required, it isreleased through turbines down to alower reservoir.
In operation for more than sevendecades, new developments to the various pumped storage applications, namely variable-speed systems, ternary systems and multi-stage pumps, are now
making this technology more effective.

So far, pumped storage was considered
an ideal supplement to nuclear andthermal base-load power plants, since it
is costly for those plants to reduce production, for instance overnight, even if
demand changes.
“Because of the ability of a hydropower pumped storage plant to increaseor reduce output within minutes, oreven seconds, pumped storage is an allrounder – it’s the wunderkind on theblock when it comes to power plants because it provides grid support and storage,” says Schechner.
A differential is made between longterm and short-term storage, where
short-term typically means a few hours,or 10 at most. Contrary to popular opinion, short-term storage is actually whatis needed most, Schechner says. “Producers need maximum flexibility to combine stored energy with fluctuating renewable energies, such as wind and sun.”
In Portugal, where the government isdeveloping a further 5,400 MW ofwind-power capacity, Voith is equipping
a pumped storage plant called Frades II
in the northern part of the country, featuring variable-speed pumped storage
units that will help local wind power become more profitable and more reliable.
The plant, with two units of Francis
vertical variable-speed pump-turbines,
will be connected to the grid in 2015
HyPower 2013 | 31

Green Energy Mix

Green Energy Mix

Wehr, the operator, Schluchseewerke
AG, recently hired Voith to modernize
the four horizontal motor-generators at
one of the world's largest pumped storage facilities in the world. The 4x300
MVA ternary system was in operation
for more than 40 years, providing highlevels of reliability and flexibility. In recognition of Voith’s expertise in this field,
the company was asked to update thetechnology with the latest features.

Aerial view of the lower and upper reservoirs at Wehr, southern Germany.

Pumped storage to the fore

80
70
2050

Hourly balancing
Daily balancing
Weekly balancing
Source: Fraunhofer Institute32 | HyPower 2013

40

50
2030

0
10
20
Power [GW]30

Renewable energy 88 %Renewable energy 68 %1050Energy [TWh]

15

20

25

30

60

40
35

45

90

The growing need for short-term loadbalancing in Germany’s power grid

2030

2050

Monthly balancing
Yearly balancing

and produce a maximum of 383 MW perunit. It will use two asynchronous motor-generators to serve the grid.
Grid frequency, which must notvary more than +/- 0.1 hertz, is stabilized when the motor-generators react
extremely fast to provide power to thegrid or absorb power from it; they canreact within milliseconds due to highly
sensitive control systems that can tap
the kinetic energy of the flywheel masses of the motor-generators.
For the project in Portugal, Voith isdelivering variable-speed technology forpump-turbines, made feasible with
asynchronous generators, namely double-fed induction machines.
Using an asynchronous generator
to regulate pump speed and power is not
new in industrial equipment. The machines operate independently of the network frequency as pump-motors withvariable power, but also optimize turbine efficiency during generation at reduced speed at partial load.

In applying the concept to hydropower
plants, the problem has always been thelarger scale. Now, however, Voith
Hydro has developed an asynchronous
motor-generator for a large-scale
pumped storage plant. This enables thepump-turbine to change its rotational
speed, meaning the pump capacity canbe adjusted using just the currently
available amount of energy, allowing forhighly efficient stabilization of the grid
during pump and turbine operation.
“Typically, pump-turbines are connected via synchronous generators to
the grid and cannot be regulated inpump mode – they always pump withthe same power,” comments Wieland
Mattern, project manager for Frades II.
“Using variable rotational speeds represents a new level of pumped storage that
better meets requirements for electricalgrids in the future. In addition to transporting variable power into the grid, aswith synchronous pump-turbines, variable power can also be pumped out.”

Modernization work carried out on one of Wehr’s generators.

