Waterpower Week in Washington | May 1-3, 2017 | Washington D.C.

Waterpower Week in Washington focuses on bringing together industry leaders, state and federal
regulatory officials and key legislative staff to discuss technology, policy and future developments for
conventional hydro, pumped storage, and marine energy.

For more information on the conference program and sponsorship opportunities please visit

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 September-October 2016

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02 VIEWPOINT:
A BRIGHT FUTURE 04 WORLDWIDE
HYDRO NEWS 16 BEARING VIBRATION
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 Volume 24. No. 5. September-October 2016

CONTENTS

10
FEATURES DEPARTMENTS

10 International Guide to Hydro Innovations and

New Technology
By Gregory B. Poindexter
2 Viewpoint:
A Bright Future
4 World News
In this first-ever international product and technology guide, we 32 Index
present data on how several companies are helping owners of hydro to Advertisers
plants and dams manage their facilities and maximize efficiency.

16 Solving High Intermittent Bearing Vibration after a

Modernization and Upgrade
By Enes Zulovic
The upper guide and thrust bearing assembly on Unit 1 at the
125 MW Tungatinah station experienced intermittent high
vibrations after an upgrade and modernization. The author developed
a novel integrated approach for vibration analysis to find the root
cause and propose an appropriate solution.

ADVISORY BOARD

26 Viewpoints from the Board Room: International Finance

Corporation
The International Finance Corp. (IFC) seeks to invest in responsibly
H. Irfan Aker
Dolsar Engineering Co.,
Turkey
Kanchit Ngamsanroaj
Electricity Generating
Authority of Thailand,
Thailand
Emmanuel Antwi-Darkwa
ETAD Consult Ltd., Ghana Christian Dalosto Pase
developed and operated hydropower projects to grant energy access Tractebel Energia, Brazil
Enrique Cifres
to impoverished people in developing nations. Morgan Landy eWATER Consultant SL,
Spain
Doan Ke Ruan
Power Engineering Con-
sulting Company, Vietnam
discusses IFCs involvement in sustainable hydro development. Ian M. Cook
ICCL, United Kingdom Leon Tromp
Lesotho Highlands Water
Jean-Louis Drommi Commission, Lesotho
Electricite de France,
France Christine van Oldeneel
Hydro Equipment Associa-
Maryse Francois-Xausa tion, Belgium
Alstom Renewable Power
Hydro, France C.V.J. Varma
Council of Power Utilities
Roger Gill and The Dams Society,
Sustena Partners, India
Australia
Raghunath Gopal
Fernando de Menezes (R.G.) Vartak
e Silva Consultant, India
Itaipu Binacional, Brazil

16 26
Luis C. Vintimilla
Peter Mulvihill Consulting Engineer,
Pioneer Generation, Ecuador
New Zealand
James Yang, PhD
Vattenfall Research and
Development AB, Sweden

www.hydroworld.com September-October 2016 / HRW 1

1609HRW_1 1 9/14/16 4:19 PM

 VIEWPOINT

A Bright Future
Vice President, Group Publishing Director,
Hydro and Water Groups Marla Barnes
+1 918 832 9353 marlab@pennwell.com

Managing Editor Elizabeth Ingram

+1 918 831 9175 elizabethi@pennwell.com

Editor Michael Harris

Theories about where technology could take us have been a staple of the +1 918 832 9363 michaelh@pennwell.com
entertainment industry for decades. Two examples that spring to mind Associate Editor Gregory B. Poindexter
+1 918 832 9330 gregp@pennwell.com
are the Star Trek movie and television show franchise (which is still
Production Manager Daniel Greene
going strong) and the Jetsons television sitcom, both of which debuted +1 918 831 9401 danielg@pennwell.com
in the 1960s. In fact, did you know that Star Trek has been cited as an Graphic Designer Kermit Mulkins
+1 918 831 9554 kermitm@pennwell.com
inspiration for such technological breakthroughs as cell phones and
Audience Development Manager Emily Martin
tablet computers? V.P. of Audience Development & Marketing June Griffin
Production Director Charlie Cole
Recently, hydroelectric power has captured the imagination of some
innovators, who are adapting this mature technology to achieve todays needs. A couple of www.pennwell.com

technologies that stood out for me are:

HRW Hydro Review Worldwide
The Barsha pump, from aQysta in The Netherlands, uses the kinetic energy of moving water PennWell Corp.
PennWell Global Energy Group
to provide irrigation water for farmers (barsha means rain in Nepalese). The pump, a waterwheel The Water Tower, Gunpowder Mill,
Powermill Lane, Waltham Abbey,
moored in a moving current, can be installed in a river, stream or canal and incorporates few Essex, EN9 1BN, UK
Telephone: +44 1992 656 600
moving parts to simplify maintenance. It can pump water to a maximum vertical height of Fax: +44 1992 656 700
E-mail: hydroreview@pennwell.com
20 m and a distance as long as 2 km. It can pump as much as 40,000 L per day, depending on World Wide Web: http://www.hydroworld.com

the speed and flow rate of the river and the height to which it is being pumped. The pump has Sales Manager:
Europe, Asia, Africa, Oceania Sophia Perry
been installed in Indonesia, Nepal, Spain, Turkey and Zambia and provides an alternative to +44 1992 656641 sophiap@pennwell.com

pumps powered using kerosene or diesel. Sales Director: Americas Howard Lutzk
+1 913 402 7119 howardl@pennwell.com
The Estream, from Enomad in South Korea, is a lightweight hydropower generator with an
For assistance with marketing strategy or ad creation,
integrated lithium-ion battery that provides a capacity of up to 5 watts of electricity. The device, please contact:
which takes 4.5 hours to fully charge, is intended to produce power for outdoor adventurers PennWell Marketing Solutions Paul Andrews
240.595.2352 pandrews@pennwell.com
who might want to charge a USB-connected mobile device. The unit is 9.7 in by 2.5 in by
8.3 in and weighs less than 2 pounds. As of Aug. 31, this device was part of a Kickstarter Chairman Robert F. Biolchini
Vice Chairman Frank T. Lauinger
campaign that still had 11 days to go but had already raised $135,554 of its $80,000 goal. President and Chief Executive Officer Mark C. Wilmoth
Executive Vice President,
Established companies in the hydropower and dams markets also are offering new technologies Corporate Development and Strategy Jayne A. Gilsinger
Senior Vice President,
and innovative applications of existing technology. Our article on page 10 features detailed Finance and Chief Financial Officer Brian Conway

information on six such technologies applied around the world, one or more of which may help
Subscriber Customer Service
you solve a problem at your hydro facility or dam. PO Box 3264, Northbrook, IL 60065-3264, USA
In addition, further information on technology innovation and application is available under Customer Service Phone: 1-847-559-7330
Fax: 847-763-9607
the Technology/Equipment topic center at HydroWorld.com, updated daily. Email: hr@halldata.com

Our current reality may not look much like what you saw on Star Trek or the Jetsons 50
Reprints Rhonda Brown
years ago (no flying cars, yet), but technology is advancing rapidly, and the hydro and dams +1 866 879 9144 pennwellreprints@fosterprinting.com

industries are keeping pace. The views expressed by contributing authors are those of the individuals
concerned and do not necessarily reflect those of HRW or the publishers.

HRW (ISSN 1072-9542) is published six times in January, March, May, July,
September, and November by PennWell Global Energy Group, The Water
Tower, Gunpowder Mill, Powermill Lane, Waltham Abbey, Essex, EN9 1BN,
UK; phone +44 1992 656 600. Printed in the U.K. Canadian GST Registration
Number 12681 3153 RT0001. Canada Post International Publications Mail
Product (Canadian Distribution) Publications Agreement No. 40029359. @
Copyright 2016 by PennWell Corp. (Registered in U.S. Patent Trademark Of-
Managing Editor fice). No part of this periodical may be reproduced without the consent of the
publisher. Authorization to photocopy items for internal or personal use, or the
internal or personal use of specific clients, is granted by HRW, ISSN 1072-9542,
provided that the appropriate fee is paid directly to Copyright Clearance Center,
222 Rosewood Drive, Danvers, MA 01923 USA 978-750-8400. Prior to pho-
tocopying items for educational classroom use, please contact Copyright Clear-
ance Center, 222 Rosewood Drive, Danvers, MA 01923 USA 978-750-8400.
Periodicals postage paid at Tulsa, OK and additional mailing offices. Annual
subscription rate: US$44 per year. Single copies: US$20. Payments accepted in
U.S. funds only. HRW is a subscriber to Business News Americas news ser-
vices and incorporates their copy in its news columns. POSTMASTER: Send
change of address, other circulation information to HRW, PO Box 3264, North-
brook, IL 60065-3264. HRW is a registered trademark of PennWell Corp.

