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

10000

Voith Siemens Hydro
Power Generation GmbH & Co. KG
Alexanderstraße 1189522 Heidenheim/Germany
Tel. +49 7321 37 68 48
Fax +49 7321 37 78 28
www.voithsiemenshydropower.com

www.msw.deCustomers magazine for Voith Siemens Hydro

March 2003

Summary

Editorial

Voith Siemens Hydro Power Generation
On the way.

Editorial
On the way

26

04

Market highlight
Boosting India’s hydro electric sector

27

05

Voith Siemens Hydro in India
28

08

Guest article
NHPC: Growth and Accomplishments

Customer contacts
12th International Seminar on Hydro
Power Plants, Vienna

High ranking visitors at the construction
site of Baglihar in India

28

Events 2003

29

China’s largest electricity and technology
exhibitions

11

12

Market splinters
Recovering the Georgian hydro power
sector30

13Modernization contract for the Bistricahydro power station

14

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

31

16

Technological leadership
New high voltage insulation will makehydro generators more efficient

32

32
18

20

22

Sophisticated automation even for smallhydro power plants
First pump-turbine unit of Germany’s
Goldisthal pumped storage plants connected to the grid
Records and moreThree Gorges: One of the largest turbine
runners in the world now being installed

24

Itaipu: Expansion of the world’s biggest
operating hydro power plant

25

More intense support and interesting
financial terms and conditions in Latin
America34

Solutions orientation
Now rendering plant operation andmaintenance services
Delivery of giant runner for Tucuruí
expansion

Locations
Facility upgrade at North American
headquarters
York, PA location celebrates 125 years ofinnovations in hydro power in the U.S.
Activities
Voith Siemens Hydro and Czech Brush
SEM decide to cooperate
Voith Siemens Hydro achieves international ISO 9001:2000 group certification
Essay
India:
With Tradition into the Modern Age

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

Service on the whole is an ever increasing share of hydrobusiness where Voith Siemens Hydro has been developing
its special concept on Integrated Solutions, with its
assessment and partnering approach. Customer relationship, where the bottom line counts at the end of not only
assessments but also fulfilled contracts and shortest
outage time management, as well as operation and maintenance of hydro power plants, are only self-understood
facets of the complete range of our services and products.

However, we are trustful that our strategic orientation
leads to the right results: as a well-positioned company
that sees itself as a project company and with the competence of a full-liner in hydro we are focusing on strong
markets with hydro potential that can add-up remarkably
to a country’s power generation mix. You can see thisespecially in India and China. And you can see in thisissue’s market highlight on India, that our activities arewell underway. The new company in New Delhi has started
working close to the market and has an impressive number of projects going on locally that are already in our
books. And we expect more to come!

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

The co-operation agreement with FKI’s Czech SEM Brush
unit will very soon enable us to provide much better
opportunities for manufacture of and service for generators up to medium-sized capacities, so especially clientsin Europe will profit from the location’s workshop vicinity
with their service needs on the electrical side of themachine. Our R&D acitivities for new insulation materials
are another effort in a series of programs to achieve
optimization and control through the whole operation
process of a hydraulic machine. At the same time, we do
not neglect sophisticated solutions for smaller plants, too,in automation and control.

Last, but not least, our participation in the record projectsof Itaipu, Tucuruí, Three Gorges, and Goldisthal, as well as
our latest awards in Eastern Europe and China strengthen
our confidence that we will – despite severed market conditions – again steer our hydro business with success on
the basis of a sound financial background, our high-end
technology and in close, trustful and reliable relationshipwith you: our customers.
Whatever your opinion and business interests are:please do not hesitate to let me have these!
Yours sincerely

Dr. Hubert Lienhard

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

hypower 4/2003

03

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

02
03

Market highlight

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

Voith Siemens Hydro in India
Last October, Voith Siemens Hydro’s Indian subsidiary started its business
operations as a private limited company in New Delhi. This step has definitely brought the company much closer to its customers. Moreover, it has
facilitated the important transfer of Voith Siemens Hydro expertise considerably. Under the leadership of Vijaynagar Prahlada Rao, Managing Director, the Indian team can now follow up the different projects from the Indian
capital.

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

Establishing a local unit, thus guaranteeing easy access to local resources
and know-how, has been consistent
with the continuous intensification ofVoith Siemens Hydro’s activities inIndia.

Voith Siemens Hydro Office in Delhi

Baglihar area

Decisive role of public corporations
Major hydro power projects targeted
for development are concentrated in
the Northern and Northeasternregions of the Indian subcontinent.
Almost two thirds of India’s newhydro projects, totalling 21,000 MWof capacity addition, shall be undertaken by public corporations of theCentral Sector (federal government)
until 2012. The remaining share ofplanned capacity addition will be
divided almost equally among privatecompanies and corporations of therespective state governments.
Furthermore, the Ministry of Power
has included 67 rehabilitation, modernization and upgrade schemeswith an aggregate capacity of over
10,000 MW in the 10th five-yearplan (2002 to 2007).

Vijaynagar Prahlada
Rao, Managing
Director

Voith Siemens Hydro India teamhypower 4/2003

Priority for hydro projects
Six years ago, India celebrated
100 years of hydro power development. Then and now, the installedcapacity of India’s hydro power
stations represented roughly one
fourth of the Indian power mix.
There is an estimated potential of
150,000 MW of hydro electric powerin the country, of which only 17%
have been harnessed so far. Since
the government clearly sees theadvantages of hydro electricity asa non-polluting and secure form ofenergy that, contrary to thermal
generation, is virtually unsusceptible
to price fluctuations, it has given highpriority to the development of hydropower projects. Plans have beendrafted to accelerate the exploitationof the vast untapped hydro potentialand expand the hydro share to 40%.

