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zek HYDRO 2022
2022 INTERNATIONAL HYDRO
FUTURE TECHNOLOGY
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HYDRO Pipe systems for hydro power plants GRP-Pipes
and
DN300 - DN4000
Cast Iron-Pipes
• are manufactured in the spinning and winding process
DN80 - DN2000 • restrained socket joint
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• ÖNORM tested • GRIS tested
• ÖNORM tested • ÖVGW tested
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Vietnamese HPP Bach Dang is on the grid Hydropower specialist relies on digitalization
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+41 79 906 28 28
New M-Line reduces delivery times by 30 per cent HPP Curnera produces green energy inside the mountain South Tyrolean hydro-tech double proves its worth in the fjord
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Visionary power. Wherever you want.
GLOBAL Hydro combines innovation, digitalization, and long-term thinking to create sustainable hydropower solutions for future generations. We turn your vision into reality and support you throughout the entire life cycle of your power plant – around the world.
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Troyer offers high-quality construction of water turbines and hydroelectric power plants. For generations, our tailor-made solutions have helped our customers optimizing energy generation from waterpower in a safe, efficient, eco-friendly and Tel. +39 0472 765 195 troyer.it sustainable way.
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05.05.2022 10:45:04
HYDRO
THE TIME FOR HESITANCY IS WELL AND TRULY OVER
B
y 2050 Europe wants to become the world’s first climate neutral continent. At least that is what it says in the EU’s ‘Green Deal’. To achieve this goal, net greenhouse gas emissions must be lowered by 55% against the level of 1990 by the year 2030. It is an ambitious goal to be sure, but a necessary one. Still, doubts are in order as to whether it can actually be achieved. As the IEA (International Energy Agency) announced in its most recent energy report, global energy production in 2021 once again generated more CO2 emissions than in the year before. The steep rise in demand for electrical energy could not be satisfied by additional renewable energy sources. As a result, coal-based energy production reached a new all-time high, increasing CO2 emissions by 7 per cent. According to IEA experts, we should expect further growth in greenhouse gas emissions over the next three years. At the same time, emissions from energy production are required to be reduced by 50 per cent by 2030, that is, within around seven and a half years. No doubt a rather gloomy perspective. Negative scenarios like these are aggravated by the war in Ukraine, which keeps pushing inflation-driven fossil energy prices even higher. Nearly half of the natural gas consumed in the EU is sourced from Russia (as per February 2022). To evade this dependence on Russia, politicians are already demanding a reopening of dis used coal-fired power plants or, as in the UK, a revival of the controversial fracking operations. However, Europe’s political leaders should be aware that there is currently no better argument for giving up fossil energy. It is not insight or political vision but the force of necessity that should encourage us to quickly press on with the expansion of renewable resources. There is no time for hesitancy. If acted on properly, the Russian threat could even turn into a turbo catalyst for an energy turnaround. A fast, massive expansion of renewable energies would also ease the current energy price tensions. After all, as energy experts universally agree, the availability of green power would lower wholesale prices by eliminating the need for expensive coal- and gas-fired power plants and driving them out of the market. In principle, this should open interesting perspectives also for hydropower. However, this oldest form of renewable energy is still struggling to overcome image problems and a strong opposing lobby in the political arena. A perfect example is the Taxonomy, a Delegate Legislative Act included in the EU’s Green Deal. Its original intention was to provide guidelines for citizens and investors as an incentive to invest in climate friendly technologies. Still, one may have one’s doubts about how many scientifically relevant details went into the decision to include nuclear energy and natural gas in the EU Taxonomy, thus giving them a ‘green’ seal of approval. Seeing a climate killer like natural gas being retroactively awarded a “sustainable” label almost seems comical, if only the situation would not be so serious. What is especially concerning, how ever, is that the small-scale hydropower sector has been denied the same honour. According to the EU Taxonomy, it is still rated as “not environmentally beneficial”. As a further consequence, small-scale hydropower stations will not be eligible for public funding, and financing such projects via banks and investors will become more expensive. It is a highly questionable decision, especially at a time when each renewably generated kilowatt-hour counts – and when the very technology is disadvantaged which, unlike volatile forms of energy such as wind power or photovoltaics, is able to ensure grid stability. It is high time to correct this unwarranted discrimination. I wish all our valued readers an enjoyable and informative time reading the latest edition of zek HYDRO.
Best regards,
Roland Gruber Editor-in-Chief
May 2022
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PP BACH DANG (VNM)
18 PP RUSSVIK (NOR)
21 PP CURNERA (CH)
28 PP ADONT (CH)
Short Cuts 06 Short News out of the World of Hydropower SHORT CUTS
03 Editorial 04 Table of Content 06 Masthead
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13 HPP Bach Dang is on the grid – powered by Austrian turbine twins [ VIETNAM ]
24 Trust in the solid power unit of the cavern hydropower plant [ SWITZERLAND ]
16 Hydropower struggles for recognition in Brussels [ POLITICS ]
26 A new crossflow turbine convinces all along the line [ GREECE ]
18 South Tyrolean hydro-tech double proves its worth in the fjord [ NORWAY ]
28 Refurbishment of the shut-off flaps guarantees safety in the headrace [ AUSTRIA ]
21 Hydropower Plant produces green energy inside the mountain [ SWITZERLAND ]
32 High-pressure hydropower plant in Grisons now generates energy [ SWITZERLAND ] 36 AUMA penstock flow control solution for world’s first ‘electric town’ [ SCOTLAND ]
May 2022
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HYDRO
URBAN SPORT
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M-LINE
48
DIGITALIZATION
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SUSTAINABILITY
Advertisers 37 Hydro-Construct rubber dam systems convince all round [ FRANCE ]
50 Upper Austrian hydropower specialist determined to digitalise [ TECHNOLOGY ]
40 Geocast ductile cast iron pipe system certified for drinking water [ TECHNOLOGY ]
54 Pelfa Group is expanding its hydropower production capacity [ TECHNOLOGY ]
43 Nuremberg ‘Fuchslochwelle’: a new face in urban sport [ GERMANY ]
57 Regionality in the hydropower industry – more than added value [ SUSTAINABILITY ]
46 Ongoing criticism of the immense crypto-mining carbon footprint [ FINANCE ]
60 Aiming high inside the mountain: ‘Construction site of the century’ [ TECHNOLOGY ]
48 Voith Hydro introduces new M-Line that reduces delivery times by 30% [ TECHNOLOGY ]
62 Energy transformation – Ready for take-off [ TECHNOLOGY ]
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zek HYDRO 2022
Global Hydro Troyer Geotrade
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Auma BHM Ingenieure Geppert Gersag Gugler Water Turbines Hitzinger Hydro-Construct Koncar Muhr Ossberger Pelfa Group TRM Voith Austria GmbH Wild Metal WWS Wasserkraft
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HYDRO
BKW INVESTS IN 40 ECO PROJECTS TO PROTECT FISH POPULATIONS BKW is a Swiss engineering company with over 120 years of experience in the hydropower-plant sector, running 40 plants in Switzerland and another 19 in Italy. Changes to the Swiss Water Protection Act have mandated the requirement for all Swiss hydropower plants to be ecologically renovated by 2030. In the future, plant operators will be obliged to guarantee fish safe and unobstructed upstream and downstream passage past dams and weirs. So, by 2030 BKW will have implemented around 40 ecological renovation measures at 14 hydropower plants. Research is still in progress to find the best possible downstream fish migration solution. Findings at the Bannwil pilot plant will serve as a basis for the new downstream migration ladders, and experts in the field are monitoring the results as a model to test technical viability and provide financial orientation. The programme of ecological renovation at the various hydropower plants is one of the largest projects in the BKW portfolio. Since the technical amendments were statutory directives, BKW’s costs of around 300 million Swiss Francs are to be covered by the Swiss Federal Office for the Environment.
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photo credits: Fritz Mondl
Impressum
The Strom-Boje floats in the river, where a chain attached to the ground serves as an anchor.
PUBLISHER
Mag. Roland Gruber PUBLISHING HOUSE
Mag. Roland Gruber e.U. zek Verlag Brunnenstraße 1, A-5450 Werfen Tel. +43 (0)664-115 05 70 office@zekmagazin.at www.zek.at EDITOR-IN-CHIEF
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photo credits: Fritz Mondl
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The innovative functional principle behind the floating small-scale power plant developed by Aqua Libre GmbH means it has immense potential for use on large and medium-sized rivers.
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INNOVATIVE STROM-BOJE® SHOWS ITS STRENGTHS IN THE DANUBE Strom-Boje® is an innovative floating hydropower plant devised for deployment on midsized and large rivers by Aqua Libre GmbH from Lower Austria. It is expected to be ready for serial production very soon. Most of the developmental work has been done by Fritz Mondl, who has been honing the system for something like 15 years. The system has already won awards, such as the Energy Globe and the Austrian Climate Protection Prize, for its universal usability, because it is environmentally benign, and because its construction enables it to be used in flood conditions and a wide range of scenarios. As the name suggests, this small hydroelectric power station floats in the river, where a chain attached to the ground serves as an anchor. Fritz Mondl achieved the most recent developmental enhancement of the Strom-Boje® with the active and expert support of Bilfinger Industrial Services GmbH, an internationally-acknowledged constructor of industrial-purpose steel infrastructure based in Linz. Bilfinger gave the most recent prototype of the floating small-scale hydropower plant a complete overhaul, optimised its aquadynamic properties and also manufactured the ‘Edith 2’ transport ship along the lines of a catamaran for the installation and maintenance of the Strom-Boje®.
201920025
The future is promising for Swiss fish. BKW is to implement around 40 ecological measures to protect the fish population at 14 hydroelectric power plants.
May 2022
09.05.2022 11:25:50
HYDRO
Vemork is a hydroelectric power plant outside Rjukan in Tinn, Norway. The plant was built by Norsk Hydro and commissioned in 1911.
photo credits: Voith
photo credits: pixabay
Aerial view of Coo-Trois-Ponts hydropower complex owned by ENGIE Electrabel
UPGRADE FOR BELGIUM’S LARGEST PUMPED STORAGE PLANT Voith Hydro won the order to upgrade the power units from the Coo I section at Belgium’s largest pumped storage power plant, Coo-TroisPonts. The project will take four years and will bring an increase in capacity of 79 MW and performance. An international team of Voith Hydro experts in Germany and the USA will be responsible for the model testing. The subsequent work on turbines and generators to increase performance will be conducted partly on site in the power plant and partly at Voith’s facilities in Heidenheim. Among other things, new runners and distributors will be manufactured for the turbines. For the generators, the priority will be to improve cooling and insulation. For Voith Hydro, the project is an important follow-up order from its customer ENGIE Electrabel. Previously, Voith had completed an automation contract that already included the supply of new control and excitation technology as well as speed governors for the power plant’s six machines.
NORWAY INCREASES ITS HYDROPOWER GENERATION 2021 was a ‘hydroelectric’ year for Norway. As reported by Business Portal Norwegen, the degree of hydroelectric development in this particular Scandinavian country reached a level last documented 30 years ago. An impressive 1.4 TWh of new hydroelectric generation capacity was made available to the grid. According to the Norwegian authority responsible for water resources and energy, it was the greatest increase in capacity since 1990. Another 1.4TWh of capacity are currently under construction. Half of the increase achieved in 2021 was accounted for by small-scale hydropower projects. 53 small-scale power plants went online with an output capacity of less than 10MW. The key reason for last year’s boom was that the deadline for inclusion in the existing green electricity certificate system expired at the end of 2021. In Norway the prevailing expectation is that the infrastructural expansion of the hydropower sector will continue over the coming years.
ENDLESS POSSIBILITIES GERSAG Krantechnik AG Industriestrasse 22 CH-6260 Reiden
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Tel +41 (0)62 749 11 11 info@gersag-kran.ch www.gersag-kran.ch
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photo credits: Wikimedia
HYDRO
The four run-of-river power plants in the Highlands of Scotland enable savings of more than 4300 tonnes of CO2 per year.
photo credits: Wikimedia/chrisaliv
The Montsalvens dam in the Swiss canton of Fribourg was erected in 1921. It is considered to be Europe’s first double-arched reservoir dam.
photo credits: pixabay
photo credits: Voith
In 2021 hydropower plant Gibárt was refurbished and fitted with a new electromechanical equipment.
12 small run-of-river hydroelectric plants on the Arno river in Tuscany will create an estimated output of 55 GWh per year.
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KOEHLER BUILDING RUN-OF-RIVER POWER PLANT IN SCOTLAND Koehler Gruppe, which is based in Baden Württemberg, Germany, is taking four run-of-river power plants in operation in Scotland. The group’s subsidiary, Koehler Renewable Energy is working in collaboration with developer Vento Ludens Ltd to implement these projects. Situated in the Scottish highlands the run-of-river power plants are part of a portfolio of six facilities. Energy production at the first one of the new plants was initiated in December 2020. “Scotland’s humid climate and mountainous landscape provide ideal conditions for hydropower projects. With their long lifecycles, these projects are a perfect fit for the long-term strategy of family-owned businesses like Koehler and Vento Ludens,” says Nicolas Christoph, Head of Business Development at Koehler Renewable Energy. The four run-of-river power plants in the Highlands of Scotland generate enough power to supply more than 2800 average British households. MONTSALVENS DAM CELEBRATES ITS CENTENNIAL Europe’s first double-arched reservoir dam in the Jauntal region in the Swiss Gruyère district is of greater topical interest than ever. Officially inaugurated in 1921, the Montsalvens dam is a technical masterpiece. Back then, its brilliant combination of a vertical and horizontal double arch made it Europe’s most celebrated construction of its kind. It took the joint genius of engineer Jean Landry and engineering firm Gruner, together with the artful calculations of Alfred Stucky and the courage of the workers to create this prime example of architectural ingenuity, which impounds the waters from the Jaunbach and makes it available for energy production at the hydropower plant Broc. Even today, experts agree that the Montsalvens dam was pure visionary genius. After all, this construction laid the foundation for an energy turnaround already 100 years ago by ensuring the production of renewable energy. POWER PLANT GIBÁRT IS OPENING A NEW CHAPTER OF ITS HISTORY Hydropower plant Gibárt in northern Hungary had never been renovated in around 50 years. It was time to bring the old, tradition-steeped power plant – the country’s first one to generate alternating current – up to modern technical hydropower standards. First and foremost, the mechanical equipment of the facility on the Hernád river had to be completely revitalised. For this purpose, the engineers of Voith Hydro’s Austrian-based Small Hydro Division replaced the two existing machine units with two modern Kaplan Kaplan bulb turbines. At their inauguration, the success of the project was obvious: the renovation had boosted the generating capacity of the Gibárt power plant by around 70 per cent. As a result, Hungary’s Methuselah among hydropower plants was able to open an all-new chapter of its long-standing history. EIB INVESTS IN ITALIAN HYDROPOWER The European Investment Bank (EIB) is providing €49 million to support the project of Iniziative Bresciane S.p.A. (INBRE) aiming to enhance and restore 13 river weirs and install 12 small run-of-river hydroelectric plants on the Arno river in Tuscany, Italy. With over 25 years of experience in the development of hydroelectric energy projects, Brescia-based INBRE will onlend the EIB funds to Iniziative Toscane S.r.l. (Intos), which will be responsible for building the hydroelectric plants and restoring the weirs. The operation will help create almost 10 MW of renewable energy capacity, with an estimated efficiency of 55 GWh/yr, as well as further improving the flood safety of the Arno river. The EIB estimates that these plants will provide enough clean energy to supply nearly 22 600 households/yr. When implementing the project, special care will be taken regarding the conservation of historical heritage in the areas of Sieci, Compiobbi, San Niccolò, and Isolotto.
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HYDRO
photo credits: Marc Boberach/Pixelio.de
Hydropower plays an important role at Ford in Cologne. Since early 2018, the firm’s industrial premises in Cologne has 100% of its energy requirements served by hydropower from Austria, Switzerland and Scandinavia.
photo credits: Pixabay.com
FORD ASSESSING ENERGY GENERATION FROM HYDROPOWER FOR E-MOBILITY Ford and start-up RheinSharing, which began as an interdisciplinary students’ initiative at the Technical University of Cologne, have signed a Memorandum of Understanding. In March 2021, six automotive engineering and architecture students had been awarded second place in the Ford Fund Smart Mobility Challenge for their idea of generating renewable energy from the current of the Rhine river and utilising it to supply power to charging points for electric cars. Based on their prizewinning concept, which they had developed for the Rheinauhafen in Cologne, RheinSharing will develop a new concept for Ford’s industrial premises on the Rhine within the framework of their collaboration.
AUTOMATION WITHOUT OIL Electric actuators for valve automation of weir penstocks, screens and valves in hydropower plants For power supply, electric actuators just require an electric cable - low-maintenance, easy to install and free of potential oil leakage.
SOUTH TYROL PIONEERS THE POWER OF HYDROGEN FROM HYDROELECTRICS The online portal UnserTirol.com recently reported that the parliament of the South Tyrol provincial government had contracted the local energy provider Alperia, and a number of other licence-holders, to investigate potential opportunities, strategies and projects for the production of hydrogen from hydropower, and – if viable – to implement them. The decision was the result of a majority vote in support of a proposal submitted by the region’s Freedom Party to favour hydrogen as a source of energy for a whole range of applications. Ulli Mair, provincial MP and head of the local Freedom Party, submitted the proposition, an explains: “The Freedom Party petition was supported by the province’s conservative SVP party and signed by their spokesperson Gerd Lanz. South Tyrol has the potential to exploit hydrogen as a clean source of energy. However, this requires investments and subsidies. These can be justified in the context of climate change and the need to protect the environment and nature.” In South Tyrol there is no lack of ideas or possible approaches, but first they need to be subsidised. South Tyrol possesses numerous hydroelectric power plants and biomass power stations, so the prerequisites for hydrogen production are excellent.
All components of AUMA’s electric actuators are located within a single housing. Designed as standard in highest enclosure protection IP68. The version for continuous underwater use (UW) is capable of continuous immersion to a depth of 15 m and in enhanced version optionally to 60 m head of water. AUMA actuators can be used for any application above or below water level. Electric AUMA actuators meet the requirements of the highest corrosivity categories C5-M and C5-I in compliance with EN ISO 12944-2. Electric actuators ensure reliable operation over many years demanding minimum maintenance. Discover our auto mation solutions. www.auma.com
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The newly-built Rekovici run-of-river hydropower plant in the south-west Serbian town of Priboj on the Rivel Lim.
photo credits: GE Renewable Energy
After its final inauguration, hydropower plant Baihetan in south-western China will have a total capacity of 16 gigawatts.
photo credits: news.con photo credits: GUGLER
A new research project in Bavaria is to assess the utilisation of existing water installations with turbines or water wheels.
photo credits: Andreas Hermsdorf/pixelio.de
HYDRO
As the sixth largest hydropower plant in Switzerland, the hydropower plant Bitsch plays a major role in the Swiss energy supply.
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GENERATING ELECTRICITY FROM AQUACULTURES AND TAILWATER A new research project at the Hof University of Applied Sciences’ In stitute for Water and Energy Management in Bavaria is to promote the potential and utilisation of hydropower in existing water facilities. Funded with a € 417,000 grant from the European Social Fund, project “NEEWa – Network for the Generation of Energy with Hydropower in Existing Water Plants” is intended to promote the knowledge transfer from the Green-Tech university at Hof to firms in the surrounding region. “Wherever you can see water flowing, you can see the power of water in action. Not utilising it means wasting its potential,” comments Dr. Harvey Harbach of the Institute for Water and Energy Management (iwe) at the Hof University of Applied Sciences, who initiated this research project. SERBIAN REKOVICI HYDROPOWER PLANT CHOOSES AUSTRIAN KNOW-HOW The commissioning of the Rekovici hydropower plant in June 2021 marked the successful completion of the first project to have been conducted in Serbia by GUGLER Water Turbines GmbH from Upper Austria. The internationally renowned hydropower specialists supplied the new run-of-river power station on the River Lim in the town of Priboj with three pit-installed horizontal-axis Kaplan turbines. At full capacity, each of the units is capable of processing a flow volume of 55m³/s for a maximum standard power output of 2.6MW. The GUGLER delivery scope for the newest and most powerful hydroelectric power plant to be operated by HIDRO-TAN was rounded off with three air-cooled synchronous generators, the requisite gear systems and the extremely solid and heavy steel pits for the machines, each 10 metres long and over 8 metres in height. TRIAL PHASE FOR WORLD’S SECOND-LARGEST HPP BAIHETAN IN CHINA In late June 2021, Baihetan, the world’s second-most powerful hydraulic power plant, was brought on line in south-western China, as reported by orf.at. Chinese government representatives referred to this inauguration as a milestone on the way to implementing Beijing's climate goals. However, environmental agencies and scientists warned of possible environmental damage. The plant’s reservoir dam was constructed near the border between the provinces of Yunnan and Szechuan. So far, construction work has been ongoing for four years. Measuring 289 m in height, the dam wall is designed to impound the headwater of the Yangtze, the world’s third-largest river. Once completed, the power plant will house 16 turbines, each of which having a bottleneck capacity of 1 gigawatt. At the initial startup stage, two of the 16 machine units have now been taken into operation. The final inauguration of the facility with its full output capacity is scheduled for summer 2022. GE HYDRO SOLUTIONS TO REFURBISH TWO GENERATORS AT BITSCH HPP In spring 2022 General Electric Hydro Solutions has signed a service contract with HYDRO Exploitation SA, acting on behalf of the asset owner Electra-Massa SA, to refurbish two 120 MVA vertical synchronous generators at the Bitsch power plant station in Wallis, Switzerland. The main objectives of the generators’ refurbishment are to extend the lifetime of the plant for several decades and increase the performance as well as reliability of the power station. In addition, Electra-Massa SA aims to maintain the plant fully operational until and after the concession expires in 2048. The 340 MW hydropower plant will be equipped with two new state-of-the-art generators tailored to meet the customer's specific operational needs. They will replace the previous equipment which reached the end of its life. Consequently, the hydropower plant Bitsch will benefit from more flexible generators that will improve the power plant’s overall efficiency.
