ENGLISCH_HN12_9.Nov. 09.11.

2007 14:42 Uhr Seite 1

news
Hydro Issue 12
November 2007
www.vatech-hydro.com

ILISU 6/7
Aschach 8/9/10
Lower St. Anthony Falls 16

Modernization StrafloMatrixTM
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 2

Content
Introduction 3

Hydro business 4/5 Radial Turbine

Modernization

Top story 6/7 ILISU

Key projects 8/9/10 Aschach

11 Box Canyon
12 Rosone
13 Jaldhaka
14 Oymapinar
15 Cloudworks
16 Lower St. Anthony Falls

Site report 17 Cabinet Gorge 4

18 Wiesberg
19 Riddes

Markets 20/21 Hydropower in Spain

Imprint
Publisher
VA TECH HYDRO GmbH
A-1141 Vienna
Highlights 22/23/24 Penzinger Strasse 76, Austria
Phone +43/1 89100 2659

Responsible for the contents

Alexander Schwab

Editorial team
Pierre Duflon, Jens Päutz,
Events/Fairs 25 Frost & Sullivan Africa - Peter Stettner, Georg Wöber,
Kurt Wolfartsberger
Customer Service Leadership
26/27 HYDRO AUTOMATION DAY Copyright © VA TECH HYDRO GmbH 2007
All rights reserved
2007
Graphic design
Idea: Gudrun Schaffer
Layout/Production: A3 Werbeservice

Edition: 19,500

2 Hydronews
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 3

Introduction

Dear Business Partners

he first year after the takeover

T of VA TECH HYDRO GmbH as
a fully owned subsidiary of Andritz
AG was characterized by a process
of integration. All the Andritz AG
hydropower activities including
pump business have been concen-
trated under the Andritz VA TECH
HYDRO umbrella, a group that
now provides around a quarter
of Andritz Group business.

The growth of the hydropower

market and the great confidence of
our customers in our competences
and experience have helped us to
attain our current, positive position.
The question that is currently
occupying the worlds of
business and politics to an
equal extent is how electrical
power can be generated in a
sustainable, i.e. safe, reasonably
priced andclimate protection
compatible manner, in years to come.
Hydropower makes a considerable
contribution to the solution of this
quandary. Accordingly, the status
of hydropower in society has
shifted markedly in recent years.
As a consequence of the debate
concerning climate change,
greenhouse gas emissions and
the Kyoto objectives hydropower is
now internationally recognized as a
renewable source of energy.
The continuing increases in peak
power demand, grid overloading and
the growing use of wind power have
led to the recognition of the necessity mean that hydropower is envisaged this path with a balance between
of employing hydropower as the only as a major element in any future economics and ecology and the
power reserve capable of offering energy mix. Accordingly, with the accommodation of social factors.
short-term utilization. correct products and solutions, we We are well equipped for this
Shortages of fossil fuels and political see ourselves as being en route to a assignment.
concepts demanded by climate significant and steadily growing future
change (20-20-20 by 2020*) also market. It will be our task to pursue Yours sincerely

*) EU Energy Summit, March 2007. A 20% reduction

in emissions, an increase in the share of renewable
energy sources in the overall mix to 20%, and an
improvement in energy efficiency to 20% by 2020
using 1990 as a basis. Franz Strohmer Manfred Wörgötter
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Hydro business
Radial Turbine
Modernization
La Villita Power Station / Mexico
he previous issue of HYDRO
T NEWS contained a discussion
of general approaches to turbine
modernization. Furthermore, the
special aspects of axial turbine
modernization projects were
described using the case study
provided by the Grossraming power
station upgrade. The following
represents a second article in this
vein and deals with the specific
features of radial turbine
modernization.
The specific features of radial
turbine modernization
The modernization of radial units
involves Francis turbines, pumps and
Installation of new Runner at La Villita
power station
4 Hydronews
Seite 4
pump turbines. The reasons for mod-
ernization can include poor efficiency
levels and thus low annual energy pro-
duction, increasing repair costs due to
cavitation, or erosion damage to run-
ners.
In most cases, only the key parts of the
machine are replaced, while the others
are retained and refurbished. This
process is often combined with increas-
es in turbine output and flow rate.
Excellent hydraulic behaviour in terms
of efficiency and cavitation, as well as
smooth running are necessary to utilize
the full potential of upgrading. A reduc-
tion in operating and maintenance
costs through improved cavitation
behaviour, reduced vibrations, or the
elimination of pressure oscillations is of
great importance to plant owners.
Computational Fluid Dynamics (CFD) is
used for the new hydraulic design of
the spiral casing, stay vanes, guide
vanes, runner and draft tube.
Typical CFD applications for moderniza-
tion and upgrading purposes include:
• The analysis of the hydraulic
behaviour of existing turbines
• The definition of upgrading potential
• The modification of the hydraulic
design of existing components
• The hydraulic design of new
components
• Testing with a numerical test rig
• The solution of operating problems.
In certain cases, the outlet diameter of
the runner must be changed because
it is too small for the nominal discharge
of the turbine. Accordingly, a new
hydraulic layout is foreseen with an
enlarged runner outlet diameter, which
means that the draft tube cone requires
modification.
Apart from the runner, new guide
vanes, bottom ring and draft tube cone
are often installed. The mechanical
design is renewed with selflubricating
guide vane bushings, stainless steel
labyrinth rings and facing plates.
In most cases new runners are
manufactured using X4CrNi13.4 with
welded blades. Modernization involves
the governor system when a new guide
vane servomotor is installed. New CFD
design and the replacement of compo-
nents improve efficiency and increase
the power output of radial turbines.
At the same time, the mechanical
properties are checked using the finite
element method, in order to ensure
mechanical safety and the long service
life of the units.
La Villita Power Station
In 2004, VA TECH ESCHER WYSS S.A.
DE C.V. in Morelia, Mexico, received a
contract from Comisión Federal de
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 5

Pressure
(Contour 1)

Hydro business

Technical data: Old - New

Output: 76 - 82 MW
Head: 44.0 - 41.8 m
Speed: 100 /120 - 120 rpm
Runner diameter: 5,314 - 5,098 mm

Pressure distribution over the new La Villita Runner

Electricidad (CFE) for the refurbishment
of two units at the La Villita power
plant. In addition to vibration and
cavitation problems, poor efficiency was
the main reason for this undertaking.
Although the four Francis turbines
dating from 1973 were designed for
maximum power output of 76 MW,
they never achieved this value and were
operated at between 50 and 70 MW.
Moreover, originally the turbines were
intended for an operating frequency of
both 50 Hz and 60 Hz and thus the
hydraulic design was a compromise.
However, due to changes in the
Mexican grid, today turbines are only
operated at 60 Hz. During operation,
severe cavitation damage occurred at
the leading edge of the runners.
The units were also suffering from
serious vibration problems, which may
CFD was utilized for the hydraulic opti-
mization of the modified and new com-
ponents. The shape of the new stay
vane profile was perfected together
with the spiral and guide vanes by
means of 3D flow simulations at differ-
ent operating points to ensure precise
interaction between the components. In
order to accommodate the variation in
the stay vane profiles over the circum-
ference, the full geometry over 360°
was modelled. Runner design was opti-
mized by means of steady state flow
simulations with the aim of achieving
minimized losses and safe cavitation
behaviour. The interaction with the adja-
cent components was carefully harmo-
nized and viscous flow analysis was uti-
lized to minimize the losses in each
component. Parallel to hydraulic opti-
mization, the mechanical properties
efficiency of 91.5 % and 82 MW of
power (only 85 % regulating ring
opening) being achieved. Other benefits
included a reduction in vibration levels
of more than 30 % and reduced
downstream water turbulence as
compared to that experienced with
the old turbines.
The refurbishment works on unit 3,
which included the repair of compo-
nents such as guide vanes, upper and
lower turbine covers, turbine shaft, etc.
were completed during 2007.
The units have been in commercial
operation since July 2006 and August
2007 respectively to the complete
satisfaction of the customer.
La Villita
Prototype Efficiency Curves From Site Tests
Head H = 44 m
1.10
Normalized efficiency [-]

have been caused by the hydraulic were checked closely with the aim of
1.05
design compromise. As a conse- ensuring safe operation and long unit
1.00
quence, cracking had occurred at service life. In order to ascertain the
0.95
several stay vanes. One of the stay hydraulic behavior of the prototype,
0.90
vanes was even fully detached from semi-homologous model testing was Old Runner - U4
0.85 New Runner - U2
the stay ring. Cracks were also evident employed to complete the hydraulic 0.80
on the runner blades between the blade design. The quality of the runner design 20 30 40 50 60 70 80 90
Power [ MW ]
and hub close to the trailing edge. was proven without major changes.

