zek HYDRO 2017

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CENTRAL EUROPE NEEDS FULL COMMITMENT TO HYDROPOWER

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arly this year, we had begun to see a glimmer of light at the end of the tunnel: facts and figures that were cause for hope that things were looking up. According to the Climate Change Centre Austria (CCCA for short), global emissions had not risen in 2015. This in itself is quite remarkable, but so is the fact that in 2015, for the first time ever, the added renewable energy capacities outpaced those provided by conventional facilities. This shows that more or less concerted action on an international level can be successful, and that climate protection agreements like the one signed in Paris are headed in the right direction. But let’s be realistic: this is only a first step. The world is still far off the mark of limiting the rising temperature levels, especially when we see U. S. President Donald Trump bringing in the wrecking balls to demolish the climate protection laws introduced by his predecessor, Barack Obama. On his decree, existing U.S. climate protection legislation is being suspended or even cancelled. In doing so, the new president makes no bones about his intention to restrict his country’s climate ­protection policy and to cut back the US Environmental Protection Agency (EPA) to the point of meaninglessness. After all, he wants to “put an end to the war against coal,” as he announced recently.

But even in Europe, which still considers itself a bastion of the Paris agreement, the ­consistent abandonment of fossil energy is far from being achieved. If it were not so sad, one might be inclined to view the whole situation as a bad joke of our recent history, considering that despite all the climate protection goals and our politicians’ grandiose promises, brown coal is now Europe’s cheapest conventional energy source – with all its consequences. For hydropower, in particular, this situation – along with the current over-subsidising of wind and solar energy in Germany – amounts to a veritable disaster in the Alpine regions. Whether it’s small-scale or large-scale hydropower, the investment climate is currently very bad indeed – even though expanding existing renewable energy sources is crucial to reaching national energy goals. For all these reasons, specific valorization schemes for small-scale hydropower are sorely needed to keep it alive. Generally speaking, sponsorship should not be overemphasised, but with fossil and nuclear energy production being de facto subsidised, it is hard to see why a clean, reliable energy source like hydropower should be deprived of financial support and marginalised to the point where it is struggling for survival.

Now as always, the critical importance of hydropower, large-scale or small, cannot be emphasised enough. After all, around 70 per cent of the world’s renewable energy pro­ duction comes from hydropower, which covers the energy needs of more than a billion people in 152 countries worldwide. All this should be reason enough to keep supporting the good cause of hydropower.

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 2017

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PP RÍO COLORADO (CHI)

24 PP QOM (IR)

34 PP CLYWEDOG (GB)

37 PP CARPAPATA (PE)

Short Cuts 08 Short news out of the world of hydropower SHORT CUTS

03 Editorial 06 Table of Content 08 Masthead

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May 2017

16 EU Energy Union - a huge gap between ambition and willingness EREF STATEMENT

32 Siemens small hydro success stories in Turkey [ TURKEY ]

18 Río Colorado power plant connec ted to grid under high voltage [ CHILE ]

34 Gugler provides new turbine for Clywedog Reservoir in Wales [ GREAT BRITAIN ]

21 Convincing South Tyrolean tech nology in new Swiss power plant [ SWITZERLAND ]

37 Austrian plant technology used in Peruvian hydro power plant [ PERU ]

24 Austrian turbine manufacturer equips drinking water power plant [ IRAN ]

40 Renexpo Interhydro Salzburg be coming a central hydropower hub EVENT

28 Modern compact turbines ensure efficient power production [ AUSTRIA ]

42 Most powerful cross-flow turbine for Vanazit hydropower plant [ TURKEY ]

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PP COTLAN (CH)

44

SCREEN CLEANING

60

GRP PIPES

66

FLOOD CONTROL (OM)

Advertisers 44 The most efficient power plant on the Linth becomes operational [ SWITZERLAND ]

60 Proven screen cleaning solution developed by Bavarian specialist [ GERMANY ]

47 Green electricity production in Zirbenland spites frosty conditions [ AUSTRIA ]

63 Lake Reschen power plant trusts in ductile cast-iron pipe system [ ITALY ]

50 Tyrolean tourism region gets serious about energy independence [ AUSTRIA ]

66 FLOWTITE Grey - new extra strong GRP pipe series [ GERMANY ]

54 Proven hydro-mechanical equip ment for Mur river power station [ AUSTRIA ]

68 Fish-friendly design of power plants [ GERMANY ]

57 Steffturbine convinces with possible uses and economic efficiency [ SWITZERLAND ]

70 Extreme service north of the arctic circle [ SWEDEN ]

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zek HYDRO 2017

Schubert Opener Amiantit U2 Troyer U3 Andritz Hydro U4

Auma 13 BHM Ing. 29 Bosch-Rexroth 10 Braun 73 Dive 69 Elin 31 Geotrade 49 Geppert 26 Global Hydro Energy 74 Gugler Waterturbines 36 Hitzinger 52 Koncar 9 Kรถssler 15 Kuenz 56 Lukas 8 Muhr 62 Ossberger 43 Pro Integris 25 Siemens 11 Small Hydro Latin America 17 TRM - Tiroler Rohre 65 Wild Metal 51 WKV Volk 27 WRH 12

71 Austrian steelwork secures new flood control system [ OMAN ]

May 2017

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CHINA’S HYDRO POWER STATIONS BREAK ALL PREVIOUS POWER OUTPUT RECORDS More than a quarter of the world’s hydropower electricity output, 1200 GW, is produced in China. No other country produces anything like as much hydroelectric power.

In the previous year, these four hydroelectric power plants along the main arm of the Yangtse River, all of which belong to the state-owned and state-run China Three Gorges company (CTG), produced over 206 billion kWh of electricity. According to IWR Online this was a record-breaking achievement. The most electricity, 93.5 billion kWh, was contributed by the machines of the Three Gorges Dam. The electricity produced by these four hydropower plants is in excess of the total volume of electricity generated by renewable energy sources in the whole of Germany.

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May 2017

photo credits: Bildpixel_pixelio.de

The Itaipú power station in the border region between Brazil and Paraguay takes the second place in the ranking of world's biggest power plants. But the power plant produced the most energy of any in the world, setting a new world record in 2016.

photo credits: Wikipedia

NINE OF THE WORLD’S TEN LARGEST POWER STATIONS ARE HYDROELECTRIC PLANTS The online portal euwid-energie.de has reported that nine out of the world’s ten largest power stations produce energy from hydropower. The ranking was compiled by the US Energy Information Administration (EIA) based on an analysis of statistics from 2015.

In fact, four of the ten largest power stations in the world are located in China. At the very top of the mega-size power stations list is the Three Gorges Dam plant in China with a maximum power output of 22.5 GW. A fair way back in second place is the Itaipú power station on the Paraná River in the border region between Brazil and Paraguay with a maximum capacity of 14 MW. It has even surpassed the Three Gorges Dam plant in the years 2016 and 2015 in energy production.

Japan’s Kashiwazaki-Kariwa nuclear power plant was only rated sixth in the world, but was taken offline in the wake of the nuclear disaster at the Fukushima plant. According to the EIA there are 62,500 power stations with a power output of 6,000 GW in operation across the globe.

photo credits: gov.br

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A giant among power plants: Last year the Three Gorges Dam in China produced 93.5 billion kWh of electricity using the power of water. It is ranked the most powerful power plant in the world with a nominal power output of 22.5 GW.

photo credits: IWES

Pumped-storage power plants on the ocean floor utilise hollow bodies to take advantage of the immense water pressure at extreme depths to store electrical power. Initial tests have proven successful.

photo credits: wapcos.gov.in

The dam was originally built in 1976 but has been damaged in wars since its construction.

Foto: ewb

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UNDERWATER PS POWER PLANT TESTED SUCCESSFULLY At the beginning of March the new concrete storage sphere was pulled back up to the surface from a depth of 100m by Überlingen, Lake Constance. At the end of 2016, researchers from the Fraunhofer Institute for Wind Power and Energy System Technology (IWES) conducted a successful four-week test run in Lake Constance to analyse and record the functionality of the new storage medium. The data is now being evaluated to enhance the efficiency of existing computer programmes. A subsequent project is to involve submerging a larger sphere in the ocean for longer test periods. The Lake Constance results will help with the selection of other potential locations. Completion of such test procedures is expected to take somewhere between three and five years. Further developments are to be financed in cooperation with industrial businesses and the public sector.

Foto: Hydro-Solar

DAM OPENING CEREMONY IN AFGHANISTAN The Afghan President, Aschraf Ghani, and the Indian Minister President, Narendra Modi, took part in a high security ceremony to mark the opening of one of the largest dams in Afghanistan. India financed the construction of the Salma dam with around 270 million Euros.

Indian and Afghan engineers worked together on this project for ­almost ten years. The country’s third largest dam holds 640 million cubic metres of water to irrigate 80,000 hectares of land. The connected hydroelectric power station produces 42 megawatts of electricity, providing for a quarter of the province’s requirements. The Taliban have made several attempts to destroy the dam. In the past few weeks, fear of new attacks has motivated the security forces to seek and eject a number of militant groups from the region. A police unit is now to be stationed there permanently.

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photo credits: Lockhead Martin

Atlantis has a goal to deploy nearly 270 turbines to generate about 400 MW of energy, enough to power 175,000 homes.

photo credits: ICE

Reventazón is the largest hydroelectric plant in Central America and is now in operation after a 6-year building phase.