Two further advantages also exist, says
Mattern. “Asynchronous pump-turbines
are particularly suitable for dynamic
peaks in grid load variation and they canbe operated at optimum efficiency inboth pump and turbine mode.”
For plants that are already operatingwith synchronous generators, particularly smaller pumped storage plants, Voith
is developing a full-scale convertor solution to provide similar functionality.
Elsewhere in Europe, Voith Hydro isalso at work with another technologythat has been further developed to improve the performance of pumped storage plants – ternary systems.
As the name implies, ternary systems are a three-part set: a turbine connected to a motor-generator on the one
side and a pump on the other. As two
separate hydraulic machines, the rotational direction of the motor-generator
can be the same in both operationalmodes, giving considerable commercial

value for a plant’s operation. “The technology enables the highest flexibility between power delivery and power consumption modes,” says Johannes Roest,
Voith Hydro project manager.
For Forces Motrices Hongrin-Léman S.A., plant owner at Lac del’Hongrin and Lac Léman in Switzerland, Voith provides two vertical multistage pump units as part of the plant’s
ternary units (together with the Peltonturbine and the motor-generator).
The technology has been recently
refined so that customers can use bothpump and turbine simultaneously to efficiently pump the water within a hydraulic short circuit. “Ternary systems
are the most flexible. They are more expensive than standard technology but
allow the plant to be customized to theoperator’s needs. Improving the application and use of hydraulic circuits enhances flexibility further,” Roest says.
Across the border in neighboring
Germany, at the pumped storage plant

The final piece in the development of
pumped storage is multi-stage technology. With this concept, water is pumped
to the upper reservoir in stages inside asingle pump.
The pumps are built in a row (infive stages at Lac de l’Hongrin) becauseof a plant’s location high up in themountains or significant height differences between the upper and lower reservoirs. Overall grid efficiency is increased since multi-stage pumps can beused during times of over-production
from renewable energies, consumingthat excess energy to get the stored energy of the water into position in theupper lake to be released when needed.
The enhancement of these three technologies is bringing pumped storage tounprecedented levels of flexibility andefficiency. Trianel, a network of municipal utilities in the western part of Germany, is designing pumped storage
plants in consultation with Voith andthe group is optimistic about the efficiency gains and additional flexibility
that the plants will provide.
“As the energy mix in Germany
transitions to a high proportion of renewables, a flexible power supply is vital,” states Christoph Schöpfer, project
manager at Trianel. “In addition, it is
now possible to design pumped storage
plants so that they are adapted to theecosystem. From the outset, designers
work to minimize the impact of thepower plant and keep in mind whatplants and animals need to thrive.” //HyPower 2013 | 33

Green Energy mix

Green energy mix

maximizing
potential
StreamDiver® is a new compact and eco-friendly
turbine from Voith, designed to step in whereconventional hydropower plants may not be viable.

Hydropower today accounts forthe largest share of renewableenergy generation in the world,with more than 3,000 TWh generated
annually. In more than 60 countries,hydropower covers at least 50 percent of
the electricity supply.
Nevertheless, there remains a large
portion of untapped hydro energy potential worldwide. The reason for this isoften economical, as energy production
can be considered unviable in some areas. Another common hurdle is ecological concerns in areas where large hydropower plants may have a profound
impact on the local environment.

Ecological concerns were a key factor in
the development of the StreamDiver. An
important feature is the bearings, which
are lubricated entirely by water to prevent
contamination from oil and grease.

