MAGAZINE FOR HYDROHYDROPOWER POWER TECHNOLOGYTECHNOLOGY HYPOWERHyPower

#1#23 | 2012| Autumn 2013

INVESTING IN SUSTAINABILITY AMET CURSUS MAURIS SIT AMET EMBRACING LOREM IPSUMTHE FUTURE

MAURIS SIT AMET FULL-LINE SUPPLIER CONSEQUAT VITAE TURKEY’S HYDROPOWER POTENTIAL

AMET CURSUS GREEN ENERGY MIX VIVAMUS ELEMENTUM SEMPER SIT TOWARD ENVIRONMENTAL ACCOUNTABILITY editorial

Imprint RESOURCE-EFFICIENT Publisher: Voith Hydro Holding GmbH & Co. KG POWERING Alexanderstr. 11 89522 Heidenheim, Germany www.voith.com How can we preserve our environment? This is a question Responsible for the publisher: Ute Böhringer-Mai that has become increasingly relevant in recent years as we Editor-in-chief: Lukas Nemela become more aware of the fragile nature of our planet and the Tel: +49 7321 37 0 importance of doing everything we can to secure its future. Fax: +49 7321 37-7828 E-mail: [email protected] While for some sustainability may simply be a buzzword, “greenwashing” to portray a company and its product as en- In cooperation with: vironmentally friendly, for hydropower, sustainability is part of Burda Creative Group GmbH www.burdacreative.com the genetic fingerprint. Being the most established and cost-efficient form of re- Paper: newable energy generation, hydropower plays a key role in HyPower is printed on Respecta Silk. This paper consists of 60% recycled fiber and the daily supply of clean energy to the world, fostering eco- was produced on a Voith paper machine. nomic and social development in many parts of it. As one of the world’s leading suppliers in the hydropower Copyright: No part of this publication may be copied, industry, we are proud to be at the forefront of sustainable reproduced or otherwise disseminated, development. Our expert teams are constantly striving to im- nor may any of the content in it be used in prove our portfolio of products and enhance sustainability, part or in whole in other works in any form whatsoever, without express written both in terms of energy efficiency and the effects our products permission of the editor. have on different environments. To be truly sustainable, however, we need to look beyond Your Feedback: If you have any our products. We are also casting a close eye over our inter- comments or questions on this issue of nal processes and tools across the globe, carefully monitoring HyPower, please contact us: [email protected] the resources we use and identifying new ways to operate more efficiently. Reducing the use of freshwater in our foundry cooling towers or advancing the lighting system in our manu- facturing workshops are just two of many examples that will Photographs: Cover: plainpicture/Stock4B; p. 4 plainpicture; p. 5 vario images/OJO Images, mauritius images/ be covered within this issue of HyPower. During the course of Alamy; p. 8-9 MaGround; p. 10-14 unit/500 gls, VISUM FOTO/Andre Kohls; p. 18 laif/Philippe Royer; the magazine, you will discover more about our individual ef- p. 19, 21 IHA (2); p. 22 Wirtschaftsarchiv Hohenheim; p. 24-25 Micha Wolfson (2); p. 29 MIGA; forts in these areas and beyond, as well as about how we p. 30 Landsvirkjun; p. 36 Entegra Wasserkraft AG; p. 38-39 Gary Roork (5); p. 44-45 Ash Mills, mauritius images/Alamy, William Pye (2); p. 46 Rhyne Represents/Allan Burch; p. 47 vario images/OJO plan to extend them in the future. Images. All other photos are from Voith Hydro. For us, sustainability is not a goal that can be achieved – it is an ongoing process for our continued business success. Sources: p. 7: IPCC SRREN; National Hydropower Association; Hydropower Equipment Association; Enjoy the read! International Energy Agency; Electric Power Research Institute; Fraunhofer Institute; Frost & Sullivan; Worldmapper.org; p. 17: J. Sathaye, O. Lucon, A. Rahman, J. Christensen, F. Denton, J. Fujino, G. Heath, S. Kadner, M. Mirza, H. Rudnick, A. Schlaepfer, A. Shmakin (2011): Renewable Energy in the Context of Sustainable Energy. In: IPCC Special Report on Renewable Energy Sources and Yours sincerely, Climate Change Mitigation (O. Edenhofer, R. Pichs-Madruga, Y. Sokona, K. Seyboth, P. Matschoss, S. Kadner, T. Zwickel, P. Eickemeier, G. Hansen, S. Schlömer, C. von Stechow [eds.]), Cambridge University Press. Figure 9.8.

All figures on installed hydropower capacity include pumped storage. Figures on hydropower potential refer to technically feasible hydropower potential. Ute Böhringer-Mai Head of Communications

HyPower 2013 | 3 CONTENTS CONTENTS

8 34 44

GREEN ENERGY MIX 22 PRESERVING HISTORY 33 MAXIMIZING RESOURCES Look back at the history of Voith Adapting existing infrastructure to 8 LOOKING TO THE FUTURE and hydropower technology bring green energy to a Czech town An overview of the dimensions of sustainability AGENDA SETTING 34 FAR-REACHING POTENTIAL A closer look at the importance of 10 RESOURCE-CONSCIOUS 24 TRADITIONALLY INNOVATIVE hydropower for Turkey Discover more Voith locations around the world Interview with Voith Hydro Board about Voith in its are contributing to sustainability Member Kirsten Lange 36 BIG PLANS FOR SMALL HYDRO other insightful publications. In Switzerland, small hydro plants 13 SUSTAINABLE TECHNOLOGY SUCCESSFUL PARTNERSHIPS hold the key to renewable energy Shaping the next generation of hydropower with HyEco solutions 26 POWERING AFRICA GLOBAL EXPERTISE Helping Africa to realize its 15 SEIZING THE INITIATIVE hydropower potential 38 UNITY IN DIVERSITY Voith is leading the hydro industry The benefi ts of multinational in environmental accountability 30 MASTERING THE ELEMENTS teamwork in Canada REGULARS Battling the weather in Iceland to PROJECT DIRECTORY 18 MEASURING SUSTAINABILITY bring the Budarhals plant online 40 READY FOR ANYTHING 2 IMPRINT Richard Taylor of the International Security and logistics play a key 47 AROUND THE WORLD 3 EDITORIAL Hydropower Association FULL-LINE SUPPLIER role in hydropower plant projects An easy-to-check reference of the Voith Hydro 6 WHAT’S NEW projects mentioned in this edition of HyPower 43 WORLD OF VOITH 20 RESPONDING TO DEMAND 32 THE POWER OF AUTOMATION 42 WORKING ACROSS 44 GUEST PERSPECTIVE Professor Dr. Godde of E.ON gives Modernizing the underground BOUNDARIES 46 COFFEE BREAK an energy provider’s perspective power plant Churchill Falls A fully integrated solution

4 | HyPower 2013 HyPower 2013 | 5 SECTIONWHAT’S NEW SECTIONFACTS

A NEW NAME, AWARD-WINNING A PROVEN PARTNER IN BRAZIL 10 FACTS ABOUT SWEDEN Voith Hydro has started operat- BRAZIL Voith Hydro has been ing under its proven brand name also in elected the best company in Sweden: The Swedish operating unit, the capital goods sector in formerly active as VG Power AB, will now Brazil for the second time in a be trading under the name of Voith Hydro row. The prize was awarded as HYDROPOWER AB. With the name change, the company part of the 40th Special Edition strengthens its presence in the Swedish of “Best and Largest” (“Mel- market and underscores the successful hores e Maiores”) of the leading More than 80% development of the Swedish branch. Brazilian trade magazine Having held a majority stake in VG Power Exame. The ranking rates 3,500 companies from 19 different business sec- of the world’s since 2006, Voith Hydro acquired all re- tors, with the assessed indicators reflecting the companies’ success in busi- up to115% maining shares at the beginning of 2013. ness. The indicators include growth, profitability, financial stabillity, invest- renewable energy Between 98% and 115% of Norway’s annual “We are convinced that, based on our lo- ments and productivity per employee. “This important award is an electricity demand is covered by hydropower cal strength and our generator expertise acknowledgment of our permanent commitment to Brazil,” commented (depending on rainfall). is generated % as well as Voith Hydro’s excellent global Osvaldo San Martin, President and CEO of Voith Hydro in Brazil. “We are 85Over 85% of all dams in the world remain reputation, we will realize many further suppliers of complete solutions for the largest hydropower generation proj- from hydropower. unused for hydropower generation. successful hydropower projects together ects in the country and in Latin America – which are deemed strategic to with our customers,” says Stefan Borsos, ensure the supply of electrical energy and hence the region’s economic de- 38 million CEO of Voith Hydro AB in Västerås. // velopment and growth.” // 35 COUNTRIES IMPORTANT MILESTONE THE SUSTAINABILITY By 2009, more than 35 countries obtained more than half of their total electricity from hydropower. REPORT 2012 PROVIDES INSIGHT CHINA The most powerful generator-turbine unit ever built by Voith has en- tered service in the Chinese hydropower plant Xiluodu on the Jinsha River. INTO SUSTAINABLE After a successful 72-hour test run, Voith handed over the first of a total of THINKING AND Using hydropower avoids nearly 200 million Hydroelectric three such machines to the customer China Three Gorges Corporation. With ACTING AT VOITH. FOR MORE metric tons of carbon pollution in the United INFORMATION, FOLLOW THE QR States each year – equal to the output of over power generation 784 MW the output of the generator-turbine unit in Xiluodu is higher than that 38 million passenger cars. of the world’s largest hydropower plants. This achievement is a milestone for CODE OR VISIT: WWW.VOITH.COM 99% per person p.a. the company and an important step toward the first one-gigawatt unit. The Pumped storage represents 99% of energy installation of the first unit in Xiluodu started about a year and a half ago in storage capacities worldwide. kWh close cooperation between Voith Hydro in Shanghai and the global research 1600 and development laboratory for water turbines and generators. // 1400

FULFILLING TURKISH 1200 POTENTIAL 1 KILOGRAM 1870 1000 The first hydraulic turbine from Voith was Each kWh produced with hydropower AUSTRIA Voith Hydro has received a major 800 manufactured in 1870. reduces CO2 emissions by 1 kg. order for equipping the new hydropower 600

plant Upper Kaleköy in Turkey, realized by a 400 consortium. Voith Hydro in St. Pölten, which 200 is responsible for the Turkish market, will be As the world’s largest affordable re- delivering three Francis turbines, each rated 1 2 3 4 5 6 7 8 9 10 11 12 at 202 MW, as well as the associated equip- newable energy source, hydropower 1 Central Africa 7 Eastern Asia ment. Voith has been active in the Turkish 2 Southeastern Africa 8 South America hydropower market for more than 75 years 3 Northern Africa 9 Eastern Europe and has so far put more than 100 projects currently accounts for over 16% of 4 Southern Asia 10 North America into practice. For more information on hy- 5 Asia Pacific 11 Western Europe dropower in Turkey, see pp. 34-35. // the total world electricity supply. 6 Middle East 12 Japan

6 | HyPower 2013 HyPower 2013 | 7 green energy mix

looking to the future

The concept of sustainability embodies the tradition and business style of Voith, says Barbara Fischer- Aupperle, Head of Sustainability at Voith Hydro. Family- owned, the company feels an obligation to conduct envi- ronmentally compatible, clean and fair business. Of course, hydropower has its inherent properties of sustain- ability: it provides green, clean and renewable energy to millions of homes and businesses worldwide, with con- siderable potential still untapped. Ensuring the further de- velopment of sustainable practices within defined action fields remains a key aspect of Voith’s strategy. “We are a company that delivers more than pure technology,” states Fischer-Aupperle. “Sustainability is a key part of our mentality, with innovation, reliability, safety and technological excellence included, and we aim to give equal importance to economic, ecological and social aspects in our management, products and processes.” This means, for example, that the company pays close attention to internal resource management at its locations around the world. “We are continuously increasing the number of ways in which we can operate more efficiently and reduce energy and resource consumption as well as waste generation without affecting quality,” she explains. Naturally, there is also a strong focus on the products the company produces. “Take our HyEco product portfo- lio: it offers forward-looking solutions to improve energy efficiency, water consumption and environmental com- patibility. It covers the full spectrum of a hydropower plant’s needs, from oil-free turbine components to energy- saving automation systems.”

