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sustainable solutions. for a better life.

Customer magazine of VA TECH HYDRO

Publisher & editor: VA TECH HYDRO GmbH & Co, A-1141 Vienna, Penzinger Strasse 76, Austria Phone +43/1 89100 - 2053, Fax 196 Responsible for the content: Folker Bocksch, Pierre Duflon, Erwin Gutlederer, Anna Kien, Rudolf Langer, Ursula Scheidl, Georg Schroeder, Susanne Schrder, Kurt Wolfartsberger Copies: 19,000



Dear readers, We are glad to present to you

TECHNOLOGY HYDROELECTRIC GENERATOR . . . . . . . . . . 4/5 UPGRADING OF PELTON TURBINE KEY PROJECTS SIRIKIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ZEVIO
........................ .........

the latest issue of the HYDRO News. In times when moaning has apparently become courteous we, in VA TECH HYDRO, are convinced of being able to master also this so-called crisis with new ideas and interesting solutions. Please feel free to look at a few examples in this magazine or see our offer of services for yourself. However, we also do not wish to miss on this occasion to thank everybody who has contributed to our success. Our special thanks go to our customers who have been loyal towards us, who accompanied our development in a benevolent and at the same time critical way and supplied us with precious In suggestions and support.


9 TAVANASA . . . . . . . . . . . 10/11
............... ...................



MIDDLE MARSYANGDI . .13 ROSEIRES . . . . . . . . . . . . . . . . . . . . . 14

this magazine you will find






15/16/17 18/19

doing so. We would like to wish you much pleasure for reading. p.s. We would like to know, if you like our magazine: Do you miss anything? How can we improve? Please be so kind as to let us have your suggestions:



COMBINED CYCLE THESSALONIKI . . . . . . . . . . . . . . . . . . . 20/21 EVENTS / FAIRS VA TECH OPEN IN NORWAY . . . . . . . . . . . 22 ICOLD 2003, MONTREAL . . . . . . . . . . . . . . . 23


Dear Business Partners,

VA TECH HYDROs business continued to develop favorably during the first two quarters of 2003. We succeeded in taking in orders worth almost EUR 600 million, thus once again exceeding the excellent figures of the previous year. Our good business results are also reflected by increased sales and improved operating results (EBIT). A regional breakdown of incoming orders over the first six months of 2003 shows Europe to be the predominant market with a share of 83%. Particularly in the gas-fuelled combined-cycle plant sector, the important European market has developed well. Capital investments are expected to continue also over the next few years. The southern European market, above all Italy and Greece, has seen some growth as well. This positive trend in the field of gasfuelled combined-cycle plant construction together with our prominent role on the European market on account of our EPC activities is further underscored by orders such as the Thessaloniki project in Greece (see pages 20 and 21). In addition to a perceptible upward trend in the combined-cycle sector, we are especially pleased to report a positive performance of our hydropower business over the first six months of the year, which has resulted in a significant number of orders. Projects in Pakistan (see page 9) as well as rehabilitation orders from several countries including Portugal, Switzerland and Bulgaria clearly testify to the sustained development of our business in this segment. Moreover, our competence in providing advanced technological solutions is gaining more and more recognition all over the world. For instance, we are the global market leader in the field of Pelton turbines (see page 6). Despite difficult market conditions and a generally weak economy we are committed to achieving the good results of the 2002 financial year thus fortifying our position as one of the top players in the industry. The implementation of the Kyoto targets will offer new opportunities also for the hydropower industry. Promoting hydropower as a renewable energy source on an international scale is expected to provide important stimuli for capital investments both in new plants and rehabilitation projects, particularly in Europe. We at VA TECH HYDRO seek to actively support governments and industries in attaining the objectives of the Kyoto Protocol. Read more about this topic in the next issue of HYDRO News. We wish to thank all our business partners as our success would not be possible without their support and continuous dialogue. Our best wishes until the next issue. Yours faithfully,

Christian Habegger Chairman of the Board

Alfred Friedinger Member of the Board

Franz Strohmer Member of the Board

Helmuth Tschabuschnig Member of the Board


CAD cutaway view, bulb-type generator

CAD cutaway view, pumped storage motor-generator

Hydroelectric Generator Development Trends

In the past the situation of the power sector was characterized by large projects with long project duration. The projects were often multipurpose, designed to meet several needs. Besides the purpose of power generation, they had to fulfil tasks in water supply, flood control as well as irrigation. The present situation can be characterized by drastic changes in the power sector. Among these transitions are the appearance of independent power producers and the unbundling of utilities into generation, transmission and distribution. The privatisation of power generation and distribution forced utilities to focus on their core competencies which resulted in a completely new market situation. Additionally, private investment and financing of hydropower projects require shorter

pay-back periods and a higher internal rate of return than it was the case with publicly owned utilities. Against the background of this global development changing customer structure, enormous cost pressure, increased profitability, reorganisation of the power markets the adaptation of our products to the new market needs and the preservation of our competitiveness are R&D goals of paramount importance. On the one hand, the aim is to ensure the technical standard of conventional products. On the other hand, additional market access has to be opened up via innovative products, for instance with the recent concept of the Matrix-generator. Product Development HYDROMATRIX , ECOBulb For technical and economical reasons, in classical hydropower

schemes, gross head is mostly more than 10 m. In the segment of low head sites, substantial potential can be utilised in an economically feasible way by a new technology called HYDROMATRIX . A module of a so-called matrix consists of a grid-like structure consisting of propeller turbine-generator units of moderate size (approximately 200 to 700 kW) arranged in rows and columns. For the application in smaller runof-river plants, a new generation of COMPACT bulb turbines called ECOBulb has been developed. The main feature of this type is the new and cost-efficient directly driven synchronous generator which eliminates the need for a gear box otherwise frequently used with small turbines. A feature common to the ECOBulb generator as well as the synchro-

nous generator for HYDROMATRIX is the use of a permanent magnet excitation instead of a conventional excitation system. This application of high-energy rare earth permanent magnets has the advantage that the electrical excitation and auxiliary systems can be dispensed with. Moreover, the rotor design is extremely simplified which leads to a maintenance-free and robust rotor. Development of Technology The increasing global competition has compelled all manufacturers to focus their business activities on their core competencies. Therefore, their traditionally small vertical range of manufacture gets even smaller and the volume of bought-in parts consequently becomes larger. In order to respond quickly and effectively to customer requirements, the links of co-ordination with suppliers have to be very close. As a result, some suppliers have to be involved in development projects as soon as possible. Altogether, it is necessary to maintain networks with a growing number of partners all over the world and to exchange data with them. These given facts form the framework of development activities in the field of generator technology. Growing networks and an increasing globalisation of external relations inevitably demand a re-orientation of the internal procedures. The approach of finding technical solutions in loops of design decisions and subsequent modifications has to be thought over. This approach has to be replaced by far-reaching integration and standardisation of the design process. Consequently, an important part