34 | HyPower 2013

In order to take advantage of this unused potential, in cooperation with its
subsidiary Kössler, Voith has developed
StreamDiver, a new compact propeller
turbine particularly suited to taking overwhere bigger plants may not be viable.
Inspired by ocean energy research,
the patented StreamDiver offers a compact and low-maintenance alternative infields where conventional hydropower
plants were previously impossible due,for example, to natural reserves. The
small turbine will allow construction
work to be kept at a minimum as the entire drivetrain, consisting of the turbine,

The StreamDiver offers a flexible alternative to conventional hydropower
plants. It can be installed as a stand-alone turbine or in sets, as seen here.

shaft, bearings and generator, is situatedin a bulb-turbine-type housing that negates the need for a visible or accessible
power house. The power unit is installed directly in the water with only
the power cable coming out. In addition, the bulb is filled with water, which
completely lubricates its bearings, ruling out any risk of water contamination.
The turbine itself is designed as apropeller turbine, meaning that neither
rotor nor stator is adjusted. Water flow
can be controlled by switching individual
turbines on and off, or by regulating
variable-speed operation. For shutdowns a separate gate is used, which si-

multaneously allows for speed to becontrolled in order to start and synchronize the compact turbines. All these design solutions allow for a comparatively
low total cost of ownership.
The technical features of the StreamDiver represent the very latest developments in the field of small hydropower,
although the underlying concept is actually a relatively simple one, says Gerald
Hochleitner, Head of Design at Kössler.
The turbine takes in water through arack, which retains branches, leaves andother debris. The remaining hydropower generation process is then taken careof by the turbine’s fully integrated drivetrain. Through its design, maintenancerequirements and the risk of unforeseen
outages are reduced to a minimum.
The compact make-up and ecofriendly features make the StreamDiverespecially helpful in locations where existing weirs or dams are already in place“StreamDiver is a serial
product with numerous
possibilities.”
Jörg Lochschmidt, Project Manager

to regulate small riverbeds, says Product Manager Jörg Lochschmidt, who
has been in charge of the StreamDiver
project since 2010.
“There are a lot of locations withexisting dam structures. In Europe, due
to new ecological regulations, thesestructures must be bypassed to recultivate the river. Combining these necessary measures with the installation of a
StreamDiver has a double effect: renaturalization and power generation at thesame time, helping to make the investment affordable,” Lochschmidt says.
“The StreamDiver is very special to us.
Conventional hydropower plants are
HyPower 2013 | 35

Green Energy mix

designed according to individual circumstances and the project at hand.
StreamDiver, in contrast, is an affordable serial product with numerous application possibilities around the world.”

Due to its small size, the StreamDiver is especially helpful infields where sills and buildings are already in place to regulate
small riverbeds. It requires low levels of maintenance and will
only need technical checks every five years.

How it works:
1

2

3

The turbine, apart from the stator entirely filled with water, takes in water
after a filtering rack has secured a steady water flow (1). The water intake
is then sent through the integrated drivetrain (2) before being converted
into clean hydro energy (3).
36 | HyPower 2013

A pilot project began in 2011 in cooperation with Austrian energy providers
VERBUND Hydro Power, Grenzkraftwerke, evn naturkraft and Wien Energie, in addition to the first prototypes
still in operation near Voith Hydro
headquarters in Heidenheim. Recently,
with the backing of German Federal
Environment Ministry and the help of
Stuttgart University, another initiative
has been started to develop a solution
adapted to the StreamDiver to meetcurrent tough ecological requirements.
In Germany alone, the new power
generation concept could generate an additional 3.5 TWh of clean, renewable energy each year, a rise of more than 15 percent on the current national hydropower
production level, or enough to power almost 300,000 households for a year. //successful partnerships

new generation
Voith Hydro’s Swedish operating unit
has a remarkable depth of hydroexpertise, particularly in the field ofgenerator manufacturing.