HyPower 2013 | 9 green energy mix

Broadening the scope, sustainability is something the whole Under pressure Saving fresh water supply chain must take into consideration, as more and more At Voith Hydro in York, compressed-air Every year, 25,000 m3 of fresh water is companies embrace it as a measure of business success. An production accounts for almost one used in foundry cooling towers at Voith increasing number of Voith’s customers measure and report quarter of the electrical consumption. A in São Paulo. Recent analysis of treated on sustainability, highlighting the importance of global prac- number of technical measures have water, however, indicates that it is of tices and standards. As a key player in the industry, Voith been carried out in order to maximize high enough quality to be used for cool- Hydro has long been working closely with the International savings – including power meters for ing tower purposes. Abandoning the Hydropower Association in the development of the Hydro- improved monitoring, shutoff valves use of fresh water and replacing it with power Sustainability Assessment Protocol, which allows all and new cooling methods in the fabri- treated water can thus save 25,000m3 partners involved to measure a hydropower project’s sustain- cation department. of fresh water every year – the same as ability. Still, this is an area that will continue to evolve in the 10 Olympic-sized swimming pools. coming years. Overall, increased awareness of the importance of sus- tainability will leave its mark on the future, as the industry changes. “Whether for Voith Hydro as equipment manufactur- ers, for electricity providers, their clients, investors or other partners, sustainability is raising the bar for what is considered Bright ideas good economically, environmentally and for our society.” // An energy analysis of Voith Hydro’s workshop in Heidenheim revealed that lighting was one of the biggest electric- ity consumers. As a result, Voith invest- ed in energy-saving LED lighting. The new lights will offer longer durability and a signifi cantly lower energy consump- tion level thanks to a better light man- reSourCe- agement system. The effect was remark- able: About 33 tons of carbon-dioxide emissions can be avoided, equal to what fi ve soccer pitches of forest could ConSCiouS compensate for. How Voith employees are helping to reduce resource consumption wherever possible.

Keeping an eye on the meter energy-saving days In order to encourage a more energy- To investigate how employee energy conscious method of working, meter consumption can be decreased, Voith displays have been introduced at Voith Hydro introduced energy-saving days Hydro in St. Pölten, Austria. These at its location in St. Georgen, Austria. show employees how much energy is During these days, extra focus was put being used, with comparison fi gures to on energy consumption and usage of previous months to encourage saving, everyday devices like computers, printers, from water to electricity or gas. coffee machines and fans. The initiative reducing waste was then followed up by an analysis, During the last three years, the Voith which showed that electrical baseload Hydro foundry in São Paulo has been can be decreased signifi cantly if energy replacing new sand with regenerated is consumed more wisely and, for ex- and recycled sand wherever possible, ample, devices are switched off. As a as well as updating certain components result, the company is considering ex- to reduce sand wastage. During this panding the energy-saving days to all period, the amount of new sand used at operating units once a year. the foundry has gone down by 30%.

10 | HyPower 2013 HyPower 2013 | 11 green energy mix green energy mix inVeSting in future SuStAinABle teChnologY generAtionS endless, ecological and The key to achieving greater sustainability is to constantly search StiMulAting effi cient: Voith Hydro’s HyEco for improvement. Hydropower is already the most effi cient way to generate green electricity. It is low in emissions and independent from solutions represent next- primary energies, as well as being endless and commercially viable. teChniCAl generation technology for utilizing The question at Voith Hydro is: How can we improve on this even fur- hydropower in a sustainable way. ther? Through constant innovation and research, the company is creat- AnD CulturAl ing a range of solutions under the name HyEco that aim at further min- imizing the impact of hydropower on the environment. “It is necessary knoWleDge to concentrate not only on the effi ciency of the power unit, like the turbine and generator,” says Oliver Hesse, Product Manager for Voith Hydro, “but also to examine all other plant systems for their ecological impact.” HyEco solutions can improve energy usage, water consump- tion and eco-compatibility. They range from cooling-on-demand sys- tems, which reduce water consumption by selectively cooling only spe- cifi c generator elements, to oil-free solutions that eliminate the risk of water pollution. Here, we take a closer look at three HyEco solutions.

energy

HyCon Plant Optimiza- tion Increased effi ciency is also a result of intelligent operations management: Here, automation has a vital role to play, providing precise reg- ulation and control across a hydro- power plant. In many multi-unit facili- ties manual regulation or classic joint control systems are used to distribute the discharge of water across the available machines – not taking into Scouting for improvements Providing education in Brazil account small differences in turbine ef- The long pipes of the compressed air The Voith Foundation helps support a Manaus, the Voith Foundation Brazil fi ciency or channel fl ow areas. As a system that run through Voith Hydro’s number of educational and cultural and the 3M Institute have recently es- result, the overall plant operation is workshop in Heidenheim can be diffi cult projects for children in Brazil aimed at tablished an innovative partnership: the theoretically effi cient – but can be im- to monitor and maintain. Remedying providing better cultural and environ- Voith Foundation Brazil & 3M Institute proved by intelligent systems and the situation is a select group of six mental awareness. Since its creation in Formare Project. The aim of the initia- technologies. Here, Voith’s HyCon trainees who have been carrying out a 2004, the Foundation has invested over tive is to provide training for disadvan- Plant Optimization comes into play: series of tests for leakages in the sys- $2 million to the benefi t of thousands of taged young people from communities Using a detailed plant model, the sys- tem throughout the production facilities. youngsters in the São Paulo region. The close to the Manaus industrial district, tem aims to achieve optimum effi cien- To date, these “energy scouts” have highlight is the ‘Formare’ program, a and to support their integration into the cy for the entire facility, increasing the found and fi xed 65 leaks. In combina- 10-month project that helps prepare labor market. // plant’s overall output. HyCon looks at tion with new standards for detection 20 young people for the world of work. optimizing the distribution of water as

and repair, this can help reduce CO2 In São Paulo, around 80 Voith employ- well as dividing the required output emissions by up to 10 tons a year. The ees help out as volunteer teachers, between the turbines in an ideal com- “scouting missions” will take place at passing on their technical and commer- bination. As a result, every drop of wa- regular intervals in the future. cial knowledge in different courses. In The HyCon system can reduce water consumption and increase energy effi ciency. ter is used in the most effi cient way.

12 | HyPower 2013 HyPower 2013 | 13 GREEN ENERGY MIX GREEN ENERGY MIX SEIZING THE

WATER INITIATIVE Auto-Venting Turbines Many hydroelectric facilities are After successfully proving hen we started on this over Schuol and his team have developed the built together with a dam to create a reservoir, from which the company’s life cycle four years ago we saw that company’s own comprehensive life cycle water is used to drive turbines and generate electricity. Looking at it W other sectors – the auto in- assessment (LCA) model to determine from an ecological point of view, the water that comes from the reservoir assessment model, Voith dustry, for example – had already gone the output of greenhouse gases from the is lower in dissolved oxygen than normal river water; oxygen that is vital is leading the hydropower down this road,” says Voith environ- construction and operation of hydro- for plant and animal life in the river. The solution is to re-oxygenate the equipment industry in mental expert Dr. Jürgen Schuol. “They power stations. More than just an water, using auto-venting turbines. These create a low-pressure region had tracked down in great detail the exercise in quantifying output and asso- below the runner that draws atmospheric air into the turbine during environmental data required to provide a good ciated costs, Schuol says, Voith also operation. “Auto-venting turbines improve the levels of dissolved oxy- accountability. understanding of greenhouse gas wanted to find out how its hydro com- gen in waterways to enhance the quality of the water for creatures in emissions involved in the making of ponents could be manufactured in an this habitat with a minimum impact on energy generation,” says Hesse, every single component, right down to even more ecologically friendly manner and Voith Hydro creates made-to-measure solutions for each plant, tak- last screw, as well as emissions from the in the future. ing into account its location as well as the desired outcome. vehicle’s engine. We recognized that Obtaining data and making certain this level of environmental accountabil- assumptions for a product with a rela- ity is going to be expected of every tively short lifespan, such as a car, can be industrial sector in years to come, even difficult. However, the initial study, un- including ones that have traditionally dertaken on Waldeck I, a pumped-stor- been seen as part of the solution age plant in Germany with an estimated ENVIRONMENT rather than part of the problem, lifespan of up to 100 years, turned out to such as hydropower.” be an enormous task. While there was Oil-Free Turbines It is an axiom of engineering that mov- sufficient information available about ing parts must be lubricated, to reduce friction and cut Instead of waiting for the issue to the masses and materials connected with down on wear and tear. Traditionally, oil was the lubricant of choice, but arrive at the door of the hydro industry, production of Voith components, col- while it has many benefits as a lubricant, there is a risk of water pollution though, Voith has taken the initiative. lecting these data as well as obtaining if it spills or leaks into the river. The solution sounds simple, but takes a similar data about parts or manufactur- lot of work to get right: oil-free turbines. For axial power units like Ka- ing processes from other companies LCA: Comprehensible assessment of environmental impact plan or bulb turbines, the hub is a complex system of gears and bear- proved to be exceptionally difficult. ings to control the angle of the blades, which is typically filled with oil. One of the lessons learned, Schuol Voith Hydro has been installing oil-free turbine hubs since 1985, and in Emissions Emissions Produced Emissions explains, is that “Whoever wants to set (e.g., CO ) (e.g., CO ) electricity (e.g., CO ) addition to preventing spills, the latest turbines are easier to maintain, 2,eq 2,eq 2,eq up such an LCA for an entire hydro- produce less friction and have good bearing performance without need- power station should ideally work with ing to increase servo size. At a hydropower plant in Galicia, Spain, for partners collecting data right from the example, five of six oil-free turbines have already been installed, and OPERATION/MAINTENANCE beginning.” Oil-free solutions help to protect the local environment CONSTRUCTION DECOMMISSIONING (top); water life also benefits from the oxygenated water when the plant goes fully online next year, HyEco technology will begin provided by auto-venting turbines. to play its part in ensuring local water quality. // Raw materials, Recycled Despite these challenges, Schuol and Energy materials, Waste his team initially developed a sophisti- cated computer model using market-

Total life cycle leading software to prepare a conclusive pilot case study. “Our timing turned out Life Cycle Assessment (LCA, ISO 14040) is a method developed to evaluate the to be good,” he notes. “Two-and-a-half Discover more about mass balance of inputs and outputs of systems and to organize and convert those Voith’s HyEco products at inputs and outputs into environmental themes or categories relative to resource years ago we received our first customer www.voith.com use, human health and ecological areas. approach on the question of carbon