Finite element solution of dynamic problems

ECOBulbTM Concept

of the design decisions should be re-shuffled towards an earlier time in project execution thus enabling an earlier placement of purchase orders and the reduction of throughput time. Standard data structures facilitate the communication between calculation, design and manufacturing departments as well as with external partners. The integration of all relevant data into a product management system supports the integrated treatment of the product generator from tendering via manufacturing down to operation and refurbishment. A possible method to reduce manufacturing costs of hydro generators is to leave the conventional path of individually tailor-made generators and to offer modular concepts. This should pave the way towards standardized components and systems from customer specific realisations employed nowadays. By doing so, the design effort as well as delivery time could be reduced considerably. An essential pre-requisite for that is the use of CAD models and the application of modern computation

methods like CFD (Computational Fluid Dynamics). Even if there will never be a complete re-use of generator designs, modular designs can lead to substantial savings in the fields of manufacturing, transport and erection. Besides risk minimisation via proven design principles and cost reduction via simple, competitive and reliable solutions with high availability, automation in the manufacturing process is another big goal. A quick and efficient feedback of manufacturing data to the design department is the basis for sound design decisions. With swiftly changing supply markets, this can be of utmost importance. In the future, it will become a frequent necessity to form global alliances for the sourcing of plant components. Against the background of the recent developments in the power sector, these considerations may give an idea how to set decisive steps in R&D in order to achieve a sustainable position on the international market. Franz Mller Phone +43/3172 606 2202




1.00 0.95

Relative efficiency

+11,8 % in h

0.90 0.85
+28 % in Q

0.80 0.75 0.70 0.6

Guarantee for refurbished unit Units #2 & #3 new runner, new casing & new injector Unit #3 new runner, injector & casing modifications Unit #2 new runner & injector modification original runner, Site tests 1981 Unit #2




1.4 1.6 1.8 Flow [m3/s]



2.4 2.6

Figure 1: Water jet after a 90 bend

Figure 2: Calcinere refurbishment project

Upgrading of Pelton Turbine with Improved Runner-Component Interaction

Following a conference held in March 2003 in Oslo, Norway, within the frame of the EBL organization (, some highlights of a VA TECH HYDRO presentation about upgrading Pelton turbines are discussed below. A large variety of Pelton designs exists and is characterized by a huge upgrading potential. Multiple sources of losses exist in these turbines, considering for example distributor head losses, jet quality, runner design and water sheet / casing interaction. The best runner design clearly cannot achieve its full performance if set in a hostile environment. Recent developments have confirmed the high importance of jet quality with respect to efficiency. Considering a vertical axis 6 jet scale model turbine, a maximum relative difference of 0.6% in efficiency was measured between the best and the worst injectors. This itself shows the utmost importance






modifying the casing for instance. Again, in the case of the model studies for FIONNAY (Switzerland), 1% was also gained at full load for the maximum head by adding specially designed plates in the casing of this 1 jet horizontal axis turbine. The last example of CALCINERE (Italy) illustrates by itself the added value of extensive component analyses, see Figure 2. This latter example is certainly an extreme case as the final turbine is almost an entirely new turbine! One sees that the rehabilitation of Pelton turbines requires a specific approach. Special attention must be paid to component interaction and not only to the runner. The added economic value of model testing is high (overview, step study) both in order to optimize performance assessment and decrease risks for the mutual benefit of customer and manufacturer. Etienne Parkinson Phone +41/21 925 78 49

designs that define the jet flow patterns, i.e. its quality. Indeed, referring to numerical simulation and experimental activities within VA TECH HYDRO, it is shown that the jet shape, see Figure 1, is defined by its secondary flow field in the injector. For instance, a jet following a bent pipe is not cylindrical, deviates from the injector axis and shows a non uniform dispersed airwater layer. Needless to emphasize the major influence of these parameters on turbine performance. For example, a 0.55 % increase of the turbine pitch diameter, i.e. changing the cient injector to angular setting, all at AMSTEG (Switzerland) was suffieliminate output saturation measured during the first performance checks. As a consequence, the high performance of new runner designs requires a thorough analysis of all components to reach their full potential. In the case of TAVANASA (Switzerland), a further relative efficiency increase of 0.8% was achieved by


Start of commercial operation of unit No. 2 of the Sirikit rehabilitation project
In August 2000 VA TECH HYDRO in Ravensburg was awarded a contract by EGAT (Electricity Generating Authority of Thailand) to rehabilitate the mechanical part of the Sirikit hydropower station located in the north east of Thailand. The scope of supply was two new runners for unit No. 2 and unit No.1, three new electronic and hydraulic governors and some mechanical balance of plant equipment. The runners shall have an average efficiency of 93%, which is a high goal to reach. However, technically this rehabilitation project was a quite complicated job since new equipment had to be implemented to work together with the old existing one. Even though some delivery problems occurred at the beginning of the project all scheduled dates have been met finally. The first unit to be equipped with a new governor was unit No.3. After some technical problems with the very complex governor control system, the PAC was issued on October 1, 2002 and the pending issues have all been solved. The rehabilitation works of unit No.2 started on schedule on August 1, All technical challenges were met during installation and commissioning, so the unit went into commercial operation on June 30, 2003 without any pending issues. On this day a start of commercial operation cereTechnical data: Output: Head: Speed: Runner diameter: 150 84.3 125 5,041 MW m rpm mm