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May 2017

MODERN TIDAL ENERGY TURBINE DEPLOYED OFF SCOTLAND COAST Atlantis Resources Limited has deployed the first AR1500 tidal energy turbine with new Lockheed Martin technology off the coast of Scotland. The installation is the latest development in the MeyGen project designed to harness the motion of the tides to provide clean, sustainable, predictable power for up to 175,000 homes in Scotland. Under contract and in partnership with Atlantis, Lockheed Martin designed the 1.5 megawatt AR1500 turbine. In addition to system design, Lockheed Martin developed, manufactured and delivered two innovative subsystems, the Yaw Drive System (YDS) and the Variable Pitch System (VPS). The two elements enable the turbine to rotate autonomously around its base, so it always faces into the tidal flow. The pitch angle of the turbine blades also adjusts to optimize the power generation in a given tidal stream. The MeyGen project is currently the largest planned tidal energy project in the world.

COSTA RICA’S POWER PLANT OF THE CENTURY NOW ONLINE The Costa Rican power station Reventazón is the largest hydroelectric plant in Central America and is now in operation after a construction period of six years. The plant with a power output of 305.5 MW was hooked up to the grid three months ahead of schedule. The project was implemented by the state-owned energy company ICE, who pointed out that Reventazón will produce energy for 525,000 households. The cost of investment was 1.4 billion dollars. “Reventazón wasn’t just a lucky strike. The project was built by talented Costa Rican specialists and was the result of ICE’s planning, education and experience”, explained Carlos Manuel Obregon, the director of the project. The majority of the energy in this small country of 5 million inhabitants already comes from renewable energy sources. In 2016 Costa Rica did without electricity generated from fossil fuels on 150 days of the year.

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photo credit: JP Elektroprivreda BiH

Animated image of the Vranduk power plant on the Bosna river.

Construction work on the 57-million Euro project commenced recently.

STRABAG BUILDS NEW HYDROELECTRIC POWER PLANT IN BOSNIA-HERZEGOVINA A consortium made up of the Austrian building and technology business STRABAG AG and the Croatian industrial sector company Končar has been awarded the contract to construct the Vranduk power plant on the Bosna river by the energy providers JP Elektroprivreda BiH. STRABAG has a controlling share of the consortium with 63.4%. The 20 MW hydroelectric power station is to be built within 46 months, approximately 57 million Euros will be invested. The contract encompasses the planning of the plant; construction, delivery and installation of the machinery, testing and commissioning. Electricity is to be produced by three Kaplan turbines. “We are delighted to be able to contribute to the expansion of the region’s infrastructure by building this power station – for today and the future”, commented STRABAG’s business area manager, Dragan Pavelic, at the signing of the contract in the presence of the Austrian ambassador in Bosnia-Herzegovina, Martin Prammer.

photo credit: Dnipro HES

ANDRITZ Hydro will take a leading part in the modernization of the Ukrainian hydro power plant Dnipro 1.

ANDRITZ HYDRO TO MODERNIZE DNIPRO 1 HYDROPOWER STATION IN UKRAINE ANDRITZ Hydro was awarded a contract by state-owned utility Ukrhydroenergo for modernization of the Dnipro 1 hydropower station on the Dnieper River, Ukraine. The project is part of a rehabilitation program financed by the European Bank of Reconstruction and Development (EBRD). The contract value for ANDRITZ Hydro amounts to approx.

60 million euros. Completion of the project is scheduled for the end of 2021. ANDRITZ Hydro‘s scope of supply includes the complete rehabilitation of three 75 MW Francis turbines and generators, including dismantling, supply of new equipment, installation, and testing. Except for the embedded parts, all major components will be replaced by new equipment. The modernization will increase the output from 64 to 75 MW and substantially enhance reliability and safety. A hydraulic model test will allow optimum performance of the new turbines to be defined and demonstrated within the geometric conditions of the existing powerhouse.

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May 2017

Belo Monte is a gigantic hydroelectric power plant under construction on the Rio Xingu river in Brazil.

photo credit: Pascalg622 / Wikimedia CC 3.0

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Minister of the Interior for Lower Saxony, Boris Pistorius.

photo credit: Bernd Schwabe / Wikimedia CC 3.0

BRAZILS BELO MONTE TURBINES ONLINE SINCE 2016 The first turbines at Brazil’s Belo Monte hydroelectric power plant were officially put into operation in May 2016 by the former President, Dilma Rousseff. An expected 11,233 megawatts of power should make it the third-largest hydroelectric power plant in the world. Completion is scheduled for 2019 with the aim of providing electricity for up to 60 million people. Mrs. Rousseff stated that the project, originally started in the 1970s, would make “an important contribution to the development of Brazil” and help guarantee a reliable power supply for this economically growing country. Environmentalists see the issue differently, having occupied the construction site several times and achieved numerous building stops with court injunctions over the past few years.

They have criticised the extreme effects on the environment, and the expulsion of up to 40,000 local inhabitants caused by the building of this immense dam.

HYDROELECTRIC POWER PLANTS UNDER ATTACK Nuclear power stations, hydroelectric plants and banks are always potential targets for cyber-crime, particularly the activities of well organised and extremely criminal groups. The Minister of the Interior for Lower Saxony, Boris Pistorius (SPD) painted a very dark and threatening scenario at the ‘cramer ampts mahl’ gathering at Hotel Landhaus Pollmeyer in Vordersten-Thüle in the district of Cloppenburg.

Facing these threats is something for which everyone has to take personal responsibility. Problems are often caused by negligence or ignorance on the part of system users. Hence, it is vital to ensure users are made aware of dangers and kept technically up to date. Pistorius stated: “That goes for private individuals, public sector administrators and every commercial operation.” The minister also said that fighting cyber-crime required people to keep lines of communication open and to be part of a strong network of contacts.

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anzeige_halbe_seite_zek_hydro_en.indd 1

May 2017

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27.03.2017 08:35:14

photo credit: Voith

HYDRO

photo credit: By MRY (Own work) WIKIMEDIA CC SA 3.0

The StreamDiver during installation.

Hydroelectric power station „Djerdap 1“, located at the danube between the border of Romania and Serbia.

SERBIAN INITIATIVE TO BOOST HYDROELECTRIC POWER CAPACITY Serbian utility Elektroprivreda Srbije (EPS) has announced a 656 million US Dollar investment program aimed at increasing the output capacity of its hydroelectric power and thermal generating fleets, reports “HydroWorld.com“ in the beginning of may. The state-owned company has already completed an upgrade of the 382 MW Bajina Basta hydropower plant, while overhauls of the 1,050 MW Djerdap 1 and 96 MW Zvornik projects are still ongoing, says the report. EPS also signed a supplementary agreement with Russia‘s Power Machines in June 2009 to supply one turbine and generator for Djerdap 1, in addition to rehabilitation survices for its original five units. The initiative supports the Serbian government‘s European Union accession process efforts by helping the Balkan country meet renewable generation obligations.

photo credit: Biswarup Ganguly WIKIMEDIA CC BY 3.0

INDIAN 100 MW HYDRO POWER PROJEKT TO BE COMMISSIONED IN MAY The 100 MW Sainj Hydroelectric Project being constructed by Himachal Pradesh Power Corporation Limited (HPPCL) in Indias Kullu district would be commissioned partially this month, says an online report of “The Econonic Times“ which cites an HPPCL official. The first unit of the project will start producing electricity by May 20 and the second unit by next month, HPPCL Managing Director Devesh Kumar said in a statement. The mechanical spinning of the first unit of the project was done on April 25, he complemented. It has an installed capacity of 100 MW with two generating units of 50 MW each. The run-of-the-river project is located on the Sainj river, a tributary of the Beas. It comprises a diversion barrage on the river near Niharni village, and an underground powerhouse on the right bank of the river near Suind village. The project includes a 6.36-km-long headrace tunnel of 3.85-metre diameter with two Pelton turbines coupled with generating units.

photo credit: TU WIEN

View of Himalayas from Beas river valley in Kullu.

Ceremony in the Museum of Military History.

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VOITH INAUGURATES SMALL HYDROPOWER PLANT “ALTE BLEICHE” Technology Group Voith has built a small hydropower plant on its factory premises in Heidenheim, Germany. A compact, environmentally friendly turbine-generator unit was installed in the river Brenz. The innovative concept will not only generate electricity for the production facilities, but will also serve as a demonstration plant for customers, employees and the interested public. The plant is equipped with the StreamDiver, a new turbine-generator unit developed by Voith. It was designed specifically for river plants with low heads and is thus ideally suited for the Heidenheim location on the Brenz. In comparison with traditional turbines, the StreamDiver impresses as a compact, oil-free submersible turbine, allowing for a standardized and cost-efficient plant concept. As a result the necessary impacts on the environment during the installation phase were minimized.

May 2017

THE CHALLENGES FOR HYDROELECTRIC POWER ON THE TEST BENCH OF SCIENCE A real highlight of the hydroelectric autumn hit the stage from 9 to 11 November of the previous year in Laxenburg, Austria: For the in the meantime 19th time, the “International Seminar on Hydroelectric Power Plants”, the “Viennahydro”, opened its doors before the gates of Vienna.

The event, which takes place every two years, has for many years been internationally counted among the best-established and most renowned hydroelectric power events. Viennahydro also lived up to its reputation in 2016. Around 260 participants from around the world arrived to inform themselves on the newest technical trends and themes. The focus of last year’s event was thereby on the broad thematic complex of “The flexible operation of hydroelectric power plants in energy systems”. The conference has traditionally been organised by the Technische Universität Wien, or more precisely by the Institute for Energy Systems and Thermodynamics and by the Institute for Hydraulic Engineering.

