Small Hydropower Has Been Under- Valued

MAGAZINE FoR HYDROROPO POWWERER TECTECHHNOLONOLOGYGY HypowerHyPower

#1#24 | 2012| Spring 2014

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IT’S A SMALL BUT POWERFUL WORLD

Good things really do come in small packages. Small hydropower is the foundation Voith Hydro was built on, beginning 147 years ago. But recently, as other green energy sourc- Imprint es have taken center stage, small hydropower has been under- valued. Yet, on a global scale, the technically feasible potential Publisher: Voith Hydro Holding GmbH & Co. KG is high. Gradually, this potential is gaining recognition. Small Alexanderstr. 11 hydropower has huge benefits: it’s favorable, clean and a prov- 89522 Heidenheim, Germany en technology. With specially adapted turbines and machinery, www.voith.com such as our newly developed StreamDiver, our eQ-Solutions or Responsible for the publisher: our Voith Small Hydro Generator range, environmental impact Ute Böhringer-Mai is minimized, and output maximized. Editor-in-chief: Lukas Nemela Tel: +49 7321 37 0 However, technology is just one part of the equation. Fax: +49 7321 37-7828 People are another essential part. Excellence in project man- E-mail: [email protected] agement is crucial – an area in which Voith is known for its

In cooperation with: high standards. At Voith, people know what they do. This is Burda Creative Group GmbH our promise to our customers. Along with our offers, we sup- www.burdacreative.com ply the best solutions, a high level of competence and proven

Paper: reliability. This is reflected in all our hydropower projects HyPower is printed on Respecta Silk. This around the globe, from modernization in Europe and the paper consists of 60% recycled fiber and Americas, to developing the world’s largest generating unit in was produced on a Voith paper machine. China, to product innovations and celebrating a 50 year mile- Copyright: stone anniversary in Brazil. No part of this publication may be copied, It is due to our customers that we have achieved such reproduced or otherwise disseminated, nor may any of the content in it be used in success and international reach in hydropower over the last part or in whole in other works in any century. Long-standing customer satisfaction is the driver be- form whatsoever, without express written hind all we do: from R&D to quality, from project offers to ex- permission of the editor. cellence in project management – always supplied with first- class service. Our promise is to never let you down. Your Feedback: If you have any In the spirit of maintaining great partnerships, we’d like to comments or questions on this issue of HyPower, please contact us: [email protected] invite you to complete our HyPower readers’ survey. Visit www.voith.com/hypowersurvey, or complete and return the insert in this issue. As we do with our hydropower solutions, we’re Photographs: working to produce the best hydropower publication we can – to Cover Ostkreuz/Dawin Meckel; p. 5 Shutterstock/jokerpro; p. 6: Foto Höfinger; p. 7 Harvard University, better serve your needs. Thank you very much for your contribution. Fotolia/Antonio Gaudencio, GlowImages/Alex Maxim, Willard Wegan, Dr. Thomas Endlein; p. 8-9 Agentur Bilderberg/Klaus D. Francke; p. 12 Ostkreuz/Dawin Meckel; p. 16 xxpool/Science Photo Library/Dr. Morley Read; p. 17 Visum/Andia; p. 19: Cimo (2); p. 20-21 Dawin Meckel (3); p. 33 action Yours sincerely, press/imagebroker.com; p. 34-36 Illustrations: Hokolo 3D (4); p. 38: Caio Coronel/Itaipu Binacional; Gilberto Rodero/Itaipu Binacional (3); p. 41: VERBUND; p. 44-45 FogQuest (3); p. 46 Micha Wolfson; p. 47 Shutterstock/jokerpro. Country maps showing hydropower capacity from Shutterstock. All other photos are from Voith Hydro.

Join us on Twitter: All figures on installed hydropower capacity include pumped storage. Figures on hydropower potential https://twitter.com/voith_hydro Ute Böhringer-Mai refer to technically feasible hydropower potential. Head of Communications

HyPower 2014 | 3 contents contents

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agenda setting global expertise 34 eyes on brazil How hydropower benefits this 8 small miracles 20 a key location fast-growing nation How small hydropower is making Engineering expertise sees India its mark – and making our world serving the hydropower world a better place from the archives 22 quality and innovation Discover more Meeting modernization challenges 37 a successful about Voith in its FULL-LINE SUPPLIER in Japanese hydropower plants other insightful half-century publications. Voith reflects on 50 great years 12 small but powerful 24 heading for new in Brazil – and looks to the future Discover the expertise of Kössler: dimensions Voith’s European center of small Voith engineers reach a remarkable hydropower milestone in China successful partnerships

REGULARS 16 good technology, 26 impressive business 40 cutting-edge technology PROJECT DIRECTORY good people New leadership and a visit to a follows heritage 2 imprint The transformative power of small hydro project in Canada History is celebrated while new 47 around the world 3 editorial hydro – and the people behind it technology goes online in Austria An easy-to-check reference of the Voith Hydro 6 what’s new projects mentioned in this edition of HyPower 7 on TOPIC 18 hydro expertise in green energy mix 42 partners in small hydro 43 world of voith italy and beyond A look at a long-term and very 44 guest perspective Voith’s Milan workshop continues 32 power on an even keel productive Voith-customer 46 coffee break to grow and serve the market The benefits of pumped storage partnership in Spain

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73 Tons in flight

russia In a spectacular undertaking, the Voith Hydro St. Pölten branch has airfreighted the first of six new Voith runners to Siberia for installation at the large Bratsk hydropower plant – part of a Voith-run modernization project at the plant. An Antonov An 124-100 cargo plane, one of the largest aircraft in the world, transported the first of the 5.6-meter, 73-ton runners from Vienna, Austria, to Siberia. The client, Russia’s largest energy provider, Irkutskenergo, requested airfreight in order to shorten the time to installation. The Bratsk plant consists of 18 units of 255 megawatts each; six of the runners are being replaced by Voith parts. Situated on the Angara River, the only outlet from Lake Baikal, Bratsk was the world’s most powerful hydropower plant when commissioned in 1967. Producing around 30,000 GWh a year, it is still one of the world’s highest-producing hydropower plants. //

Voith finalist in Innovation Award Jinping Wins

Germany This March, Voith reached the China Last year Voith was awarded the “May 1st Labor Medal” by the finals of the German Industrial Innovation Sichuan municipal government in China for the excellent performance in the Award. The new, efficient and particularly Jinping II project, making it the only hydropower equipment supplier to re- environmentally friendly small hydropower ceive this award. More than 160 companies were involved in the construc- plant concept StreamDiver took Voith to the tion of Jinping, but it was the high production quality and service of Voith upper echelons of a highly competitive field Hydro Shanghai that won the client’s commendation. “What impressed us of around 320 participants, finishing among most about Voith is their relentless drive to improve and refine technology the top four competitors in the large com- and design,” said Mr. Zhaocheng Wang, Director of Yalong River Hydro- pany category, which was eventually won by power Development Company. // BMW. The German Industrial Innovation Award is the first of its kind in the world, awarding the most important scientific, technical, entrepreneurial and intellectual innovations of the German economy. //

Energy-Saving Days

Worldwide Voith Hydro shows how con- scious behavior can save resources and protect the environment: on the Energy and Water Saving Day in February, employees in all units were called upon to turn power- and water-consuming equipment off or down when leaving their workplaces. The results were impressive: energy savings of 20% on average could be realized, and water consumption was also cut down remarkably. The initiative aimed to raise awareness in daily use of energy and water and sustainably conserve resources. Figures on the consumption of resources are also important for Voith’s sustainability reporting. //

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The tiniest drone

It looks like a bee, and flies like a bee, but it’s really a robot: researchers at Harvard have created the world’s smallest drone, affectionately dubbed Robobee. They hope the miniscule flying drone will serve in fields such as search- and-rescue, crop pollination, and traffic monitoring. // Great and small It’s often said that good things come in small packages. To mark our focus on small hydropower in this issue of HyPower, we take a look at some remarkable, small – but great – things.

Ant power Small big seller

They’re tiny, ubiquitous – and more Though small and humble, the 500 mod- powerful than appearance belies. el from Italian car maker Fiat was, as an According to different estimates, the example, one of Britain’s top-selling humble ant can carry between 10 and cars of 2013. According to figures from 50 times it’s own body weight. In fact, Britain’s Society of Motor Manufacturers some ant species can support up to and Traders, the petite Italian came in at 100 times their own weight – even up- a respectable number 12. This small side down on glass, such as this Asian favorite continues to be a big hit, over a weaver ant, caught on camera holding half-century after the first production run 500 mg weight by zoology specialist of the original Fiat 500. // Dr. Thomas Endlein. //

Heart- stoppingly small art

English artist Willard Wigan, MBE, creates remarkable, microscopic sculptures: they fit inside the eye of a needle, and require a microscope to view. In fact, the sculptures are so tiny and delicate that the artist must enter a meditative state when working, controlling his breathing and hand movements. Wigan’s fine technique has made him the subject of many discussions, not just among art lovers, but also within the research, science and medical communities. //

HyPower 2014 | 7 Agenda Setting Agenda SECTIONSetting Small miracles It’s reliable, economical, efficient and clean. By accelerating development and decreasing greenhouse gases, small hydropower is gradually – but markedly – improving our world. But to reach its full potential, it needs support.

ith the push toward re installations are bolstered by strong newable energy in Eu lobbies and large government subsi W rope, and the world, one dies, small hydro has been left behind would think small hydro would be in certain countries, despite the tech enjoying a boom. It is one of the nology’s obvious benefits. Units have cheapest forms of clean energy to been dismantled, or permits may be produce. Yet, says the European difficult to receive for new projects, Small Hydropower Association often due to a large volume of en (ESHA), less than half of the poten vironmental regulations that are be tial has been tapped. Small hydro coming increasingly complex and contributes about 44 TWh a year to may be implemented in an uncoordi ward Europe’s energy needs, but nated way. In Europe, legislation like more than 50 TWh a year can be the Natura 2000 and the Water brought on line in the future, says Framework Directive has impacted Dirk Hendricks, the secretary-gener the small hydro sector significantly. al of ESHA. “Done right, small “The sector can be financially hydro can play a big role in the future sustainable if fair market rules are architecture of the electricity grid,” provided,” says Hendricks. Policy Hendricks said. makers need to keep in mind that In Germany, there are about hydropower does far more than pro 50,000 dams or weirs already in duce green electricity. It is a highly stalled, but only 7,000 of those are efficient way to do so, and it also con equipped with hydropower plants, tributes to grid stability, can be used leaving a large majority untapped. for flood protection and irrigation, From a technological perspective, and has a long life cycle. This is a small hydro is already mature and central point from an investor’s per highly developed. Many weak points spective: a hydropower plant can last have been overcome, such as the up to 100 years, supplying steady rev need for better fish passage. Regula enue for decades from the cost-effec tion and policy have disadvantaged tive generation of electricity. But it small hydro. While wind and solar can take some time to obtain a return