2002. On June 26, 2003 the efficiency test was carried out by EGAT and the runner delivered by VA TECH fully reached the high guaranteed values. The efficiency test was a great success. On Mai 23, 2003 the newly delivered runner No. 2 was turning for the first time and the very good VA TECH working team on site (Steve Sgier and Julius Walz) arranged a big party in the evening of that day. The client not only complimented Mr. Sgier and Mr. Walz on ther good work at the power station, they also praised this party even days afterwards.

mony was held at Sirikit hydropower station which was attended by Chalermchai Ratnarak (Deputy Governor of EGAT Hydro Power section) and M.L. Chanaphun Kridakorn (Deputy Governor of EGAT Policy and Planning section). From VA TECH HYDRO Jean-Claude Riesterer (CEO VA TECH HYDRO Ravensburg) was present. In the evening a large ceremony for all people involved in the project was given by EGAT where commissioning engineer Steve Sgier and installation supervisor Julius Walz of VA TECH impressed with their cooking skills. A food booth arranged by VA TECH including also some specialities from Switzerland and the Black Forest in Germany gained a lot of compliments from all guests.

Thilo Pohlmann Phone +49/751 83 3209


Modernization of turbine and generator
The ZEVIO hydropower plant approx. 20 km southeast of Verona in Italy was built in the fifties. The two vertical Kaplan units with existing spiral case have a power output of 7.94 MW each. In May 2003, VA TECH HYDRO was awarded a contract for the modernization of the Zevio hydropower plant with two Kaplan turbines as well as the two vertical generators of a power output of 95 MVA each by the Italian energy supplier ENEL POWER. ENEL POWER intends to modernize a great number of additional hydropower plants in Italy. The improvement of operational efficiency and the benefit of Green Certificates were decisive factors for the modernization of existing plants. For these reasons VA TECH HYDRO sees a good opportunities and a great potential for further offers in the near future. In this project a special challenge for VA TECH HYDRO is the extremely tight time schedule specified by the client ENEL POWER. In particular, the short execution time for manufacturing and erection and the overall tight project schedule required a perfect, competent and well experienced team during the whole project lifetime. Unit 1 will start its commercial operation already in May 2004 and unit 2 will follow in June 2004. The concept for the modernization plans provides for installing the generators rotor with a solid rotor-rim construction - on the existing foundation. Also the forced air-cooling will use the existing inlet and exhaust channels. Mirco Magnabosco Phone +39/0445 678 225
Technical data: Output: 7.94 MW / 9.5 Voltage: 9 Head: 11.64 Speed: 136.4 Runner diameter: 3,500 Stator diameter: 5,500

MVA kV m rpm mm mm



Two hydropower plants in Pakistan
In June 2003 the Pakistani WAPDA (Water and Power Development Authority) awarded a new contract to VA TECH HYDRO for the design, manufacture, supply, installation, testing, training and commissioning of the electromechanical equipment incl. all auxiliaries for Allai Khwar and Duber Khwar power plants. These projects will be connected to the National Grid via 220 kV transmission lines at Mansehra. VA TECH HYDROs scope of supply consists of: Four Pelton turbines (two at Allai Khwar and two at Duber Khwar) Four digital governors Four spherical inlet valves (1,050 mm Allai Kwar and 1,200 mm Duber Kwar) Cooling water equipment Cranes Workshop equipment Four vertical synchronous generators (two at Allai Khwar and two at Duber Khwar) including excitation system The project Allai Khwar is located in the northwest Frontier Province (NWFP) of Pakistan on Allai Khwar, a left bank tributary to the Indus River, in the Mansehra District, at a distance of 245 km from Rawalpindi/Islamabad, the capital of Pakistan and 270 km from Peshawar, the capital of NWFP while the Duber Khwar project is located on the Duber Khwar, a right bank tributary to the Indus River. The project area is at a distance of 270 km of Rawalpindi and 300 km from Peshawar. Transformers Allai Khwar: 220 kV generator block transf., 220 kV autotransf., station unit & station transfer transformer Duber Khwar: 132 kV block transf., station unit & station transfer transformer HV-Switchgear (Allai Khwar 220 kV + 132 kV; Duber Khwar 132 kV) MV-switchgear Station supply Control system
Technical data Allai Khwar: Output: 62.5 MW / 71 Voltage: 11 Head: 516 Speed: 500 Runner diameter: 2,190 Stator diameter: 4,050 Technical data Duber Khwar: Output: 67 MW / 76 Voltage: 11 Head: 662 Speed: 428.6 Runner diameter: 2,130 Stator diameter: 4,900 MVA kV m rpm mm mm

Protection system HV, MV, LV cables, control cables & fibre optical Ccables Main earthing system Power station electrical services HVAC and fire fighting equipment Fire alarm system Telecommunication equipment LV distribution and street lighting MV distribution lines (only Allai Khwar) These projects will start operation in 2007 resulting in a positive impact on the countrys economy.

Andor Kristoff Phone +43/1 89100 3619

MVA kV m rpm mm mm


Our Pelton runners do not fear competition: A successful showdown in Switzerland
For the upgrading of the four twin turbines of HPP Tavanasa in

Switzerland, the customer performed a competitive field test comparing a new runners of VA TECH HYDRO and another turbine manufacturer. The final contractual tests showed a clear superiority of VA TECH HYDRO, which led to a contract for all remaining runners.

2nd VA TECH runner optimized & tested in modified casing



casing improvement



1st VA TECH runner optimized & tested in original casing 2nd VA TECH runner optimized in modified casing but tested in original casing

runner adaption



H=478.2m, 2-jet operation

In 1994, NOK utility planned to order 8 new runners for the Tavanasa plant in Grisons, Switzerland. To find the best solution in a competitive test, the plant owner ordered one new runner from VA TECH HYDRO and one from a competitor. The field tests of both runners were planned to take place in the original, suboptimum casing. Due to these contractual In conrehab