In order to solve these multiple prob-
lems, it was decided to provide two
units with new runners incorporating an
improved hydraulic design. The profile
of the stay vanes was to be modified
and optimized with respect to efficiency
and mechanical behaviour, while the
draft tube was to remain unchanged
although the hydraulic design did not
correspond with modern criteria. Finally,
draft tube fins were to replace the aera-
tion tripod, in order to ensure smooth
operation behaviour.
ASTM A743 grade CA6NM was utilised
for the welded 53 t runners and there-
fore these had to undergo thorough
heat treatment after welding to alleviate
What’s next?
residual stresses. In the next issue of HYDRO NEWS
During the second half of 2006, we will be discussing in detail possible
VA TECH ESCHER WYSS S. A. DE measures for the restoration of the
C. V. concluded the installation of the reliability and safety of shut-off valves.
first of two runners, as well as the
modifications of the stay vanes and
draft tube and other site repairs. The Peter Stettner
performance tests were successfully Phone +43/1 89100 2957
concluded with mean weighted peter.stettner@vatech-hydro.at

Hydronews 5
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Top story
ILISU
Contracts signed for a
Large Turnkey Power Station
s the leader in an international
A consortium, Andritz VA TECH
HYDRO has captured an order for
one of Turkey’s largest hydropower
projects. The consortium also
includes the Alstom Hydro
Switzerland, the Turkish construc-
tion companies Nurol and Cengiz,
the German construction company
Züblin and the engineering firms
Stucky/Switzerland and
Temelsu/Turkey. The contract has
been concluded with the Turkish
Office for Hydraulic Engineering
(DSI) and for at least seven years
will provide employment for
thousands of local people in
the poor Tigris province of
southeastern Turkey. One aspect
of the project is the provision of
the complete financing with the
participation of export loan
agencies in Austria, Germany
and Switzerland.
6 Hydronews
Seite 6
The power station is to be located on
the Tigris, roughly 100 km from the
border with Iraq and the lake formed
by the Iraqi Mosul barrage. Project
construction is scheduled to take
seven years and following completion,
the power station will supply valuable
peaking electricity to the Turkish grid
via 400 kV lines. This will represent a
significant step towards grid stabiliza-
tion and thus the security of supply.
As a result of the size of the project,
DSI has contracted an international
engineering consortium, consisting of
the Swiss firms Colenco and Maggia
and the Turkish companies Dolsar and
Rast, with the supply of supportive
planning and construction supervision.
Once finished, the power station will
have a rated capacity of 1,200 MW,
which will make it the fourth largest in
Turkey. Moreover, the increased use of
hydropower represents a major contri-
bution by Turkey to climate protection,
as well as bringing a reduction in the
dependency on imported fuels, as the
national reserves of coal are slowly
coming to an end.
Other positive effects of the project are
effective flood protection and above all,
the sustainable development of one of
Turkey’s most economically backward
regions.
The scope of delivery of Andritz
VA TECH HYDRO includes the model
testing, design, production, transport,
installation and start-up of:
• The complete hydraulic steel
structures including penstocks
and gates
• Six vertical Francis turbines with
digital governors, shut-off valves
and ancillary systems
• All the main transformers
• Electrical protection, control tech-
nology and surveillance systems
• Electrical auxiliary systems for the
power station
• Cabling
• An in-house auxiliary unit with an
output of 4.5 MW / 5.5 MVA.
The power station represents a
pioneering project and a model for
environmental protection. For the
first time in Turkey, the planned envi-
ronmental protection measures will
be on the level required by the OECD
recommendations and the World Bank
standard. These benchmarks define
the minimum requirements in the
areas of:
• Resettlement
• Cultural heritage safeguards
• Environmental protection (biology,
wastewater).
The additional, special measures
related to the project include:
Resettlement
• Preliminary information and involve-
ment of those affected in basic
decisions relating to resettlement
• The introduction of a “grievance
redress mechanism” for the rapid
handling of claims
• The use of at least one additional
harvest by the affected population
• The definition of comprehensive
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
measures for the restoration of
income
• An educational, training and further
training drive, aimed above all at giv-
ing the disadvantaged (vulnerable
groups) greater opportunities
• The provision of sufficient land of at
least equal qualitative standard.
• The monitoring of the specific meas-
ures agreed for the project.
Cultural heritage safeguards
• Joint definition of the most
important cultural assets in
Hasankeyf with the Ministry of
Culture and Tourism
• Comprehensive securing and rescue
plan for the main cultural assets in
Hasankeyf
• Agreement concerning the principal
safety measures for other sites where
cultural assets are thought to exist.
• Provision of a budget of around
USD 100 million, of which some
USD 30 million is to be financed by
the consortium. To date, the size of
this budget is unparalleled in Turkey.
Seite 7
Environmental protection measures
• The construction of at least three
large wastewater treatment plants
(in Diyarbakir, Batman and Siirt) in
order to improve the quality of the
water in the reservoir
• The implementation of improved
irrigation for agricultural land in order
to reduce nitrogen and phosphorus
levels
• An inventory of the aquatic, eco-
system, in order to establish suitable
measures for a reduction in environ-
mental damage
• Measures for the reduction of
stratification in the reservoir,
which would lead to biological
impoverishment
• The supply of guaranteed, minimum
amounts of water, which are marked-
ly higher than current values
• Coordination of the measures with
Syria and Iraq.
The planned programme will be sub-
ject to comprehensive coordination by
a Project Implementation Unit (PIU) in
line with World Bank stipulations,
Technical data:
Output: 204 MW / 223 MVA
Head: 110 m
Speed: 187.5 rpm
Runner diameter: 4,300 mm
G. Holzer during groundbreaking ceremony
which will make certain that all the
measures in the construction, infra-
structure and environmental sectors
are completed as scheduled.
The measures have been defined by
respected, international experts and
agreed with DSI. Implementation will
be completed by local specialist com-
mittees, which in turn will be advised
and monitored by a multinational
Committee of Experts (CoE).
This CoE will report directly to the
export loan agencies, thereby ensuring
maximum efficiency.
The costs for the entire environmental
measures are only marginally lower
than those for the power station and
like the power station costs they have
already been budgeted and will be
available in yearly tranches.
Alexander Schwab
Phone +43/1 89100 2659
alexander.schwab@vatech-hydro.at
Hydronews 7
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Key projects
Aschach
Successful Modernization of Danube
Hydro Power Plant in Austria
Runner during factory assembly
Lowering the runner hub of turbine 4
The Austrian hydropower market
If one considers the development of
the Austrian energy industry over the
past few years, a steady increase in
energy demand is apparent, which
mirrors the trend in the rest of Europe.
Coverage of this rise in demand repre-
8 Hydronews
Seite 8
sents a considerable challenge in spite
of intensified measures aimed at reduc-
ing consumption and the integration of
new energy sources, especially as old
coal-fired power plants have been shut
down due to climate and environment
protection considerations and econom-
ic constraints. In Austria, hydropower
has traditionally played a major role
and due to the impulses provided by
the Kyoto Agreement, the economic
framework for future expansion with
small and micro-plants is becoming
increasingly attractive. This is reflected
by the growing number of private and
municipal operator projects.
A completely different factor in this
connection is market liberalization
throughout Europe and expansion in
the wind energy sector, which have led
to a high demand for regulating energy
and consequently to a pumped storage
plant renaissance. This technology is
especially suited to Austria for reasons
of its topography and new pump stor-
age plants such as Limberg II, Kops II
and Feldsee are set to play an impor-
tant future role in the regulation of the
European grid (UCTE). Austria covers
most of its energy needs with
hydropower and as a consequence,
high potential is available with regard to
the upgrading and efficiency improve-
ment of a large number of existing
plants. This has now become possible
due to new methods in hydraulic devel-
opment and electrical layout, superior
materials and manufacturing tech-
niques and digital regulating.
Accelerated plant ageing in tandem
with tougher operating conditions has
increased the danger of reduced
availability and has resulted in automa-
tion and modernization projects
becoming an economic necessity.
The Aschach power plant on the
Danube
One of the largest modernization
projects to be completed in recent
years is the Verbund Austrian Hydro
Power AG (AHP) power plant at
Aschach on the Danube. In the cas-
cade formed by the nine AHP
Danubian power plants, Aschach
demonstrates several particularities.
While the other plants are equipped
with 6-9 units, the second oldest plant
on the Danube has only four units.
At the same time, these units are the
largest with regard to output and
dimensions and their availability is a
major factor.
After over 40 years of largely trouble-
free operation, it was evident that
Aschach required substantial repairs
and modernization. Separation of the
turbine runner chamber and the loos-
ening of the stator core, as well as
aging in the generator stator winding
insulation led the owner to conclude
that a general overhaul was the best
answer. This solution also offered a
possibility for the raising of efficiency
and output. Following the modification
of all four units, regulating capability
will increase by 45 GWh, allowing the
supply of roughly 11,000 additional
households.
A major criterion in the decision to
award the contract to VA TECH
HYDRO GmbH and Andritz AG (in a
consortium with Voith Siemens for the
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Generator floor
turbine lot) was the extremely short
outage time of only 6 months per unit
and the increase in output. Close coor-
dination between the contractors as,
well as extensive manufacturing capa-
bilities and engineering capacity in
Austria, were essential prerequisites in
the achievement of the customer’s
demanding requirements.
In addition to increased regulating
capabilities and greater efficiency, the
main target was an improvement in
the cavitation behaviour of the turbine
during full load operation. After full
modeling of the existing turbine, the
CFD (computational fluid dynamics)
analysis reconfirmed the location of
previously identified cavitation.
Two runner designs were followed up
for optimization purposes and the
cost-benefit analysis resulted in a
change of runner diameter to 8,600
mm with a hub-to-shroud diameter
ratio of 38%. This decisively increased
the flow capability as compared to the
old turbine (hub-to-shroud diameter
ratio 44%). The automatic runner
optimization process was performed
using an evolutionary strategic
algorithm coupled with 3D EULER
and provided an improvement in tur-
bine efficiency and a shift in the cavita-
tion limits to higher discharge values.
Following the CFD analysis, a series of
model tests was completed at ASTRÖ.
During model testing it became clear
that the numerical optimization process
had to be repeated because the initial
assumption concerning the velocity
profile did not correspond with the
Seite 9
existing draft tube. The final shape of
the runner was obtained by replacing
the target-velocity profiles with profiles
derived from sample measurements.
This procedure provided an ideal pro-
file, which finally fulfilled all require-
ments.
Disassembly and reassembly repre-
sented a major challenge for our instal-
lation team. Firstly, the old runner
chamber had to be cut out with a dia-
mond-tipped, steel wire rope, prior to
the concreting of the new spherical
runner chamber. Due to this spherical
design it was no longer possible to
install the runner in one piece and
therefore the blades had to be joined
to the hub on the spot. Furthermore,
the shaft sealing was completely
renewed. Maintenance-free bushings
were installed in the wicket gates and
the guide vanes were plated with stain-
less steel. All the main components
Winding termination in twelve layers
Installation of the new stator unit 4
were crack tested. During commission-
ing, all the planned load points were
easily reached. Moreover, there was a
tangible improvement in the smooth-
ness of unit running within the upper
operating range. The design capacity
of the generators was increased from
85 MVA to 98 MVA and efficiency was
enhanced to 98.6% (relative 0.5%).
In view of the tightness of the schedule
and the possibility to install four similar
units, the original plan to simply replace
the stator core and winding was
changed in favour of the replacement
of the complete stator, gliding shoes
compensating for the radial expansion
of the stator frame. In order to allow
transport, the 13m-diameter stator
housing was designed in four parts.
The stator housing joints were welded
on-site and continuous stacking was
used to avoid any joints in the finished
core.
Hydronews 9
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 10

