More. Powerful. Solutions

HyPower The magazine for: More. Powerful. Solutions.

Issue three November 2002 Summary

03 Editorial 24 Higher reliability with improved Voith Siemens Hydro Power Generation Pelton turbine nozzle design Expertise for growth 25 Kaplan turbine rehabilitation – 04 100 years of hydro electricity in Turkey – San Men Xia anti-erosion research project 100 years of Voith Siemens Hydro in Turkey 26 Numerical calculation 08 Sharp growth in the Iranian of unsteady flow in draft tubes hydro power market 28 Hydrovision 2002, Portland, Oregon, USA – 10 Voith Siemens Hydro a review continues to be the world leader in pump-turbine technology 30 Succsessful IAHR symposium

14 Streamlining project management 31 SHEC to participate in EP China 2002 and completing 450 MW project in record time 31 Upcoming: international seminar in Vienna

15 Change in the management 32 Recent contract awards of Voith Siemens Hydro, Brazil 34 Essay 16 Advanced governor technology The invigorating power of water for Cornetu and Kühtai Editorial 18 Grosio, Italy – fourth unit successfully supplied in 28 months

19 Successful model acceptance tests for Middle Marsyangdi and Peixe Angical

20 Modernization of the turbines and generators in the Dychow hydroelectric power plant

22 Solina power plant – maximum client satisfaction after modernization

23 Mechanical and electrical modernization for Kiskoere, Hungary Voith Siemens Hydro Power Generation

Expertise for growth.

Dear clients and partners, Perhaps it is time to learn from the countries surrounding dear readers, Turkey, learn from their capability to harvest this clean energy and make use of the natural resources these coun- First of all I would like to thank all tries have, eliminating the need to import prime energy for of you who have sent me comments, Dr. Hubert Lienhard these Megawatthours generated in these hydro power plants. information, also critical letters and Chairman of the Board of Voith Siemens Hydro encouraging e-mails. It was inter- Power Generation It is our goal to continue to bring to this important region esting for me to receive all your our know-how and our expertise which Voith Siemens feedback which we will integrate in our plans and which Hydro has acquired during the 135 years of operation in will help us to grow further. Once more, you will find my this field. As you will read in this issue we can base our e-mail for further feedback at the end of this editorial. offers on a vast number of contracts in this region but also in other parts of the world. Among those is our contribu- As of September 30, 2002 we ended our fiscal year 2001/ tion to the newest and largest pumped storage plant for 2002. We will report the highlights during the coming VEAG in Germany, a marvel of technology of which we are months. Let me say it has been a rewarding year, but we proud to be given the chance to participate. cannot rest on our laurels; now we must focus on the new year. In November, we will participate in the Hydro 2002 in As you will agree, this industry has unbelievable chances Kiris, Turkey. As you will see, Turkey is well-known to us; and opportunities to serve our society. We will use the we have installed numerous hydro power plants there Hydro 2002 event in Kiris to focus on this region and to as well as in neighboring Iran and in the entire region bring its expertise to the world. surrounding Turkey. I hope you will enjoy reading this magazine and we can in- This area has shown and will show – we believe – large spire you in your areas of activity to make things even better. growth in the coming years. In these countries, hydropower still enjoys the reputation as renewable, green Sincerely yours, power, matching ecology with economy. I sometimes wonder why we have lost this basic understanding in Europe, an understanding our forefathers had when they

Dr. Hubert Lienhard hypower 3/2002 utilized hydro resources which in today’s modern world of liberalization help to keep our grids stable. My e-mail address is [email protected]. 02 03 100 years of hydro electricity in Turkey – 100 years of Voith Siemens Hydro in Turkey

Turkey can look back on a century-long tradition in generating electricity from water. In 1902 the very first power plant was built in the Turkish town of Tarsus: a small hydro power plant equipped with an 60 kW Voith Siemens Hydro turbine installed to supply a privately owned textile factory. The beginning of hydro power generation in this small plant in Tarsus also marked the beginning of Voith Siemens Hydro’s presence in the Turkish market – a presence which has continued successfully for 100 years of partnership.

Situated at the meeting point of two The main objective of Turkey’s energy continents, Turkey stands as a bridge policy is to meet these increasing More. between Asia and Europe. The social demands in line with economic devel- and economic development through- opment targets, population growth, Powerful. out the last decades has been consid- industrialization and social changes, erable. Turkey today is an emerging in a reliable manner and environmen- nation with a massive increase in tally compatible. Hydropower devel- Solutions. energy demand. Having installed a opment has extensively contributed to total of more than 28000 MW of meet these demands, and an ambi- generation capacity (producing over tious development program of hydro- 122000 GWh), of which nearly 12000 power for the years coming is under MW are hydro installations (produc- execution. ing over 24000 GWh), Turkey’s future electricity demand is predicted to grow by 4% per year. Voith Siemens Hydro has been Borçka Ermenek involved in a number of recent hydro The 306 MW hydro power project is The 306 MW hydro power project power projects in the country. located on the Çoruh river in north- is located on the Göksu river at the Here’s a brief outline: eastern Turkey, close to the border Ermenek canyon in mid-southern with Georgia. Construction work has Turkey and includes the Ermenek dam begun in September 1999 and is with the main power station and an scheduled to be completed within auxiliary hydroelectric power plant, 69 months. Voith Siemens Hydro Erik. The ground breaking ceremony manufactures and delivers two at the Ermenek site took place in Francis turbine units including the May 2002. Voith Siemens Hydro, as governor system and turbine inlet a member of the supplier group for valves and is also responsible for electrical and mechanical equipment the installation and commissioning is responsible for the mechanical of the two 153 MW machines. design and delivery of the two The respective model acceptance 153 MW Francis turbines and spheri- test was successfully performed in cal inlet valves for the main power June 2000 in Voith Siemens Hydro’s station. It is also responsible for the hydraulic research laboratory in hydraulic and mechanical equipment Heidenheim, Germany. Commercial of the auxiliary power station of Erik. operation of the first unit is scheduled Commercial operation is scheduled for April 2005. The contracting author- to start in April 2007. The contracting ity is the Ministry of Energy and Natur- authority is also DSI. al Resources, General Directorate of State Hydraulic Works (DSI).