04
05

Market highlight

Baglihar
The first 450 MW stage of the 900 MW
Baglihar hydro power plant is currently being set up in the Northern Indianstate of Jammu and Kashmir. Voith
Siemens Hydro is the leader of theconsortium responsible for theturnkey execution of the electrical andmechanical works. Erection of embedded parts and development of theinfrastructure as well as civil works
are already under way. The first stageof the project, consisting of three
150 MW units, is due for commissioning by the end of December, 2004.
The remaining units of the second
stage shall be put into operation two
years thereafter.

Baglihar area

Hirakud
Two units of 24 MW each of the
Hirakud hydro power plant are now
being renovated and uprated to
32 MW each. Voith Siemens Hydro is
the turnkey contractor and has been
entrusted with the complete responsibility for all mechanical/electrical andassociated civil works for this project.
Commissioning of the uprated units
is planned for the end of October,
2004.
Baspa Stage II
Voith Siemens Hydro has supplied
the generators and the associatedelectrical equipment for the Baspa
Stage II 300 MW project. The projectis due for commissioning early in
2003. Baspa II is a good example ofdeveloping a project together with a
private promoter, Jaiprakash Industries Ltd., who also executes all thecivil works.
Hirakud contract signing

GhatgarVoith Siemens Hydro is charged withthe electrical and mechanical works
for the two Ghatgar 125 MW pumped
storage units in Maharashtra state.

Afghanistan
Baglihar I 450 MW
Baglihar II 450 MW
Nathpa Jhakri 1500 MW

China
Baspa 300 MW
Srinagar 330 MW

PakistanNathpa Jhakri
The 1,500 MW Nathpa Jhakri hydroelectric project is an undergroundpower station consisting of six unitsof 250 MW each. Voith Siemens
Hydro is a member of the EUCONA
consortium group, which is responsible for the electrical and mechanicalworks of the project.

Nepal

BhutanBangladesh
Bhivpuri / Khopoli
72 MW / 72 MW

Myanmar(Burma)Hirakud 48 MW (64 MW) R&M
Ghatgar 2 x 125 MW

Thailand

Bhira 150 MW

For more information:
P.Rao@vs-hydro.com

Sri Lanka

Bhira site erection

Burla machine view

Bhivpuri inside view

hypower 4/2003

The company has been involved
in several key projects on thesubcontinent:

06
07

Guest article

NHPC: Growth and accomplishments

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

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

Important steps during the last
5 years which have raised NHPC
to the top of its fieldElimination of time and cost overrun:
NHPC eliminates time & cost overrunin the implementation of hydro power
projects through the use of effective
contract management & project monitoring. As a result, all of NHPC’s
ongoing projects are running onschedule or ahead of schedule.
Expansion Plan:
NHPC has undertaken a large numberof medium, large and mega size projects for investigation & construction.
During the Xth Plan (2002-2007) it
plans to complete 11 projects with ayield of 4,357 MW, during the XIth
Plan (2007-2012), 14 projects with ayield of 11,194 MW, and during XIIthplan (2012-2017), it plans to add
13,000 MW.
Aggressive project monitoring:
A professionally managed MIS has
been put into place for the pro-active

monitoring of program implementation, resulting in on-time decision
making.
Emphasis on information,technology, and communication:
Major emphasis has been placedon the use of state-of-the-art information technology solutions in NHPC’s
projects to achieve a smooth, uninterrupted and faster flow of information.
Since NHPC’s projects are situated inremote, hilly areas, this has done
wonders for project implementationand crisis resolution.
Human Resource Development:
Special emphasis is being given to thefield of human resource development.
The officers and staff of NHPC are
regularly sent to various training programs and seminars, both within the
country and abroad, to keep them up
to date on the latest technologies on
the market.
Expansion through joint ventures:
NHPC has started subsidiary companies under its joint venture plan, in
cooperation with state governments,
for the development of hydro &pumped storage projects in Madya
Pradesh and West Bengal, which wereon hold due to a lack of available
funds and of necessary expertisefrom state executive agencies.

Basin-centered development:
In order to coordinate time & efforts,
NHPC has been implementing basincentered development in areas suchas the Ravi basin, the Parbati basin,
the Chenab basin, the Teesta basin
and the Siang & Subansiri basins.
The corporation currently has six
projects under construction, with acapacity of 2,280 MW. In addition,
two projects are being constructed
as joint ventures, with a capacity of
1,520 MW, and two projects on adeposit/turnkey basis with a capacityof 65,25 MW.
NHPC has drawn up a massive capacity addition plan for the hydro sector,
extending up to 2017:
Projects to be completed in X plan
(2002 - 2007)
Sl.
Project (state)
Total
No
Capacity(MW)
1 Dulhasti (J & K)390
2 Chamera – II (HP)300
3 Dhauliganga – I (UP)280
4 Teesta – V (Sikkim)
510
5 Sewa – II (J & K)
120
6 Bav – II (Maharashtra)
37
7 Indira sagar (NHDC) (M.P.)*
1,000
8 Teesta low dam stage – III (WB)132
9 Omkareshwar (NHDC) (M.P.)*520
10 Purulia pss (W.B.)*
900
11 Teesta low dam stage – IV (WB)
168
Total
4,357
* Joint Venture

Initiatives & Suggestions
Some of the initiatives taken by NHPC
for hydropower development in the
country:
NHPC has taken advance action tocreate a range of bankable DPR’s fora number of viable hydro projects,
which will help in the projects’ earlyphases.
Conducting a survey & investigationof mega projects in Dihang & Subansiri Basin in Arunachal Pradesh,which will have an installed capacityof more than 20,000 MW.
NHPC has started subsidiary companies under its joint venture plan incooperation with state governments
for the development of hydro &pumped storage projects in M.P andWest Bengal, which were on hold due
to a lack of available funds and ofnecessary expertise from state executive agencies.