There is a proverb that goes, “Only Sweden has Swedish
gooseberries.” It is a statement of pride about the unique characteristics of this northern country that says Sweden is different; Sweden is special. And, over the years, a number of companies have emerged onto the world stage with the lessons
they learned in the Swedish market.
Sweden is ideally suited to hydroelectric generation, both
geographically and politically. With plenty of mountains toprovide a drop and precipitation to generate running water,
there is no shortage of locations suitable for hydro facilities,
and following the oil crisis in the 1970s, the government
moved to decrease the country’s dependence on fossil fuels.
This involved heavy investment in both nuclear and renewableenergy generation, and hydro currently accounts for almost
50 percent of the nation’s electricity. All of this means that thehydro market in Sweden is different to most of the rest of theworld. “It’s a mature market,” says Magnus Wenna, Marketing
Director for Voith Hydro Västerås (VHV), “with 80 to 90 percent of feasible hydro locations already utilized.”
Formerly known as VG Power AB, VHV is the Scandinavian market leader in large generators. Founded in 2002, it
specializes in large generators and the refurbishment andmaintenance of Hydro facilities. Voith Hydro became majority
shareholder in 2006, and at the turn of this year moved to cement its stake in the company by taking the ownership to 100
percent.
In a mature market like Sweden’s, projects to build newhydro facilities are rare and most of the market is in refurbishment and optimization of existing facilities. The country wasan early adopter of hydroelectric power and many of its morethan 1,000 operating hydro facilities date from the first two
decades of the 20th century. Refurbishing and upgrading thegenerator equipment in these older facilities is the perfect opportunity to provide benefits for the operator without the environmental impact of building a brand new facility. And it is on
projects like these that VHV has developed its expertise.
VHV designs and builds state-of-the art generators to fit
new or existing hydro facilities, as well as offers maintenancesupport and full refurbishment and upgrade services for hydrogenerators and turbines, pump motors and generators, bulb
generators, synchronous condensers, rotating and static excitation systems, and other components. “Our services give
operators a range of benefits, including increased lifetime andpower output alongside reduced service costs,” says Stefan
Borsos, who took over as President and CEO of VHV in October 2012. “We offer the best way to increase capacity andefficiency in a mature market with only rare opportunities tobuild new generator facilities.”
The expertise that VHV has accumulated will continue tobe central to a number of Voith Hydro products around theworld, including the Red Rock project in the United States
plus sites in Norway, Iceland, Wales and Switzerland. In theseand other future projects, VHV will deliver new generators orcomponents, while local Voith Hydro offices provide the turbines and overall project management. It’s a partnership for
the future, forged in Sweden. //VHV brings expertise to the Voith Hydro portfolio in several
areas, as seen in the US, Norway, Wales and Switzerland.
HyPower 2013 | 37

Greensuccessful
EnergyPartnerships

Runners for improved fish passage will be installed for testing at Ice Harbor.

Safe Passage
A new technologicalachievement makes
hydroelectric facilities
safer for native fish
and improves the efficiencyof this invaluable
energy source.

Schematic view of a minimum gap
runner Kaplan turbine
38 | HyPower 2013

The huge benefits of hydroelectric power for humans are indispensable. However, it must not be forgotten that rivers,
streams and oceans are the natural habitat of many species of fish. As hydropower is a truly sustainable energy source,
advancements in technical equipment for
improved fish migration is a constant focus for Voith Hydro engineers.
For traditional applications, spilling
water over the dams, collecting fish in
the upper reservoir or diverting themaround turbines has helped improvefish survival rates during downstream
migration, although they are costly solutions that can impact efficiency.
From the fish’s point of view, threats
stem from low pressure, high shear,high-pressure change rates, blade
strike and poor flow quality. Large gaps
at the inner and outer peripheries of turbines can increase the probability thatfish will be exposed to these harmful
flow characteristics due to the leakage
vortices originating at the gap.
To improve fish survival for smaller
radial flow applications, Voith partneredwith Alden Research Laboratory to develop and test a new three-bladed runnertechnology that reduces mortality causedby strike, pressure and shear. The predicted juvenile survival rate for passage
through the Alden turbine is 98 percent
or higher for various species of fish.