Borçka: signing of model acceptance test protocol. Ermenek ground breaking ceremony. Suat Ugurlu hydro power station. hypower 3/2002

04 05 Alpaslan I The 167 MW hydro power project is located in eastern Anatolia. This contract is the most recent one realized in cooporation with Temsan for the contracting authority DSI, as where the hydro power projects Kürtün and Suat Ugurlu, and others. For Alpaslan I, Voith Siemens Hydro designs, manufactures and will deliv- er the four 41.75 MW Francis turbines including governor systems and butterfly valves, and will supervise the installation on site and be responsible for the commissioning.

Kürtün dam site. Karkamis Kürtün The 213 MW hydroelectric power The 80 MW hydroelectric power plant More. plant is located on the Euphrates is situated in northeastern Anatolia on river, close to the Syrian border. the Harsit river. Voith Siemens Hydro Powerful. The Karkamis plant comprises six delivers the two 40 MW Francis 35.5 MW bulb turbine units, the turbines, adapted for synchronous turbines manufactured, delivered, condensor operation, including gover- Solutions. installed and commissioned by nor systems and butterfly valves, Voith Siemens Hydro. will supervise the installation on site Commercial operation of the first and be responsible for the commis- Karkamis: final acceptance. unit started on December 20, 1999, sioning. Main installation has begun 11 days earlier than planned. in spring 2002 and commissioning All other Karkamis units were handed of the first turbine is expected to take over to the contracting authority DSI place soon. at least one month ahead of schedule. On February 7, 2002 the final acceptance protocol was signed. Voith Siemens Hydro also success- Dinar Hacilar fully serves the emerging private Commissioned in November 2000, The plant with an installed capacity market in Turkey. the small hydro power station Dinar of 13.34 MW is currently under con- A brief record of recent projects: is located about 200 km north of struction, commissioning is sched- Antalya. Operated by the Turkish uled mid of 2003. Hacilar is located Sucati private company METAK Enerji VE in Darende-Malatya with two units. This small hydroelectric power plant Ticaret A.S. on BOT basis, the plant Voith Siemens Hydro is the turnkey was erected in 1998/1999. It is oper- is equipped with Francis bulb turbines contractor and delivers the entire ated by the Turkish private company and two generators with a maximum mechanical and electrical equipment ERE, Elektrik Üretim ve Dagitim output capacity of 1,950 kVA each. including control and protection Sanayi ve Ticaret A.S. on BOT basis, Voith Siemens Hydro was the turnkey system and medium voltage equip- and equipped with two double-regu- contractor and has delivered the ment. Hacilar will be operated on lated Kaplan bulb turbines and two entire mechanical and electrical equip- auto-producer basis for 49 years. generators with a maximum output ment including the control and pro- The owner of the plant is Bilgin capacity of 5,100 kVA each. It is tection system and the medium-low Elektrik which already operates located near Kadirli, approximately voltage equipment. Hazar I and II hydro power plants. 50 km southeast of Kayseri. Those plants were taken over from Voith Siemens Hydro was the turnkey DSI under the TOR (Transfer of Rights) contractor and has delivered the entire model and were equipped with Voith mechanical and electrical equipment Siemens Hydro turbines and shut-off including the control and protection valves in the fifties and sixties. system and the medium-low voltage equipment. For more information: [email protected] [email protected]

Sucati hydro power station. Dinar penstock view. Hazar: inside power house. hypower 3/2002

06 07 With over 31,000 MW installed nominal capacity, the Islamic Republic of Iran has a leading position on the energy sector in its region. In 1998, the Energy Ministry unveiled its long-term plans to nearly quadru- ple the capacity of the national grid by 2022. Several hydro power plants are currently under construction and will be completed in due time.

The Islamic Republic of Iran is still For hydro power generation govern- forging ahead with its ambitious ment plans foresee an additional energy program. Considering the 11,700 MW of generation capacity by country’s feasible hydro power poten- the year 2022. Voith Siemens Hydro tial, estimated at about 50,000 GWh/ has a remarkable share in this devel- year, and a current utilization of less opment program. than 15%, the hydroelectric field will certainly be developed extensively. More. Powerful. Solutions.Sharp growth in the Iranian hydro power market Shop assembly of high-pressure oil units and digital governors. Construction site Masjed-e-Soleyman extension.

Major contracts awarded to Masjed-e-Soleyman Extension Karun IV Voith Siemens Hydro The dam with a height of 180 m and Also located on the Karun river in the FARAB, an Iranian contracting com- the hydroelectric power plant is country’s south-western province of pany set up in 1992, was awarded located on the Karun river, about Khuzestan, Karun IV is yet another with several contracts for hydro 25 km north-east of the city of Masjed 1,000 MW project. The hydroelectric power projects in Iran. To date, FARAB in the Khuzestan Province. power plant will receive four vertical has awarded various major contracts The 1,000 MW project, equipped with Francis turbines with an output of to Voith Siemens Hydro, comprising four 254 MW vertical Francis turbine 255 MW each. It is scheduled for design, manufacture, installation and units, is scheduled to become opera- commissioning in 2006. commissioning of turbines, genera- tional by 2004. tors and governor systems. Ostour Upper Gotvand The 170 MW project is located on Digital governor The hydroelectric power plant at the the Ghezel Ozan river, near the city inside view. foot of the Gotvand-e-Olia dam will be of Mianeh in Iran’s north-western equipped with four 254 MW vertical province of Azerbaijan. Francis turbines. The plant is located Contracts foresee equipment com- on the Karun river, 90 km south of the prising four 41 MW vertical Francis city of Godarlandar, and its commis- units. sioning is planned for 2006. hypower 3/2002 For more information: [email protected] 08 09 Voith Siemens Hydro continues to be the world leader in pump-turbine technology

With almost a century of experience in the design and manufacture of pump-turbines and motor-generators, Voith Siemens Hydro is indisputably the leader in this field of hydro technology. Since the first pumped storage plant was developed in Voith’s hydraulic research laboratory in Germany in 1908, Voith Siemens Hydro has been supplying the world’s largest and most powerful units, continually breaking through existing barriers. The latest developments, already utilized in current projects, include variable speed technology and wide head range applications.