8 | HyPower 2013 HyPower 2013 | 9 Green energy mix

Until recently, LCAs have been open to voirs during the operation phase should social effects on communities. It is cru- variations in approach, yielding a spread be included as an input to LCAs but cial, therefore, that project promoters of detail. The task for the Voith team there is still an ongoing discussion on are in a position to use clear science and was to identify where the focus should the proper determination of these emis- clear data to demonstrate the reality be in its own model, ensuring the main sions. No account might be taken, for about any given proposal. elements are assessed accurately and in a example, of emissions prior to reservoir “At Voith, we seek to participate in standardized way. This is essential for impoundment or to emissions due to projects that are truly sustainable and to compliance with EPD requirements, anthropogenic sources (e.g. sewage). this end, along with customers, sources which are concerned with producing Due to the importance of this issue as of finance such as banks, and govern- comparable results between plants. well as the knowledge and expertise re- ments, we promote and support the Hy- “Having started on our own, so that quired, Voith – as a member of the dropower Sustainability Assessment we could learn exactly how to do it, we Hydro Equipment Association – sup- Protocol as a tool to achieve this. The are now in a position to implement it on ports and sponsors research in this area hydropower sector these days in most request from customers. Currently, the through the International Hydropower countries is working hard to deliver main interest comes from Europe,” says Association [see pp.18-19].” sustainable projects with the least Schuol. To carry out an LCA correctly is environmental and social impacts. In a very complex task, he emphasizes. “In Opponents of hydropower projects taking this initiative in relation to LCAs the past, there were on-off approaches, may be concerned for various reasons, our aim is to help the sector, and Voith but these can be very misleading. Net from the potential effects on fish migra- in particular, graduate from good prac- greenhouse gas emissions from reser- tion to general environmental impact or tice to best practice.” //

Greenhouse gas emissions among different forms of energy generation

Electricity Generation Technologies Electricity Generation Technologies Powered by Renewable Resources ElPowerectricedity by Gen Non-eratioRennew Teablechnologies Resour ces 2,000 Electricity Generation Technologies Powered by Renewable Resources Powered by Non-Renewable Resources 2,000 1,750 Maximum 1,750 Maximum 1,500 75th Percentile Measuring the impact of hydropower on the surrounding environment is becoming 1,500 75Medianth Percentile increasingly important for all industry partners. 1,250 25Medianth Percentile

1,250 th Minimum25 Percentile 1,000 MinimumSingle Estimates 1,000 with CCS footprints. They were keen to certificate want to buy electricity produced by of emissions results from combustion of Single Estimates 750 with CCS q / kWh] e their electricity generation and to do it renewable sources, such as hydro,” fuel used in the production of electricity. 2 750 q / kWh] e in a way that would help them create an comments Schuol. “These days, many It is a similar story for producers of con- 2 500 [g C O 500 [g C O Environmental Product Declaration people want to know where their elec- crete or steel, traditionally regarded as ons 250 ss i [EPD].” tricity is coming from.” ‘dirty’ industries from an environmental ons 250 ss i Em i An EPD is an internationally recog- perspective. 0 Em i Gas 0 er Oi l Coa l erg y LCAs provide a valuable basis erg y nized and standardized way of for this However, hydroelectricity produc- Gas -250 er Oi l ra l Ga s Energ y Coa l erg y house erg y quantifying the environmental impact approach and, while its main focus is on ers are also coming under closer scruti- -250 Biopo wer * ra l Ga s Energ y house Nat u

-500 Solar P ow Hydropowe r

Biopo wer * Wind Photovoltai cs of a product or system. It includes infor- the carbon footprint, it is actually con- ny today, even though the sector has Ocean En Nat u Nuclear E n

-500 Solar P ow Hydropowe r Wind Photovoltai cs Ocean En Nuclear E n

mation on the environmental impact of cerned with far more than that. “Other traditionally been regarded as a clean -750 Geothermal E nerg y Lifecycl e Gree n raw material acquisition, energy use and considerations include, for example, source of power, observes Schuol. In -750 Geothermal E nerg y

Lifecycl e Gree n -1,000 Concentrati ng efficiency, content of materials and acidification and energy used for manu- reality, greenhouse gas emissions associ- -1,000 Concentrati ng chemical substances, emissions to air, facturing and production of a plant ver- ated with hydropower are extremely low -1,250 -1,250 Hydropower, like soil and water, and waste generation, as sus its lifetime output. The ­energy pay- and primarily attributable to the inputs *Avoided Emissions, no Removal of GHGs from the Atmosphere -1,500 other renewables, *Avoided Emissions, no Removal of GHGs from the Atmosphere well as other product and company back ratio is ­an important one.” of key building materials – concrete and -1,500 has a relatively information. Today, Schuol says, Voith’s custom- steel. Nevertheless, like every industrial low greenhouse gas emission rate. ers are seeking greater levels of informa- “If you can put an EPD stamp on sector, hydropower also has its critics Count of Knowledge on 222 (+4) 124 42 8 28 10 126 125 83 (+7) 24 169 (+12) something, that’s a message you can tion related to their environmental and LCAs provide a scientifically objec- CountEstimates of emissions during 222 (+4) 124 42 8 28 10 126 125 83 (+7) 24 169 (+12) CountEstimates of the entire process show in public and use for promotion impact in order to establish their tive approach to demonstrating that its 52 (+0) 26 13 6 11 5 49 32 36 (+4) 10 50 (+10) ReferencesCount of is required to 52 (+0) 26 13 6 11 5 49 32 36 (+4) 10 50 (+10) purposes. In Germany, for example, as a credentials with their customers. For a associated emissions are indeed low References evaluate the consumer you can select whether you conventional coal plant the main source while the energy payback ratio is high. Source: Intergovernmental Panel on Climate Change (full source listing on page 2). whole life cycle.

16 | HyPower 2013 HyPower 2013 | 17 green energy mix

From 2008 to 2010, IHA entered into the multi-stakeholder Hydropower Sustain- ability Assessment Forum with key partners from government, finance and NGOs. The forum reviewed and tested the original tool, covering all types of hydropower and the perspectives of both the developed and developing world. The process was supported by various reference groups and interested parties. It was a major and protracted effort to distill many aspects and concerns, involving 1,933 individuals in 28 countries and 20 field trials in 16 countries. The outcome of this work was the Hydropower Sustainability Assessment Protocol, launched in 2011. The protocol’s aim is not to define a project as good or bad; we don’t aggregate results into a pass or fail. Each of the 20 or so sustainability topics are assessed on a calibrated scale, where the lowest represents significant gaps against basic good practice, and the highest represents best performance. A spider diagram plots the performance for each of the assessment topics, mapping project sustainability by highlighting project strengths as well as opportunities for improvement, thus allow- ing for more informed decision-making. Quality control is a cornerstone of the protocol, and only licensed accredited assessors will be authorized to provide commercial protocol services, including of- ficial assessments. To date, six assessors have been accredited, with another tranche expected to complete the process by the end of 2013. Official assessments have already been carried out on projects in Australia, Brazil, Germany, Iceland and Measuring sustainability Norway – with several others nearing completion. We have found that those being Richard Taylor, assessed greatly value the protocol’s feature of targeting the areas in need of Executive Director, IHA further work, and the process of stakeholder dialog during the Richard Taylor, Executive Director at the International assessment process.

Hydropower Association, outlines the process behind Progress since the launch has been good. External stake- introducing the Hydropower Sustainability Assessment holders are now recognizing the protocol, including the OECD Sustainable Partners Protocol and the progress made since its launch in 2011. and the World Bank. Assessments are being conducted in sev- eral countries in Europe, Asia, and North and South America. As a member of the Hydro Equipment The protocol is available in six languages, and in Europe the Association (HEA), Voith Hydro is an im- EU-funded Hydro4Life project promotes the protocol’s use in portant Sustainability Partner for the There’s little doubt that hydropower has a major part to play in delivering cleaner the region’s member states. IHA and a supporter of the protocol. In energy and freshwater management to the world. It has a uniquely multipurpose role In Africa and Asia, the Norwegian Development Agency, 2013, the company hosted workshops­ in the provision of energy, water and climate services. However, for hydropower to Norad, is supporting the use of the protocol in several of the in Sweden and Heidenheim in conjunc- realize its optimum potential, all involved will need to become increasingly least developed countries. The IHA has entered into sustainabil- tion with the IHA, with a focus on imple- accountable to sustainability values. ity partnerships with 15 organizations (including private devel- menting the protocol. In addition to In the past, there was no agreed way of measuring sustainability. The sector opers, utilities, government and lending agencies, contractors participants from Voith, a number of ex- was stuck for many years, with open-ended and inconsistent decision-making. This and suppliers) providing training and assistance leading toward ternal participants took part, including was true at both the policy and project levels. Consequently, many proponents and incorporation of the protocol. I’m pleased to say that Voith WWF representatives and employees investors were dissuaded from involvement. Hydro, as a member of the Hydro Equipment Association, was from numerous finance institutes that It was clear a new approach had to be found with a better definition of good one of the first organizations to become involved as a Sustain- support sustainable hydropower proj- practice and a way of measuring performance. For several years, we have been ability Partner. ects. “The workshops are an excellent working toward a framework to help guide hydropower planning, implementation Among other things, an official protocol result can be used opportunity to bring together the vari- and operation from a sustainability point of view. We listened to concerns about the by many parties, whether that’s giving permission to proceed, ous stakeholders in hydropower, plan- kinds of impacts that were being experienced and reported, especially those affect- funding decisions or entry into premium markets. It could also ning and finance and to discuss the ing environmental and social aspects. We also looked at good practice around the assist in CSR reporting, informing stakeholders, and demon- protocol as a practical tool for assess-

The IHA is a non-profit world, to avoid or minimize negative impacts, but also to make the most of positive strating the performance of an asset to investors and share- ing the sustainbility of hydropower,” organization, working impacts and the sharing of benefits. Importantly, we also looked at the types of holders. It recognizes that no project is perfect and highlights says Barbara Fischer-Aupperle, Voith with a network of mem- evidence needed to demonstrate good practice. In 2006, the International Hydro- areas that may need attention. It will certainly go a long way Hydro Head of Sustainability. // bers and partners to advance sustainable power Association (IHA) developed a prototype tool for measuring sustainability toward making the dialog about projects more constructive and hydropower. performance and began testing it with the collaboration of various members. less polarized. //