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THE EU ENERGY UNION – A HUGE GAP BETWEEN AMBITION AND WILLINGNESS

photo: Andritz Hydro

photos: ZT Eberl

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In February the European Commission published its second report on the State of the Energy Union which summarises recent activities and provides an outlook on the next steps of European Energy policy and priorities. EREF a federation of national renewable energy associations from EU Member States comments about the status quo.

E

REF welcomes the exercise as such, ­since it introduces pathways towards a more holistic view of energy system c­ hange in the Union and the endeavour to link the pri­ orities in the Energy Agenda with priorities in other key European policies such as the sus­ tainable development goals , the circular eco­ nomy or the new skills agenda for Europe.

Nevertheless, the report is not aligning the review of all energy related policies under the overarching priority to fully de­carbonise the European Energy system by 2050 and to evaluate the Paris achievement potential for each of the pathways screened under this re­ port.

The report suggests that emission reduction is a positive trend in the Union but does not consider whether this current decrease is ­sustainable and how it ensures reaching the 2050 decarbonisation target especially in light of the failed ETS.

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May 2017

A coherent report should not gloss over serious shortcomings such as the renewed and conti­ nuing subsidy policies for old and incumbent coal and nuclear power plants and for nuclear new built. The report does not refer to own Commission’s request of internalisation of externalities and what non internalisation ­ ­means in consequence for the pathway towards a sustainable energy union. By highlighting that most Member States were above their in­ dicative trajectories for their 2020 RES targets two years ago the Commission asserts that the EU as a whole is on track for the targets, thus insinuating that no significant action is needed.

Already the minute progress of only 0.4% in the last reported year should ring an alarm bell.

And the bell should ring even louder when ta­ king into account the lack of commitment in several Member States, frustrating citizens, in­ vestors and regions in countries such as Spain, Poland, Bulgaria, the Czech Republic.

MISSED OPPORTUNITY The alleged probability that Europe reaches its 2020 targets for RES despite certain Mem­ ber States going backwards is another attempt to disguise the blatant lack of ambition and willingness in these States. And it also means that where the target will eventually be rea­ ched the level of ambition for the respective national target may have been too low.

Furthermore, it means that more ambitious Member States such as Denmark, Portugal, Germany and Austria will have done more and already delivered a de facto gap filler, ­saving Europe from complete embarrassment.

In this context the Commission missed an ­opportunity to question whether the mini­ mum EU-wide 27 % target for 2030 would not need to be raised, since – despite the unambitious and, at times, restrictive RES ­national policies of certain Member States – the positive momentum in committed others

would most probably suffice to reach it.

Moreover, the dwindling commitment of ­ ­certain Member States needs a strong answer by the Commission and Europe and new ­binding national targets. EREF will call on clear improvement in the debate on the legis­ lative energy package.

There is a growing recognition, both locally and regionally, of the wealth-creating effect of lowering the fossil bill on citizens and public budget. The voters nowadays know about the job-creating effects of renewables and their central role to sustainable policies. photo: Andritz Hydro

photos: ZT Eberl

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THE FUNDAMENTAL ENERGY SYSTEM QUESTION EREF welcomes that the Commission’s ­address is focusing on the importance of citi­ zens in the new energy systems. EREF how­ ever regards this as a fundamental energy sys­ tem question. To sustainably enable citizens, energy cooperatives and independent power producers to participate in the European energy market on equal terms with established incumbents, continued national renewable energy remuneration schemes and priority access and priority dispatch are essential and required for the next decade. They are a pre­ condition to enable sufficient incentives to invest in new renewable energy installations in a distorted market.

EREF is worried that despite the fact that the report is urging Member States to be Europe minded in their policies and not to create stranded costs situations, the Commission still forgesahead with policies and financial programmes to support new gas corridors and LNG terminals. For EREF the majority of such projects do not contribute substantially to securing energy supply for Europe or to the

achievement of climate goals and entail an enormous risk of becoming stranded invest­ ment.

The European Union faces a massive missing money problem when it comes to urgently needed phase out of old nuclear plant and old carbon plants. Investments in new gas pipe­ line and terminals may be added to the list of mounting subsidies to the incumbent energy sector, sometimes hidden under capacity ­mechanism schemes. The state of the Energy Union report should be the place to start the debate for a structural reform programme ­enabling the Union to get rid of the old and dangerous legacy of nuclear and coal and to start phasing out fossil gas, encouraging socie­ tal consensus under clear and open conditions for change.

A MORE AMBITIOUS POLICY IS NEEDED EREF reminds that in 2015, the Commission in its Renewable Energy Progress Report highlighted the urgent need to develop a more ambitious policy. The now published progress report over 2016 shows once again that insufficient performance of several ­Members States persists.

“There is no reason for the EU to be compla­ cent. Adequate governance is lacking and the EU is about to miss even the 2020 targets; and this is confirmed by the progress reports of the European Commission itself, although they do not draw the obvious conclusions from the facts. This is even more serious given the fact that the Paris Agreement on Climate Change has now been ratified, which sets key additional conditions for a strong and effecti­ ve governance”, comments EREF President Dr. Savvas Seimanidis.

Dirk Hendricks Senior Policy Advisor European Renewable Energies Federation (EREF)

EREF a federation of national renewable energy associations from EU Member States represents all renewable energy sectors at EU institutions. Its objective is to promote the interests of independent power, fuel and heat production from renewable sources and to esta­ blish non-discriminatory access to the European energy market.

EREF strives to create, maintain and further develop stable and reliable framework conditions for renewable energy sources.

For more informations, please contact Dr. Dörte Fouquet EREF Director doerte.fouquet@eref-europe.org

7TH ANNUAL December 5th & 6th 2017, Medellin, Colombia

official media partner www.zek.at

May 2017

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After around 2.5 years of construction, the newly built diversion power plant on the Río Colorado began operating normally in March 2017.

All the hydroelectric equipment at the power plant was supplied and installed by the Austrian company Global Hydro Energy GmbH.

photo credit: GPE

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CHILE’S RÍO COLORADO POWER PLANT CONNECTED TO GRID UNDER HIGH VOLTAGE

The Chilean utility company “Gestión de Proyectos Eléctricos” (GPE) began operating a new hydropower plant in the Región del Maule in March 2017. The plant, which is equipped with two Francis turbines, utilises the potential energy from the Río Colorado, which has its source close to the national border with Argentina. The Austrian manufacturer Global Hydro Energy GmbH was able to supply a complete electromechanical package and in so doing add another perfectly implemented hydro­power plant to its extensive list of international reference projects. In addition, the turbine manufacturers gained valuable know-how for future projects by implementing compact high-voltage switchgear for the first time.

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May 2017

CLASSIC DIVERSION PRINCIPLE The plant in the Chilean Región del Maule was implemented using the classic diversion principle; the construction work lasted for a total of around 2.5 years. A transverse structure constructed with a solid concrete design dams the Río Colorado and guides it into an

open weir channel. According to the official specifications, the prescribed delivery rate will fluctuate in a range of at least 1.5 to no more than 3 m³/s. According to project manager Schweiger, the construction of the open weir channel stretching over many ­kilometres required a great deal of structural

In the Región del Maule in the central region of the country, clean green electricity is produced at a whole host of hydropower plants.

photo credit: GPE

A

s the world’s longest range of mountains above ground, the Andes extend along the west coast of the South American continent through Colombia, Ecuador, Peru, Bolivia, Argentina and Chile. They extend for a vast 7,500 km from north to south.

Together with the Amazon, the river containing the most water in the world, the huge mountain range forms the backbone of the potential for hydropower in South America.

“In Chile, for example, the region in the central area of the country in which the Río ­Colorado rises is the source of around 20% of the hydropower which is generated across the country,” remarks Thomas Schweiger, GPE project manager for the new hydropower plant which was completed in spring 2017.

Although the amount of water available at the location naturally fluctuates with the different seasons, the operators expect a comparatively high capacity utilisation factor of between 50 and 70%.

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photo credit: GPE

photo credit: GPE

Up to 11 m3/s are diverted at the weir and are transported through an open weir channel and a penstock to the powerhouse to be turned into energy.

The electrical and control technology was also provided by the Austrian hydroelectric power specialists.

TURBINES IN THE MEDIUM POWER RANGE “The bid for the ‘Río Colorado’ project fitted our technical portfolio precisely from a hydro­ mechanical point of view. Although the two Francis turbines with a spiral casing were not the biggest machines that we have ever manufactured, with a power output of

Technical Data • Flow Rate: 2 x 5,5 m3/s

around 8.4 MW each they still fall within the medium power range of what is offered

by GLOBAL Hydro. The benefit that this produces for the end customers is that they can rely on a well-developed product that is manufactured at a very high technical level as standard. All machines are subjected to our tried-and-tested quality procedure both during and before construction, and ultimately arrive at their intended destinations as highly effective suppliers of electricity,” says GLOBAL Hydro project manager Dietmar Lehner. The company delivered this contract as what is known as a “water to wire” project – all of the electromechanical components were fully manufactured or provided by GLOBAL Hydro, properly installed and commissioned. For the new power plant on the Río Colorado, two completely identical Francis machines with a horizontal shaft and photo credit: GPE

and organisational effort and outlay. The ­rocky terrain meant that there was no option but to use explosives on multiple occasions.