Pumped storage plants have been Though all pumped storage plants are developed as “energy storage sys- based on this main principle, there tems” capable of quickly responding are no two facilities in the world that to fluctuations in power demand. are alike. Each plant has its own In times of reduced energy demand, unique hydrology and physical con- More. excess electric capacity in the grid is straints. Pumped storage plants used to pump water, previously used operate on daily or weekly cycles that Powerful. to generate power, back into an upper vary based on the time of the year reservoir. This water can then be used and the plant’s location. Operating to generate electricity when needed. conditions may require a reversible Solutions. pump-turbine or an optimally de- Guangzhou II, China. signed combination of turbine and Pumped storage pump. In some cases, optimum power station. results may be achieved through a pump-turbine equipped with a fixed distributor, in other cases an adjustable distributor may be necessary. Depending on the required change- over speed, separate turbine and pump units may best be equipped with synchronizing torque converters or a clutch operable at standstill. Guangzhou II, China. Pumped storage power station.

Having installed more than 200 pump- Guangzhou, China turbines worldwide with a combined The Guangzhou pumped-storage plant Voith Siemens Hydro supplied the output of well over 24,000 MW, Voith is located about 100 km northeast of complete electrical and mechanical Siemens Hydro can offer the right the provincial capital of Guangzhou equipment for the second group, machines for the most variable condi- (Canton), and about 200 km north of including pump-turbines and motor- tions and pump-turbine technology Hongkong. It is the first high-head, generators, high voltage starting fre- which has proved to be extremely large-capacity pumped storage facility quency, PROKON LSX control system. reliable. Consequently, it does not in China. With a total output of Since commercial operation began come as a surprise that Voith Siemens 2,400 MW, it ranks among the largest two years ago, these units have been Hydro is involved in today’s most in the world. Guangzhou comprises operating very reliably for more than important pumped storage projects: two groups, each with four 300 MW 35,000 hours. reversible pump-turbines with a head of 535 m. hypower 3/2002

10 11 Pumped storage station: spiral casing. Goldisthal, Germany.

More. Powerful. Solutions.

Goldisthal Goldisthal, upper reservoir. Goldisthal, Germany Bath County, USA Goldisthal pumped storage power Situated in a mountainous region in station is located in southern Virginia, USA, Bath County pumped Thuringia, Germany, on the upper storage plant is currently being mod- Schwarza river. With a total capacity ernized by Voith Siemens Hydro of more than 1000 MW, it is one of specialists. The station consists of the biggest pumped storage plants in two large reservoirs – one 385 meters Europe. Voith Siemens Hydro sup- higher than the other, a massive plied two 270 MW pump-turbine units power house and the huge tunnels capable of operating at variable that connect them. The upgrading speeds ranging from 300 to 346 rpm. covers the combined turbine/genera- The adjustable speed control of the tor scope of supply. pumped storage units makes it possi- The refurbishment of the stator wind- ble to control input during pumping ings and new runners will push the operations and increase the electricity six 350 MW units installed to an yield in turbine mode. astonishing 480 MW/530 MVA each. After completing the modernization, Bath County will again become the world’s most powerful pumped storage generating station. hypower 3/2002 For more information: [email protected] 12 13 Streamlining project management and completing

When the go-ahead was given at the end of May 1999 for the construction Cana Brava hydro power station. of the Brazilian hydro power plant Cana Brava in the north of the federal state of Goiás, expectations were high. The work was to be completed in a record time of 37.5 months, commissioning was planned for August 2002. From the very beginning, Voith Siemens Hydro, responsible for the engi- neering, the complete electrical and mechanical equipment, installation, tests and commissioning, brought everything to bear on safeguarding the ambitious time goal with its streamlined project management. With overwhelming success. In the late Brazilian summer of 2001, Optimum interface management More. an increasing number of power cuts Optimum interface management and throughout the country documented unconditional support from the client, Powerful. an acute energy shortage. Brazil began Tractebel Energia, for the increased to suffer from a serious energy crisis. efforts finally set tremendous syner- Additional capacities for electricity gies free. In this way, the first rotor Solutions. production were urgently needed. blade of the first of the three 150 MW In view of the extremely tense situa- turbines for Cana Brava was delivered tion on the Brazilian energy market, considerably earlier than accounted the Voith Siemens Hydro project for in the already very ambitious Cana Brava hydro power station. managers responsible for Cana Brava original plans. With the early delivery streamlined their planning to the limit. of the runners, the overall progress of The deadlines for all work packages the hydroelectric project speeded up were brought a long way forward, significantly. At the handover of the critical paths in the part-projects were first turbine, Sérgio Parada, Director shortened and optimally adapted to of Voith Siemens Hydro’s São Paulo the work of the partners, which for its location, promised to save at least part was also accelerated. two months of time. 450 MW project in record time Cana Brava in operation four months ahead of schedule Sérgio Parada was proved to be right. The finished power plant will produce Contract Manager Amiro de Sousa The other two turbine units were also more than 2700 GWh per year, enough looks on this achievement with pride: delivered with a considerable time to supply 1.5 million households in “Everybody remembers the difficulties saving. His prognosis even turned out the central-west and north-east of we had to overcome, but the memory to be quite modest. The Cana Brava Brazil, chiefly in the federal state of is of a positive result. It is a feeling of hydro power plant, situated on the Bahia, and to make a valuable contri- personal satisfaction, everyone saw river Tocantins, went into operation bution to checking the Brazilian the effort rewarded with success.” as early as April this year – a full four energy crisis. months before the contractually For more information: agreed date. The time gain which had [email protected] been fought for so hard exceeded all expectations.