18 | HyPower 2013 HyPower 2013 | 19 GREEN ENERGY MIX

hen E.ON Kraftwerke set out competitors, too. We are asked, ‘What now understand how to talk jointly tance of a project – we can discuss a to use the Walchensee hydro- are you doing?’ more and more,” he about the topic. Before the Protocol was project with stakeholders before its im- W power plant to test the IHA’s says. available they had di culties discussing plementation. In this way we can arrive “WE ARE new Hydropower Sustainability Assess- “If you look at safety and health, the notion of sustainability. The Proto- at the best project. This is where we be- ment Protocol (“the Protocol”), director there is a longer tradition. But the col teaches us to use a common lan- lieve the Protocol can help us the best – Prof. Dr. Dominik Godde knew that he energy industry is confronted with quite guage,” Godde says. “And that is impor- to allocate and optimize resources with was facing a large and potentially en- some challenges today. Worldwide en- tant.” For companies like E.ON, respect to sustainability performance. In ASKED MORE lightening task. Documents had to be ergy demand is growing, and we are however, there are also other clear ad- terms of cold cash, it reduces business dug out of the archives of the faced with debates on climate protection vantages attached, in terms of capacities, risks, giving us an economical advan- decades-old hydropower plant, and and fi nite fossil resources. All this brings expertise and money. tage, too.” resources had to be freed for project us to think about sustainability. We, as “The idea was to train our own management and training of sta . All to an energy company, have to play an ac- people in the use of the Protocol in or- Following the success of the Wal- AND MORE, assess the notoriously intangible con- tive role in fi nding a solution. We are der to understand it and use it for future chensee plant, Prof. Godde is not afraid cept of “sustainability.” keen to be involved in sustainability top- projects, too. You can call it ‘capacity to share his optimism for the future of “We chose the Walchensee plant, ics and also to be recognized as sustain- building.’ We can use it in the future, both the Protocol and its infl uence on because it is one of the oldest plants in able energy providers.” inside and outside Europe. It gave us in- the industry. Prioritizing and investing our portfolio. After so many decades of sights into and understanding of perfor- in sustainability, he says, is not only at ‘ WHAT ARE operation, we wanted to know if we Using the International Hydropower mance gaps, too. If we could identify the very heart of E.ON’s business, but were still up to the task of pursuing the Association’s Hydropower Sustainability performance gaps at the Walchensee also an obligation for any energy pro- best practices,” says Prof. Godde when Assessment Protocol to assess and eval- plant, as a mature power plant, then we vider who aims to be a part of tomor- asked about the reasons for implement- uate practices at Walchensee is an im- were likely to have similar gaps at row’s energy landscape. YOU DOING? ’” ing the Protocol at Walchensee. “It is portant step in this direction, Prof. other power plants. Of course I was also “We have so many interfaces with the fi rst plant in Europe to assess sus- Godde explains. The Protocol was de- interested in our scores. Maybe we are society – particularly when it comes to tainability using the Protocol. It’s a big veloped by the association following in- performing extraordinarily well in some hydropower. I think there is no way e ort, but it will pay o .” tense reviews of sustainability practices areas, while others might need improve- around it. It’s at the heart of our busi- The IHA’s Hydropower Sustainability between 2008 and 2010, before being ment. All these questions have been an- ness and our ethical behavior as a Assessment Protocol gives modern Built in 1924, the Walchensee plant in launched in May 2011 at the IHA world swered and can tell us something about corporation,” he says. “E.ON’s strategy hydro-energy providers a common southern Bavaria boasts a capacity of congress in Iguaçu, Brazil. It covers where we stand with respect to this is coined by the slogan to provide ‘clean- 124 MW and lies at the heart of more than 20 sustainability topics and plant, and what we can use our experi- er and better energy.’ Wherever we go tool for understanding the importance E.ON’s European hydropower opera- o ers an assessment tool based on ob- ences for at other plants. And I am hap- we aim to contribute to a better energy of sustainability, says Professor Dr. Dominik tion. The company runs plants in vari- jective evidence and standardized re- py to report that the Walchensee power situation by working toward imple- Godde, director of E.ON Kraftwerke GmbH. ous countries in Europe, and according sults. The standard is not thought of as a plant assessment showed excellent re- menting a level of sustainability that to Prof. Godde, sustainability has long ranking system or a stamp of approval, sults, with respect to public health, la- lives up to our own expectations.” earned its status as a priority across the but rather as an engine for operating bor, and working conditions or infra- E.ON portfolio. Using the Protocol to with “sustainability” as a stringently de- structure safety.“ Ultimately, and despite great effort, pilot an assessment run at the historical- fi ned term across the sector. “We now also have a further tool dusty documents and hundreds of man- ly signifi cant Walchensee was therefore “The partners who have been con- for evaluation of projects that can help hours, Walchensee was a big success, a straightforward decision. The plant tributing to this assessment, they also us decide whether it is worth investing Prof. Godde sums up. “Having applied not only provides the ideal setting for money into a project or not. Besides a the Protocol, I can certainly say that we the testing the Protocol, but also allows general ecological and social view on the understood how it can help us a lot. We E.ON to pursue increasingly sustainable Prof. Dr. Dominik projects until now, we had two major will do it again as soon as we have a case Godde practices, Prof. Godde explains. is Director Hydro Fleet categories of questions we would ask where that makes sense.” “It is a necessity to recognize sus- Germany at E.ON when discussing a project: does it fi t our Such a case may already be on the tainability. The license to operate our Kraftwerke GmbH and strategy? And how is the economic via- drawing board, Prof. Godde reveals, a member of the IHA power plants is given to us by society. board. He also teaches bility of this project? Now we have a although “it is too early to speak about There are ethical reasons involved. But energy economics third group of clear and measurable cri- specifi c plans just yet.” // we also feel that to provide a certain and hydroelectric teria, which are: how is the sustainability installations as a pro- level of service, we need to adhere to fessor at the Technical performance of this project? The Proto- sustainable principles. It makes a di er- University of Munich. col gives us an opportunity to discuss ence to fi nancial markets, investors and and foster internal and external accep-

20 | HyPower 2013 HyPower 2013 | 21 green energy mix preserving history

The commercial archives of Baden- Hanitsch on the company’s archival holdings. The innumera- Württemberg in Germany offer a ble documents make the company’s tradition and its remark- able ability to develop and innovate both visible and telling. fascinating insight into the history of And they show what has determined the character of one of Voith and hydropower technology itself. the oldest family companies in Europe. “The company always came first,” she notes, glancing at the papers and correspon- dence with customers, partners and family members. For a company like Voith that is proudly aware of its tradi- radition and history are important, they’re not just tion, the archive is a real treasure chest. On special occasions dusty old papers,” explains Jutta Hanitsch as she re- such as anniversary celebrations, the archives can be used as a T moves a 19th-century drawing of a turbine from a file in rich source to hunt for milestones, historic projects or impor- the archives. “A long tradition is a real marketing asset for a tant events in the company’s history. company like Voith,” she points out. “And Voith is a company that makes wonderful use of its history.” Hanitsch is Deputy Amusing stories and telling anecdotes can also be found in Director of the Wirtschaftsarchiv (commercial archives) the archive. These include information about Friedrich Baden-Württemberg, which collects, preserves, archives and Voith’s friendship with another genial Swabian inven- studies historical documents and materials from companies lo- tor of his day, automobile pioneer Gottlieb Daim- cated in the southwestern German state. ler, with whom he often went on quick spins in his The archive is situated within And there are plenty of companies in the region sharing a motor carriage. Or diary entries by a young Voith en- the attractive grounds of the University of Hohenheim, in an rich tradition that features a justified reputation for being gineer who traveled to America in 1909 for negotiations 18th-century castle. ­especially hardworking and highly inventive. The historical on the delivery of turbines for the power plant on Niagara documents of some 600 companies from the southwest of Falls and who – besides making business notes – commented Germany are the responsibility of the 12 employees of the on the quality of the meals he was served, including steaks that commercial archives. There are 11 kilometers of shelves hold- he found much too rare for his taste. ing archived materials in the basement of Hohenheim Palace Numerous examples in the archives show that Voith has on the outskirts of Stuttgart and in a nearby storage facility long been an extremely active global company. There are Japa- just outside the city. “No other archive looks after materials ­colored blue and red, as well as neatly listed columns of num- nese registered designs, along with applications submitted to from the past of private companies,” says Hanitsch. “It is our bers for calculating raw material requirements and sales bro- the Imperial Patent Office for impulse turbine and Francis tur- job to locate, collect and preserve these invaluable historical chures featuring Art Nouveau stylistic elements. bines from the early 20th century, for example. The patents is- sources.” These pieces of Voith history have been in the archives in sued by the United States Patent Office at the end of the 19th Stuttgart since the mid-1980s, which was created as a founda- century likewise reflect the inventiveness and technical exper- The Voith materials bear witness to a long tion only a few years earlier. There had been no systematic tise of the company. Indeed, the purchase agreement for the history. There are close to 10,000 in- Voith archives until then. Much of what is now properly ar- Brunnenmühle, now stored in the archives, represents the dexed items, dating back over 300 chived and indexed had been haphazardly stored in cellars and foundation of the Voith Hydro research and development cen- years to 1707 and stored on 200 meters cabinets in offices and boxes on the company’s premises. Some ter that is still making the company’s technical knowledge of shelving. Many of these old documents items were maintained as archives by employees on a casual available to its engineers from around the world. relate to hydropower, the oldest of the re- basis, including the most important documents and papers Certain qualities have characterized the company from newable energies, and they succeed in making from the company’s history. “We often obtained important the very first day of its existence: long-term, sustainable think- us aware of the unbelievably long history of this technology. materials by accident,” notes Hanitsch, as the result of moves ing and constant innovative genius. As Jutta Hanitsch says, There are sketches, design drawings and contracts for the first or cellar clean-up campaigns, or because attentive employees “Voith is a company that has always been modern.” In 1870, Voith turbines, delivered in 1870. That was when the company Witness to a long recognized the value of the materials they came across. Voith recognized the hunger for energy inherent in industrial- history: a turbine first developed its reputation as a hydropower expert, one it construction ization and began to develop and produce water turbines. still proudly holds. drawing from The oldest document involving hydropower actually pre- Today, hydropower is an important contributor to supplying The archive contains brochures and other promotional 1881 for a cus- dates Voith: an 1856 design drawing for a turbine including an environmentally friendly and reliable energy to modern indus- tomer in Bavaria. materials that provide a vivid reflection of their times and estimate of its power requirement. Even the casual observer trial companies and newly developing countries. Many of the Tradition as a marketing asset: historical turbine brochure, most serve as evidence of the longevity of the company and hydro- cannot fail to be impressed by the significance and age of the ideas of the past remain the basis of sustainable energy produc- probably from 1905. power technology: pen-and-ink design drawings, carefully materials. “Voith has an incomparable tradition,” comments tion using hydropower. //

22 | HyPower 2013 HyPower 2013 | 23 AGENDA SETTING

that has been around for a long time – view of an outsider, however, I can also some plants have been operating for say this: in its 140-year history, a great TRADITIONALLY over 100 years. At the same time, there many things have been done well at is a great potential for innovation, in ar- this company. We can be proud of our eas ranging from small hydro plants to capabilities. the use of ocean energy. I fi nd this com- INNOVATIVE bination extremely interesting. And what could be improved in the hydropower industry in general? After joining Voith Hydro in 2012, Chief Business What attracted you to join Voith? I am troubled by the occasionally nega- Voith is a hidden champion with an ex- tive image that hydropower still has for Development Offi cer Kirsten Lange refl ects on a year in cellent reputation, a company that suc- some of the public. The entire industry hydropower and plans for expanding aftermarket business. cessfully combines a long tradition and needs to act more decisively and em- set of values with a modern approach. phasize the advantages very clearly and This can be seen in both the strategy distinctly: a safe, stable energy supply and the day-to-day interactions with is the prerequisite for social develop- After a little over a year of working in son with thermal power stations. A third the customer. This special corporate ment opportunities and economic the hydropower industry, what fasci- aspect: the positive side effects, such culture really distinguishes Voith. growth. It can lead to greater educa- nates you the most? as fl ood protection and navigability. tional opportunities, increased prosper- What I fi nd intriguing is the fundamental When I lived in China in the 1990s I ex- Do you think these values are prac- ity, more jobs and improved living con- importance of hydropower. It consti- perienced myself how important these ticed actively at Voith around the ditions in developing and emerging tutes such a large share of renewable factors are. world? economies. As the biggest contributor energy, making a very decisive contri- Yes, defi nitely. They are a very unifying in the area of renewable energy, hydro- bution toward the attainment of climate What else has impressed you so far? element. We are represented locally in power has a vital role here. objectives. I am also impressed by just Hydropower is a unique combination of markets all over the world, and yet how effi cient it is, especially in compari- tradition and innovation. It is a sector there are the same strong values and You are in charge of aftermarket a common understanding of what is business, among other things. What important for the customer and what innovations and developments are “engineered reliability” means. there in this area? The service business is a global growth So, for you, Voith Hydro is both a market and a very important one. We global and a local company? want to be a comprehensive problem- We are active all over the world; there solver for our customers. Service is are very few companies globally that more than replacing parts, it is about have such a high share of sales – and comprehensive asset management. value-added – outside of their home There are many possibilities for us to country. And in all of these markets we contribute our technical expertise and Tell us about the developments in modern automation systems can be are truly local companies with local help our customers. the automation sector. simulated in real time. This is a solution employees. Automation is also a core component that has been very well received by Will these changes take place in for us. We have our own products in many of our customers. Where could Voith Hydro improve? conjunction with customers? the market and want to continue to I would like to move from an “either-or” It only works in close collaboration with grow. We have not only an integrated What would you like to see in the up- mentality to more of an “and” approach. our customers, when combining the spe- product offering for large plants, but coming year? In other words, instead of focusing on cifi c issues of our customers with our ex- also competitive solutions in individual I would like to see satisfied customers, either technology or costs, we need to perience and expertise to create win-win components. In modernization projects who notice time and again that we are think more about technology and costs. solutions. We are continuing to invest in particular a lot can be achieved with a reliable partner, not just for turbines “Service is more than just replacing parts; We won't put restrictions on techno- and we will further build our local pres- up-to-date control systems. Our spe- and generators, but also in automation we want to be a comprehensive problem- logical development just to save mon- ence. To this end, we already took over cialists are available worldwide, such and in the service business – in other ey. We want to be both quick and thor- Vortex Hydro earlier this year to strength- as in our automation laboratory in Brazil, words, that our traditional strengths are solver for our customers.” ough simultaneously. From the point of en our business in North America. where the advantages and efficiency of also effective in newer business areas. //

24 | HyPower 2013 HyPower 2013 | 25 successful partnerships

Powering Africa Sustainably After successful rehabilitation of Cambambe I in Angola, Voith will soon start a second project: the company’s biggest in Africa to date and a further step towards realizing the continent’s huge hydropower potential.