Output per runner [MW]

projects it is common practice to select a modern runner and to modify the existing components (intake, nozzles, casing) as closely as possible to resemle a modern design to get a good overall performance. But this time, a modification of the components was not accepted since all competitors had to use the same ones. Therefore, VA TECH HYDRO developed a special bucket design with an optimum fit to the existing com-

ponents. Thereby the interactions between runner and components, e.g. the casing and the jets, were taken into account and optimized to avoid feeding water into reflecting zones. This elaborate strategy was possible due to an enhanced understanding of the flow patterns in the different buckets and their resulting exiting water sheet. This complex development was shortened significantly by the application of our enhanced numerical simulation tools. When the first model tests were

straints, we followed an unusual development



completed, the idea of a further comparison in a modified casing came up at NOK. During contractual field tests with the first two runners in the original casing, only the one with the VA TECH HYDRO runner gave valid results since there was a short circuit in the grid during testing the competitors runner. Comparisons between the tests performed for the original and a modified casing indicated that a

developed a second runner, but this time to provide an optimal match with the modified casing. By chance, this new runner was also tested in the original casing as shown in the diagram. The following conclusions can be drawn from this: The tests clearly showed, that the first runner was adapted successfully to the exceptional, original casing. The performance of the second

ance with a difference in peak efficiency of 0.6%. The difference in weighted efficiency was 0.44% which gave an amortization of its price within approximately 10 years. The results demonstrate that a detailed consideration of interaction effects between runner and casing is of key importance in all rehabs with suboptimum casings. The performance increase achieved

through numerical methods and model tests not only comes from

modification of the casing could improve efficiency between 0.5 1.0 %. Unfortunately, the performance of the VA TECH HYDRO runner was not fully exploited in the modified casing since it was optimized for the other casing. Due to these results, and because there were cracks in some cut-outs of the competitors integrally cast runner, the utility decided to repeat the competitive tests in a modified casing with another two new runners one more from each competitor. In this second phase, VA TECH HYDRO

VA TECH HYDRO runner in the modified casing was considerably better than with the original casing, even when the first runner was used in the original casing. Finally, both runners of the second phase, the one from VA TECH HYDRO and the one from its competitor, were tested in the modified casing. They showed the same efficiency at full load, whereas over the whole operating range from a 90% down to a 30% load, the VA TECH HYDRO runner showed superior perform-

the analysis of each component independently. Indeed the turbine behaviour nents. is closely related to the interaction between the compo-

Lothar Geppert Phone +41/1 278 2782

Technical data: Output: Head: Speed: Ext. runner diameter:

49.8 478.2 375 2,868

MW m rpm mm


Renovation, modernization and uprating of turbine and generator
Kerala State Electricity Board (KSEB) has signed a contract with VA TECH HYDRO for the renovation, modernization and uprating of six units at the Sabarigiri power station. The project will be led by VA TECH HYDRO in India with support from VA TECH HYDRO Vienna. The Sabarigiri project originally commissioned in 1968 is located on the Pamba & Kakki rivers in the Moozhiyar Dense Forest 65 km east of Pathanamthitta city in the Kerala State of India. The range of supply comprises design, engineering, installation, supervision, training and commissioning of new turbine runners, new parts for refurbishing the main inlet valve, new digital governors incl.

sation, excitation and protection, the renewal of equipment for the 220 kV switchyard incl. circuit breakers and disconnectors, new battery chargers & batteries, DC distribution and one emergency Diesel set. The contract commencement date was January 27, 2003. The entire project is due to finish at the beginning of 2007. Rahul Varshney Phone +91/7480 233714 18
Technical data: Output: 50 MW / 55.5 MVA Voltage: 11 kV Head: 761.7 m Speed: 500 rpm Runner diameter: 2,590 mm Stator diameter: 3,454 mm

controls as well as for the rehabilitation of the six generators, a new 11kV MV switchgear, a new 25 MVA transformer, new control and monitoring systems including synchroni-


Contract for hydraulic steel structures signed
With the award of the hydraulic steel structures contract of the Middle Marsyangdi HEP, VA TECH HYDRO continues its presence in the Nepalese hydropower market. annual energy to be fed into the national grid. Once completed the project will be an important contribution to the further development and strengthening of the Nepalese economy. Although the project features with regard to the hydraulic steel structure work are not record breaking, it is quite a challenging project being located in a little developed area characterized by heavy monsoon rainfall which results in high maximum flow rates and considerOn July 22, 2003 the contract was signed jointly with the employer Nepal Electricity Authority (NEA) and the engineer Fichtner Joint Venture (FJV) in Kathmandu, Government Nepal. of His Majestys Nepal VA TECH HYDROs scope of supply includes the design, delivery, installation and commissioning of: Radial gates, stoplogs and gantry cranes for the spillway Radial gate, service gate, stoplogs and flap gate for the bedload sluice Stoplogs, trashracks, raking machine, roller gates, calming racks, flushing systems, bulkhead gates, sliding gates, bridge cranes and monorail cranes for the intake and HMG/N has received a grant from the government of the Federal Republic of Germany through Kreditanstalt fr Wiederaufbau (KfW) to finance the majority of the foreign currency cost of the project, and HMG/N and NEA will provide the local currency cost. Middle Marsyangdi HEP (MMHEP) is a peak load run-of-river scheme and will generate about 400 GWh of Work under this contract is to be completed within 34 months desander structures Steel liners, butterfly valve incl. bridge crane and accessories, penstock and manifold Powerhouse crane Draft tube gates Auxiliaries
Technical data: Hydraulic steel structures, cranes and valve: Total weight of supply: 1,700 tons Steel liners, penstock and manifold: Total weight of supply: 1,150 tons






mence. Particular care shall be taken to coordinate the execution with the progress of the Lot C Civil Contractor, a joint venture led by DYWIDAG International from Germany. With a technically feasible hydropower potential of 43,000 MW in Nepal and the growing demand, not only within Nepal but also in neighbouring India, there is a considerable potential for further development of hydropower. VA TECH HYDRO will continue to contribute to this development with its experience and capabilities in the future.

able sediment loads.

(HMG/N) has decided to start construction of the Middle Marsyangdi hydroelectric project (2 x 36 MW) located in the Marsyangdi river valley approx. 170 km west of Kathmandu. The project is executed by NEA, an undertaking of HMG/N.