Change in the management of Voith Siemens Hydro, Brazil Edgar Horny, President of the Board of Management for Voith Siemens Hydro Power Generation Ltda., São Paulo, Brazil, resigned from the company management on September 30, 2002. Edgar Horny Julio Fenner Sergio Parada

He will continue as an advisor to Voith On October 1, 2002, Julio Fenner Siemens Hydro Power Generation Ltda., became Edgar Horny’s successor as Voith Paper Máquinas e Equipamentos President of the Board and, together Ltda. and to Voith Turbo Ltda. with Sergio Parada, now constitutes hypower 3/2002 the Board of Management of Voith Siemens Hydro Power Generation Ltda. 14 15 Advanced governor technology for Cornetu The Cornetu hydro power plant in Romania and Kühtai hydro power station in Austria have several things in common. This year, Hidroelectrica, the operator of Cornetu and TIWAG, operator of Kühtai, both awarded contracts to Voith Siemens Hydro to replace the existing analog governors by modern digital governor systems. Moreover, manufacturing, installation and commissioning deadlines meant that the time scheduling for both projects was extremely tight, which posed a major challenge for the respective project teams. Nevertheless, through the unique partnership and cooperation between Voith Siemens Hydro specialists and the clients’ staffs, both projects were completed successfully and on time. Kühtai pumped storage plants.

Voith Siemens Hydro digital governor in Romania: When the Romanian Prime Minister After manufacturing and delivery, Adrian Nastase together with Minister installation of the governors and of Industry and Resources, Dan Ioan commissioning was executed in an More. Popescu and General Director of enormous effort and excellent cooper- Hidroelectrica, Eugen Pena, opened ation between Hidroelectrica, the Powerful. the Cornetu power plant in a ceremo- erection company and Voith Siemens ny this year, just 15 weeks had Hydro staff within two weeks. passed since award of the governor The scope of supply and services also Solutions. contract to Voith Siemens Hydro. covered the supply of governor valves, electrical feedback and speed measuring system for the two Kaplan units.

Cornetu hydro power station.

Inauguration of Cornetu. The unit was started by Dan Ioan Popescu, Minister of Industry and Resources, Adrian Nastase, Prime Minister, Eugen Pena, General Director, Hidroelectrica. and Kühtai New digital governors for pump turbines in Kühtai The turbines of Kühtai pumped storage plant are equipped with single wicket gate blade control. The replacement schedule for the analog turbine governors with engi- neering and installation works was again quite tight. As part of this project, the previous main functions of the governor, such as opening, speed and power control were to be supplemented by a range of new functions through the upgrade to digital governor technology. For service and maintenance reasons, data acquisition and storage func- tionalities were implemented. Data can be read and displayed on a direct or modem-connected PC. Drift compensation was another Satisfied faces Kühtai pumped storage scheme: feature to be newly implemented. The successful works’ acceptance by aerial view. Safe behavior, during different modes both clients confirmed the quality and Kühtai pump-turbine. of operation, was a main requirement efficiency of the Voith Siemens Hydro also. Therefore, new functions were digital governor systems. installed, such as: Within a few weeks, both hydro power - feedback of turbine inlet pressure plants had been successfully updated for damping of pressure oscillations to advanced technology. - blocking of the actual wicket gate opening in case of unallowed For more information: pressure oscillations [email protected] - redundant speed measuring [email protected] hypower 3/2002 and speed direction detection [email protected] 16 17 Grosio, Italy – fourth unit successfully supplied in 28 months

Erection of the new runner.

The Italian operator Azienda Elettrica Municipale (AEM) di Milano has awarded Voith Siemens Hydro a contract for increasing the power of their most important hydro power plant. One part of the contract comprised the supply and installation of a new Pelton turbine. Once this new turbine, in a total of four, was commissioned in September this year, the plant’s overall capacity increased to 450 MW.

Further to the vertical Pelton turbine The importance of the Grosio project with a diameter of 3750 mm, Voith is not only due to the fact that it is Siemens Hydro’s activities comprised the main operative center as far as More. the installation of a new control the electrical production and output system. Above this, the runners in of all hydroelectric power plants of Powerful. the existing turbine units were re- Azienda Elettrica Municipale di Milano placed by runners weighing 20 tons is concerned, but also because it is each. This replacement allowed the the central site of the remote telecon- Solutions. performance of each unit to increase trol of all AEM plants in the Lombar- considerably. dian region of Italy.

For more information: [email protected]

Front view of Grosio hydro New runner with deflectors. power plant. Successful model acceptance tests for Middle Marsyangdi and Peixe Angical In July 2002, successful model acceptance tests were again held in the Central Technology facilities of Voith Siemens Hydro. The model turbines for the hydroelectric power plants of Middle Marsyangdi in Nepal and Peixe Angical in Brazil were on the test stand in Heidenheim, Germany.

Successful model tests and their teams: Middle Marsyangdi and Peixe Angical.