Member: BPA International

Printed in the U.K.. GST NO. 12681 3153 RT0001

Publications Mail Agreement No. 40029359
2 HRW / September-October 2016

1609HRW_2 2 9/14/16 4:19 PM

 Dr. Jiri Koutnik, Managing Director of the international Voith Hydro Engineering Center, in a
conversation with Susanne Kathirvel, Product Manager, and Mauricio Kondo, Design Engineer.
International Experts
Ensuring Technological
Leadership
As Managing Director of the international
Voith Hydro Engineering Center I deal
with lots of interesting and challenging
projects. After more than twelve years
with Voith I saw how we managed to
nd optimal solutions countless times.
What I like most is the interdisciplinary
character of the tasks, mostly touching
the complete power unit or even power
plant behavior. It is always interesting
to confront our theoretical approaches
with practical experiences and site mea-
surements.
I am still fascinated by physical pheno-
mena in hydraulic and electrical machines
and enjoy discussing them with my
1609HRW_3 3
colleagues. Together we invest all our
http://hrw.hotims.com RS #2
time and energy to meet customer
expectations and assert our competitive
position with state-of-the-art technology.
With a global R&D network, Voith Hydro
is always close to customers needs
and familiar with local conditions. As our
Engineering Centers are spread across
the globe we ensure a high-class inter-
national expert exchange and techno-
logical leadership.
Dr. Jiri Koutnik
www.voith.com
A Voith and Siemens Company
9/14/16 4:19 PM
 NEW DEVELOPMENT
Pakistan announces agreement signed
for 870 MW Suki Kinari project
The government of the province of Khyber
Pakhtunkhwa, Pakistan, has signed an agree-
ment with SK Hydro Private and Industrial
and Commercial Bank of China to develop
and construct the 870 MW Suki Kinari
hydro project.
Under the agreement, the hydro project
would be built on the Kunhar River in the
Mansehra district of Khyber Pakhtunkhwa at
a cost of US$1.9 billion and is expected to be
completed by 2021. The electricity produced
would be transferred to Pakistans national
grid for distribution to the entire country.
According to a press release, the parties
have agreed to a 30-year power purchase
agreement, after which the government of
KP would assume operation and ownership
of the facility and receive all income from the
sale of electricity.
More New Development news is
available on HydroWorld.com:
Presidential order reinstates study for
proposed 6,000 MW Myitsone project
in Myanmar
Final unit at Brazils 220 MW Cachoeira
Caldeirao enters commercial operation
SMALL HYDRO
3 MW Cia Aig hydropower project
commissioned in Scotland
Forestry Commission Scotland and Loch Eil
Estates, in partnership with RWE Npower
Renewables, commissioned the run-of-river
US$15.9 million 3 MW Cia Aig small hydro-
power scheme in August, after more than a total
of six years of development and construction.
The project is located on the Abhainn
4 HRW / September-October 2016
1609HRW_4 4
Chia-aig River, at the eastern end of Loch
Arkaig. According to RWE, it received consent
from the Scottish government in June 2010.
The Scottish Environment Protection Agency
under the Controlled Activities Regulations
granted a water license for the project.
An intake weir directs water to a
3.2 km-long buried pipeline, into a power-
house that contains two vertical five-nozzle
Pelton turbines, one each at 1.01 MW and
1.99 MW.
Paul Wheelhouse MSP, minister for
Business, Innovation and Energy, together
with Hans Bunting, chief operating officer
for Renewables of RWE, were onsite for the
plants inauguration.
Bnting said, We value the skilled supply
chain that Scotland can offer and when devel-
oping our renewables projects, it is important
to us that we are able to work with local
companies and to maximize the economic
benefits to the local economy.
After the commissioning of the Cia Aig
scheme, RWE now operates 15 hydroelectric
power stations in Scotland.
More Small Hydro news is
available on HydroWorld.com:
Hedcor to upgrade Bineng small hydro
plants, more than triple capacity
Peterborough Utilities commissions
expanded 9.8 MW London Street small
hydro station
TECHNOLOGY/EQUIPMENT
Siemens providing GIS to
3,600 MW Rogun plant in Tajikistan
Germany-based Siemens AG is supplying two
gas-insulated high-voltage switchgear (GIS)
for the 3,600 MW Rogun plant in Tajikistan.
The amount of the award is not immediately
available, but the GIS should be installed and
ready for operation by 2018, Siemens says.
Rogun Dam has a planned height of
1,099 ft and is located on the Vakhsh River
in Pamir.
Siemens said it is supplying:
8DQ1 switchgear, which covers voltage
ranges of up to 550 kV and has 21 circuit
breakers;
8DN9 switchgear, which covers up to
220 kV and has four circuit breakers; and
Online monitoring devices on the GIS to
enable automatic remote diagnosis and
self-monitoring.
A total of six turbines at 600 MW should,
according to Seimens, annually generate
13.3 billion kWh.
More Technology & Equipment news
is available on HydroWorld.com:
IHA expands knowledge networks to eight
hydropower topics
Hydro Equipment Association announces
dissolution
MARINE HYDROKINETICS
2 MW tidal energy test project
coming to Japan
A consortium led by Kyuden Mirai Energy Co.
plans to test a tidal energy project near Goto
in Japans southwestern Nagasaki Prefecture. It
is expected to have a capacity of about 2 MW
when it begins operation in 2019.
Kyuden Mirai a subsidiary of Japans
Kyusuhu Electric Power Corp. is joined
in the effort by Nippon Steel & Sumikin
Engineering, Nagasaki University, the
Nagasaki Marine Industry Cluster Promotion
Association (NaMICPA) and OpenHydro.
OpenHydro said site surveys are expected
to begin this year, with procurement,
www.hydroworld.com
9/14/16 4:19 PM
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 WORLD NEWS
fabrication and cable laying set to begin in
2017. The Scottish manufacturer will build
the projects generating unit in France before
shipping it to be anchored on a subsea base
built by Nippon Steel & Sumikin Engineering.
This 16-metre turbine will be the first
commercial-scale tidal device to be deployed
in Japanese waters, OpenHydro Chief
Executive Officer James Ives said. Through
this demonstration project, we will work with
our consortium partners to foster local skills
and expertise.
Once installed, the pilot turbine will
undergo a year of tests that will, developers
hope, lead to the development for larger
installations around Japan.
More Marine Hydrokinetics news
is available on HydroWorld.com:
Tidal energy company tests prototype in
Canadian archipelago, Haida Gwaii
MHK turbines possible for Indias power
infrastructure
DAMS/CIVIL STRUCTURES
ICOLD releases four new
technical bulletins on dams
The International Commission on Large
Dams has released four new technical bulletins
related to various aspects of dams.
Bulletin 146, Dams and Resettlement
Lessons Learnt and Recommendations,
is intended to be an information source for
policy makers and implementers. It highlights
the latest policies, criteria and resettlement
measures adopted, their implementation
aspects and the performance or effectiveness of
the mitigation measures taken to improve the
living standards and quality of life of the relo-
cation. The bulletin deals with issues implied
by resettlement, explains case histories and
lessons learned, and recommends strategies.
Bulletin 148, Selecting Seismic Parameters
for Large Dams Guidelines, is a revision
of previous Bulletin 72, with the same name
and published in 1989. This bulletin takes
into account current practice in a number
of countries, with a view toward providing
a guide for the selection of parameters to be
6 HRW / September-October 2016
1609HRW_6 6
used in the seismic design, analysis and safety
evaluation of new or existing dams and their
appurtenant structures, as well as promote
consistency in handling the earthquake aspects
of dam performance evaluation among owners,
designers and various organizations involved
in the planning, design, construction, opera-
tion, maintenance and regulation of dams.
Bulletin 157, Small Dams: Design,
Surveillance and Rehabilitation, was prepared
as a guide for small dam owners, engineer-
ing, government agencies, developers and
contractors who are in charge of the design,
construction, operation, maintenance and
safety of small dams. The bulletin says, Design
criteria and typical features for small dams are
generally different from those for high dams,
because the construction methods focus upon
economy. This bulletin presents the main
recommendations to ensure that the dams will
behave appropriately and with minimum cost.
Bulletin 166, Inspection of Dams follow-
ing Earthquake Guidelines, is a revision of
previous bulletin 62A, published in 1988.
Inspection of dams following earthquakes
is an important aspect in the integral safety
concept of dams, ICOLD says. Since 1988,
earthquakes have occurred that have caused
damage to dams. Large dams should be able
to resist the effects of the strongest ground
shaking to be expected at the dam site.
However, major damage is accepted as long
as there is no catastrophic release of water
from the reservoir, the bulletin says.
The bulletins can be purchased at www.
icold-cigb.org/GB/Publications/bulletin.asp.
More Dams & Civil Structures news
is available on HydroWorld.com:
BC Hydro responds to concerns about
fracking and dam safety
Pennsylvania announces $25.7 million in
funding for dam safety improvements
BUSINESS & FINANCE
Aneel sets cap price for upcoming
Brazilian hydroelectric power auction
Brazilian power regulator Agencia Nacional
de Energia Eletrica (Aneel) has set wholesale
cap prices for an upcoming power auction that
includes more than 130 small hydro plants.
According to a statement issued by the
agency in mid-August, there was to be a
US$77 per MWh cap in the Sept. 23 reserve
power auction.
In Brazil, power purchase agreements are
awarded to developers who submit the lowest
bids for the price of power to be sold from
their plants, with the government buying
capacity using a reserve model to protect
against a future supply deficit.
The cumulative capacity from the upcom-
ing auction is about 990 MW, Aneel said, with
PPAs to be awarded in 30-year deals.
The auction was scheduled for late July
but rescheduled. Aneel plans to hold another
reserve auction for renewables later this year.
More Business & Finance news is
available on HydroWorld.com:
Green Fuel needs $300 million to build
Condo Dam, 200 MW hydro powerhouse
in Zimbabwe
China loans Argentina US$25 billion for
energy projects, including hydroelectric
ENVIRONMENTAL
Brazilian regulator rejects environmental
license for 8,000 MW Sao Luiz do Tapajos
Brazils Institute of the Environment and
Natural Resources, Ibama, will not award an
environmental license for the Sao Luiz do
Tapajos plant, effectively ending development
of the 8,000 MW project.
The federal regulatory agency announced
its decision in early August following reports
by public prosecutors that the project would
destroy traditional lands of the Munduruku
Indians near Itaituba in Brazils Para state.
The land, known as Sawre Muybu, was
officially acknowledged by indigenous pop-
ulation authority Funai earlier this year. The
designation gives the land protection from
potentially invasive developments.
The US$8.6 billion plant was being devel-
oped by state-run utility Eletrobras and was one
of more than 250 hydroelectric plants and dams
publicly opposed by hundreds of members from
www.hydroworld.com
9/14/16 4:19 PM
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 WORLD NEWS
four Amazonian tribes in May 2015.
A concession auction for the projects
development was also previously revoked in
September 2014 after Brazils Ministry of
Mines and Energy determined that the pro-
posal did not meet a number of environmental
and social criteria.
Sao Luiz do Tapajos is the largest com-
ponent of the proposed12,000 MW Tapajos
complexon the Tapajos and Jamanxim rivers
in northern Brazil. The complex also is to
include the 2,300 MW Jatoba, 528 MW
Cachoeira dos Patos, 881 MW Jamanxin and
802 MW Cachoeira do Cai projects.
More Environmental news is
available on HydroWorld.com:
US$7.3 million Tibble Fork Dam rehabil-
itation project temporarily ceases reservoir
drainage
Strategies used at 18 MW Rwegura
hydroelectric facility in Burundi to deal
with low water levels
PUMPED STORAGE
Andritz awarded supply contract for
880 MW Gouvaes pumped-storage plant
Equipment supplier Andritz Hydro GmbH
has been awarded a contract by utility
Iberdrola Generacion to supply electrome-
chanical equipment and a penstock for the 880
MW Gouvaes pumped-storage hydropower
plant in Portugal.
The order, worth about US$156 million,
includes the design, manufacture and instal-
lation supervision for four 220 MW turbines
that will operate with a net head of 660 m.
The penstock will have a total weight of about
12,000 tons, an average diameter of 5.4 m and
a length of 2.5 km.
Andritz said Gouvaes will be the heart
of a new 1,200 MW complex on the Tamega
River in northern Portugal. A pair of smaller
conventional hydroelectric plants will also
eventually be constructed.
Gouvaes will cover the need for peak-load
energy and provide fast-responding regulating
power, Andritz said in a release. Together
with this base load generation from the other
8 HRW / September-October 2016
1609HRW_8 8
two power stations, this scheme will ideally
complement the volatile electricity generation
from wind power, which has been growing
significantly in recent years.
More Pumped Storage news is
available on HydroWorld.com:
Plans announced for 300 MW
pumped-storage project in Scotland
Duke receives 30-year FERC license for
868-MW Keowee-Toxaway project
REHAB & UPGRADE
Final upgrade testing begins at Statkrafts
350 MW Nedre Rossaga plant
A three-month test period for a new unit at
Norways Nedre Rossaga hydroelectric plant
is under way, utility Statkraft announced. The
225 MW unit is located in a new powerhouse
built by Statkraft over the past three years and
will replace three of the facilitys original six
units once the test period ends.
The company said the remaining three
units in Nedre Rossagas old station have
already been upgraded, giving the upgraded
project a total installed capacity of 350 MW
following the installation of the new unit.
The plants cumulative capacity was 100 MW.
HydroWorld.com reported in March 2013
that the contract to supply the equipment
was awarded to Voith Hydro as part of a
US$12.9 million package that also included
turbines for Statkrafts Oevera Roessaga and
Vessingfoss plants.
By increasing the tunnel capacity and the
efficiency of the new equipment, the total
power output of Nedre Rossaga will increase
by 200 GWh per year, Statkraft said. In
total, the annual generation of the power plant
will reach 2,100 GWh, or 2.1 billion kWh of
renewable energy.
The upgrade was part of a $165.5 million
project announced by Statkraft in March 2010.
Construction began in January 2013 and also
included more than 19 km of tunnels and
environmental improvements.
More Rehabilitation & Upgrade news
is available on HydroWorld.com:
Phase two of rehabilitation and upgrade
beginning at 40 MW Matala in Angola
Tractebel awarded contract to modernize
Perus 1,008 MW Mantaro plant
REGULATION & POLICY
EC approves Czech Republic hydroelectric
power support scheme
The European Commission has found that a
scheme which supports hydroelectric power
production in the Czech Republic to be con-
gruent with European Union state aid rules,
the organization said earlier today.
The announcement stems to September
2015, when the Czech Republic notified
the EU of its plan to provide the opera-
tors of hydropower projects up to 10 MW
in capacity with support totaling up to
US$9 million.
Under environmental protection and
energy guidelines established by the EC in
2014, member states can support the produc-
tion of energy from renewable sources under
certain conditions.
According to the guidelines, hydro
installations with a capacity below 500 kW
will receive support in the form of a market
premium paid on top of the market price,
while those below will receive a feed-in tariff.
The EC said this, alongside a similar plan
for the Czech Republics biogas sector, will
minimize the potential distortion of competi-
tion brought about by the public financing by
ensuring that these payments do not exceed
the minimum level necessary to achieve the
schemes objectives.
Both initiatives are part of the Czech
Republics effort to increase its target of
making renewable sources account for 14%
of its total image consumed by 2020.
More Regulation & Policy news is
available on HydroWorld.com:
Slovenske Elektrarne to petition
Constitutional Court of the Slovak
Republic
Group suing Portland General Electric
over operation of its Pelton Round Butte
project
www.hydroworld.com
9/14/16 4:19 PM
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 T E C H N O L O GY A N D I N N O VAT I O N