Christian Stoebich Phone +43/70 6987 3406


Eroded runner blades

Annual flood of the Blue Nile at Roseires dam

Shop inspection of new runner blades

Rehabilitation of turbine No. 4 successfully completed
Successful completion of the Turbine 4 rehabilitation contract improves performance, extends life time and marks another highlight in the longstanding between business National of relations Electricity Sudan and better withstand erosion. The new runner hub and the new guide vanes are manufactured from stainless steel, while new coating technologies were used on other critical components in the water ways. All these measures will contribute to give the turbine an extended new service life time of 20 years. At the same time, the governor was refurbished and the hydraulic and electronic control system was rehabilitated and renewed under a different contract. This contract is the last in a line of several service and rehabilitation contracts completed by VA TECH HYDRO: Between 1985 and 1987, turbines 1, 2 and 3 were refurbished the first time by extensive repair welding and grinding of the turbine runner blades. Under this contract, the 44 MW vertical Kaplan turbine was equipped with a new turbine runner and new guide vanes, the other turbine components were overhauled and repaired where necessary. The new turbine runner blades are designed to give their best performance in the operating range required by the prevailing load regime. Additional thickness was added to the turbine runner blades for them to

VA TECH HYDRO was called in for emergency repairs, after 3 months of on-site weld repairs the turbines were back to service. In 1998 NEC ordered VA TECH HYDRO to comprehensively rehabilitate Roseires turbines 5, 6 and 7 with new turbine runner blades, improvements in turbine vibration level and general refurbishment work. Great emphasis was placed on technology transfer and training of the power station personnel. In between, inspection and repair work was done on turbine intakes and other auxiliary equipment. All these projects were completed in time and to the full satisfaction of National to Electricity and Corporation. enhancing They are a substantial contribution maintaining reliability and availability of the Roseires power station, the largest and most important generation utility in Sudan.


VA TECH HYDRO. The Roseires hydropower station is located on the Blue Nile some 500 km south of Khartoum. The power Kaplan station comprises The Blue seven Nile turbines.

contains a high amount of silt with extremely abrasive sand particles, which results in heavy erosion of the water carrying parts, in particular the runner blades. The condition of turbine No. 4 supplied and installed 25 years ago had worsened due to the impact of erosion so that modernization and rehabilitation of the turbine became necessary.

Between 1994 and 1995, the same turbine turbines runner received blades, new and

additional thickness was added to increase their life. Roseires turbines 5, 6 and 7 were severely damaged. Erosion on the runner blades caused unbalances, excessive vibrations and cracks in structural parts commanded immediate remedy. useful service

Rudolf Hammelmller Phone +43/70 6987 4330

Technical data: No. of units Output: Head: Speed: Runner diameter:

1 (7) 44 36 136 4.5 (4.8)

MW m rpm mm

Rehabilitation of turbine, generator, governor and auxiliary equipment for unit no. 4. In June 2002, in response to an international inquiry made in February 2002 by EDP-Energa, VA TECH HYDRO in Spain submitted a quotation for the integral rehabilitation of Belvers unit no. 4. In January 2003, the order to carry out work on unit no. 4 from 2003 until January 2004 was placed with our company in Spain. EDP Energa reserved the right to place an additional order for units 1, 2 and 3, for the years 2004, 2005 and 2006.

The signing of a contract for the installation of 2 ECOBulbTM units at the Paullo power plant near Milan marks the successful continuation of the introduction of the ECOBulbTM series into the market. The features and advantages of the ECOBulbTM have once again convinced a customer. The general contractor, the Italian company S.T.E. srl, has


Belver power station is located on the Tejo river, 27 kilometres from the city of Abrantes, and comprises four Kaplan units of 8 MW each manufactured in 1951 (Escher Wyss TACEC), one Kaplan unit of 15.5 MW built in 1971 and the sixth unit (a 31.6 MW bulb turbine) dating from 1984. The scope of supply covers the turbine (guide vanes, predistributor, runner, runner cover, top and bottom covers, shaft seal, shafts, bearings, oil introducing system, cooling system), a new turbine governor, generator (rotor isolating poles, stator, bearings and breaking system), new excitation, voltage control and vibration control devices, and a new power plant crane. As an alternative we also quoted the replacement of runner blades, increasing efficiency, flow and output, but this additional work was not included in the contract due to economical reasons. The project is processing to schedule.
Technical data: Output: Voltage: Head: Speed: Runner diameter: 8 6.35 11.9 166.7 3,300 MW kV m rpm mm

awarded VA TECH HYDRO in France a contract for the installation of 2 runner regulated ECOBulbTM units. The scope of supply includes the turbines inclined at 15 degrees with a runner diameter of 2,600 mm and commissioning. A complete CFD calculation of the intake significantly improved the quality of the flow pattern and therefore the units efficiency. Start of operation is scheduled for early 2004.
Technical data: Output: Voltage: Head: Speed: Runner diameter:
Pierre Duflon Phone +33/4 76 85 95 25

The scope of supply for the modernization project included a new stator core with the corresponding windings and new pole windings. Following the successful modernization, VA TECH HYDRO received an additional order in 2002 for the supply of the protection systems for the generators and step-up transformers for SAN AGATON. The scope of supply comprises the engineering and supply of 6 digital protection relays DRS-C2, two ground-fault protection relays and two type SYN-3000 relays for synchronization control.
Technical data: Output: Voltage: Frequency: Head: Speed: Runner diameter: Stator diameter:
Carlos Sgro Phone +58/212 991 70 44

1,185 33 3.4 150 2,600

kW kV m rpm mm

153 13.8 60 357 225 3,330 7,450

MW kV Hz m rpm mm mm

This contract marks the sale of the 200th MicroGuss TM Pelton runner by VA TECH HYDRO! The customer Skagerak Energi AS Norway has placed an order with VA TECH HYDRO for 2 new Pelton runners for Hjartdla power plant. Hjartdla power plant has 2 vertical 4-nozzle Pelton turbines and is situated approximately 180 km to the west of Oslo. VA TECH HYDRO presented the customer with the best technical as well as economical offer. The scope of supply comprises two new runners and new needle tips and seat rings for all injectors. Casing performance will also be improved by water shields positioned on the


Modernization of mechanical and electrical equipment and first digital protection system supplied by VA TECH in Venezuela. Following the execution of different orders in the field of spare parts for hydropower plants operated by CADAFE in Venezuela such as supply of 4 MicroGuss TM Pelton runners (4 x 60 MW), repair of 11 injectors, supply of 8 screw pumps and the supply and installation of digital governors, in 2001 VA TECH HYDRO was awarded a contract for the repair of generator no. 2 at SAN AGATON hydropower plant.