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Often the development of new sites for large-scale plants is not possible either small talk for economic or ecological reasons, so smaller sites become more promising. Klaus Schädler, Head of Small Hydro at Voith, In this context, Voith is also explor about developments in the small hydro industry. ing the idea of small hydro in combina tion with wind energy. Windmills can be connected with small hydro pumped What is the history of small hydro at Voith? storage plants, so that surplus electricity Small hydro is a Voith tradition. 147 years ago when the company generated by the windmill can be used was founded, it started with small hydro. We produced only small for pumping – and vice versa: to pro hydropower turbines until the 1970s, when we entered the market for duce energy when wind is not blowing. large hydro, and today we are once again one of the largest small The combined plants allow for an easier hydropower manufacturers in the world. forecast on energy production. What is the outlook for Voith’s development efforts lead to suc small hydro? Klaus Schädler cessful new products, as shown by the In Southern Europe, there joined Voith in 1985. A mechanical engi- example of Voith Hydro’s small hydro is low demand right now This small hydro plant in Blaichach, Germany, features an eco-friendly instream flow drain. neer, he has headed generators: “We have thoroughly devel due to the dampened econo Voith’s small hydro oped special generator solutions, de my. Other regions are look division since 2009, and previously after upfront investment costs. If elec hydro components in order to improve launched, the StreamDiver is a turbine signed to meet the specific requirements ing for increased energy served as the VP of tricity prices are fluctuating due to project economics for customers. Klaus generator unit constructed to be com of small hydropower,” says Schädler. production. I expect grow Operations at Voith changes in the energy market and subsi Schädler, Head of Small Hydro within pact, simple and therefore low-mainte “They focus on a long lifetime, stable ing demand in South Amer Hydro Canada. dies for other technologies – and at the Voith, says, “All small hydro makers and nance. In addition to the technical and operation at grid, and optimum life cycle ica and Southeast Asia. Also, same time costs must be recovered – it’s buyers are in a very competitive situa ecological benefits, this innovative prod costs, and are designed to reliably and ef Canada’s rich natural water resources give many hydro energy options. easy to understand an investor’s hesita tion, therefore standardization is key. uct provides the opportunity to develop ficiently exploit small hydro potential.” tion. However, many companies are still With Voith’s broad engineering knowl new and previously unusable hydropow Why would a company install four small machines producing 25 MW pushing ahead with small hydro invest edge, we are able to standardize in a er locations. The power unit is installed For Hendricks and the ESHA, as well as instead of one large machine producing 100 MW? ments due to the inherent benefits. highly sophisticated way, while keeping directly in the water with only the pow other participants in the industry world To ensure the optimal output of energy, it often makes sense to avoid enough room for customized solutions.” er cable coming out. The bulb is filled wide, small hydropower represents installing a larger machine and instead install several smaller ones. Small hydro units are far more than with water, which completely lubricates enormous potential economically, so Then, when less water is available, one machine can run at full capac just smaller versions of their larger Voith R&D is working on low-head ap its bearings, ruling out any risk of water cially and environmentally: as a provider ity instead of having a large machine running at partial load. When a counterparts. Engineers have adapted plications – for instance less than 10 me contamination. This new compact tur of jobs, a provider of income to rural large machine is run at low capacity, its efficiency is low in comparison turbines and the machinery for the ters of head. Research has been examin bine has an output of up to 800 kW per communities, a provider of clean ener to the amount of water that is let through the machine. The operator application. One clear advantage of ing ways to make the technology more unit, which can be used for modular ex gy, and a way to better manage irriga would produce less energy to sell. small hydro is a limited impact of the efficient and less cost-intense, since on a tensions as a minimum-flow turbine, or tion and flooding. // construction on the environment. Typi global scale huge potential exists in low- as an alternative to existing small hydro What are good arguments for small hydro? cally, small hydropower stations are run head applications. Again referring to the power plants. The technology comes with a long list of environmental benefits. We of river, and no reservoir is needed. example of Germany: a majority of the In addition, Voith is also research have developed oil-free machines and turbines that rotate slower than They are usually connected to the grid, country’s dams or weirs that are not ing ways to simplify the civil engineer www.voith.com/SH usual, to reduce fish mortality due to blade strikes. Voith has also de while even smaller versions – called equipped for hydropower are low-head, ing involved in small hydropower veloped the Minimum Gap Runner technology, which minimizes the pico, micro or mini hydro – may be used according to Schädler. “If you already projects. “We’re working on smarter effects of gap flows on fish survival and is used both in small and large in an isolated way. have a dam, and you just add a hydro solutions to build the powerhouse or the hydropower plants. Another benefit is that operators can have a com To keep small hydropower moving plant to it, you could have a new hydro infrastructure that houses the machine Global status of Small Hydropower plete unit assembled in the workshop, which limits assembly time forward, Voith conducts special R&D power plant with low impact on the and equipment,” says Schädler. onsite. Then there’s delivery time. It is shorter because the smaller (<10 MW/unit) activities in this area, which are closely environment, because the dam is already components can be manufactured faster and we offer a modular connected to and strongly profit in par built. The owner would have revenue Another area of research is small hydro Potential: Installed: product concept in small hydropower. 98 GW, 74 GW, ticular from Voith’s R&D in large hy from the dam, and not just maintenance pumped storage. Due to the shift to a 57 % 43 % dropower as well as from the company’s costs for it,” said Schädler. more and more decentralized and vola 100 % How would you describe the Voith small hydro product portfolio? gigawatts overall innovative approach. The focus tile energy production, the need for Our portfolio covers all equipment that an operator needs for a hydro in small hydropower is on improving Voith has already come to market with flexible energy storage has been increas power plant. This includes the turbine, the generator, the automation, the ecological standards of the technol a breakthrough small hydro innovation ing during the last years, raising the and the balance of plant equipment – the complete water-to-wire so ogy, and works to standardize small for low-head applications. Recently interest in pumped storage solutions. Sources: Voith Hydro and smallhydropower.org lution. Together with our partners, we are a full-line supplier. //

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1 Harnessing the power of nature: the river at the Brunnenfeld run-of-river small hydropower plant in Austria. 2 Kössler technicians working on the StreamDiver. 3 An artist’s depiction of Kössler’s new Small but headquarters in St. Georgen, Austria. powerful They may be little, but small hydropower plants deliver good return.

emand for smaller, more stan- er everything from single components dardized hydropower plants is to complete power plant solutions. The D on the march. At a time when merger has put Kössler in a position to feed-in tariffs for most renewable ener- attract new customer segments known gy technologies have begun to decline, for rigid standards and high project as they were designed to do, small hydro management requirements. Today, has never been so heavily promoted. Kössler acts as Voith Hydro’s European To help cope with the growing number center of competence for small hydro. of customer inquiries, Voith acquired Austria-based small hydropower manu- One of the advantages of small hydro- facturer Kössler in 2007. Founded in power plants is that they are able to gen- 1928 as a repair workshop for turbines erate energy despite low flows and and generators, Kössler has become one heads. Voith and Kössler were able to of the European market leaders in small exploit their expertise to deliver a new hydro. Welcoming the Kössler employ- compact turbine specifically designed ees into the company, Voith Hydro for low water levels, for which conven- CEO Dr. Roland Münch’s message was tional turbine technology was previous- clear: Kössler was to grow based on its ly not economically viable. The new roots and competencies by developing product, StreamDiver, offers a compact further in technology and growing vol- solution that makes it possible to mount ume in the range of its products. the generator directly into the turbine. Water-lubricated bearings allow oil- Kössler has a lot to bring to the table: and grease-free operation, reducing the over 80 years of experience in small hy- environmental footprint. “The success- dropower, a mature and proven technol- ful cooperation between engineers from ogy, a strong customer base and a very Voith and Kössler is a good example of skilled workforce. Profiting from Voith how well Kössler has integrated into the StreamDiver ®: the latest Hydro’s engineering excellence and Voith Group,” says Josef Lampl, Man- innovation in small hydropower. global network, Kössler is able to deliv- aging Director of Kössler.