Key projects

Technical data: Old - New

Output/Generator: 85 - 98 MVA
Power factor: 0.8 - 0.85
Voltage: 10.5 kV
Head: 15.9 m
Speed: 68.2 rpm
Runner diameter: 8,4 00 - 8,600 mm

Lowering of generator rotor

A further design and installation chal-
lenge concerning limited space condi-
tions was the request for accessibility
of all parallel stator winding paths.
The winding termination is done in 12
layers where each phase is extended
to an outside termination box. The
stars have external neutral ties.
The 88 pole windings were reinsulated
in the workshop in Weiz, the asbestos
insulation having been professionally
removed and disposed of. The rotor
was tested for cracks in the power-
house in teamwork with the Institute
for Testing and Reseach in Material
Technology (TVFA) and in addition, the
brush holders and exciter leads were
renewed. Evidence regarding the
impact of an increase in output repre-
sented a vital element and a govern-
mental precondition for the reuse of
existing components. For this purpose
the recalculation of the rotor shaft
dynamics (critical bending moment,
critical speed, torsion frequencies,
max. shaft and coupling torque), as
well as mechanical calculations for the
Shaft removal
10 Hydronews
rotor and stator, were all completed in
Weiz. The Aschach rehabilitation is part
of a superordinated Verbund AHP proj-
ect. In future, all nine Danube power
plants will be operated and monitored
from the Danube control room at the
Freudenau power station and to this
end, the unit and plant automation at
all the power stations is to be renewed.
In this connection and independent of
the unit rehabilitation project, the
automation unit of Andritz VA TECH
HYDRO (former VA TECH SAT) was
awarded an order for the renewal of
the unit control, water management,
excitation equipment and parts of the
electrical auxiliaries. Due to the easier
Hydro Service – Austria
Hydro Service - Austria (SR-Austria)
is not only completing the large
Aschach project, as Austria’s
power plants continually require
a diversity of small and medium
rehabilitation, repair and mainte-
nance work. With its SR-Austria
organization, Andritz VA TECH
HYDRO alone has a market share
amounting to over 600 orders
annually. The scope of services
includes spare parts and compo-
nent supply, installation services,
inspection and assessment, short-
term repairs and modifications,
large audits and overhauls, which
extend to complete automation,
modernization and output increases
as previously described. Our
strengths in this regard consist of
extensive manufacturing capacities
in Austria, an experienced installa-
tion pool and complete engineering
and development competence.
The authors of this article are also
the contact persons for Hydro
Service projects in Austria.
coordination of the project team, this
proved of great advantage during the
extremely short time available for the
modifications to the first unit, enabling
the combined turbine, generator,
excitation, control and protection
equipment commissioning within only
3 weeks. Through 2-shift and partly
3-shift working, the complete outage of
6 months was only exceeded by a few
days and AHP suffered no production
losses. All of AHP’s requirements were
met to its complete satisfaction.
Disassembly of the second unit started
at the beginning of September 2007
and the final two units will follow in
2008 and 2009.
Mechanical (& Lead)
Franz Grundner (middle)
Phone +43/316 6902 2984
franz.grundner@andritz.com
Electrical
Gerhard Hofstätter (left)
Phone +43/3172 606 2282
gerhard.hofstaetter@vatech-hydro.at
Automation
Michael Hager (right)
Phone +43/1 81195 6724
michael.hager@vatech-hydro.at
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Box Canyon
Rehabilitation Contract
n June 2007, the Pend Oreille
IPublic Utility District awarded a
contract to Andritz VA TECH
HYDRO USA for the rehabilitation
of four Kaplan turbine/generator
sets at its Box Canyon facility.
The project includes the upgrading
of total plant capacity from 77 to
90 MW through the provision of new
runners to replace the originals from
Allis-Chalmers.
In addition, Andritz VA TECH HYDRO
will provide a fully homologous model
test, new governors, static exciters
and local unit controls, and the existing
Elliot generators will be rewound.
Andritz VA TECH HYDRO is also to
install all the equipment and perform
associated site works.
As part of the project’s FERC relicens-
ing, Andritz VA TECH HYDRO will
supply runners of fish- friendly design
Seite 11
Key projects
Technical data:
Output:
Voltage:
23.5 MW / 25 MVA
13.8 kV
Head:
Speed:
13.7 m
100 rpm
Runner diameter: 5,283 mm
Stator diameter: 7,700 mm
with increased hydraulic capacities to
cut the total dissolved gas produced
during operation. This project will also
represent the first US contract for coils
manufactured by Andritz VA TECH
HYDRO’s generator facility in Bhopal,
India. Site works are expected to
commence in 2009 with final unit
commissioning in 2013.
Box Canyon, which is located 13 miles
south of the Canadian Border in Ione,
Washington, was the first hydropower
plant built in the United States by a
PUD and went into service in 1956.
The plant is sited on the Pend Oreille
River, which contributes about one-third
of the natural flows to the Columbia
River system and is one of the few
rivers in the US to flow northwards.
The Pend Oreille Public Utility District
(PUD), established in 1936, is a
consumer-owned, locally controlled
State. The PUD has three primary
electric and water utility in Washington
operating divisions comprised by the
Production Division, which produces
hydroelectric power from the
Box Canyon Dam, the Distribution
Division, which distributes electricity
to approximately 8,500 customers in
Pend Oreille County and the Water
Division, which owns and operates
nine individual water distribution
systems within the District.
Vanessa L. Ames
Phone +1/704 943 4343
vames.@vatechhydro.com
Hydronews 11
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Key projects
Rosone
Two New Pelton Turbines
he Rosone plant belongs to
T IRIDE Energia S.p.A (a company
involved in power production and
related services, which was
formed last year by AEM Torino
and AMGA of Genova, two of Italy’s
main utilities).
The plant is part of the Orco Valley
system, which in total consists of five
power plants:
• Villa power plant
• Rosone power plant
• Telessio power plant
• Bardonetto power plant
• Pont power plant.
The total installed capacity in the valley
amounts to approx. 280 MW and six
seasonal reservoirs have a total capaci-
ty of 88.5 mio. m3.
The maximization of the benefits of
12 Hydronews
Seite 12
green certificates and the rising
demand for peak power, which is
creating a completely different market
approach, were of special importance
with regard to this particular power
plant. It was designed during the
pre-tender, feasibility phase in close
cooperation with IRIDE Energia S.p.A.
A detailed techno-economical study
was performed, to define and optimize
the unit size and rehabilitation philoso-
phy to the greatest possible extent,
while taking IRIDE’s need to minimize
the outage time of the power plant into
particular consideration.
To match the very tight schedule
regarding power plant downtime, a
committed project consortium was
formed by:
• Andritz VA TECH Escher Wyss
mechanical works
• Voith Siemens Power Generation –
mechanical works
• ATB Riva Calzoni S.p.A – manifold
• COGEIS S.p.A – civil works.
The rehabilitation/modernization con-
tract was finally signed with IRIDE
Energia S.p.A in June 2007.
The awarded contract foresees the
complete substitution of all the old units
and offers a very different scenario for
Technical data:
Output: 41.2 MW
Head:
Speed:
1,217
600
m
rpm
Runner diameter: 2,740 mm
the typology of the machines installed
in the powerhouse. Substitution will be
completed by means of two by two
groups of identical units. One specific
operating detail is that the Rosone
power plant is fed by two different pres-
sure penstocks with different hydraulic
conditions:
• Ceresole Orco Rosone pressure
penstock
• Telessio Eugio Rosone pressure
penstock.
New ROSONE configuration after
rehabilitation
• Orco, fed by the Ceresole Orco
Rosone pressure penstock
- 2 new horizontal shaft Pelton tur-
bines with two runners per unit and
total output of 49 MW per unit at a
speed of 600 rpm
• Piantonetto, fed by Telessio Eugio
Rosone pressure penstock
- 2 new horizontal shaft Pelton tur-
bines with two runners per unit and
total output of 41.2 MW per unit at a
speed of 600 rpm.
As the leader of the project consortium,
Andritz VA TECH Escher Wyss will
have a share in the scope of supply
and services, which comprises two
horizontal shaft Pelton turbines, a single
runner unit, four spherical valves from
six and the cooling and lubricating
systems for the units. The stainless
steel Pelton runners will be manufac-
tured using MicroGuss™ technology.
The commissioning of the first unit is
scheduled for April 2009, while the
entire works are scheduled for
completion in autumn 2010.
Giancarlo Di Zazzo
Phone +39/044 56 78 263
giancarlo.dizazzo@vatew.it
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 13