International Guide to Hydro Innovations and

New Technology
In this first-ever international product and technology guide, we present
data on how several companies are helping owners of hydro plants and
dams manage their facilities and maximize efficiency.
By Gregory B. Poindexter

H
ydropower represents about 80% of
the worlds installed renewable power
generation capacity, according to the
International Energy Outlook 2016. As
such, the power source is a key ingredient in
the worlds commitment for developed and
developing countries to reduce greenhouse gas
emissions in the coming decades.
A variety of methods are needed to
efficiently manage and expand uses of this
incredible resource. New software develop-
ment for hydropower control and monitoring
applications is essential for this industry, as
well as hardware that is applied at projects in
innovative ways.
HRW-Hydro Review Worldwide has
identified new technologies; hardware that
is in development, testing or deployment; and
innovative applications for existing methods.
What follows are short descriptions of each
product and information on case studies and
practical applications.
Cavitation monitoring software
Voith Hydros HyConMD cavitation moni-
toring module has been tested in Switzerland,
Norway, Canada and Germany in seven
hydropower plants that include 210 MW
Wallsee-Mitterkirchen owned and operated
by Verbund Hydro Power GmbH, according
to Voith.
Two recently completed case studies from
operational hydropower facilities and turbine
prototypes indicate the HyConMD cavitation
monitoring module provides reliable online
information about the cavitation behavior of
a hydraulic machine. Cavitation potentially
limits the operational range of hydraulic tur-
bines. It causes noise and vibrations and can
even erode the surface of turbine components.
The monitoring system consists of a set of
robust high-frequency sensors and amplifiers,
a high-speed data acquisition and signal pro-
cessing unit, and an analysis software module.
The sensors can be attached from the
outside to the turbine.
Based on the measured acoustic emissions
and commonly available machine data such
as rotational speed, the software module
calculates a characteristic value classifying
the state of cavitation (no, acceptable, strong,
severe). A key advantage of the method is
the fact that no individual calibration of the
system is necessary. This allows the user to
assess the cavitation in different machines
independent of machine size and speed and,
most importantly, without prior knowledge
of machine characteristics.
Both long-term and short-term obser-
vations are possible, each giving important
insights into the machine behavior and
providing directions for the operation of the
machine. The instantaneous or short-term
data can be used for an optimization of the
operating range, while a long-term evaluation
of the signal supports an individual, condition
based adjustment of the revision intervals.