Valeriano Arreba Phone +34/91 425 10 05

injectors. The delivery period for the first Pelton runner is 12 months and commissioning will take place in May 2004. In 1992 the first MicroGuss Pelton runner was manufactured and successful ly commissioned just one year later. The new manufacturing process supported by a robot was a consequence of the increasing demands by our customers. It is well known that Pelton runners manuactured of conventional steel more often show cracks or even bucket breaks which can put the safety of the workers at risk and reduce availabiliy. The MicroGuss manufacturing process differs from the steel casting in so far as the most suitable material is used in the right place. This has been achieved by forging


material to the most stressed bucket root zones and also welding the MicroGuss material to the remaining bucket zones of the runner. Today we may look back on 11 successful years and have set a milestone with the award of the contract for MicroGuss Pelton runner No. 200. The success of our innovation is mainly due to the fact that so far no failures have occurred during the operation of our MicroGuss runners. We see this as a confirmation of the success of our continuous process optimization efforts.
Technical data: Output: Head: Speed: Runner pitch diameter: Runner weight:

VA TECH HYDRO in Ravensburg and VA TECH ELIN EBG Salzburg together have successfully won an order for the delivery, erection and commissioning of two modern PIT turbines for the Rott hydropower station. The scope of delivery includes the mechanical and electrical hydro generating equipment such as turbines, gears, generators and digital control equipment. The new PIT turbines, will replace the existing three Arno-Fischer bulb turbines (runner diameter 1,950 mm) built in the 1950's. Meanwhile two virtually identical turbines have also been sold for the Jettenbach hydropower station in Bavaria. The new Rott hydropower station will replace the aged Saalach plant located between Salzburg and Freilassing built during WWII and completed in 1950 due to shortages in construction materials. Since then, the three single regulated turbines have deliv-

stream of the Saalach plant. The new Rott hydropower station will feature two new VA TECH HYDRO PIT turbines with spur gear and a runner diameter of 2,350 mm as well as two high-speed synchronous generators by ELIN EBG. The energy output of the new Rott hydropower station will be 47% more than that of the existing Saalach hydropower station, an increase in annual energy from 19,000 MWh to 28,000 MWh, primarily due to the higher efficiency of the new equipment. The Rott project will positively stimulate the environment and provide a boost to the local economy. Beginning in autumn 2004, the Rott power station will supply more than 7,000 households with green water energy.
Technical data: Output: 2x2,614 kW / 2x3,125 Head: 10.28 Speed: 205 / 750 Runner diameter: 2,350
Edwin Walch Phone +43/70 6987 3473

kVA m rpm mm


Hidroelctrica Aconcagua has signed a contract with VA TECH HYDRO in Switzerland for the design, supply, installation supervision and commissioning of six injectors plus one spare injector without nozzle heads. The components to be supplied will be installed in a vertical Pelton turbine which was originally supplied in 1993 by another manufacturer. It will have a special design to avoid the introduction of sediments in the servomotor zone and thus solve operational problems. The new injectors are designed for a higher flow rate to assure an increase in output of up to 17%.

66.57 555 428.6 2,240 9,150

MW m rpm mm kg

Jack Buchmann Phone +41/41 329 53 38 Walter Keiser Phone +41/41 329 53 21

ered 19,000 MWh annually to the city of Salzburg. Today, the existing power station can no longer be run economically without major redevelopment work due to its age and the deterioration of the generating equipment. Consequently, the local energy provider, Salzburg AG, decided to build the new Rott hydropower station as well as a new dam and fish ladder down-


Delivery took place in July 2003 following assembly and factory tests including pressure tests on all injectors to be supplied.
Technical data: Output: Head: Speed: 46.7 MW 658 m 600 rpm


In February 2003, VA TECH HYDRO signed a contract with Corporacion Dominicana de Electricidad (the Owner) and Dessau-Soprin International Inc, the Owners representative, engineer and manager of the project.

In the meantime the dam and the penstock (supplied and installed by VA TECH HYDRO) have already been completed and the three new vertical Francis-type units with auxiliaries as well as associated civil and construction work yet to be done will be designed, supplied, installed and commissioned according to specification. A fully equipped workshop is also part of the supply. Prior to the procurement of any material and start of manufacturing, respectively, a model test will be conducted. The project site is located approx. 40 km north-east of Kotamadya Benkulu, the capital of the Bengkulu province on Sumatra island. Installation is scheduled to start in July 2004 (first embedment parts for the 2nd stage concreting) and the entire project works will be completed by April 2006.
Technical data: Output: Head: Speed: Runner diameter: 73.6 396 500 1,550 MW m rpm mm

Carlos Contreras Phone +41/21 92 57 721


In addition to the contract signed in 2001 VA TECH HYDRO was awarded a new contract for the refurbishment and modernization of 8 bulb turbines and generators on the Danube river.

VA TECH HYDRO is responsible for the supply, installation, cabling, start up and commissioning of the generating equipment for the J.J. Puello mini hydropower plant located in the Dominican Republic. VA TECH HYDROs scope of supply includes two horizontal Francis turbines, synchronous generators, inlet valves, HPU, electrical, protection and control equipment, installation, cabling as well as start up and commissioning.
Technical data: Output: Head: Speed: Runner diameter: 1,801 54.4 900 670 kW m rpm mm

Norbert Kuehpacher Phone +43/70 6987 3461

Hidroelectrica S.A., the largest hydropower utility in Romania, placed a contract with VA TECH HYDRO for the refurbishment of additional 2 units as part of the Gogosu extension project of this power plant. The separate power plant with similar equipment as the main powerhouse (Iron Gates II) is located on a side arm of the Danube river at the same reservoir. The model tests for both contracts were successfully performed in the VA TECH laboratory in Linz under the supervision and participation of a delegation of Hidroelectricas experts in January 2003.
Technical data: Output: 27.0 MW / 27.55 MVA Voltage: 6.3 kV Head: 7.45 m Speed: 62.5 rpm Runner diameter: 7,500 mm Stator diameter: 9,000 mm
Edgar Crnert Phone +49/751 83 2109


In late December 2002, VA TECH HYDRO in Canada was awarded a contract by Furry Creek Power for the supply, technical direction and start-up and commissioning of the generating equipment for the Furry Creek hydroelectric plant situated near Squamish in British Colombia. The Furry Creek generating station will house one single vertical 4 jet Pelton turbine including a synchronous generator, inlet valve and electrical, control and protection equipment. The engineer is Sigma Engineering of Vancouver B.C.
Technical data: Output: Head: Speed: Runner diameter:

Claude ONeil Phone +1/450 449 1228

A VA TECH HYDRO consortium comprising VA TECH HYDRO, Linz, Austria and PT VA TECH Indonesia has signed a contract with PT. PLN (Persero) for the supply and installation of three turbines including digital type governors, three spherical valves and auxiliary equipment inclusive of civil and construction work (Lot III A).