NHPC has taken up projects which
had long been pending due to interstate disputes. These include four
projects in the Cauvery basin with acapacity of 1,150 MW, and the Upper
Krishna projects with a capacity of
810 MW in Karnataka.
NHPC commissioned the first hydroelectric project in the A & N Islands inAugust 2001.
NHPC is eliminating time & cost overrun in the implementation of hydropower projects through the use ofeffective contract management & project monitoring.
This sends a positive signal to policy& decision-makers that hydro projects can be completed within a fixed
time frame.
Professionally-managed MIS has been
instituted for the pro-active monitoring of program implementation.
The general atmosphere of the corporation has been made conducive tofaster decision-making, with a professional approach which will movethings in right direction. Empowering
employees with latest technologies intheir respective fields has also helped
in dealing with the unique problems
associated with hydro projects.

hypower 4/2003

In its over 27 years of existence, the National Hydroelectric Power Corporation (NHPC) has become the single largest organization for hydro power
development in India, with the capacity to undertake all of the activities
involved in administering hydro projects, from conceptualization to commissioning. NHPC, a public limited corporation, ranks among the top ten companies in the country in terms of investments. It has been granted ISO-9001
and ISO-14000 certifications.

08
09

Guest article

High ranking visitors at theconstruction site of Baglihar in India

Projects to be completed in XII plan(2012 - 2017) Tentative
Sl. No Project (state)
Total
Capacity(MW)
1
Siang upper site
11,000(Arunachal Pradesh)2
Subansiri upper site
2,000
(Arunachal Pradesh)
Total
13,000In order to ensure that the maximum
capacity of hydro power is added to
the national power system, NHPC
suggests:
Fixing a strict time frame for various
agencies involved in granting
approval/clearance, and at the sametime reducing the time limit for all
such approvals.
Adopting a three-stage clearance
procedure for hydro project clearance.
Making dedicated funding available inagreed-upon installments.
Implementing a national policy for thesettlement of R&R plans.
Shifting security costs, especially inultra-infested areas, to central andstate governments, rather than adding
them to the project costs and ultimately to the tariff.
Simplifying land acquisition procedures.

Challenges facing India’shydro sector‘State of the art’ technology is now
required in place of conventional technology in order to accomplish bettersite investigation & to deal with geological surprises.

Better desilting arrangements areneeded, as well as erosion-resistantmaterial for the underwater portionsof turbines.
A high voltage network connected to
the national grid to bring emergency
power to power-starved regions is tobe taken up on priority basis.
Standardization of features & equipment for hydro projects is not possible.
The young Himalayas are very unstable mountains. Underground facilities
in these mountains require the highest level of expertise and the courage
to face all challenges.
Silt-laden river water flows out ofyoung Himalayan rivers.
Transmission problems occur fromthe northeastern region due to
Chicken Neck.
In spite of the above challenges, thedevelopment of hydro power is a technical necessity for attaining the idealhydro : thermal mix of 40:60 for providing quality power. Now, with theshift in focus towards hydro power,
NHPC is prepared to harness the vast
untapped hydro potential of India.

Recently the Chief Minister of Jammu and Kashmir, Mufti Mohammed
Sayeed and the Chairman, Coordination Committee Ghulam Nabi Azad, paida visit to the construction site of India’s Baglihar hydro power station. He
was accompanied by the Deputy Chief Minster Mangat Ram Sharma and theMinister for Power Development Mohammed Sharief Niaz as well as further
governmental representatives. Voith Siemens Hydro participated with
Juergen Sehnbruch, Member of the Board of Management, and Karl-Heinz
Schmidt, Project Manager for Baglihar.

The Chief Minister, while inspecting
the execution of work, expressed his
satisfaction over the pace of execution. This 900 MW hydro power
station will be built in two stages:
450 MW should be commissioned by
end of 2005, while the second phasewill be completed by end of 2007. The
construction site also provides jobs inthe region: nearly 4000 employees are
locals.

After the commissioning of Baglihar,
the State of Jammu and Kashmir will
be self sufficient in power and become
an ideal place for setting up industries as the State has an attractive
package of incentives, both from theState and the Central Governments.
The Indian State of Jammu andKashmir has a hydro power potentialof 20,000 MW out of which only
1,500 MW have been tapped.

Baglihar site view

Voith Siemens Hydro Power Generation, as consortium leader, signed
contracts on 17th of July 2002, for
supply of the electro-mechanicalworks for the second stage. Once
commissioned this will be the largest
power station set up in the IndianState of Jammu and Kashmir andtherefore gives a considerably contribution to the power generation for
the total State of India.
For more information:
Anil.Pinto@vs-hydro.com

Dignitaries visiting Bagliharhydro electric project

hypower 4/2003

Projects to be completed in XI plan(2007 - 2012)
Sl.
Project (state)
Total
No
Capacity(MW)
1
Parbati – II (H.P)
800
2Parbati – III (H.P)
520
3
Chamera – III
231
4
Siang middle site
1,000
(Arunachal Pradesh)
5
Siang lower site
1,700
(Arunachal Pradesh)
6
Subansiri middle
1,600(Arunachal Pradesh)
7
Pakal dul (J & K)
1,000
8
Bursur (J & K)
1,020
9
Subansiri lower
2,000(Arunachal Pradesh)
10
Loktak D/S (Manipur)
90
11
Uri – II (J & K)
280
12
Bav – I (Maharashtra)
18
13
Farakka Barrage (WB)
125
14Upper Krishna projects
810(Karnataka)Total
11,19410
11