Voith has completed a major upgrade of the Cambambe plant on the Kwanza River. Now, a second plant is planned for the region.

he numbers tell the story. Al- population 47 million. All this is chang- in Africa to date. It will add 700 MW of “The national energy company, ENE, was very though Africa has an estimated ing rapidly, however. New hydropower power to Angola’s energy grid, almost T 400 GW of technically feasible developments are bringing sustainable doubling the country’s installed hydro- satisfied with the work we did on the first hydropower, its installed capacity is only energy to people and businesses all over power capacity. “The national energy around 25 GW. This means that Africa Africa, and many more projects are in company, ENE, was very satisfied with Cambambe project. Not only did we deliver has a higher percentage of untapped hy- the works. Angola – with an estimated the work we did on the Cambambe I on time, but the plant’s power output is even dropower potential than any other con- 18 GW of hydropower potential, only project. Not only did we deliver on tinent. Africa is a new frontier for hy- 4% of which has been harnessed so far – time, but the plant’s power output is better than expected.” dropower companies, and major projects is one of Africa’s most promising hydro- even better than expected. ENE had Patric Kiehlmann, Project Manager, Voith Hydro are coming on stream – none too soon power markets, and Voith Hydro is never tackled a project like that before for the continent’s population. ­rapidly expanding its presence there. and we have earned their trust,” says Only one in four people living in Patric Kiehlmann, Voith Hydro Project Africa has access to electricity, and sup- Voith Hydro supplied complete turbine Manager for both projects. Angola’s needs are great: over 70% of the government plans to boost genera- plies are often disrupted by blackouts. technology along with related equip- the country’s infrastructure was de- tion capacity from around 900 MW to The situation is especially dire in Sub- ment and services for the modernization Angola offers the right conditions for stroyed in a long civil war and since the over 6,000 MW by 2017, with a focus Saharan Africa, which has around 900 of the 1960s-era Cambambe plant on hydropower development, explains fighting stopped in 2002, the Angolan on hydropower and other renewables. million residents but generates about the Kwanza River, a four-year project Jörg-Peter Albrecht, Head of Sales and government has been engaged in a mas- In spite of Angola’s great progress, the same amount of power as Spain, completed in December 2012 that Marketing at Voith Hydro in Heiden- sive development drive. Fueled by oil getting projects off the ground is not

Africa upped the plant’s output by 40%. heim. “Not only is the country making and gas exports, international financing easy. Investors must cope with a hot cli- Now, Voith has been commissioned major long-term investments in hydro- and public-sector spending, the Ango- mate, limited transport infrastructure, a Hydropower in Africa to supply and install four generators power, but also commissioning Western lan economy achieved average annual lack of skilled labor, bureaucratic tangles, Installed capacity: 26 GW and turbines as well as controls and as- companies for its hydropower projects, GDP growth of 11.1% up to 2010. and problems left over from the war. Potential not yet installed: >400 GW sociated systems for a new plant in the even though these companies might cost The country continues to invest For Cambambe I, for example, it took same area: Cambambe II, with an order more. Because of its oil revenues, Angola heavily in infrastructure projects. Only six months to clear away landmines be- Ethiopia, South Africa, Angola and the DRC volume of over €100 million for Voith, has the means to go for higher quality, 30% of the population has access to fore a new spillway could be built, and – some examples of Voith’s presence in Africa. is one of the company’s biggest projects and is choosing to do so.” electricity (only 10% in rural areas), and throughout the project workers had

26 | HyPower 2013 HyPower 2013 | 27 successful partnerships

inVestinG in africa Why the World Bank Group is backing Voith technology at Cambambe II.

the World Bank has stepped up its support for hydropower projects in developing countries as part of its commitment to pro- moting sustainable, clean energy generation where it is needed most. The Bank’s defi ning vision for energy projects is the United Nations’ “Sustainable Energy for All” initiative. In line with this strategy, the World Bank group’s Multilateral Investment Guaran- tee Agency (MIGA) is providing essential sup- cambambe i is just one of a number of infrastructural investments made by the country in recent port for Cambambe II antonio Barbalho years as it strives to recover from a long civil war. is Sector Manager, by underwriting around Energy & Extractive €470 million for the Industries at MIGA. project’s international Prior to this, he held several senior posi- lenders. Antonio Barb- tions at Deutsche to stay within de-mined areas. Cultural we’ll continue to do this for Cambambe Other projects in Africa are also under alho is MIGA’s Sector Bank in the energy, diff erences also come into play, Kiehl- II. We have made a long-term commit- analysis, including in Angola and in the Manager, Energy and utilities and financial sectors. mann says. “The time factor was a chal- ment to Angola and to ensuring these DR Congo. Albrecht also cites Mozam- Extractive Industries, lenge. Angolans say to us Europeans: projects are sustainable.” bique, Zambia, Cameroon and Ethiopia and leads the team that ‘You have watches; we have time.’ as other potential markets. “Virtually is handling MIGA’s involvement in the Cambambe project. Things we thought would be done one the cambambe projects signal Voith any African country with hydropower “The critical message is that the World Bank Group is defi nitely day would not get done until the next Hydro’s increasing focus on Africa, resources is on our radar,” he says. supporting hydropower development in poor countries worldwide, day, or later. In addition, almost where the company has had a presence In addition to hydro potential, other whether the project is considered large or small in the country all materials for projects like this must as a supplier for decades. Voith was in- factors must be considered, such as sta- involved,” he says. “Of course, Africa gets a lot of our attention be imported and each shipment takes volved in Ethiopia’s Gigel Gibe II, bility and access to adequate fi nancing. because of the continent’s energy poverty, and our support for three months. You have to plan ahead.” which doubled the country’s installed “Large hydropower projects involve Angola in particular is part of our commitment to assist post-con- Since local workers on Cambambe I hydropower capacity and raised the per- high initial costs and international mon- fl ict countries.” lacked the skills needed to build, operate centage of the rural population with ac- etary bodies have often avoided them,” and maintain a modern hydropower cess to electricity from 15% to 50%. In says Albrecht. In recent years, however, in choosing its projects, MiGa focuses on sustainability. “What plant, Voith Hydro played a signifi cant South Africa, the company is providing organizations like the World Bank and matters most is that whoever develops a project, it must be sustain- role in human resources training. Kiehl- all the electromechanical equipment for the African Development Bank have in- able at every level, from costs to compliance with MIGA’s rigorous mann explains: “We provided support the Ingula Pumped Storage Scheme. creased their investments. Voith, too, performance standards, including environmental and social crite- beyond what our contract required and A further recent agreement will see has a role to play: for Cambambe II, the ria,” Barbalho explains. “We take a very holistic approach and we

ANGOLA Voith Hydro lead a consortium to mod- fi nancing is backed by cover from Euler monitor projects at every stage. One aspect of sustainability is clar- ernize the Inga I plant on the Congo Hermes and was structured and arranged ity in the legal framework, and in Angola we paid close attention to Hydropower in Angola River in the Democratic Republic of by Voith Financial Services. “Interna- the government’s plan for the power sector.” Installed capacity: 1 GW Congo (DR Congo). This €58-million tional funding is recognizing that hydro- According to Barbalho, MIGA is very satisfi ed with the project Potential not yet installed: 41 GW project for local energy supplier SNEL power has the best chance at reducing so far. “Our partnership with the Angolan government has been ex- will involve a comprehensive rehabilita- the carbon footprint and providing the tremely good. Their willingness to cooperate and fi nd the right so- cambambe ii is one of Voith’s biggest projects tion of two 55-MW generator-turbine most sustainable energy while driving lutions is defi nitely on the table. Cambambe is our fi rst energy in africa to date. units in the 1970s-era plant. the economic development.” // project in Angola, but we hope it will not be the last.” //

28 | HyPower 2013 HyPower 2013 | 29 SUCCESSFUL PARTNERSHIPS

The Budarhals power station is located on ccess to the site is not easy. About a one-hour drive from “The wind in Iceland the Tungnaá river, around 150 kilometers the nearest small town, along a road and across a new east of the capital, Reykjavik. A bridge, almost hidden from view, Voith engineers are in- can be harsh, and stalling electro-mechanical equipment, excitation systems, turbine it’s hard to work with governors, and mechanical and electrical auxiliary systems. The company is also providing powerhouse cranes and the control sys- a face full of sand.” tem, as well as handling both installation and commissioning. Lothar Ritter, Project Manager, When Iceland’s Budarhals plant goes online for testing at the end Voith Hydro Heidenheim of the year, it will run with a harnessed discharge of 240 m3/s, an installed capacity of 95 MW and an energy generating capacity of an estimated 585 GWh annually. The project is not without its challenges. “The weather was a

bit of a problem,” says Lothar Ritter, Project Manager for Voith ICELAND Hydropower in Hydro. “Especially when compared to some of our other projects, Iceland in India for example.” On some days, freezing blizzards made it vir- Installed tually impossible for the engineers to get from their accommoda- capacity: 2 GW tion to the site, only 500 meters away. Water seeped into the ma- Potential not yet installed: 15 GW chine area and froze in a sheet 30 centimeters thick. “We used heaters,” says Ritter matter-of-factly, “and we kept going.” Before Budarhals, Voith’s last full tur- A further issue is the wind, which whips up sand and grit from bine installation in Iceland was in 1912. the ground. “With little-to-no vegetation to o er shelter, the wind in Iceland can be harsh, and it’s hard to work with a face full of sand.”

In spite of the challenges of nature the Voith Hydro team is set to fi nish on schedule when the plant is handed over in January 2014. Indeed, the national power company in Iceland, Landsvirkjun, is also doing its best to respect the surrounding nature during con- struction. “We have a commitment to reduce waste and environ- mental impact at every stage of the project and have been working together with Voith to achieve this,” comments Kristján Kristins- son from Landsvirkjun, responsible for safety and environment on the project. “Waste from the building site is separated and recy- cled whenever possible. Accurate data is collected on how much waste is produced, and fuel consumption is carefully monitored to maximize e ciency.”