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Price and performance wins Good ecological footprint 1 installing a StreamDiver the bid The community of Arjeplogs Allmän- compact turbine. 2 At work on an eQ-Solutions Kössler was able to meet high price-per- ning in Sweden launched an initiative in compact turbine. formance expectations of the Bosch 2005 to optimize its 85-year-old small 3 upgrades and expansion Group when submitting a tender for the hydropower station. The goal of the at Walchau, Austria. 4 the new turbine propeller is modernization of a 100-year-old hydro- project was to increase energy produc- installed at Arjeplog. electric plant in Blaichach, Germany. “To tion with a minimum of environmental 5 A look inside Arjeplog’s new win that order, we had to fight hard to impact. By introducing a Kaplan bulb Kaplan bulb turbine. 6 Arjeplogs Allmänning, come up with a competitive price,” says turbine with a runner diameter of 2.2 Sweden: undisturbed nature. But development doesn’t stop there. One advantage of small hydro is shorter Karl Wieder, Head of Sales and Project meters, Kössler was able to increase en- Kössler engineers are continuously manufacturing and installation times. Development. “In the end, it was a com- ergy output by more than fivefold, with working to find new materials, develop Kössler has developed standardized con- bination of best price and best technical little adverse effects to the natural sur- maintenance-friendly designs and intro- struction manual, shortening delivery performance letting us win the tender.” roundings. The upgraded plant went duce simplified, innovative technolo- times, and cuts installation times by car- into production in autumn 2013. gies. One example is its eQ-Solutions, a rying out construction in the factory and High quality at a fair price Gerald Hochleitner, Head of De- standardized compact turbine optimized delivering them to sites pre-assembled. After modernizing an existing plant in sign at Kössler, says: “The ecological for smaller output ranges. Produced ac- “There’s a lot of competition in the small Walchau, Austria, in 1987, Kössler was impact is minimal as the turbine flow is cording to high standards of quality hydropower market. Customers put a invited in 2013 to counteract efficiency approximately 25% of the average natu- and using state-of-the art hydraulics, premium on a good price-performance losses caused by wear and tear by carry- ral flow in Skellefte River and requires eQ-Solutions is helping to meet the ratio and a reliable partner,” explains ing out a gap correction and fitting the no man-made dam. It was a solution challenges of a changing market – one Lampl. Kössler has increased its volume system with new bearings. Kössler was provided by nature.” // in which building requirements are so successfully that it became necessary also asked to expand the plant by sup- more strenuous, environmental regula- to expand its existing facility in St. Geor- plying a Francis spiral turbine with a tions are more stringent and customers gen, to be opened in 2015. “The invest- runner diameter of 540 mm. As a result are looking for a less costly small hydro ment is a commitment towards the po- of the remediation, the output of the More information on A striking red eQ-Solutions solution – without forfeiting quality, tential of small hydropower,” said Lampl power station was increased by approxi- StreamDiver: standardized spiral casing. reliability or safety. at the ground-breaking ceremony. mately 420 to 630 kW. http://voith.com/StreamDiver

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Good technology, good people

Small hydro contributes to the positive transformation of the region it serves – but deploying a project successfully requires particular perseverance and talent.

The Baba Multipurpose Project in the Los Ríos province of “Projects like Baba require an expert team, and at Voith we Projects like Baba help establish strong Ecuador has transformed the lives of local people since, and have a great one – especially the engineering and field service infrastructure, critical for agriculture: Ecuador’s banana production benefits. even before, commercial operation began in 2013. The dam teams. But the success of the project was due to the commit- mitigates flooding and helps prevent erosion during the rainy ment of the entire project team,” says Martins. season over about 20,000 hectares in the Buena Fé, Valencia Luiz Marighetti is one of the most experienced members and Quevedo cantons. During the dry season, it provides of the Voith Brazil team. He joined Voith more than 30 years clean water for local people and farmers. The 42 MW small ago and has worked variously as a turbine design engineer, hydropower plant, meanwhile, provides renewable energy to sales manager, application engineer and lately as proposals the region. manager for small hydro. It is experience like his that enables 1 Here, Voith installed two Kaplan turbines, the first ever in projects to be planned and executed smoothly. “I have par- 2 the country, as well as the two generators for the plant’s units. ticipated in all the small hydro contracts we have signed since Seeing the plant enter into commercial operation with satis- 2000. It means I can usually give the team the answers they fied customers and colleagues was a thrill for Ronaldo Mar- need quickly to technical and contract questions,” explains tins, Voith’s Project Manager at Baba. “Being part of the offi- Marighetti. cial plant inauguration in the presence of Ecuador’s president, Finding and teaching the next generation of engineering Rafael Correa, and having my photo taken with him was a trainees to ensure Voith has the skills and resources it needs for great feeling,” says Martins. With more than a decade’s expe- the future is another important aspect of his work, he says. “We rience working on small hydro projects in the region, Martins have very good career planning for the young engineers. We was responsible for making sure Voith’s part in the project rotate them in different roles and give them early knowledge was a success – and his job was not without its challenges. about various departments, as interns, within a training pro- Small hydro projects are arguably tougher than large- gram lasting one and a half to two years.” scale ones, says Martins. “Managing a multipurpose project is Each project is different and each teaches new lessons, much more interesting and challenging than managing a proj- adds Martins. “We always learn something on new projects, Luiz Marighetti ect with just one goal, because of all the elements that are whether in small or large hydro. We log what we learn and im- has worked for Voith for over three de- required.” Usually, the biggest challenge of a project in small prove our processes.” cades in the small hydro is the time limits for construction – which tend to be There is great potential to apply lessons learned from Baba hydro field, in areas very short. The complexity is similar to that of a large hydro to projects in Ecuador and beyond, adds Martins. “Small as diverse as turbine engineering and pro- project, but the deadlines are shorter, so proper planning is hydropower plants are becoming more important worldwide as posal management. 1 Small hydro plants like Malagone in Brazil generate local jobs essential for project success. Managing deadlines and risk solutions for low-cost construction and low environmental im- Experience like his is and bring environmental and educational programs to the region. a treasured asset. 2 projects such as Baba protect and benefit agriculture: from management are two very important skills, especially when pact become more important. Ecuador is a country that has a flooding and erosion, and with supplementary water supply. the project is in a foreign country. big potential for the installation of new projects.” //

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Italy will move its headquarters to the The project has been a success. As 1 A distributor ring receives workshop location, bringing all Voith Baillifard points out, “Modernization final touches after refurbishment at the Hydro expertise Hydro Italy’s activities under one roof. has allowed us to boost the plant’s en- Milan workshop. “Having the headquarters here will ergy production by 10% to 12% per 2 A Voith Milan AMB service allow for closer exchanges with Voith year, of which the new Voith Hydro center technician at work. 3 Getting equipment onto in Italy and beyond Hydro engineers, and our customers Italy production unit accounts for 5%. the Vièze site. will be able to count on even more com- Before this project, the plant produced 4 Inside the refurbished Cimo With their new service center and headquarters prehensive and efficient services.” an average 50 million kWh per year. power plant. together under one roof, Voith Hydro Italy is bringing its We hope to increase that to about Italian expertise in Switzerland 56 million kWh per year. We can now expertise closer to their customers in Italy – and beyond. Modernizing a 100-year-old small- fully exploit the energy resources of the hydro plant on a site with a number of Vièze, providing reliable, renewable logistical hurdles was not easy, but Voith energy for the local chemical industry ith a new after-market-busi- exceptional expertise. Voith Hydro ac- Hydro Italy met such a challenge re- and for future generations.” The mod- ness (AMB) service center in quired Italian hydropower supplier Riva cently for Switzerland’s Compagnie ernization, begun in 2011, was com- W Milan, Voith Hydro Italy in 1992 along with all Riva’s technical Industrielle de Monthey (Cimo). The pleted on time in spring 2013. Baillifard brings a full line of top-quality services drawings, including plans for more than company’s Vièze hydropower storage says, “We are very satisfied with the re- closer to its customers. The workshop, 1,100 power plants. Today, of Italy’s 23 plant plays a key role in the local econo- sults of this project and with Voith which opened last October, has com- GW of installed hydro capacity, more my by providing power for chemical gi- Hydro Italy’s contribution, especially pleted its first orders and has many more than half is working with Voith equip- ants BASF and Syngenta, but it urgently the quality of their equipment, the under way. Roland Kühnel, Head of ment. All of Italy’s main energy provid- needed an upgrade. Its original pressure competence of the team that installed Voith Hydro Italy, explains, “Our cus- ers and a growing number of smaller in- pipes dated from 1910 and 1921, and it, the subcontractors chosen and the tomers like the fact that they can dependent power producers are clients. production units had been operating plant’s performance. The plant contin- visit us in the new workshop and see for The workshop responds to new since 1959 and 1960. ued to operate while the work was themselves what we are doing. We can trends in Italy’s hydropower sector. Daniel Baillifard, who oversaw the going on, our time and budget targets also more easily provide customized “Italy is one of Europe’s biggest hydro- project for Cimo, explains that when were met, and we are especially happy solutions, and since we are cutting out power markets, and the need for after- Cimo chose to modernize the existing to report that we had no accidents dur- the middleman and handling more work market service and rehabilitation is plant, it selected Voith Hydro Italy for ing the two-year project phase.” // in-house, we have a stronger competi- great, so we want to increase our after- the project based on a number of fac- tive advantage.” market business. At the same time, since tors, including price, respect for dead- The workshop, which covers some almost no new large hydro projects are lines, track record, and the security and Hydropower in Switzerland 1,300 m2, is equipped with two cranes of planned here, we are expanding our quality of materials to be used. Voith Installed capacity, five and 20 tons. With three installation small hydro services,” says Kühnel. The Hydro Italy supplied turnkey electro- incl. pumped storage: 15 GW areas as well as material testing and dis- workshop aims to establish more long- mechanical equipment, a 14 MW Potential not yet installed: 2 GW tribution, it is designed to carry out a term maintenance contracts in Italy and Pelton turbine, a vertical synchronous Refurbished distributor for a minimum of three projects at once. It worldwide, and involve itself in new generator, complete automation and Switzerland was among the first nations 38 MW vertical Francis turbine. also benefits from Voith Hydro Italy’s hydro projects. In summer, Voith Hydro other equipment. to use pumped storage (ca. 1890s).

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1 t he interior of the Vadodara turbine-manufacturing facility. 2 a Voith India employee at work. 3 proudly Voith: the exterior of the Vadodara premises.