Key projects

Jaldhaka StageI Technical data:

Output:
Voltage:
9.35 MW / 10.6 MVA
11 kV
Renovation & Modernization Head:
Speed:
155 m
600 rpm
Runner diameter: 1,035 mm
in West Bengal Stator diameter: 3,700 mm

he West Bengal State

T Electricity Board (WBSEB), an
Indian utility, and Andritz VA TECH
with new mechanical auxiliaries and a
variety of refurbishment activities.

HYDRO have signed a contract for A total project duration of 28 months

is scheduled for all units, which will
the renovation and modernization
be completed in July 2009. Andritz
of the Jaldhaka Stage-I hydropower
VA TECH HYDRO has already proven
project. its expertise by executing rehabilitation
and restoration work for the Jaldhaka
Local units consisting of Andritz Stage II project (2 x 4 MW) in 2003.
VA TECH HYDRO, VA TECH HYDRO As a consequence of the related
India Pvt. Ltd., Bhopal and VA TECH performance, WBSEB has shown its Signing of the contract
Escher Wyss Flovel Ltd., Faridabad par- confidence with the award of the
ticipated in the competitive bidding for contract for Stage I.
this project and were able to secure the Andritz VA TECH HYDRO has estab- 4 x 3 MW Shivasamudram (VVNL)
contract in December 2006 against lished a leading position for refurbish- Recently Andritz VA TECH HYDRO
competition from the local giant, BHEL. ment projects in India. obtained orders for the following
The Jaldhaka I hydropower station is Some of the rehabilitation and projects in India:
located in Darjeeling District of West modernization projects in India 4 x 35 MW Periyar (TNEB)
Bengal in northeastern India. The facili- under completion/completed are: 4 x 15 MW Bassi (HPSEB)
ties are fully owned by the WBSEB. 6 x 50 MW Sabarigiri (KSEB)
The run-of-river plant utilizes the flow of 3 x 135 MW Nagjhari (KPCL)
the Jaldhaka Rivers and includes the 4 x 8 MW Papanasam (TNEB) Raghvendra Singh
Stage I and Stage II powerhouses. 4 x 12.5 MW Mettur Dam (TNEB) Phone +91/7480 400344
The Stage I powerhouse is equipped 4 x 6 MW Shivasamudram (VVNL) raghvendra.singh@vatech-hydro.com
with three units. Units No. 1 & 2, con-
sisting of vertical Francis turbines from
Dimension verification at the old generator
Litostroj and generators from Rade
Koncar, were commissioned in 1967,
while unit No. 3 from Fuji was commis-
sioned in 1972. Bhopal is carrying out
the work related to the generator and
electrical auxiliaries. New stators and
poles are to be installed, while under
this contract static excitation will be
supplied along with new electrical
auxiliaries and diverse refurbishment
work. Faridabad is completing the work
related to the turbine and mechanical
auxiliaries.