The Budarhals project also represents a welcome return to the MASTERING Icelandic market for Voith Hydro, which last carried out a full tur- bine installation more than 100 years ago, in 1912. The power plant at Fjardarsel was the fi rst of its kind in the country, the fi rst to generate alternating current. As well as housing a museum and visitor center, the plant is still running today – it is the oldest op- THE ELEMENTS erational power station in Iceland. When the Budarhals plant goes into full operational service early next year, this will be an important contribution to sustain- At the cold edge of Europe, Voith Hydro engineers are working When completed in 2014, the Budarhals able energy generation in Iceland, and Voith Hydro will once again power plant will have an installed capacity hard to bring the Budarhals Hydroelectric Power Station online. have played its part in writing a new chapter in the history of green of 95 MW. energy in the country. // HyPower 2013 | 31 FULL-LINE SUPPLIER FULL-LINE SUPPLIERSECTION

simply continue to flow over the existing THE POWER OF AUTOMATION construction, avoiding any flooding of the surrounding area.” The project was Voith modernizes one The height of a 15-story building and support the original technology any- recognized by the European Union for of Canada’s largest the length of three football fields, the more,” says Sidney Martz, Offer Project its minimal impact on the Elbe’s land- subterranean Churchill Falls Generating Manager at Voith Hydro in Montréal. scape, qualifying for financial support hydropower plants. Station, with its 11 Francis turbines, “As this system is the brain of the whole from the European Regional Develop- has a capacity of 5,428.5 MW, produc- plant, if you have a breakage, you can ment Fund. The extra money ensured es 34 billion kWh of energy a year – have a serious problem. It’s vital that that nature conservancy requirements roughly 1% of the world's hydroelectric the customer can get spare parts.” The could be better addressed. power. Located in the Canadian prov- new generation of automation is all Since the conversion, life has be- ince of Newfoundland and Labrador, electronic. “You’re able to have much come much easier for the local fish. The the plant opened in 1971. It was the more control and input, to conduct me- previous weir had no measures in place largest civil engineering project ever un- tering, prevention and maintenance,” to protect migrating fish species swim- dertaken in North America at the time. Martz says. The largest of their kind in Europe: the Kaplan pit turbines at Litoměřice ming upstream; they had no way of It's the second-largest underground hy- Ronald Rochon, Business Develop- getting past the obstacle in their path. droelectric plant in Canada, and ninth- ment Manager at Voith Hydro for East- However, the conversion equipped the largest in the world. ern Canada, says the upgrade will help structure with a fish ladder – “a clear With the units having given 40 future-proof the plant by standardizing sign of progress,” says Boden. Thanks on a modern system. “This does not to the fishway, fish traveling upstream CANADA Hydropower in years of service, the Churchill Falls Lab- Canada rador Corporation Limited (CF(L)Co) de- only apply to this plant, but also to oth- can now reach their spawning grounds. Installed cided to replace unit controls, exciters, ers that customers are going to be MAXIMIZING RESOURCES This successful solution in Litoměřice capacity: 74 GW protection, communication and gover- looking at modernizing.” Thanks to has spurred on further work 20 kilome- Potential not yet nor controls for the 11 generators. modern systems, power output is set to In the Czech Republic, Voith Hydro is proving ters upstream, where the project is installed: 162 GW Components will be replaced at a rate become more reliable, which is proba- that supplying green energy can be achieved by currently being replicated at Štětí. Voith Churchill Falls is the second-largest of one to two units per year, commenc- bly the No. 1 factor for the customer. adapting existing infrastructure. Hydro is in the process of installing two hydropower station in Canada. ing in 2014. “Manufacturers do not “The new systems will provide better identical pit turbines for the Štětí hydro- control and diagnostic, and the reaction power station. The conditions there are time is much faster, giving more stability To generate energy from water, it is simply ran over it unused,” explains comparable, with a weir also being to the whole system.” not always necessary to build brand Herbert Boden, project manager for retrofitted. new hydroelectric stations. With many Voith Hydro in St. Pölten, Austria. “But Voith must work against the clock to of the weirs and dams found in Europe’s now, this untapped potential is being Remaining flexible while working with install the new system during sched- rivers and waterways not being utilized put to use.” what nature has provided has been the uled outages, says Martz. “It’s a big job for power generation, considerable un- Driven by the Elbe’s current, the key to the success at Litoměřice and and it must be done in a very short tapped hydropower potential exists. power station has two 3.5 MW Kaplan Štětí. “In both projects, we intensively time, because the customer still needs Take Litoměřice. This small Czech pit turbines, each measuring 5.1 meters discussed the on-site factors and made to guarantee some operation.” town is located south of the Bohemian in diameter – the biggest of their kind in adjustments accordingly,” says Boden. To date, Churchill Falls is the largest Forest and 60 kilometers north of Europe. This record-setting size is a “As a result, we were able to come up Controls and Automation project under- Prague, where the Elbe meets the Eger. result of the low fall height of slightly with an optimal solution to utilize existing taken by Voith in Canada, notes Pierre Protecting the landscape and preserving over 2.5 meters at the dam wall. “The weirs on the Elbe despite the challenge Seguin, Head of Business Development natural resources have always been subsequent electrification of dams is of dealing with a low fall height.” // for Voith Hydro in Canada. “Strategical- local priorities. That also applies to the especially sustainable because we are ly, this project was identified as a target power supply. Litoměřice covers almost upgrading existing parts of the weirs to propel our Voith automation products its entire electricity demand with renew- and putting them into use. As a result, and systems in Canada.” Cooperation able energy, with hydropower contrib- any impact on nature and the environ- CZECH REPUBLIC Hydropower in the with Voith Hydro in York was vital in uting since the end of 2012. To do so, ment is kept to a minimum,” explains Czech Republic helping to guarantee the project’s suc- an existing weir was converted and Boden. Installed cess, he adds, with assistance in the upgraded, meaning the station now This is a key factor for residents in capacity: 2 GW development strategy as well as through supplies around 12,000 households the Litoměřice region because most of Potential not yet continual technology transfer. “This, in with green electricity. them earn a living from their vineyards, installed: <1 GW

After about 40 years of service, CF(L)Co decided to replace control systems at Churchill Falls. turn, will add to our consistent growth “Prior to converting the weir into a fruit orchards and grain farming. “During The Litoměřice station provides around Electronic automation will enable optimized operation thanks to more available information. in the automation market in Canada.” // hydropower station, the Elbe’s water construction, the river’s water could 12,000 households with green energy.

32 | HyPower 2013 HyPower 2013 | 33 Sectionfull-line supplier SECTION

Beyhan I is the first of four hydropower plants in this area of the Murat river. Voith Hydro is fitting the plant with three generators. far-reaching potential

Away from the beaches of the tourist ccording to calculations, Turkey holds 16% of Europe’s under 30 MW. “We have been able to establish ourselves as a There are challenges in expanding the Turkish energy market. resorts and the cultural highlights hydropower potential. On a global scale, it makes up strong partner for our customers in Turkey,” says Dr. Leopold Much of the grid infrastructure is old and overloaded, leading A 1% of the world’s entire hydropower potential. A total Heninger, CEO of Voith Hydro in St. Pölten, Austria. “With to power outages in certain areas. And while the country pro- of Istanbul, Turkey is home to a of 25 river basins and a varied topography combine to provide this large-scale project, we are further strengthening our posi- duces most of its own electricity, as of 2012, only 26% of the vast natural resource crucial to its the drops necessary for hydroelectric generation. tion as a leading hydropower supplier in this country.” total primary energy consumption was based on local resourc- continued development. “Without doubt, the potential for hydropower plants here es, leaving Turkey reliant on foreign suppliers with the worry is enormous,” says Dr. Artur Pfeiffer, General Manager for In the north of Turkey at Kargi, close to the Black Sea coast, of currency fluctuation and dependence that this entails. Voith Hydro in Ankara. “It is estimated at up to 60,000 MW of another plant is under construction. The Norwegian energy Thus, utilizing local resources is key. In order to redress technically feasible projects, of which 45,000 MW are consid- company Statkraft has awarded to a consortium led by Voith the imbalance and provide the energy that Turkey will need to ered economically viable under current conditions. There are Hydro the construction of a new facility on the longest river in progress, the country has been undergoing a process of deregu- currently 20,400 MW of hydropower plants in operation, ac- the country, the Kizilirmak. lation, opening up the energy market for foreign investors. counting for 34% of total installed capacity. 6,000 MW of hy- Voith Hydro is supplying the entire electromechanical This has led to a construction boom and a very competitive dropower plants are currently under construction.” systems for the 102-MW facility in a turnkey delivery, a com- market. The goal is not just energy independence for future mon solution in the Turkish market. “In Turkey, turbine, gen- growth, however. Turkey wants to establish itself as a modern O ne of these new projects is the Beyhan I plant in eastern erator, automation and electrical balance of plants are usually energy-trading hub, using its location to connect the EU with Anatolia, on the Murat river. It is the first of a planned cascade tendered as one package,” says Pfeiffer. “For large projects the energy markets to the east. To this end, an energy exchange will

Turkey of four hydroelectric plants on this stretch of river, and Voith equipment is designed and manufactured by Voith Hydro in be launched in October, with electricity futures trading. Hydro is providing Beyhan I with three generators, each with Austria as the market responsible for Turkey, while local man- Hydropower in Turkey an output of 235 MVA, as well as excitation and monitoring ufacturing and installation is done by Voith Hydro in Turkey.” The future is bright as far as new construction projects is con- Installed capacity: 21 GW systems. This is the largest order Voith Hydro has ever filled And Turkey needs power. At the moment, energy use is cerned, but other opportunities await. As older facilities are Potential not yet installed: 39 GW for a private client in the Turkish market, and the continuation still low, with the average per-capita consumption one third of privatized, the new commercial owners will look to modern of a long tradition. Voith Hydro has been market leader in the that in the EU, but that is all set to change as the economy technology solutions to increase efficiency and maximize their Voith Hydro has been active in Turkey for 75 country for 75 years, supplying equipment and expertise for grows. Within a decade, Turkey is expected to overtake Britain output. “This should open up great potential for the rehabili- years and has worked on more than 100 projects. over 100 projects, from the largest facilities to small systems as the third-largest consumer of electricity in Europe. tation business in the future,” concludes Pfeiffer. //

34 | HyPower 2013 HyPower 2013 | 35 full-line supplier

n early pioneer in hydropower, Switzerland maintains a leading Big PLans for A position in the sector today, generating around 60% of its electricity by hydropower. While it already gener- small Hydro ates 85% of its technically feasible potential of 41,000 GWh per year, it is Hydropower may be long established in Switzerland, ambitious about developing further. but scope for further development remains. New The Swiss government features hydropower substantially in its plans to and refurbished small hydro plants hold the key to source half of the country’s total energy the government’s ambitious renewable energy goals. needs from renewable supplies. Several new schemes, many of them for pumped storage, are under way or planned, but there are also extensive opportunities for the refurbishment of aging existing installations large and small. In particular there is scope for new small hydro schemes and an even larger opportunity for refurbishments of the approximately 1,000 existing small hydro plants of up to 10 MW. The total combined capacity of these plants is 780 MW. “Small hydro has significant Moulinets’ narrow Switzerland streets made access potential in Switzerland,” confirms Hydropower to the site tricky, Georg Neuber, sales and project engi- while the steep, Installed capacity: 14 GW neering manager at Kössler, a Voith rocky banks on either Potential not side of the river yet installed: <1 GW Hydro subsidiary in Austria specializing presented a further in small hydro. “Many old plants have logistical challenge. There are over 1,000 small hydro plants of up to been closed or are due to be refurbished. 10 MW in operation in Switzerland. A number of them are 70, 80, even 100 years old and must be rebuilt with new or in villages or towns, as they often are. Kössler has had to innovate to meet cient, says Hochleitner. “Direct-drive turbines and generators.” Kössler also had responsibility for both strict new environmental and noise generators with no gearbox, for exam- the design and installation of the Mouli- requirements for schemes such as these, ple, can run at low speeds to avoid vibra- Two recent installations handled by nets plant. Installing the unit presented says Hochleitner. “We are finding solu- tion and noise. A gearbox solution may Kössler are good examples of the poten- a range of practical challenges, says tions – for example, the use of water- be cheaper initially but in the long term tial as well as the challenges facing mod- Gerald Hochleitner, Head of Design cooled generators – as well as modifying it’s better in relation to maintenance and ern small hydro schemes. The 1.8-MW Engineering at Kössler. “This was a the construction process. In Tambobach reliability to avoid a gearbox.” capacity Tambobach plant has been gen- unique project that demanded a some- we modified the turbine housing to re- erating electricity since the autumn of what different approach with special duce noise levels by encasing part of the Despite these positive developments, 2012, using water from the catchment materials. It was a challenge due to the housing in concrete. From the outside it the sector has faced economic challenges area of the River Tambo. Projects like limited space during construction, mak- looks small and flat and there are no in recent years, with the crisis in Europe these must meet strict environmental ing it difficult to move the machines openings for aeration because the affecting investment, says Neuber. safeguards on noise levels and vibration, into position. There were also challeng- generators are water-cooled. Every- Volatile energy prices are also a fac- especially when they are located close to es with the positioning of the turbine thing is maintenance-free, with oil-free tor, with low prices due to solar and wind relative to the generator.” Fortunately, designs eliminating the risk of waterway power. “It makes funding these schemes the installation went as planned, says pollution.” more difficult. I think the market will Hochleitner. “It was a perfect execution. And there is further scope for inno- remain this way for the next year or two, The Tambobach plant produces 7.2 million The team operating the mobile crane vation that will make future installations but there is certainly a future for it. We kWh a year – enough for 1,400 households. did a lot of preparation on the road.” cleaner, more reliable and more effi- will see new projects happening.” //