Market splinters

Recovering the Georgianhydro power sector

Inside view of power house
cavern with unit 3 alreadydismantled

Until the mid 1990s, Georgia had one of the fastest growing economies
among the former Soviet Republics and nearly 5,000 MW of installed power
generation capacity, about 60% of it hydro electric. However, political
disturbances in the Caucasian state have led to serious economic problems.
Due to these difficulties, fuel for thermal power plants has become increasingly hard to afford and hydro power stations have started to produce aneven larger share of the total electric energy. The CIA World Factbook forthe year 2000 indicates an annual gross generation of 7,404 GWh, whereby
21% is thermal and 79% hydro. Regardless, service and maintenance havebeen neglected for years.
Voith Siemens Hydro modernizes
Georgia’s largest hydro plant
The Enguri hydro power plant will
now undergo extensive modernization
work in three of its five units, whichhave an output of 306 MVA each.
Modernization work includes design,
supervision, erection and commissioning of electro-mechanical equipment, such as new water-cooled
generator stator windings, statorcore, re-insulation and cooler, as well
as digital and hydraulic governors andthe inlet valve control systems. The
voltage regulator and excitation, thegenerator circuit breaker and discon-

Voith Siemens Hydro Power Generation, St. Poelten,
Austria, in consortium with Siemens, Greece, recently
received a modernization contract for the hydro power
stations Bistrica 1 and 2. The total volume of order is
18 million Euro.

nector, as well as the systems for
medium and low voltage switchgear,
the battery, and the compressed air
and drainage systems will also be
upgraded. Furthermore, plant employees will be trained “on the job” foroptimized operation and control of theunits. Unit 3, which was dismantled in1991 and has been out of order eversince, will be the first unit to be completed. Its completion is scheduled
for early in the second half of 2004.
Levan Mebonia handing overthe signed contract to Claus
Schmitt, Voith Siemens
Hydro, under applause ofDavid Mirtskhulava

The modernization of the Georgianplant by order of the state-run company Engurihesi Ltd. is financed by
the European Bank for Reconstruction
and Development, with co-financing
from the European Union. The execution will be managed by the Enguri
Rehabilitation Project Implementation
Unit (PIU), established by the Bank,and supervised by the French Electricité de France as the Independent
Engineer. It will essentially contributeto the stability of the electricity supply in Georgia.
For more information:
Ernst.Bruckner@vs-hydro.com

Within a period of 26 months thescope of supply for Voith Siemens
Hydro Power Generation covers themodernization of the equipment of
Bistrica 1, including hydraulic steel
structure, penstocks with butterfly
valves, three Francis turbines withan output of 8 MW each, generators,
turbine governors, automation andcontrol as well as mechanical andelectrical auxiliary equipment.
Voith Siemens Hydro is the consortium leader. Apart from the modernization, the establishment of a 110 kVtransmission line, substations in theSouth Albanian cities Sarande andGjirokaster, as well as modernizationof the distribution network in Sarande
were assigned to the consortium. The
plants are operated by the Albanian
power supplier Korporata Elektroenergjetike Shqiptare.
The modernization of the hydropower station enables future reliable
electricity supply to approximately
300,000 inhabitants in the sourrounding area of Sarande.
For more information:Thomas.Maurer@vs-hydro.com

hypower 4/2003

As a result, Georgia’s hydro power
generation facilities invariably require
rehabilitation. The five largest plants
account for more than two thirds ofthe country’s total hydro power
capacity. The largest of them is located in the western province of Abkhazia on the Enguri River, which is
fed by the glaciers of the southern
Caucasus. This underground hydropower station has the world’s largest
arch concrete dam.

Modernization contract for the
Bistrica hydro power station

12
13
David Mirtskhulava, Minister of Energy,
in TV interview

Levan Mebonia, Director of
Engurihesi Ltd. signing contract

Market splinters

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

Considering this breathtaking pace,hardly any country has increased its
hydro power generation capacity
faster. Still today, only one fifth of
China’s vast feasible hydro power
potential is being utilized. As air
pollution worsens due to the traditionally overwhelming share of coalfired power plants in the electricity
production, environmental awarenessis on the rise. The Chinese government therefore plans to increase thehydro power sector by 8% annually.
Efforts to significantly expand thegeneration of emission-free hydroelectricity are already under way.
There are several major hydro electric
projects presently under construction.
The biggest of them is the Three
Gorges plant on the Yangtze River

with its foreseen world record output
of 18,200 MW. When fully commissioned in 2009, it will supply morethan 100 million people and industry
in the coastal areas of South-east
China.
Voith Siemens Hydro deeply involved
Through its Chinese joint venturecompany Shanghai Hydro-Power
Equipment Company Ltd. (SHEC),
Voith Siemens Hydro is deeply
involved in this project, delivering thelargest turbine runners and stator
frames ever manufactured. Three
Gorges will spare the environment
100 million tons of carbon dioxideand 2 million tons of sulphur dioxide,
which would be released annually if
the corresponding energy were to be
produced from coal.

The Taian pumped storage plant
Voith Siemens Hydro’s most recent
project in China is the Taian pumpedstorage plant in the province of Shandong in cooperation with Japan’s
Marubeni Corporation. This plant will
be equipped with four Francis-typereversible units, each with a capacityof 250 MW. Voith Siemens Hydro will
supply the pump-turbines, motorgenerators and a computer supervisory and control system.
With financing provided by the Japan
Bank for International Cooperation,and following a public bidding opening on June 12, 2002, the contract
was awarded to Marubeni Corporationof Japan as prime contractor andVoith Siemens Hydro Power Generation as the manufacturer of the four
sets of complete units for this important project.