New runners, MIV and governors will be

supplied under this contract together

Hydronews 13
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Key projects
Oymapinar
Plant Automation –
Modernization in Turkey
n Turkey, the topic of hydropower
I in the media has been completely
dominated by the Ilisu project,
which led to the recent opening
ceremony of the Borçka hydropow-
er plant and other new facilities
currently under construction being
overlooked. For example, a sub-
stantial modernization contract for
the complete secondary equipment
for the Oymapinar plant has been
awarded to Andritz VA TECH
HYDRO.
The Oymapinar Dam on the Manavgat
River is located in the Taurus
Mountains, approximately 80 km east
of Antalya. The underground station
was put into operation in the 1980s
and is equipped with 4 units, each of
138.5 MW. Recently, this EÜAS plant
Oymapinar – View onto the dam crest
14 Hydronews
Seite 14
was acquired by the GENGIZ Group, a
member of the Ilisu consortium.
70% of the generated output goes
directly to the ETI Alüminyum A.S. alu-
minum plant in Seydisehir. This also
belongs to the GENGIZ Group, which is
the official principal behind the moderni-
zation work. The target of this project is
a fully automatic power plant with a
remote control capability. The outdated
relay technology will be replaced with
new digital equipment. Moreover, the
turbine governor and instrumentation,
excitation equipment, electrical genera-
tor and transformer protection system,
unit and common control system will
also be substituted. A modern SCADA
system with new synchronizing equip-
ment, as well as an online monitoring
and diagnosis system for the units pro-
Technical data:
Output: 138.5 MW / 150 MVA
Head:
Speed:
143 m
214 rpm
Underground station of Oymapinar
vide an important basis for remote con-
trol. The new joint controller guarantees
increased capacity and improved water
management. In future, this plant will
play an important role in the primary
frequency control of the Turkish trans-
mission grid. At present, the Turkish
transmission grid is being prepared for
interconnection to the European trans-
mission grid (UCTE). For this reason,
measures have to be taken regarding
the turbine governors in various Turkish
power plants together with the installa-
tion of Power System Stabilizers (PSS).
In addition, the 380 kV line protection
is also to be modernized.
The tremendous challenge for the
project team is the very short time
schedule. Only 9 months are available
for engineering and supply ex- works.
The outage of all units will start in
spring 2008 and will be completed
after seven months.
Ferdinand Schedl
Phone +43/1 89100 2085
ferdinand.schedl@vatech-hydro.at
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Cloudworks
14 Compact Turbines for
IPP Customer in British Columbia
eter Kiewit Sons Co.,
P Richmond, British Columbia,
Canada has awarded VA TECH
HYDRO Canada Inc., a member of
the Andritz VA TECH HYDRO
Group, a large order for the supply
of electromechanical equipment for
six hydropower stations in the
Harrison Lake region of British
Columbia.
The development project, with a total
installed capacity of approximately
150 MW, in the Harrison Lake region
consists of six run-of-river power sta-
tions, which will supply energy to BC
Hydro under two power supply agree-
ments. These agreements encompass
the Kwalsa Group with its Fire Creek,
Douglas Creek, Tipella Creek and
Stokke Creek power plants, and the
Upper Stave Group with its Lamont
Creek and Stave River plants.
With gross heads ranging from 280 m
to 320 m at Kwalsa, it was fairly
evident from the outset that a solution
using identical units under the different
head and flow would be a decisive
factor in optimizing project feasibility.
In an intensive phase of coordination
and concept refinement with respect
to the turbine and generator layout,
the corresponding energy generation
and the implied civil work impact,
PKS and Andritz VA TECH HYDRO
were able to find an elegant and cost-
effective, globally optimized solution.
For the Kwalsa Group, Andritz
VA TECH HYDRO will supply eight
identical six-jet Pelton turbines with
a maximum unit output of 13 MW,
including inlet valves, generators,
and digital speed governors.
Seite 15
Under the Upper Stave Group con-
tract, the Lamont Creek will be
equipped with two vertical five-jet
Pelton units of 15 MW each, and the
Stave River with three large horizontal
Francis turbine units of 12 MW each
and one small horizontal Francis unit
of 5 MW. Each unit will be supplied
with inlet valve, generator and digital
speed governor.
A special technical feature of the BC
projects is that they very often require
a so-called ramping capability consist-
ing of a slow flow change rate in the
creek after an incidental trip off the
grid of the generating equipment.
While the Pelton turbine solution is
fairly obvious and uses the deflectors
to cut energy generation almost
instantaneously, while maintaining the
flow and then slowly decreasing it,
Francis units do not allow this and in
addition create overpressure when
choking at overspeed.
On the Stave River project, the ramp-
ing question is solved by a special
generator design, which allows run-
ning at overspeed for several hours,
the passing of a high percentage of
the nominal flow, and the slow closing
of the wicket gates until each unit is
stopped entirely. This ramping proce-
dure, which has a total duration of
several hours, can be interrupted at
Technical data:
Project: Fire Douglas Tipella Stokke Lamont Stave Stave
Output: 11.2 13
Head: 282 291
Speed: 600 600
Runner diameter: 1,115 1,115 1,115
Key projects
From November 1st, 2007
New Branch Office:
at 13,700 International Place
Richmond, BC, V6V 2X8 Canada
Contact: Pierre Duflon
any time and the units resynchronized
to the grid without passing through
the full stop stage.
In addition to two ongoing large hydro
projects and one compact project
currently totalling 24 units, this
contract is to be completed in BC
within 3 years, and the fast pace of
development of hydropower in the
province of British Columbia has
prompted Andritz VA TECH HYDRO
to plan the opening of a new branch
office in the Greater Vancouver region
in late 2007 to enhance the sales and
project management activities in the
region.
Pierre Duflon
Phone +1/778 835 2101
pierre.duflon@andritz.com
8.8 11 14.8 11.2 5 MW
283 297 383 95 100 m
600 600 600 514 600 rpm
1,115 1,300 1,250 912 mm
Hydronews 15
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Key projects
Lower St. Anthony Falls
First major StrafloMatrix™
Project awarded
n March 9, 2007, SAF
O Hydroelectric, LLC awarded a
contract to VA TECH HYDRO USA
Corp. for the supply and installation
of a water-to-wire HYDROMATRIX®
plant including sixteen
StrafloMatrix™ units, hydraulic
steel structures, balance of plant
equipment, switchgear and plant
automation, and civil works for the
Lower Saint Anthony Falls Lock &
Dam in Minneapolis, Minnesota.
Lower St. Anthony Falls will be another
textbook example of the application of
the HYDROMATRIX® turbine-generator
concept. This innovative technology
for the development of hydropower at
low-head sites with existing dam or
gate structures, utilizes a factory-
assembled grid or “matrix” of small,
fixed blade turbine-generator units.
Projects, which to date could not be
realized in a financially viable manner
Architectural rendering of new powerplant
16 Hydronews
Seite 16
Technical data:
Output (total): 10 MW
Voltage: 4.16 kV
Head:
Speed:
7.6
327.3
m
rpm
Runner diameter: 1,320 mm
when using conventional turbine solu-
tions can now be profitably developed.
The plant will be located in an auxiliary
ship lock, which in the past was used
solely for flood control purposes.
A newly constructed concrete bulk-
head will house the draft tubes, the
hydraulic steel structures and most of
the hydroelectric equipment, which is
going to be located in an underground
gallery. Since the release of flood water
still has to be possible, all the turbine
generator units must allow removal
from the water during the flood
Aerial view of St. Anthony Falls
season, a capability that is one of the
key features of the HYDROMATRIX®
concept.
The plant will utilize StrafloMatrixTM
turbine-generator units equipped with
permanent magnet synchronous
generators.
The unique turbine-generator arrange-
ment of these units results in smaller
unit dimensions and reduced weight,
thus making the system more flexible
and allowing its deployment in water
passages with limited space.
Andritz VA TECH HYDRO will be
responsible for the design, supply,
installation and commissioning of the
entire electro-mechanical equipment.
The plant is scheduled to go online
in 2009.
Alexander Bihlmayer
Phone +43/732 74261
alexander.bihlmayer@vatech-hydro.at
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Cabinet Gorge 4
Final Rehabilitation steps
at Clark Fork River
ollowing completion of turbine
F Unit 4 rehabilitation, the
process of lifetime extension for
the Cabinet Gorge hydroelectric
plant is complete.
The Cabinet Gorge hydroelectric plant
is located on the Clark Fork River
(named after William Clark of the
Lewis and Clark Westward Expedition
of 1805) on State Highway 200 near
Clark Fork, Idaho, USA.
The plant was built in 1952 and houses
one Kaplan and three propeller turbines
supplied by the Baldwin Lima Hamilton
company (a predecessor company to
VOEST-ALPINE and the current Andritz
VA TECH HYDRO). The power plant
has the second-largest generating
capacity of any of Avista Utilities
(formerly Washington Water Power Co.)
eight hydroelectric developments.
Designed to help solve the critical
north-west energy shortage of the late
1940s and early 1950s, the concrete
arch dam was completed only 21
months after initial groundbreaking.
A total of 1,700 men and women
worked 24 hours a day to excavate
600,000 m3 of rock and pour
180,000 m3 of concrete to form
the dam and powerhouse.
The Noxon Rapids hydroelectric plant
is located approximately 40 km
upstream of Cabinet Gorge and has
a combined turbine hydraulic capacity
of 1,444 m3/s, as compared to the
Cabinet Gorge turbine capacity of
963 m3/s.
Because of this difference in plant
capacity, the four turbines of the
Seite 17
Site report
Technical data:
Output: 64.9 MW
Head:
Speed:
30.5
120
m
rpm
Runner diameter: 5,385 mm
Cabinet Gorge hydroelectric plant have
been undergoing an upgrade since
1990, when VOEST-ALPINE MCE (now
VA TECH HYDRO GmbH) was awarded
an order for the model test and runner
replacement of the Unit 1 turbine with a
modern design Kaplan runner. In 1994
and 2002, respectively, the original Unit
2 and Unit 3 propeller runners were Heavy load passes the narrow tunnel
replaced with mixed flow turbine run- at Cabinet Gorge
ners, in order to take advantage of the
Department in Linz. The runner uses a
small water storage capacity upstream
relatively unique design, the hub being
of the dam and the high flows through
NC milled with the runner blade root
the plant in the spring and early sum-
shape. This allowed the high precision
mer from the snowmelt in the surround-
positioning and welding of the blade
ing Cabinet and Rocky Mountains.
onto the hub. The manufacturing and
final balancing of the runner took place
In April 2005, Andritz VA TECH HYDRO
at the workshops in Linz and it was
USA was awarded the Unit 4 turbine
delivered to Cabinet Gorge in
model test and runner replacement.
December 2006.
The test was completed in the Group’s
Since April 2007 Unit 4 has been in
hydraulic laboratory in Linz, Austria and
service and is performing very well.
witnessed by the customer in July
2005.
The design of the prototype, six-blade Michael Ganglbauer
propeller runners was completed in the Phone +43/70 6987 3456
Andritz VA TECH HYDRO Engineering michael.ganglbauer@vatech-hydro.at
The runner in the Linz workshop
Hydronews 17
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Site report
Wiesberg
Successful Reconstruction
and Ceremonial Reopening
Generator 8 covered with mud and debris
I n August 2005, flooding in western
Austria caused damage amounting
to millions of Euros. The Wiesberg
hydropower plant in Landeck,
Tyrol, was also largely destroyed
by mud and boulders. The plant,
owned by Donau Chemie AG,
provided 2/3 of the power supply
for a local calcium carbide plant
and therefore production was
seriously affected.
As part of the overall rehabilitation, the
Andritz VA TECH HYDRO Service
Center in Weiz, was awarded the reha-
bilitation of generator 8 and the supply
of a new static excitation system.
Wiesberg with new flood protection
18 Hydronews
Seite 18
Donau Chemie’s ambitious target was
to reopen the plant and start operation
in May 2006. This was a great chal-
lenge and all the involved parties were
required to reduce the lead-time to a
minimum. After the first visual inspec-
tion, the initial plan was to replace the
stator winding, renew the instrumenta-
tion, clean and dry the rotor, rotor poles
and the remaining parts and carry out
repairs where necessary. However,
during disassembly of the stator wind-
ing, it was discovered that the stator
core also required renewal. Accordingly,
the original schedule could only be
maintained though a non-bureaucratic
manufacturing process at our plant
involving day and night working. Part of
the success of the project can also be
attributed to the German company,
Partzsch, which as the stator coil and
laser-cut stator core sheets supplier,
was also able to meet the very short
delivery deadlines. The rehabilitation of
the rotor poles created further chal-
lenges. The rotor winding insulation was
contaminated with asbestos materials,
CEO of Donau Chemie Alain de Krassny,
Governor DDr. Herwig van Staa and Plant Manager Roland König
Technical data:
Output: 13.2 MVA
Power factor:
Voltage:
0.8
4.3 kV
Speed: 428.6 rpm
which had to be handled and dumped
in compliance with strict health and
safety requirements. On March 27,
2006 the first rehabilitated components
were delivered to the site and reassem-
bly commenced. Commissioning took
place on May 12, 2006, and on May
19, 2006, generator 8 was released for
commercial operation. In line with the
generator rehabilitation, the rotating
exciters of all units were modified to
form modern static excitation systems.
These were supplied and commis-
sioned by Andritz VA TECH HYDRO’s
automation unit. The Wiesberg power
plant, along with the renewal of the
intake, flood protection of the power-
house and remaining civil works, was
finally completed in May 2007. On
September 24, 2007, the official
reopening ceremony took place in the
presence of the Governor of Tyrol and
all those involved in the project.
Manfred Raith
Phone +43/3172 606 2235
manfred.raith@vatech-hydro.at
ENGLISCH_HN12_9.Nov. 09.11.2007
Riddes
Plant Optimization
successfully completed
n 2005, Andritz VA TECH HYDRO
I in Kriens received an order from
Kraftwerke Mauvoisin AG, Sitten,
for the supply of twelve Pelton
runners and the modification of
five double Pelton turbine units.
In addition, Andritz VA TECH HYDRO
was to renew the complete
secondary equipment. The last of
the five units was back in operation
by mid-August 2007.
The over 50-years-old power plant is
located in Switzerland, 15 km south-
west of the cantonal capital of Sitten.
The order granted to Andritz VA TECH
HYDRO included the supply of 10+2
newly optimized Pelton runners, which
were manufactured using our patented
MicroGussTM welding method. As part
of the optimization process, the flow
was increased and this change in oper-
ating conditions necessitated the adap-
tation of the nozzles, jet deflectors,
housings, runner shaft couplings and
generator shafts. The guaranteed
efficiencies were confirmed with a
The runner with our proud installation engineers
14:42 Uhr Seite 19
Excitation, protection, turbine governor and unit control of unit 3
homologous model test and the
evidence provided by the prototype
was verified using the thermodynamic
measurement method.
A separate order was placed with the
Andritz VA TECH HYDRO automation
unit in Switzerland and Austria (former
VA TECH SAT) for the renewal of the
generator excitation, protection, unit
automation and turbine governor.
Site report
Technical data:
Output:
Old - New
50.3 - 55.7 MW
Head:
Speed:
1,005 m
600 rpm
Runner diameter: 2,450 mm
The engineering and manufacturing for
the optimization started in July 2005.
The site works for the first unit com-
menced in mid-July 2006 and were
completed at the end of August 2006
with the efficiency tests.
The outage time between shutdown
and recommissioning was very short,
which challenged the entire project
team. During the outage of one unit,
the others remained in operation.
The site activities of all units were
scheduled consecutively and by the
end of June 2007, three units had
already been successfully rehabilitated
and handed over for commercial
operation. The remaining fourth and
fifth units were finished on time in
mid-August 2007. Plant optimization
was concluded on the contractual date
to the complete satisfaction of all the
parties involved.
Josef Brunner
Phone +41/41 329 5312
josef.brunner@vatech-hydro.ch
Hydronews 19
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Markets
Hydropower
A fundamental Element in Spanish
Electricity Generation
ince the end of the 19th
S century, when the first “light
factories” were installed, hydraulic
power has played an important
role in the generation of electricity
in Spain and, as a consequence,
in its industrial development.
The erection of the first hydropower
plant in 1886 for the supply of electrical
power to the public lighting system in
the city of Gerona, represented the
beginning of a hydraulic policy that was
20 Hydronews
Seite 20
to be continuously developed
throughout the entire 20 th century.
This was because until the emergence
of other renewable energies in the last
years of the past century, hydropower
was the only energy source to be
independent of external supplies.
The ease with which hydropower
plants can obtain load is a key feature
that has allowed them to become a
very important factor in the electrical
system, covering peak demands and
the quick disconnections of thermal
power plants from the grid.
This ability to quickly connect and dis-
connect from the grid has been used
by the hydropower sector in its capacity
as an “electrical power storage battery”,
as it absorbs the excess power gener-
ated by thermal and nuclear plants
when there is insufficient demand, and
produces electricity when the system
so requires.
This function of accumulating energy
has become of paramount importance
due to:
• The necessity to synchronize power
generation with electrical demand in
real time
• The significant development of wind
power generation in Spain.
As the need to synchronize power
generation/electrical demand is not
always compatible with wind power
generation, a new element that
can solve this problem is required.
The answer may lie in reversible
pumped storage hydropower plants
and this possibility has created a
renaissance for this type of project in
the short- and medium-term in Spain
and Portugal.
As a consequence of this reactivation,
Iberdrola is in the last phase of
awarding the works and equipment
supply for Phase II of the La Muela
hydropower plant, with a total output
of 840 MW, and EDP is in the same
situation with respect to the 189 MW,
Picote II hydropower plant.
The rest of the big electrical utilities on
the Iberian Peninsula also have the con-
struction of large pumped storage
power plants on their agenda for the
near future.
The Andritz VA TECH HYDRO
Group is well integrated into the
Spanish hydropower scene
Escher Wyss, and later Sulzer, which
provided the historical background
for today’s Andritz VA TECH HYDRO,
collaborated in the development of
hydropower in Spain from the very
beginning at the end of the 19th
century and this support has been
maintained over the years by means
of a technological evolution, which
has permitted the coverage of the
changes that have taken place with
regard to hydropower demands.
Among the results of this evolution
are new designs aimed at obtaining
more ecological turbines, innovative
materials that extend the useful life of
equipment and the full development
of simulation tools, which allow the
study and optimization of hydraulic
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 21