In the presence of the clients, Nepal The performance of the Peixe Angical The Nepalese hydroelectric power Electricity Authority for the Nepalese unit was particularly gratifying: plant uses the water of the Marsyangdi and Enerpeixe for the Brazilian hydro- the guarantee of the highest perfor- river and is located approx. 160 km electric power plant, the model sys- mance in an ambitiously short period west of Kathmandu. This will be served tems were tested under all relevant of just 2.5 years until commissioning by two Francis turbines, which will operating conditions. The guarantees was a real challenge of planning and each produce 40 MW with a runner of performance made during the design, construction and manufacture diameter of 2.2 m and a head of tender process and contract awards including installation. The successful approximately 100 m. were fulfilled in full. test run means that the first major milestone has been reached. For more information: [email protected] Peixe Angical, located in the Brazilian [email protected] state of Tocantis on the river of that name, will be equipped with three Kaplan turbines, each of which will hypower 3/2002 produce 169 MW with a runner diameter of 8.6 m and a head of 29 m. 18 19 Modernization of the turbines and generators in the Dychow hydroelectric power plant Punctually to the 50-year celebrations in September 2002, the official go-ahead was given for the beginning of extensive modernization work in the Dychow power plant in Poland. Built in the 30s, the plant was re-equipped in 1951 and had been in continuous operation since then. Due to this long operation period, wear and tear deteriorated the units to an extent that jeopardized reliable operation. Elektrownie Szczytowo- Pompowe (ESP) entrusted Voith Siemens Hydro with the modernization of the units. Thus, peak power provision and increased annual generated energy are secured.

Two contracts from Warsaw ESP in Warsaw awarded two contracts All supplies and services for this to Voith Siemens Hydro to carry out project are being provided by the modernization of three Kaplan Voith Siemens Hydro in cooperation turbines and generators, four storage with local partners. The challenging pumps, and one motor including implementation time table is based ancillary equipment in Dychow hydro on the strong commitment of a suc- More. power station in the last two years. cessful team between ESP and Voith Siemens Hydro which has already Powerful. proven successful in earlier projects with ESP. Solutions.

Dychow hydro power plant. Dychow inside view.

Customized solutions for increased Results performance The consequence of this optimization Even though one part of the contract Extensive tests are carried out to process is that once the moderniza- is to renew turbine components, assess the condition of parts to be tion is completed, the parameters simply replacing old parts with new renewed. Residual life time calcula- guaranteed in the contract will even ones is not enough to increase effi- tion is executed for the units. be exceeded partially: turbine perfor- ciency. An improved customized mance will increase from 26.1 MW hydraulic layout was developed for to 31.6 MW (12% increase) and dis- the given hydraulic profile of the charge from 110 m3/s to 122.7 m3/s. hydraulic machines by application of Pump discharge will increase from CFD (Computational Fluid Dynamics). 17.5 m3/s to 19.2 m3/s. All in all, thanks to a customized Voith Siemens Hydro solution, and proven close cooperation between ESP and Voith Siemens Hydro, the Dychow hydroelectric power plant will in future not only use 100% of its newly installed capacity, but also have a significant increase in operational reliability. Recommissioning for the whole plant is scheduled for 2004.

For more information: hypower 3/2002 [email protected] 20 21 Solina power plant – maximum client satisfaction after modernization When Voith Siemens Hydro was awarded the contract for the modernization of the units of the Polish hydroelectric power station Solina, the owner, Elektrownie Szczytowo-Pompowe (ESP), was assured of significant improvements in part-load behavior and remarkable increase in performance. Most advanced Voith Siemens Hydro IT technology and special in-house software, helped to provide extremely precise statements on results, time- lines, cost and extent of the modernization work before the project was started. Once, modernization work had been completed, the contractually guaranteed parameters were subject to verification, carried out by an independent consulting engineer.

These tests, were carried out by the The extensive tests done by the renowned Institute of Fluid-Flow Institute covered efficiencies, dynam- Machinery at the Polish Academy of ic operating behavior and turbine Science in Gdansk. Data on runner loudness reduction. Results were con- performance had been awaited with vincing with all parameters guaran- particular interest, as Voith Siemens teed in the contract being verified More.Hydro had based their hydraulic in all areas. ESP now operates two optimization of the runner design on quiet turbine units with remarkably ComputationalPowerful. Fluid Dynamics (CFD) improved performance at their dis- solely. posal for unlimited operation.

Solutions. As part of the official opening celebra- tion, Elektrownie Szczytowo-Pompowe expressed their great satisfaction with Letter of appreciation from ESP. the hand-over of a letter of appreciation to Voith Siemens Hydro. Pressure High For more information: [email protected]

Low

Solina CFD runner. Mechanical and electrical modernization for Kiskoere, Hungary Voith Siemens Hydro in consortium with Siemens RT, Budapest, recently received a modernization contract from Tiszaviz Vizeroemue, KFT, Hungary, for the modernization of mechanical and electrical equipment of Kiskoere hydro power station in Tiszaloek in Hungary.

Kiskoere is equipped with four bulb Kiskoere is located on the Tisza river turbine units. Modernization works and was originally put in operation will start in summer 2003, including 1974. The power plant generates modernization of all mechanical and around 90 GWh per year. The modern- electrical components of the units, ization works thus not only ensure such as new runner blades, rehabilita- electricity to the public grid of Hun- tion of runner discharge rings, re- gary, but also help the plant to con- design and parts renewal of distribu- tinue to serve its primary purpose for Kiskoere hydro power plant. tors, including new wicket gates, new water supply and irrigation. shaft seals, re-wind of generators, installation of new excitation equip- Technial data: ment and re-design and renewal of Runner diameter 4.3 m hydraulic, governor, automation and Head range 2 - 10 m control equipment. The units will be Discharge per unit 140 m3/s re-worked and re-commissioned at Speed 107.1 rpm one-year intervals. Completion of re- Generator output per unit 7 MW commissioning is planned at the end of 2006. For more information: [email protected]

Kiskoere hydro power plant. hypower 3/2002

22 23 Higher reliability with improved Pelton turbine nozzle design

After a service life of almost 30 years, the reliability of the two Bulgarian hydroelectric power plants Belmeken und Sestrimo had dropped tremendously. The source of the defect was found to be the dramatically short lifespan of the springs in the nozzle system of the Pelton turbines. Within a short contractual period of just six months for the modernization of the first turbine, Voith Siemens Hydro specialists adapted highly sophisticated Pelton nozzle design to ensure highest operational reliability. Belmeken hydro power plant.