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photo credits: Uniper
photo credits: Wikimedia/Peter Bond
HYDRO
The compact residual water machine now enables fish to migrate up and down past dam walls and weir infrastructure in complete safety and without physical strain.
HYDRO-CONNECT AWARDED DOUBLE-SCREW-TURBINE CONTRACT IN SWEDEN Within the framework of the EU LIFE CONNECTS project, UNIPER- Sydkraft Hydropower AB, one of Europe’s largest and most innovative energy providers, awarded the Austrian company Hydro- Connect contracts to manufacture and deliver a double-screw-turbine as a bidirectional fish ladder. The superordinate goal of the LIFE CONNECTS project is to improve the general conservation status of target species, and enhance ecological conditions for them along 150 km of seven target rivers. Hydro-Connect provided the entire hydro-technology infrastructure, including the electric drives and hydraulic steel construction for the River Emån. The double-screw-turbine was devised to enable the main species of fish – salmon of up to 120 cm in length – to migrate up a head of 5.5 metres and a dotation of at least 800 l/s.
Tummel Bridge power station is a listed monument in Scotland whose machinery is to be modernised by 2023.
NEW TURBINE TECHNOLOGY FOR TUMMEL BRIDGE POWER STATION Last August plans were announced for the modernisation of one of Scotland’s best-known small-scale hydropower plants at Tummel Bridge in the Scottish Council Area of Perth and Kinross. The plant was originally built between 1931 and 1933, and for the last ten years it has been registered as a category-A listed monument. As a result, the neo-classically-influenced architecture, which to this day houses the two vertical Francis turbines with a total power capacity of 34,000 kW, is also a protected structure. The turbines process the potential of a 58-m gross head. Most of the water in the River Tummel flows out at the end of Loch Rannoch. The operators, SEE Renewable, are now planning to update the machinery as part of a 50-million-pound project aimed at increasing the power output of the plant and extending the working life of the technical infrastructure.
Tailor made generator manufacturer since 1946 MAIN ACTIVITIES research and development, engineering and design, manufacture, testing, installation, commissioning of inhouse products; maintenance, overhaul, upgrading, refurbishment and modernization of in-house products and products made by other manufacturers
Fallerovo šetalište 22, 10000 Zagreb, Croatia phone: +385 1 3667 499 e-mail: gim@koncar-gim.hr www.koncar-gim.hr
PRODUCTION PROGRAMME - hydrogenerators up to 300 MVA - references of delivered generators worldwide, compact generators for small hydropower plants
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HYDRO
New units reduce delivery time up to 30% Voith Hydro M-Line Short delivery times combined with low operating costs are emerging as an aspect of growing importance.
We were able to simplify and accelerate the entire process, from the product choice to the commissioning.
Voith Hydro has been working on further evolving its machine portfolio with a focus on these aspects to benefit customers.
Our customers can benefit due to the many advantages of our M-Line turbines.
Scan the QR-Code with your smartphone camera to learn more about the M-Line!
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photo credits: GUGLER
Hydropower plant Bach Dang in North-eastern Vietnam went on-line in May 2021. The entire electromechanical equipment was provided by GUGLER Water Turbines GmbH from Austria.
VIETNAMESE HYDROPOWER PLANT BACH DANG IS ON THE GRID POWERED BY AUSTRIAN TURBINE TWINS Last May, hydropower plant Bach Dang in the Northern Vietnamese province of Cao Bang was for the first time able to gene rate clean energy. The facility was established by operator Thanglong Construction Group, who entrusted the implementation of the electromechanical equipment to the expertise of an Austrian hydropower specialist of international acclaim. GUGLER Water Turbines GmbH provided a comprehensive engineering package for this new construction, whose core elements are two horizontally aligned Kaplan turbines. Built for a flow rate of 13,85 m³/s and a 21 m net head, the machines provide a bottle neck capacity of 2.65 MW each. GUGLER’s equipment was complemented by two directly coupled synchronous generators by Siemens Gamesa and the entire electrical and secondary equipment.
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n Vietnam, which has a population of around 90 million, hydropower is one of the principal sources of electrical energy. More than a third of the country’s generated power is produced with the renewable resour ce of water; the other two thirds are generated from coal, natural gas or nuclear energy. Of Vietnam’s annual hydropower potential of around 120,000 GWh, less than half is cur rently being utilised for energy production. This makes Vietnam one of the most attrac tive hydropower markets in South-east Asia. NEW POWER PLANT IN NORTHERN VIETNAM Criss-crossed with a network of rivers, the north-eastern Vietnamese province of Cao Bang provides ideal conditions for hydropow er generation. In the mountainous region near the Chinese border, Bach Dang was one of the country’s newest hydropower plants to be connected to the grid for the first time. The facility was erected by Vietnamese operator Thanglong Construction Group, which is ac tive in both the construction and energy sec tor. In accordance with the plant’s classic di version design, the water dammed up by a
massive concrete construction. In case of a flood, an alignment of three gates ensures the proper discharge of excess water. In the intake area on the orographically right side of the ri ver, the water supply is regulated by two head gates. A crane construction running on a mov able carriage controls the raising and lowering movements of all of the weir’s sluice gates. The power house right below the weir gate has its works water supplied through two parallel DN2300 penstock pipes, which are made from fibre reinforced plastic and mea sure about 70 m in length. MANUFACTURING ON TWO CONTINENTS Concerning the technical equipment for the power house, the operators relied on the in ternationally well-known competence of Aus trian hydropower allrounder GUGLER Wa ter Turbines GmbH. As Stefan Falkner, GUGLER’s project manager, explains, “When we were awarded the contract for the Bach Dang project in January 2019 we went straight into the machine designing and plan ning phase. The core elements of our delivery were two horizontally aligned Kaplan tur
bines, including the generators and the entire electromechanical equipment. What made this project special was that the customer wanted the draft tubes, the inlet pipes and the turbine spirals to be manufactured in Viet nam, based on design plans from GUGLER.
With a height of 7.5 m each, the spirals of the two horizontally aligned turbines had to be delivered in four parts and welded together on-site.
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Built for a design flow rate of 13,85 m³/s and a 21 m net head, each of the identically constructed turbines provides a bottleneck capacity of 2.65 MW.
The mechanical parts, such as the guide vane assembly, the runners, the runners chamber liners and the adjustment mechanism for the runner blades were provided by our Slovenian partner.” As Falkner admits, the design of the 7.5 m turbine spirals required considerable effort to calculate. To prevent the steel parts from warping out of shape under their own weight, the construction had to be specially reinforced. Due to their large size, each of the two spirals had to be delivered in four parts, which were then welded together on-site. CORONA WRECKS THE PROJECT PLANS When the Corona pandemic hit in the Spring of 2020, it did not leave the Bach Dang hydropower project unaffected, as Falkner confirms: “Originally, we had scheduled on-site construction work to start in April 2020. In late 2019 we had done a workshop testing, where the customer’s representatives had inspected and approved the equipment that was
manufactured in Slovenia. In early 2020, the components were shipped to be delivered to Vietnam. After that, however, the restrictions and entry limitations caused by the pandemic put a halt on the project for quite some time.” It was only in October 2020 that the installation of the turbines finally went ahead. Local specialists performed the installation work under the supervision of a GUGLER engineer, who had been forced to stay quarantined in a hotel for two weeks after arriving in Vietnam. Installing the guide vane assembly required the turbines to be rotated by 90 degrees at the installation site. With that accomplished, the machines were repositioned and hoisted into their installation position with an indoor crane. “That was a bit of a challenge, as the guide vane system is usually pre-assem bled at the factory. But thanks to the excellent collaboration, we were able to complete initial installation work as scheduled, by Christmas 2020,” says Falkner.
Each of the five-bladed Kaplan runners measures 1,550 mm in diameter.
HIGH-PERFORMING TURBINE TWINS A casual glance over the structurally identical machine units might lead one to believe they are Francis turbines. A closer look at the runner adjustment mechanism, however, reveals that they are horizontally aligned, double-regulated Kaplan turbines. The precise regulation of the guide vane and runner blade adjustment mechanism is taken care of by two hydraulic pressure units, which were also provided by GUGLER. Each of the turbines is optimised for a design flow rate of 13,85 m³/s and a net head of 21 m. As a result, the machines can achieve a bottleneck capacity of 2.65 MW each. Thanks to the low amount of sediment in the works water, there was no need to apply a protective coating to the five- bladed stainless steel runners, each of which measures 1,550 mm in diameter. Two synchronous generators by Spanish provider Siemens Gamesa are coupled directly to the runners to convert the kinetic energy into
Technical Data
Due to the delays caused by the Corona pandemic, installation work under the supervision of a GUGLER engineer was put on hold until the autumn of 2020.
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• • • • • • • • • • •
Flow rate total: 27,7 m³/s Net head: 21 m Turbines: 2 x Kaplan Turbine axis: Horizontal Ø Runner: 1,550 mm Maximum capacity: 2 x 2.65 MW Manufacturer: GUGLER Water Turbines GmbH Generators: 2 x Synchronous Voltage: 2 x 6,300 V Capacity: 2 x 2,993 kVA Manufacturer: Siemens Gamesa
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electrical current. “Our customer requested mechanical seals to be installed between the turbines and generators. These seals are rela tively large components, and the Bach Dang plant was the first one where we installed them,” says Falkner. The air cooled generators were designed for a rated apparent power of 2,993 kVA and a voltage of 6,300 V. Two oil lubrication units combined with cooling cir cuits and underwater heat exchangers keep the oil of the maintenance-free slide bearing reliably cool. GUGLER HARD AT WORK IN VIETNAM The installation of the plant’s electrotechnical equipment was carried out primarily by local engineers. They were supported by a long- standing GUGLER partner from Croatia, who acted as a sub-contractor for the delivery of the electrical and secondary equipment. The SCADA system with intuitive user inter face allows the facility’s energy production to be fully automated. A secured on-line connec tion enables the operators to monitor and re mote control the plant’s equipment. Any malfunctions or alarms are forwarded auto matically to operating staff. Moreover, each of the machine units is designed for autonomous operation, which allows energy production to continue even if a unit fails. The energy gene rated is transmitted from the generator termi
Included in GUGLER’s scope of supply is the electromechanical equipment, which was installed on the power house’s upper level.
nals to the medium-voltage switchgear on the power house’s upper level. From there, the electricity is fed to two G UGLER transfor mers and on into the public grid. Hydropow er plant Bach Dang was officially inaugurated after the completion of the final installation work around a year ago, in May 2021. “De spite the delays because of the Corona pande mic, we were able to complete the project successfully. First and foremost, this was
Kaplan Turbines Pelton Turbines Francis Turbines
thanks to the highly constructive collabora tion and communication with the customer’s representatives. We are also grateful to all the other providers for a job well done,” says pro ject manager Falkner. For the Austrian hydro power experts the South-east Asian region re mains a highly attractive market. In Vietnam alone, two further power stations are about to be inaugurated, and three further projects are already at advanced stages.
• Worldwide active • Upgrading and modernization • Financing and AfterSales-Service • Water-to-wire solutions • Highest European quality and efficiency • Operator know-how • Long-time experience
up to 25MW
Liquid Energy - Solid Engineering
info@gugler.com www.gugler.com
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photo credits: pixabay / ACMOMENTS
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Foto: Glanzer
There is a good potential for development, especially through the refurbishment of decommissioned small hydropower plants and unused weirs and transverse structures, estimated at about 280,000 in the 27 EU countries.
HYDROPOWER STRUGGLES FOR RECOGNITION IN BRUSSELS In addition to the urgent need for rapid decarbonisation as a prerequisite for meeting the Paris climate target, as highlighted in the last three IPCCC reports, the war in Ukraine also clearly shows the weaknesses of an energy system dependent on fossil fuels. Though decision-makers across party lines regard nowadays renewables as an essential instrument for an energy-independent and decarbonised EU, the majority of politicians focus primarily on wind and solar energy as well as green hydrogen.
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ccelerating the transition to renewable energy sources is absolutely the solu tion – but increasing just the quantity alone is not enough. Diversifying supply has always been a core principle of energy system security. Together with wind and solar PV, Europe can rely on a range of sustainable sources, including geothermal, solar heat, wave, hydro, concentrated solar power, bio energy and tidal energy. Collectively these renewable sources can provide decarbonised energy at any point in the day, season or year, and keep our systems in balance. Small hydropower plays an important role for the new energy system that will be based on renewables and energy efficiency. Yet, many decision-makers tend to overlook benefits and opportunities of small hydropower and even make it harder for the sector. According to EREF’s recent calculations based on vari ous databases, the small hydropower sector in the 27 EU countries comprises around 22,000 small hydropower plants. These gene
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rate renewable electricity for about 13 of 195 million households. The sector directly em ploys ca. 60,000 professionals in more than 4,500 companies – mainly small and medi um-sized enterprises and family businesses. GOOD POTENTIAL FOR DEVELOPMENT Databases such as EREF’s RESTOR Hydro Database or the AMBER Barrier Atlas show good potential for development, especially through the refurbishment of decommis sioned small hydropower plants and unused weirs and transverse structures, estimated at about 280,000 in the 27 EU countries. Recent developments in kinetic turbines and very low head turbines allow for the expan sion of the sector in flat areas. Especially the Dutch provinces regard small hydropower as an opportunity to complement PV and wind within the development of energy self-suffi cient villages and communities. The new HYPOSO Handbook showcases the Euro pean expertise of innovative small hydropow
er. In addition to information on the history and on the application areas of small hydro power, this handbook shows and describes various technical solutions for the small hy dropower sector. Valuable information on planning and financing models complete this book. IMPORTANT FOR ENERGY TRANSITION European hydropower equipment manufac turers are considered global technology lea ders and export their products to small hy dropower “boom” regions in Africa and Asia. Yet, the development of the small hydropow er sector in the EU looks different. Only 16 of the 27 EU countries plan to ex pand the hydropower sector in their national energy and climate plans, especially with large hydropower and storage facilities. Small hydropower with its characteristics however could play an important role in the European energy transition process. It enables flexibili ty and promotes the integration of variable
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Approximately 22,000 small hydropower plants generate renewable electricity for about 13 million households in the EU.
OVERALL ENGINEERING & CO N S U LT I N G S E R V I C E S
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Foto: Glanzer
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renewable energies such as wind and solar power. Thanks to its decentralized contribu tion to electricity supply, small hydropower helps reduce losses in electricity transmission and regulate voltage in the operation of local grids. Recent studies show that small hydro power avoids significant investments in grid modifications and saves grid costs. SHP – “NOT ENVIRONMENTAL BENEFICIAL” Despite these advantages and opportunities, the European small hydropower sector faces tough times. The taxonomy framework, which the European Commission uses to set standards for green business practices, does not include small hydropower as it is not considered as environmental beneficial. It la bels however nuclear and gas as environmen tal friendly. The exclusion of small hydro power from the taxonomy framework excludes small hydropower from public fun ding and makes it more difficult and expen sive for plant developers to secure financing from private banks and investors. The Commission is also in the process of im plementing general licensing reform. Here, EREF is working to ensure that the new rules do not require competitive bidding for exis ting small hydropower facilities at license ex piration. DISCUSSIONS ABOUT FISH LADDERS Important decisions are being prepared in the working groups on the implementation of the EU Water Framework Directive. The work program for 2022-23 puts the abolition of exemptions for licenses for small hydro power plants and stricter residual flow requirements up for debate. In addition, new provisions for hydropower in water bodies
characterized as “heavily modified” are to be developed. The current proposals would make the construction of new small hydro power plants in these water bodies much more difficult. As part of the EU’s goal of having 25,000 km of “free-flowing” rivers in EU countries by 2030, the EU will publish a new guidance document in July 2022 that will include, among other things, guidelines for the de commissioning of hydropower facilities. As a result of, among other things, EREF’s contri bution to last year’s public consultation, the Commission has agreed to find more bene ficial solutions for the small hydropower sec tor in this regard. Currently, the most intense discussion is on whether fish ladders can be considered effective solutions and whether they can be used to consider a river barrier- free. This guideline is flanked by a package of measures to restore nature which is scheduled for summer 2022. Furthermore, the commis sion will still publish a guide on sediments and before the summer break. EREF VOUCHES FOR SHP In the area of research, the Commission is fo cusing its attention on the promotion and development of innovative turbines in the pumped storage sector, as well as on so-called hidden hydropower in existing systems such as drinking water networks, sewage treatment plants and irrigation canals. Thanks to the support of its members, EREF is able to defend the interests of small hydro power in the EU institutions. Due to the on going political dossiers and the European and national campaigns against small hydropow er by so-called environmental associations, there is much to do.
Hydro Power Thermal Power Biomass Special services
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SOUTH TYROLEAN HYDRO-TECHNOLOGY DOUBLE PROVES ITS WORTH IN THE NORWEGIAN FJORD In northern Norway, not far from the well-known port city of Narvik, two new, high-performance small hydropower plants were put into operation in spring 2021. The expert operational managers at the Norwegian Russvikkraft AS relied on the technical know-how of the South Tyrolean hydropower all-rounder Troyer AG, which supplied the entire electromechanical equipment for the two plants. In an average year the two hydropower stations – a 2.85 MW Francis turbine, and a 4-nozzlePelton turbine producing around 5 MW – feed a total of 19 GWh of energy along the cable beneath the lake. For Troyer this was a successful entry in an exciting hydropower market in the far north.
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ysfjord in the province of Nordland boasts some of the most scenic land scapes in the whole of Norway. The eponymous fjord is the deepest in northern Norway, while the steep surrounding moun tains reach far up into the sky. There are glaciers, limestone caves, and the largest na tural canyon in Northern Europe. No won der it’s considered a paradise for all brands of hikers, anglers and nature-lovers – not to mention the inland possibilities for skiers not far from the port of Narvik. The online US outdoor pursuits magazine ‘Outside’ lists Narvikfjellet as one of the ten best undis covered skiing regions in Europe. Narvik, the regional capital, is famous for several reasons. Thanks to the Gulf Stream, the climate here is relatively mild and the harbour is ice-free all year round. For centuries it has been a hub for the transportation of the iron ore mined in Lapland. This strategic importance made the port a target during the Second World
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War. Numerous monuments and a special war museum in the town still bear witness to the 2-month Battle of Narvik in the spring of 1940. Narvik is also famous around the world as a tourist magnet for guests seeking the midnight sun. On long summer days the sun never dips behind the horizon and bathes the surrounding scenery in dreamy tones of orange and red. HYDROELECTRIC POWER IS A POPULAR EXPORT It is obvious that in such a natural landscape worthy of protection, energy supply is based on natural resources. Indeed, hydropower has been the prevailing source of energy in Norway for a long time. The country is bles sed with immense volumes of water and ex treme topography. In 2020 Norway boasted around 1,700 hydroelectric power plants, accounting for approximately 88% of the country’s electricity production. Hydroelec tric power is also an export hit: Norway
recently exported around 14 TWh of green electricity abroad. Two experienced power generation compa nies joined forces here to share expertise and increase the amount of hydroelectric power generated in the Tysfjord region around Nar vik. Småkraft AS is referred as Europe’s ‘largest small-scale power supplier’ and runs around 110 small-scale hydropower stations across Norway. Småkraft AS was joined by Nordkraft AS, whose portfolio encompasses 15 hydropower plants, to build two power plants on the Russvikelva river. Russvikkraft AS, founded together with five landowners, is the official operator of the two plants, which have been in operation since spring 2021. MACHINERY TRANSPORTED VIA FERRY The region housing the site is very remote and cannot be accessed by land. This meant that the delivery of machinery and building mate rials would pose a challenge. Thomas Fiechter
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Foto: Glanzer
Not far from the northern Norwegian port town of Narvik the South Tyrolean Troyer AG equipped two new small-scale power plants with electromechanical equipment and control technology. In a regular operating year the plants achieve a power output of around 19 Gigawatt hours.
photo credits: Troyer AG
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Troyer AG also delivered the ball valve to Norway.
photo credits: Troyer AG
photo credits: Troyer AG
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was employed in executive project manage ment for Troyer during the project: “The use of hydroelectric power was not something new here, however. After all, the landowner had a small hydropower plant in operation on site for self-supply.” In January 2020 the site owner contacted the renowned South Tyrol hydropower company with a request to provi de all the electromechanical infrastructure re quired for both Russvikelva power stations. Scope of delivery included turbines, water conduit pipes, valves and shut-offs, genera tors, hydraulic aggregates, cooling systems, low- and medium-voltage systems, general electrification, machine transformers and energy supply and control system for the wa ter catchment. A classic water-to-wire job for the hydropower allrounders from South Tyrol.