With support from the Electric Power
Research Institute, the US Departmentof Energy and industry partners, thisdevelopment is set to enter the market. “The technology is unique,” says
Voith Hydro hydraulic engineer Jason
Foust. “It incorporates the latest environmental criteria for fish passage into
one design.”
In the area of adjustable blade axial
flow turbines, Voith’s Minimum Gap
Runner (MGR) has already been providing safer fish passage for several large
units, including Bonneville and Wanapum Dams in the Pacific Northwest.
MGR concepts are also being implemented in a recent collaboration with
the US Army Corps of Engineers, andwill be installed for testing at Ice Harbor
Lock and Dam.
The goal is to identify blade turbine
geometries that improve fish passage
by addressing each cause of mortality.
“We are working with the US Army
Corps of Engineers to develop fixed
and adjustable blade replacement runners on Kaplan turbines,” Foust explains. “These turbines are being developed and evaluated according tofish-passage design criteria and the
new components tested in our laboratory.” Ice Harbor fish survival rate is expected to surpass the 95 percent forprevious MGR applications. //World of Voith

Fire protection for Danish oil terminal

3

miles of undergroundwater pipes

Voith industrial services has equipped Dan-

Sustainablepaper
production in
TurkeyModern Karton – one of
the largest manufacturers ofboard and packaging paper inEurope – has commissioned
Voith Paper to supply its new
PM 5 for lightweight packaging paper production at its
plant in Çorlu, Turkey. The
machine is expected to startup by the middle of 2015 at a
speed of 1,500 m/min. It will
have a wire width of morethan 8 meters and will produce around 400,000 metrictons of packaging paper. The
paper machine will be a particularly sustainable investment for Modern Karton, as it
consumes little fresh water.
Due to installation of an innovative dosing system in theapproach flow system of thePM 5, it is possible to precisely coordinate the use ofchemicals. In addition, software localizes and visualizes
all energy consumption in thepaper production process.
So, energy and water are
saved. Modern Karton will
also set up a power plant on
the mill premises to fully utilize
residual materials from the
manufacturing process andgenerate additional energy. //ish oil terminal operator Inter Terminals with a
new automatic fire-protection system. New regulations mean 12 oil tanks built in the 1960s will
be fitted with modern firefighting and coolingsystems. Voith worked for 12 months on the
project, building three miles of underground water pipes as well as three miles of an
above-ground piping system that will distribute foam in case of an emergency. The
work brings the system in line with the latest standards, providing the Danish company
with an up-to-date manual and automatic protection against fire hazards. //gearing up brazilian
FPSO units
Voith has received a major order forthe delivery of 60 variable-speed planetary
gears of the type “Vorecon.” The Vorecons
will enter service in offshore production at
the oil fields on the huge pre-salt cluster inthe Atlantic, approximately 300 kilometers
outside Rio de Janeiro. The operator is a
consortium led by the Brazilian Petrobras
Group. With this order, which will run forseveral years, Voith Turbo is strengthening
its leading position in the growing oil andgas markets of Latin America and the
NAFTA region. Voith, active in Brazil fornearly 50 years, will also build a new dedicated assembly hall with a test field in São
Paulo. The Voith technology is an important building block for the technically reliable and commercially viable exploitationof the oil reserves located off the Brazilian
coast. By 2017, the consortium of operators is setting up eight floating production
storage and offload units (FPSO) in
the area for a total of $3.5 billion. TheseFPSOs are to extract the oil reserves contained in the pre-salt cluster up to seven
kilometers below the water surface.
The exploitation involves the penetration of a salt layer with a thickness of up to
two kilometers, as well as a three-kilometerstone layer. To overcome this, the operator
is taking a new approach: first, a mixture ofoil, gas and water is moved to the surface
from the oil fields. The three constituentsare then separated on special vessels. The
crude oil is bunkered on ships, while thegas is returned to the subsea oil field andthus preserved for later utilization. In thepast, most of the gas was combusted andtherefore lost. Special compressors densify
the gas for return transportation into the oilfield. The compressors, whose speed iscontrolled by the Voith Vorecons, are driven
by electric motors. Due to its compact, robust design and its high reliability, the Vorecon is ideal for the rough conditions in the
Atlantic Ocean. The variable-speed planetary gear from Voith is a product that has
proven itself for decades in reliable operation in the oil and gas industry. The Vorecons for the Brazilian pre-salt oil field buildon this technology and experience. //HyPower 2013 | 39