When the state electricity company NEK By application of simultaneous engi- (Natsionalna Elektricheska Kompania neering, time and mechanical con- EAD) entrusted the project for the straints could be met and even modernization of a total of 32 turbine exceeded. In this way, the critical nozzles to Voith Siemens Hydro, the parameter – the too high load on the More. task was obvious: a re-design of the springs – was reduced to a level, actuating mechanism inside the noz- enabling significant increase of life- Powerful. zles had to be carried out with the span and reliability of the units. constraint of the given dimensions of Excellent cooperation between NEK the unchanged nozzle body in order and Voith Siemens Hydro ensured Solutions. to achieve significant improvements that all targets set could be achieved. of the force transmitting system by reducing the load on the springs. For more information: [email protected]

Nozzles in workshop. Kaplan turbine rehabilitation – San Men Xia anti-erosion research project

The San Men Xia Hydropower Station is located on the middle reaches of the Yellow River in Henan Province, China.

There have been two major problems In order to solve the above problems, After returning the modified unit to in this power station: San Men Xia awarded the rehabilita- operation, Voith Siemens Hydro/SHEC 1.The sandy water (max. sand con- tion contract for the No. 1 unit to and San Men Xia made three joint tent over 100 kg/m3 ) passing Voith Siemens Hydro in 1997. inspections on May 29, 2001, through the turbines during the This rehabilitation was combined November 6,2001 and May 8, 2002 flood season cause serious erosion with a research project addressing respectively. damage to the wet components of the problem of sand erosion of the the turbines. turbines. Following the contract The inspections show that the unit 2.Runner blade cracks – 80% of the award in 1997, Voith Siemens Hydro operates stable at all heads and blades in this station have devel- optimized the hydraulic design, con- meets the design output. The actual oped cracks, and one blade even firmed in a model test carried out in efficiency is improved significantly. broke during operation. 1998. The runner blades with coatings No cracks appear on the blades. (tungsten carbide hard coating and The rehabilitation has reached the Layout comparison polyurethane soft coating) were made expected goals. With regard to the between original and in Voith Siemens Hydro Heidenheim anti-erosion program, after one and modernized design and the other equipment with coat- a half years of operating experience, ings was manufactured at the Shang- it is confirmed that both coatings hai Hydro-Power Equipment Company have helped to significantly reduce (SHEC) – Voith Siemens Hydro’s sand erosion. The tungsten carbide operation in China. The unit was re- has shown particularly good anti- commissioned in December 2000. abrasion performance. The long-term comprehensive effect of the coating will be further verified during the next Old New two years of operation. Output 50 MW 60 MW Blade No. 8 7 hypower 3/2002 Runner diameter 6000 mm 6100 mm For more information: Hub ratio 0.55 0.53 [email protected] 24 25 Numerical calculation of unsteady flow in draft tubes

t = 1/8*T t = 2/8*T t = 3/8*T t = 4/8*T t = 5/8*T t = 6/8*T t = 7/8*T t = 8/8*T

Calculated vortex rope at different times.

The numerical calculation of the flow in the components of hydraulic turbo Deficits in the conventional machines has become a standard during the past decades. The implementa- calculation process tion of this approach in the hydraulic turbine design process has led to the The entire turbine is conventionally development of powerful machines. One weak point of the traditional pro- separated into single components – cess previously used was the purely steady calculation. In particular, the spiral casing, tandem cascade, run- flow conditions under part load could not be adequately described in this ner, and draft tube – and each compo- way. This meant that under unfavourable circumstances, pressure pulsations nent is then calculated in steady More.could arise with serious consequences. Voith Siemens Hydro has now devel- mode, thus neglecting pressure oped an improved calculation process. pulsations, i.e. time-dependent varia- Powerful. tions in the flow. As a result, part- load operation of Francis and pump- turbines – in turbine mode – is Solutions. measured frequently accompanied by such Draft tube mesh and pressure pulsations. predicted incalculable pressure pulsations. Especially within the range of the 20000 natural frequency of the mechanical 16000 components or the water circuit, 10000 these pulsations can cause severe 5000 damage to the machines and lead to 0

p [Pa] 4 56fluctuations in the rotational speed -5000 and the torque of the runner. -10000 Worst case, a destabilizing effect on -16000 the electrical grid could be the conse- -20000 t [s] quence. Bifurcating cavitating vortex rope in the model test stand.

The need for a holistic approach When applying the conventional ana- lytical method, the fluid and gaseous phase in the draft tube, responsible for pressure pulsations, is incalculable. Voith Siemens Hydro specialists realized that the synergetic complexi- ty of the whole system with various Breakthrough in Heidenheim Outlook components interacting could not be Throughout the past year, an exten- The research project provided a broken down to separate elements: sive research program has been detailed insight into the complex under conditions of part-load opera- conducted at Voith Siemens Hydro flow situation and the far-reaching tion, the flow regimes of both compo- in Heidenheim covering theoretical comprehension of the formerly nents can never be separated proper- foundations, numerical calculations incalculable pressure pulsations. ly. Instead, a holistic approach con- and experimental measurements. This will enable Voith Siemens Hydro sidering the runner and the draft tube Researchers have developed sophisti- specialists to improve the part-load together was needed. cated physical models, fundamental behavior of Francis and pump-tur- for the explanation of the decisive bines, with regard to both, rehabilita- fluid-gaseous phenomena. tion projects and the development Comparisons of the numerical results of new hydraulic turbines. with experiments performed at our test stands revealed excellent agree- For more information: ment with regard to both, visually [email protected] hypower 3/2002 observed flow phenomena and quanti- tative data. 26 27 Hydrovision 2002, Portland, View of the Portland cityscape from the Willamette River.

Over 2000 participants from 51 countries attended the Hydrovision 2002 conference held at the Oregon conven- tion center in Portland, Oregon. The conference presented opportunities to learn, network and share with those in the hydropower industry.