“Our strong plant engineering skills differentiate Voith Hydro India from the competition as a full-line supplier in the small hydro business.” Amresh Dhawan, Managing Director, Voith Hydro in India

“India is one of the most important small hydro markets With customers enquiring about small hydropower capabili- tems, fire detection, alarm and firefighting systems. Moreover, in the world,” says Amresh Dhawan, the Managing Director ties, Voith began developing a special generator for the mar- says Dhawan, “Our capability extends to engineering, supply- A key of Voith Hydro in India. “It was necessary to establish a local ket, adapted to the requirements of small hydro. For the ing and commissioning substations and other electrical plant footprint by setting up a workshop to be competitive and to manufacturing of these generators, a cooperation has been items.” It is, he says, “our strong plant engineering skills that set new quality standards in the Indian market.” set up with TD Power Systems (TDPS), an India-based com- differentiate Voith Hydro India from the competition as a full- Rohit Uberoi, Head of Small Hydro Engineering at Voith pany with Japanese roots. The international scale of this co- line supplier in the small hydro business.” location Hydro Noida (VHN), tells how in 2007 the company started operation is reflected in the end projects, the first ever order And the next step in this development is just under way: small hydropower operations in India: “The goal was to de- being a horizontal small hydropower generator for faraway together with the automation department from Voith head- The strong team at Voith Hydro India velop standardized solutions for small hydropower turbines Cubujuquí, Costa Rica. Indeed, this was Voith’s first project in quarters in Heidenheim, the engineering team in India is cur- provides production and engineering – a ‘common standard design.’” This was followed in 2009 Latin America using a power unit designed and manufactured rently working on the development of a specially designed by a separate small hydro division within VHN, which is “fo- by the Voith India Vadodara branch. “This clearly established automation solution with complete functionality, but at the expertise to supply markets all cused towards small hydropower business,” explains Uberoi. Vadodara as a quality manufacturer and supplier of full-line same time adapted for small hydropower applications – around the world. The next step in the development of Voith Hydro in small hydro solutions,” says Kalra. Dhawan confirms that “the another cost-effective, standardized small hydropower solu- India was a manufacturing facility for turbines at Vadodara, quality management systems at Vadodara are an exact replica tion with room for modular adaptations. in the state of Gujarat. Operations are so successful, says of Voith quality systems employed in its factories world wide.” Voith’s future in this highly competitive energy market Ravi Kalra, Head of Small Hydro for Voith Hydro India, that looks particularly good, says Kalra: “A successful small hydro within three years “the unit fulfilled initial expectations by This fundamental focus on quality, as well as the breadth arm with its own manufacturing facilities in India helps Voith manufacturing and delivering state-of-the-art hydropower and depth of expertise, have also impressed Voith’s clients. Hydro expand its operations, not only in India but also in products to all corners of the world, including Japan, Italy, Voith Hydro India has the capability to engineer an entire South East Asia, which hitherto was not fully served out of Canada and Brazil.” plant, supplying turbines, generators, cranes, auxiliary sys- Europe. There is a large potential waiting to be tapped. //

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Quality and innovation

Recent modernization Voith has come up with solutions to to be done with due regard for the over- projects by Voith have particularly complex challenges during riding safety requirements. the recent undertaking of two individual This was also Voith Fuji Hydro’s first injected new life into projects in Japan, resulting in very sat- experience of procuring equipment en- traditional hydropower isfied customers. gineered and manufactured at the com- plants in Japan. Umamichi power station in Tochigi pany’s specialized small hydro work- Prefecture is operated by Furukawa shop in India (see pages 20-21 for more Nikko Power Generation. It began ser- on Voith Hydro in India). It was a suc- vice in 1937 fitted out with equipment cessful collaboration, particularly in 1 supplied by Fuji Electric, which has now terms of the quality of the equipment 3 2 become Voith Fuji Hydro. supplied by the Indian Voith Hydro Furukawa Nikko Power Generation team. Due to the success of this proj- 4 recently contracted Voith Fuji Hydro to ect, the same customer has just or- renovate the aging equipment and to dered Voith to undertake another proj- improve overall performance. This in- ect at Uwanoshiro power station. This volved replacing the turbine, generator project is set to involve an even wider and control system, increasing the flow range of refurbishment activities – a of water to the turbine in the process to challenge which Voith is ready to meet. uprate output from 4,410 kW to 5,430 Voith’s other current challenge in kW. The refurbished power station was Japan is the modernization of Chugu handed over in April 2013 and is per- power station, operated by the forming exactly as intended. Hokuriku Electric Power Company. Voith As Hiroaki Onaka, Manager of the emerged as the only company in com- 1 t he exterior of the Chugu Project Management and Contracting petition capable of providing the power station. 2 t he generator at the refur- Department at Voith Fuji Hydro, ex- innovative technological approach re- bished Umamichi plant. plains, this was a particularly challeng- quired to work within the confines of the 3 o utflow at the Umamichi ing project because it required the in- existing narrow powerhouse. Voith’s power station. 4 the upgraded Francis stallation of new equipment into an innovative proposal involves replacing turbine at Umamichi. existing building – which had to be re- two existing twin-nozzle horizontal tur- tained. Just one example: the installa- bines, with a total output of 3,000 kW, tion of the new spiral casing in a single with a single triple-nozzle unit of Voith piece required a large hole to be made Fuji Hydro’s original design, with an in the side wall of the turbine floor, and output of 3,100 kW. the construction of a temporary bridge Due to restrictions on crane capac- over the tail race channel. This all had ity and powerhouse space, the Chugu power station project has required con- siderable advance planning. Due for Hydropower in JAPAN completion in December, this is only the

Installed capacity, second installation of a triple-nozzle incl. pumped storage: 50 GW unit carried out by Voith Fuji Hydro, and Potential not is also the largest. It is an undertaking yet installed: 12 GW that reflects Voith’s unequaled level of

Hydropower is Japan’s leading competence and emphasis on unparal- renewable energy resource. leled quality. //

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and related thermal stability, while even better mica-paper- Voith’s solution is an elegant one in engineering terms, and is al- Heading for new dimensions based insulation, suitable for higher voltages, is required so ready installed in power stations in South Korea, South Africa, that such machines can be air cooled. The thrust bearing chal- the UK, Norway and Japan. Voltage represents one of the larg- Voith takes an important step toward a major goal at the Xiluodu lenge may have a practical solution, which is a unique Voith in- est challenges to designers of massive generators. So far there plant, in partnership with the China Three Gorges Corporation. novation: the employment of a magnetic thrust bearing to ab- are only a few hydro generators worldwide rated higher than sorb part of the load and to reduce friction losses. 20 kV. None over 23 kV are yet in service. Since 1970, when Voith provided 23 kV generator bars for the Raccoon Mountain hydropower sta- onsider a bearing that has to carry a load equal to the capacity of 13.86 GW, making it the world’s third-largest hy- tion in the US, the company has been a weight of 17 fully laden Boeing 747 aircraft ready for dropower plant. From Necaxa to Xiluodu: The most powerful generators leader in pushing this boundary. Voith takeoff. That’s just one of the challenges being em- Thomas Hildinger, Vice President Generator Technology Hydro in Shanghai has produced samples C How Voith Hydro generators continue to grow braced by Voith’s engineers as they develop the next genera- at Voith Hydro, says the successful introduction of the 855.6 of the 25 kV insulated bars with the same tion of 1 GW generators ahead of further expansion of capac- MVA generators at Xiluodu provides a useful stepping-stone Rating [inMVA* megavolt-amperes] (MVA) dimension that will be required for the ity by the China Three Gorges Corporation at the Baihetan toward even larger machines. “Each unit is tailor made, of 1000 gigawatt machines. They have been suc- Three Gorges (CN) and Wudongde hydropower plants. course. There is no room for failure,” he says. “But you still 900 water cooled cessfully tested, achieving excellent per- air cooled Developing the most powerful hydro generators ever seen learn from every project, and it enables you to further refine 800 Itaipu (BR) formance in terms of their mechanical presents challenges at a number of technical levels, including your mathematical models and design solutions. In particular, 700 Guri II (VE) Xiluodu (CN) and thermal properties. the design of thrust bearings which will cope with the enor- it helps you manage residual risk, which is fundamental to 600 How large can hydro generators be- mous loads imposed over a lifetime of use. But it is one that Voith’s approach to engineering.” The design of a modern come? “We can go to 1.2 or 1.3 GW for 500 Bath County (USA) Voith has already met with the successful commissioning of hydro generator is a well-considered balance between compet- Paulo Afonso IV (BR) certain, or even higher,” Hildinger be- 400 784 MW generator-turbine units at the Xiluodu plant on the ing demands: reliability, performance, ease of maintenance and Raccoon Mountain (USA) lieves, although this is unlikely before 300 Samrangjin (KR) Jinsha River – one of the largest single projects ever undertak- – last but not least – project economics. Wehr (DE) 2020, and there are few sites with the 200 en by Voith, with Voith Hydro in Shanghai supplying three As air-cooled generators increase in output, the design Furnas (BR) flows and damming potential to achieve 100 Herdecke (DE) complete sets of generating units: the three 784 MW Francis challenge is to find optimized and reliable mechanical solu- Necaxa (MX) Vianden (LU) this scale. For now, the 1 GW generator turbines as well as three 855.6 MVA generators. When it is ful- tions. Thrust bearings must be able to carry loads of several 0 Suiho (CN) is a sufficient challenge to keep Hilding- ly connected to the grid later this year, it will have a nominal thousand tons, improvements are needed in cooling systems 1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 Year er and team well occupied. //

1 Voith engineers discuss a 3-D plan of the generator. 2 Inside the immense Xiluodu generator.

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The stay ring is lowered to the turbine floor.

IMPRESSIVE BUSINESS A “project of many firsts” in Canada provides the stage for a grand display of Voith’s multifaceted potential.

“What Voith Hydro does is impressive,” says Wally Penner when asked what he finds special about the Waneta Hydroelectric Expansion Project. Hav- ing worked in various roles on many hydropower projects over the years, Penner knows what he’s talking about. He’s now the Regional Project Manager at SNC-Lavalin, a Prime Contractor for the Waneta Hydroelectric Expansion Project and also Voith Hydro’s customer for the Waneta project. His enthusi- asm knows no bounds, as revealed by Marc Gagnon, Voith his comments on the project figures, Hydro Project Manager the tunnel, the runner – all of them for the Waneta Expan- sion Project, on the pow- are “impressive!” he says. And he’s erhouse ground level. quite right. Anyone who visits such a

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4 Inspecting a new equipment arrival: Marc Gagnon standing inside one of the head covers. 5 Workers inside the scroll case, which is almost as large as an underground train tunnel.