Following an open-air section of around 5 km, the waterway transitions into a closed penstock made from steel pipes laid largely above ground. The final section of pipework has a consistent dimension of DN2200 and extends for a length of 530 m. Shortly before the water is turned into power in the powerhouse, the penstock is divided by a Y-branch pipe which is laid underground.

a design discharge capacity of 5.5 m³/s each were manufactured. The turbines are provided with a net drop height of 168.7 m, which allows a maximum power output of 8,402 kW to be achieved by each of them.

Each of the hydraulically controlled turbines has a rotational speed of precisely 750 rpm.

The energy converters used are two synchronous generators, which also have exactly the same design and are each coupled directly to the turbine shafts. A high-voltage power line stretching for around three kilometres above ground was constructed to feed the power into the public power grid.

SWITCHGEAR WITH HYBRID DESIGN “When it came to the electrical part of the assignment, we opted for a special solution that we had never before implemented in this form,” explains GLOBAL Hydro project

The two Francis spiral turbines of completely identical design are provided with a net drop height of almost 170 m, their design discharge capacity is 5.5 m3/s each.

• Net Head: 168,70 m • Turbine: 2 x Francis • Nominal Output: 2 x 8.402 kW • Runner speed: 750 rpm • Manufacturer: Global Hydro Energy GmbH • Generator: 2 x Synchronous • Total avarage capacity: ca. 79 GWh

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mer was dismantled into individual parts capable of being transported and then reassembled on site.

Ideally each turbine can generate a maximum power output of more than 8.4 MW.

photo credit: GLOBAL Hydro

EVERYTHING INTERLINKED According to Thomas Stütz, another challenge of the project was meeting the control requirements of the Chilean grid operator. For example, to do this it was necessary to set up a communication ­control system which is based on the “DNP 3.0 protocol” (software protocol for network communication) and enables a constant transfer of data between the hydropower plant and the grid operator.

“Implementation of the system in consultation with the grid operator on site was extremely complicated in organisational terms. ­Thomas Schweiger from GPE was a big help to us when it came to ­interacting and clarifying matters with the companies and local contacts on the ground,” states Dietmar Lehner. In terms of network­ing, apart from the connection to the grid operator’s ­system, further electrical components and substations belonging to the ­client were also integrated into the plant control system.

manager Thomas Stütz: “And specifically for the first time we s­ upplied high-voltage switchgear with extremely compact dimensions. To be more precise, the equipment has a hybrid design – the switchgear consists of both air-insulated and gas-insulated components and is fully preassembled during the manufacturing stage. This design, which we implemented together with the manufacturer ABB, won over the clients primarily thanks to its comparatively small dimensions. As only a limited amount of space was available on the back of the powerhouse, compact high-voltage switchgear was the ideal solution for the end customer. By implementing switchgear of this design for the first time, we also acquired very substantial know-how. This means we are now also able to offer our customers a 110 kV high-voltage output on the electrical side.” Another new aspect for GLOBAL Hydro in the Río Colorado project was the size of the transformer. As this could not be transported in one piece due to its size, the transfor-

POWER PLANT SCADA SYSTEM For turbine control, GLOBAL Hydro supplied the intelligent “heros 3” control software which it developed itself. Thomas Stütz adds: “When it comes to the turbine controller, the term ‘power plant SCADA system’ is really more accurate. Starting with the generator and turbine control, the entire medium-voltage and ­ high-voltage system and a separate high-voltage station of the end customer several kilometres away was also added to the visualisation of the control system. With “heros 3” electricity is produced in f­ ully automated fashion and, thanks to online connection, there are ­extensive options for remote control and maintenance. Incidentally, last year we installed a control system of similar complexity at the “Oxec I” hydropower plant in Guatemala in Central America.”

ON THE GRID SINCE THE SPRING With regular operation having commenced in March 2017, GPE project manager Thomas Schweiger can now draw a positive ­conclusion: “The plant is running very satisfactorily and effectively, which at the present time is down to the high quality of the machinery equipment and software. The project was definitely also boosted by the excellent collaboration and communication with the companies involved.” In a normal year, the new power plant on the Río Colorado will generate around 79 GWh of green electricity, with all of the power going into the public power grid. During the course of this year, GPE is planning to complete another 27 MW hydropower plant on a reservoir in the Región del Maule.

After passing through the turbine, the works water which is removed is guided back into the natural course of the waterway.

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photo credit: GPE

photo credit: GPE

For the hydropower project on the Río Colorado, GLOBAL Hydro supplied compact high-voltage switchgear with a hybrid design in cooperation with a partner company for the first time.

photo credits: zek

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The new small hydroelectric power plant Steineraa in the Canton of Schwyz generates around 5 GWh in a standard year with its vertical axis Pelton turbine from Troyer. The walls of the central building were refined by the spectacular painting of the artist Ralph Hospenthal.

CONVINCING SOUTH TYROLEAN TECHNOLOGY IN NEW SWISS HIGH PRESSURE POWER PLANT The Steineraa power plant in the Canton of Schwyz officially commenced operations with the festive inauguration in September of last year. Behind the 12 million Swiss franc project is ebs Energie AG (ebs), which was not only able to realise the ambitious power plant project within the prescribed construction schedule, but also within the targeted costs framework. For the technical equipment, the operators primarily relied on the know-how of the renowned hydroelectric power specialist ­Troyer AG from South Tyrol, which was responsible for the entire machinery, as well as for the control and process control engineering equipment of the power plant. The power plant generates around 5 GWh in a standard year with the new 4-nozzle Pelton turbine. This makes it possible to supply 1,250 households with clean, regional power.

FOUR-YEAR APPROVAL PROCEDURE The Steineraa has its source in the municipality of Rothenthurm and, over its around 16 km long course, flows through the municipa-

lities of Sattel and Steinen, to then finally flow into Lake Lauerz. The catchment area amounts to approx. 20.8 km2. A highly interesting body of water for water power utilisa-

Relatively compact catchment structure with side water extraction.

photo credits: zek

T

he vote was a clear signal: in 2009, around 97 percent of the residents of the Schwyz district spoke out in favour of awarding ebs with the concession for water usage on the Steineraa, a mountain torrent in the Schwyz district. The vote had become important to the extent that several private operators, who in some cases had already operated old plants in need of refurbishment on the body of water, had also worked on plans for hydroelectric power projects. “The district decided at that time that only a single concession would be granted. And this ultimately went to the ebs, which also belongs to the district. The private owners were then paid out, and supported by the strong vote, we then commenced with the subsequent planning for a single power plant in this segment of the body of water”, says Claus Jörg, technical manager at ebs, and at the same time project manager of the new power plant Steineraa.

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photo credits: zek

A penstock tunnel was broken out of the rock over a length of 200 m.

EFFICIENT HYDROELECTRICAL USAGE For the electromechanical equipment of the new ebs power plant, the operators secured the services of the well-known water-to-wire specialists Troyer AG from Sterzing in South Tyrol. “We were already familiar with the Troyer company previously and knew that they deliver very good quality. We were therefore also very pleased that Troyer was able to make us an excellent price offer”, according to the project manager. In concrete terms this meant a vertical axis, 4-nozzle Pelton turbine was produced for the new power plant in the factory in Sterzing, featuring a spiral distribution piping with internal servomotors for the injector needles.

The runner of high quality X4 CrNi 13/4 steel with a diameter of 995 mm was milled from a monoblock, and thus demonstrates excellent strength values as a result. The runners from Troyer AG generally score points with modern design, which guarantees highly efficient hydro­electric usage of the water.

The power house was harmoniously integrated into the surrounding natural landscape.

photo credits: zek

SAND TRAP CANCELLED The new Steineraa power plant is principally a high pressure power plant that uses a natural drop step of 207 m. To this purpose, a water catchment with side water extraction was

built on the municipal territory of Sattel, which, despite extensive construction mea­su­ res, could be kept relatively compact. The reason for this is primarily found in the ­ ­absence of a sand trap. Instead, subsequent to the extraction, a three-chamber system was implemented, with which the water is calmed and ultimately purified of sediments with a Coanda grill of the type Grizzly/Wild Metal.

“In this way we saved ourselves a 40 to 50 m long sand trap. We found this solution very convincing”, says Claus Jörg.

Subsequent to this, the water finds its way to the pressure pipeline, and then encounters the turbine around 200 m deeper in the turbine hall. The machinery control centre was built in the district of Steinen, not far from the bank of the Steineraa. The turbine-propelled water is fed back into the stream bed of the mountain torrent via a short return. The generated electric energy is fed into the 15 kVgrid of ebs through a transformer station.

Foto: Hydro-Solar

PENSTOCK TUNNEL AS A CHALLENGE The ground-breaking ceremony took place on 19 November 2014, and construction work could commence. These ultimately took more than two and a half years before the turbine was set in motion with water from the Steineraa. As expected, the realisation of the penstock turned out to be the most difficult part of the construction work. Especially the construction of the around 200 m long penstock tunnel which starts directly at the catchment area, turned out to be a real tough nut to crack. Claus Jörg: “Following the first geological expert opinions, we expected to find relatively compact rock. However, instead we found a great deal of unstable loose rock. The construction company thus often had to change from the conventional blast heading to the more complicated loose rock heading. The securing measures were of cour­ ­se also much more complex. The rock was anchored with long iron rods and a 30 cm thick layer of shotcrete.”