36 | HyPower 2013 HyPower 2013 | 37 GLOBAL EXPERTISE

UNITY IN DIVERSITY At Voith Hydro Mississauga, employees from around the world, as far-fl ung as China and Burkina Faso our goals as a team comprising unique – 15 nationalities in all – strive to achieve personalities and diverse backgrounds. both young and old, are cooperating to help boost customer satisfaction. INNA KREMZA top-notch performances from turbines Working together is where we really and generators for a variety of demand- shine.” In this context, technical training Head of ing customers. in what are known as “Lunch and Learn” Engineering --- Inna Kremza, who heads a team of sessions, where senior employees hold Nationality: Ukrainian 20, explains: “Voith in Mississauga is a lectures on a certain component or sys- --- center of excellence and a worldwide tem, are proving to be an inspiration. Languages spoken: Ukrainian, English, supplier of multi-turn stator coils. We Anyone can attend, and young profes- Russian have more than 35 years of experience sionals can turn to a senior colleague in modernizing and refurbishing hydro for guidance. generators through a full-service, 24/7 This was the case for Mehrzad package. An example is our client, Shahouei. Originally from Iran, he has FORTIS. They called to say the genera- been working as a senior turbine engi- NENAD VUJCIC tor’s main leads had burned out and neer at VHMS since 2008. His unique Mechanical damaged the stator winding. Within 24 20-year experience in hydroelectric tur- Designer – hours, we had sent an engineer to as- bines, unlike that of his colleagues, who Generators --- sess the unit and proposed a solution.” are more skilled with generators, has Nationality: Such quick response times require sparked renewed customer interest in Serbian in-depth knowledge of equipment from turbine rehabilitation. --- Languages spoken: all major manufacturers, she adds. Neal Cumming, a young Canadian Serbian, English trainee and mechanical design en- Key skills in the team include knowl- gineer, has worked in the depart- edge of reverse-engineering processes ment since 2012. Neal is benefi ting and hydropower. But most young grad- from Shahouei’s expertise. “Rehabilita- NEAL CUMMING

uates have yet to learn the ropes – at tion projects require quick solutions to Mechanical this point, theory and practice simply issues that cannot be foreseen in an ini- Designer – Turbine must merge. Mentoring at group and tial assessment,” Cumming explains, --- Nationality: individual levels proves crucial, ensuring before adding, “Mehrzad is very open Canadian that an enriched transfer of knowledge and lets me fi gure out problems.” For --- Engineers of different backgrounds and experience levels work together to provide top service. ensues, bridging generations and hon- Shahouei, it is important that all designs Languages spoken: English ing expertise on every echelon. are approved based on a common de- Nenad Vujcic joined Voith Hydro in cision made by the turbine team, in- 2012 in a supportive role as a mechani- cluding young engineers. “The diverse cal designer. After quickly impressing input makes our work more dynamic.” Imagine arriving at Voith Hydro Missis- units in Quebec, she says. They have to both his colleagues and his clients, he MEHRZAD sauga (VHMS) to start your new job as be modernized to increase generator has already moved up the ladder to be- “Clients are often impressed by our SHAHOUEI a trainee mechanical designer – you power to earn more revenue. Then, come the lead engineer on a seven- professionalism and creative approach Lead Engineer – overhear a colleague chatting in Persian Nenad Vujcic, a young engineer from person team. Everyone’s input is to problem solving,” says Kremza. Turbine (Farsi). Mehrzad Shahouei, an engineer the Serbian capital, Belgrade, arrives considered, regardless of hierarchy, Her background also comes in --- Nationality: from Iran, then welcomes you in Eng- with a progress report on another proj- emphasizes Vujcic. Coupled with diver- handy when communicating with new Iranian lish. Seconds later, head of engineering ect. This polyglot of languages and sity of culture and experience, such fac- customer Saratov Hydro Generation, --- Inna Kremza, from Ukraine, enters the diversity of cultures is reality in the engi- tors are key to the team’s success. for whom VHMS is supplying stator Languages spoken: English, Farsi, Kurdish offi ce. A customer is coming to review neering section at VHMS in Greater “The most important aspect is that no winding coils; she speaks fl uent Rus- manufacturing of multi-turn coils for fi ve Toronto. There, people from countries individual is above another. We achieve sian as well. //

38 | HyPower 2013 HyPower 2013 | 39 GLOBAL EXPERTISE

The key to successful on-site security is detailed risk as- sessment. “Once risks are identifi ed,” explains Rosenbach, READY FOR “the necessary measures can be taken to deal with them.” With years of experience in the fi eld, he has come across just about everything. These experiences range from troubled ar- eas in the Congo and Angola to Columbia and Kashmir, and ANYTHING cover a variety of security issues, from areas suffused with ethnic tension to sites in danger of attacks by rebel groups. With hydropower plants located in some But the odd incidents, as well as the dangerous ones, are at of the world’s more remote, unusual and the forefront of Rosenbach’s mind, such as receiving fi nger- print “signatures” from ministry workers in Afghanistan; fi nd- sometimes dangerous locations, the ing the telephone in an Iranian hospital in the disinfection company’s security and logistics teams ward; or discovering a site with snakepits instead of a fence. must be prepared for every eventuality. Not quite as dramatic, but certainly as important in ensuring successful project completion, is the work of Gebhard Sal- cher, Head of Voith Hydro Field Services. Similar to Rosen- bach, working in remote locations is central to Salcher’s remit. The fi eld services team oversees the installation and commis- sioning of partly prefabricated components, and as with secu- “If you ask me to tell you anecdotes about what I've expe- rity, good planning and fl exibility underpin everything. “If a rienced around the world, that could take some time – be- problem arises,” says Salcher, “we can’t just claim it’s not in cause there are a lot,” says Winfried Rosenbach, Head of the plan. It doesn’t matter what the problem is – with us, on Corporate Security at Voith. Guards at a site in Angola carry- the civil side or a subcontractor – we have to come together ing weapons but no ammunition, having no radios and just to deal with it. The focus must always be on the whole proj- one shoe – that’s one example. An aircraft at full speed swerv- ect.” As an example, Salcher cites the installation of a pow- ing round a pothole in a runway in Congo is another. Or, more erhouse in the United States, where the crane intended for intimidating, the nervous atmosphere in Kashmir, created by the job could not lift the huge parts being embedded. He the bubbling political confl ict in the contested region where came up with a fl exible solution that by-passed the approved Voith Hydro works on the Baglihar hydropower plant. plan, changed the sequence of installations and ended up It can be a challenging and nerve-racking task to develop successfully fi tting the unit. fi rst-rate security for sites and employees as well as logistic Salcher and his team also ensure that skilled workers and processes for complex hydropower projects across the globe. the right equipment are in position for each project – some- While not all the issues are as dramatic as those in Kashmir, thing that’s complicated in remote areas of Tibet, Iran and geopolitical challenges, sometimes fraught with danger, have China. Cultural differences naturally play a role, too. It is only an impact on sites, particularly in isolated locations. In such by using those decades of experience and garnering the help cases, Voith’s security expertise, detailed planning, fl exibility of local experts that projects get completed. He fondly recalls and overall project management come into their own. working with four female engineers in Tibet, jointly coming up Due to the special locations of the sites, around 75% of with solutions by communicating in “an unconventional mix of security issues for the Voith Group involve the hydropower Chinese, Tibetan and English.” business, says Rosenbach. The company is one of a few Largely unheralded, security and logistics clearly play key globally active fi rms ideally placed to deal with many of the roles in maintaining Voith’s exceptional standing in the hydro- most trying security issues. Voith is part of the Global Player power industry. With every project prone to throwing up unex- 1 Initiative, set up by Germany's Federal Criminal Police Offi ce, pected challenges, expert planning can take a project only so and in cooperation with other fi rms, offers security advice and far. The realms of security and logistics, however, perfectly 2 3 4 support wherever and whenever it is needed. Indeed, such is highlight that with the right ex- 1 Diffi cult access: works the excellent reputation of Voith in the fi eld, various partners pertise and a high degree of inside a cavern. rely on the company for much of their own on-site security. fl exibility, even seemingly in- 2 Challenging transport of The issues in question are wide-ranging, from the dangers of tractable problems in the most heavy components. 3 Lifting of a pump spiral. kidnapping or local crime to the more sedate considerations challenging locations can be 4 Security assessments in- of hospital facilities and perimeter fences. overcome. // clude housing conditions.

40 | HyPower 2013 GLOBAL EXPERTISE WORLD OFSECTION VOITH WORKING ACROSS BOUNDARIES

The Dasque Creek project demonstrates the value of a fully integrated offering.