At the official contract signing ceremony on Nov. 29, 2002, in Beijing,
Voith Siemens Hydro was represented
by Voith Fuji Hydro of Kawasaki, Japan– supplier of the electrical portion –,Voith Siemens Hydro of Shanghai,
China, – supplier of the mechanicalportion – and the company’s German
business unit – supplier of the Computer Supervisory Control System.

Voith Siemens Hydro turbinesfor 4,900 MW Hydro Project Longtan
in China
Voith Siemens Hydro Power Generation, in a consortium led by Dong
Fang Electrical Machinery Company,
has been selected to supply the seven
700 MW, 140 m head Francis turbines
for the Longtan hydro-electric projectin Guangxi Province, China.

The first unit is planned to be commissioned in the beginning of 2007.

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

This most recent cooperation
between Voith Siemens Hydro andMarubeni Corporation confirms theimportance of the company’s Japanese unit, Voith Fuji Hydro in Kawasaki, Japan and follows a number of
earlier successes of Voith Siemens
Hydro in large international hydroprojects in Asia.

Negotiations Longtan

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

Longtan areaof the seven runners. Since the sizeof these 8 m turbine runners exceeds
the transport limitations to the project
location, they will be manufactured ina specially erected facility at the project site.
Dong Fang will manufacture thebalance of the equipment.
The Longtan project, located on
Hongshui River, a tributary of thePearl River, will be among the world’s
largest hydro-power projects. The
project is internally financed in China.
Following start of generation at Longtan in 2007 the energy from thisproject will be transmitted to Guangdong, Hong Kong and to Guangxi.
For more information:
Michael.Liu@vs-hydro.com
The Longtan project team of Voith
Siemens Hydro: Huang Qing, Fu Huawei,
Goetz Pfaefflin and Tang Xu.

hypower 4/2003

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

14
15

Technological leadership

New high voltage insulation
will make hydro generators
more efficient

Bildlegende

The most important insulated component of a high voltage machine is thestator winding, particularly its bars
and coils. Even under normal operating conditions, the mechanical andthermal stress on the insulated parts
is quite high. Vibrations and disparate
expansion rates of the copper and theinsulating material due to power
output changes require an insulation
system with high resistance qualities.
This is especially true for combined
motor-generators in pumped storage
plants where turbine and pump modeschange frequently. Moreover, theintra-winding current during failures
can cause extraordinarily high magnetic forces, and possible machine
overloads place high demands onthermal resistance.

The other outstanding characteristics
of MICALASTIC, such as a life
expectancy of about 40 years underreal operating conditions, a low dissipation factor, and thermal resistancemeeting the standards of IEC 34
class F, remain unchanged as well.

Effective insulation is of vital importance for the stator bars and coils,
and for the functioning of the wholegenerator unit. For decades, MICALASTIC, a bubble-free and homogeneous insulation system, has guaranteed a long life to the winding components with its high 1-minute breakdown voltage of about 30 kV/mm.
After 2 years of development work,
Voith Siemens Hydro engineers have
improved the MICALASTIC production
process and optimized the materials
used, thus significantly increasing the
supportable dielectric strength. As aresult, the ground wall thickness of
this new MICALASTIC Advanced insulation can be reduced by 15% while
maintaining the high breakdown
strength of the traditional system.

New MICALASTIC Advanced has
already proven to be a key factor in
the production of smaller and more
efficient machines. In a case study,
Voith Siemens Hydro engineers compared the performance of two basically identical generators, one equippedwith the traditional system, one with
MICALASTIC Advanced. The findings
were more than promising: While all
performance parameters, including
efficiency and power output, proved

to be the same, the generator designed using the new insulation isabout 8% lighter. Furthermore, therespective costs have been reduced
by 7% compared to the traditionallyequipped machine.
MICALASTIC Advanced is the firststep towards a whole new generationof high tech insulation systems. The
prospects for this high performanceinsulator are bright. Combined withmodern basic designs for hydro generators, it will make possible the production of smaller and more efficientmachines. MICALASTIC Advanced
will be officially released soon.
For more information:
Caio.Kramer@vs-hydro.com

hypower 4/2003

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

1617Technological leadership

Sophisticated automationeven for small hydro power plants
The successful modernization of the German hydro power
plant at Donaustetten marks the first result of the cooperation
between SWU Energie GmbH and Voith Siemens Hydro. The
partners are thus taking a new path in project planning andrealization: engineering is done by the contractor; installation
work is carried out by the customer. This also allows to equipsmaller power plants with modern control system technology
for an optimized and cost-efficient operation.
Power house Donaustetten

Regulating unit after renovation

small plants in a fully automated way
including optimization modules likethey are known for large hydro power
plants only. Furthermore, Voith
Siemens Hydro through a close cooperation in partnership with SWU
Energie GmbH, has found a way to
reduce the installation costs effectively. After a joint, precise planningphase the complete installation of thecontrol system was carried out by
qualified power plant staff. Moreover,under the guidance of the Voith
Siemens engineers the staff members
could gain profound knowledge ofthe system.

A challenge for the specialists
The pre-requisites for this project at
the Donaustetten power plant wereanything but ideal. The technicalequipment for instance the roller
pump was not immediately suitablefor conversion to a modern, digital
control system. They had to be fittedwith two Voith Siemens moving coilswith integrated servomotors. The
existing governor system also caused
problems in speed control mode since
the time needed from unit start up
until closing of the circuit breaker
was quite long. Furthermore, thecurves for the gate blade relationshipwere not available and had to be
initially measured from the runningmachinery using a special measuringmethod.