The penstock, consisting of ductile DN800 cast iron pipes, was laid over a total length of 1,900 m. The greater part of the pipeline was laid in the neighbouring Rossbergstraße, which primarily presented construction logistics challenges. Especially in the summer months of 2015, the road had to be kept open for traffic in parallel with the construction works by means of implementing an alternating one-way routing in both directions. “The solution was that the thoroughfare was always open, especially for service vehicles, special transports, etc.”, explains Claus Jörg.

Sophisticated laying of pipe in the lowest and steepest section of the line route.

photo credits: EBS

tion. However, profound planning and intensive consultation with the authorities was required to finally receive the green light for the realisation of the project. “Especially the negotiations with the environmental groups weren’t easy. In the end, the entire approval procedure took four years before we had the approval on the table”, says Claus Jörg. Today the operators are proud of the high ecological compatibility of the new system. This is ensured on the one hand by the ecological flow of 250 l/s, which is consistently discharged at the catchment, and on the other hand by the compensating measures that provided for a fish ladder to be constructed upstream. This now guarantees the passage for fish over an existing 1.20 m high step in the headwaters of the Steineraa.

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However, not only the mechanical engineering “hardware”, but also the “software” in the form of the complete control system and the integration into the higher level control technology of ebs convinced the experienced operators from the Canton of Schwyz. User-­ friendly surfaces for SCADA systems have long been seen as trademarks of the software specialists from Troyer AG. The recording, representation and archiving of process variables, as well as the operation, alarm function and remote maintenance are of course optimally integrated today.

STANDSTILL IN WINTER The turbine runner is directly coupled with a modern, brushless synchronous generator via a vertical shaft. When in operation, the rotor of the 13 ton energy converter is driven at 750 RPM. The water-cooled synchronous ­generator is designed for an output of 2,500 kVA. The turbine was tailored to the prevailing hydraulic conditions. designed for a net head of 198.7 m and a rated flow of 1,250 l/s. ­Under full load, the machine achieves a power output of 2,017 kW. “We have now already tested the turbine several times under full load conditions and are absolutely satisfied with the performance. The guaranteed efficiency values were clearly achieved”, Claus Jörg is pleased to announce. In accordance with the technical report, the operators from ebs anticipate 47 full load days annually. Seen from the perspective of an annual average over many years, however, the experienced power plant specialists from Switzerland anticipate only approximately 178 production days. In contrast, around 140 arithmetical standstill days are anticipated. “We presume that we will often have to shut down the plant over the winter months. Luckily, the turbine demonstrates such good ranges of ­efficiency that we can still generate electricity

Technical Data

Installation of the new 4-nozzle Pelton turbine by the Troyer installation team. The turbine is designed with internally controlled nozzles.

with low water quantities as of approx. 100 litres and remain on the grid with the plant”, according to the Technical Manager of ebs.

POPULATION SUPPORTS THE PROJECT On 16 September 2016, the persons responsible were able to carry out the festive in­ auguration of the new Steineraa power plant.

An invitation was given for an open house one day later, which attracted many interested parties to the new green power plant. ­Today, project manager Claus Jörg can draw an all-round positive summary of a project that posed considerable structural and logistical challenges: “We had a big construction site here. This is also shown by a look at the figures: The total excavation material, for example, amounted to around 27,000 m3, while approx. 3,300 m3 of concrete in total were installed. The great thing was that we enjoyed support from the population, which completely supported the project. Luckily there were no accidents of any kind, and the project was generally very professionally carried out by the companies involved.”

POWER FOR 1,250 HOUSEHOLDS The costs estimate for the new Steineraa power plant was initially 13.5 million CHF. That the final bill was then significantly lower was a slight surprise. “Although the construction of the pressure tunnel turned out to be much more expensive than anticipated, we were ultimately able to conclude the entire project for 12 million CHF. Not least thanks to the at that time very favourable exchange rates, we saved around 1.5 million CHF”, the project manager summarises. Thanks to the funding from the KEV (feed-in remuneration at cost), the economic efficiency of the power plant is in any case secured. ebs has relied entirely on domestic resources for years, especially on hydroelectric power. With its power plant complex, the company today has an installed total output of more than 60 MW. This means that around 220 GWh of power can be generated annually. The new Steineraa power plant contributes 5 GWh in an average year. This at least means that 1,250 households in the Schwyz district can be supplied with green energy.

www.ebs.swiss

The Technical Manager of ebs, Claus Jörg, is also very pleased with the user-friendly control system.

Flow Rate: 1,250 l/s Net Head: 198.7 m Sedimentation: Coanda Type: Grizzly (Wild Metal) Turbine: 4-nozzle Pelton turbine Manufacturer: Troyer AG (IT) Nominal Speed: 750 Upm Output: 2,017 kW Runner Size Ø: 995 mm Generator: synchronous Nominal Output: 2.5 MVA Voltage: 6,300 V Penstock: Length: 1,900 m Material: ductile cast iron Diameter: Ø DN800 Total Average Capacity: 5 GWh

photo credits: zek

• • • • • • • • • • • • • • •

photo credits: EBS

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all photo credits: Geppert

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Geppert Sales Manager International Christian Moriel, Project Manager Stefan Veiter, Designer Lukas Zingerle and CEO Guntram Geppert (from left) next to the ready-to-ship Francis turbine for the Iranian drinking water power plant Qom.

AUSTRIAN TURBINE MANUFACTURER EQUIPS DRINKING WATER POWER PLANT IN IRAN With the construction of a new hydroelectric power plant, one of the main drinking water supply lines of the Iranian metropolis of Qom (Ghom) has been given an additional energy economy usage. The project was commissioned by the Iranian “Roshd Sanat Co.”, a company that is primarily active in the energy, industrial and construction sectors. The order for the electromechanical implementation of the project was secured by the Austrian-based hydroelectric power specialist Geppert GmbH at the beginning of 2016. A Francis spiral turbine with a maximum output of nearly 3.5 MW is used as an energy generator. If everything goes as planned, the new power plant should already be generating power from the drinking water mains in only a few months.

T

he city of Qom is located in northern Iran and is the capital of the province of the same name with around one million inhabitants. The urban area is located around 130 km to the south of the Iranian capital of Tehran and is primarily known as a religious pilgrimage site. Due to the geographical location in an extremely dry region, Qom depends to a great extent on the neighbouring provinces for its water supply. “One of the main drinking water supply lines of the city was rebuilt around 10 years ago. The to-date unused energy potential should be converted into current by a power plant as early as 2017. For purposes of power generation, the drinking water is diverted through a newly built short bypass route with the dimension DN1200 and utilised by a Francis turbine”, is how Geppert project manager Stefan Veiter explains the basic principles of the project still in progress.

In addition to the fulfilment of the technical task, the Austrian turbine builder couldn’t avoid a great deal of organisational effort for the official and financial processing. The reason for this is found in the economic sanctions in place against Iran being implemented by the EU. “Because only a few banks in the European region are able to enter into direct financial transactions with Iranian companies, these circumstances re-

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sulted in a complicated situation for all parties. An own export approval also had to be applied for with the responsible Austrian federal ministry

Visualisation of the power plant technology. The plant has a net head of 96 m at its operating point. With a water discharge of 4,040 l/s, the turbine can generate a maximum output of 3,462 kW.

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Power house during the construction phase.

The runner produced from corrosion-resistant stainless steel for use in the drinking water mains.

with regard to the export of the hydroelectric equipment, for example. This procedure alone took several months”, is how Veiter ­ ­describes a central aspect of the organisational work involved.

35 KM LONG DRINKING WATER LINE Due to the enormous length of the drinking water line, extensive water hammer calculations were required, the project manager explains. The reason for this lies in the distance of the power plant control centre from the surge tank, which amounts to around 35 kilometres. With a line diameter of DN1800, the closed pipe system naturally contains a very large quantity of water, which, in the event of an abrupt cut-off procedure, can result in considerable hydraulic forces. In order to avoid damage to the mechanical equipment and the drinking water network, the closing time of the turbine guide vane

Technical Data • Flow Rate: 4.040 l/s • Net head: 96 m • Turbine: Francis • Runner: 13 blades • Runner Diameter: 705 mm • Nominal Output: 3,462 kW • Manufacturer: Geppert GmbH • Generator: Synchronous • Total avarage capacity: 15 - 20 GWh

amounts to approximately 200 seconds, and even 500 seconds for the main inlet valve in front of the machine.

COUNTER PRESSURE REQUIRES A ROBUST DRAFT TUBE Another special feature of the turbine planned by the Geppert designer Lukas Zingerle involved the layout of the draft tube. Because a permanent counter pressure of approx. 2.5 bar is required on the “underwater side” of the turbine in order to maintain the drinking water supply, the draft tube had to be designed to be correspondingly robust. For the concluding pressure and leakage test, it was ascertained at the factory that the draft tube can also withstand potential water hammer of up to 12 bar undamaged. Veiter emphasises that the important steps of turbine manufacture, such as the production of the Francis runner and the guide vane took place in Gepperts new factory. The entire turbine was manufactured in Austria. Due to its usage in the drinking water system, the Francis runner is entirely made of corrosion-­ resistant stainless steel. All interior surfaces of the turbine that come into contact with water were also provided with a food-­ compatible special coating.

The plant has a net head of 96 m during normal operation, the water discharge is 4,040 l/s. At full flow the turbine can achieve a maximum output of 3,462 kW. A synchronous generator from the manufacturer GENET coupled directly with the horizontal axis turbine shaft serves as a power transformer. The air-cooled generator, like the turbine, turns at 1,000 RPM and has a connection voltage of 6,300 V, as well as a rated apparent power of 4,500 kVA. The entire generated energy is finally fed into the public power grid.