Individual presentation sessions Expertise shared Voith Siemens Hydro’s exhibition The conference offered 8 sessions booth focused on the individual each day in 9 different tracks focus- products and technology that are ing on every aspect of hydropower. involved in the Integrated Services Voith Siemens Hydro specialists pre- solution for project evaluation, sented a technical paper “Application planning and implementation. of Fish-Injuring Shear Criteria and These products and services were Computational Fluid Dynamics to More.Winfried Stach, Director, depicted in photos and descriptions Investigate Fish Survival in Kaplan Hydro Automation, York, of some of the projects currently Turbines” and served as moderator explaining automation for the interactive session on automa- Powerful.concepts as the moderator under way in the North American of the interactive session market. As a highlight for those tion entitled “Automation/Remote on automation. customers interested in the details of Control: How much is enough?” Solutions. Voith Siemens Hydro’s most recent technological developments and Voith Siemens Hydro's booth in the exhibition hall. service approach, presentations were available in a separate room at the conference center. These individual presentation sessions provided the venue necessary to discuss and explore the Integrated Services Tool Box, Automation and Waterview.

Alan Roth (right), Vice President Marketing and Sales, Mississauga, during booth duty. Oregon, USA – a review

Historic tour Celebrate Science Party View of the Columbia River Voith Siemens Hydro provided a picnic The sponsorship of events at the at the Bonneville Power Plant.

lunch for participants during the tour conferences provided a chance for all Bonneville Power Plant – of the historic Bonneville Power Plant attendees to socialize and experience Powerhouse No. 1. organized by the U.S. Army Corps of the conference city. Voith Siemens A tour guide from the US Park Engineers. Approximately 100 atten- Hydro’s sponsorship of the Thursday Service provides answers dees spent a beautiful sunny day in evening event “Celebrate Science during the tour of Bonneville. the Columbia Gorge, learning about Party” held at the Oregon Museum of the history of the project along with Science and Industry provided an the technical and environmental enjoyable evening of relaxation and enhancements that have been made learning. Complete with an Omnimax to produce electricity with respect theatre and interactive displays and reverence to the needs of the including a submarine, the museum river system. Voith Siemens Hydro allowed time to socialize during the and its predecessor companies in dinner provided and to explore the The OMSI Museum, site of the Celebrate Science Party. the United States have been a part advances in science and industry. of the Bonneville Hydro projects from The event proved to be so popular the first 518 MW powerhouse com- that it was difficult for everyone to pleted in 1938 to the second 558 MW leave at the end of the evening. powerhouse completed in 1982 and the current rehabilitation of the first For more information: powerhouse. [email protected] hypower 3/2002

28 29 Succsessful IAHR symposium For the 21st Symposium of the International Association of Hydraulic Research (IAHR) in Lausanne, Switzerland, from September 9-12, around 170 participants could share progress in hydraulic research in the hydro industry in a relaxed engineers’ atmosphere. In a round of technical sessions, Voith Siemens Hydro’s international set of speakers presented latest inside view on: IAHR opening ceremony.

Numerical Investigation of the Flow Development of New Generation in a Pelton Turbine of High Speed Reversible Pump- Reiner Mack, Winfried Moser Turbines (Heidenheim) Hidetoshi Yamanaka, Yutaka Kimoto (Kawasaki, Japan), Experimental Analysis and Armin Schuh, Martin Giese, Numerical Calculation of the Gilbert Grosse (Heidenheim) Rotating Vortex Rope in a Draft Tube Operating at Part Load Development of a Broad-Band Micro Thomas Scherer, Peter Faigle, Hydraulic Turbine More. Thomas Aschenbrenner (Heidenheim) Morihito Inagaki, Akira Suzuki, Mitsuhiro Ishiguro, Powerful. The Importance of the Unsteady Tadashi Tsukamoto, Shoichi Yamato, Friction Term of the Momentum Kengo Izutsu, Michihiro Nishi Equation for Hydraulic Transients (Kawasaki, Japan) Solutions. Hans Günther Poll (Sao Paulo, Brazil) A Case Study in Resonant Hydroelas- tic Vibration: The Causes of Runner Cracks and the Solutions Implement- ed for the Xiaolangdi Hydroelectric Project Richard K. Fisher, Werner Gfeller (York, PA; USA) Ulrich Seidel, Gilbert Grosse, Roland Klinger (Heidenheim) Succsessful symposium: the IAHR participants. Co-authored papers were: Design Optimization of Hydraulic Simulation of Vortex Rope in a Machinery Bladings by Multi Level Turbine Draft Tube CFD-Technique Albert Ruprecht, Thomas Helmrich, R. Schilling, S. Thum, N. Müller, Voith Siemens Hydro: S. Krämer, Thomas Aschenbrenner, Voith Siemens Hydro: Thomas Scherer N. Riedel, W. Moser For more information: [email protected]

SHEC to participate in EP China 2002 From Nov. 13 to 16, 2002, The booth will be located within the For more information: Voith Siemens Hydro’s Joint-Venture German Pavilion in the Beijing China [email protected] company SHEC of Shanghai will be International Exhibition Centre. presenting itself at Electric Power The event is organized by the China China 2002. Electricity Council International.