“The origins of this double project go back to 2014, when Nordkraft AS began developing it”, explains Bernt Grimstvedt, Troyer’s re presentative in Norway. Grimstvedt goes on to point out how strict the environmental guidelines are for the construction of small-scale hydropower plants in Norway. “Hydroelectric power stations are evaluated according to a whole range of ecological parameters, which all play a key role in the decision of the authorities on whether to approve a project.” WATER FROM THE LAKES All the necessary permits had been approved for construction of the two hydropower plants – Øvre Russvik and Nedre Russvik by summer 2019, the project was ready to start.
photo credits: Troyer AG
Foto: Glanzer
The 4-jet Pelton turbine in the upper power plant is set up to provide around 5 MW of power.
Conceptually, both plants are high-pressure systems. The upper station, Øvre Russvik, guarantees a natural head of around 400 me tres. The lower stage, Nedre Russvik, uses a head of around 100 m. Thomas Fiechter ex pands: “Both of these plants are fed by lakes and both intake structures consist of a steel intake cone with large slightly-angled, al most-vertical rakes. The water is drawn into the catchment shaft via an intake pipe. The catchment shaft is made completely from PE and contains the pipe rupture shut-off valve, residual water supply, subsistence transfor mer and the control panel.” The DN700 ductile cast iron penstock down to the pow erhouse at the upper plant is around 2,230 metres long. The lower stage penstock is around 650 metres long and made of
Technical Data
Foto:Wien Energie
Øvre Russvik • • • • • • • •
Flow Rate: 1.444 m3/s Net Head: 390.2 m Turbine: 4-nozzle Pelton Turbine Manufacturer: Troyer AG Nominal Output: 4,996 kW Penstock: Length: approx. 2.23 km Material: cast iron Ø DN700 Average annual production: approx. 12 GWh
Nedre Russvik
The high-power Francis turbine is designed to produce 2.86 MW, efficiently processing the works water a stage below.
• • • • • • • •
Flow Rate: 3.363 m3/s Net Head: 95.06 m Turbine: 4-nozzle Pelton Turbine Manufacturer: Troyer AG Nominal Output: 2,858 kW Penstock: Length: approx. 0.65 km Material: GRP Ø DN1100 Average annual production: approx. 7 GWh
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All the automation and control technology for both power plants was produced and installed by Troyer.
ON-THE-JOB OBSTACLES Thomas Fiechter recounts: “We delivered the first components in August 2020: The cabling for both plants, the control cabinets and supply transformers for the catchments. The remaining mechanical infrastructure was delivered starting in January 2021.” This was no ordinary order, even for such an experienced project manager. Every single machine component and item of equipment had to be delivered by ferry as there is no road access to the site. The various pandemic- related rules and restrictions applied during this period affected the project in a number of ways, and posed challenges for everyone invol ved. “Our assembly staff was on site from mid-March last year, but first had to spend 10 days in quarantine, and then accommodation units were strictly separated. Obviously, the restrictions made life that bit harder, and the various delays they caused triggered extra expense” Fiechter explained. By the end of May, beginning of June 2021, Troyer´s commissioning specialists had successfully connected both plants to the grid.
A WIN-WIN PROJECT The operational benefit of both plants is that they can be run through out the low-water winter period. The plants are expected to supply around 3.2 GWh of electricity from the beginning of October to the end of April; a fact that delights both the cooperation partners, Små kraft AS and Nordkraft AS, and the five local land owners. The coope ration model is not only intended to provide more green electricity in the region, but also to secure value creation in the region, as Terjo Vedeler, CEO of Småkraft AS, outlined in an official statement: “Our model is about building a bridge between the national need for more renewable energy and local value creation and competence building. The projects on the Russvikelva are a good example of how we can collectively develop more forward-looking renewable energy use.” Both energy businesses see the two-plant project as another building block in a strategy of expansion that will now include even more small-scale hydropower plants in the Nordland region. For Troyer, having equip ped both plants, it was certainly a positive signal. Realisation of the Øvre Russvik and Nedre Russvik power plants marks a successful start to activity on the exciting Norwegian hydropower market, and several new projects follow soon. The signs are definitely promising!
photo credits: Nordkraft
POWER FED ALONG AN UNDERGROUND CABLE BENEATH THE LAKE Øvre Russvik runs a 4-jet Pelton turbine designed to process a standard flow rate of 1.444 m3/s. A net head of 390.2 metres allows the machi ne to reach a nominal output of 4.996 MW. The lower stage Nedre Russvik hydroelectric set-up is slightly different. A Francis turbine was installed with an intake capacity of 3.363 m3/s. The net head of 95.06 metres equates to a nominal power output of 2.858 MW. The technical engineers at Troyer set up both machines with absolute precision to deal with the hydrological conditions at each site. Each machine is ex tremely efficient, durable and low-maintenance. These were the attri butes that had ultimately won over the Norwegian hydropower plant
operators as Bernt Grimstvedt explains. “The extremely attractive combination of quality and a good price was the deal-maker that en sured Troyer’s bid was successful.” In an average year Øvre Russvik feeds around 12 GWh onto the grid, while the lower-stage Nedre Russvik plant feeds around 7 GWh. All of the electricity generated is transported via a cable below the lake and into the local 22-kV grid power supply.
photo credits: Troyer AG
DN1100 GRP pipe. The whole construction phase took around 18 months to complete, after which the plant began to produce electricity for the first time.
photo credits: Troyer AG
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Nordkraft’s CEO Eirik Frantzen and Småkraft’s CEO Terje Vedeler joined forces on the project to build the small-scale Russvik hydropower plants in Tysfjord.
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One special feature, indeed one major challenge of this Norwegian project, was that there were no access roads to the project site. All construction parts, machines and power station components had to be delivered by ferry.
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photo credits: Axpo
At the end of 2021, under the management of Axpo, KVR AG went online with a new small-scale hydropower plant at the Curnera reservoir. The set-up was integrated into the existing underground infrastructure. In an average year it is expected to generate around 10 GWh of clean electricity to exploit previously untapped potential.
CURNERA SMALL-SCALE HYDROPOWER PLANT PRODUCES GREEN POWER 250 M INSIDE THE MOUNTAIN Right at the end of last year Kraftwerke Vorderrhein AG (KVR) went online with a new small-scale hydroelectric power station at the Curnera reservoir in Grisons, Switzerland. The plant is situated within a storage chamber 250 m down inside the mountain and exploits the previously untapped hydro-energetic potential of water travelling down from the Curnera reservoir to the Nalps dam. Integration of the entire power plant into the existing infrastructure below ground ensured the new structure could be completed without causing any noise or environmental pollution whatsoever. The centrepiece of the plant is a Francis spiral turbine, built to guarantee 5 m³/s of discharge capacity and 2,500 kW of maximum durable power output, and provided by the Austrian hydropower specialists at WWS Wasserkraft GmbH.
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ssentially, the Vorderrhein Power Station Group (KVR) in the Swiss canton of Grisons comprises three reservoirs: Curnera (40.8 million m³ effective volume), Nalps (44.5 million m³) and Santa Maria (67 million m³) and the two power station centres at Sedrun and Tavanasa. Now, for the first time, three Pelton turbines at the Sedrun cavern centre with a maximum power output of 150 MW are being used to turn the potential of the works water into electrical power. Subsequently, the works water is channelled to the Tavanasa plant – 23 kilometres away as the crow flies where four Pelton turbines with a maximum power output of 180 MW reprocess the water before it flows into the Rhine. Operational management of the power station cascade is the responsibility of Axpo, the largest KVR shareholder with 81.5%. 10% of the of the AG is owned by the Canton of Grisons, and the remaining 8.5% is divided among a number of participating local autho-
A temporary cable lift for materials was constructed to transport structural components weighing up to 6 metric tons to the tunnel entrance area.
rities. On an annual average the KVR, with its large-scale power plants included, produces 840 GWh of green electricity. GENERATING ELECTRICITY INSTEAD OF WASTING ENERGY According to André Schluep, Axpo’s project manager for machine building technology, the idea for integrating an additional small-scale hydropower plant into KVR’s existing system originally came from a study evaluating unused potential carried out 6 yearsago: “Ever since the power plant was built, the water had been transported from the higher-altitude Curnera reservoir to the Nalps dam via a 3,680 m pressure tunnel and through a pressure reduction facility. In 2016, a plan was devised to build a small-scale hydroelectric facility in the water storage chamber where the pressure reduction unit was located to take advantage of previously unexploited energy potential.” The project really May 2022
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From mid-May 2021, at an approximate altitude of 2000 m above sea level, the project zone access road had to be cleared of a covering of snow 8 metres deep.
began to gain traction about three years later. In 2019, the project was granted entitlement to the Swiss cost-covering power contribution subsidy’(KEV) for the generation of green electricity over a period of 15 years, thereby ensuring the economic viability of the project. Last summer, once the project details had been defined, it was time to commence implementation. CHALLENGING LOGISTICS Project implementation was subject to a wholeseries of challenging conditions, as André Schluep remarked: “At an altitude of just under 2000 m above sea level the enormous amounts of snow in winter and the danger of avalanches they created meant work had to be completed within a narrow window. How ever, the fundamental problem was how to transport individual parts weighing almost 6 metric tons to their final destination. The sole point of entry for equipment was an access tunnel leading to the water storage chamber;
a tunnel not accessible by road.” A temporary 250 m materials cable lift that navigated a change in altitude of 130 metres had to be erected to gain access to the tunnel. Taking elements weighing several tons, like the generator rotor, stator, transformer and turbine spirals, from the tunnel entrance to the water storage chamber was achieved using an electrically-driven tow truck and a special transport vehicle. As the project manager explains: “The complicated access challenge involved a materials cable lift, narrow tunnels and minimal space for intermediate storage, thus demanding a well-planned sequence of logistical steps and precise delivery schedules”. In the water storage chamber 250 m into the mountain, the machine group was connected to the flange of the pressure reduction nozzle – situated on the right as seen from the direction of flow – where room to manoeuvre was extremely limited. When positioning the turbine, it was essential to guarantee access for necessary repair and maintenance work on
the pressure reducer, throttle valve and machine group. The second nozzle on the pressure reducer was retained in case there was a breakdown with the new machine group or repair and maintenance activities were required. Mid-May last year commencing project work was made difficult by the need to clear the access road of 8 metres of snow, and compounded by the risk of avalanches. Work on removing the pressure reduction system in the water storage chamber began in June. Subsequently, heavy equipment was required to break through the old concrete foundations, which then had to be reconstructed to hook-up of the new machine group and existing Y-pipe. UPPER AUSTRIANS PROVIDE CENTREPIECE Tightly-organised delivery, assembly and installation of the hydromechanical components in the structurally-adapted water storage chamber commenced mid-July. After a public call for bids to provide equip and build the new plant, WWS Wasserkraft GmbH from Austria was awarded the contract for delivery of the project’s centrepiece, a Francis spiral turbine with a directly-coupled generator. The company, based just outside Linz in the state of Upper Austria, is an all-rounder in the hydropower sector and relied on internationally for its expertise. It boasts a client reference list for projects completed all over the world. Five years ago, WWS renewed KVR’s infrastructure for self-sufficient production at the headquarters of the Sedrun power plant. The ultimate set-up of the turbine was determined in collaboration with the Prof. Dr. Jaberg & Partner GmbH. The vertical-axis machine was devised to manage a maximum
Technical Data
Plenty of activity at the works water storage chamber, refunctioned into a power plant, shortly prior to going online at the end of last November.
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Flow rate: 5 m³/s Head range: ca. 40 - 75 m Turbine: Francis-spiral Turbine axis: Vertical Turbine control: Hydraulic Rotation speed: 750 rpm Maximum capacity: 2,500 kW Manufacturer: WWS Wasserkraft GmbH Generator: Synchronous Rotation speed: 750 rpm Voltage: 900V Capacity: 2,500 kVA Manufacturer: Hitzinger Average annual output: ca. 10 GWh/a
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discharge capacity of 5 m³/s, a head range of 40 – 75 m, to enable the fluid hydraulics-optimised unit to achieve a maximum power output of 2500 kW. The Francis runner with a diameter of 780 mm drives the directly coupled Hitzingersynchronous generator at precisely 750 rpm. The air-cooled energy converter can produce a voltage of up to 900 V and was set up to guarantee nominal apparent power of 2.5 MVA. The electricity generated is conducted to the grid using an existing power connection at the dam. The plant was hooked up to the KVR’s central control facility via an existing mains link in the water storage chamber. Programming the controls was tasked to a Swiss sub-contractor, WWS Rittmeyer AG. The new hydropower unit was completed with a medium-voltage switch system and a transformer. Axpo technicians took on full responsibility for the cabling and wiring of the electrotechnical equipment. 10 GWH OF GREEN ELECTRICITY PER YEAR At the end of November 2021, once all installation work was completed it was time to switch on the new machine set – and before the end of the year the plant was already in regular operation. “Except for heavy snowfalls in the early that were a cause for concern the project went completely according to plan. All project steps and deadlines were met
WWS Wasserkraft GmbH is an internationally renowned Austrian business and provided the machine set for the plant. Working at full capacity, with a gross head ranging from 40 to 75 m combined and a 5 m³/s maximum discharge capacity, the Francis spiral turbine is able to achieve a maximum power output of 2,500 kW.
to the day. This success was mainly due to Axpo’s team and all of the companies involved, each of whom did very good work” enthused André Schluep. Overall KVR invested around 3 million CHF in a lighthouse project which did not cause any negative ecological consequences during implementation. In an aver age year KVR expects its latest small-scale power plant to generate around 10 million
kWh of green electricity. Jörg Huwyler, Divisional Head for Hydro-Energy and Biomass at Axpo stated: “Investment in the Curnera small-scale hydropower plant emphasises Axpo’s commitment to renewable energy in Switzerland. Projects like this help to encourage development in the commercially competitive Swiss hydropower sector, even if the potential for such plants is limited.”
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WWS WASSERKRAFT GmbH Oberfeuchtenbach 11 4120 Neufelden, Austria office@wws-wasserkraft.at +43 7282 5922
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AXPO TRUSTS IN THE SOLID POWER UNIT OF THE CURNERA CAVERN HYDROPOWER PLANT For many years, the hydraulic pressure in the works water conduit between the Curnera and Nalps reservoirs in Grisons in Switzerland had to be lowered via a pressure reduction regulator. The installation of a new Curnera hydroelectric unit 250 metres into the mountain now enables this hydroelectric potential to be exploited. To this end, the Vorderrhein KVR power generation group, of which Axpo has a majority holding, integrated a WWS Francis spiral turbine to drive a high-power, high-quality generator manufactured by Hitzinger in Linz. In a regular year this reliable combination of machines guarantees the production of around 10 GWh - enough to supply approximately 3.000 average housholds with green electricity.
Foto: Glanzer
The 2.5 MVA Hitzinger generator has been installed in the old vane chamber.
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photo credits: KVR
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he works water is transported through a complex 3.7-kilometre system of pipes owned by the Vorderrhein power generation group – from the upper ‘Curnera’ reservoir down to the lower ‘Nalps’ reservoir and navigating a drop of 40 – 75 metres. In 2016, KVR devised a new concept to exploit this previously untapped energy potential. The new small-scale hydropower system was installed in the vane chamber that originally also housed a pressure regulator. The Axpo project team, responsible for operation of the plant cascade, faced several tough challenges, not least those caused by the extremely cramped working conditions and restricted cavern accessibility at around 2,000 metres above sea level – and particularly the logistics of bringing in the components for the power plant infrastructure. Ultimately, a temporary cable car relay had to be set up for the purpose. An electrically- powered towing unit and a carriage wagon were installed to manoeuvre the 6-ton generator into the tunnel via the cavern opening. The extremely limited space available in the vane chamber 250 metres into the mountain made installing the individual parts of the machine very challenging. However, despite all difficulties, work was completed without any hitches.
UPPER AUSTRIAN TECHNOLOGY BEATS AT THE CORE After commencement of installation in the narrow window afforded last summer, the plant went into trial operation in November 2021, and in the same year was put into regular service. The small cavern now houses a Francis spiral turbine manufactured by WWS and built for a nominal power output of 2.5 MW. As well as the turbines, the new generator at the Grisons power plant was also produced in Upper Austria. The rotor of Hitzinger’s synchronous generator is also directly connected to the turbine runner. Set up for 900 V, the generator achieves a power output
of 2.5 MVA and the rotor turns at 750 rpm. In an average year, the new Upper Austrian machine group can be expected to deliver 10 GWh of green electricity to the grid. DESIGNED FOR A LONG LIFE The operating company boasts a wealth of experience across the entire spectrum of hydropower projects, from small to large, and quality was its number one priority when choosing this machinery. After all, KVR invested around 3 million CHF in a small-scale hydropower plant that needs to be as self-sufficient and maintenance-free as possible due to its extreme inaccessibility. The choice of
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Foto: Glanzer
photo credits: KVR
The rotor is integrated in the stator.
turbines and generator are seen as guarantees for the requisite durability and reliability. Rather than being built for years of operation, Hitzinger generators are made to serve for decades – officially, for a working life of 35 to 40 years. One of the oldest hydropower generators built by Hitzinger – and one still in operation – has been running for over 70 years. The secret of ‘a long generator life’ is a far-sighted, simple approach to the use of
metal housing and magnetic set-up. Hitzinger generators remain cool, or moderately warm, when other comparable machines would be getting hot. BACK STORY TO A SUCCESS STORY There are several other reasons for Hitzinger generators being amongst the most commonly chosen solutions for small-scale al pine hydropower plants; one key explana
tion being that the generators are custom-built solutions from the Austrian ‘steel city’ Linz. Every single machine is de vised to meet precise customer demands in terms of design, performance and in-situ requirements. Hitzinger has been developing and refining its own software for decades. All the available parameters are integrated, be fore the programming, electrical and mechanical set-ups of each machine are precision- tuned. The result is a unique, tailor-made generator. In the case of the new Curnera power plant it was the ultimate location of the generator at around 2,000 metres above sea level that played the major role in the overall design of the unit. Further qualitative benefits of Hitzinger generators include the relative lack of noise production, limited emissions, high-rev re liability and, of course, their efficiency. In an age of expensive electricity, it is becoming increasingly important to improve performance behind the decimal point. Hitzinger constantly processes market feedback and observes trends to guarantee on-going development. The Curnera power plant machine is yet another reference project for the Linz manufacturer in a very competitive Swiss hydropower market.
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photo credits: Ossberger
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A powerful machine group in the Skra power plant in northern Greece: The Ossberger crossflow turbine is dimensioned for a design output of 1,320 kW.
A NEW CROSSFLOW TURBINE CONVINCES ALL ALONG THE LINE IN GREECE The new Skra power plant in the northern Greek province of Kilkis was connected to the grid in Spring 2020. It is the first hydropower plant owned by the operating company Karpi Energeiaki A.E., using the hydro-energetic potential of the River Kotza Ntere, not far from the famous Skra waterfalls. The electromechanical heart of the plant is the hydrodynamically advanced crossflow turbine from the German market leader, Ossberger GmbH; configured for a design output of 1,320 kW. The powerhouse has already generated more than 2 million kWh of electricity during its first year of operation – despite extremely dry weather and extended low flow conditions.
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ommissioning of the new Skra power plant marked the final milestone in a long project development history that began 15 years ago. "The project was originally developed in 2006 by the company Nigel O.E., which also obtained the production licence for it in 2008. This was subsequently acquired in 2012 by a specialist in renewable energies, the investor Karpi Energeiaki A.E., who then ultimately brought the project to fruition", explains Ioannis Garatziotis from the planning office Marsa Services. The engineer explains that the approval procedure took about a decade and was one of the main challenges for the project realisation. "Basically, the permit consists of three parts: the production licence, the installation licence and the operating licence. In addition, these licen-
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ces are subdivided into various sub-licences – around 40 in number. This makes gaining a licence both lengthy and onerous." But the patience of the developers was to eventually pay off. In 2016, the permits were all finally issued, and the construction could begin. TOLERANT OF WIDE WATER FLOW VARIATIONS The construction schedule commenced with the water intake and the penstock, and the construction work generally went very smoothly, as Ioannis Garatziotis confirms: "Only the powerhouse was a little delayed, as the building permit for it arrived a little later. It was then completed in 2019." Basically, the Skra power plant is a diversion power plant that uses the natural head of almost 80 metres. Up to 2,200 l/s can be drawn at the water
Connection of the steel pressure tube to the supply line into the new turbine house.