ELECTRICAL AND PROCESS CONTROL TECHNOLOGY FROM PRO INTEGRIS Generally high security technology standards had to be taken into account for the electrical technology specifications, Stefan Veiter notes: “In the field of electrical technology, especially for the monitoring and control of turbines,

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Spiral case of the Francis turbine in manufacturing.

The draft tube of the turbine is ready for shipping.

standards must be met which in some cases even exceed the usually high European specifications.” Geppert commissioned the Croatian company PRO INTEGRIS for the implementation of the electrical technology equipment for the power plant. The delivery package includes the turbine governor, relay protection as well as the entire process control technology. The extensive electrical technology “package” on the one hand ensures effective current production, while on the other hand the maintenance of the drinking water supply is of course a high priority. The plant control system is based on a SCADA system and enables both fully automatic and manual operation, as well as the synchronisation with the public power grid. Through the use of the ETHERNET TCP/IP protocol, the control system software is possessed of extensive possibilities for remote control.

REGULAR OPERATION SHOULD START IN AUTUMN The new power plant should commence operation for the first time in the coming months. The turbine and the electrical technology were just about to be installed at the end of April. Project manager Veiter can nonetheless already come to a positive interim summary: “From a technical perspective, valuable experience could be gathered due to the special circumstances involving the enormously long penstock and the related requirements of the machine. With these basic conditions, we have developed detailed new technical approaches that can be used in future for other projects.” When everything goes as planned, the plant can already start with trial operation in July. The handover to the end customer and the commencement of regular operation is planned for autumn.

www.geppert.at www.facebook.com/geppert.hydropower

MORE HYDROELECTRIC GENERATION ELECTROMECHANICAL EQUIPMENT FOR HYDROPOWER PLANTS FROM WATER TO WIRE Geppert GmbH Geppertstraße 6 6060 Hall in Tirol Austria

T +43 5223 57788 F +43 5223 57788 2 office@geppert.at www.geppert.at

AUSTRIA

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photo credits: Andritz Hydro

photos: ZT Eberl

The new Rothleiten power plant replaces a facility from the 1920s, which had served the local paper industry for almost 90 years.

MODERN COMPACT BULB TURBINES ENSURE EFFICIENT POWER PRODUCTION IN STYRIA On June 3rd last year, MeinAlpenStrom GmbH (“My Alpine Power”), Austria’s most recently established power provider, ­celebrated the official inauguration of their new hydropower plant in Frohnleiten in the Austrian province of Styria. The ­company, a part of Prinzhorn Holding, invested a total of around € 42.5m in the complete revitalisation of the facility, which was originally built in 1925. At its core, the power station consists of two ultra-modern Compact bulb turbines by ANDRITZ HYDRO, each with a capacity of 9.9 MW, generating a total of 50 GWh a year. This is enough to supply 14,300 households with clean energy. Compared to the original facility, the refurbishment of hydropower plant Rothleiten was not just a quantum leap in terms of energy technology, but also introduced comprehensive ecological improvements.

F

or centuries, the central Mur valley has been considered an important industrial area. Paper production, in particular, used to be a leading industry in this region, and the proximity to the River Mur was an essential enabling factor. The region’s first hydraulic power station was built in the mid-1920s to supply the paper mill in Rothleiten with ­electric energy. Designed as a diversion power plant, this facility had a flow capacity of 80 m3/sec and a design head of 4.6 m, with five Francis turbines providing an overall output of 2.2 MW. The facility’s annual production of around 13.8 GWh was usually spent entirely on keeping the paper mill going.

When the equipment no longer met the ­required technical and safety standards, the operator decided to replace the old power ­station with a new, larger facility. One of the

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first challenges in this project was the need to pass the environmental impact assessment (EIA). In 2009, the project underwent the EIA process and was finally approved.

Another essential factor in the reconstruction project was the decision to increase the design flow rate from 80 m3/s to 200 m3/s. That ­alone would ensure a significant increase in the ­facility’s productive capacity. Also, the plans called for the power house to be set up in a different location, the old discharge channel to be filled in, and the course of the Mur to be diverted – all based on an ecologically viable concept that was yet to be developed. “Together with our panning associates from BHM in Linz we ran a project analysis, which ­showed that it was possible to increase the head to boost efficiency even further,” says project manager DI Helmut Murlasits.

DRILL-BLASTING DOWNWARD In 2013, when the EIA certificate for the last of the required adaptations was granted, the operators were finally able to start the implementation process. On November 4, 2013, the time for the official project kick-of had finally come. The construction crew launched into the preparatory excavation work for the new weir gate. From March 2014, they ­worked on securing the building pit. As DI Gerhard Schönhart, BHM’s engineer in char­ ge, comments, “We began by setting up a deep-anchored bored pile retaining wall and integrated into the left buttress, facing the ­river. Around this we erected a diaphragm wall in combination with grout-anchored dense sheet piling.” The result was in full compliance with legal requirements, which require the excavation inflow volume to be

With an output20ofGrizzly 9.9 MWOptimus and an modules average from capacity 50 GWh, the new WildofMetal combine to form the largest Coanda screen hydropower plant to provide clean energyisfor4,000 14,300 households. in allisofable Europe.

Its intake capacity liters per second.

Overall engineering & CO n s u lt i n g s e r v i C e s

Industry

Power Plants

Roads & Railways

photo credits: Andritz Hydro

limited to between 10 and 14 litres per ­second. As for flood protection, the excavation pit was designed for an HQ20.

Work on the foundation plate began in February 2014. This turned out to be not at all easy, as the team had to dig their way through a massive phyllite layer. It took around 20 rock blastings to reach the required depth.

“The blasting meant that we had to implement comprehensive safety measures. There were rail tracks running past the site, so we had to install several pressure cells. Of course, the safety measures were also intended to protect the existing turbines, which were still generating power in the old station. To ­ ­protect the facility against rockfalls, we had to cover the blasting area with mats,” says Murlasits, adding that “for special geotechnical reasons we had to re-seal the exposed phyllite layer within 24 hours. Although the material is rock-hard under ground, it tends to be­ come brittle once it’s exposed to air.”

SMOOTH-RUNNING TURBINES Summer 2014 saw the delivery of the first turbine components, which were provided by the ANDRITZ HYDRO facilities in Ravensburg. For the turbines, the power plant operators relied on ANDRITZ HYDRO‘s knowhow and quality, not least because of their positive experience in working with Andritz on the Niklasdorf power plant in 2013. Compared to the much smaller machines in Niklasdorf, however, the two Compact bulb turbines for HPP Rothleiten have some additional technical advantages. „Apart from their dimensions – each of the machines has a flow capacity of 100 m3/s – these units also run more smoothly. The machines for Niklasdorf had anti-friction bearings, and these have slide bearings – one can easily hear and feel the difference. We also installed a hydraulically

Special Topics Public Clients

integrated cam lift mechanism, which minimises frictional resistance at start-up. This is rather important, especially as it helps to ­ensure a long useful life,” as the plant manager explains. With ANDRITZ HYDRO the operators had found a partner to implement individual ideas and requirements in the best way possible.

KNOW-HOW AND PRECISION REQUIRED The high product quality of the machine units is rounded off by high-quality generators provided by ELIN Motoren. “Using an ELIN generator was important to us, as this guarantees a long service life,” says project leader Murlasits. In September 2014, while the hydraulic steelwork was gradually taking shape, the remaining turbine components were installed. A month later, the existing ground sill was removed, allowing the construction to be lowered by another 2 m. Meanwhile, installation work was under way at the power house. The ANDRITZ HYDRO engineers first installed the guide vane system, followed by the shaft with auxiliary spindle and, finally, the generator’s stator unit. In several successive stages, a team of experienced ELIN technicians working in cooperation with Andritz engineers installed both generators in parallel. Both rotors, each of them equipped with 50 poles and weighing 26 tonnes, were lowered into the turbine shaft with hoisting equipment and attached onto the turbine units. With wiring complete and the generator rotors installed, the two stators – each weighing around 27.5 tonnes and measuring 4,100 mm in diameter – were placed over the rotors and fastened to the turbine flange. This required extreme precision on the part of the installers, as the required air gap between the components is only a few millimetres wide. In the end, after a full month of uninterrupted Foto: Hydro-Solar

photos: ZT Eberl

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Hydro Power Thermal Power Biomass Special services

BHM INGENIEURE Engineering & Consulting GmbH Europaplatz 4, 4020 Linz, Austria Telephone +43 (0)732-34 55 44-0 office.linz@bhm-ing.com

feldkirCh • linz • graz vienna • sChaan • Prague

ZEK_E_58x262_4C_20170117.indd 1

May 2017 17.01.201729 14:52:54

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Each of the turbines has a flow capacity of 100 m3/s.

work and with both generators finally in place, the units were handed over to the ­ customer, ready to be put into operation.

Once the throat ring was closed, the generator was sealed with an end cover. Finally, the guide vane assembly, server motor joint and falling weight were installed.

OPTIMISED WATER FLOW Optimising the plant’s operational efficiency was by no means limited to the installed ­machine unit but included adjustments to the overall building structure. In collaboration with Graz University, the planners at BHM fine-tuned the intake structure, among other things.

As Gerhard Schönhart explains, “The original design of the power station had been model tested already at the Graz Technical Uni-

versity’s Institute for Hydraulic Engineering.