“It’s a project of many firsts,” explains with Voith is very collaborative, very re- and employees from Voith Hydro alone Gagnon: in this project, Voith Hydro in sult-oriented, and there is a great will- are involved in the success of such a Canada is supplying heavy electrical ingness to deal with all the issues com- project; second is how fully all of them balance-of-plant equipment such as ing up in a project like this.” are committed to achieving this suc- generator circuit breaker, ISO phase cess. One gets a sense of how they duct and excitation systems, thereby Back on site, Gagnon has another fa- identify with the project when they say, adding new expertise and new possi- vorite spot: the project office – or the “We need to adapt it to Waneta. It has bilities to VHM’s business. VHM is also “hub,” as he calls it – where Voith Hydro to be Waneta-style.” And it really is: ex- leading the commissioning of the proj- colleagues meet daily to discuss the tensive hydropower engineering exper- ect. And, after many years of experi- status and issues. “You can feel the en- tise, custom-tailored to the project. // 1 Detail of a turbine runner being installed at Waneta. ence in the hydroelectric sector, it’s Ga- ergy, you can feel the team spirit in the 2 Working on the stator of Unit 2 of the Waneta plant. gnon’s first project as a large hydro project,” he explains. This team spirit 3 An aerial view of the Waneta Expansion Project on the Pend d’Oreille River. project manager. Yet, he comes across also becomes apparent when represen- Hydropower in CANADA as fairly relaxed. “This is a major project tatives of all VHM departments involved Installed capacity, for Voith Hydro in Canada because it’s a in the project meet for a two-day proj- incl. pumped storage: 73 GW good reference for similarly sized project conference to further improve inter- Potential not yet installed: 160 GW construction site and takes a look in- Project Manager at Voith Hydro in on this chilly January day. Wearing ects and because we can acquire ad- nal collaboration and project flows. Two side is bound to be impressed. From Montreal (VHM). From here, he has an brightly colored hard hats and reflective ditional valuable expertise,” says Ga- things emerge quite clearly: first is how A large majority – over 60% – of elec- the outside, it all seems fairly straight- overview of almost all the site’s sec- safety vests, workers focus diligently on gnon. The contract with SNC-Lavalin is many different specialties, departments tricity in Canada is supplied by hydro. forward, but inside, the dimensions are tions, to assess the steady progress of their tasks. Inside the stator frame of being executed as a design-and-build truly astounding. Inside the under-con- the tasks being performed. “The site one of the two power units supplied by contract, which results in a differently struction Waneta, you must descend changes every day,” he says. “When Voith Hydro, the workers are installing structured, intensive collaboration. hundreds of stairs to reach the bottom you return after three weeks, it feels like sheet metal panels for the generators. “Their issues are ours and the other The Waneta Expansion Project will see the construction of a second powerhouse to share the level, known as the pump floor. The a different place, every time.” That Various Voith Hydro operating units way round,” explains Gagnon. “As a re- hydraulic head of the existing Waneta Dam on the Pend d’Oreille River, in British Columbia, Cana- da, and just a stone’s throw away from the US border. The 335 MW hydroelectric project is owned various floors in a power station have comes as no surprise, given the hustle from around the world have supplied sult, there is a lot of communication in by a consortium of Fortis Inc., Columbia Power Corporation and Columbia Basin Trust, with SNC- different names: pump floor, turbine and bustle that pervades the Waneta various pieces of equipment, applying this project. We work very well together Lavalin being the Prime Contractor. Voith Hydro is supplying the complete electromechanical equip- floor, generator floor and so on. That construction site. their respective specialized areas of ex- in a joint effort.” That is important, too, ment including the two generators, Francis turbines as well as automation systems. alone speaks to the magnitude of the Everywhere, people are drilling, pertise. The generator poles, bars and given that one of the challenges of the building’s interior, where the cleanly torquing, stacking and welding. Metal cores were made in São Paulo, Brazil, as Waneta job is that many civil- and Involving the Community: “We are doing it differently,” says Audrey Repin, Director External Rela- poured, cool gray concrete walls reach clangs on metal, and instructions are were the two runners, while the bright- hydro-engineering tasks are occurring tions at Columbia Power Corporation, proud of their high standard of quality, safety and environ- about 30 meters down into the rock. At called out. It smells both damp and red head cover comes from Shanghai – simultaneously, which makes good co- mental stewardship. They manage the Waneta construction on behalf of the owners, and are committed to consulting local communities and executing socio-economic monitoring and various ground level there’s a good view over the dusty, of freshly poured concrete and of the first time that Voith in Canada has ordination especially important. The environmental programs. The Community Impact Management Committee, made up of local stake- construction site and the ongoing work. welded steel. And it feels pretty warm collaborated with colleagues in China on customer is also pleased, as Wally holders and corporate representatives, provides ongoing input to encourage a positive impact. It’s a favorite place of Marc Gagnon, despite the wintry outside temperatures a large hydro project. Penner confirms: “Working together

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has very deep roots in Canada, it’s what have a high service culture across all power as a clean and reliable source of Leading the way built this country and it goes back to disciplines. Plus, Voith in Mississauga is energy. Today, wind and solar experi- over 100 years ago and is really a core the center of excellence for winding and ence far more support from some of our component of our history. coil technology, both for domestic and government entities. I believe over time, in Canada international customers. We tailor our the public and governments will again Based on this, do you see the future products on demand to customer’s realize the far-reaching and sustainable Talking to William Malus, the new CEO of Montreal-based Voith Hydro in Canada, of hydropower in positive terms? needs, and we want to continue to ex- benefits of hydropower. and Peter MacLennan, the new COO of Voith Hydro in Mississauga. Malus: Yes. Hydropower is the back- pand our expertise and activities to cre- Malus: Budget and environmental ap- bone of the Canadian electricity sector. ate more value for our customers. provals could be further improved. The It represents about 63% of the electrical Canadian government made good de- supply in Canada. With approximately Apart from that, what are your future cisions in the last five years and worked You’ve both been working in the William Malus 1,500 units there is a tremendous in- goals in your new positions? hard to make the process of approvals hydropower business, and at Voith, has been working in the hydropower industry stalled base, and the average age is Malus: We see automation and after- faster and less bureaucratic. It can al- for 15 years and joined Voith in 2007. for many years. What is special to you Hydropower, as he puts it, “is in the DNA of around 60 years old, which is a great market services as very good segments ways be better, but the good part is: the about hydropower and Voith Hydro? Canada.” In his role as CEO, Malus aims not opportunity to support this infrastruc- to further develop in Canada. Also in dialogue is occurring. MacLennan: Hydropower is a long- only to further improve technology and Voith ture with our after-market services and small hydro, both new and refurbish- Hydro’s activities, but also to make the term industry. It is steady, it makes company a great place for employees to in modernization projects. ments, there is huge potential. In addi- You described hydropower as a very sense, and it stands for continuous develop and grow. tion, asset management is an element mature technology. Is it also a mod- progress. To me, Voith, as a market Do you see Voith Hydro in Canada as we are examining to see what we can ern technology? leader in this business, stands for the being well prepared for this? do to help our customers in terms of Malus: Although it’s a mature technol- same principles. It is a company based “I don’t think there is Malus: Yes, we are: as of today, we are looking at their full hydropower station ogy, hydropower is very dynamic and on values, following a long-term vision any other technology starting off a very solid foundation. Voith and seeing how we can best support continuing to evolve. The use of new and a clear purpose. Hydro in Canada has grown and devel- their assets. materials, new processing techniques, Malus: To me, hydropower represents that generates power oped tremendously over the past years. MacLennan: We want to further im- new engineering tools – these are all one of the most natural conversions of as sustainably as With our teams in Montreal and Missis- prove cycle times. This is something very innovative aspects. I also think in a the earth’s resources into energy. As a sauga, as well as Vortex Hydro in Gran- our customers are working on as well lot of cases hydropower is taken for technology, hydropower is a demon- hydropower.” by, we have a good footprint that posi- and where we can work together. Our granted. It’s in the background, it does stration of perseverance, stability and tions us well and with very unique improvements can help them to im- its job, and it has still the lowest cost of stands the test of time. And in this capabilities across these locations. Es- prove their cycles. This helps the cus- energy when you look at it in the long respect, Voith Hydro, through its long we put people with this service culture lucky to share our expertise with them tablishing Mississauga as a location tomer to get their plants back on time term. I don’t think there is any other history built on technical expertise in their DNA into leading positions. And because in the end this makes the in- dedicated to services, for example, was ensuring their availability to produce source of technology that generates and strong customer relationships, is a we have a strong reputation with regard dustry move ahead. an important step. power. power that has such sustainability in life company of creditability and reliability. to our technical expertise and one of MacLennan: We have a diverse mix of MacLennan: The Mississauga service than hydropower. Each of us as people I really see very congruent aspects be- the deepest OEM (original equipment customers: the major state-owned utili- center is gaining importance, covering Is there anything that would help in hydropower are stewards to promote tween hydropower and Voith Hydro. manufacturer) knowledge bases in the ties, private utilities as well as indepen- all of Canada, especially remote loca- support the prospects of hydropower this message: hydropower is a good industry … dent power producers. They have dif- tions, which face logistical challenges. in Canada? aspect for the future and an important Are these the characteristics Voith Malus: … and together with the Voith ferent approaches, and it is important Not only do we have a deep know-how MacLennan: Equal conditions for all re- part of the renewable mix globally sup-

Hydro is particularly known for in the know-how, this allows us to bring the for us to be close to the customers to of generator modernization, but we also newables would further support hydro- porting CO2 reduction. // Canadian market? best design and solution perspectives understand their needs and what’s im- Malus: Yes, the values in Voith really to our customers. We are very respon- portant for their success and viability. emulate our approach in the market. sive to the market requirements and Peter MacLennan The company has been around for over see how we can adapt our offering to What is special about the hydropow- joined Voith 10 years ago. Working in project management and field service, he gained experience “on the front line,” which he says is 140 years. This is built on trustful cus- meet the market demands. er market in Canada? essential for the business. As COO he wants to continue with tomer relationships. “Never let a cus- MacLennan: We are blessed with an sustainable growth and ensure the continued high quality of products tomer down” is very important to Voith How would you describe the customer abundant natural water supply. Pretty and services and, to achieve this, focus on people management, based on his motto: “Once you are in hydropower, you stay there.” in Canada, and we definitely work be- structure in Canada? much all of our provinces have hydro- hind this philosophy. Malus: Our customers are very well power potential, and roughly only 45% MacLennan: Customers know they educated in hydropower. Some of them of this has been developed. “It is important for us to can count on us. They would say we are leading the way in terms of hydro- Malus: The other aspect: Canada is be close to the customers are fair and straightforward. We have a power development and where the probably one of the most mature hydro- service-oriented company culture, and technology could go. We are really power markets in the world. Hydropower to understand their needs.”