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The new Skra power plant is located about 30 km from the northern Macedonian border. It went into operation in April 2020.
New Siemens control unit for the power plant. It can be controlled locally as well as remotely.
intake to operate the plant. The drive water is then led to the powerhouse via a 4.2-kilometre-long DN1300/DN1200 steel pressure pipeline. Over a typical year, the available water quantity can drop to as little as 200 l/s. For the operators, this meant that only a flexible turbine that is tolerant of wide water availability fluctuations and at the same time efficient and robust could be considered. Reasons enough why the choice fell on a crossflow turbine from the well-known industry specialist Ossberger. The German hydropower company subsequently developed a customised solution that was optimally adapted to the conditions on site. Specifically, a crossflow turbine with the classic division of the cells in a relation of 1:2. Both cells can work independently of each other to maintain efficiency at very low flows. The machine rotates at 415 rpm in standard operation and is designed for a maximum of 1,320 kW. It performs efficiently and reliably in both the peak and part-load ranges. SPECIAL ATTENTION TO SAFETY Particular attention was paid to the potential for pressure surges; as Dipl.-Ing. (FH) Holger Franke, who supervised the power plant from
Germany for the Ossberger company, explained in more detail: "In order to avoid impermissible pressure surges that could possibly occur in the unusually long penstock – 4.2 kilometres after all – a few special solutions were needed: Firstly, the turbine was designed to operate at low control speeds. Secondly, the closing time in the event of an emergency shutdown was set to a particularly long 120 seconds. When designing the special turbine construction, attention was also paid to any changes in flow rates during the transition from the nominal speed to the runaway speed." The operator's first experiences were accordingly positive, as Ioannis Garatziotis confirms: "The first operating experiences were really great. The operators were thrilled." And this despite the fact that the first months since commissioning in April were not marked by an abundance of water. "Although it was exceptionally dry, the new plant still generated around 2.1 million kWh of electricity in its first year of operation," says the planner. COMMISSIONING FROM AFAR The installation of the new electromechanical equipment was carried out in September
and October 2019 by an Ossberger technician on site and regional support staff. The commissioning of the plant in March and April last year proved to be somewhat more challenging. "Due to the Corona situation, it was not possible to travel to Kilkis at that time. Therefore, the commissioning had to be carried out on site remotely from Germany with our partners in Greece. This was more time-consuming, but it worked out very well in the end," Holger Franke sums up. The new Skra power plant, named after the famous waterfalls in the vicinity, produced its first electricity on 6 April 2020. The generated electricity is fed into the public 20/24 kV grid via a medium-voltage system. The economic basis is guaranteed by a subsidised feed-in tariff: the operator receives 9 cents per kWh secured over the next 20 years. The operator, Karpi Energeiaki A.E., which had previously only realised photovoltaic projects, can thus also draw a highly positive conclusion from its first hydropower project. And the turbine specialist Ossberger can be pleased about another reference power plant. Ossberger crossflow turbines can today be found on every continent in the world.
Technical Data • Type of plant: Run-of-river
• River: Kotza Ntere (GR)
• Flow rate: 2.2 m3/s
• Netto head: 70.8 m
• Turbine: Crossflow
• Manufacturer: Ossberger
• Speed: 415 rpm
• Runaway speed: 935 rpm
• Cell division: 1:2
• Cell width: 160 mm + 320 mm
• Output: 1,320 kW
• Weight: 3,9 t
• Generator: Synchronous
• Manufacturer: Hitzinger
• Voltage: 600 V
• Rated Power: 1,600 kVA
• Penstock: 4,2 km steel
• Diameter Ø: DN1200 & DN1300
• Control system: Siemens
• Planing: Marsa Services
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VALVE RENOVATION GUARANTEES HEADRACE SAFETY AT KÜHTAI PUMPED-STORAGE HYDROPOWER PLANT The mighty DN3500 valves were in operation in the headrace at the Kühtai pumped-storage hydropower plant for around 40 years. When the Tyrolian plant operator TIWAG lowered the level of the adjoining reservoir in the late autumn of 2019, it provided a perfect opportunity for a fundamental maintenance sweep of the headrace. Particular attention was paid to restoration of the two PN25 pressure category butterfly valves. The work was conducted by Geppert, the Tyrolian hydropower specialists. The contract posed several technical challenges and took around half a year to complete.
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he Längental and Finstertal reservoirs form the hydraulic basis for the Kühtai pumped-storage hydropower plant, part of the Sellrain-Silz group under the auspices of Tiroler Wasserkraft AG (TIWAG). The reservoirs are connected via a DN3500 pipeline. Safety is ensured along the works water route by two mighty butterfly valves installed in a cavern-like service chamber at over 2,150 metres above sea level, directly under the Finstertal reservoir dam. The valve service chamber can only be accessed via a 300-m tunnel in the mountain. At the beginning of 2020 there was an ideal opportunity to subject the valves of the works water pipeline to a comprehensive programme of restoration. Hugo Götsch, the TIWAG project manager, commented on the initial situation: “At first
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there were no external signs of wear or da mage to the valves, but when the decision was made to empty the reservoir, we seized the opportunity to inspect these essential shut-off devices – and repair them if required. Fortunately, the drawdown of a reservoir is a fairly rare occurrence.” Geppert Hydropower, the Tyrolian hydropower allrounders, were charged with the refurbishment of the two valves, the bottom outlet infrastructure, the dead space draining system and of the regulating gates. COMPREHENSIVE PREPARATIONS Before deinstallation could commence in the valve service chamber there were several issues in need of attention, as Markus Klotz of Geppert Hydropower remarks: “Along with the necessity of scheduling work, equipping
the site, organising assembly teams and coordinating with the various subcontractors, it was first necessary to plan dismantling work. This involved a carefully-sequenced task framework. Moreover, we needed to agree points of contact with the TIWAG team, and establish in advance how much leakage water could be expected from the bottom outlet. This was important because a large degree of leakage would have necessitated a different sitework plan, and it wouldn’t have been possible to remove both valves simultaneously. We would have had to remove them one after the other.” Activities ultimately commenced in January 2020 when Geppert began dismantling the original valves. This was no easy task, since each of the 3.5-m valves weighed around 60 tons. Luckily the assembly team had access to
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Foto: Glanzer
photo credits: Geppert
Butterfly valves after completion of maintenance work. Geppert needed around 6 months for the refurbishment of the valve components.
graphics: Tiwag
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photo credits: Geppert
Dismantling the upstream side valve DN3500.
CHALLENGING DISMANTLING PROCESS Geppert’s Markus Klotz explained the main steps in the dismantling process: “First, the dismantling team had to remove all attachments, such as the bypass pipes, measuring conduits and supply channels, the parts of the drive systems on both sides, hydraulic cylinders, drive levers and counterweights. Subsequently we loosened the flanges of the dismantling joint to provide an axial gap of around 12mm. This enabled us to move the downstream side valve on a purpose-built track towards that gap and to lift the intermediate pipe out of its position. Having relieved the disc’s weight with assembly supporters, the technicians were able to remove the first half of the housing sideways. Subsequently, the disc was removed from the remaining half of the housing.” Once dismantled and removed, the components were prepared for transportation. The procedure was performed in the same way for the dismantling of the upstream side valve. HANDLING HEAVY WEIGHTS TIWAG’s overhead hall crane had already been upgraded to a maximum capacity of 30 tons ahead of transportation to enable it to lift the 25-ton valve discs and the trunnions. Transporting the items along the access tunnel was a first test for the viability of the operation. Due to the cramped conditions, as
soon as each individual component had been removed from the overall set-up it was transported out through the tunnel. “Since the system was originally built, the size of the tunnel cross-section had shrunk by the height of the road. As a result, components that couldn’t be disassembled any further, like the intermediate pipe and the dismantling joint, had to remain in the valve chamber to be refurbished there. For this reason, special tunnel ventilation had to be installed for corrosion protection work” Markus Klotz explained. He emphasised the need for ex tremely detailed planning regarding transportation of the valve parts out of the tunnel. This required very precise cross-sectional measurements of each section of the uncladded tunnel, the aim being to facilitate trans-
portation of components, such as the housing parts and the valve discs, out through the tunnel using a manoeuvrable heavy-duty trailer. Klotz continues: “We developed a support frame to transport the valve discs with the trunnions attached. So the adapted heavy-duty trailer was able to manoeuvre its bulky load along the tunnel, and then a special heavy-load transport convoy to the factory in the town of Hall, without exceeding an effective width of 3 metres.” On top of the technical difficulties encountered in the cramped valve service chamber, Geppert’s team of technicians were also confronted with the challenges of an Alpine winter. Hugo Götsch outlined the scenario: “In January 2020 it was mid-winter up there at 2,000 metres above sea level, and the snow
Discs and transport frame being manoeuvred in the access tunnel on a heavy-duty trailer.
Foto:Wien Energie
the original plant installation plans from 1979. This allowed dismantling to be conducted as an exact reversal of the original installation procedure. Nevertheless, both the dismantling work, and subsequent transportation of the individual components out of the access tunnel, involved considerable technical challenges.
photo credits: Geppert
Foto: Glanzer
3D visualisation of the valve service chamber
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photo credits: Geppert
photo credits: Geppert
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The removed disc and transport vehicle on the way to the Geppert's works facility
photo credits: Geppert
DAMAGED TRUNNIONS Once the old components had arrived at Geppert’s works halls they were subjected to detailed inspections. Geppert’s specialists worked together with the experts from TIWAG to identify damage to parts and comprehensively document their current state. The inspection process also involved 3D measurement scans of the positioning and orientation of the valve discs and trunnions in relation to each other. This revealed corrosion damage in numerous places at the hard chromium plating of the
trunnions. Markus Klotz outlined a further technical obstacle: “Under these circumstances there was no alternative but to remove the trunnions from the valve discs. The thermically pretensioned bolts that had been used to affix the trunnions to the valve discs had to be warmed up with purpose-built heating rods in order to loosen the round locking nuts that had become particularly difficult to move due to the build-up of dirt and corrosion.” Once the trunnions had been dismantled the remaining bolts in the valve disc were removed. The 600-mm chrome-coated trunnions were then machined on the factory’s own turning machine, and all surfaces and materials were checked for cracks. A fortifying tungsten carbide coating was applied to the surfaces where the bearing is in contact. “In contrast to simple chrome-plating, this coating is de signed to cope with stress and wear far longer” Hugo Götsch adds.
Valve disc in a purpose-built mounting during sandblasting
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RESTORATION OF STEEL COMPONENTS The valve discs were subjected to thorough non-destructive testing after the sandblasting process. “All of the relevant cracks and damaged areas were ground down and a special filler applied to key points. Then the anti-corrosive protection layer was renovated in our own sandblasting facility and our paint application chamber. The profile sealing on the edges and surfaces of the valve discs, as well as all sealing elements on the bearing points, were all renovated” stated Markus Klotz. Following the original assembly instructions, the trunnions were mounted to the valve discs with thermically pretensioned bolts. Correct orientation of the trunnions to the valve disc was analysed in 3D again, set and verified. After sandblasting, as with the valve discs, the halves of the housings were also subjected to non-destructive testing – and all significant cracks were ground away. The existing stopDN600 trunnions after the surfaces have been coated with tungsten carbide
photo credits: Geppert
was around 1.50 metres deep. Fortunately, however, the weather was good.” Under these conditions it was still possible to use a mobile crane to load the components onto AWD articulated vehicles that drove down the toboggan run to Kühtai, cleared of snow for this special purpose, and the along the Sellraintal valley to Geppert’s factory in the town of Hall.
Milling on one side of the housing
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The image shows the two new butterfly valves DN1000 PN25 from the bottom outlet of the Finstertal reservoir. They must open against maximum water pressure and close against water at maximum flow. The renewed DN350 PN25 dead space closure slides can also be seen.
The Längental reservoir gate was also serviced by Geppert.
per points for the valve discs were milled down and rewelded. Superficial corrosion was filled-in and then coated with an anti-corrosive protection layer. Subsequently, the hollow spaces were sealed off and all threads were recut. REINSTALLATION OF RESTORED COMPONENTS The cramped conditions in the valve service chamber meant the restored components had to be delivered and reinstalled individually, and this depended upon the speed of assembly. The bolts with dimension M110 for connecting the housing halves were replaced completely. In contrast to the original hot bolting, the connection was pretensioned with multiple new threaded screw elements. “In the
course of reinstallation, all seals, hydraulic power units, all hydraulic supply pipes, greasing of the trunnions, a variety of pressure gauges and the whole sensor system was renovated or replaced” says Markus Klotz. Once the upstream side valve had been mounted again, it was possible to authorise a leakage test in the works water pipeline and to reopen the reservoir intake. Finally, the intermediate pipe, the downstream side valve and the dismantling joint were installed, rendering the works water pipeline operationally ready again. Geppert completed the maintenance and refurbishment procedures by renewing the shut-off valves of the DN1000 bottom outlet, and the DN350 closure slides for dead space draining. In addition, the operational and protective gates at the bottom outlets of both reservoirs were improved, and the hydraulic power units, hydraulic cylinders, all seals and all anti-corrosion sealing renewed.
RE-COMMISSIONED AFTER SIX MONTHS The technical challenges were compounded at this time by Corona lockdown restrictions. This played a key role in the progress and procedures during the entire project phase. “We had a very effective hygiene plan for the construction site. In fact, we didn’t have a single case of Corona” Hugo Götsch recalls. Overall, he awarded top marks to the project partner, Geppert, and for the successful management of the project. Since such opportunities to work in the works water conduit are fairly rare, extreme care and supreme working standards were essential. These were qualities the Geppert project team most certainly brought to bear. Following completion of the 6-month maintenance period, detailed analyses and optimisation activities enabled tests at higher flow rates than the original tests for commissioning had been. Finally, with all tasks completed, TIWAG put the pumped-storage power plant back online.
Geppert GmbH Geppertstrasse 6 | 6060 Hall in Tirol | Austria T +43 5223 57788 | www.geppert.at
Foto: zek
Geppert Hydropower
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Foto: Energiedienst
photo credits: Geppert
photo credits: Geppert
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photo credits: ewz
The control centre of the Adont hydropower plant in the village of Surses in Grisons was built on the edge of the Burvagn equalisation basin at Tiefencastel West power station. In a regular year the new EWZ small-scale hydropower plant can provide environmentally-friendly power for around 4,300 average households.
ADONT HIGH-PRESSURE HYDROPOWER PLANT IN GRISONS NOW GENERATES ENERGY FROM HIGH ALPINE RIVER In October 2021, just 1½ years after the ground-breaking ceremony in the Swiss village of Surses in Grisons, the small-scale Adont hydroelectric power plant went online. The plant operators EWZ had chosen to build a new high-pressure plant to generate electricity and take advantage of the immense difference in altitude (620 m) between the catchment basin and the operations centre. Installation of the 4.2 kilometre penstock posed considerable construction and logistics challenges, since routing had to avoid a whole series of protected areas. At 1,720 m above sea level, the reservoir had to be equipped with the generally self- cleaning GRIZZLY Coanda system by Wild Metal, the South Tyrol hydraulic steel construction experts. A 4-jet Pelton turbine in the power station headquarters was also produced by South Tyrolians, Troyer AG – a guarantee for maximum efficiency. EWZ forecasts this latest small-scale hydropower plant will reach an annual green-power output of around 10.2 GWh.
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he realisation of the first hydropower plant on the River Adont, which joins the River Julia in the village of Surses, began with a study of existing power potential carried out in 2009 by the City of Zurich electricity authority (EWZ). Martin Klauen bösch, EWZ’s project manager, explains: “Once subsidisation for hydropower was in creased in Switzerland from 2009 onward, EWZ seized the opportunity to identify areas of unexploited potential – particularly with villages in regions in which EWZ was already licensed to run hydroelectric infrastructure. Of the many studies of potential, the con struction of a small-scale water power station on the River Adont was clearly the most pro
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At an altitude of over 1,700 metres above sea level snow can be seen around the water catchment into the summer months. Construction projects at these heights require precise scheduling to make best use of the period in which work is possible.
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mising.” Klauenbösch also remarked how long and complicated dealings with the au thorities had been on the road to licensing. One major obstacle was posed by the nume rous protected natural areas along the route of the penstock. “The investigation of possible environmental effects took around 3 years. It was essential for us to involve all of the en vironmental associations and authorities, and several of the (at that time) independent towns and land owners. This proved to be the right approach as we ultimately found a satis factory solution for all parties involved.” CONSTRUCTION COINCIDES WITH PANDEMIC Although the building permit was issued in 2017, it still took several years before the power plant went online. However, once the KEV green electricity tariff subsidy was agreed – rewarding customers who contribu ted energy to the grid – the project became a financially stable proposition. Building activi ty finally commenced at the beginning of 2020, just as the Corona pandemic began to take a hold. According to Klauenbösch: “De spite initial insecurity about the situation, we decided to implement the project subject to safety and hygiene guidelines. In view of the current shortage of building materials on the market, and the price spikes triggered across the entire building sector, we’re lucky we didn’t decide to build the plant later.” The above and below-surface construction work, and the installation of the penstock, was car ried out by three companies based in the regi on. “We were fortunate renowned companies from the construction and hydropower sec tors submitted the best offers during the call for bids. It was good to see local construction companies receiving contracts and generating profit in the region” Klauenbösch remarked. TOP PRIORITY FOR NATURE PRESERVATION When building began in April 2020, the first step was to move the control centre further uphill from the area known as Savognin. The routing and installation of around 4.2 km of penstock began at the end of May, work on the reservoir infrastructure at the start of July. Klauenbösch points out that the River Adont cuts deeply into the Alpine terrain at some points, making it extremely inaccessible: “The site is unusually accessible for an alpine water catchment, and even has its own access road. Nevertheless, a transport helicopter was used in some sections to fly out felled trees to cause as little ecological influence as possible. Rou ting for the penstock had to meet multiple criteria. The land around the project site is composed of fenland, dry grassland and other protected biotopes around which the pen
Utmost priority was given to protecting areas to be conserved, such as fens and dry grassland when making routing decisions for the 4.2 km penstock.
stock had to be navigated.” In addition, geo logical measurements were taken around the location of the water catchment over a period of roughly 10 years. The minimal earth move ments registered necessitated a particular structural approach to the building of the water catchment. To protect the structure of the catchment basin in the case of the earth moving, the two limbs of the L-shaped con struction were built separately from one another. The longer limb in which the sand collector is situated, and shorter limb angled at 90°, where water intake occurs, are connec ted to each other via two pipes. On the ends of each of the DN600 pipes are joints to allow earth movement compensation. GRIZZLY PROTECTS THE WATER CATCHMENT Agreeable weather conditions, even at 1,723 metres above sea level, allowed all of the con crete elements for the reservoir to be comple ted within the first year. The patented, mostly self-cleaning GRIZZLY Coanda system, is made by the hydraulic steel construction spe cialists at Wild Metal in South Tyrol, and was installed in 2020. The undisputed quality of this system has now been installed and used throughout the Central Alps over 500 times. The eponymous Coanda principle combines with the shearing effect to ensure water is re directed automatically. Similarly, the narrow ness (0.6 mm) of the gaps prevents organic and inorganic solids from entering the basin. A coarse rake mounted further up protects the fine rake from rocks and branches. Up to 600 l/s pass through the GRIZZLY every second. They are then guided on to the two-chamber desander basin where the Adont’s fine sedi ments are filtered out before the purified
works water is guided down into the pen stock. Wild Metal’s scope of delivery also in cluded a whole series of hydraulic gates, stop logs, hydraulic power units, piping and the emergency closing valve. Environmental flow is released via an underwater pipe. In the col der months the water has to be drawn from a special winter intake facility at a prescribed constant minimum flow volume of 90 l/s. In the summer months the fixed minimum is raised to 105 l/s, plus 1/8 of the respective influx. THREE BREEDS OF GRIZZLY Since operational requirements and condi tions on site at the location of a catchment basin vary considerably, Wild Metal has de veloped three basic versions of its GRIZZLY system. Modular construction allows each GRIZZLY to be easily adapted to the size of the respective water catchment. The three ver sions are the GRIZZLY Power Protec – the module also in operation at the water catchment at the Adont power plant; the GRIZZLY Power Titan, and the GRIZZLY Power Optimus. Wild Metal is able to meet most of the basic requirements of all projects worldwide with these three versions. The GRIZZLY Power Protec is particularly well-suited to powerful Alpine rivers carrying large volumes of debris. The profile bars on the upper part of the structure are usually spa ced between 30 to 50 mm apart to protect the fine screen below from bulkier elements. The special arrangement of the bars ensures very few stones or pieces of driftwood are caught in the rake. Fish and other creatures inhabi ting the water, if no larger than 0.2 to 2 mm, can easily pass through the fine rake with the May 2022
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Wild Metal essentially offers three basic types of its Grizzly Power: the Protec (left), designed for mountain streams which carry a large amount of debris with an efficient protective screen; the Optimus (middle) does not require a coarse screen upstream, and the Titan (right), which was developed for fishing waters with large amounts of leaves. The Grizzly is generally noted for its good absorption capacity and high degree of separation.
flowing water; as can leaves, pine needles and smaller water-borne debris. Resultantly, maintenance work and manual cleaning of the catchment basin is reduced to a mini mum. Wild Metal developed the GRIZZLY Power Titan for bodies of water with large fish populations, large volumes of fallen foliage, but only small volumes of rocks. The Titan is typically installed at the outlet of a lake. The fine grille of this version of the GRIZZLY is protected by robust, rounded steel ribs. Tree trunks, branches and roots glide over the Ti tan easily with the motion of the water. The final member of the GRIZZLY system trio is the Optimus, designed to work without the larger protective rakes above. Optimus can be installed wherever a catchment basin is alrea dy protected by a larger rake. This mostly ap plies to catchment basins with water release
outlets along the side, but is also found in water treatment plants, fish breeding farms, water intakes for industrial cooling systems, snowmaking or irrigation purposes. Depen ding on the type of GRIZZLY required, Wild Metal can provide Coanda screen systems with slot gap sizes between 0.2 mm and 2.0 mm, and customers can choose from a variety of wedge wire profiles. ZIG-ZAG PENSTOCK At approximately 200m below the catchment basin the upper section of the penstock, built with DN600 piping, crosses an above-ground pipe bridge. A 35-m rectangular-cross-section truss bridge was built to span the water. For roughly the first 1000 metres the penstock routing runs along a relatively shallow gra dient, after which the terrain of the penstock
drops away dramatically on its way down to the control centre. The final 1,000 metres of the penstock are built using narrower DN500 sections. “Routing the penstock was one of the major challenges of the project and requi red multiple changes of direction. The also explains why it wasn’t possible to build for a constant gradient. Instead, it was necessary to install a highest and lowest point, and to in clude an air intake and release valve” Klauen bösch told us. The sheer physical stress on a pipeline in the Alps meant it was necessary to construct the entire pipeline using robust ductile cast iron pipes, using sleeve connec tors resistant to shearing and crushing. Brea king through the mountainside enabled the penstock to be routed under the local canton road. Around two thirds of the entire pipeline had already been installed by the end of No
Technical Data • Flow rate: 600 l/s • Gross head: 620.80m • Water intake: Coanda-system „GRIZZLY“ • Manufacturer: Wild Metal GmbH • Turbine: Pelton vertical-axis • Jet control: Hydraulic • Rotation speed: 1,000 rpm • Maximum output: 2,950kW • Manufacturer: Troyer AG • Generator: Synchronous • Voltage: 6,300 V • Maximum output: 4,000 kVA • Manufacturer: Hitzinger At full dam capacity the Troyer turbine achieves a maximum standard power output of around 3MW. Even with limited volumes of water, four hydraulically controlled jets allow the machine set to guarantee maximum efficiency.