Seal management system

Wartsilas REvolution digital management
system can revolutionize sealing technology
for hydropower customers. It incorporates
machine learning, predictive modelling and
The HyConMD cavitation module monitoring system can help prevent runner erosion. model predictive control (MPC) techniques

10 HRW / September-October 2016 www.hydroworld.com

1609HRW_10 10 9/14/16 4:19 PM

 to provide hydropower plant owners and
operators with intelligent, real-time active
management of the sealing interface fluid film
(pressurized water interface), minimizing wear
and removing the turbine sealing components
from the maintenance schedule critical path,
the company says.
The application of advanced control
techniques enables modern mechanical face
seals to overcome operational issues such as
excessive leakage and degradation of wearing
components. Both are caused when the off-
design-point operation of the seal occurs. This
can be transiently, such as during start up or
shut down conditions when the hydrodynamic
lubricating film of a traditional mechanical
face seal degrades and asperity (abrasive)
contact occurs, or it can be a result of debris The REvolution system collects performance data, including seal interface wear and pressure.
or abrasives entering or possibly occluding
the interface. conditions enables real time predictive wear types of dams that include: roller-compacted
The adaptation of a balanced mechanical forecasting, which enables optimal mainte- concrete, concrete faced rockfill, rockfill,
face seal to incorporate an optimally con- nance routines. earthfill, thin arch, multiple arch, buttress,
trolled injection of clean lubricating water and gravity.
directly into the sealing interface mitigates Dam facing geomembrane Carpi geomembrane installation can be
excessive interface wear, eliminates abrasive Carpi Tech B.V., established in 1963, works performed in dry conditions and underwater,
contamination and optimally manages leak- with geomembrane scientists and formulators when dewatering is not an option.
age. An adaptive MPC is used to manage to deploy watertight, flexible polyvinylchloride A case study indicates an innovative use
the pressure and flow of the injection fluid. (PVC) geomembrane for specific site applica- of the system in waterproofing the upstream
The analysis and predictive control action tion. Carpi watertight geomembranes provide face of the Nam Ou 4 Dam in Laos. The study,
yields optimal sealing performance and can waterproofing and protection of all types of Nam Ou VI: Geomembrane Face Rockfill
balance costs associated with leakage, wear hydraulic, civil, underground and environment Dam in Laos, was presented at the 2015
and maintenance. protection structures. Australian National Committee on Large
The REvolution system combines the Typically, Carpi uses its patented geomem- Dams conference.
Wartsila REguard (a pump guard) mechan- brane mechanical anchorage system and acts The system is being constructed as part
ical shaft seal technology with a control and as a specialty contractor to install exposed of the 1,156 MW Nam Ou River basin
monitoring system package that includes PVC geomembrane on the upstream face project. The entire river basin project will
pressure, flow, temperature and wear sensors of a dam. feature seven dams and powerhouses with
within the seal. Since 2006, Carpi has performed extensive projected installed capacity of 1,156 MW
Seal performance data are fed into a central research to adapt geomembrane systems for and annual generation of 5,017 GWh. The
controller running proprietary data analysis new installation and rehabilitation for several project is in the provinces of Phongsaly and
and control software. This enables the modifi-
cation of the seal interface injection pressure in
real-time. Data are accessed via a supervisory
control and data acquisition system that can
also operate as a standalone system.
The application of advanced digital con-
trols and data acquisition provide the capa-
bility of optimizing performance throughout
the seals entire operating envelope. The
collection and use of historical data collected
during operation through monitoring, local
analysis and logging of the seal operating The longevity of this patented system is one a the main benefits of Carpi geomembranes.

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1609HRW_11 11 9/14/16 4:19 PM

 of Munich in Germany, and Italys Istituto Sperimentale Modelli E
Strutture, which many in dam safety and the hydropower industry
consider a top hydraulic research institute.

Ultrasonic flow measurement

Ultraflux is able to install probes for pipe diameters up to 10 m.
Luang Prabang, and the total cost is expected to be US$2.8 billion.
According to Carpi, the Nam Ou 4 scheme includes an 88 m-high
geomembrane faced rockfill dam (GFRD), which will be the highest
GFRD in Laos. The only element providing watertightness to the dam
is an exposed composite PVC geomembrane, installed according to
an innovative design now being increasingly adopted to construct safe
rockfill dams at lower costs.
The liner is a composite geomembrane (geocomposite), SIBELON
CNT, comprising a watertight PVC geomembrane that can withstand
elongation exceeding 250% of its original shape and an anti-puncture
geotextile heat-bonded to the geomembrane during manufacture.
Carpi geomembrane systems have been tested by the U.S. Army
Corps of Engineers, Hydro-Quebec in Canada, the Technical University
Ultraflux has tackled accurate flow measurement at hydropower
facilities (i.e., better than 1% accuracy) in tough hydraulic conditions
(e.g., insufficient straight length). These applications used up to eight
ultrasonic chords, and in some cases required the installation of probes
inside pipe where external access for use of insertion probes was not
possible. The resulting precision flow measurement was used to calculate
turbine capacity.
Ultraflux installed products for hydropower generation applications
in France and all over the world, including: Brazil, South Africa,
Morocco, Georgia and in the UK. Ultraflux has been tasked with
installing multi-chord ultrasound flow meters on existing pipes that
have 1,800 mm to 2,700 mm diameter and, in one case, pipes exceeding
7,000 mm in diameter.
In the South African hydroelectric plant operation for four penstocks
at 7.4-m in diameter, the measurement system installed by Ultraflux
uses clamp-on probes to regulate the plants flows and protect against
the risk of flooding in the valley. The project combined an acoustic
transmission test using a portable flow meter and SE 1599 probes in
direct configuration that helped optimize system application.
Ultrasonic flow measurement is one of the technologies that still
has the potential for improvement and growth.

Harness the power

from the water
At Ingeteam each project is addressed from the
concept of i+c, innovation to develop the best solutions
and commitment to provide the best service.

We provide comprehensive solutions for hydropower

plant electrical and control systems, integrating
proprietary technologies for automation, protection,
regulation and synchronisation.

Our independence, capability and experience in

renewable energy generating plants allows us to
offer protable solutions, with the highest levels of
availability, reliability and safety. Solutions tailored to
meet the specic needs of each and every customer.

The formula of the new energy

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Control, Protection
www.ingeteam.com
and Regulation Systems
Electrical Systems
hydro.energy@ingeteam.com Substations READY FOR YOUR CHALLENGES

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 --




 


 

 

 

   

  -


 
 

   
 
  
 
 

 

   
   
 
 

   

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The Kuenz floating bulkhead system can be floated in for use.
The company says it is able to: offer system analyses and diagnostics
to customers on site; measure speed over several [pipe] sections so that
the various flow speeds can be taken into account; provide controlled
and reliable measurements to reduce uncertainty about flow dynamics;
mount probes under load; and allow for consistent repeatability of
applications throughout entire projects.
Floating bulkhead
Hans Kuenz GmbH specifically developed its floating bulkhead tech-
nology for the needs of Verbund Hydro Power GmbH in Austria. The
power producer was seeking a system for some of its hydroelectric
facilities that could be used to dewater spillway gate bays to allow
for inspection, without the need for major civil work rehabilitation
or new construction.
Hydro-Mechanical Equipment
Gates, Flaps, Stop Logs, Screens, Trash Rack Cleaning Systems
Hans Kuenz GmbH | 6971 Hard - Austria
T +43 5574 6883 0 | sales@kuenz.com | www.kuenz.com
http://hrw.hotims.com RS #9
14 HRW / September-October 2016
1609HRW_14 14
The floating bulkhead system is comprised of individual modular
components that are floated into place to enclose the area being
dewatered. The system Kuenz designed for Verbund Hydro was used
for operation at the spillways of the 12 m-high by 143 m-long Mixnitz
Dam and the 19 m-high by 53 m-long Moetschlach Dam, both located
on the Mur River in Bruck an der Mur, Styria, Austria.
In creating the technology for Verbund Hydro, Kuenz says it
now has the ability to develop multiple construction kits applicable
to address varied spans and heights of intakes, affording choice to
hydro project owners.
The elements are lowered by a mobile crane upstream into water
before being floated in place in front of the gate bay. Once all bulkhead
elements are mounted, the bay can be dewatered.
The floating bulkhead systems main advantages are:
Systems elements can be lifted directly from the shore into the
reservoir because they are floatable, negating the need for relatively
large gantry-type cranes;
Construction kit can cover several different types of intakes;
System is designed for temperatures between minus 20 degrees
Celsius and 40 C; and
Expected lifecycle of system components is more than 70 years,
according the European Standard DIN 19704.
Because it is not possible at the Mixnitz Dam spillway to remove
the bulkhead gates using a gantry crane, the floating bulkhead system
resulted in a dewatering mechanism of the gate bays with minimal
civil work modification, which helped reduce overall on-site costs.
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9/14/16 4:20 PM
 Low-head turbine-generator
Verterra Energy is developing the Volturnus, a modular hydropower,
3 m-diameter, low-profile vertical-axis riverine turbine-generator that
has a capacity of 5 to 10 kW.
The company has received three U.S. utility patents and eight foreign
fillings, including within the European Union. The pioneering patent
issued for this technology was issued on July 16, 2013: Turbine System
and Method United States (U.S. 8,487,468 B2).
Volturnus uses the power of flowing water to generate electricity and
the company says its units have minimal impact on the environment.
The device has a patented vertical axis design that allows it to
operate in water at depths of less than 2 m. Its design includes the use
of a parapet a low protective wall along its upstream edge that The low-profile Volturnus unit has a capacity of 5 to 10 kW.
allows the Volturnus to deflect and self-clear debris, which is ideal for
reliable operation in man-made canals and rivers. low-profile riverine turbine-generator component, which is significant.
The company has designed, developed and built three generations The device recorded nearly 32% efficiency in a 1.1 meters per second
of prototypes over the past five years. Verterra is in talks with four (mps) flow with turbine rotation approaching 100 rpm. That velocity
cities in the U.S. and international project developers in Italy, Haiti range of 0.5 to 1.1 mps for the scaled-prototype is the equivalent of a
and Tajikistan. commercial scale turbine in flows of 1.5 to 2.5 mps.
In September 2015, the company tested a 0.5 m-diameter scale Volturnus, V-PODS with a nameplate capacity of 50 kW each, will
prototype in the Crow River in Rockford, Minn., and a manmade be deployed modularly scaling up to 1 MW with 20 V-PODS. This
canal. The testing was performed in multiple locations over the course is analogous to the solar industry in which solar panels are deployed
of six weeks. The overall water depth ranged from 20 to 30 inches with in arrays rather than as one large and costly unit.
the depth over the lip of the device varying between 3 to 7 inches.
Verterra saw between 29% and 50% coefficient of power depending
on water velocity, as calculated by the forward swept area of the Gregory Poindexter is associate editor for HRW-Hydro Review Worldwide.