Using Voith Siemens Hydroknow-how to reach a solution
To control the existing machinery
each machine was equipped with anautomation system including a digital
governor. The automation system isconstantly exchanging data with acommon control unit. This unit controls the common functions of theplant: for instance the interfacing to atelecontrol center which provides thecommon control unit of the power
plant with required setpoints for thelevel and the flow. This information isprocessed in the common unit withthe joint control function whichcalculates the number of machinesnecessary to realize the demanded
flow or level. The output of start andstop commands to each machine isalso carried out by the joint control
module. Moreover, a new monitoring
system is installed. All analogue
values are stored and their behaviour
as a function of time can be displayed. All event and alarm messages
are stored, can be displayed andreports can be generated. Furthermore this monitoring system enables
faster reactions in the event of problems because remote diagnosis andoperation can be carried out bymodem via this unit.

Results and future prospects
Even shortly after the initial start-upof the new control system in Donaustetten positive results can be seen.
The common control system not only
processes the instructions of thetelecontrol center but also calculates
both the most favorable load partitioning among the automated units
and the most efficient relationshipbetween blade and gate using its
optimization modules. These optimization measures enable constantoperation within the optimum efficiency range and thus result in asignificantly increased annual output.
For more information:
Hans-Joachim.Hanke@vs-hydro.com

hypower 4/2003

Modern technology for smaller
power plants
The SWU Energie contract includes
the installation of a new control
system in one further hydro power
plant as well as the option for two
further plants on the Danube and theIller canal. A contract of this sort isalmost unprecedented. Up to now it
was thought unprofitable to fit small
and medium sized hydro power plants
with sophisticated automation systems that include modules for optimized operation and interfacing toremote control systems. The Voith
Siemens Hydro Control System now
makes it possible to operate evenGeorg Schneider, Head of
Section Power Plants of
SWU Energie in front of new
automation unit

18
19

Technological leadershipFirst pump-turbine unit of one of themost modern European pumped storage plants
connected to the grid

A consortium, in which Voith Siemens
Hydro Power Generation is responsible particularly for the hydraulicdesign and the complete control system, including the technology ofvariable-speed turbine regulation in
two of four machines, supplied thehydro-electric machines. Technologically speaking, Goldisthal sets newinternational state-of-the-art standards in several aspects. The gigantic
machines can be synchronized to thegrid from standstill to full power inrecord time in world comparison.
A novelty for European pumped-storage plants: Two of the four machines
accomplish so-called “variable-speed”
operation and for this reason variations in the electrical grid are by far
better to balance than with former
pump-turbine units.

Voith Siemens Hydro is more thanpleased with the operation: “Ourmachine runs as quietly as a sewing
machine” said Managing Director
Arno Hoepner, “certain operating
mode conditions are so quietly passed
through that you can hardly hear thechange”. Voith Siemens Hydro also
provides latest state-of-the-art technology in control and automation:
The Goldisthal control centre is themost modern one in the world’s hydropower stations.
Goldisthal installation

For more information:
Frank.Felber@vs-hydro.com

hypower 4/2003

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

20
21

Records and more

One of the largest turbine runners
in the world now being installed
A giant turbine runner manufactured at SHEC, the joint
venture of Voith Siemens Hydro in China, is currently
being installed at the Three Gorges construction site on
the Chinese Yangtze River. After a 10-day trek that started at the manufacturing facility in Shanghai, the runnerarrived at the site on December 11th. It has a maximum
diameter of 10.07 meters and weighs 416 tons – thesame weight as 381 Volkswagen Golf cars. The energythat the Three Gorges hydro power plant will produce
after completion in 2009 will equal the output of approximately 15 nuclear power stations.

hypower 4/2003

The runner in all its
magnificence together withSHEC employees

Dr. Roth, President of SHEC speaking
at the runner delivery ceremony
Three Gorges runnerDistinguished guests attending
the ceremony

Revealing ceremony

For more information:
Michael.Liu@vs-hydro.com

22
23

Records and more

Expansion of the world’s biggest
operating hydro power plantMore intense support andinteresting financial terms
and conditions in Latin America

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

Itaipu runnertransportation

When the two new generator units
enter operation, in February and May
2004, the power plant will have sufficient energy available to supply acity of three million inhabitants.
Though, when fully erected in 2009,
the Chinese Three Gorges project on
the Yangtze will surpass Itaipu interms of total installed capacity, theSouth American power station willremain unrivaled in its annual energy
production. Expectations are that,with all 20 machines in operation andfavorable hydrological conditions,
Itaipu can attain an annual productionof almost 100 million MWh comparedto the estimated 84 million MWhconsidered possible for Three Gorges.

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

Consulting and support
Already in the pre-project phases, thecustomers will profit from distinctly
more comprehensive project consulting and support. Seminars, workshops, and presentations can thus be
specifically tailored to the existing
demands. Also in smaller countries,
where Voith Siemens Hydro does not
yet have a local branch, this new
standard is to be guaranteed throughcooperation with the individual
Siemens companies in each country.

Excellent financial terms
and conditions
In addition, it was possible to gain
support for Voith Siemens Hydro projects throughout all of Latin America
from the Brazilian state developmentbank BNDES (Banco Nacional de
Desenvolvimento Econômico e Social),
and from the credit insurer SBCE
(Seguradora Brasileira de Crédito à
Exportação). Specifically for the Latin
American customers, the financial
possibilities are thus extremely

attractive. Voith Siemens Hydro wasable to announce this piece of goodnews last November in São Paulo,
during a 4-day conference of its representatives from all Latin Americancountries. The conference served toreflect on the progress of customer
support and analyze the specific needsof clients in Latin America. It will now
take place annually.
For more information:
Camila.Varussa@vs-hydro.com

hypower 4/2003

The new turbine runners are currently
being manufactured at Voith Siemens
Hydro in Brazil. They will be deliveredin the first half of this year and havethe same characteristics as thoseinstalled at the beginning of the plant’s
construction. The Voith-manufactured
machines already installed at theplant have made an essential contribution to the plant’s outstanding
operational performance. Itaipu’s
indexes of availability, forced unavailability and the low failure rates of its
generator units are international reference points. It didn’t come as a surprise that the bi-national plant owner
demanded similar machines not only
for reasons of standardization.