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• Avarage annual production: ca. 10.2GWh
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vember 2020 as the first snowfall ended the construction season.
activity of the entire project. The energy is conducted from the air-cooled 11kV trans former into the grid via an existing feed-in point around 15 metres away. Martin Klauen bösch pointed out that superior-quality equipment was a general priority for EWZ: “EWZ comes from the large-scale hydroelec tric power sector in which higher quality and safety standards are basic expectations, so it’s obvious quality equipment is chosen for smaller projects, too. Of course, high stand ards also apply to the plant software and au tomation solutions.” Troyer and EWZ colla borated on the programming of the power plant control technology required for fullyautomated operation of the infrastructure. The plant is monitored and regulated at the EWZ control centre in Sils, 15 km away. 10.2 GWH OF GREEN ELECTRICITY EVERY YEAR The turbine was finally ready to go online last October around 1½ years after construction
activity commenced. “Final commissioning was a special moment. After such a long pre paration period, requiring so much patience, the actual building phase progressed very rapidly. And suddenly the machine was in operation. This success was down to the hard work of all the project staff involved at EWZ, and the cooperation with all the external bu sinesses”, summarised Martin Klauenbösch. After a two-week trial period in the autumn the plant was taken off-grid again in order to complete all remaining tasks. With the snow melt season imminent Klauenbösch is opti mistic the power plant will soon be working at full capacity. In total EWZ invested around CHF 15 million in the project. An average yearly output of around 10.2 GWh of green electricity is expected to cover the annual requirements of approximately 4,300 average households, so it’s easy to see why this project has been such a resounding suc cess.
freund.bz
4-JET POWERHOUSE Electromechanical expansion of the control centre began in May 2021. All of the equip ment was provided by the hydropower all rounders Troyer AG from South Tyrol. The centrepiece of the Adont hydroelectric plant is a vertical-axis 4-jet Pelton turbine. The hy draulically-regulated Pelton jets within the housing guarantee excellent degrees of effec tiveness across a broad operating spectrum. Operating at full capacity the plant processes 600 l/s from a 620.80-m gross head. Being designed for this capacity, the turbine achie ves a constant standard maximum power out put of 2,950kW. The physical forces applied by 62 bars of pressure acting on components in contact with the water meant components like the runner and turbine ring pipe had to be built to be extremely robust. The milled monoblock stainless steel runner is directly connected to a turbine shaft driving a Hitzin ger synchronous generator rotating at 1,000 rpm. To ensure the generator operates at ideal temperatures it was given special water-coo led housing, drawing water from an under water heat exchange unit. The generator pro duces 6,300 volts and is set up for a nominal apparent power output of 4,000 kVA. The generator shaft transmits the power produced to the machine transformer hooked up to the medium-voltage switch system. Troyer’s s cope of delivery also encompassed the secondary technology at the control centre, including the hydraulic engines, plant power supply transformer and the emergency power supply batteries. Hooking up to the public power grid was the least challenging and expensive
Wild Metal GmbH from South Tyrol provided all the hydraulic steel construction equipment for the reservoir at the new hydropower plant. The Coanda system is mostly self-cleaning and the GRIZZLY ensures loose rocks, gravel and floating debris are automatically flushed back into the residual watercourse.
• Hydraulic steelwork • Patented Coanda-system GRIZZLY • Trash rack cleaning machines • Different type of gates • Safety valves • Different fine and course screens • Entire water intake system made of steel Wild Metal GmbH Handwerkerzone Mareit Nr. 6 • I-39040 Ratschings (BZ)
Tel. +39 0472 759023 Fax +39 0472 759263
www.wild-metal.com info@wild-metal.com
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photo credits: Wikimedia Commons
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AUMA SAV variable speed electric actuators optimise water flow through the dam system at Blackwater Reservoir.
AUMA PENSTOCK FLOW CONTROL SOLUTION FOR WORLD’S FIRST ‘ELECTRIC TOWN’ AUMA SAV variable speed electric actuators optimise water flow through the dam system at Blackwater Reservoir near Kinlochleven, Scotland. The small Scottish town of Kinlochleven has an extraordinary claim to fame as the first place in the world in which every home was connected to electricity. That was courtesy of a 1907 hydroelectric dam project that generated power for an aluminium smelter near the town.
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n the late 1960s the hydroelectric station was mothballed. Now the hydro plant with its ten Pelton turbines has been reinstated as a source of local green energy. Electricity generation has been boosted to 27.5 MW. During the redevelopment, several formerly manually operated penstocks were automated. Water flow control specialist Aquatic Control Engineering (ACE) chose AUMA variable speed electric actuators. These provide highly
accurate flow control when opening and closing penstocks, increasing efficiency and reducing energy requirements. Maximum efficiency requires that the culvert supplying the hydroelectric station is operated almost full. The water level is measured by a sensor that signals the AUMA ACV intelligent actuator controls via a control panel. The AUMA actuator then drives the penstock open or closed. Thanks to their high positioning accuracy, AUMA SAV variable speed actuators are ideally suited for challenging flow control tasks.
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CONTRIBUTING TO AN ECONOMIC OPERATION The variable speed actuators are configured to start and stop at low speed, increasing speed through the middle part of the actuation cycle. This reduces mechanical stress on the actuators and penstocks, and greatly reduces the motor inrush current compared with a hightorque, full-speed start. As the generation plant operates 24/7 and the penstocks are ex tremely remote, an uninterruptible power supply was installed to cover for any loss of power. Thanks to the low inrush current of the AUMA variable speed actuators, a rela tively simple and small uninterruptible power supply could be used, significantly reducing the overall cost of the project. Water flows to the hydroelectric station through 6 km of concrete aqueduct and 2 km of steel pipe. In the early days, it was a full- time manual job to maintain ‘almost full’ flow through a box culvert at the power station end, with an operator remotely stationed to raise and lower the penstocks and keep them clean. This high labour requirement contributed to the plant becoming uneconomic and falling into disrepair. The new automated solution using AUMA electric actuators plays a big part in the economic operation of the power plant today. www.auma.com
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photo credits: Hydro-Construct
The new and flexible Hydro-Construct Barrage de Vaux replacement rubber tube weir dam on the Yonne has been damming the river since the end of 2019. At around this time the second system installed by the Upper Austrian company in France was commissioned successfully at the Aqua Bella power plant on the river Arc.
HYDRO-CONSTRUCT RUBBER DAM SYSTEMS CONVINCE ALL ROUND IN FRANCE
Hydro-Construct GmbH is an internationally renowned company from Steyr in Upper Austria. In 2019 and 2020 the company gained an initial foothold in the French market by installing two rubber dam systems. Hydro-Construct provided a single field water-filled rubber dam across the River Arc for the new Aqua Bella hydropower plant, measuring 34.5 m across, holding a water depth of 4.15 m and serving 4 VLH (Very Low Head) turbines. Renewal of the Barrage de Vaux dam on the Yonne River near Auxerre involved replacing the ‘original’ 19th-century two-field, water-filled needle dam. Each individual weir field can be regulated in parallel with the other, ensure a dam-wall water depth of 1.9 m and is 27.3 m wide. Now these first two French reference systems have gone online, Hydro-Construct is confident they will lead to follow-on contracts in France in the near future.
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here is one major benefit of deploying flexible rubber dam systems on broad, large-surface bodies of water. In con trast to conventional damming or water-level regulation solutions, rubber tube dam systems can be installed across extremely broad rivers, without immense structural changes to the natural course or banks of the river. For several years Hydro-Construct GmbH from Upper Austria has been providing its triedand-tested air- and water-filled rubber dam systems for a wide variety of purposes all over the world. Based in Steyr, in 2012 the company completed a project in Albania, installing Europe’s broadest rubber dam at 265 m end-
The interior of the Barrage de Vaux rubber dam weir. Installa tion of the filling and water-release pipes, and the anchor rails.
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turbine started or stopped. The adjustment times for the entire weir system refer to the complete raising (90 minutes) or lowering (120 minutes for emptying) of the membrane under normal operating conditions. In special cases the entire rubber dam can be dropped completely in less than one hour”, explained Rudolf Fritsch.
Delivery of heavy-duty rubber dam membranes for the Aqua Bella hydropower plant.
to-end and a height of 2.3 m. Italy’s Casale Monferrato hydropower plant on the River Po commenced operation in 2020 and Hydro-Construct provided a rubber dam with the largest dam surface area in Europe. The Upper Austrians outdid their previous record with a bank-to-bank length of 200 m and a regulated depth of 4.3 m. In 2017 the largest rubber dam ever installed in India was set up in Uttar Pradesh, measuring 270 metres across and 3.2 m in depth. Hydro-Construct built its first two reference dams in France with the Aqua Bella weir in 2019, and the replacement Barrage de Vaux dam in 2020. “The French market is of great interest to us. We estimate in excess of 200 needle dams in the country, all of which, over time, will require renewal”, enthused Hydro-Construct’s CEO Rudolf Fritsch (Dipl.-Ing. Dr. tech.). RUBBER DAM REGULATES WATER LEVEL FOR VLH TURBINES The Aqua Bella hydropower dam was built by the AKUO Group, specialists in technology
harnessing renewable energy sources, on the territories of the towns of Aiguebelle and Randens in the Eastern French Département Savoie. Located on the Arc River, it integrates four VLH (Very Low Head) turbines that offer the advantage of limiting construction at power stations built to harness low heads and large flow volumes. When all four turbines work together at full capacity the machines can generate a maximum power output of 2.2MW. The power plant officially went online after completion in December 2019. In a regular year the plant can cover the demand for green electricity generated by 4800 aver agehouseholds. The general above- and below-ground construction work required for the project was conducted by the French Léon Grosse construction company. As their subcontractor, Hydro-Construct provided 34.5 m of water-filled rubber damming for the single-field weir at a dam-wall height of 4.15 m. “The use of four VLH turbines necessitated rapid adjustment times for the dams in reaction to water-level fluctuations when one
The Aqua Bella arc power station uses four VLH turbines to generate electricity. Altogether they produce a maximum power output of around 2.2 MW.
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TRIPLY-SECURED SYSTEM A key challenge of the Aqua Bella project was posed by delivery of the rubber tubing. “The membranes are made with four material inlays with a total thickness of 18mm and an overall dam weight of 20 metric tons. This complicated the manoeuvring logistics. Lifting the membrane delivered in two rolls necessitated the deployment of a mobile heavy -load crane. Furthermore, installation work had to be conducted in cramped conditions”, Rudolf Fritsch reported. The membrane was manufactured by one of Hydro-Construct’s associates and co-partners Rubena Nachod in Czechia. The extremely stress-resistant material is made using a vulcanising press and can, theoretically, be produced in any length required. Hydro-Construct was supported in the project engineering phase by another Czech co-partner, Aquatis from Brno. The regulation mechanisms within the rubber dam, such as the pumps, rams and reset drives are housed in a shaft built alongside the rockbed lock of the power station. Continuous regulation of the water storage height, from full capacity to an empty rubber dam, is rea lised using high-power pumps. Hydro-Cons truct secures the plant dam in three ways: Firstly, by limiting the risks of pressure excesses. Secondly, by allowing water to be released from the dam manually via a ram or a valve. Thirdly, a pre-defined pressure overload triggers a water-release via gravity drive. Hydro- Construct developed its own automation solution to regulate the rubber dam system. ESA from Wolfern near Steyr was the automation partner chosen to provide the control technology. The controls are hooked up to the overall power plant management technology, but also operate fully autonomously – so safe, fully-automated operation of the rubber dam system can be ensured at all times. REDUCED VIBRATIONS In 2019, the renewal of the Barrage de Vaux weir system in the eastern French Bourgogne-Franche-Comté region was Hydro-Cons truct’s first chance to demonstrate its expertise on the French market. VNF is France’s national administrative body for French waterways, and was responsible for calls for bids for the project in the town of Vaux on the River
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The rubber dam is 34.5 m across with a top-to-bottom dam height of 4.15 metres. It ensures the Aqua Bella power plant VLH turbines can rely on constant water levels and adjustments can be made rapidly.
Yonne. The needle dam weir was originally built in the 19th century and the last major rebuilding work had been carried out in 1896. The weir next to a ship lock was seriously damaged during floods in 2018 and the need for repair and renovation became urgent. In its role as the general contractor, VNF chose MAÏA SONNIER to conduct its construction work. For each of the two weir fields Hydro-Construct delivered a water- filled rubber tube dam system – each 27.3 m across, with a maximum water level of 1.9 m. In contrast to the Aqua Bella project, cooperation was sought with a French company for the implementation of the dam controls. Rudolf Fritsch recounts that the main challenge for the Barrage de Vaux project was how to solve the issue of vibrations: “Basically it’s all about minimising dam vibrations caused by the constant underwater pressure of moving water on the dam to avoid operational da
mage to the membrane or the anchor points. Moreover, ahead of the project the Technical University of Graz conducted an analysis of the effects of vibrations on the components responsible for anchoring and securing the dam. We devised a general solution for the problem of vibrations based on the applicable guidelines and the experiences reported by other institutes. Ultimately, we developed a special regulating procedure for the two weir fields to minimise vibrations and optimise switching from parallel to serial operation for increased flow volumes, thus facilitating rapid passage through the critical parts of the rubber dam.” AN ATTRACTIVE MARKET Favourable weather and exemplary coopera tion between the companies involved ensured the Barrage de Vaux project was completed in autumn 2019. The commissioning of the new
and modern rubber dam system on the River Yonne has guaranteed local boats and ships in the Vaux area unlimited navigation of the river. Now Hydro-Construct has completed its first two French projects successfully, Mr. Fritsch is optimistic that subsequent orders in the ‘Grande Nation’ will soon appear further downstream, figuratively speaking: “We have installed two highly-impressive reference dams in France, and expect them to open more doors for us. Indeed, we are currently submitting offers for another rubber dam project in collaboration with the MAÏA SONNIER construction company. The AKUO Group, operators of the Aqua Bella plant, are also planning to build a new hydroelectric power station which will also include a rubber dam system. Based on positive feedback from the plant operators, it can be assumed that Hydro-Construct’s next French projects will soon be underway.”
Partially-filled membrane ready for a water tightness test on the Aqua Bella rubber dam during the final phase of the project in April 2019.
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photo credit: Geotrade
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The GEOCAST ductile cast iron pipe portfolio from the Upper Austrian distribution specialists at Geotrade Tiefbauprodukte GmbH is designed to cope easily with challenging geological conditions. The pipes have been awarded ÖVGW certification and can also be deployed to convey drinking water.
GEOCAST DUCTILE CAST IRON PIPE SYSTEM CERTIFIED FOR DRINKING WATER
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eotrade was originally founded 18 years ago in Ried in the Riedmark area of the Mühlviertel region of Upper Austria. In 2020, it was re-established as Geotrade Tiefbauprodukte GmbH. Over the years, what started as a one-man-show has grown into a team of skilled specialists and experts. Today, Geotrade also runs bases in Switzerland and Germany. During zek HYDRO’s visit to the company in the Mühlviertel region CEO Robert Frühwirth underlined the immense importance of the hydroelectric sector for Geotrade: “As our name suggests, we mainly trade in civil engineering products such as piping, shafts, containers and the requisite accessories for drinking water, sewage water and infrastructural projects such as road
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photo credit: Geotrade
Geotrade Tiefbauprodukte GmbH is based in the Mühlviertel region of Upper Austria, and is respected and renowned as a reliable distributor of hydropower parts far beyond Austria’s national borders. Mainly serving the needs of the construction industry, the company’s portfolio includes pipes, shafts, moulded parts and related accessories for a wide range of applications. Geotrade’s portfolio for the hydropower sector focuses on glass-fibre reinforced plastic (GRP) pipes and ductile cast iron pipes for the GEOCAST product line. The robust material properties of GEOCAST pipes ensure the system is predestined for use wherever geological conditions are challenging. Last year the GEOCAST system was awarded ÖVGW certification, so it can now be used for drinking water conduits too.
GEOCAST pipes’ longitudinal force connecting systems RJ and RJS guarantee extremely powerful and reliable connections.
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The inner surface of GEOCAST pipe portfolio products is given a protective, anti-corrosive cement mortar coating. During the manufacturing process a zinc-aluminium layer and epoxy resin coat are applied to the exterior.
TRANS-EUROPEAN SUPPLY CHAIN Geotrade doesn’t limit its choice of suppliers to within Austria’s borders, Frühwirth con tinues: “We source products from manufac turers all over Europe to guarantee customers an immense range of supreme-quality, attractively-priced components.” Geotrade offers hydropower station water conduit infrastructure in the form of glass-fibre-reinforced plas tic (GRP) pipes and ductile cast iron pipes. GRP pipes are manufactured via winding and centrifugal casting methods as DN300 to DN4000 elements, and are supplied by SUPERLIT. Excellent material properties such as low weight, homogenous wall structure, excellent wear coefficients, high static stress resilience and an extremely smooth inner surface ensure GRP piping is in demand far beyond the field of hydropower applications. ÖNORM B5161-certified pipes are used for waste water disposal, industrial applications, for building shafts and containers, storage systems and in trenchless pipeline construction. GEOCAST APPROVED FOR DRINKING WATER APPLICATIONS Geotrade distributes its ductile cast iron pipe portfolio under the banner of the GEOCAST brand, states Robert Frühwirth: “Our GEOCAST system and the TJ, RJ and RJS connection systems comply with internationally ap-
plicable standards, as well as the domestic ÖNORM EN 545 and ÖNORM B2599-1 inspection benchmarks. ÖVGW certification means these products can also be used for drinking water conduits. Ductile cast iron pipes and moulded parts, using the TJ, RJ and RJS connection systems for untreated water, also meet the recognised, market-specific stipulations of the current ÖNORM B2599-1 and ÖNORM EN 545.” The CEO rounded off by explaining the strictly regulated certification process was particularly tough and complex. Material tests were staged by an in-
dependent institute. Production samples were randomly chosen at the manufacturing plant, after which an entire range of tests was carried out in compliance with the applicable norms and regulations. The results of the complex range of material tests were submitted to the ÖVGW. Relevant certification was only awarded when all ÖVGW inspections had been passed. Approval for the use of these pipes for drinking water applications has now been granted. GEOCAST pipes and accessory moulded parts are available in sizes from DN80 to photo credit: Hölzl
construction. Our pipe material is of course also used for hydropower applications – which have always been a central source of commercial demand.”
photo credit: Geotrade
photo credit: Geotrade
The storage hall of the long-serving Central Russian company Svobodny Sokol.