Markets

Project Type of turbine

Patico Semi-Kaplan
Pego do Altar Francis vertical
Quatre Pobles Francis horizontal
Vale Do Gaio CAT
Fragoso Francis horizontal
Ribeira da Teja Pelton
Novo Pindo Francis horizontal
Palomarejo Semi-Kaplan
Portodemouros Francis vertical
Talavera Semi-Kaplan
Gomil Francis horizontal
Tambre Francis horizontal
Rehabilitation and Upratings Fontanar I Kaplan
Fontanar II Kaplan
Serós 4 units Castrelo 1 unit Arroibar Francis vertical
Buendía 1 unit Talarn 1 unit Anllo Francis vertical
Gavet 1 unit Camarasa 4 units Avia Francis horizontal
Fervenza 1 unit Ribarroja del Ebro 4 units Pedrezuela Francis horizontal
Salime 4 units Arenas 2 units Valmayor Francis horizontal
Aldeadávila 4 units Castelo do Bode 2 units Los Molinos Francis horizontal
Estangento / Sallente 1 unit Conso 1 unit Teixo Pelton horizontal
Flix 3 units Villarino 1 unit Caneido Francis horizontal
Belver 4 units Alto Rabagão 2 units
Guillena 3 units Tajo de la Encantada 3 units
Pedro Marín 1 unit Menuza 1 unit
Montamara 1 unit Lanuza 2 units to adjust to the specific needs of each
Silvón 2 units Camarmeña 1 unit
client and every project and this is the
Pontenovo 2 units
reason why the company participates
regularly in projects with major Spanish
electrical utilities, self-producing com-
turbines, penstocks and the transient customised solutions and plays an panies and leading, national contrac-
conditions of the hydraulic systems in important role in quick reactions in tors.
especially problematic environmental response to critical situations at opera-
situations. tive plants. Manuel Orueta
At local level, Andritz VA TECH HYDRO The experience gathered over many Phone +34/91 425 10 14
has the human resources and materials years allows Andritz VA TECH HYDRO manuel.orueta@vatech-hydro.net
needed to collaborate with its clients
in the equipping of hydropower plants,
both in the large hydro segment and
in the renewable and reversible
hydropower plant areas. This team is
strengthened and complemented by
the rest of the Andritz VA TECH
HYDRO structure at global level,
especially though the existing capabili-
ties in surrounding countries such as
Austria, Germany, Switzerland, France
and Italy.