GUEST PERSPECTIVE

GUEST PERSPECTIVE

thinking, ‘Here is the world’s greatest power, with the greatest
economy, and it cannot provide clean drinking water.’”Though Pritchard, from England, does not have a classic
science background – insofar as he doesn’t have a science
PhD, for example – he does have the mind of a radical innovator. His clean-water concept is both simple and ingenious: his
initial creation, the LIFESAVER bottle, looks pretty much likemany other bottles for carrying water: it is largely plastic, lightweight, fits in one hand, and has a drinking nozzle and cap. In
fact, the only noticeable difference with most bottles is that it
has a “pushable” bottom, which happens to be a pump, andthe magic ingredient in producing clean water.

SAVINGLIVES
Inspired by two of the worst
natural disasters in recent years,
Michael Pritchard’s simple but
ingenious LIFESAVER invention
is living up to its name.

Creating genuinely innovative solutions to the most intractableproblems is a talent possessed by few. When that problem
happens to be supplying water to people to whom it canmean the difference between life and death, the innovation is
all the more significant.
Like millions across the world, in 2004, Michael Pritchard
watched on television in horror as an Indian Ocean tsunami
killed more than 200,000 people. He was astonished to discover that in its aftermath people continued to die as a resultof a lack of access to clean drinking water. “I kept thinking
how ridiculous it was,” he recalls, “This, in the 21st century –why couldn’t we get clean water to them?”
The tragedy planted a seed for future action, though it took
Hurricane Katrina a year later to spur him on to establish amethod of providing clean water to disaster areas. “I remember
40 | HyPower 2013

1
3

2

1 Michael Pritchard’s invention has already broughtclean water to many communities …
2 … by allowing them to make the most of the natural
resources around them.
3 LIFESAVER technology provides an appealing alternative
to transporting vast amounts of drinking water.
For more information: www.lifesaversystems.com

The science of Pritchard’s clean water is filtration, thoughseveral steps beyond the usual systems based on “holes”
measuring 200 nanometers – at such a size, they are unable
to prevent all bacteria and viruses creeping through. In contrast, Pritchard’s way of producing 100-percent-clean drinking water is to filter dirty water through holes of just 15 nanometers, “a size that does prevent all living things getting
through.” The challenge, however, was to create sufficientpressure to force the liquid through such small holes.
Knowing that it is pretty much impossible to compress
water, his solution was to create a bottle with a pump, which
is used to compress air, subsequently forcing the water
through the filter holes. The corollary to this was to ensurethat water, not air, went through the filter, so Pritchard turned
to nature for inspiration: “Certain natural materials absorb
water; with others, water bounces off,” he explains. “I realizedthat if I had a membrane that was hydrophilic – somethingthat prefers liquid to gas – then the gas would not passthrough and I could build up huge pressure.” In short, the effect is that the compressed air forces dirty water into the filter’s 15-nanometer holes, leaving the “dirt” behind and cleanwater in the bottle.
It didn’t take long for Pritchard to implement a similar principle on a 18.5-liter jerry can, giving users access to far larger
amounts of clean drinking water. The results of this innovation
have already had a positive impact in disaster areas and otherregions where access to clean water is a problem. With eachfilter providing thousands of liters of water before clogging up,
villages from Malaysia to Africa and across disaster zones area few easy pumps of a plastic bottle away from converting
dirty water into clean drinking water.
And such has been the impact of Pritchard’s LIFESAVER
that it is standard issue for the British army, while Oxfam uses
the bottles and jerry cans in the field. This, however, is just theinitial stages of a much bigger challenge, hopes Pritchard. “It
may sound great,” he says, “but I want to end water poverty,
and hopefully in my lifetime.” //HyPower 2013 | 41

Regulars

Coffee BreakVoith Hydro CEO Dr. Roland Münch reveals his
personal connection to the world of hydropower.