10,546 326.5 600 1,250

kW m rpm mm

Claude ONeil Phone +1/450 449 1228





During the 1970s, the U.S. saw their challenges in the growth of the electric energy business. The rising oil price as well as increasing concerns and problems with the nuclear power industry forced the U.S. to look back to hydropower as a cost-competitive source of energy. New projects, the introduction of private customers in the market, and the large rehabilitation potential opened the door for VOEST ALPINE (VA) to build on its industry-leading rehabilitation skills. In 1957, VOEST in Austria started its activities in the turbine business as a licencee of Baldwin-Lima-Hamilton. In 1971, VOEST acquired the hydro business of Baldwin-Lima-Hamilton. In 1973, VA International created a division in their New York City office to handle the enormous hydropower market in the United States. By the early 1980s, the Hydro USA division had grown large enough to move to their own office in Berlin, New Jersey. In 1991, the division became a licensed subsidiary by the name of VOEST ALPINE MCE Corporation and, in 1998, moved headquarters to Salisbury, North Carolina.
18 Walterville

In the year 2000 the company became VA TECH VOEST MCE Corporation and began adding staff to accommodate their growing business. By mid-2001, the staff had tripled and the company moved to a larger office in Charlotte, North Carolina. In the summer of 2003, the company officially changed its name to numerous small and medium projects. So how and why did VA TECH HYDRO USA grow so quickly? To answer that question one must first look at the history of the hydropower business in the United States. In 1878 Baldwin Locomotive of Philadelphia, Pennsylvania invented the Pelton waterwheel. Then in 1903 I.P. Morris of Philadelphia manufactured their first water turbine. Sulzer (Escher Wyss) installed their first turbine in the U.S. at Osoro in 1912. In 1975, VA got the order for American Falls, later, in 1983, Bouvier of France installed their first small turbine in the U.S. at Cottonwood Canyon Ranch in California. What do all of these manufacturers have in common? They are now all a part of VA TECH HYDRO. This means that VA TECH HYDRO USA has more than 160 years of experience in the hydroelectric industry. VA TECH HYDRO USA Corp. to more accurately reflect the nature of its business. As of July 2003, the company has had more than 70 employees and is now handling 6 major and

Grand Coulee

VA TECH HYDRO USA realized that the U.S. marketplace demanded a more comprehensive portfolio of services and products from their manufacturing partners. Likewise, it became much more important for a manufacturer to provide fast and accurate responses to customer i n q u i r i e s . To meet these n e e d s VA TECH HYDRO USA not only moved to a more modern and large office in Charlotte but also added experience and expertise to their Sales, Field Service, Engineering and Customer Service departments. Our customers can rest assured that each employee of VA TECH HYDRO USA is there to provide services and products that go beyond their

needs are met. That is our commitment to the U.S. market. Currently the installed capacity for hydropower in the U.S. is between 88,000 and 90,000 MW. Hydropower has a share of 7% of the U.S. electricity generation. Clearly, hydropower has a significant role in the future energy plans of the US. VA TECH HYDRO USA ensures that electricity is produced as efficiently and cleanly as possible. Stephen Wacker Phone +1/704 943 4343
Office USA

expectations. We will do everything possible to ensure our customers

Walter F. George


New station switchgear system, rewind and upgrade six generators incl. new generator shafts, new station service transformer, new static exciters, six new Francis runners, new turbine shafts & wicket gates, rework/repair of major turbine components like head covers, etc. Modernization of 18 Francis turbines comprising furnishing new die pressed runner blades, wicket gates and associated equipment and all field works including disassembly and reinstallation of units. Joint project with General Electric - Canada. Modernization of three Francis turbines comprising of model testing, delivery of new runners, wicket gates and associated equipment including disassembly and reinstallation. Modernization of four Kaplan turbines including model testing, engineering, refurbishment of major turbine components, delivery of new runners, hydraulic and digital governors, upgrading of generators. New Francis runner, refurbish governor, new electronic governor control system, rewind and upgrade generator, rework turbine shaft, wicket gates and all bearings, upgrades to hydraulic system, new cooling water system, new static excitation, start-up and operations training.




Runner diameter
3.2 m

10.73 MW

18.3 m

97.3 rpm

Grand Coulee

130 MW

100.5 m

120 rpm

4.4 m


140 MW

187.5 m

200 rpm

3.5 m

Walter F. George

41.9 MW

22 m

112.5 rpm

5 m


9.4 MW

16.8 m

171.4 rpm

3.1 m

Goat Rock

Provide two new pit type horizontal propeller turbines, speed increasers, and generators. Scope also includes new distributor 8.7 MW intake, pit liner, governor hydraulic units, spare parts, and special tools. Provide three Francis runners, three sets of stationary wearing rings, three sets of coupling elements, three sets of wicket gates, and associated bushings and bearings. Includes model test. 48 MW

18.9 m

229 rpm

3.0 m

Flaming Gorge

130 m

400 rpm

2.3 m



VA TECH HYDRO to build a Combined Cycle Power Plant in Greece
VA TECH HYDROs Combined Cycle division has signed a major contract for the construction of a gas combined cycle power plant for Thessaloniki, Energiaki Greece. The

contract was awarded by the client Thessalonikis S.A., a 100% subsidiary of the Greek mineral oil supplier Hellenic Petroleum S.A. The plant is being built on the premises of the client, the refinery, located about 10 km left of the center of Thessaloniki. This contract represents an important step towards further expanding the market position of VA TECH HYDRO in Europe. It confirms the strategic direction taken by VA TECH HYDRO by focusing on Europe as its local and key market.