Voith Siemens Hydro representativesof Latin America

2425

Solutions orientation

Voith Siemens Hydro São Paulo
now rendering plant operationand maintenance services
The first plant operation and maintenance contract has just been signed for
the Jauru hydro power plant, located in the Brazilian state of Mato Grosso.
The plant, equipped with Voith Siemens Hydro technology, has three generating units with a total capacity of 118 MW.

With the outsourcing of the operationand maintenance services, the plantowner directly benefits from thevaluable know how and the technological expertise of Voith Siemens
Hydro, the company that has developed and manufactured the respective
machines. There is no one else who
knows the plant as intimately. Voith
Siemens Hydro’s operation and service team consists of highly experienced personnel. The service teamlocated in the power plant, will constantly be in contact with the engineering staff in São Paulo that will

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

support them in determining theplant’s ideal operation parameters
and optimizing maintenance.
The client can be completely sure of
optimum operation and ideal machine
maintenance, which will keep thecosts for unscheduled service repairs
low and the plant’s life expectancy
high.

Excellent teamwork and new technologies used in the manufacturing
process insured the runner’s extraordinary quality. The fully milled buckets guarantee perfect erection andhomology between the model and theprototype. A porosity index of virtually zero was achieved through theremoval of the surface region that isalways more susceptible to pores.
In addition to the superior quality,
the application of these new manufacturing technologies resulted in
shorter manufacturing cycles andlower costs.

The 4,240 MW Tucuruí hydro power
plant is currently being expanded.
Located on the Tocantins River in theBrazilian state of Pará, the power
station utilizes a reservoir 80% bigger
than that of the world’s biggest operating plant, Itaipu. In this phase,
Voith Siemens Hydro is responsible
for the supply of three runner/shaft
sets. The other two sets will be delivered in November 2003 and 2004,
respectively.
For more information:
Camila.Varussa@vs-hydro.com

hypower 4/2003

Jauru hydro power plant

Delivery of giant runner
for Tucuruí expansion

Tucuruí hydropower plant
Tucuruís runner transportation

26
27

Customer contacts

The 12th International Seminar on
Hydro Power Plants took place at theTechnische Universität in Vienna on
November 27-29 of this past year.
The event’s coordinators welcomed a
total of 150 delegates from 14 nations
to the conference, which offered a
two-day forum for exchanging information and ideas in various fields ofhydro power.

In his paper, Helmut Buchmaier ofVoith Siemens Hydro presented thelatest developments relating to theconference’s main theme, “Safety and
Risks of Hydro Power Plants”. Hehighlighted considerations relating to
the typical run-away speed behaviorof Kaplan turbines. Based on theinformation which he provided, it ispossible to apply more differentiatedcriteria to the dimensioning of therotating parts of generator-turbine
units, rather than simply using the
maximum possible speed without
taking its influence on the total load
into consideration.

Events 2003
Waterpower in Buffalo, N.Y., USA
29-31 July, 2003
Booth 810
2003 Annual Conference
6-9 April, 2003
National Hydro
Association
Washington, USA

Montreal 2003,
ICOLD
16-20 June, 2003
Montreal, Canada
Peninsula 213/312

Hydro 2003 Dubrovnik,
Croatia
3-6 November, 2003
Booth 54-55

A focal point of interest
at China’s largest electricity
and technology exhibitions

Night scenery of the entrance to Beijing’s forbidden city

SHEC booth view

In November 2002, China hosted twolarge electrical apparatus and expertise exhibitions – the 9th International
Exhibition of Electrical Power Equipment and Technology (EP China 2002)
and the 2nd International Exhibitionof Electrical Engineering, Electrical
Equipment and Contractors’ Supplies(Electrical China 2002). Voith Siemens
Hydro presented its newest developments and projects alongside otherinternationally leading companies in
Beijing’s China International Exhibition Center.

Along with the increasing significanceof environmentally-relevant subjects
in recent times, interest in corresponding solutions has been growing
as well. Consequently, Voith Siemens
Hydro’s information regarding theThree Gorges Project attracted theinterest of several hundred delegates,
including the senior executives ofState Power, one of the major sponsors of the exhibition. All told, theVoith Siemens Hydro booth in theGerman pavilion offered an excellent
platform for the exchange of technicalknowledge.
For more information:
Clare.Chen@vs-hydro.com

hypower 4/2003

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

28
29

Locations

Facility upgrade at
North American headquarters

Upgrade work on the facilities at theNorth American headquarters in York,
Pennsylvania, USA are well underway.
Voith Siemens Hydro’s commitment
to the North American market isreflected in the continuation of the
upgrade and renovation project whichbegan when the Voith company purchased the facilities in 1986. The
current modernization of the buildings will not only improve their overall appearance, it will also create amore energy-efficient environment
for the almost 400 employees who
work there.

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

As an environmentally sensitive company, Voith Siemens Hydro wants tosubstantially increase the insulationof the factory walls, which will greatly
reduce the amount of natural gas consumed in heating the factory, andconserve natural resources. The final
phase will be completed soon. On
your next visit to York, please stop in
and provide your comments on our
project.

In October 2002, Voith Siemens
Hydro celebrated the 125th anniversary of its York-based U.S. subsidiarywith a open house for its employees
and invited guests. For more than acentury, this company based in Pennsylvania has stood for ground breaking developments in turbine and generator design. This drive for innovation has helped it to become one ofNorth America’s largest engineeringand manufacturing centers devoted
to the production of hydroelectric
equipment.