In 2017 penstock at the Köberlbach small-scale hydro-electric power station in Styria is over 1 km in length and constructed using DN400 GEOCAST pipes.
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DN1000, and delivered in industry-standard lengths of 6 m. “As a rule, whenever additional pipes and moulded parts are required on the construction site, our contracted suppliers are able to deliver within a matter of days. To cover all eventualities, we usually send addi tional moulded parts to construction sites and, if not used, they can be returned without complications. Geotrade provides all installation workers with relevant training before pipe installation procedures commence” the CEO concluded. SOLID PARTNER Products from the GEOCAST portfolio are sourced by renowned international manufacturers from the cast iron pipe sector, such as Svobodny Sokol and Materbud. All manufac-
photo credit: Geotrade
The operators of the Styrian Radhof power plant also chose to take advantage of the GEOCAST portfolio for a new construction project that commenced in 2021.
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turers guarantee ISO 9001-compliant quality management. Svobodny Sokol is one of the oldest companies in Central Russia and has been active in the field of metallurgical production for more than 100 years. Based around 400 km south of Moscow, the company now focuses on the production of pipes and moulded ductile cast iron elements. GEOCAST’s moulded parts are sourced from Materbud, a Polish company founded in Gdansk in 1992 after the fall of the Iron Curtain. It has since become a major European manufacturer of ductile cast iron pipeline parts. PIPES FOR EXTREME CONDITIONS In alpine environs the geological conditions affecting the installation of turbine pipelines are often exceedingly challenging. “Using ductile cast iron pipes well known for their robust material properties allows plant operators to be sure they can cope with even the toughest ground conditions”, says Robert Frühwirth. Basically, the ductile cast iron pipes are made from recycled metals; clearly a ‘plus’ in ecological terms. Production begins with conventional grey cast iron – to which magnesium is added, generating spheres of carbon that create ductile cast iron with significantly enhanced mechanical and stress-bear ing properties. The outer coating of the GEOCAST pipes with TJ, RJ and RJS connectors consists of a zinc coating and an epoxy resin protective coat. In most underground conditions, this coating protects the piping systems from corrosion damage for decades. The interior is protected by an anti-corrosive cement mortar layer. Cement mortar is used during
centrifugation for GEOCAST pipes. At the end of the processing phase the limited proportion of cement, and the use of filling material requiring the addition of very little water, produces a very, hard, compact and impermeable protective layer. The material benefits of ductile cast iron pipes are the sums of their parts, and appreciated by far more than just the operators of hydroelectric power plants around the world. These properties include high static strength, indestructibility and longitudinal force-lock connection technology. Depending on dimensions, the pipe ends allow a change of direction of up to 5° within the connecting sleeves. GEOCAST pipes also offer several commercial benefits, such as rapid, low-cost installation, in most cases excavated material is suitable to re-use, they age slowly and exhibit excellent technical and functional longevity. COMPREHENSIVE LIST OF REFERENCES Geotrade now has a reference list featuring several successful projects with the GEOCAST system. One of the most recent hydropower projects was completed in almost record time last autumn in the Styrian town of Eisenerz. Between September and November 2000 m of DN700 pipeline were installed within three months for the penstock during the construction of a new hydropower plant. Four excavators worked in parallel to com plete the project before winter arrived. Robert Frühwirth explained: “Once again, the Eisen erz project showed the remarkable building progress that can be achieved with the GEOCAST system; and the award of ÖVGW certification now allows us to offer our ductile cast iron pipes for drinking water conduit applications too.” The Eisenerz power plant turbine pipeline is over 2000 m long and was manufactured with GEOCAST DN700 pipes within just three months in the autumn of 2021.
photo credit: Geotrade
photo credit: Schweighofer
In 2018, the 1.3 km DN350 and DN300 penstock at the Arbesbach small-scale hydropower plant in eastern Styria was installed completely using ductile cast iron pipes from Geotrade.
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photo credits: Andi Schiefer — “It’s nice out there.”
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Training activity at the new river wave facility.
NUREMBERG ‘FUCHSLOCHWELLE’: A NEW FACE IN URBAN SPORT Anyone who takes surfing seriously knows it takes far more than a board and a broad smile. Stamina, focus and the readiness to skilfully adapt to changing conditions are essentials. The southern-German river surfing community has shown just what can be achieved by realising projects such as the recently-opened ‘Fuchslochwelle’. The relatively new sport of river surfing is now trending. Increased environmental awareness has led to a more critical view of long-distance flights to the classic surfing destinations of the world. Attention has turned to the possibilities provided by regional venues, and to the question of how to exploit them sustainably. In keeping with this line of thinking, the project was realised by local companies: The Bavarian hydraulic steel component manufacturers Erhard Muhr GmbH, and the Rhineland civil engineering office, Dreamwave GmbH, a business in close cooperation with the University of Innsbruck. River surfers know what it’s like to jump into cold water; and now these two businesses know the feeling too – this being the world’s first installation of its kind.
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he ceremonial opening of the Fuchslochwelle stationary wave facility on the 25th February 2022 marked the keeping of a promise made to the southern-German river surfing community by the Nürnberger Dauerwelle e.V. association over 10 years ago: The promise was to build a stationary wave in the heart of the city as a place for N.D. e.V. members to train and an easily accessible facility for the public to try the sport. Over ten years of planning, convincing politicians and more than 2000 hours of voluntary work were invested in the Fuchslochwelle. The centre piece of the facility is the standing wave, integrated into a channel built parallel to the main arm of the river. The weir required to
create a build-up of water and the fishway were integrated into the original Pegnitz riverbed. The weir and wave ramp can be set up independently of one another in reaction to the natural fluctuations in flow volumes along the river. The facility design guarantees a stable water level further upstream, as well as the creation of various types of waves. The structural designs for this standing wave were developed and patented by Dreamwave GmbH. The wave was built by Erhard Muhr GmbH, also responsible for the layout of the surrounding wave production engineering, manufacture of the dam gates, the complex hydraulics set-up and sophisticated control system. The association’s new sports and leisure infrastruc-
ture is a non-commercial contribution to the encouragement and diversification of activity in a publicly-accessible local urban area. How ever, development of a technical concept was required to adapt the facility to the variety of river-flow conditions in order to make it avail able throughout the year. NUMEROUS SET-UP OPTIONS Lasse Bauer, Dreamwave engineer and surfer, explains the basic principle behind the standing wave facility: “The wave infrastructure consists of three modules, each with three main components: a segment, a plate and a kicker. The segments hold back the water, the plates determine the water-speed transition May 2022
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Foto: zek
An overview of the steps and requirements involved in constructing the Fuchslochwelle
Mit der Situierung des neuen Krafthauses unmittelbar vor dem Öllschützenspeicher fällt das zuvor bemängelte Schwank-Sunk-Problem weg.
Selection of materials and coatings • Seven types of steel were used, each suited to the requirements for the component in question. • Permanently-operating underwater rust-free, leak-free hydraulic cylinders, made with suitable materials and coatings, and fitted with sensor technology. • Choice of suitable lubricants and bearing materials for uninterrupted underwater operation. • Each module to be completely sealed from the overall structure and the other modules.
The companies Muhr and Dreamwave joined forces with the surf club members to complete the new standing wave.
photo credits: MUHR
Layout of the individual components
from ‘flowing’ to ‘shooting’. The water accelerates down the plate until it shoots over the kicker to guarantee the ideal direction of the ultimate jet. The water flows in a similar way as it does into a dissipation basin, the key difference being that we manipulate the hydraulic jump to create a wave ideal for surfing purposes.” There is no other modular arrangement like this in the world. Dreamwave and Erhard Muhr GmbH broke new ground with this construction. Lasse Bauer explains it was the love of river surfing that drove them to set the bar so high: “We wanted to give anyone using the facility as many wave options as possible. Normally the standing wave system runs in a three-module mode and produces a ‘standard wave’. The automated water level regulation adapts to the prevailing conditions, such as water level and descending water flow volumes. An app enables the standard wave to be shaped to suit the wishes of the surfer. Two-module operation allows the wave to modelled in a way that enables the system to compensate for lower flow rates, significantly extending the period during which the standing wave can be used.” Climbing in is made easier for beginners by regulating the rate of flow. If considerably less water flows into the wave system, the wave produced is less extreme.
Foto: zek
RETHINKING FAMILIAR PRINCIPLES Erhard Muhr GmbH was responsible for manufacturing the entire stationary wave infrastructure and the company is proud of the results. Fabian Böttger, Muhr’s project manager in Nuremberg, was delighted to have contributed many years of hydraulic steel construction expertise to a completely new product and project: “The variety of our projects and customers we serve qualified us for this project. Our readiness to find viable, load-bearing solutions for all the unanswered questions, and to think issues through to the end are what won us this contract. We are delighted that, alongside sustainable energy production, we now have green sport in our portfolio.” Particular praise was found for the collaboration between Muhr and Dreamwave, each having brought all their own special strengths to the table. A mock-up of the construction concept devised by Dreamwave was tested using scale models in the flow channel. The forces affecting the various components in a whole variety of flow situations enabled Muhr to draught a full-scale layout. Fabian Böttger outlined procedures: “Our hydraulic steel construc tion solutions are nearly always created in two planning steps. The
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• Conversion of forces calculations for material stress loads and a selection of suitable raw materials and formats, at all times in adherence with the site dimensions provided and the available budget. • Extreme care required for the positioning of the bearing mountings between the individual components - which need to be mobile within their intended spaces.
Dimensioning of connecting and welding parameters • An absolutely smooth surface was required for surfing purposes. Special developmental consideration had to be given to the producing, welding and mounting of an extremely rigid and sturdy carrier structure capable of withstanding the powerful forces involved.
High standards set for the hydraulics • The set-up feeds 14 hydraulic cylinders in constant operation and requires very precise positioning. • Operation of the hydraulics and controls is guaranteed by buffer storage to cover the risk of power failure. This is essential for the safety of those using the wave facility, and in line with the regulations issued by the local authorities.
Sophisticated control technology required • A major challenge for controlling the set-up was posed by the interaction of weir and water, since the system employs two regulative elements that mutually affect each other. The strict directives issued by the authorities state that the standing wave infrastructure must always guarantee the required water storage level, whether in operation or not.
General safety standards • The highest safety standards apply, since the wave infrastructure is installed for sporting purposes and is in direct contact with the people who use it. • The manufacturers developed a proprietary emergency stop function to allow flow rates to be reduced to a safe level very quickly. The modules go into a kind of standby-by mode to allow surfers in trouble to be helped.
Assuring accessibility for component installation and maintenance • The facility includes a maintenance window for entry into the installation and a safety bolt to secure anyone servicing the infrastructure. • Points of separation and sectional links have been integrated to allow worn-out parts to be replaced without a full facility removal.
Extremely efficient construction procedures • The fact much of the structure had to be preassembled in the factory, where a subsequent comprehensive inspection was required prior to transportation, all enabled on-site installation and commissioning to be completed very rapidly. • The lack of other technical infrastructure obstructing integration meant the entire installation procedure could be conducted quickly and easily.
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data Dreamwave provided formed the basis for our calculations regarding the forces acting upon the future components, and for their corresponding dimensions. The production process was then planned, organised and all the components manufactured.”
photo credits: MUHR
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Xaver Storr (Erhard Muhr GmbH) and Markus Aufleger (Dreamwave GmbH) explain how the facility works to Nuremberg’s Senior Mayor, Markus König, and to Markus Söder, Minister President of Bavaria.
ENVIRONMENTALLY SUSTAINABLE WATER SPORTS FOR ALL In contrast to wave generators that consume large amounts of energy to create waves in pools, the main source of energy for Nürnberger Dauerwelle e.v. is the river itself. Another demand was to ensure the conditions in the immediate area were altered as little as possible. The channel in which the wave modules are located was built parallel to the main run of the river, so of course the fishway and weir have also been integrated into the natural course of the river. The entire facility permits river life to enjoy access up and downstream. The fishway brushes also enable boats and kayaks to navigate the channel, so there’s unrestricted passage for the river’s fish population, and for other leisure-time river users. A NEW CORNER OF FRANCONIA The ‘Fuchslochwelle’ is the proud result of stamina, willpower and skill, and allows this Franconian city to promise even greater quality-of-life. Muhr’s Fabian Böttger is delighted with the project: “The collegial collaboration between the numerous groups involved in the project made this joint success possible.” Congratulations at the ceremonial opening came from Bavaria’s Minister President, Markus Söder, from the Mayor of Nuremberg Marcus König, and Markus Aufleger – CEO Dreamwave GmbH. There is now collaboration with Erhard Muhr GmbH on subsequent projects in several German cities, including Hanover and Augsburg.
#TRASH-RAKES #BAR-SCREENS #FLOW-CONTROL #HYDROMECHANICAL-EQUIPMENT #FLOOD-PREVENTION #RIVER-SCREENING #DEEP-TUNNEL
+49 8034 90 720 info@muhr.com Two intake safety gates (Picote II, Portugal), 4.600 by 10.900 mm each, water column: 33.200 mm
find us at muhr.com May 2022
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ONGOING CRITICISM OF THE IMMENSE CRYPTO-MINING CARBON FOOTPRINT
graphics: pixabay
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Bitcoin Client software. Bitcoin transactions then take place without an intermediary, such as a bank. Hence, the technology is innovative, decentralised and transparent. But there is a drawback; the immense power consumption. STUCK IN AN UPWARDLY-MOVING VORTEX Crypto-mining requires immense computing capacities with correspondingly enormous demand for energy. When Bitcoin first saw the light of day in 2009 it could be done on any average-quality home computer. However, as the popularity of the cryptocurrency grew and, correspondingly, the number of computers hooked up to the system, the demand for computing power rocketed. The larger the network of computers and users, the more complex and complicated the computing tasks required to mint new digital coins – and the greater the need for energy. This ever-accelerating vicious circle has led to the need for special breeds of computer, like the Antminer S9,
For the cryptocurrency Ethereum, a drastic reduction of the required energy use is already scheduled.
still capable of computing for such complex encoding calculations. The CBECI (Bitcoin Electricity Consumption Index) was developed at Cambridge University in the UK in order to analyse the entire demand for energy generated by this technology. As a consequence, the global Bitcoin network, the entire crypto-miner community, consumes 145 TWh every year. If Bitcoin were a country, it would be globally ranked 29th in terms of power consumption. Put another way, crypto-mining accounts for approximately 0.65% of all the electricity now consumed on the planet. Seen in context, the electricity consumed by all the data centres in the whole world serves a storage capacity of 2 billion gigabytes of data, and Bitcoin mining accounts for 40% of this energy. The staggering rate at which the demand for energy is growing is revealed by figures recently published on the ‘Digiconomist’ website: In 2018, a single Bitcoin transaction generated a carbon footprint it would take 80,000 credit card transactions to fill. Not even four years later that trans action Bitcoin-to-credit-card ratio has now grown to 1 to 453,000. CHINA SWITCHES OFF It was logical that miners raced to base themselves in regions competing to provide ever-cheaper power and accommodation. Until recently 65% of the world’s Bitcoin miners were situated in China, where they benefitted from cheap hydroelectric power in the summer and cheap coal-powered electricity in the winter. China’s considerable surplus of energy
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Foto: Glanzer
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ryptocurrencies are based on the basic principles of blockchain technologies. People began working on manipulation-proof digital entries via cryptographical encoding as early as the 1970s. The unique quality of this cryptological and technological endeavour was the generation of an entity in the digital realm which could not be copied or duplicated. The central concept of this building block system is the blockchain, to ensure the cryptocurrency is secure. A blockchain is a complete chronological list of all transactions conducted using a cryptocurrency such as Bitcoin. Every transfer in the currency adds new blocks to the list. Each transaction block also contains a record of all the previous blocks and becomes part of the chain of blocks – or ‘blockchain’. The built-in records of previous earlier blocks make a chain almost impossible to fake. The basic precondition for participation in general crypto-mining activity is a powerful computer equipped with the requisite
Whatever positive properties the most familiar cryptocurrencies may have, the amounts of energy required to mine them are exorbitant. Globally speaking, if Bitcoin were a country, it would have the 29th largest demand for energy.
graphics: pixabay
For many people, the ever-increasing numbers of media reports on digital currencies are still as unfathomable as the book with seven seals. What Bitcoin, Ethereum and various other originally-named currencies all have in common is that they are generated by computers. Current estimates put the number of such computers at over 2 million around the globe. The myriad interlinked supercomputers used for the purpose of ‘crypto-mining’ consume colossal amounts of energy. The current global power consumption estimate for this task is 145 TWh, slightly more power than the country of Norway consumes in a year. To ensure maximum profitability for this process, the vast majority of Bitcoin servers are currently located in countries offering cheap electricity. Initially, coal-power was the dominant source of energy, the share of which has fallen significantly as the industry strives for a greener image. However, even if more power is now generated by hydroelectric plants, there is still strong criticism of the excessive consumption of energy in general.
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Foto: Glanzer
graphics: pixabay
Bitcoin transactions are added to a blockchain in chronological order.
from state-subsidised coal power infrastructure enabled crypto-miners to be offered ex tremely cheap power for a long time. However, the whole scene had a ‘dirty’ image that needed to be shed. There were stories of ingenious Chinese local authorities tempting crypto-miners to the outskirts of former coal mining towns with electricity price discounts of up to 30%. For a period, these newcomers were a welcome beacon of hope for areas aware the sun was setting on the coal industry. Nevertheless, China has now decided to put a stop to the trend and is successively forcing these energy-intensive modern operations out of the country. Now crypto-miners are having to seek new operational bases in countries offering affordable and preferably clean energy. Countries like Canada, Russia, Iceland, the USA and Norway are currently the most popular choices for crypto-miners. All of these countries produce immense volumes of hydroelectric power; some very cheaply, too. Hydropower has now become the most important source of energy for the work of crypto miners. Indeed, according to researchers at Cam-
graphics: pixabay
Cryptocurrencies have the powerful potential to become the pillars of tomorrow’s world of global finance, although time is running out for the extremely energy-intensive variants.
bridge University, hydropower now makes up the lion’s share at 60% of the energy consumed. EXCESSIVE USE OF HYDROELECTRICS Frequently, as shown by many cases recently published by Wirtschaftswoche in Germany, even the immense volumes of electricity produced by hydropower plants are still not sufficient to cover demand. One example comes from the northern US town of Plattsburgh. Thanks to the abundant supply of hydroelectric power generated every year in the broad area surrounding the Niagara Falls the town is allocated a certain volume of this energy at a discount. However, since two crypto-mining operations alone were responsible for the consumption of 11.2 MW – or approximately 10% of the total available capacity – the town’s allocated quota was soon exhausted. Another case revealed by Wirtschaftswoche took place in Washington State where a moratorium was announced for crypto-miners after Bitcoins had been illegally mined at prices of 1.9$C/ kWh. Even Hydro-Québec, Canada’s largest
hydroelectric power producer, seem to have been pushed to their limits by the digital mining activity. According to Bloomberg’s news service, the above-named electricity producer had received inquiries about its capacity to provide 9 GW of power – a quarter of the Hydro-Québec hydropower park output, or around one tenth of Canada’s total hydroelectric power capacity. Notwithstanding, there are still countries like Russia prepared to welcome crypto-miners with open arms. The aim is to attract the miners forced out of China with offers of cheap hydroelectric power. It is believed several such crypto industry parks have been planned for the far north of Russia. ECOLOGICAL FOOTPRINT TO BE ENHANCED Researchers at the Technical University of Munich claim the total CO2 footprint created by crypto-mining can be calculated at around 22 megatons of carbon dioxide – comparable with the CO2 footprint of cities like Vienna or Hamburg. The entire global internet only produces another half of emissions again at 33 megatons of CO2. No wonder the industry is trying to improve its emissions record. In the meantime, the tendency in the crypto-mining sector has moved toward renewable energies. Efforts are being made to make optimum use of excess electricity generated by wind and photovoltaic plants and it has been argued such initiatives make a contribution to their economic viability and development. It remains to be seen whether hydroelectrically-generated power maintains its status as an attractive proposition for crypto-mining in the future. ALTERNATIVES ON THE WAY In general, experts agree that blockchain technology is here to stay, although it is very doubtful that the delicate topic of the exorbitant amounts of power it consumes will be a sacrosanct issue beyond debate – especially since alternative cryptocurrencies have already been developed that consume significantly less electricity. The majority of new technologies are no longer dependent upon computing power for the generation of blockchains, and simply represent a given value. Alongside Bitcoin there are something like 6,000 alternative cryptocurrencies, the newest of which are already distancing themselves from the immense energy consumption of the best-known representatives of this breed. One of the newest advocates of such an alternative approach is the Swiss cryptocurrency, Signa. To run the new currency, according to Signa’s own figures, the company requires just 0.002% of the energy consumed by Bitcoin. Although still in the minority, these currencies are pioneering new routes for the years to come. May 2022
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VOITH HYDRO INTRODUCES NEW M-LINE THAT REDUCES DELIVERY TIMES BY 30% While extending the product family and range of application of its StreamDiver, Voith Hydro has also been working on further evolving its machine portfolio – with modularised Pelton and Francis turbines. By adapting the machine units into a new kind of building-block system, the new M-Line Series dramatically reduces delivery times to benefit customers. Of course, they can also rely on the new turbines living up to Voith’s proven quality standards.