Standard and customized seals

for hydro power plants 




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installation time
  
 

Sealing solutions from SKF

Gabelhoferstrae 25, A-8750 Judenburg
SKF Sealing Solutions Austria GmbH
Phone: +43 (0)3572 82555-0,
Gabelhoferstrae 25, 8750 Judenburg
Fax: +43 (0)3572 42520,
Phone: +43 3572 82555-0, machined.seals@skf.com
Fax: +43 3572 42520
skf.com/seals
machined.seals@skf.com, www.skf.com/seals

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 BEARINGS
Solving High Intermittent Bearing Vibration after
a Modernization and Upgrade
The Unit 1 upper guide and thrust bearings at 125 MW Tungatinah
experienced intermittent high vibration after an upgrade and
modernization. The author developed a novel integrated vibration
analysis approach to find the root cause and propose a solution.
By Enes Zulovic
T
he 125 MW Tungatinah Hydro Power Station in central
Tasmania has five vertical shaft generating sets commissioned
from 1953 to 1956, each comprising a 26.1 MW Francis turbine
and a 31.25 MVA synchronous generator. From 2010 to 2014, Units
5, 1 and 2 in that order underwent upgrade and modernization.
Unit 1 was returned to service (RTS) in January 2013 and almost
immediately experienced unpredictable, intermittent and unacceptably
high vibration. A condition monitoring system is installed on this
unit, and a portable vibration system was used for commissioning. The
increase was recorded at all three bearings but was particularly noticeable
at the upper guide and thrust bearing assembly (see Figure 1 on page
20).1 Maximum shaft orbits increased for all three bearings and upper
guide bearing housing vibration reached 3.8 mm/s (unacceptably high).
The unit was inspected in March 2013, initially focusing on the
upper guide, lower guide and turbine guide bearings. Clearance on all
was acceptable, with the upper guide bearing showing no damage and
This view of Unit 1 from the turbine floor, looking up, shows the two heavy
steel I-beams that replaced the removed concrete reinforced beams.
16 HRW / September-October 2016
1609HRW_16 16
the oil thrower ring on the lower guide bearing found to have contacted
the stationary oil pot. Testing over three days showed improvement in
all vibration levels and the machine was RTS.1
Five days later, a significant increase in bearing orbits and housing
vibration was recorded. The vibration trends captured show significant
variation in amplitude for each machine start despite operating at
consistent loads.
Novel integrated approach for vibration analysis
This article proposes a systematic, analytical approach to resolving
vibration problems. Basic elements of the approach are:
System of logic
Integrated approach
Definition of vibration as a ratio of the dynamic forces acting on a
machine to its support stiffnesses.2
System of logic
Ask: Why did this turbine fail and not the nearly identical turbine
next to it?3
Example: Unit 1 experienced high intermittent vibration but not Unit 5.
Idea: Compare the failure case and a case as similar as possible that
did not fail.
The Unit 5 concrete beams at the generator level were cut to allow
for spiral casing assembly and replaced with a heavy steel welded
structure that restored the foundation stiffness.
Integrated approach
Vibration analyses should include a review of the following:
Shaft alignment: Evaluate against major acceptance criteria hori-
zontal level <0.02 mm/m, shaft static runout at the journal of the turbine
guide bearing as a percentage of bearing diametral clearance <35%,4
generator air gap stator eccentricity 3% and rotor eccentricity 1.5%.5
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9/14/16 4:17 PM
 Repair - Retrofit - Design - Align

Large Bearing
Specialists

www.hydrotech-inc.ca

Hydro Tech Inc., Sault Ste. Marie, Ontario, Canada

T +1 705 946 3182 info@hydrotech-inc.ca
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 Balancing: ISO 1940-1 gives recommenda-
tions for maximum allowed unbalance, deter-
mined by rotating mass, rotational speed and
balancing grade. Balance quality grades (in mm/
sec) are designated according to the magnitude
of eper, the distance of the mass center from the
shaft axis. But it makes more sense to define
balance quality grade in terms of eccentricity.
We recommend precision dynamic runner
workshop balancing and site rotor two-plane
precision balancing be performed to a balance
quality grade <Q1.6, or calculated eccentricity
be 70% of bearing radial clearance.
Machining tolerances: Standard IEEE
3
810 to be applied for the shaft.
Vibrations: According to some hydro
industry experience and proven practice, ISO
7919-5 and ISO 10816-5 are not sufficiently
defined as vibration standards.
Stiffness: Vibration is a ratio of the
dynamic forces acting on the machine to its
stiffnesses. Viewed this way, the focus becomes,
What has changed in the machine, the forces
acting on it or its stiffnesses?2 Vibration is a
result of other root causes occurring. To prove
the relationship between vibration and stiff-
ness, the following actions were conducted:
a) Concrete foundation vibration testing
using seismic accelerometers: The founda-
tion responded with vibration amplitudes
of 30%, exceeding the recommend values
of 25% of the bearing housing vibrations.
Unit 4 is very sensitive to machine load and
the concrete foundation vibration increased
up to 2.5 mm/s root mean square (rms)
when load exceeded 24 MW;
b) Turbine shaft bump test for natural fre-
quency: Shaft natural frequency is less than
calculated;
c) Stator frame bump test for natural fre-
quency: Result not repeatable;
d) Trial by compactor of excitation of the
concrete foundation to determine its nat-
ural frequency: It was not possible to excite
the concrete foundation at the generator
level with the small compactor when speed
control was not variable;
e) Exciter shaft balancing: Exciter shaft reso-
nant frequency is about 36 Hz, but due to
the low stiffness of the exciter support, it
was subject to high vibrations in dynamic
operating conditions;
f ) Adding two metal stiffeners to the concrete
foundations: This increased the foundation
stiffness, reduced overall machine vibration
and moved the shaft resonance far from

We embrace your vision the operating speed;

g) Adding eight radial stiffeners to the thrust
as our own. bracket: Vibration testing provided confi-
dence that the additional radial stiffeners
Your challenges are transforming the way you were providing a stabilizing effect on the
do business. We understand that your needs thrust bracket assembly; and

are changing rapidly and that you need a h) Trim rotor balancing: This provides addi-
tional margin on the shaft critical speed
partner who is proactive in identifying the larger,
by reducing dynamic unbalanced forces.
long-term issues affecting your business.
Welcome to a new era. Together we can build Shaft critical speed
positive change. In traditional design processes, the only
needed check is calculating the shaft first
Contact us at hatch.com natural frequency and assuring this is at
least 1.25 higher than the highest runaway
rotational speed. This frequency was calculated
under the assumption that the bearings are a
rigid support model, so that the calculated
natural frequency was always much larger
than the frequency experienced in operation.
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 To calculate the shaft system natural fre-
quencies and machine steady state response, the
computational model for a hydro rotor should
combine a finite element model (FEM) with
varying guide bearing stiffnesses, foundation
stiffnesses, the gyroscopic effect, unbalanced
magnetic pull (generator air gap), and hydraulic
and mechanical forces (shaft misalignment and
runner and rotor unbalance).
The turbine generator shaft rotating system
natural frequency of lateral vibrations varies
with bearing stiffness and can be significantly
less than calculated if this stiffness is insufficient.
Figure 1 shows that once the unit is steady
at 0 MW, it oscillates between a resonant
and non-resonant condition, evident by the
dramatic variation in vibration levels at the
upper guide bearing.
Foundation structure
During work on Unit 1, sections of flooring
concrete were removed to install a new spiral
casing down to the turbine floor. Enlargement
of the existing openings included removing a
concrete floor beam and slab in the operating
and generator floor. As left alignment was
good, with a shaft plumb of 0.005 mm/m and
the runner centralized in the wearing rings.
However, as found shaft plumb was 0.029
mm/m (acceptance <0.020 mm/m) and the
runner was about 0.500 mm offset in the seals.
Station foundation vibrations
To understand the relationship between
vibration and foundation stiffness, tests were
conducted using seismic accelerometers from
PCB Piezotronics installed at the generator

PRODUCTS
Detailed investigation
Hydro Tasmania technical personnel conducted

BUILT ON
root cause analyses from April to June 2013 to
help identify the cause of the unusual machine

EXPERTISE
condition. Tests of changing conditions, loads
and sequences on Unit 1 and the other machines
in service were performed. Results showed the RELATIONSHIPS BUILT ON