The York facility, which serves as
Voith Siemens Hydro’s North American headquarters, is the only turbine
specialist in the U.S. with a centerfor continued hydroelectric research.
It has spearheaded hydro power
projects around the world and North
America, including work with theRobert Moses /Niagara Project andthe Bonneville Dam Project on the
Columbia River.
For more information:
Carol.Rose@vs-hydro.com

hypower 4/2003

York, PA30
31
Building site 1952

Building frame 1952

Building 1953

Activities

At the end of last year Voith Siemens
Hydro and FKI Energy Technology
decided to cooperate in the hydrogeneration sector. The contract brings
together the top-level competence ofVoith Siemens Hydro in Engineeringand Design with the experience ofBrush SEM in the production of hydrogenerators. Brush SEM is a Czech
company of international FKI Group.
Thus Voith Siemens Hydro’s mediumsized hydro generators will be produced together with the Czech company up to maximum output of
150 MVA.

Signing ofcooperationagreement

Voith Siemens Hydro achievesinternational ISO 9001:2000 group certification

The production of competitive generators, both in terms of price andquality, will form the focus of thecooperation. This development is,however, only the starting point for
further projects. Besides the foundingof a Voith Siemens Hydro company
in the Czech Republic emphasis will
also be put on modernization projects
and high-quality after-sales services.

Identical quality standards of all
products and services throughout
the worldwide organization of afull-lining supplier are an essential
aspect in customer relationships andpart of customers’ expectations allover the globe.

For more information:
Martin.Andrae@vs-hydro.com

Voith Siemens Hydro management
has, therefore, implemented an internal management system thatguarantees the control of identicalquality standards and their certification worldwide at all locations. Representatives of TÜV (Technischer Überwachungsverein, the major auditing
enterprise in Germany) of South
Germany and Rhineland, Berlin and
Brandenburg, had audited the headquarters and each of 15 Voith Siemens
Hydro locations around the world in
November and December of last year.
TÜV has now come up with theresults: the Voith Siemens Hydro
headquarters as well as all operating
units of the group have been certified
according to the new ISO 9001:2000
standard.

Dr. Lienhard, President and CEO of
Voith Siemens Hydro Power Generation and Member of the Board ofVoith AG, where he holds the responsibility for the corporation’s quality
management, highlights the excellent
cooperation with the TÜV auditors:“I know, preparation for the simultaneous group certification was definitely a challenge to the local managementin the operating units, but in today’s
market situation, it is exactly what weowe our customers.”

Voith Siemens Hydro’s current plans
aim at including the newly founded
locations in India and the Czech
Republic into this system in thecourse of this year.
For more information:
Michael.Kuehne@vs-hydro.com

hypower 4/2003

Voith Siemens Hydro
and Czech Brush SEM
decide to cooperate

32
33

EssayIndia has many faces. On the one hand this huge
subcontinent is on the threshold of becoming
an industrialized nation. But on the other, thecountry has been shaped by numerous ancientcivilizations with different religious roots.

Hardly a city or town – even the verysmallest – is without its temple. Such
temples influence many aspects ofthe country’s day-to-day life andculture. Animals that are among theoldest on Earth play an important
part: one cannot imagine a temple
festival – these are noted for highspirituality and genuine joie de vivre –without lavishly adorned elephants.
The dutiful Mahouts who look afterand guide the elephants treat themin a profoundly kind, gentle way.
Elephants, contrary to the generalassumption and despite their proverbial thick skin, are in fact distinctly

sensitive to the many parasites thatlive in the folds of their skin. A dailybath and an extensive washing ritualby the elephants’ keepers are therefore among the most important measures in elephant care.
The elephants repay the Mahouts’
kindness by offering them a copious
shower later on! Elephants have a
proverbial good memory and aredefinitely able to register and recall
kindly or threatening gestures.
Regardless of the more modern
methods that prevail in many regionsof India, they work hard and withoutcomplaining.

This situation is related to the country’s difficult climatic and geographical conditions. Since heavy machinery
is difficult to maintain because of thehigh temperatures and extreme
humidity, elephants can still ensure
their owners a profitable income, forexample in the timber industry.
Despite all its traditions, this multicultural country is on the verge of
becoming a highly industrialized
economic zone. 3,287,263 square
kilometers in size, India is the world’s
fifth largest country. With approximately one and a half billion inhabitants –over 7 million people live inthe capital city of New Delhi alone –it has long since caught up with theWestern World in many industrial
sectors. Whether in software programming, telecommunications, thetextile industry or the mining of
natural resources, modern India hasestablished itself as a competent andefficient partner. This applies to member states of the European Community in particular, which are among

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

sible people in India have long since
discovered the advantages of hydroelectric systems.

The agricultural sector, which accounts for one third of India’s grossdomestic product, has of course beenindustrialized in many areas too.
Otherwise it would not be possible
to satisfy the immensely high daily
demand for food. More than 100
million people earn their living in the
agricultural sector. India’s farmers
mainly grow rice, wheat, corn, potatoes, sugar cane, cotton and tea.

Four large religions shape the country’s spiritual world. Hinduism,
Buddhism, Jainism and Sikhism also
influence India’s everyday life, dayto-day culture and the fine arts. Elephants have a major part to play here
as well. These gigantic animals areworshipped here – the god Ganesh
had appeared in this guise and is still
respected in modern India. And as
we have seen, in many regions ofIndia these giants are still essential
to cultivate this fertile country.

All those activities would not function
without an efficient energy supply.
This industrial sector is therefore ofgreat importance with regard to thecountry’s modernization. The respon-

hypower 3/2002

India – with Tradition
into the Modern Age

3435