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inal machinery is removed and taken to HSE policies is very important in all our the Voith facility in Heidenheim, where power plants, and thus also our rehabili- Power on an it is disassembled into its individual tation projects, and Voith is meeting our components. The pieces are tested to expectations” comments Dennis Geyer- check for stress fractures and other de- mann, project manager for Erzhausen at structive wear, before being repainted, Statkraft. even keel sealed and re-assembled, ready for re-in- Facilities like the one in Erzhausen stallation. “The goal is to reduce down- were once built to perform a role that The Erzhausen pumped storage plant is refurbished to time and have the facility operational as no longer exists in Germany’s 21st cen- keep contributing to Germany’s energy transition. quickly as possible,” says Daniel Christ, tury energy market. Originally, pumped Project Manager for Erzhausen at Voith storage plants were filled at night using Hydro in Heidenheim. “During a proj- cheap power from nuclear power sta- n the River Leine, close to the ect like this many technical challenges tions, and drained to cover the midday geographical center of Germa- arise. To solve them reliably, we use peak in electric consumption. Nowa- O ny, lies the small village of proven methods and the benefit of our days, the noon peak is amply covered by Erzhausen. At only 99 meters above sea experience with such power units.” This solar power, and pumped storage has level at the riverbank, it is the lowest doesn’t mean that the refurbished facili- started to play a different role, powering point in Northeim district. It is this geo- ty will not benefit from technological up and down many times a day to even graphical situation, along with the hills advancements that have occurred since out the fluctuations of a system that in- to the east of the river, that makes its original construction. “Where re- creasingly includes input from volatile Erzhausen ideal for a pumped storage quired and possible we are installing renewable sources like wind and solar. Voith stands behind plant like Erzhausen, which, run by en- new grease-free bearings to replace the Besides this flexibility, pumped storage ergy company Statkraft, has been oper- previous systems,” says Christ. “They plants score with stabilizing the grid and pumped storage ating here since 1963. are safer and more environmentally other services to the system. // friendly.” New processes are used to This energy storage solution can play a key After several decades of reliable ser- coat original mechanical components, role in Germany’s “Energiewende.” vice, Statkraft has hired Voith Hydro to reducing wear and protecting against Hydropower in GERMANY completely overhaul and service the me- corrosion, and worn seals and bearings Installed capacity, chanical components of Unit 3 of their are replaced. incl. pumped storage: 10 GW A debate is currently going on in Germany on the best direction facility, including turbine and pump as In addition, Voith is fulfilling and Potential not the “Energiewende,” or energy transition, should take. Positively, yet installed: 6 GW well as the corresponding spherical even exceeding the demanding Health, the field of renewable energy is rapidly expanding. But one thing is Voith employees work in the interior of the Erzhausen valves, to ensure smooth, uninterrupted Safety and Environment (HSE) setup The shift to green energy is currently a certain: the transition to greener energy won’t succeed without pumped storage plant. operation for further decades. The orig- of Statkraft: “Keeping in line with our hot topic in Germany (see right). efficient energy storage. Voith has brought their expertise in the area of short-term energy storage into the public arena with the platform “Pumpspeich- erwerke – Partner der Energiewende” (pumped storage plants – partner of the energy transition), a joint venture with the German Energy Agency (dena) and other prominent industry partners. The platform champions the unique benefits of pumped storage, and makes clear that pumped storage can store energy from solar and wind sources in an efficient and climate-friendly manner. At the same time, Voith has recently conducted a study with the Rheinisch-Westfälische Technische Hochschule (RWTH) of Aachen, which shows that additional pumped storage in Ger- many could go into operation as an economically viable replacement to a significant number of conventional power plants currently being used as cold reserve. The capacity of additional pumped storage plants instead could be used to take up even more energy from wind and solar that would otherwise be lost due to down-regulation. //

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Eyes on Brazil 2 As Brazil takes center stage in 2014, Voith Hydro’s work behind the scenes is supporting development and growth. 4 3

5 razil has been reaping the bene- tion systems as well as the electrical and new unit. You have to be ready with a 6 fits of its vast hydropower re- mechanical balance of plant equipment. mitigation plan for any number of approaches that allow for low water lev- B sources for decades. Eager to Roberto Avigni, Business Develop- things that could go wrong.” els, to guarantee the continuity of supply generate more clean, reliable energy, er for Modernization Projects at Voith, Part of the reason Voith won the in all circumstances. After 2010, howev- the nation is upgrading these resources said both were critical to the grid due to contract over competitors is its reputa- er, the government permitted producers and has tasked Voith Hydro with several their location near the center of demand tion for never letting the customer to generate more than their allocation. of these projects. They include the for electricity in one of Brazil’s most in- down, Avigni points out. “You have to Conditional on improved equipment 1,420 MW Salto Santiago plant, where dustrialized areas. Taking such units out be sure that in 10 months you still de- output and efficiency, plants can increase Voith is completely refurbishing and of service in a national energy system liver everything ready. It’s not just the their supply, and reap the financial re- renewing four power units, as well as that relies so heavily on hydropower is customer but also the government ex- wards of doing so. making upgrades to electro-mechanical not done lightly. pecting everything to be punctually “Salto Santiago is the first to benefit equipment and automation technology. The main challenge in completing back in operation. We have to be from the new regulations and we have Voith’s scope of work includes building the projects successfully is the time on schedule. No matter what, the worked closely with the customer to gen- the 130-ton, 6-meter-diameter runners pressure imposed by the schedule – unit will be there on time.” erate 24 MW extra. We did the calcula- and delivering them to site in a single which cannot be permitted to slip. Re- Voith is also providing innovative 1 Voith Hydro Manaus and the Arena da tions and the return on investment was piece – a logistical challenge that in- furbishments can be challenging in this solutions at Salto Santiago, which will Amazônia stadium. good – so the customer decided to move 2 The Água Vermelha dam on the Grande River. volves trucking them safely through regard, because unforeseen issues can be one of the first plants in Brazil per- 3 Voith Hydro in Brazil headquarters and ahead,” Avigni says. “In fact, they were densely populated regions. At Água Ver- always arise, says Avigni. “As the proj- mitted to increase the amount of energy the Arena Corinthians stadium in São Paulo. very happy with tests by an independent melha hydropower plant, meanwhile, ects unfold, inevitably new challenges it supplies commercially. Brazilian gov- 4 The Maracanã stadium in Rio de Janeiro – lab showing that the results were better home of the 2014 World Cup final. Voith is refurbishing the six generators, arise that no one has anticipated. It’s ernment mandates the amount each 5 The impressive dam at Itaipu hydropower plant. than we promised, so they may be able to six Francis turbines, complete automa- completely different from installing a plant can supply, based on conservative 6 Under Voith refurbishment: Salto Santiago plant. claim even more energy.” //

34 | HyPower 2014 HyPower 2014 | 35 Green Energy Mix

ITAIPU Hydro powers Brazil’s future World Cup football and hydropower meet in the city of Manaus: home to a world-class stadium and an important

This project in the state of Paraná marked Voith Hydro manufacturing facility. Voith’s first major excursion into the Brazil- ian market. The first unit of the plant went into service in 1984. For more on Itaipu and Voith’s history in Brazil, see pages 37-39. he city of Manaus is a microcosm of Brazil. New build- ings are sprouting up and development is bringing high- Installed capacity: 14,000 MW T er living standards and great pride in rapid progress. Turbines: 20 x 715 MW Francis The city’s crowning achievement is the showpiece Arena da Generators: 20 X 737 MVA synchronous Amazônia, which will host four World Cup games this year. With all this development, however, comes huge growth in de- SALTO SANTIAGO mand for electricity – and the risk of blackouts if it is not met. The need for reliable energy is greater than ever, as the eyes of the world turn to Manaus and the whole of Brazil in 2014. This scenario underlines Voith’s central role in contributing to the success of hydropower. Brazil will have to increase electricity-generating capacity by about 6,300 MW per year, says Wellington Capelari, Head of Sales for the Brazilian market. “Hydro energy represents nowadays around 71% of total electrical energy production.” Voith is undertaking a complete refurbish- The economic and political importance of hydropower in ment of Salto Santiago hydropower plant, also located in the state of Paraná. The size the region was highlighted by the recent visit of Brazil’s Presi- of the new parts has posed a big – but not dent Dilma Rousseff to Estreito and other hydropower proj- insurmountable – logistical challenge. ects in the region. “We will need full capacity there during the World Cup, and the role of Voith Hydro in this development Installed capacity: 1,420 MW is very important. Our expectation is to have 30 machines op- Turbines: 4 x 355 MW Francis Generators: 4 X 350 MVA synchronous erating by then. We should have enough to use all the river capacity,” says José Fozzate, Project Manager at Voith for the Santo Antônio project. água Vermelha Back in Manaus, Voith’s factory in the city is key in supporting all the projects in the region. Leonardo Nuzzi, Man- ager at Voith Hydro Manaus, says the city is well-positioned close to existing and future major hydropower projects in Brazil. “We already manufacture components here while other competitors are far away from the region. We have a modern workshop with equipment including a state-of-the-art vertical lathe and a crane capable of lifting more than 350 tons. And we are well-positioned for the large hydropower projects The Água Vermelha dam, where Voith’s work under development in northern Brazil,” says Nuzzi. includes the modernization of six turbines and generators. The facility, straddling Minas The factory is also providing much-needed jobs and train- Gerais and São Paulo states, provides both ing for local people, he says. “Although it’s a big industrial dis- energy generation and flood control. trict, there was no heavy industry, so this kind of business is new to the region. We trained the local people to weld and op- Installed capacity: 1,396 MW Turbines: 6 x 232.7 MW Francis erate big machines. A major part of the workforce is now made Generators: 6 X 323.7 MVA synchronous up of local people.” //

36 | HyPower 2014 from the archives

years

The beginning: opening of the Voith facility at São Paulo in 1966.

here have been many high points in the history of Voith in Brazil, T such as the opening of the manufacturing workshop in São Paulo (1966) and of the foundry (1970), the inauguration of the new facility in Manaus (2011), A successful or major landmark projects like Teles Pires, Estreito, Xingó and Peixe Angical. In fact, Voith’s presence in Brazil stretches back to 1905, when the company deliv- half-century ered five turbines to the Itatinga hydropower plant in the city of Santos. The real Reflections on50 years of Voith Hydro in Brazil – and landmark year, though, is 1964, with the the commissioning of a landmark hydropower project. foundation of Voith Brazil in São Paulo.