But since the flow rate of the new design was 20 m3/sec higher and the overall construction of the power station had been lowered, we had the inflow recalculated. The result showed us instantly that the intake could be shortened and arranged at a rather steep 35 degree slant. It also turned out that the planned upstream retaining would cause a sub-optimal inflow to Turbine 1. So we moved the wall back a little and capped it with a calotte. Doing it this way not only improved the turbine inflow, it also saved us some construction work.”

PROJECT SUCCESS WITHIN EIGHTEEN MONTHS In retrospective, the figures of the construction project are quite impressive: Overall, 388,000 m3 of earth were moved, 44,000 m3 Installation of the 50-pole ELIN generators requires utmost precision. The rotor and stator units have a combined weight of more than 50 tonnes.

photo credits: Andritz Hydro

photo credits: Andritz Hydro

Mounting of the Compact bulb turbines

of armour stones were used, 27,000 m3 ­concrete was poured, and 2,600 tonnes of reinforcing steel were incorporated into the construction. Most of the excavated material was reused to fill up the original river bed and the original 400 m discharge channel.

In total, the main construction work took around eighteen months to complete. By May 2015, the first turbine start-up tests had begun while final construction work was still ongoing and individual ecological compensating measures were being implemented. The overall project was finally completed in time and in optimum quality, thanks not least to Helmut Murlasits and his construction management team, which included Josef ­ Kreuzer, overall project leader and Managing Director of Added Value GmbH, Gerhard Schönhart and Rudi Kandler of BHM, as well as power plant specialist and chief electrical engineer Werner Machazek.

The turbine control and automation system was provided by ANDRITZ HYDRO, and

Technical Data • Flow Rate: 200 m3/s

l

Head: 5.7 m

• Turbines: Compact Bulb Turbines (2 pc.)

• Manufacturer: ANDRITZ Hydro • Output: 4,900 kW each • Runner Size Ø: 3.650 mm

• Generatores: Synchronous (2 pc.)

• Manufacturer: ELIN Motoren • Nominal Speed: 120 rpm • Nominal Current: 569 A l Weight: 56 t each

photo credits: ELIN

• Nominal Output: 6.212 MVA

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l

Voltage: 6,300 V

• Control and communication system: Siemens • Hydromechanical Equipment: Kuenz • Planning: BHM INGENIEURE • Total Average Capacity: 46.9 GWh

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photo credits: MeinAlpenStrom

River Mur and relocating the Gamsbach estuary ensures sufficient protection up to centennial floods.

Cord Prinzhorn, CEO of Prinzhorn Holding, and Johannes Wagner, the Mayor of Frohnleiten, placing fish in the River Mur.

the primary control and automation system, as well as the medium-voltage switchgear and low-voltage distribution system were provided by another, equally competent partner: Siemens.

ECOLOGY AND FLOOD PROTECTION Ecological measures were a key item on the project agenda. For one thing, a perfectly designed fish migration support system was constructed in the form of a natural pool pass.

Its most distinguishing feature is an integra-

ted pool, from where the fish can reach a branched-off rivulet. In addition, several ­amphibian biotopes were set up, and a number of ecological compensating measures were implemented. Particular care was taken to preserve the ecology of the surrounding ­r­iparian zone.

Previously, the outflow reach had dried out frequently at low tide, whereas the new construction ensures a continuous flow of water at all times. Another item on the agenda was flood protection. Diverting the course of the

MASSIVE BOOST TO POWER PRODUCTION November 12, 2015 saw the successful completion of the uninterrupted 30-day trial operation of the two bulb turbines. The power plant was now ready to go into regular operation. Equipped with two new 4.49 MW bulb turbines by ANDRITZ HYDRO, the newly constructed power plant at Rothleiten uses Mur hydropower to generate around 46.9 GWh of clean energy per year.

This is more than three times the output of the old facility, which had a capacity of around 13.8 GWH/year.

Together with the modernised Rothleiten power station, a bit of industrial history has been preserved in the tradition-steeped Frohnleiten region. Today, the facility is the core element of a group of four small-scale hydropower stations with a total capacity of 17 MW that Prinzhorn Holding operates to generate and market clean, inexpensive hydropower. Under the new label, “MeinAlpenStrom” (“my Alpine power”) Prinzhorn is currently establishing itself as one of the national energy providers, offering 100% green electricity from Styria.

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Images: SIEMENS photo credits: SIEMENS

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HEPP Yumrutepe, Giresun City Province in the Black Sea Region: Modern cross-border cooperation.

SIEMENS SMALL HYDRO SUCCESS STORIES IN TURKEY Siemens can draw on decades of experience and hundreds of small hydro-power plants installed worldwide. The company is renowned for technical excellence and outstanding service and can serve as a system provider with comprehensive expertise in the implementation of turnkey projects. This can translate into high profitability and availability of the plant and low total cost of ownership. As one of very few integrated energy company that serves the entire energy conversion chain with products, solutions, and services, Siemens provides both sophisticated technology and substantial know-how. This includes the construction of new small hydropower plants as well as the modernization of existing ones. Siemens is able to provide comprehensive solutions for small hydropower plants up to 30 MW from various reachable offices. Siemens Small Hydro Turkey has realized 5 projects in the recent past and demonstrates once again to be one of the best and most competitive partners for hydro business in the huge Turkish market. Please find below a short overview of the biggest challenges and the best practice solutions for each power plant.

I

kiler HEPP is located in Karabuk City’s province in the Black Sea Region. The plant has 2 Kaplan turbines each with 3.5 MW. Siemens Turkey has delivered a complete package of electrical and automation balance of plant that will maximize the availability and efficiency on the one side and minimize the maintenance cost of the power plant on the other side. The automation system is based on a standardized SIMATIC S7 Software and WinCC Professional for the SCADA system. The contracted scope of supply includes the engineering, delivery, supervision of installation and commissioning of the ­turbine and generator automation, SCADA, transformers, medium

HEPP Yumrutepe control room

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voltage switchgear and the grid connection. The PAC of HEPP Ikiler has been signed in May 2016 and the power plant is producing energy to the highest satisfaction of the customer.

EXEMPLARY INTERNATIONAL COOPERATION Almost at the same time HEPP Kuzey located in Ordu City’s province in the Black Sea Region, has been realized. The PAC was signed in ­autumn 2016 after the customer D-Energy has been working with ­Siemens engineers in a very close cooperation for optimizing the whole civil concept. In this project, Siemens Turkey and the Center of Com-

German Small Hydro technology installed at the HEPP Yumrutepe power plant.

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Online since autumn 2016: HEPP Kuzey in Ordu City Province in the Black Sea Region.

petence for Small Hydro in Salzburg showed again, that a professional and most efficient collaboration regarding knowhow transfer and support over country boarders brings the customer at the end the best possible solution for his investment. Beside of the complete Electrical and Automation scope delivered by Siemens Turkey, the Center of Competence in Salzburg provided the Turbine Governor Sipocon-H based on SIMATIC S7 for both Francis units with each 3,5MW. A very effective commissioning period in cooperation with the Center of Competence at the end of the project reflected the successful project execution.

SINGLE-SOURCE ENGINEERING AND SERVICE Just a few months later, the PAC for the new built HEPP Yumrutepe, located in Giresun City’s province also in the Black Sea Region, has been signed in January 2017. The plant has three Francis Units, each with a different power (1x12MW, 1x8MW, 1x4,5MW). Siemens Small Hydro Turkey was responsible for the whole Electrical Balance of Plant incl.

Medium- and Low Voltage Switchegars, Transformes, Cables, Automation and SCADA System based on SIMATIC S7-400 and Win CC Professional.

As a result out of the performance, the excellent quality of engineering and service and the best products out of one hand, Siemens Small ­Hydro Turkey and the customer signed another contract for the new built power plant HEPP Kalecik.

The currently two running projects are HEPP Kalecik and HEPP Karatas, both located in the Black sea Region. HEPP Kalecik has 2 Francis Units each with 15 MW Turbine power and HEPP Karatas has 3 Francis Units, two with 2 x 4.65 MW and a smaller unit with 2.65 MW. For both projects, the scope of supply contains the whole electrical

Siemens’ state of the art technical solutions.

b­ alance of plant incl. medium voltage and low voltage switchgears, transformers, cables, Automation and SCADA system, installation and commissioning.

HIGH PERFORMANCE SOLUTIONS Just as for the project HEPP Kuzey, Siemens is using the existing concentrated Small Hydro know how in Istanbul and the CoC in Salzburg to engineer the best possible and most economical solution for the customer. The Turbine Governor Sipocon-H will be engineered and developed in Salzburg and commissioned by local specialists. This assures the customer to get the whole automation and SCADA solution from one source and additional interfaces will be eliminated. Further the contact person for the customer is during the whole project lifetime a local Siemens Turkey employee.

Both projects are in time and shall be commissioned by highest qualified commissioning engineers of Siemens Turkey in September 2017.

SIEMENS’ LOCAL PRODUCTION IN TURKEY One of the big and main advantages of Siemens Small Hydro in Turkey is the local production of the air-insulated medium voltage as well as the low voltage switchgears in Gebze.

This guarantees the customer a maximum degree of safety, reliability and availability. In this way, the Siemens well-proven technology and products for Small Hydro applications enables cost-efficient and reliable operation. The great advantages of air-insulated medium-voltage switch­ gear are: The insulating medium air is available always and everywhere, without further technical efforts, such as for example gas pressure monitoring.

Siemens’ proven technology and products for Small Hydro applications enable cost-efficient and reliable operation.

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photo credit: GUGLER

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Installation of the Kaplan syphon turbine was successfully completed at the foot of the Clywedog Reservoir before the end of 2016.