TRUST
vibration was not speed (mechanical balance)
related but that increased vibrations of the
stator frame and stator core when excitation
(electrical force) was applied were evident.
Comprehensive inspection and partial strip
down of Unit 1 was performed, and a thorough
investigation of the surrounding structure.
When the unit operates at its resonant
frequency, it responds more strongly, which is
observed as higher vibration levels. If the unit
is operating close to its resonant frequency,
a small change in force or perturbation may
cause the resonance to be excited. Analyzing
a polar plot of the shaft displacement after
a Unit 1 overspeed test suggests a resonant
frequency exists close to synchronous speed.
Resonance is indicated by a 180 degree phase
shift in vibration and is displayed in polar
coordinates as a circle formed by changing
machine speed, with actual resonant frequency
Whatever your challenge, weve got the
being the furthest point on the circle. people, skills and products to meet it
Evidence was seen of a resonant frequency head on. Were a company steeped in
experience and rich in innovation. We are
at the upper guide bearing around 608 rpm,
American Hydro. Speak to our skilled team
very close to the operating frequency of 600 and set a performance challenge for us.
rpm. With a resonant frequency so close Call | +1 717 755 5300
to the synchronous speed, the sudden step Email | info@ahydro.com
changes in vibration may be explained by only American Hydro
a small perturbation to the machine causing A Wrtsil Company

the resonance to be excited. Likewise, a similar

ERINN G | P ERF ORMAN CE UP GRAD ES | RE HABI LI TATI ON | N EW UN
EN G IN E ERI IT S | FIE L D S E R V IC E
UNIT
perturbation could de-excite the resonance
and cause a step down in vibration.
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1609HRW_19 19 9/14/16 4:17 PM

 Figure 1 Vibration Data low stiffness of the exciter housing combined
5 with its shape as a cantilever beam extending
MW 25 from the operating floor caused it to vibrate
4 up to 12 mm/s rms on occasion as the foun-
20
UGB US dation structural vibration initiated from Unit
Amplitude

3 UGB 90 degree 4 tuned in to the exciter housing at 36 Hz.

15

MW
2
10 Stator design
The stator is assembled in two halves. The key
1 5 bars are welded into cut-outs in the frame and
shimmed dovetail strips are bolted to the inner
0 0
11:11 11:21 11:31 11:41 11:51 surface of the bars for stacking of the lamination
Time plates. The stator frame/core consists of 32 key
UGB US LGB US TGB US Axial bars welded to the frame diametrically around
UGB 90 LGB 90 TGB 90 MW the inner bore. A dovetail key is spaced from

This vibration data captures the upper guide bearing housing step change in vibration
levels after excitation as measured on March 28, 2013.
level on all five machines.6 Vibration analysis
revealed the power station structure is suscep-
tible to vibrations produced particularly by
Unit 4. With Unit 1 shut down, vibration up
to 0.4 mm/s was recorded outside the Unit 1
alternator enclosure (see Figure 2 on page 22).
High sensitivity accelerometers from PCB
Piezotronics were installed outside the Unit 1
stator. Further analysis conducted during RTS
testing revealed that as Unit 4 load fluctuates
above 24 MW, it would occasionally initiate
structural vibration up to 1.4 mm/s in the
station floors. Similarly, high vibration was
observed in the Unit 1 exciter housing. The
the key bars using small sections of plate and
fastened by 11 countersunk 0.5-inch screws.
Based on stator core and frame vibrations
increasing when excitation is applied, it
appeared Unit 1 was experiencing a loss of
core to frame connection. Specifically, the
loss of the dovetail to keybar connection was
identified as the likely possible root cause
due to inherent flaws in the dovetail design
arrangement using screws.1,7

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 The core assembly shows the presence
of a split core design, which is inherent to
occurrence of vibrations of 100 Hz. In the
split design, the joints between the stator core
sections should be tight to reduce the core
vibrations amplitude due to the pole passing
magnetic forces. If the joints become loose,
high amplitude core vibrations at 100 Hz
7,8,9
frequency could develop.
Stator frame shims
The Unit 1 stator frame was shimmed using
10 mm-thick plates to correct axial alignment
of the rotor and stator, which was found to be
incorrect during the upgrade and moderniza-
tion alignment. This contributed to a decrease
in stiffness of the stator supporting assembly.
with the natural frequency too close to the
operating frequency;
Removing the concrete beams reduced unit
stiffness and shifted the natural frequency
at the upper guide bearing support assem-
bly closer to the operating frequency;
As the upgrade and modernization included
the installation and concreting of a new
metal spiral case, the changed shaft lean and
shift in position is most likely due to settling
of concrete components. This corresponding
change in position at the turbine increased
the perturbation on the machine, helping
excite the resonance during operation;
Station concrete structure is not rigid and
is noticeably affected by the operation of
Unit 4 when above 24 MW;
There is no simple method for determining
the vibration root cause on hydro gen-
erating units. The integrated approach
described in this article provided distinctly
better results;
Results presented here indicate the value
of site testing for quantifying vibration,

Other issues
Other minor abnormalities discovered and
tests performed during the investigation are:
Stator frame weld cracks. During upgrade
and modernization of Unit 5, non-destruc-
tive testing (NDT) of the stator frame
revealed many weld cracks. Inspections of
the other four units revealed similar crack-
ing. The investigation revealed the cracks
were welding defects from manufacture of
the frames and there is a low risk of failure
even with multiple failed joints.
Alternator concrete foundation. Samples of
the concrete inside the alternator enclosure
revealed it to be of poor quality and soaked
with oil after years of leaks from the lower
guide bearing.
Thrust bracket bolts. The thrust bracket
hold-down bolts had been over-torqued
during installation.
Bump tests. A bump test of the shaft was
conducted with the unit free on the thrust
bearing. The shaft at the turbine pit recorded
a distinct natural frequency of 3.9 Hz.

Discussion
Combining the vibration definition (dynamic
force/stiffness) with results of the detailed
analysis and inspections, the following was
discussed to identify the root cause of the Unit
1 high intermittent vibration and provide a
corrective action plan.
Unit experiences a resonant condition at
the upper guide bearing support assembly http://hrw.hotims.com RS #15

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1609HRW_21 21 9/14/16 4:17 PM

 Figure 2 Unit 1 Foundation Vibration Response It was decided to: increase the stiffness of
2.0 the upper guide bearing and shift the resonant
frequency away from the operating frequency
by re-installing the floor beams and adding
1.5 stiffening beams, realign the unit to the set-
tled position of the turbine components and
Amplitude

perform a trim balance of the rotor.

1.0

Corrective work

0.5
Work was carried out to increase overall
stiffness of the unit foundation and at the
upper guide bearing support and to reduce
0 the dynamic forces: alignment and rotor
07:29 07:39 07:49 07:59 08:09 08:19 08:29 unbalance to control response of the unit
Time
during operation, by shifting the resonant
Unit 1 Alt Axial Unit 3 Alt Axial Unit 5 Alt Axial Unit 4 Alt Radial frequency from rated speed and reducing the
Unit 2 Alt Axial Unit 4 Alt Axial Unit 1 Alt Radial Unit 1 Op Axial
subsequent vibrations.
This figure shows the concrete foundations vibration response (green TU4load related Stiffening metal beams: The concrete floor
high levels of 1.38 mm/s rms, blue TU1- low level of 0.1 mm/s rms) of Unit 1 in June 2013,
beams were replaced with steel I-beams. To
after corrective work.
provide additional stiffness to the upper guide
natural frequencies and stiffness, as the exciter/shaker testing, to obtain the bearing assembly, eight more steel beams were
Additional stiffening of the supporting natural frequency of the components, stiff- installed at each upper guide bearing bracket
system reduces vibration below the accep- ness calculations, and site verification tests leg extending outwards to the alternator
tance by a big margin; and by using a vibration diagnostic software such enclosure wall attached to the reinforced top
A challenge is to use new technologies, such as Veski (stiffness, shaft critical speed).8,10,11 concrete beam. The new beams were mounted

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22 HRW / September-October 2016 www.hydroworld.com

1609HRW_22 22 9/14/16 4:17 PM

 with only light contact to allow for thermal Unit 1 RTS and dramatically lower than the previous high
expansion once the unit is online. RTS testing was performed in June 2013. vibration recorded in March 2013.
Alignment: The unit was realigned to the The unit was subject to machine and station Further evidence suggests the stiffening
settled turbine components and with the runner conditions previously shown to induce the beams have shifted the resonant frequency away
centralized to the wearing rings. The upper resonant vibration, as well as other conditions from the operating frequency (see Figure 3).
guide bearing was offset to achieve a shaft common during normal operation. The unit The machine is again decreasing in speed after
plumb of 0.011 mm/m. Besides shifting the was subject to multiple starts and stops as an overspeed test, but there is no indication
resonant frequency of the upper guide bear- well as long term operation, and the previous of a resonant frequency close to the operating
ing by improving the stiffness, the improved resonant condition could not be excited. frequency of 10 Hz (600 rpm) in the polar plot.
alignment will help minimize the machine Overall, the shaft orbits and bearing hous- Since the Unit 1 RTS, vibration levels have
perturbation exciting the resonant frequency. ing vibration were much lower than during remained well below the previous levels and
Balancing: During RTS testing of Unit 1, commissioning in January to February 2013 the unit has continued unrestricted operation.
the balance grade of G1.0 achieved during
initial commissioning was again recorded.
Further minimizing the unit perturbation, the
rotor was successfully trim balanced to a grade
of G0.8 according to ISO 1940.12 Bearing Problems?
Exciter shaft: The new exciter shaft installed
during the upgrade and modernization was
Leading the industry in longevity and
out of balance. The shaft was removed and durability, Lignum-Vitae water lubricated
dynamically balanced in April to June 2013.
bearings are the solution.
Unit 4 restriction: Structural vibration orig-
inating from Unit 4 operating above 24 MW
was recorded to similar levels during the Unit
1 RTS. To prevent long term damage to the
concrete foundation and further minimize any
disturbance exciting the resonance on Unit 1, a
23 MW load restriction was placed on Unit 4.