1905 1964

Delivery of first 5 turbines to Brazil Foundation of Voith Brazil for Itatinga hydropower plant

HyPower 2014 | 37 from the archives from the archives

1 2

3 4 5 6

7 8

1 t he official opening of the Voith works in São Paulo. 2 a 250-ton turbine cover is installed at the Itaipu plant. 3 Working on the new regulator at Itaipu. 4 h ere, the immense size of the Itaipu plant is evident: a rotor is installed as workers look on. 5 a big order from China: preparing the world’s then-largest turbine for service. 6 t he central control room at Itaipu. 7 immense power: Itaipu from the air. 8 President Dilma Rousseff visits Estreito hydropower plant.

When introducing his country, Gilson strong issues,” he says. But with a dedi- ating unit and turbine heralded the three decades. In the 1980s, when he clean, reliable energy, but also brings on the future: “We have the technology, Campos, Head of Communications for cated and highly skilled workforce, launch into service of the plant. The was just 20 years old, he knew that Itaipu ongoing social initiatives to the region, the manpower, the quality and the reli- Voith Hydro in Latin America, talks training programs, and a good work project was a long time in preparation, represented the “biggest hydropower provided by the operator Itaipu Binacio- ability,” says Marcos Blumer, the new with justifiable pride: “Brazil,” he says, ethic based on continual improvement, remembers Werner Lacher, Sales Di- plant to be built in the world.” Filled nal, notably promoting education, sci- president and CEO of Voith Hydro “is a big country with many natural re- Voith has succeeded in securing a strong rector for Voith Hydro Brazil. “I worked with anticipation, he boarded a plane for ence and technology, plus supporting in Brazil. “There is still plenty of room sources, and it has a lot of potential for market position. in the technical field, and as Head of the first time in his life at São Paulo, and programs that protect children from ex- to grow.” // generating clean and renewable energy Engineering, I managed all the design within a few hours – on seeing the ploitation. Though not without its ups with hydropower plants.” Amidst countless high-profile proj- activity here in Brazil and the accompa- “three-meter-diameter wheels of the and downs, in the past couple of decades Hydropower in BRAZIL Campos, along with the rest of his ects, Voith’s work on the Itaipu hydro- nying manufacturing and site assembly,” trucks” employed at the Itaipu site – be- Brazil has undoubtedly become one of Installed capacity, colleagues, is celebrating 50 successful power plant, located on the Brazil- he says. And, he adds that he “had the gan to grasp the scale of the project. the world’s strongest emerging econo- incl. pumped storage: 90 GW years of Voith in Brazil. He appreciates Paraguay border, is particularly impres- opportunity to see all the work done.” mies – a development the likes of Gilson Potential not yet installed: 178 GW that it has not been without its challeng- sive. Construction work started at Itaipu Current Site Manager Alberto Neto By 2007, Voith had supplied 13 of the Campos, Werner Lacher and Alberto es. “Competitive prices, deadlines and in the mid-1970s, and by 1984, now 30 charts his involvement in the ground- 20 turbines and 11 of 20 generators for Neto have experienced first-hand. As al- No. 1: Brazil is the nation with the social responsibility have all been very years ago, the start-up of a Voith gener- breaking Itaipu project over more than Itaipu. The project not only generates ways, however, Voith is keeping an eye world’s greatest volume of fresh water.

1966 1970 1978 1984 2000 2011 2014

Official opening Opening of the Delivery of turbines First generating unit of To date, Voith has sup- Opening of the Voith Voith celebrates of Voith facility Voith foundry for Brazil’s Itaipu Itaipu hydropower plied 260 turbines to Hydro Manaus manu- 50 years in Brazil in São Paulo hydropower plant plant goes into service hydro plants in Brazil facturing facility

38 | HyPower 2014 HyPower 2014 | 39 successful partnerships Successful Partnerships

Cutting-edge technology follows heritage Modernity has caught up with tradition at a small but captivating hydropower plant in Pernegg, Austria.

Some may have had pangs of regret on bidding farewell to dable hurdle was the unusual, vertically positioned engine the historic Francis semi-spirals – affectionately named Eva, room gate. This made delivery of large parts difficult. Delicate Margot and Irmgard – after 80 years of valiant service at Per- operations ensued and cranes were needed outside the pow- negg power plant, near Graz in Austria. But old age and the er plant to uncoil heavy components such as the stator, the renewal of water rights made an overhaul of the plant neces- rotor arm of the generator and the support blade ring. All this sary to raise efficiency and the standard operating capacity. huge machinery had to be reloaded onto special vehicles to In 1927, Pernegg was Austria’s most powerful run-of- get it into the engine room. river plant when the original turbines were first installed. Built Despite the restrictions and the pressure of keeping pow- by Voith in Saint Pölten, it has supplied over 600,000 hours of er outages to a minimum, the entire project went exceedingly reliable, successful service. well. Its success is due in no small part to the cooperation From 2010 to 2013, the facility underwent a thorough among all those involved, and the project team’s zest to reach modernization, with Voith delivering three new generators, their target. “All contractual values and also short time mile- Kaplan turbines and all associated control systems. Today, stones were reached and even surpassed. It was a brilliant after Voith has concluded the extensive refurbishment on the experience for the whole team working on this project,” says plant, it is one of the most productive power plants on the Emsenhuber. In May 2013, the client took over commercial Mur River in Styria and will supply electricity to 35,000 house- operations, with a grand opening held in September. holds in the region. Rupert Emsenhuber, Project Manager at Voith St. Pölten, Thanks to the upgrade, output per unit has risen from has vast experience in hydropower turbine rehabilitation and six MW to 8.1 MW at a net head speed of 16.5 meters, a flow modernization projects. He said that the company decided to of 53 meters and a runner diameter of 3 meters. The efficien- replace the old Francis semi-spirals with new Kaplan turbines cy of both turbines and generators has increased, reducing rather than installing new Francis turbines or building a maintenance costs and making the entire plant more reliable new power plant. “We faced several daunting challenges, not in the process. least because the building housing the plant is a protected And the proud old ladies have not been banished: visitors historical structure. Therefore, only minor structural changes can view one of the three original hydroelectric generating 1 in the area where the machines were to be installed could sets in a newly built, light-flooded museum located opposite 2 3 be undertaken.” the power plant. The set consists of a Francis turbine provid- Cavitation safety was another key issue, as the hydraulic ed by Eva, Margot’s generator and turbine control unit, and development of the project had to account for limited space small parts from Irmgard. A permanent exhibition tells the to install new suction pipes as well as the Kaplan turbines. story of Pernegg and explains how electricity is generated Eventually, all three suction pipes were changed simultane- using hydropower. // ously and a subaqueous dam was made. A four-month stand- still at the power plant gave the client time to refurbish the 1 On site is a stunning glass- walled museum housing upper channel, renew the inlet rake, the rack-cleaning system parts of the historic old and high stop-logs, and install suction pipe locks in addition Francis turbines. to doing other hydraulic works. But in terms of logistics, just 2 the exterior of the historically significant Pernegg plant. entering the power plant was the first proverbial bridge to 3 t he new, modern machinery – cross, as the gate could not be altered, either. Another formi- completely upgraded by Voith.

40 | HyPower 2014 SectionSUCCESSFUL PARTNERSHIPS

The Talleres de Tolosa SA plant, now Voith Tolosa SA, in the 1960s (left). Long-term satisfied Voith customer Julian Romeral pictured with his grandson as well as Carlos Aguerre and family after visiting Vadocondes hydropower plant (right).

development of our presence in the Partners in small hydro market. He was one of the first investors to install a plant after small hydro Celebrating a productive partnership and installations were promoted,” says a milestone anniversary for Voith in Spain. Carlos Aguerre, General Manager of Voith Hydro in Tolosa. Now, having reached the milestone of 50 years in Spain, the Tolosa branch is involved in several international proj- Eighty-year-old Julian Romeral has partnership spanning 30 years. “During ects, having supplied more than 200 small hydropower in his blood. From site installation, I met a person who ce- small hydropower turbines to 22 coun- the 1930s, his family ran flour mills mented my trust in Voith: Manfred Merz, tries. The branch is also engaged in powered by Francis turbines alongside the ‘square head’ (a Spanish expres- modernization of large hydropower the Duero and Arandilla Rivers in Spain. sion meaning a rigid, mathematical, plants in Spain. Romeral studied engineering, but logical thinker),” says Romeral. “He was “We are actively working on supply- went into business. Spain’s Energy a perfectionist, very focused on details ing new units and the refurbishment of Conservation Law of 1980, incentivizing – on microns. This was something I was existing plants in Spain as well as in hydropower production, moved him to not – I just wanted to see the works some Latin American countries, where buy the old hydropower plant Vado- done as soon as possible.” Spanish investors develop activities. condes on the Duero River in 1982. Vadocondes went into operation in We have a long history and exciting fu- But Vadocondes needed new tur- 1984, with an output of 1,080 kW. ture producing machines that produce bines. Romeral contacted small hydro Since then, Romeral has contracted clean, renewable energy,” says Aguerre. suppliers with installations in Spain, and Voith to carry out a further four small This success is grounded in great finally, a visit with Hermann Fierenz at hydropower projects. customer relationships, as Romeral can Voith in Heidenheim and observing Voith in Tolosa was established in attest: “Every time I needed them, Voith Voith small hydropower plants helped 1963, and in hydropower first special- was there, for support of any kind.’’ // him to decide on Voith. ized in turbine refurbishment. They ex- “At Voith, I observed meticulous- panded during the 1980s following the ness in every process, and quality con- promotion of small hydropower by the Hydropower in SPAIN

trol. These factors led me to choose Spanish government – at the same time Installed capacity, turbines that were more expensive: but Romeral engaged in the industry. “Cus- incl. pumped storage: 20 GW Voith offered the best price-quality ra- tomer relationships are the basis of our Potential not yet installed: 4 GW tio, and the most trusting relationship I business, and one of the fundamentals

had found,” explains Romeral. And so in Voith. Our relationship with Mr. In Spain’s renewable energy landscape, began work on Vadocondes – and a Romeral was important for us in the hydropower is second only to wind.