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elivery time can be a particularly critical factor when it comes to equipping hydropower plants with electromechanical components. For this reason, reduced delivery times were Voith Hydro’s highest priority in developing the latest additions to their portfolio. The key to their solution lies in the modularisation of the Pelton and Francis turbines. “The small-scale hydropower market is highly dynamic. What’s needed today are fast, innovative solutions that ensure high efficiency and reliability. With the M-Line we are setting new standards to meet these new challenges,” as Florian Trost explains. He is “Product Owner” for Francis Turbines at Voith Hydro in St. Georgen. Apart from economic evaluations of existing facilities, his function includes the further development of applied technologies as well as innovation management. One key task consists in developing and defining latest-generation
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technical standards, and upgrading produc tion methods accordingly. FOCUS ON DELIVERY TIMES The faster operators are able to get their machine on the grid, the more likely they are to meet the economic preconditions for operating it successfully. This is why, just like capital costs, short delivery times are emerging as an aspect of growing importance. As Florian Trost explains, “With this particular aspect in mind, we have subjected our developments to numerous tests and optimisations until they showed clear benefits for our customers.” In addition to enjoying economic advantages, customers benefit especially from the significantly shorter lead times compared to individually con structed facilities. Further advantages include lower transportation and installation requirements, as the
electrical engineering components and balance-of-plant equipment are pre-assembled at the factory. M-LINE – MODULAR SOLUTIONS FOR POWER PLANTS The new M-Line is designed as simplified, maximally standardised turbine-generatorunits, which come complete with the required auxiliary systems. As the system is fully pre-assembled, it arrives at the power station as a compact ‘ready-made’ unit. This means it can be installed on-site and taken into operation right away. Together with the electrical equipment, the M-Line therefore provides a comprehensive, compact and reliable ‘waterto-wire’ system. “There’s a lot of our engineering know-how, as well as decades of experience in turbine construction and latest insights from our R&D centre in every single facility we help to build – and the same is true for our M-Line
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graphics: Voith Hydro
The modular structure of Voith Hydro’s new M-Line opens up a world of new economic perspectives for operators. Pictured: M-Line Francis
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The M-Line Francis model is likewise pre-assembled at the factory: a genuine ‘plug-and-play’ module.
INFORMATION ADVANTAGE FROM THE START At project kick-off, the customer is provided with an application diagram, which indicates whether an M-Line Turbine is suitable for the job. Taking into account the head and flow capacity, the application diagram provides a simple readout of the optimal size. Based on the resulting recommended layout, the power station project is ready to advance to the planning stage straight away. If there are two possible layouts for a particular use case, the Voith Hydro team assists with its trusted expert advice in deciding on a final concept. AUTOMATION SYSTEMS The automation system offers a standardised low-voltage and medium-voltage platform for all M-Line products. The underlying design concept minimises complexity by focussing only on the essentials. Additional functions and systems are available as further options to meet local grid-specific requirements or customer needs. M-LINE PELTON The M-Line Pelton turbine is designed for heads from 80 m to 340 m and a flow rate of up to 1.60 m3/s. Following an initial customer assessment, Voith Hydro’s experts optimise the turbine size as well as the rotor and nozzles. This gives the M-Line a modular, standardised design that can still be tuned to individual project requirements in order to ensure optimum performance. To simplify the next steps in the project, the turbine is then pre-assembled at Voith Hydro’s facilities. There it is prepared for transport in five modules: generator, casing, HPU (hydraulic power unit), intake valve, and automation system. Transport is much easier this way, and on-site work is greatly reduced as well. Only a single concreting step is required once the turbine is fully assembled.
bled at the factory and then prepared for transport in four modular parts: intake, turbine, suction pipe and automation system. Factory testing and the configuration of the electrical components are completed at Voith’s facility in St. Georgen. The M-Line Francis turbine also requires only a single concreting step once it is fully assembled. This way, it is ready to be taken into operation within a very short time.
Key benefits of the M-Line Pelton and M-Line Francis turbines include: + Short delivery time + Proven Voith quality + Viability check via application diagram + Minimum power house dimensions + Simplified power house design that saves building costs + Reduced installation and startup times through pre-assembled modules + e-BoP will be included
The M-Line Pelton model is designed for heads from 80 m to 340 m and a flow rate of up to 1.60 m3/s.
graphics: Voith Hydro
Series. When it comes to the quality of our components, we’ll never compromise,” as Florian Trost asserts. This is why the same – or at least nearly the same – hydraulic contours are used for small-sized turbine versions as for larger facilities. This way, Voith is able to guarantee ultimate performance and a high level of investment protec tion. All components and production steps are subject to Voith Hydro’s notoriously stringent quality controls.
Foto:Wien Energie
Foto: Glanzer
graphics: Voith Hydro
The M-Line Pelton turbine is delivered in five component parts.
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Global Hydro is a widely-acknowledged specialist in the field of hydropower and has been investing in a comprehensive programme of digital transformation for several years. Today the company is recognised as a pioneer in the fields of Machine Learning and Predictive Maintenance.
All photos: photo credits: Global Hydro
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UPPER AUSTRIAN HYDROPOWER SPECIALIST DETERMINED TO DIGITALISE ‘Digovation 2025’ is the banner under which the Upper Austrian hydropower experts at Global Hydro are combining digitalisation and innovation to achieve some very ambitious goals. As well as innovations under consideration in machine building, geometry and manufacturing technology – efforts are also being invested in various digitalisation projects. These include popular trending developments in the thematic field of artificial intelligence: machine learning and predictive maintenance. Self-driven learning processes are soon expected to enable machines to make their own decisions and to predict probable scenarios. These are no longer visions of the future at Global Hydro, since several power plants are already testing their prototypes.
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from the Mühlviertel area coined the phrase ‘Digovation 2025’ a couple of years ago as they launched an ambitious plan that divided digitalisation transformation thematically – on the one hand into digital workplaces, and the digitalisation of power stations and products on the other. Richard Frizberg is Managing Director at Global Hydro and responsible for business development, finances, HR and the allocation of expertise within the company. He explains: “In order to be able to implement these projects we established our
own new department, ‘HydroLab’, and formed a new ‘DataScience’ team within the software development department. Depending on each task and each set of requirements there is collaboration between members of various teams from data engineering, data science, software engineering and gauging technology.” A TEAM OF EXPERTS HydroLab was set up in its present form more than a year ago. It is now responsible for the
graphics: Pixabay
ver the past few years very few issues have fascinated the hydropower industry more than the phenomenon of digitalisation. There has been feverish activity in the various R&D departments of the industry’s leading companies on hearing buzzwords and phrases like ‘Digital Twin’, ‘Big Data’, ‘Machine Learning’ and ‘Predictive Maintenance’. One company pioneering these developments is Global Hydro, the well-known hydropower allrounder from the Upper Austrian town of Niederranna. The specialists
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Teamwork is decisive for the success enjoyed by Global Hydro.
overall development of basics, for testing and for the interpretation of serial test results in order to gain a basic understanding of how development can progress. Thomas Stütz, Head of Electrical Engineering and Software Development sketches out the modus operandi: “Most of our team members are experts in the fields of hydraulic engineering and measuring technology. The DataScience team takes these data, attempts to generate interpretations based on the data, and develops machine learning models.” This is done in regular cooperation with highly-reputed research institutes, universities and technology partners. HOW THE MACHINE LEARNS When asked how to define machine learning in the context of hydropower technology, Global Hydro’s head engineer explains it’s just one field of A.I. – artificial intelligence, the foremost task being to devise models that are cap able of learning without assistance. The model recognises patterns from previous event data, enabling it to make better sense of current events and, if successful, to make meaningful predictions for the future. “Generally speaking, machine learning is continuing to grow in importance, although the exercise is nothing new. Some of the algorithms currently in use were developed in the 1960s”, states Stefan Plank, a Global Hydro Data Scientist. Ultimately, the answer to the question of how machines learn is less thrilling than the ques tion itself: The same way humans learn – through repetition and optimisation. “There’s always a concrete training data set linked to a target vector. One common example is the way machine learning allows handwritten figures to be recognised. In this case, the training data consist of lots of hand-written numbers. The target vector always contains the
Depending on the task in hand, experts from the new HydroLab and DataScience departments collaborate with specialists from various other fields.
correct number the model is expected to re cognise. An algorithm is used to solve the test with the training data. This is a process of optimisation that is repeated until the desired result is achieved”, outlines Plank. CUSTOMER BENEFITS AT THE FOREFRONT Although there may still be several obstacles en route to the self-organising hydropower plant, the goals are clear – certainly for the decision- makers at Global Hydro. “For us digital transformation is about two main goals: The findings we require to develop our products, and about how to optimise the operation and maintenance of plant infrastructure for our customers. Our primary objective is to guarantee benefits for our customers”, Managing Director Richard Frizberg emphasises. He enlarges the perspective to declare the intent to provide comprehensive
solutions: “What this means in practice is that instead of concentrating on just a turbine or an auxiliary generator, we aim to deliver all-round solutions for the entire plant – meaning the whole network of engines, generators and electrical infrastructure.” INITIAL PRACTICAL APPLICATIONS Several impressive findings and practical observations of customer benefits have already been made, not least in the field of hydraulics, as Thomas Stütz details: “Most control mechanisms in a turbine are driven hydraulically. The hydraulic pressure this requires is stored intermediately in a hydraulic accumulator from which it is sourced when required. Activity during the filling procedure is analysed very precisely using an ML model in order to guarantee very precise hydraulic system mainArtificial intelligence (AI) enables new systems to learn autonomously about how a power station can be operated more efficiently.
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Ultimately, customer benefits lie at the heart of all developments.
FOUNDATIONS FOR ONGOING DEVELOPMENT As well as being primarily intended for integration into hydropower plant operations, the research findings from machine learning models also deliver core information for the development of Global Hydro products. As Richard Frizberg emphasises: “It’s also important for us to learn these lessons within the company in order to continue to refine our own solutions.” One comprehensive example is the need to record and contextualise the entirety of physical forces, torque and momentum levels to which the control mechanisms and generator are subjected, both during normal operation, and in the case of the emergency shut-down of the turbine, since these are generally extremely difficult to calculate. Thomas Stütz details the benefits of ML in such
cases: “To enhance calculation methodologies it often makes sense to calibrate readings. In the future, Global Hydro will ensure turbines automatically send these readings to a cloud server where corresponding calculations and visualisations are stored, thus enabling con struction designers to use these data to continually improve turbine construction. Furthermore, it will also be possible to use ML models to make meaningful estimates regarding the forces working on, and generated by, similar hydropower systems. More specifically – con struction designers calculating the forces and momentums to which a system may be subjected, can compare them with ML model findings and check their plausibility.”
DEVELOPMENT OF PROPRIETARY SOFTWARE In line with Global Hydro’s general approach, all data are uploaded to a cloud solution as well as being stored at the power station. Ultimately the station requires raw data for local visualisation on power station computers. The team of Upper Austrian developers processes
A vast array of readings is combined to optimise the company’s own products.
Foto: Stockinger
tenance, particularly servicing the hydraulic accumulator. The results facilitate an estimate of bladder accumulator status, whether a nitrogen refill is necessary, or if the bladder is defective.” Another practical example considers the numerous physical forces and conditions that need to be measured and monitored in the course of managing the turbine – such as pressure, temperature, momentum etc. The ML model is trained on the basis of these data, and is able to predict a result using the wide range of input features. “Finally, an anomaly recognition check is run to identify deviations between the predictions and the actual readings. This allows the system to discover problems long before dangerous levels are reached. In turn, in many cases they are problems that can be solved quickly, cheaply, and without the need for the long and expensive downtimes required by extensive repair work”, he rounds off.
QUALITY BEFORE QUANTITY Accurate readings lie at the core of effective machine learning. There is no doubt that in frastructure, such as turbines, generators and auxiliary power units, delivers a far greater volume and complexity of data than was previously the case. However, just because more sensors have been installed, this doesn’t automatically guarantee better analyses. GH Head of Electrical Engineering and Software Development, Thomas Stütz, highlights the advantages: “Many of today’s sensors commonly deliver a combination of signals and readings, rather than just one single signal. Around two years ago Global Hydro reprogrammed all its sensors to IO Link technology, meaning the sensors are now hooked up to a software protocol, rather than working with hardware signals like +-10V or 4/20mA. The benefits are that this requires much less wiring and cabling, and that a single sensor can provide far more information.” Has he points out, the main goal is to collect the greatest viable volume of data in the highest possible quality, although there are limits to the amounts of data that can be processed: “Computing times rise accordingly, and the risk of receiving more noise than data can be the result. Data quality is still a greater priority than data volume.”
Foto: zek
Mit der Situierung des neuen Krafthauses unmittelbar vor dem Öllschützenspeicher fällt das zuvor bemängelte Schwank-Sunk-Problem weg.
Foto: zek
Foto: zek
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With the help of ML models and the use of comparative data, Global Hydro’s construction designers will soon be able predict the physicalforces hydropower infrastructure can be expected to face.
data in the cloud where all the signals are collected and managed in a central database. “The software for the whole procedure – data generation at the hydropower station, transfer to the cloud via secure channels, and the subsequent analytics, is developed completely proprietarily in Global Hydro’s own software development department. Our main task is to create the models, and the architecture they require, to make them available to customers. We deploy a Microsoft product within the Azur Cloud to manage and analyse data. The platform draws together the entire process chain – from data storage to machine learning-generated event predictions. It also allows us to process almost unlimited volumes of data”, as Thomas Stütz explains. CHALLENGES REMAIN Despite the broad scope of the progress made so far, the digitalisation specialists at Global Hydro still face several challenges. The foremost challenge being the need for automation. Richard Frizberg highlights the issue: “It’s a major challenge in terms of the need to roll out our models causing as little extra work as possible for all our hydropower plants. We expect technical generalisation to be a hurdle for a while. In the end, one key to success will be ensuring all the specialist disciplines work together efficiently like gears. For example, data scientists are not capable of constructing models on their own. This requires experts in other fields, who understand the contexts causing relations between various readings, and who can make the right conclusions.”
outdated. Global Hydro is working especially intensively on the market viability of its technology. Richard Frizberg: “The entire control, operation and data conduit technology at the hydropower station is 100% linked up to this technology and the cloud infrastructure has already gone live. All of the machine learning models and data analyses methods are currently undergoing protype testing, and are already in test operation at numerous hydropower plants. We plan to make the first prototype available at the end of 2022. A subsequent test phase will then be followed by final development toward market readiness.” In the interview Global Hydro’s CEO points out that the company has always given R&D a leading role, and that the topic of digitalisation has been a central consideration for technologi-
cal development for a long time. “Our pioneering power plant management system, HEROS, is further evidence of the fact that we have been leaders in the small-scale hydropower market segment for years. We were among the first people to work with these ideas, and we are taking the same approach toward machine learning, data science and predictive maintenance, digitalisation and automation. They are all highly prioritised at this company.” READY FOR NEW CHALLENGES The Corona pandemic gave Global Hydro an added incentive to tackle the issue of digitalisation, according to Richard Frizberg, although energy transition is also important in this field: “In the short to medium term power stations will be expected to offer an increasing degree of flexibility, and to communicate and coordinate better with each other. In fact, soon intelligent systems will be essential for the development of hybrid solutions – such as hydroelectrics combined with wind power – or with photovoltaic technology. All this depends on continued developments in the field of digitalisation and on integrating certain aspects of artificial intelligence” Frizberg ex plains. For many years it has been claimed that hydropower has reached its technological limits and very few developmental steps can still be made. Yet the introduction of machine learning and other digital technologies has opened up a whole new scope for progress – as well as providing real benefits for plant operators. Global Hydro is a pioneer in this field, and is well on the way to setting new standards in small-scale hydropower solutions. The first prototypes are already being tested: Global Hydro is working hard to get its new ML models ready for the market.
PROGRESSING TOWARD MARKET READINESS It already looks like the new ML models will be ready for everyday operation very soon. The notion of them being futuristic is already May 2022
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photo credit: PELFA Group
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For more than 15 years PELFA Group has been a reliable partner in the hydropower industry, proving its competence with a series of international large-scale projects.
PELFA GROUP IS EXPANDING ITS HYDROPOWER PRODUCTION CAPACITY Headquartered in Buja near Udine, Northern Italian steelwork engineering specialist PELFA Group is taking its performance capacities to the next level. PELFA is currently delivering variable-speed turbines for hydropower plant Segozerskaya in the Karelia region in Northern Russia. The project is implemented by the world’s second-largest aluminium manufacturer, EN+ Group. For PELFA this marks a further significant business development milestone – yet another impressive proof of the firm’s professional competence and flexibility in serving a variety of markets.
KAPLAN TURBINE WITH VARIABLE ROTATIONAL SPEED “Project Segozerskaya was planned by the Russian planning office PMCB – Power Machine Construction Bureau. They put their full trust in our competence. What makes this particular plant so special are the highly fluctuating water levels of two lakes where the new facility is situated,” explains Andrea Forgiarini, who has been serving as PELFA Group’s CEO since 2004. The machine concept calls for a single-regulation direct flow Kaplan turbine with a diameter of 2.8 m and variable rotational speed. This means that only the guide vane assembly can be
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regulated. The facility is to be equipped with three identical, horizontally aligned machine units in a highly compact design. “This specific design with variable rotational speed is used because the altitude varies between 1.9 m and 8.6 m up to four times a day. As a result, the rotational speed varies between 60 and 183.3 rpm,” as Forgiarini explains. Owing to the low installation height, and not least because of the cost saving potential, high-speed direct current generators are coupled up photo credit: zek
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ccording to business news platform Bloomberg, the overall technical hydropower potential of Russia, the world’s largest country, amounts to a whopping 800 TWh. Currently it is Sibiria’s hydropower potential in particular that is attracting a growing number of investors. One of them is EN+ Group, a conglomerate of Russian aluminium manufacturer Rusal and a group of hydropower operators. Today EN+ Group not only ranks as the world’s second-largest aluminium manufacturer but is also considered Russia’s largest independent energy provider. The firm is currently investing in a series of hydropower plants in Siberia. First and foremost among them is project Segozerskaya in the far Northern region of Russia. This plant is designed to provide the energy for a new data centre, DCLab Karelia. It is a groundbreaking hydropower project not far from the Finnish border, whose implementation involves a number of challenges that had – and still have – to be overcome.
With a total length of around 12 m and a rotator diameter of 2.8 m, the machines for the Segozerskaya power plant in Russia have impressive dimensions.
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Foto: PELFA Group
photo credit: zek
photo credit: zek
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For large-scale project HPP Segozerskaya PELFA provided all the machine parts up to, and including, final assembly. Housing components for machine 2 are being worked on at the CNC controlled floor type boring and milling machine.
GAINING GROUND IN THE HYDROPOWER SECTOR With the machine units for this new project in Russia’s Karelia region PELFA has once again proven its efficiency, know-how and great flexibility in serving current market needs. By successfully completing numerous international projects in the face of constantly growing challenges, the firm has by now evolved into a well-established, competent partner in the hydropower industry. However, the firm has risen from very modest beginnings. It was in 1979 when Redento Fabbro founded the firm that was to evolve into today’s PELFA Group. Starting out as a pure steelwork construction operation, PELFA in the following 45 years developed into an industry specialist that to-
INVESTING IN THE HOME BASE Steady investment in new machine generations is a proven, forward-looking strategy, especially when it comes to maintaining a competitive edge in completing orders. “This creates added
photo credit: PELFA Group
day provides a wide product portfolio, from facility construction and machines to mechanical and welded components for a variety of industries on the worldwide market. PELFA Group is a tradition-steeped provider that specialises in the manufacture of large-scale products for the steel industry, from construction to assembly of plant components or fully equipped systems, including ladle carriages, turrets, ladle tilters, oscillators, continuous casting segments, straightening machines, stave coolers, flame cutters, roller conveyors, roll stands, and shearing machines. The firm also serves the oil and gas sectors with a variety of equipment for plant components that are custom tailored to suit the individual requirements of its international customer base. Further business segments that profit from PELFA Groups’s long-standing experience in manufacturing industrial components include civil engineering, industrial equipment engineering, earth moving, hoisting technology, and even the recycling industry. PELFA covers the entire production process, from receipt of order to the final ‘turnkey’ product. All processing steps can be performed on-site, including comprehensive contract management, engineering, materials purchasing, cutting of sheet metals and structural shapes, pressing, bending, calendering, welding, heat treatment, machining, sand blasting and painting, as well as pre-assembly and mechanical final testing. The mid-sized industrial firm currently employs about 150 staff, generating an annual turnover of around € 30 m. On its premises with 70,000 sqm floor space, PELFA Group processes around 15,000 tonnes of steel each year.