This collaboration also continues

during plant operation, contributing to
preventive and corrective maintenance,
refurbishment and upgrading.

The Andritz VA TECH HYDRO plant in

Algete (Madrid) is dedicated exclusively
to hydropower products. It provides

Hydronews 21
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 22

Highlights

GERMANY TURKEY ITALY

GOTTFRIEDING &
WASSERBURG
Andritz VA TECH HYDRO has
finalized the contracts for delivery,
installation and commissioning of
the equipment for two low head
power plants for E.ON.
Both plants are equipped with a pit
turbine with a step-up gear unit, turbine
governor and low voltage distribution,
water cooled 6.3 kV generator, trans-
formers and 20 kV switchgear.
The new turbines will be installed next
to the already existing power stations
on the rivers Inn and Isar in Bavaria
and will significantly increase their
power output. The new contracts
are part of the successful series of pit
turbines which have been built at the
COMPACT HYDRO manufacturing
site in Ravensburg in the recent years.
These turbines have been highly rated
amongst the customers due to their
high quality, reliability and efficiency.
Amongst these satisfied clients is
also E.ON who is operating the similar
pit turbine Jettenbach (D1 = 2,350 mm)
since 3 years.
Martin Heutele
Phone +49/751 83 2750
martin.heutele@vatew.de
Technical data: Gottfrieding
Output: 4,950 kW
Head: 6.09 m Phone +33/4 75 23 05 08
Speed: 118.8 rpm
Runner diameter: 3,650 mm
Technical data: Wasserburg
Output: 4,950 kW
Head: 5.88 m Speed:
Speed: 136.48 rpm
Runner diameter: 3,650 mm
LAMAS III & IV
Andritz VA TECH HYDRO in France
has been awarded with an order
to supply four vertical Pelton units
in Turkey.
The customer, TGT ENERGY CO-
ORPORATION AND TRADING CORP.
is building two hydropower plants in
cascade on the Lamas River, near the
city of Mersin, in Turkey. LAMAS III
HEPP is to be equipped with 2 vertical
Pelton units 5 jets 7.4 MW each, while
LAMAS IV HEPP is to be equipped
with 2 vertical Pelton units 4 jets
10.8 MW each.
The contract was awarded to a
consortium lead by VA TECH Bouvier
Hydro and comprising also the genera-
tors and the control, protection and
switchgear.
The order includes the supply of
turbines and inlet valves, as well as
supervision of erection and commis-
sioning. Both sites are expected to
enter in operation by the end of 2008.
The same customer just awarded
the Consortium with an additionnal
contract for the Cakirlar powerplant
equipped with two similar vertical
Pelton turbines.
Dominique Leleux
dominique.leleux@bouvierhydro.fr
Technical data: Lamas III / Lamas IV
Output: 7.4 / 10.8 MW
Head: 223 / 325 m
Speed: 500 / 600 rpm
Runner diameter: 1,180 / 1,230 mm
FAUBURG
The project Fauburg, located
in Valle d’Aosta near the Mont
Blanc – Italy, has started in
July 2007 for the regional utility
CVA (Compagnie Valdotaine
des Eaux).
The two vertical units have four jets
each. Following past experiences with
the same customer, the scope of
supply is based on a “water to wire”
philosophy including besides the
turbines, 2 synchronous generators,
spherical valves, auxiliaries, plant
automation (NEPTUN platform) and
low and medium voltage electrical
equipment.
We are working in consortium
with a local civil partner in order to
realize the building near La Thuile
one of the most famous ski resort
of the alps and the old “roman
alps road”.
Stefano Rizzi
Phone +39/0445678247
stefano.rizzi@vatew.it
Technical data:
Output: 5,235 kW
Head: 297 m
600 rpm
Runner diameter: 1,150 mm