Dr. Münch, do you start to think
about hydropower as soon as you
turn on the water in your bathroom inthe morning?
To be honest, no. I really enjoy working
in the hydropower business, and I am
convinced of the advantages of hydropower as a climate-friendly and efficient
way to produce energy. But in themorning, I am much more likely to be
thinking about a cup of coffee.

a great deal of this electricity comesfrom hydropower.

Which also contains water …
Yes. And to brew coffee, you needelectricity. What we do at Voith has ensured – for more than 140 years – that

Why is an electrical engineer like you
working in hydropower?
Predominantly because of generator
and automation technology. Since the42 | HyPower 2013

I see. So you are more likely to thinkof hydropower when you switch on
your coffee machine in the morning?
Actually, that’s quite rare, as well; eventhough we make a significant contribution to producing eco-friendly electricity, and even though I have a PhD inelectrical engineering!

joint venture in 2000, when Voith andSiemens merged their hydropower operations, we have been a true full-line
supplier. Voith Hydro covers the whole
range of services, including turbinesand generators, all the way to complete
plant automation.
What role does the generator play atVoith, a company with a long tradition as a turbine supplier?
It is a vital one. We have been at homein both sectors for a long time and weare very successful in them. We makeuse of our high level of expertise in ourown generator workshops in Shanghai,São Paulo and Västerås.
Speaking of generators, we’re talking about big numbers when it comesto power output now.
Indeed. We’re getting close to a generator class with a capacity of 1,000 MVA– an amazing development.
So, you’re a numbers person?
Yes, definitely. In both positions, as anengineer and a CEO, numbers are absolutely essential. //2All plants mentioned inthis issue and Voith’sscope of supply

Project
Directory

3

1 Guri II, Venezuela:
Rehabilitation of five Francis
turbines plus automation
systems with increased output of 770 MW.
2 Cubujuquí, Costa Rica:
Supply of two 11.4 MW
Francis turbines plus
balance-of-plant andautomation systems.
3 Gordon M. Shrum,
Canada: Rehabilitation and

1

7

6
9

5

10

upgrade of five turbines withan increased output of 310
MW each.
4 Kissakoski, Finland:
Supply of a special bulb turbine and synchronous generator with 1.5 MW output.
5 Wehr, Germany: Modernization of four 300 MVA horizontal
generators including rotor andstator rehabilitation.
6 Rheinfelden, Germany/

8

4

Switzerland: Supply of four
new 25 MW Kaplan bulb turbines quadrupling the power
plant’s output.
7 Hongrin-Léman, Switzerland: Supply of two verticalmulti-stage pump units fortwo 120 MW ternary units.
8 Frades II, Portugal: Twovariable-speed vertical pumpturbines, each with 383 MW
output and two asynchronous12

motor-generators with rated
output of 419.5 MVA.
9 Roncovalgrande, Italy:
Rehabilitation of eight turbine
units with a total capacity of
1,000 MW.
10 Uglich, Russia: Newmachine set for one generating unit with an output of 65
MW, including vertical Kaplan
bulb turbine, generator, electrical and mechanical equipment,

11

and automation system.
11 San Men Xia, China:
Modernization of two turbines,
including components andautomation to increase output
to 60 MW.
12 Toyomi, Japan: Refurbishment of the plant by replacing
six Francis turbines with two
new vertical bulb turbines plus
generators with an output of
61.8 MW.

Published by:Voith Hydro Holding GmbH & Co. KG
Alexanderstr. 1189522 Heidenheim, Germany
Tel: +49 7321 37 0
Fax: +49 7321 37-7828
www.voith.com
A Voith and Siemens Company