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1609HRW_23 23 9/14/16 4:17 PM

 Figure 3 Unit 1 Polar Plot
0 Experience on this project highlights the importance of the following
90 270
180
This polar plot from Unit 1 shows the shaft displacement at the
upper guide bearing during a run down from overspeed after
the corrective work was performed.
Following completion of the Unit 2 upgrade and modernization
project and installation of new metal support beams, which increased
the overall stiffness of the foundation at adjacent Unit 2, vibration
levels at Unit 1 unit have been stabilized and reduced.
Recommendations
recommendations:
A hydro-generator rotor model shall combine a FEM with vary-
ing guide bearing stiffnesses, foundation stiffness, the gyroscopic
effect, unbalanced magnetic pull (generator air gap), hydraulic force
and mechanical forces (shaft misalignment and runner and rotor
unbalance) to calculate natural frequencies and machine steady state
vibration response.
Technical specifications shall include all the factors above and
vibration levels determined in conjunction with machining tol-
erances, runner workshop balance specified as eccentricity (not
residual weight), site shaft alignment tolerances, rotor site balancing,
sufficient stiffness of the support and concrete foundation to keep
the shaft critical speed 15% above overspeed and vibration levels
within acceptance.
An integrated approach to vibration analyses should be applied
that considers machining tolerances, installation tolerances, run-
ner workshop dynamic balancing, shaft alignment, rotor dynamic
balancing, stiffness, stresses, dynamic forces.
Install and monitor vibration equipment on each unit. Vibration
information is crucial to timely identification and diagnosis of
machine problems. Use vibration software such as that from
Veski that can produce such data as shaft orbits, shaft deflection,
slow roll vector, guide bearing alignment, air gap, calculation of

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24 HRW / September-October 2016 www.hydroworld.com

1609HRW_24 24 9/14/16 4:17 PM

 shaft critical speed and stiffness of the Notes 8
Oreskovic, O., Implementation of Total Machine Condition

supporting structure. 1
Zulovic, Enes, and J. Vandervelde, The Tungatinah Vibration Monitoring System on Pump Storage Generator in PSPP

When conducting major work on a unit, Station; Multiple Vibration Issues Requiring Unique Avce (Slovenia), Proceedings of HydroVision International

consider its impact on unit stiffness, which Solutions, Proceedings of 16th HPEE, Hobart, Tasmania, 2013, PennWell Corp., Tulsa, Okla., USA, 2013.

directly affects vibration. Australia, 2014. 9

Instructions on Measuring and Interpreting the Vibrations

During the rebuild of a unit, ensure the 2

Sabin, S., Understanding and Using Dynamic Stiffness A on Machines, VDI 3839.

alignment is within the design specifi- Tutorial, Bently Nevada, 2000. 10

Internal documentation prepared during testing of

cation, and allow time for unit balancing 3

Keith, G.G., P. Loustau and M. Melin, Lloyds Register: Tungatinah unit number 1, Hydro Tasmania, Hobart,

during RTS. Failure Analysis of Rotating Equipment using Root Tasmania, Australia, 2013.

Consider the acceptable levels of vibration Cause Analysis Methods, Proceedings of POWER-GEN 11
Oreskovic, G., Computerised Diagnostic System, CoDis,

within the power station concrete foun- International 2011, PennWell, Tulsa, Okla., USA, 2011. Veski, Melbourne, Victoria, Australia.

dation structure. There are no specific 4

Hydroelectric Turbine-Generator Units Guide for Erection 12
API Standard Paragraphs Roto Dynamic Tutorial: Lateral

hydro machine standards addressing this, Tolerances and Shaft System Alignment; Part V Critical Speeds, Unbalance Response, Stability, Train

but other standards referencing rotating Maintenance of Vertical Shaft Units (All Types of Turbines Torsional, and Rotor Balancing, American Petroleum

machinery concrete foundation vibration or Pump-Turbines) Limits for Key Parameters, Canadian Institute 684, 2005.

state acceptable vibration is up to 25% to Electricity Association.

30% of the bearing housing vibration. 5

Nasselgvist, M., R. Gustavsson, and J.-O. Aidanpaa, A Reference
Due to the complexity of vibrations of Methodology for Protective Monitoring of Hydropower Zulovic, Enes, A Novel Approach Solving High Intermittent

vertical-shaft units, it is important to Units Based on the Mechanical Properties, ASME Journal Vibrations Following Modernisation and Upgrade

periodically present advances in analytical of Dynamic Measurements, March 2011. Project, Proceedings of HydroVision International 2015,

and diagnostic tools and methods and 6

Machinery Protection Systems, American Petroleum Institute PennWell Corp., Tulsa, Okla., 2015.

standards and any new knowledge and 670, 2003.

experience (Unit 1 is a good example), 7

Vladislavlev, L.A., Vibration of Hydro Units in Hydroelectric

as well as to review prior knowledge and Power Plants, (translated from Russian) Amering Enes Zulovic, MIEAust, CPEng, is specialist hydro

concepts. Publishing, New Delhi, India, 1979. mechanical engineer with Acutel Consulting in Australia.

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1609HRW_25 25 9/14/16 4:17 PM

 EXECUTIVE INTERVIEW

Viewpoints from the Board Room:

International Finance Corporation
The International Finance Corp. (IFC), part of the World Bank
Group, seeks to invest in responsibly developed and operated
hydropower projects worldwide to grant energy access to impoverished
people in developing nations. In this interview, Morgan Landy
discusses IFCs involvement in sustainable hydro development.

T
he World Bank Group was
established in 1944 and provides
financial and technical assistance
to developing countries. Its mission is
straightforward: Fight poverty with
passion and professionalism, for lasting
results. To accomplish its mission, the
World Bank Group consists of five dis-
tinct organizations:
International Bank for Reconstruction
and Development;
International Development Associ-
ation;
International Finance Corporation;
Multilateral Investment Guarantee
Agency; and
International Centre for Settlement
of Investment Disputes.
HRW-Hydro Review Worldwide
recently interviewed Morgan Landy, co-
director of the Transactional Risk-solutions
Department for IFC, to learn about efforts to
make hydropower more sustainable in Asia.
Landy leads IFC in fulfilling its strategic
commitments to sustainable development.
He also helps ensure IFC operational growth
is achieved through prudent environmental
and social governance risk management and
fosters sustainable practices for improved per-
formance in key sectors, including hydropower.
The following is a transcript of that
interview.
Morgan Landy
Q: Briefly outline the structure
of IFC and its principal role
in the hydropower sector.
Landy: Lets first emphasize why IFC invests
in sustainable hydropower development:
Worldwide according to the World Bank
Group, about 1.4 billion people lack access
to electricity. Of these, 700 million are in Asia.
Hydroelectricity accounts for one-fifth of the
worlds electricity supply but remains severely
underexploited in many developing countries
and regions with strong hydro potential. For
example, in Africa, less than 10% of the
continents hydropower potential has
been tapped.
IFC has a long track record of
investing in the hydropower sector.
Since the early 1990s, IFC has invested
more than US$1 billion in 25 countries,
which include: Chile, Guatemala, Nepal,
India, the Philippines, Uganda, Turkey,
Georgia and Pakistan. IFC now has
43 active hydropower projects in its
portfolio with a total installed capacity
of 9,942 MW.
IFC plays a key role in bringing hydro
projects to fruition, providing long ten-
ors to match the lives of the assets and
taking on risks that traditional banks are
reluctant to even contemplate. We offer
innovative ways of providing support to
hydropower companies, including early-stage
risk capital to help projects get off the ground.
As a member of the World Bank Group,
IFC is the largest multilateral source of
debt and equity financing for companies in
emerging economies worldwide. Our indus-
try experts provide clients with solutions to
strategic financing, blending investment with
advice and resource mobilization.
With the right approaches in place,
hydropower can be sustainable. This is where
IFC comes in. Our environmental and social
experts are based across the globe and provide

26 HRW / September-October 2016 www.hydroworld.com

1609HRW_26 26 9/14/16 4:20 PM

 hydropower clients with the tools they need to
make this happen. By investing in sustainable
operations upfront, our clients learn how to
improve their business outcomes.
Q: Could you highlight some
key activities in which IFC is
currently engaged within the
Asian hydropower sector?
Landy: In Asia, IFC is working in key hydro-
power markets that are challenging environ-
ments but also have the potential to have
the most development impact. Our active
portfolio includes a pipeline of five projects
in Nepal, followed by four in India, four in
Pakistan, three in China, two in Indonesia,
and two in Fiji.
IFC is also looking at opportunities to
develop small hydropower projects in Asia,
including supporting platform companies for
small hydropower development in Indonesia
and other markets where relevant. For exam-
ple, IFC recently made its first investment
in Vietnams largest private-sector indepen-
dent small hydroelectric company Gia
Lai Electricity JSC helping to support
renewable energy development to provide
critical power to the domestic market.
Were working to untangle the environ-
mental and social challenges that IFC faces
when developing hydropower including
how to develop sector sustainability. This is
where IFC plays a unique role, especially when
IFC now has 43 active hydropower
projects in its portfolio with a total
installed capacity of 9,942 MW.
working with governments. For example, in
Myanmar, we are working with officials to
prepare a countrywide strategic environmen-
tal assessment for the hydropower sector. In
Nepal, we are helping develop guidelines for
environmental impact assessments. In Lao
PDR, we are assisting with guidelines on
cumulative impact assessments. By helping
strengthen policies and regulations, we aim
to lay the foundation for better investments
to enter the market.
Q: What role do institutional investors
play in the sustainable development
of hydropower in Asia? How has
this role changed over time?
Landy: Developing hydropower in Asia
is especially challenging with regard to
cross-border projects. IFC often engages
in markets with serious environmental and
social issues, political sensitivity, financing
challenges and lack of government capacity to
implement.IFC is tackling these challenges
but cant do this alone. We need to work with