42 | HyPower 2014 World of voith

Dynamism and precision

Voith Turbo is leading the way in the 60%, compared with that of single-circuit field of high-performance punching, nib- systems. Additional pressure sensors and bling and forming machines. The newly integrated process monitoring provides launched HDE high-performance punch improved diagnostics, and the software system offers convincing performance tool “PunchMaster” can retrieve diagnos- with high-dynamic behavior and a precise tic data from the HS4 punch controller via control mode, specifically tailored to the Ethernet from anywhere in the world. high-end segment. Maintenance needs can thus be detected Newly developed valves and intelli- quickly, reducing machine downtime – gent hydraulic and electronic control cir- hence costs for repairs and service calls cuits enable the high-dynamic behavior of can be avoided. // the HDE, which has a punch stroke of 4 mm and can achieve a cycle time of around 18 milliseconds – highly beneficial for the machine operator. The new DECV valves (Direct Elec- tronic Copy Valve) deliver accurate con- From waste trol of the HDE. A fast and precise im- back to pulse response is achieved via direct actuation by a servo motor. A repeatability resource of up to 0.01 mm permits high-precision bending and forming processes. With its Thanks to Voith Paper, rugged, compact valve, and flexibility of treatment of paper mill waste- application, integration into a machine or water is now more economical. system is simple. Voith’s anaerobic reactors ef- The HDE’s load-controlled “two-pres- fectively break down paper mill sure system,” featuring supply circuits for wastewater, dissolving organic low pressure and high pressure, assures contaminants into biogas. In a optimal power balance: using the HDE mill producing 1,400 metric will reduce energy consumption by up to tons of paper daily, up to 780 m3 of methane can be produced per hour. Paper pro- ducer Saica chose to include a Greener transport Voith R2S reactor in the wastewater treatment system of its Voith Industrial Services is assuming responsibility and contributing to environmen- new mill. The system breaks tally friendlier transportation with an e-mobility pilot project at their Schweinfurt, down up to 80% of the sludge, Germany, location. Here, as one of the first steps of the initiative, three electric cars are producing up to 25,000 m3 of now in operation, serving transport needs such as delivery and service trips to custom- methane gas daily. The result? ers. The Voith Schweinfurt branch offers technical services to industry in the region. Lower energy costs for paper “Acting responsibly and in an innovative manner is a tradition in Bavaria,” said Klaus mills, easily adhered to legal Rehberger, deputy mayor of Schweinfurt, at the limit values for wastewater, unveiling of the cars. This is also a standard and dramatically reduced on which Voith bases its own perfor- sludge – leading to lower mance. “Electric vehicles are ideal sludge disposal costs. In some here – they are sustainable, cases, the treated wastewater future-oriented and eco- can be reused instead of fresh nomical,” says Schwein- water: all in all, an economical furt branch manager and environmentally friendly Helmut Walter. // solution. //

HyPower 2014 | 43 guest perspective

Out of thin air 3

A practical and low-cost 1 Finding an optimal location is crucial for a successful fog collection system. technology is providing water 2 Fog collection technology is simple – but highly effective. to those who need it most. 3 Locals learn to help maintain the installations.

ater is everywhere around us on earth. In developed nine individuals from seven countries have visited the Tojquia nations, we are fortunate enough to have it on tap. project in Guatemala,” Rosato says, noting that this is the larg- W But in many other regions of the world, water can’t est fog-collection project in the world. The charity is also work- always be accessed via conventional collection means. Water ing on projects in Chile, India, Morocco, Peru and Tanzania. supply and collection may be difficult, hazardous, or unpre- Local people must become the agents for sustainable fog- dictable due to geographical and meteorological factors. collection technology, insists Rosato. Locals are involved at Fog collection, the practice of harnessing water directly every step: from first accessing the terrain, through to building from the air, is helping communities with little to no access to the collectors and planning ongoing maintenance. “This pro- water gain access to hundreds – even thousands – of liters per cess sets in place the knowledge and confidence needed by the day. It’s a simple concept, but one that is making an enormous users to ensure there is a sustainable source of fresh water over impact, thanks to Canadian charity FogQuest: Sustainable the long term,” says Rosato. “Sustainable technology needs to Water Solutions, which set up fog collection installations (such emphasize local capacity, knowledge, training and access to as those pictured at right) around the world. resources,” she says. “Education and participation need to be FogQuest is the creation of the charity’s executive director central to a project.” Dr. Robert S. Schemenauer, a cloud physicist and atmospheric So, could fog collection perhaps work in our own cities scientist. Schemenauer spent 15 years developing fog collec- 1 and backyards? “Fog collection works best when there is fog, tion technology, and organized the First International Confer- 2 light wind and ample areas that are relatively free of obstruc- ence on Fog and Fog Collection in Vancouver in 1998. But he tions that would interrupt the wind carrying the water drop- had even greater plans for fog collection. “I decided that in or- lets,” says Rosato. In a densely built environment this might be der for the technology to benefit more people, a formal orga- nization with more resources was required,” says Schemenauer. Subsequently, FogQuest was founded in 2000. “Sustainable technology needs to emphasize local capacity, So, how does fog collection work? Systems of wide, fine- mesh nets strung up between posts (imagine a volleyball net), knowledge, training and access are set up in fog-rich spots: generally on slopes or summits, to resources.” facing prevailing winds. Water drops carried on the breeze are caught in the nets. Droplets combine on the mesh surface and Melissa Rosato, associate executive director of FogQuest trickle down into a trough. From here, a hose drains the water to a collection tank. As Melissa Rosato, associate executive difficult to find, she acknowledges – not to mention that the director of FogQuest, explains, “It is a passive technology in demand that a larger population would place on a fog collec- that no energy is required, and there are no moving parts.” tion system would be too great. These factors make fog collection an ideal system for remote locations in the developing world, she says. However, Rosato notes that there are interesting applications for fog collection in developed countries where the pri- It’s in these locations where this volunteer-run charity is mary purpose might not be daily human consumption. “In making a major difference. Since 2000, dedicated teams of some regions, fog collection is currently being used to provide FogQuest volunteers have initiated and developed fog collec- a water source for fighting forest fires. For educational or eco- tion systems in places as diverse as Nepal and Guatemala – tourism type of activities, fog collection can be used in parks as where the charity has its longest-standing initiatives. “Fifty- a supplementary source of water for hikers or fauna.” //

44 | HyPower 2014 HyPower 2014 | 45 Is small hydro currently benefiting from the experience and expertise that Voith Hydro has in large-scale hydropower stations? Yes, quite clearly. As one of the world’s leading providers in hydropower technology, we have comprehensive expertise in this field. Our small hydro portfolio benefits from the engineering excellence of the global Voith Hydro network. We offer outstanding technology, ranging from engineering, through to the products themselves. That includes 3-D model drawings, complex flow calculations, high-tech equipment featuring five-axis milling machines, and our plants, known for their high operational reliability.

How do small hydro products differ from those created for the large hydro segment? Besides the size of the plants, small hydro plants have a higher degree of standardization. The focus here is on mature, highly reliable technology and quality products available at optimized Coffee Break costs. With our modular packages in the area of small hydro, we offer a wide Voith Hydro CEO Dr. Roland Münch on the significant range of options and custom-tailor strength Voith displays in the area of small hydropower. them to the needs of our customers.

Is small hydro also an innovation Dr. Münch, how would you describe industry. Does that also apply to the driver at Voith Hydro? “small hydro” in a very simple and small hydro segment? Yes. For example, with the StreamDiver, visual manner? The history of hydropower began with we brought a newly developed, innova- Small hydro plants are small but so- small plants that grew to become big- tive product to market, to generate phisticated. They are small machines ger and bigger over the course of time. electricity from hydropower in locations with a large output. Just imagine: a We have been actively involved in shap- where this was previously not possible single 25 MW turbine can safely and ing this history for more than 140 years. – perhaps due to environmental rea- reliably supply a small to medium- Today at Voith, we are developing and sons, or insufficient heads. The Stream- sized town with electricity. Just be- able to offer complete systems for small Diver scores points thanks to its com- cause they’re small in size doesn’t and large-scale hydroelectric power pact design, water-lubricated bearings, mean they’re small in performance. stations. We have specifically devel- and minimal maintenance and operat- oped and optimized our solutions in the ing costs. It’s just one example of how Voith Hydro is positioning itself as a small hydropower segment for this area Voith continues to make advances in complete provider in the hydropower of application. small- and large-scale hydropower. //

46 | HyPower 2014 5

6–10 1 12–13 11

4 3

1 Waneta Expansion, Canada: and electromechanical equipment. pump and corresponding spherical generators, 8.1 MW Kaplan turbines Project Expansion project including two 4 Água Vermelha, Brazil: Six valves. and control systems. 167 MW Francis turbines, generators generators, vertical Francis turbines 7 Blaichach, Germany: Three 11 Xiluodu, China: Three 784 MW and complete electromechanical with a total output of 1,396 MW, vertical Francis turbines with a Francis turbines and three 855.6 MVA Directory balance-of-plant equipment. automation systems and electrome- total output of 5 MW. air-cooled synchronous generators. 2 Baba, Ecuador: Two Kaplan chanical balance-of-plant equipment. 8 Rénovièze, Switzerland: 14 MW 12 Umamichi, Japan: Modernization turbines and generators with a total 5 Arjeplog, Sweden: Expansion of a Pelton turbine, synchronous generator project including replacement of a All plants mentioned in output of 42 MW including balance- community small hydro project, with a and complete automation system. vertical Francis turbine, generator and of-plant and automation systems. Kaplan bulb turbine and synchronous 9 Brunnenfeld, Austria: Kaplan S control system for the 5,430 kW plant. this issue and Voith’s 3 Salto Santiago, Brazil: Four generator with 0.6 MW output. turbine, synchronous generator and 13 Chugu, Japan: Modernization 360 MW vertical Francis turbines, 6 Erzhausen, Germany: Revision of automation system with 321 kW output. involving three-nozzle horizontal scope of supply generators, automation systems a horizontal pump unit with turbine, 10 Pernegg, Austria: Three turbine with an output of 3,100 kW. Published by: Voith Hydro Holding GmbH & Co. KG Alexanderstr. 11 89522 Heidenheim, Germany Tel: +49 7321 37 0 Fax: +49 7321 37-7828 www.voith.com

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