Each of the three machine units is being fitted with a 6.7-tonne planetary gear by Czech gearing manufacturer WIKOV. The transport lock doubles as an installation aid.
value, both environmentally and in terms of technological progress. And it boosts quality along the entire production chain,” says Andrea Forgiarini. The firm has invested around € 5 m in its local facilities in 2021 alone. To further optimise the manufacturing processes, a large-scale boring mill with a working height of 3.5 m, a fully equipped processing centre, and a new grinder for cylindrical components with lengths of up to 8 m have A surveying technician from DS Machine (also headquartered in the Czech Republic) is finetuning the turbine shaft’s exact positioning.
photo credit: PELFA Group
directly to the turbine shaft. A complete machine combination measures around 12 m. It consists of the turbine, a planetary gearing that weighs around 6.7 tonnes and is provided by Czech-based manufacturer WIKOV, as well as a 360 to 1100 rpm high-speed generator, an inverter, and a rectifier unit. However, the turbine shaft is held in place at only two points, resting on a plain bearing and an anti-friction bearing at each point. Except for the drive units, all engineering parts were manufactured, assembled, tested, disassembled again and prepared for transport by PELFA. Final delivery (machine units 1 to 3) wad begun in late April. The generator housings were also manufactured in Buja before they were transferred temporarily to Moscow, where they are to receive their winding from a Russian generator manufacturer. When completed, the power plant is expected to achieve an installed capacity of around 8.1 MW. “We’re proud to be part of this innovative project. Our long-standing experience allowed us to contribute significantly to this sustainable project,” says Andrea Forgiarini. Final installation of the turbine units at their destination nearly 3000 km away is scheduled for 2023.
Once hauled into place, the gearing is shifted into its exact final position.
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been installed. This enables streamlined workflows, allowing projects to be implemented even more efficiently. The engineers’ specialist skills need consistent further development as well: “To be ready for future challenges, we have reinforced our staff training programmes and intend to expand them even further in the future,” says Forgiarini. Another priority at PELFA Group is the improvement of air quality in its production halls. The firm’s management is currently reviewing various concepts to reduce dust pollution throughout the entire production environment. Also high up on PELFA’s list of priorities is sustainability. The in-house photovoltaic system was upgraded only recently by a full 200 kW. Together with the existing system, the firm is profiting from a panel area with a total output of 500 kW, which covers around 60 to 70 percent of energy costs. “Combined with our newly installed LED lights, this translates into overall cost savings of around 80 per cent,” says Forgiarini.
photo credit: zek
HYDROPOWER: ALL COMPETENCIES UNITED IN-HOUSE Staying its course through the crisis of 2008, the firm has since increased its focus on the energy sector, which proved a highly successful move. In addition to hydropower equipment, PELFA today also provides components for wind power, offshore, oil and gas projects, as well as for the nuclear energy sector. The majority of business activities is dedicated to the hydro sector, which accounts for more than 60 per cent of the firm’s productive capacity, as Forgiarini explains. PELFA Group offers all their products in the form of turnkey solutions, from individual turbine components to fully assembled machine units in various designs, including Francis, Kaplan and Pelton turbines, as well as hydrodynamic screws. All production steps are performed at the firm’s premises. Apart from the manufacture of new facilities, PELFA also provides the services required for overhauling and restoring existing ones. “In recent years we have acquired all the necessary knowledge to manufacture high-quality system components for hydropower projects, and to repair and service existing facilities. By now we have consolidated all these competencies in-house. And that’s precisely our strong point,” says Forgiarini. This comprehensive knowledge, as well as the firm’s reliability in terms of contract implementation and deliveries, have convinced a long list of hydropower businesses to choose PELFA Group as a trusted project partner.
Left to right: Erich Feldtänzer, Regional Head of Sales for German-speaking markets, Igor A. Zharov, Head of Technology at PMCB, J. Hovorka, DS Machine.
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photo credits: TRM / Löwenzahm
TRM’s ductile iron pipes have always been marked by a sustained commitment to regionality.
REGIONALITY IN THE HYDROPOWER INDUSTRY – MUCH MORE THAN JUST ADDED VALUE FOR REGIONS In spite of ubiquitous globalisation, ‘regionality’ is emerging as an issue of growing importance in the hydropower industry. Regional creation of economic value and awareness of CO2 footprint issues are by far not the only reasons behind this development. Another key factor is the realisation that in-house real net output ratio has a significantly positive effect on a business’s profit generating power. One of the firms that practice and live by the multifaceted concept of ‘regionality’ is well-known pipe system provider Tiroler Rohre GmbH (TRM): Short transportation distances, recyclable materials, long product lifecycles, and the use of renewable forms of energy have earned TRM the reputation of a pioneer in terms of ‘regionality’. One thing seems certain: the advantages of a strong commitment to regionality are not limited to the region as such, but also benefit the customer and, ultimately, the business organisation itself.
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espite its popularity, the concept of ‘regionality’ is lacking a clear, legal definition. While some view it as being limited to district boundaries, others interpret it in broader terms, as extending to national borders, to the German-speaking region, or even to the EU’s outer perimeter. In general, there are two key parameters that are considered to be definitional for the concept of re gionality: the effects of keeping transporta tion expenditures at a low level, and of keeping the value created within the local region. But focussing only on these two aspects would keep issues of ecology and sustainability out of the picture, even though they are essential building blocks of a living commitment to regionality today. Especially when considering the product as such, for example, certain questions arise: Where have its raw materials and the expended energy been sourced, and where is it produced? And what about product quality? Is it
a short-lived product that lasts only a few months, or is it designed for decades of con tinued use? Along the line of answers to these questions it becomes clear to what extent attributing truly sustainable regionality to the product is justified. ACTIVE COMMITMENT TO REGIONALITY By now, regionality is also gaining in impor tance in the hydropower industry. For example, a growing number of businesses are committing themselves to a deliberate reduction of their CO2 footprint or regional value creation as part of their Corporate Social Responsibility. One firm that has been playing a pioneering role in this respect in the Alpine region is Tiroler Rohre GmbH, or TRM for short. For 75 years TRM has been developing, producing and marketing high-quality pipe and pile systems that are manufactured from ductile iron at their facility in Hall in Tyrol, Austria. Regionality at TRM is an inte-
gral part of the firm’s holistic sustainability concept. “The raw material for our ductile iron pipes and piles is made up of nearly 100% recycled scrap iron, which is recycled after a hundred years of useful product life. Our products have very low operational servicing and maintenance requirements, which prevents waste and saves resources as well as CO2 emissions. We can actually guarantee a low CO2 footprint, thanks to our optimised delivery logistics for our recycling material, and because of short transportation routes to our construction sites,” explains Walter Korenjak, TRM’s Regional Head of Sales for pipe systems in the Austrian market. A GOOD REAL NET OUTPUT RATIO IS WELL WORTHWHILE Crucially, firms like TRM have an above-average vertical range of manufacture that translates into a high real net output ratio. A wide- ranging scientific study published jointly by May 2022
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ting photovoltaic system. This will allow us to cover most of our energy requirements with environmentally friendly energy. The use of self-generated renewable energies alone contributes quite a bit to the region’s creation of value – and it is a climate protection measure well worth taking into account.
Foto: zek
photo credits: TRM / Löwenzahm
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Mit der Situierung des neuen Krafthauses unmittelbar vor dem Öllschützenspeicher fällt das zuvor bemängelte Schwank-Sunk-Problem weg.
In-house expertise is a key priority that helps TRM to achieve a high vertical range of manufacture.
ENERGY FROM RENEWABLE RESOURCES Where the CO2 footprint is concerned, the energy being used is of course a crucial factor. “We take great care to make our production sustainable – by using photovoltaics, for example. We have already fitted the roofs of our factory halls with photovoltaic modules that generate around 900,000 kilowatt hours a year. We also put our process heat to good use by feeding it into our local district heating grid,” as Max Kloger, TRM’s Owner and Managing Director, explains. Solar power is also the way to go for EFG, as Werner Goldberger explains: “We’ve been serving numerous customers in the hydropower industry for nearly four years now. When it comes to sustainable energy for our own facilities, solar energy is our best bet. We’re currently planning to expand our exis-
WANTED: CUSTOMER PROXIMITY There is one aspect that is seldom mentioned when it comes to regionality, although it is one of its most essential benefits: customer proximity. Customers appreciate having their project partners close by. As a result, flexibility and immediate availability of resources and trained staff is in higher demand today than ever be fore. As Walter Korenjak points out, “By pro-
By producing locally TRM can contribute a lot to improving the overall security of supply for its customers and partners.
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photo credits: TRM / Löwenzahm
Foto: zek
EMPLOYEES: THE MOST VALUABLE CAPITAL Pipe systems specialist TRM is not the only provider to confirm that the real net output ratio is crucial to the hydropower industry. Other suppliers in the industry have been convinced of this for years. One of them is generator specialist Hitzinger, which is headquartered in Linz, Austria. “Our vertical range of manufacture is around 50 to 60 per cent. This adds to our flexibility and overall resilience against crises,” explains Volker Schmid, Business Unit Manager, Alternators & Converters at Hitzinger. Ing. Werner Goldberger, Managing Director of Carinthian-based hydropower allrounder EFG, has a very similar story to tell. When asked, he confirms that his firm achieves a high real net output ratio, adding another important factor to the equation: well-trained employees. “Virtually everything, from con struction to manufacturing and installation of
our in-house products, is taken care of by our employees. Highly qualified employees are a firm’s economic potential and hallmark. The majority of our employees is from our local region.”
Foto: Stockinger
the University of Technology and Economics at Karlsruhe and the ISI department of the Fraunhofer Institute shows a direct correlation between a firm’s real net output ratio and its economic success. The study’s authors devised a model that showed that increasing the real net output ratio by 1% translates into a 0.2% increase in earnings. As it turned out, the real net output ratio is by far the most important explanatory factor for a firm’s likelihood to achieve a yield on sales of more than 2%. Conversely, the authors were unable to find any significant causes for the productivity or profit status of businesses that relied primarily on the use of global delivery chains. One explanation offered by the economists is that possible cost reduction effects might be lost again along the delivery chain due to the higher coordination and organisation costs for ensuring the ability to supply. It seems, therefore, that expanding in-house value creation pays not only in terms of sustainability, but also economically.
DESIGNING FOR PRODUCT LIFE CYCLES THAT LAST FOR DECADES With sustainability having a direct bearing on a product’s regionality, its life cycle is a crucial factor as well. High-quality manufacturers such as TRM, EFG or Hitzinger are able to achieve technical product lifespans that sound almost incredible in times of planned obsolescence and disposable products. TRM’s duc tile iron pipes, for example, are designed to last for up to 100 years. Likewise, high-quality hydropower machines and components are built to keep running not just for years but for decades. Just like Hitzinger’s generators, for example – a case in point in terms of longevity. “It’s been said that generators of previous generations used to be designed on a larger scale than today’s. But we still put a lot of effort in making sure that none of our machines runs hot, so it can keep running without any problems for decades on end. Our generators are typically designed for a lifespan of 35 to 40 years. But the oldest one of our generators is 70 already,” says Volker Schmid.
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the resulting environmentally sensitive ap proach to implementing projects. As Walter Korenjak explains, it’s not just the environment and the region but the customers that benefit as a result. After all, he says, the key factor in earning the customer’s trust is personal contact with service staff, which is still a top priority at TRM. A small CO2 footprint, as well as sustainable manufacturing practices, a high real net output ratio, the reliability of a trustworthy local employer, short routes of transportation, and staying in close personal REGIONALITY HELPS TO CREATE VALUE At TRM, the ability to provide personal on- contact with the customer: these are the hallsite services with trained staff is considered marks of an active commitment to regionality. another important benefit of regionality. So is At the same time, they are a winning formula
for firms whose commitment to sustainable development contributes greatly to the prosperity of their local regions. That said, regionality does not necessarily have to stand in absolute opposition to globalised economic concepts. After all, we all are living in a networked world in which niche products are particularly dependent on transregional sales, and in which key components of a global supply chain will therefore remain indispensable. A growing number of hydropower providers are becoming aware of a simple truth: regionality ensures local value creation, which eventually helps to sustain local structures, and with it our climate and our environment.
TRM PIPE SYSTEMS
Water flows through our pipes. Safe water supply. www.trm.at
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Foto: Energiedienst
ducing locally we can contribute a lot to ensuring the overall security of supply for our customers and partners. If you are able to oper ate more or less independent of global suppliers and make use of local expert knowledge, that allows you to find flexible solutions quickly even in times of crisis. That’s precisely why TRM uses local suppliers and relies on the long-standing experience of in-house trained staff in all of its departments.”
photo credits: TRM / Löwenzahm
Regional production at TRM’s facilities provides employment for around 230 staff.
photo credits: Pixabay
Recent economic data show that a high real net output ratio pays off for businesses.
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AIMING HIGH INSIDE THE MOUNTAIN: ‘CONSTRUCTION SITE OF THE CENTURY’ AT LINTH-LIMMERN The Linth-Limmern power plant complex comprises the three power plants of Muttsee, Tierfehd and Linthal. With construction work to boost the output of the Linth-Limmern facilities from 480 MW to 1,480 MW, the Swiss energy sector’s largest construction project was brought to a successful completion. The plant’s output is now equivalent to that of nuclear power plant Leibstadt or the Cleuson-Dixence hydropower facility.
Installing the crane bridge
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they also convert surplus electricity into valuable peak energy. The plant’s construction was a logistic feat of genius. Far more than 3,000 workers from numerous engineering and construction firms, suppliers and specialists were kept busy in high mountain regions, as well as underground and in the valley area at Tierfehd. photo credits: Gersag Krantechnik AG
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verall, planning and construction took around ten years to complete. The new underground pumped-storage plant is designed to pump the water from the Limmernsee back into the Muttsee some 630 above it. Pumped-storage power stations like this one not only generate energy; during off-peak times,
BRIDGE CRANES SUPPORTING CONSTRUCTION LOGISTICS UNDERGROUND Among other things, bridge cranes and ceiling travelling cranes were required during the construction phase to support on-site logistics. Lucerne-based crane manufacturer Gersag provided seven crane systems to five sites. Four double-girder ceiling travelling cranes were installed at the central control cavern; three further cranes were fitted to serve the smoke extraction shaft, the concrete preparation site and the workshop. The project involved various challenges in terms of logistics, installation and engineering. CONSTRUCTION SITE TRANSPORTATION VIA AERIAL CABLEWAY The central control cavern was fitted with four double-girder ceiling travelling cranes. Located 1,700 m above sea level, the cavern forms the central part of the new power stati-
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photo credits: Gersag Krantechnik AG
The crane systems in the machine cavern of hydropower station Linth-Limmern are being put into operation.
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on. All crane components were delivered from Tierfehd (800 m above sea level) to Kalktrittli (1,850 m above sea level) via an aerial cableway. From Kalktrittli the equipment was then hauled to the installation site with special vehicles. Transporting the components this way posed a series of challenges to Gersag. The cableway is designed only for actual loads of up to 25 tonnes and lengths of up to 15 metres. To ensure that the components could be transported safely, the crane manufacturer had to construct various multi-part crane bridges. As a result, four crane bridges (with spans of 22 m) for the two double-girder ceiling travelling cranes were built from three parts, while the bridges for the double-girder gantry crane (with a 16.24 m span) for concrete preparation site were constructed from two parts. Two wheeled loaders then hauled the long parts through the uneven tunnel to the installation site, with the parts being secured to the frontshovel of a bi-directional wheeled loader by means of lashing straps.
COMPLEXITY IN ENGINEERING It was already clear during the planning stage that the cavern ceiling would give way by up to 6 cm due to the extensive height (up to 50 m). To counterbalance this uncertainty, Gersag had constructed a ‘floating’ trolley, which allows the span to be adjusted by 10 cm either way. NO CHALLENGE TOO GREAT Gersag crane technology is able to prevail in challenging situations, thanks to the firm’s meticulous approach and unique ideas: qualities that allow the crane manufacturer to serve an extensive customer base in the energy and hydropower sectors. Projects are implemented in-house all the way, from planning to production, installation and transport. This allows the crane manufacturer to guarantee smooth project processes and a high level of quality to
boot. Especially hydropower plants are often constructed in mountainous areas, where delivery routes for special transports are particularly challenging. In some cases, narrow adits or the need to transport parts by aerial cableway add to the challenges. As a result, smooth collaboration between the project leader and experienced operators is key. If nothing else, the sensitive environment inside the power station is a frequent issue to be dealt with. Cranes often have to be mounted and unmounted above running machines or expensive turbines while ensuring the uninterrupted operation of at least one crane. Working conditions like these require diligent qualified engineers with lots of experience, as a Gersag representative explains. “SWISS MADE” INTO THE FUTURE Gersag prefers to keep its manufacturing base in Switzerland. Doing so gives the firm great leverage in meeting individual requirements and staying close to its customers. Thanks to this high level of customer proximity, requirements can be met more quickly, and project implementation is less complicated. Switzerland as a production location is publicly funded, which allows Gersag to build a new production hall at its facilities in Reiden, thereby expanding its production space by around 3,300 square metres. With this enlarged production capacity, the course is set for more efficient workflows and digitalised manufacturing. As a result, Gersag is supporting Switzerland as a production location while promoting job security. All of this is made possible by the winning formula of combined quality, innovation and automation. For further details visit www.gersag-kran.ch Hauling the crane girder through the tunnel.
Foto:Wien Energie
Foto: Glanzer
photo credits o: Gersag Krantechnik AG
A crane girder on its way up the mountain on the aerial cableway
photo credits: Gersag Krantechnik AG
INSTALLATION INTERRUPTIONS DUE TO PIT BLASTING WORK Despite careful planning and preparatory work, installing the cranes turned out to be quite a challenge. 72 support plates were cemented in already during the the excavation phase in preparation for the later installation of the crane runway. However, subsequent work to secure the crane runway to the cavern vault and for the installation of the crane bridge was interrupted repeatedly by blasting work. This meant that the installation of sensitive parts such as travel motors, switch control boxes or power supply lines had to be delayed accordingly. This way, possible damage by falling rocks could be avoided. May 2022
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HYDRO
photo credits: voest alpine Foundry Group
3D sand printing competence center of voestalpine Foundry Group.
ENERGY TRANSFORMATION – READY FOR TAKE-OFF Hydropower is an efficient and sustainable way of generating electricity and, at around 60%, accounts for by far the largest share of Austrian electricity generation. In the hydro power segment, the voestalpine Foundry Group has been a longtime partner of many well-known turbine manufacturers. In the last five years alone, a total of 130 projects have been successfully implemented at the Linz and Traisen sites. With the new 3D sand printing technology the competitiveness in this area will further increase.
I
n recent months in particular, a clear upward trend has been noticeable in the industry. The growing focus on decarbonization is reflected in the increasing number of many new projects in the international arena. In addition, many existing plants are currently being revitalized, thus ensuring sustainable power generation for the next decades. In the hydro energy segment, the voestalpine Foundry Group, a subsidiary in the Steel Division of the voestalpine Group, supplies essential components for the energy infrastructure, such as blades or guide vanes or even entire runners made from a single casting. These are used in a wide variety of turbine types, such as Kaplan, Francis or Pelton. All weight ranges can be covered, from a few kilograms to 50 tons and more. Highest quality of castings as well as reliable delivery times are important aspects in a well-functioning customer partnership. Especially in the case of power plants, security of supply is a prerequisite to ensure unrestricted power supply. The voestalpine Foundry Group can look back on many years of expertise in this area and works only with the highest-quality metallurgical equipment. The wide range of materials complies with all standards and norms of the hydro power industry and is characterized above all by its special durability.
TRADITION MEETS INNOVATION The traditional manufacturing process is supported by 3D sand printing technology, especially for complex geometries or time-critical spare parts. In addition to design freedom, this innovative process also enables optimization of the production steps, which has a positive effect on the delivery time to the customer. Francis blade 3.000 kg:
During the process, a 3D printer uses CAD data to directly produce sand molds into which liquid steel is poured. The sand molds are created by the repeated application of 300-micrometer-thick layers of chemically bonded silica sand.
More information about this technology you can find here:
STEEL DVISION As a global manufacturer of high-quality steel products, the Steel Division of the voestalpine Group is a driving force toward a clean future worth living. It has been setting environmental benchmarks in steel production for years, working simultaneously on future hydrogen-based options to help bring about steelmaking routes low in CO2. The Steel Division is the first point of contact for major automotive manufacturers and suppliers worldwide when it comes to high-quality steel strip. It is also one of the most important partners to the European white goods and mechanical engineering industries. The Steel Division produces heavy plates for applications under the most extreme conditions in the energy sector, supporting the oil & gas industry and renewable energy generation with custom solutions. It operates the world’s most advanced direct reduction plant in Corpus Christi, Texas, USA, producing high-quality pre-materials (HBI) used in steel production for both Group companies and external entities alike. In the business year 2020/21, the Steel Division generated revenue of EUR 4.2 billion, reported an operating result (EBITDA) of EUR 487 million, and had around 10,500 employees worldwide.
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Visionary power. Wherever you want.
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photo credits: istock
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