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1609HRW_27 27 9/14/16 4:20 PM

 strategic sponsors and good EPC [engineer-
ing-procurement-construction] contractors
and ensure commitments address environmen-
tal and social challenges. We require the com-
panies we invest in and their sub-contractors
to adhere to IFCs Performance Standards,
which are our guiding framework on achieving
environmental and social sustainability.
Recently, banking regulators are tak-
ing more proactive roles. In China, they
have established green-lending guidelines,
encouraging the financing of new projects to
help manage environmental and social risks.
Vietnam, Indonesia and the Philippines have
also adopted green credit policies. However, we
have to continue to work with the state-owned
enterprises as they invest abroad to ensure they
follow both these policies, set up domestically,
and international standards.
Q: How does IFC work with national
governments to establish support for
sustainable hydropower in Asia?
Landy: IFC advises government agencies on
environmental and social standards in the
hydropower sector. In Asia, this begins with
intensive capacity-building to help officials
gain an understanding of environmental
and social risks in hydropower development
and how they can mitigate risks, followed
by policy and regulatory development to lay
the foundation to secure good investments.
Q: How else can IFC positively
influence Asian hydropower
development, for example, through
advisory services, education, etc.?
Landy: If you want hydropower to be sustain-
able, you need to get the private sector into the
debate. In late 2013, IFC, with government
support from Australia and Japan, established
the Hydropower Developers Working Group
in Lao PDR. Many of the members of this
group also develop small hydro projects, and
they provided the government with feedback
on the countrys then-draft regulations on
small hydropower development. This feedback
was well received; it was the first time the Lao
PDR government involved the private sector
in policy formulation. We are looking forward
in the near future to similar groups being set
up in Myanmar, Pakistan and Nepal.
IFC, together with our clients, can influ-
ence how stakeholders are engaged in the
hydropower sector. Our continued experience
demonstrates that meaningful engagement
is invaluable and central to a companys
performance.
Q: How can IFC help address
cross-border resource-use issues?
Landy: From the energy perspective,
cross-border hydropower projects can help
stabilize regional electricity grids and reduce
costs through coordination with thermal
plants. While we believe in the benefits
cross-border projects bring, they face many
challenges. Cross-border projects often have
serious environmental and social issues,
political sensitivities, and financing and
implementation challenges.
One example is the 185 MW Shuakhevi
hydroelectric plant in Georgia. Shuakhevi is
planned to meet electricity demand during the
winter, reduce dependence on imported fuel

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28 HRW / September-October 2016 www.hydroworld.com

1609HRW_28 28 9/14/16 4:20 PM

 and increase renewable energy output. It will
also foster cross-border electricity trading at
other times of the year by exporting electricity
to Turkey through a transmission line financed
by the European Bank for Reconstruction
and Development. The project demonstrates
that non-recourse cross-border financing is
available for green projects in Georgia and
is an example of hydropower strengthening
regional cooperation.
Another example of cross-border power
engagement closely tied to hydropower is in
Nepal. In Nepal, IFC is supporting the first
real movement to harness potentials to export
power to India and Bangladesh.
Q: What are some of the key
challenges IFC faces in executing
its objectives with regard to
hydropower development in Asia?
Landy: The challenges we face are two-fold.
First, we must ensure that we choose the
right projects. This is one reason we pursue
sector-wide strategic environmental assess-
ments, for example, in Myanmar. Then, we
20
4102
http://hrw.hotims.com RS #26
www.hydroworld.com
1609HRW_29 29
must ensure that we support projects in the
right manner, which includes applying IFCs
Performance Standards.
In Myanmar, were working to help clients
walk the talk and address complex environ-
mental and social issues. Complexities include
managing river basins where multiple projects
are planned; conserving biodiversity; and
stakeholder engagement. As our experience
elsewhere has shown us, stakeholder engage-
ment is key if we want to build a sustainable
hydropower sector in Myanmar. With this
in mind, we plan to engage through forums
and platforms where internal and external
stakeholders can exchange perspectives. The
government is supporting our efforts and has
a true commitment to learning, enabling our
experts to build officials knowledge.
Q: What is IFCs perspective on
future hydropower development
in the region and the future role of
IFC in achieving that vision?
Landy: IFCs vision includes a more sustainable
hydropower sector in Asia beyond what is
1000
The Hydro Industrys
Proven Authority
http://hrw.hotims.com RS #27
currently in place. By tapping hydropower
resources sustainably, we plan to deliver energy
to the people who most need it in the region,
thus helping to alleviate poverty. We want to be
able to look back 20 years from now and see a
measurable surge created in access to electricity
thats affordable and generated in the cleanest
and most renewable manner possible.
IFC action notes
IFC, a member of the World Bank
Group, is the largest global development
institution focused on the private sector
in emerging markets. Working with
2,000 businesses worldwide, we use
our six decades of experience to create
opportunity where its needed most. In
Fiscal Year 2016, our long-term invest-
ments in developing countries rose to
nearly US$19 billion, leveraging our
capital, expertise and influence to help
the private sector end extreme poverty
and boost shared prosperity. For more
information, visit www.ifc.org.
Visit
September-October 2016 / HRW 29
9/14/16 4:20 PM
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24 28
www.koncar-gim.ht
29 Andritz Hydro GmbH www.andritz.com OBC Lignum Vitae North America LLC
17 23
www.lignum-vitae-bearings.com
15 Canyon Hydro www.canyonhydro.com 21
21 National Electric Coil www.national-electric-coil.com 25
23 Fugesco www.fugesco.com 27
7 Obermeyer Hydro Inc www.obermeyerhydro.com 13
5 GGB Bearing Technology www.ggbearings.com 9
22 Oiles Corporation www.oiles.co.jp 27
20 Gilbert Gilkes & Gordon Ltd www.Gilkes.com 25

26 Gugler Water Turbines GmbH www.gugler.com 29 19 RST Instruments Ltd www.rstinstruments.com 24

9 Hans Kuenz GmbH www.kuenz.com 14 18 Seals Unlimited Inc www.sealsunlimited.com 24

12 Hatch Associates Consultants Inc www.hatch.ca 18 4 Siemens AG www.siemens.com 7

HCS Hydro Component Systems LLC SKF Sealing Solutions Austria GmbH
1 IFC 10 15
www.hydrocomponentsystems.com www.skf.com/seals
14 Hibbard Inshore LLC www.hibbardinshore.com 20 16 Sotek and Belrix Industries Inc www.Sotek.com 22
11 Hydro Tech Inc www.hydrotech-inc.ca 17 3 Thordon Bearings Inc www.ThordonBearings.com 5
27 HydroWorld.com www.hydroworld.com 29 25 Vesconite www.Vesconite.com 28
6 Ingeteam S A www.Ingeteam.com 12 2 Voith GmbH www.voith.com 3
International Hydropower Association
28 IBC 8 Wasserkraft Volk AG www.wkv-ag.com 13
www.hydropower.org

*IFC=Inside Front Cover, IBC=Inside Back Cover, and OBC=Outside Back Cover

PROFESSIONAL LISTINGS

Oil Mist Separators

for hydro turbines
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Simply equip your turbine with a custom-
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lube oil.
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+ 44 (0)1539 720028

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Wiedhof 9 D-31162 Bad Salzdezfurth Germany hydro@gilkes.com www.gilkes.com
Fon +49 5064 904-0 Fax +49 5064 904-18
info@franke-lter.com http://franke-lter.com

Member of JSC
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32 HRW / September-October 2016 www.hydroworld.com

1609HRW_32 32 9/14/16 4:20 PM

 Save the date
From 9-11 May 2017, leaders and specialists from government,
industry, finance, UN agencies, academia and civil society will
gather in Addis Ababa to set the course for hydropower over
the next 10 years.

Ask for an early registration pack at congress@hydropower.org

9-11 May 2017

Addis Ababa

MAIN ORGANISING
SPONSORS PARTNERS

http://hrw.hotims.com RS #28

1609HRW_C3 3 9/14/16 4:20 PM

 Newest technology by ANDRITZ HYDRO
for the worlds largest HYDROMATRIX plant

HYDRO
2016
Visit us at
Montreux,
Switzerland
10. 12. October 2016
Booth 79

Water has always been a source of
fascination and inspiration. But to us at
ANDRITZ HYDRO, it means even more
because it presents us with the con-
stant challenge of creating up-to-date
technological innovations. In 2012, the
worlds largest matrix hydropower plant
was inaugurated at Ashta, Albania. The
plant consists of two stages: Ashta 1 and
Ashta 2, with 45 x HYDROMATRIX TG
units each and a total output of 53 MW.
ANDRITZ HYDRO supplied the entire elec-
tromechanical equipment, including all
HYDROMATRIX units.
We focus on the best solution from
water-to-wire.

ANDRITZ HYDRO GmbH

Eibesbrunnergasse 20, 1120 Vienna, Austria
Phone: +43 50805 0, Fax: +43 50805 51015
contact-hydro@andritz.com http://hrw.hotims.com RS #29 www.andritz.com

1609HRW_C4 4 9/14/16 4:20 PM