22 Hydronews
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
BHUTAN
CHHUKHA
VA TECH HYDRO AG, Vevey,
Switzerland has received an order
for the supply of four MicroGussTM
Pelton runners weighing more
than 17 t each for the Chhukha
hydropower plant in Bhutan.
The Kingdom of Bhutan is a land-
locked, south Asian nation situated
between India and China. The entire
country is mountainous except for a
small strip of sub-tropical plain in the
extreme south, which is intersected by
valleys. Bhutan is one of the world’s
most isolated nations and the govern-
ment regulates foreign influences and
tourism in order to preserve its tradi-
tional Tibetan Buddhist culture.
Bhutan has been a monarchy since
1907. The different Dzongkhag dis-
tricts were united under the leadership
of Trongsa Penlop. King Jigme Singye
Wangchuck, who has made some
moves toward constitutional govern-
ment, announced in December 2006
that he would abdicate in 2008 in
favour of his eldest son. He also stated
that he would start handing over
responsibility to his son immediately.
Stéphan Viennet
Phone +41/21 925 7712
stephan.viennet@vatech-hydro.ch
Technical data:
Output: 84
Head: 435
Speed: 300
Runner diameter: 3,656
Seite 23
Highlights
INDONESIA FRANCE
CIRATA PINET
At the beginning of 2007, Andritz Electricité de France (EDF) has
VA TECH HYDRO Indonesia awarded a contract to VA TECH
received an order from PT HYDRO AG in Vevey consisting of
Pembangkitan Jawa-Bali (PT. PJB) four 8.5 MW Francis runners for
for the modernizing and upgrading the Pinet hydropower plant.
of the existing control system at the
Cirata power plant.
Cirata, which is located in West Java,
is the world’s fourth largest cavern
power plant and represents the back-
bone of the Indonesian grid. In 1986
and 1994, Andritz VA TECH HYDRO
installed a total of eight vertical Francis
turbines and generators with a total
capacity of 1,000 MW at this site. The
scope of supply includes the complete
replacement of the control system, i.e.
all eight unit controllers, the power-
house 1 and powerhouse 2 computer The scope of supply also includes four
systems and the central SCADA locat- sets of fixed labyrinths and coupling
ed in the 500 kV switchyard and the bolts. Delivery of the first runner is to
dam control room. The voltage regula-
take place in August 2008 and the
tors of the first four units are to be
last unit will be supplied by July 2011.
upgraded to digital type regulators as in
units 5 – 8. Due to Cirata’s key role in
We received the order thanks to the
the Java-Bali grid, special functions
outstanding performance of the first
such as plant black start, line charging,
runner, which Vevey commissioned in
load frequency control, joint control and
2006. At that time, the tests showed
remote control from the Gandul Load
an increase in output of 15 per cent
Dispatch Center will be incorporated
and a 7 per cent improvement in
into the control system. Andritz
efficiency.
VA TECH HYDRO Indonesia is to imple-
ment the project within 15 months.
The power plant is situated on the
River Tarn and constitutes the first of
four dams, which form the Pinet lake.
It is located 30 km from the famous
bridge of Millau in the south of France.
The installation has been in operation
since 1929 with an average output of
105 GWh per year.
Gerhard Enzenhofer Carlos Contreras
Phone +62/21 3906929 Phone +41/21 925 77 21
enzenhge@vatech.co.id carlos.contreras@vatech-hydro.ch
Technical data: Technical data:
MW Output: 129.6 MW Output: 8.5 MW
m Head: 130 m Head: 32 m
rpm Speed: 187.5 rpm Speed: 250 rpm
mm Runner diameter: 3,400 mm Runner diameter: 2,150 mm
Hydronews 23
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
Highlights
PAKISTAN
TARBELA 11-14
VA TECH HYDRO AG, Vevey, has
received an order from the Water
and Power Development Authority
(WAPDA) in Pakistan for the sup-
ply of four new digital turbine gov-
ernors TC1703, which will replace
the existing digital governors in
the Tarbela Units 11 – 14 hydro-
electric power station.
The Tarbela hydroelectric power sta-
tion is located on the Indus River in
Pakistan, about 50 km northwest of
Islamabad. It is a major factor in
Pakistan’s overall hydroelectric
production. The power plant was built
between 1968 and 1978 when the
operation began with the aim of com-
bining hydroelectric power generation
with the use of water for irrigation and
industrial purposes. The units 11 to 14
were supplied and installed by Andritz
VA TECH HYDRO between 1992 and
1993 to provide additional capacity of
1,728 MW. These units have a unique
feature as they are equipped with the
largest penstocks in the world.
The units 9 and 10, which were also
supplied by Andritz VA TECH HYDRO,
were completed in 1985.
Carlos Contreras
Phone +41/21 925 77 21
carlos.contreras@vatech-hydro.ch
Technical data:
Output: 446.6
Head: 135.6
Speed: 90.9
Runner diameter: 7,150
24 Hydronews
Seite 24
USA ANDORRA
J. F. CARR ESCALDES
In April 2007, the US Bureau of Andritz VA TECH HYDRO in France
Reclamation, Mid-Pacific Region has received an order for one
awarded a contract to VA TECH vertical, 5-jet Pelton unit to be
HYDRO USA for the Judge Francis
installed in Andorra.
Carr hydropower plant located in
Redding, California.
The plant is part of the BOR’s Central
Valley Project, one of the nation's major
water conservation developments.
The Project was built primarily to
protect the Central Valley from water
shortages and floods, however new
project units have been installed to
provide water and power to match the
continued growth in the state. Although
developed primarily for irrigation, this
multiple-purpose project also provides
flood control, improved navigation along
the Sacramento River, domestic and
industrial water supplies. The customer, Forces Electriques
Judge Francis Carr is a peaking plant, D’Anodrra (FEDA), is responsible
which is intended primarily to meet the for electrical power generation,
energy requirements of the Project transmission and distribution in the
facilities. Any remaining energy is mar- Principality of Andorra, and has
keted to various preferred customers in decided to enlarge its existing
northern California. Under this contract,
ESCALDES hydropower plant,
VA TECH HYDRO USA will replace the
which is currently equipped with two
existing Hitachi runners, originally
vertical, 3-jet Pelton units of 13 MW
installed in 1963, along with a fully
each, built in 1934. The expansion
homologous model test and some
project consists of a new vertical,
appurtenances. The units at this facility
5-jet Pelton unit.
run at a combined output of between
The Andritz VA TECH HYDRO
143-154 MW due to algae growth,
scope of supply includes the inlet
which causes variable tunnel friction.
valve, turbine and generator.
In addition, the order incorporates
erection, commissioning and training
on site. The contract was signed at
the beginning of 2007 and the new
unit is expected to be in operation
by the end of 2008.
Vanessa L. Ames Rudy Yvrard
Phone +1/704 943 4343 Phone +33/4 76 85 56 45
vames.@vatechhydro.com rudy.yvrard@bouvierhydro.fr
Technical data: Technical data:
MW Output: 78.3 MW Output: 17.2 MW
m Head: 200 m Head: 482 m
rpm Speed: 225 rpm Speed: 750 rpm
mm Runner diameter: 2,280 mm Runner diameter: 1,170 mm
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr
2007 Frost & Sullivan
Award for Customer Service
Leadership
n Sub-Saharan Africa, Andritz
I VA TECH HYDRO is the current
leader in the hydro generation and
refurbishment services area
Based on its recent analysis of the
Sub-Saharan Africa power plant
maintenance, repair, and overhaul
(MRO) market, Frost & Sullivan has
presented Andritz VA TECH HYDRO
with the 2007 Africa Frost & Sullivan
Award for Customer Satisfaction
Leadership in Hydro Turbine Service.
The award was bestowed for the
achievement of the highest levels of
customer satisfaction through overall
excellence in quality of work, techni-
cal know-how, pricing, and delivery
times.According to Frost & Sullivan
Research Analyst Jeannot
Boussougouth. “In Sub-Saharan
Africa, Andritz VA TECH HYDRO is
the current leader in the hydro gener-
ation and refurbishment services area.
Andritz VA TECH HYDRO has suc-
cessfully risen to the challenge of
offering services that provide greatly
enhanced value to the customer,
and this is no mean feat in a rapidly
growing and increasingly competitive
market.”
Seite 25
Frost & Sullivan has talked to a large
sample of plant managers and main-
tenance managers (58) across 12
Sub-Saharan Africa countries and
power plants with installed capacity
of at least 10 MW.
When interviewed by Frost & Sullivan,
customers ranked Andritz VA TECH
HYDRO as the leading hydro turbine
service provider in terms of quality of
work, technical know how, price and
delivery times.
Several factors have combined to
help achieve superior customer satis-
faction in hydro turbine services. Not
only does the company boast a well-
trained workforce and state-of-the-art
technology, but it also offers various
value additions such as a flexible war-
ranty period and assistance in finan-
cial planning for utilities that have diffi-
culties in keeping to repayment terms.
In future, the company intends to dif-
ferentiate itself further and is looking
to improve its delivery time by
revamping internal process capabili-
ties.
It also plans to leverage its mix of
solutions in such a way that it can
continuously address the needs of
end users.
Events
“Frost & Sullivan is of the opinion that
Andritz VA TECH HYDRO will remain
the leading company in the hydro tur-
bine segment in the medium-term,”
says Mr. Boussougouth. In a sector
that is becoming increasingly compet-
itive, these factors come together to
make Andritz VA TECH HYDRO the
deserving recipient of the 2007 Africa
Frost & Sullivan Award for Customer
Satisfaction Leadership in Hydro
Turbine Service in the Sub-Saharan
Africa power plant MRO market.
About Frost & Sullivan
Frost & Sullivan is a global growth
consulting company. The company's
industry expertise integrates growth
consulting, growth partnership services,
and corporate management training to
identify and develop opportunities.
It serves an extensive clientele that
includes global 1,000 emerging companies,
and the investment community by providing
comprehensive industry coverage that
reflects a unique global perspective and
combines ongoing analyses of
markets, technologies, econometrics,
and demographics. For more information,
visit www.awards.frost.com.
Peter Stettner
Phone +43/1 89100 2957
peter.stettner@vatech-hydro.at
Hydronews 25
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 26

Events

HYDRO AUTOMATION
DAY 2007
from SAT to HYDRO AUTOMATION

uccessful integration into

S Andritz VA TECH HYDRO and
the seamless continuation of
former SAT traditions will continue
to secure the customer-orientation
of HYDRO AUTOMATION in years
to come. This fact was also
stressed by Dr. Franz Strohmer,
the VA TECH HYDRO GmbH
Board spokesman, during his
address of welcome to the
HYDRO AUTOMATION DAY,
which was held on May 10, 2007
at the Palais Ferstl in Vienna.

The day bore the motto, “From SAT to

HYDRO AUTOMATION – Continuity
and Innovation” and was attended by
over 200 participants from ten coun-
tries and contributed to a successful
exchange of ideas. As a result of the
change of owner, the presentation of
the new HYDRO AUTOMATION as an

integral part of Andritz VA TECH

HYDRO and the answering of impor-
tant questions concerning the theme
of continuity were at the very top of
the agenda.

A long-term concept for the securing

of product and service continuity,
specially designed for the domestic
markets with their numerous installa-
tions, which have grown over the
years, was presented in detail.
Embedded in a leading company in
the hydropower sector and supple-
mented by additional services,
HYDRO AUTOMATION will ensure
that the cooperation with customers
will continue in its tried and tested
manner based on partnership.

26 Hydronews
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 27

The contributions form our customers

also perfectly matched the event
motto:

• Continuity in hydropower plant

control technology (Dipl.-Ing. Josef
Schernthanner, head of the Electrical
Engineering and Control Technology
Department, Verbund-Austrian
Hydro Power AG, Austria)
• Renewal of electrical block protec-
tion and synchronization in the
power plants of Schluchseewerk AG
between 1994 and 2007 (Dipl.-Ing.
Dietmar Kastner, Schluchseewerk Music from Elisabeth and the
Blues Brothers, a silhouette artist
AG, Germany)
• Modernization of the SCADA system and live saxophone music ensured Events &
in the Stechowice central control that a successful and informative
day drew to a close in a pleasant
Fairs
room (Dipl.-Ing. Zdenek Saturka,
CEZ a.s., Czech Republic). atmosphere.
AUTOMATION DAY 2008
The Vienna Museum of Technology
May 8, 2008
provided a perfect backdrop for the Vienna, Austria
evening part of this event.
Apart from the technical masterpieces HIDROENERGIA
of earlier engineering genius on Jens Päutz June 11-13, 2008
display, the splendid gala buffet Phone +43/1 811 95 6715 Bled, Slovenia
was also able to impress. jens.paeutz@vatech-hydro.at

Hydronews 27
ENGLISCH_HN12_9.Nov. 09.11.2007 14:42 Uhr Seite 28

Hydro Power

focus on
performance

Your partner for renewable and clean energy

Water generally implies fascination and inspiration. But to us at VA TECH HYDRO GmbH
Andritz VA TECH HYDRO it means even more: a constant challenge to create
HP.HN12.7500.en.11.07

Penzinger Strasse 76
up-to-date technological inventions. A-1141 Vienna, Austria
Phone: +43/1 89100-2659
Utility companies from all over the world value our know-how and commitment
Fax: +43/1 8946046
and trust in the safety and reliability of our tailor-made energy generation
solutions: from equipment for new, turnkey hydropower plants to refurbishment and
overhaul of existing installations and comprehensive automation solutions.

We will continue to set up milestones in harnessing water power jointly with our contact@vatech-hydro.com
customers. We focus on the best solution – from water to wire. www.vatech-hydro.com