Upcoming: international seminar in Vienna The bi-annual event of the Vienna Within the three days program More information on the event can University of Technology’s Institute from November 27-29, 2002, be found under for Waterpower and Pumps will Voith Siemens Hydro will present www.tuwien.ac.at/wup/tagung2002 feature a series of paper presenta- a paper on “Runaway speed of double tions under the theme of “Hydro regulated Kaplan turbines – aspects power plants – safety and/or risk?” of different safety philosophies and solutions” (authors are A. Oeguenc, H. Buchmaier, J. Klein of Voith hypower 3/2002 Siemens Hydro in Heidenheim, Germany). 30 31 Accounting for one third of the world’s hydroelectric power with its turbines and generators, Voith Siemens Hydro Power Generation is a true global player. Recent contracts awarded to Voith Siemens Hydro operating units all around the globe underline its position as a worldwide leading company for hydropower equipment: Pedra do Cavalo, Brazil Baglihar, India The hydro power station Pedra do The 900 MW Baglihar project is Cavalo, located on the Paraguaçú located in the north of India. river in Brazil’s north-eastern federal Voith Siemens Hydro, as a consor- state of Bahia, will be supplied in full tium leader, will supply three vertical by Voith Siemens Hydro’s Brazilian generators with an output of 168 MVA unit in São Paulo. The 165 MW project each, excitation systems, bus ducts, will be equipped with two Francis tur- phase transformers, switchgear and bines, designed to generate 82.5 MW cables. The contracting authority is each at a head of 105 m, and two the Jammu & Kashmir State Power generators with an output of 90 MVA. Development Corporation. Both units are scheduled for commis- More. sioning in August and October 2004 respectively and will be able to cover Powerful. the complete annual electricity demands of about 290,000 households. Solutions. Recent contract awards

Site assembly of the draft tube liner at the Tomada hydro power station. Final assembly of the draft tube liner before embedment at Tomada hydro power station.

Shin-Asaka, Japan The small Shin-Asaka hydro plant, located in the Fukushima prefecture in central Japan, will be the heart of an irrigation project. Voith Siemens Hydro’s Japanese unit, Voith Fuji Hydro K.K., Kawasaki, will supply the entire electrical and mechanical equipment, including a 2.4 MW hori- zontal Francis turbine and the generator. Voith Fuji Hydro is responsible for the balance of plant, erection and supervision of the power station, Tomada, Japan Shin-Taishaku, Japan scheduled for commissioning in July Tomada hydro power station will be Shin-Taishaku Power Station is part 2003. part of a multi-purpose dam project of a re-development project of an in the Okayama prefecture. aging dam in the Hiroshima prefec- Besides being responsible for erec- ture and will include the utilization of tion and supervision, Voith Fuji Hydro a 10.08 MW vertical Francis turbine. will provide all electrical and mechan- Most of the power station equipment ical equipment, including a 4.8 MW such as turbine and generator will be vertical Francis turbine and the gener- supplied by Voith Fuji Hydro. Com- ator. The commissioning is scheduled missioning is planned for June 2006. for February 2005. hypower 3/2002

32 33 The invigorating power of water Modern people tend to begin and end their day in the bathroom. This was The water emerges from the ground not always the case: until well toward the middle of the nineteenth century, at a temperature of 35 degrees Centi- even intellectuals and the aristocracy were not convinced of the value of grade and cools as it flows over the a daily bath. Water was regarded as a carrier of disease and excessive cascades, so that the calcium is pre- hygiene was considered to be a health risk. Yet for thousands of years cipitated and forms these wonderful before the cleansing, relaxing and invigorating properties of water had been natural basins as the deposits build up. known throughout the ancient world. In the Islamic cultural regions, the People have enjoyed bathing in every One of the best-known examples is development of bathing had a primar- era of the world’s history. All cultural in Turkey; the snow-white sintered ily religious significance. For this regions built their own bathing facili- terraces of Pamukkale. These cascades, reason, there were baths in the ties, but long before that people were consisting of sparkling limestone mosques. The true believer visited using natural rivers, ponds and pools deposits, located deep in the country- them mainly as ritual, with the plea- for ritual bathing or on account of side bordering the southern Aegean sure of bathing a secondary consider- their healing properties. Sea, have been celebrated since time ation. Cleansing of the soul and the immemorial for the regenerative body are closely linked in Islam. powers of their waters, which contain The prophet called for believers to Essay calcium and are slightly radioactive. pray five times a day and to wash themselves each time before prayer. If no water is available, for instance in the desert, the use of sand is permitted.

Pamukkale terraces in Turkey. Turkish hamam bath. It is either piped into the buildings, or the bathing and regeneration process is enjoyed in the open air. The bather cleanses his or her body prior to, before the actual ceremony. One sits on a small stool and soaps one’s body thoroughly with the onsen cloth from Ganges river one’s own small vat. After rinsing in India. down, one plunges into the actual bath, which is usually at a tempera- Today’s Turkish baths are more secu- Now let us turn to Hindu culture in ture that the average European finds lar in character, but a cultural experi- India. Every year, millions of people unbearably hot. ence none the less. Whoever has make the pilgrimage to the holy city relaxed in the “hamam” will have of Varanasi (Benares) on the Ganges The traditional Japanese bathtub is learned to value this pleasant for of river. To bathe in the river, which made of wood, the temperature being total physical and mental relaxation. is considered holy at this point, is maintained at a constant level by a The alternation of rooms heated to to be cleansed of the sins one has metal boiler located inside, regardless various temperatures, refreshment in committed and granted absolution. of how many bathers at a time are ice-cold water, resting in dimly lit The bells ring, the priests chant hymns seeking relaxation from the day’s rooms and the deep penetration of and the hypnotic scent of the innumer- hectic stress. the pleasantly scented soapy water able flowers scattered on the water massaged with a brush into the pores accompany this age-old spiritual rite, As we can see, despite all the cultural of the skin by the bath attendant – which is still practised with great awe and ritual differences that have grown all this restores the well-being of the and respect. up between the peoples of this world, guest to a most remarkable degree. they have always remained aware of In Japan people have for several the healing and purifying power of Japanese onsen. millennia bathed communally every water and have also learned, in the day in exceptionally hot water, for most prosaic way, to use this natural reasons of hygiene and also social element purely for their own pleasure contact. In many cases thermal and delight. springs (onsen), of which there are many in Japan, supply the water. hypower 3/2002

34 35 Voith Siemens Hydro Editorial coordination: Power Generation GmbH & Co. KG Barbara Fischer-Aupperle Alexanderstraße 11 89522 Heidenheim/Germany Copyright 2002 Tel. +49 7321 376848 Reproduction permitted, Fax +49 7321 377828 provided source is given.