The power plant is a project with top priority for Greece as a supply shortage is already emerging for 2004. This anticipated situation is further aggravated by the fact that Greece is hosting the Olympic Games in the summer of 2004. The necessary

development of infrastructure will provide another strong boost to the Greek economy and increase the country's energy consumption on both a medium and long-term basis. At the same time the power plant is the first project built by an

IPP and can be considered a pilot project for the liberalization of the Greek Energy Market. The Pre Notice to Proceed with the project was received in May 2003. The site has been mobilized and civil construction works has started beginning of October. The Thessaloniki project encompasses the planning, supply, erection and commissioning of a combined cycle power plant with an output of approx. 400 MW. The heart of the plant is a 9FA gas turbine supplied by General Electric, which has been the partner for the Combined Cycle division for many years. The turbine produces a power output of approx. 260 MW, and in addition waste gas with a temperature of around 600C. A waste-heat boiler is used to convert this to steam, which then results in a power output of approx. 140 MW via a steam turbine. The scope of supply for VA TECH, Combined Cycle, also includes all electrical systems und instrumentation and control, all auxiliary plant units such as fuel supply,





additional behind



have in

supply, and the entire structural engineering. The technical configuration of this 400 MW power plant unit has been extensively standardized by VA TECH HYDRO, Combined Cycle, and is modelled on the power plants at Coolkeeragh in Northern Ireland or Ankara/Turkey. This type of power plant is characterized by maximum efficiency and minimum emission levels. In comparison with coal-fired power plants, even the latest technology including high-tech flue-gas cleaning systems, the CO 2 emissions of a combined cycle power plant are merely a third to a quarter with the same output size. This benefit, combined with relatively low investment costs and the extremely short construction period, 26.5 months, has ensured that this type of power plant has been the most successful over the last ten years. VA TECH HYDRO continues to view Europe as a sound market, unlike the USA, where in the last years

already been erected. The reason further development Europe is the necessity of replacing old oil or coal-fired plants.

Technical data: Gas turbine: GE 1 x type 9FA 253 MW output fuel: natural gas, distillate fuel Dry Low Nox Steam turbine: Franco Tosi condensing turbine 146 MW output Generator: GE, VA TECH 1 x 324 MVA, 15.75 kV (for GT) 1 x 166 MVA, 15 kV (for ST) HRSG: 1 x HRSG vertical, 3 pressure range and reheater

Gerhard Mara Phone +43/1 89100 2680



VA TECH Open invited to Norway

From 3 to 5 July VA TECH Open was held for the 8th time - an event which has meanwhile become a must for investors and analysts. After Austria, France, Germany, the UK and South Africa, Norway was now the venue for this highly informative gathering that also has a social dimension to it. 33 external attendees from Austria, Germany, Switzerland, Italy, Great Britain and France all met up in Oslo, also including 6 Austrian journalists for the first time, hoping to find out more about VA TECH, especially VA TECH HYDRO, and to enter into discussion with recognized experts and managers from VA TECH. In his opening address Dr. Roland Scharb, CFO of VA TECH, spoke about the key figures and highlights as well as the strategies and prospects of the Group. Richard Taylor from the International Hydro Power Association (IHA) then demonstrated with an impressive number of examples that the use of hydropower and environmental protection need not be a contradiction. Chris Head, a specialist in hydropower for many years, opened up entirely new perspectives for innovative solutions relating to the financing of hydropower projects. Christian Habegger, Chairman of the Managing Board

of VA TECH HYDRO in Norway, with a description of the hydro market in Sweden and Norway. The afternoon then finished with a very lively panel discussion, when views were expressed not only by Nils Andersson (Vattenfall) and Tron Engebrethsen (Statkraft) but also by customer representatives. The audience actively seized the opportunity for discussion with acknowledged experts. After this very compact info session the day ended with an evening with a Norwegian flavour to it. Early the next morning the attendees then set off for Stavanger a move from theory to practice. The tour of the newly renovated power plant in Lysebotn went down very well with all participants, many of whom were visiting a power station for the first time. VA TECH Open was a resounding success for everyone involved, offering not only plenty of information but also sufficient opportunity for in-depth individual discussion.

of VA TECH HYDRO, emphasized the significance of hydropower as an economical and renewable source of energy and the role played by VA TECH HYDRO in conjunction with the Kyoto Protocol. The series of papers was rounded off by Erik Pike, Managing Director

Papers are available on VATECHHYDRO/Media/EventCenter/ PastEvents.

Ursula Scheidl Phone +43/1 89100 2053



HYDROMATRIX on show at ICOLD 2003, Montreal

at the event reflected both the global nature of our company and the results that can be achieved with effective co-operation between our different business units. Sales personnel from the Canadian Thomas Taylor Phone +1/905 323 3267 VA TECH HYDRO decided to take a stand at the 21st Congress of the International Commission on Large Dams ICOLD. The decision was influenced by the fact that several of our key customers as well as our target customers the event. opportunity were to sponsors promote of result of the presence of severe acute respiratory syndrome (SARS) in Canada, attendance was reasonable. Those people who had the opportunity to see the scale model of the Cannelton/Smithland HYDROMATRIX Turbine project in operation were intrigued with and engaged in some lively discussions. Mr. ONeil from VA TECH HYDRO in Canada the It also gave us the offices, the USA office and the German office were present. In spite of the natural concerns as a arranged presentations to senior engineers at Hydro Quebec on both HYDROMATRIX and bulb turbines, two specialities of VA TECH HYDRO.

HYDRO 2003 November 3-6, 2003 Dubrovnik, Croatia HANOVER FAIR April 1924, 2004 Hanover, Germany ICOLD May 1621, 2004 Seoul, Republic of Korea POWER-GEN EUROPE May 2527, 2004 Dsseldorf, Germany

HYDROMATRIX Turbine which is very suitable to be installed in existing Dams. The event was held at the Palais de Congres in Montreal, with some 750 delegates attending the whole Congress and nearly 500 visitors attending the exhibition only. The representation of VA TECH HYDRO


eHYD.25.8500.W.D03 HYDRO News 5