The wheel is now turning full circle in all types of manufac- Securing the contract against stiff competition reflected turing industries. For years many producers have tried to im- Voith’s underlying strength as a fully integrated hydropower prove their cost competitiveness by subcontracting. Today, company that shares technical knowledge between design- however, customers are increasingly recognizing the real ers, engineers and factories worldwide, explains Eric Leblanc, value to be added from doing business with large, fully Head of Small Hydro at Voith Hydro in Canada. ADVANCED integrated suppliers with genuine global reach. Voith fits The project was thus a joint effort of Voith Hydro in Cana- TURBINE squarely into that camp, as demonstrated by one relatively da, the two Voith Hydro locations in India, and Voith Hydro in small but significant recent hydropower project on Dasque Sweden, as well as a partnering company in Bangalore. The VOITH LAUNCHES NEW BLUELINE PRODUCT CONTROL Creek in British Columbia, Canada. After receiving a request specialized units each contributed with their engineering and PORTFOLIO FOR PAPER PRODUCTION for proposal from Veresen Inc., Voith opted to submit two manufacturing expertise to the project, with one location be- LINEAR DRIVES – Voith Turbo workable, but quite different, solutions. Eventually, the client ing responsible for the complete system engineering, another NEW PRODUCT LINE – Voith Paper has launched its new BlueLine product portfolio for has unveiled a new turbine decided for the installation of two units with different capaci- supplying the generator units, while a third location provided waste paper treatment. BlueLine features new or improved components that all have control system, which offers ties: a 4.8 MW and a 10.3 MW Francis turbine. The entire two fully assembled and tested turbines, along with all related one thing in common: They save energy, water and fibers with very low levels of mainte- high performance combined arrangement enables the hydropower plant to achieve a con- equipment. This division of work has advantages also for the nance. The first BlueLine machines have already been installed at various paper mills. In with cost-effectiveness and sidered balance between energy production and flow ramping client: As a result of the specialization in manufacturing cer- particular, the new disc filter, which is used for stock preparation, has demonstrated very reliability. The new electrohy- over 12 hours, taking into account the owner’s technical re- tain components, the particular expertise and quality assur- good results. By adding a new disc filter with a corrugated surface, capacity is increased draulic linear drive regulates quirements and the need for compliance with the licenses and ance contributes to developing a deep understanding of the and there is no need for a filter bag, making maintenance a minor concern. The installa- control valves on turbines pre- permits for the project. client’s needs and sustaining a strong customer relationship. tion and startup proved to be easy and problem-free. Holger Hampel, director of the cisely and dynamically. The Schönfelder paper mill in Annaberg, Germany, emphasizes: “We were impressed with drive is self-contained and op- Voith’s ability to work across boundaries, specifying solu- how quickly and flawlessly Voith commissioned and implemented the disc filter.” The erates completely without a tions and sourcing components from its in-house suppliers, is BlueLine project is still ongoing: Other resource-saving Voith components for waste pa- hydraulic power pack. An inte- the only way it believes it can ensure consistent delivery of per treatment are already in development. // grated spring assembly allows value and quality to customers. “Voith simply does not com- the drive to close its control valve in less than 200 millisec- onds in the event of a mal- “Voith simply does not DIW BUILDS CHINA’S drops below a certain value. With this function. The linear drive energy-efficient lighting management, DIW works as a Plug & Play solu- compromise on quality.” BIGGEST LED has implemented a sustainable approach tion, suitable for both new Eric Leblanc, Head of Small Hydro at Voith Hydro in Canada INSTALLATION and therefore meets the criteria for a LEED systems and existing equip- certificate. Voith continues its work to ob- ment. The design of the tur- EFFICIENT LIGHT CONTROL – 480 lamps tain a LEED Gold Certificate, which would bine control system allows it promise on quality,” Eric Leblanc points out. “We are able to fitted with 1,920 LED tubes, spread across allow the company to rank among the top to reduce energy costs by up ensure consistent quality standards, no matter which factory 15,000 m². These are the numbers behind 10 manufacturing companies in China. // to 50% and ensures lower

a machine is produced in.” During the initial phase at Dasque the new Voith Paper production hall in CO2 emissions to contribute Creek, for example, careful analysis was undertaken to look at Kunshan, China. Here, DIW has devel- to climate protection. The the balance between transport costs and local manufacture. oped and realized a new energy-efficient modular design also enables The importance of the customer’s reliance on Voith’s engineer- lighting concept in just six months. All very flexible integration op- ing integrity cannot be overstated, he adds. “Because we have lighting in the production hall is now com- tions in turbine control sys- strong systems for sharing information and we fabricate in our puter-controlled. This allows the lamps to tems. Installation into new own factories, it means the client can be reassured about our respond to the daylight conditions through systems or during a retrofit is

Quality: Voith’s global reach ensures quality commitment to them. That reassurance on quality can be hard a DALI system, which ensures that they therefore kept simple, quick products that fit every client’s needs. to quantify, but we know it is significant to the customer.” // are only switched on when natural lighting and cost-effective. //

42 | HyPower 2013 HyPower 2013 | 43 GUEST PERSPECTIVE THE FASCINATION OF WATER Displayed around the world, English “The sound of a waterfall or a babbling brook can be beauti- artist William Pye’s works highlight ful,” explains an enthusiastic William Pye. For a leading sculp- tor who has become renowned for integrating water in such his lifelong attraction to the beauty an elegant way into his art, expounding on the beauty of his and power of water. principle inspiration is no surprise. Pye’s fascination with water, however, is much more pro- 1 found than his sculptures alone: “The physicality of water is 2 3 also a major part of the attraction.” He talks with passion about visiting Kielder Water, a large reservoir and hydro- electric plant surrounded by a forest park in the north of England, and watching in awe as the 2.5-meter inlets were 1 The Aquarena sculpture in opened and “columns of water many metres in diameter Bristol, UK, combines run- ning water with a stainless- belted out.” He describes it simply as “thrilling.” steel planetarium sphere. Citing other “hydro-electric schemes,” Pye has a fascina- 2 Pye’s personal favorite, the tion with what he calls “the power of water,” though his own Salisbury Cathedral Font in Wiltshire, UK. particular use is clearly somewhat more refi ned, if equally 3 Only by taking a cable car alluring. His water sculptures grace numerous corners of the can viewers discover the globe, with his work on permanent public display in countries secret atop Attica. such as Brazil, Canada, Hong Kong, Norway, Spain, and across the length and breadth of England.

With a father who was a noted engineer, and later became “As you climb the mountain, fl owing down a mirror-polished surface. And if you are obser- the president of the prestigious UK Institute of Mechanical En- vant, you will notice that it appears to be an Attic helmet.” gineers, and an infl uential aunt who was a sculptor, perhaps you see this wonderful abstract there should be little surprise that Pye took from both shape with water fl owing down Now in his mid-70s, Pye is as busy and enthusiastic as ever. disciplines when he made his way as an artist. After attending He travels the world for his art and is currently working on a the Royal College of Art, he worked predominantly with a mirror-polished surface.” piece in Baku, the capital of Azerbaijan. Pye’s own favorite, stainless-steel cables in order to refl ect “very fi ne shafts of William Pye, water artist though, is his cruciform-shaped font in England’s Salisbury light.” He soon discovered, however, that pairing water with Cathedral, a fi ne example of the artist’s deep appreciation of stainless steel had an even greater impact, and water has fea- With many vaunted works under his belt, Pye is actually best placing contemporary works in historically signifi cant settings. William Pye tured in most of his works since. known for Aquabar, an installation at London Gatwick “The basic principle is that there is water constantly fl owing 1938: Born in London Though born in London, and still retaining a house in the Airport’s North Terminal, which is made up of three transpar- from spouts at four corners,” he says, “with the life-giving 1958-1961: Studies at the Wimbledon School of Art 1961-1965: Studies at the Sculpture School of the Royal College of Art British capital, Pye’s family spent a great deal of time at a ent vessels of different diameters. As the vessels are fi lled with properties of water expressed in this font.” 1960s: Makes name as expert in creating refl ective stainless-steel property 40 miles southwest of the city, on common land now water, passengers stand transfi xed as air-core vortexes surge William Pye’s fascination with water – whether it is sculptures designated as an area of outstanding natural beauty. On this upwards, subsiding only when the water reaches the rims. delighting in the sounds of a “babbling brook” or gasping at 1969/70: Makes transition to combining stainless steel with water for their complementary form, movement and refl ective qualities ground, which he now owns, “I built a waterfall across the An arguably more fascinating piece, however, is Attica, the might of hydro-electric power – has informed his art for 1970s – stream that runs through the garden when I was 17 years old. commissioned by a wealthy Greek businessman who owns a decades. His work is refi ned and mesmerizing, never icono- present day: Wins numerous commissions, with highlights such as The magic of the place, with water all around, gave me a site north of Athens. Ingeniously, visitors only discern the se- clastic, and best seen when he engages with areas rich in Downpour (British Embassy, Muscat, Oman); Water Wall (Seville, Spain); Cedra (Sussex, UK); Vannpaviljong deeply routed fascination with water. It was natural, therefore, cret atop this towering, shiny metallic sculpture when rising history. Few better than in the contrasting locations of Athens (Drammen, Norway); and Caribdis (Campinas, Brazil) that at some stage this enchantment would be refl ected in my up the adjacent cable car. “As you climb the mountain,” ex- and Salisbury Cathedral, two centuries-old sites graced with work as a sculptor.” plains Pye, “you see this wonderful abstract shape with water creative works from an innovative sculptor. //

44 | HyPower 2013 HyPower 2013 | 45

SECTION

to education, while jobs and infrastruc- ture are created.

Nevertheless, there is still criticism

from some areas of the environmen- Cambambe-I, Angola: Rehabilitation of 10 four 67 MW Francis turbines. 11 Cambambe-II, Angola: Supply of four new 179 MW Francis turbines and tal impact of hydropower. How does 195 MVA generators, plus control and associated systems. 12 Inga-I, DR Congo: Rehabilitation and supply of two 55 MW turbine-generator units. it all fit together?

All large infrastructure projects have an impact on the environment and result in changes for local people. I’m convinced, 9 though, that the advantages of hydro- power far outweigh any disadvantages. Of course relocation is a burden, but ul- timately it leads to improvements. The Three Gorges Dam in China, for exam- ple, has made a considerable contribu- Supply of three sets of Xiluodu, China: Supply of three sets Kargi, Turkey: Complete electro- tion to the country’s economic and Beyhan-I, Turkey: Supply of three mechanical equipment including two turbines and generators. Francis MW 51 9 784 MW Francis turbines and generators. monitoring systems. monitoring systems. 8 vertical Pelton turbine. 7 235 MVA generators, excitation and social development. It also provides

people with much improved flood pro-

tection – in an area where, in the first half 7 of last century, millions lost their lives 8 due to a complete lack of flood control. 4 6

11

5 Social aspects in particular are often 12 10 the focus of criticism. I’ve personally visited a number of large hydropower sites. I’ve been there before a project has started and seen poverty, 3 Supply of Tambobach, Switzerland: Supply of inadequate living conditions and a lack Litoměřice, Czech Republic: Dam Moulinets, Switzerland: Supply of two complete generating unit with 1.8 MW complete generating unit with 1.8 MW auxiliary systems for the 95 MW plant. 4 upgrade with two new 3.5 MW Kaplan pit turbines, associated controls systems and synchronous generators. 5 0.6 MW Kaplan pit turbines plus generators. 6 COFFEE BREAK of infrastructure. I am convinced that lo- cally produced energy from hydropower Voith Hydro CEO Dr. Roland Münch on the ecological contains many long-term benefits. Local ­ as well as social sustainability of hydropower. development brings schools and hospi-

tals, giving access to education and 1 medical care. The key is that local inhab-

Dr. Münch, coffee consumption has of developing countries… itants have a choice, that they have new Complete electro risen considerably in recent years, … which is something that you could perspectives and opportunities for edu- particularly in developing countries. also apply to hydropower. As the larg- cation, prosperity and a better future. Do you recognize parallels with the est provider of renewable energy, it hydropower industry? plays an important role in sustainable Do you also provide institutional

There are certainly some similarities: energy supply, particularly in develop- support for sustainability? Budarhals, Iceland: two new 10.3 MW and 4.8 MW Francis two new 10.3 MW and 4.8 Francis turbines and generators. 3 mechanical equipment, turbine governors and

developing nations, particularly those in ing countries. The local populations of For years, we have been campaigning 2 South America and Asia, are among these countries can certainly all benefit for high standards in hydropower proj- the most dynamic markets for hydro- from this. ects by working together with organiza- power. This is where we are seeing the tions such as the International Hydro-

strongest growth in demand for envi- In what way? power Association. We were involved in Replacement of ronmentally friendly energy supplies. Hydropower provides a secure and af- the creation of the Hydropower Sus- fordable source of energy. It contrib- tainability Protocol. As a supplier, we The demand for sustainably pro- utes to economic and social develop- can’t have the decisive vote in how duced coffee is rising around the ment, and so to an improvement in projects are run, but we are contribut- world. This is beneficial for residents living conditions: people receive access ing as strongly as possible. // PROJECT DIRECTORY Supply of Canada: Supply of Dasque Creek, 46 | HyPower 2013 HyPower 2013 Churchill Falls, Canada: | 47 All plants mentioned in this issue and All plants mentioned in this issue and scope of supply Voith’s 1 automation/control systems in the 5,428.5 MW underground hydropower plant. 2 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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