The entire electromechanical and water distribution control equipment was manufactured by the Austrian company, GUGLER Water Turbines GmbH.

GUGLER PROVIDES NEW TURBINE FOR CLYWEDOG RESERVOIR IN THE HEART OF WALES

T

he River Severn is the longest flowing body of water in the UK at a length of 354 km. Its source is located close to Llanidloes, a small town in the Cambrian Mountains in central Wales, at an altitude of 610 m above sea level. From sourceto-sea the river flows through several English counties before the estuary ultimately meets the Atlantic Ocean at the opening of the Bristol channel. Note: Due to the extreme height difference of 15 m between high and low tides at the mouth of the Severn Estuary the British government had once planned to build an immense tidal power station. However, a negative ­viability study ensured the project was rejected. In the 1960s Clywedog Reservoir was installed near the source of the Severn to improve the regulation of the river.

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FREQUENTLY-USED RESERVOIR The 50 million cubic metre reservoir was created during the construction of a dam wall on one of the tributaries ‘Afon Clywedog’, and plays an important role in protecting the regions lower down from flooding. The area surrounding Clywedog Reservoir is also a popular attraction for tourists and trekkers, and even sailors indulge in their favourite pastime on its waters. The potential energy stored in the reservoir is also exploited by a hydropower generating plant. In order to extract even greater potential from the water, the local operators – Severn Trent Water ­Limited – decided to install an additional turbine. GUGLER Water Turbines GmbH supplies systems all around the globe and was success in bidding for the contract to supply the entire electromechanical and

photo credit: GUGLER

Clywedog Reservoir was constructed close to the small Welsh town of Llanidloes between 1963 and 1967. The 50 million cubic metre capacity reservoir is primarily used to regulate the flow of the Severn River, which originates in the region and is the longest river in the United Kingdom. The reservoir covers an area of around 2.5 km² and is up to 80 metres deep in places. It also considerably reduces the risk of flooding along the riverbanks. A further benefit of the Clywedog Reservoir lies in its capacity to generate hydroelectric power. Up until half a year ago electricity was only generated by two Francis turbines. In November 2016, these two machines were complemented by an additional turbine installed at the foot of the dam. The additional unit is a Kaplan syphon turbine made by the Austrian hydropower allrounders at GUGLER Water Turbines GmbH. Several months of sophisticated advance planning made it possible to complete structural implementation before the end of the year – of what, in terms of organisational issues, was a very challenging project.

Completed Unit

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The Thedoubly-regulated doubly-regulatedturbine turbinehas hastotodeal dealwith withaamaximum maximumwater water flow of 2.2 m3/s and an overall height difference of 5.46 m

NEW OUTDOOR POWER PLANT GUGLER’s responsible project manager, Thomas Danner, explains: “One stipulation made by the customer was that no structural adaptions should be made to the dam while installing the additional turbine. Further­ more, the controls for the new hydroelectric infrastructure had to be integrated into the control technology installed for the older turbines.” Another condition was that every part of the new system would need to be ­placed outside the dam. According to Mr. Danner, the key advantage of this was the elimination of the necessity and associated costs of installing structural concrete.

and it was comparatively affordable and easy to use the water storage basin for the generation of electricity” said Danner.

KAPLAN SYPHON TURBINE The system was installed right at the foot of the 72 m-high dam wall where there is an equalising basin with a total drop distance of almost 5.5 m. The new turbine is able to utilise the remaining water from the existing water power infrastructure. Below the dam, the water running through the turbine is then processed a second time. “The conditions set down for a project in this location meant the ideal solution had to be a double regulated Kaplan syphon turbine.

The installation of this type of turbine does not require any extra structural concrete

TURBINE STARTED VIA VACUUM PUMP One distinctive feature of the Kaplan syphon turbine at the new Clywedog power plant is that a vacuum pump is required to start it. Water is drawn up a short pipeline from the equalising basin via the pump and arrives at a 4-blade rotor with a diameter of 645mm. After completing the start-up procedure, the turbine can operate normally without the vacuum pump. The turbine receives a standard flow volume of 2.2 m³/s.

In optimum water flow conditions the vertical-axis-mounted machine can produce up to 100 kW. A Schorch asynchronous ge-

photo credit: GUGLER

­ ater control infrastructure for the new hyw droelectrics project. The Austrian company has built and installed several turbine systems for international customers in Chile, South Korea and all over Europe, and this was the first order to have been awarded by a client in the United Kingdom.

nerator is coupled directly with the turbine shaft to serve as an energy transformer. All of the electricity this plant generates is fed into the municipal power grid.

OPTIMALLY INTEGRATED CONTROLS The modern technology built into the system ensures that energy production at the new power plant is fully automated. All of the new electronics, control and guidance technology at the plant was also provided

by GUGLER. The challenge for the project manager, Mr. Danner in terms of control technology was to integrate the ultra-modern command technology into the control system used for the existing turbines: “We had to adapt our proven automation solution to suit the older control system. The

Sophisticated advance planning made it possible to complete all installation tasks in just 4 weeks in November 2016.

Technical Data • Flow Rate: 2,2 m3/s • Head: 5,46 m • Turbine: Kaplan-Siphon, double-regulated • Runner : 4 blades

• Nominal Output: 100 kW • Manufacturer: GUGLER Water Turbines GmbH • Generator: Asynchronous • Total avarage capacity: 430,000 kWh

photo credit: GUGLER

• Runner Diameter: 645 mm

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Clywedog Reservoir has a capacity of approximately 50 million cubic metres. As well as serving as a water retention option for flood prevention, this gigantic reservoir is also a popular day-trip destination in the heart of Wales. Clywedog Reservoir is also used for the generation of green electricity.

knock-on benefit for those running and maintaining the plant is that each of the ­access terminals uses identically structured control visualisation.”

INSTALLED IN JUST A FEW WEEKS The turbine constructors were also subject to strict customer in terms of the selection of electrical and electronic components. Since safety legislation and norms in the UK are very strict as regards electrical technology, it was a considerable challenge to acquire the necessary components. Thomas Danner explained the general challenge posed by the comprehensive organisational tasks ahead of the actual structural implementation thus: “In principle, we had to bring the specific requirements of three different groups under

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May 2017

photo credit: GUGLER

photo credit: Wikimedia/By Badgernet CC BY 3.0

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Aerial view of the new hydro power plant.

one roof: the operators, the planning agency, ANF Consulting Ltd, and the construction contractors J.N. Bentley Ltd. The difficulties were exacerbated by the relatively remote location of Clywedog Reservoir. The transportation of immensely heavy power plant equipment to its final destination was a challenge in itself.”

INSTALLATION AND SUBSEQUENT G59 INSPECTION PASSED WITH DISTINCTION Ultimately, the complexity of organisational activity ahead of implementation paid off in the smooth running and rapid completion of the installation phase in November 2016.

Local installation engineers working under the supervision of GUGLER specialists managed to finish the entire installation within

the time limit of four weeks set by the dam operators. Rapid installation enabled the plant to be subjected to the so-called G59 test in mid-December. The G59 test is an inspection carried out by UK grid operators on plants producing electricity fed into the public grid. The test pays particular attention to safety aspects with a precise inspection of all electronic components. As expected, it was completed successfully.As a result, normal operation of the new power plant started up at the beginning of 2017. As the G59 test was successfully completed before the end of the year it ensured eligibility for subsidised electricity rates. The plant operators expect the new turbine to produce an additional annual power output of around 430,000 kWh.

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photo credits: Schubert

Successful cooperation of the international team. In addition to Schubert, another Austrian company was represented with Gugler. The generators were provided by the Spanish manufacturer INDAR, with local support from the „Hydro Power Andina“ installation team. The person responsible for commissioning the plant from Schubert was Johannes Hölzl (right in the photo).

ADVENTUROUS JOURNEY OVER THE ANDES: AUSTRIAN PLANT TECHNOLOGY USED IN PERUVIAN HYDROELECTRIC POWER PLANT While mountains didn‘t have to be moved for this transport, several thousand metres of altitude had to be overcome. The ­specialist for plant engineering, Schubert, delivered the entire electrotechnical equipment for the Carpapata III power plant located in central Peru, and, besides the turbine manufacturer Gugler Water Turbines, was the second company from Austria involved in the project. To this purpose, a trip through the Andes wasn‘t shied away from, despite threatening mudflows and rock avalanches, as well as the local, especially extensive safety measures, including bureaucratic hurdles. With precise planning, team spirit among the international team and technical know-how, the hydroelectric power plant was successfully commissioned in the Andes in August 2016.

A

n adventurous and long journey lay ahead of the electrotechnical equipment of the Carpapata III power plant in Peru. This is because the technology of the hydroelectric power plant was delivered from overseas, more precisely, from Ober-Grafendorf in Lower Austria. Schubert, the specialist for electrical systems engineering based there, delivered the complete electrotechnical equipment for the Peruvian power plant. It was not only a geographically long distance to the ­destination, but a challenging journey. The first actual adventure only started following the transport from Italy to Lima.

EXTENSIVE ORDER FOR INSTRUMENTATION AND CONTROL ENGINEERING But back to the start: following the successful commissioning of the Nuevo Imperial

hydroelectric power plant in 2012, in which Schubert was decisively involved and had its premiere in the electrotechnical equipping of a Peruvian hydroelectric power plant, the operator, Union Andina de Cementos SAA (UNACEM), promptly submitted the next order. Like with the predecessor power plant, the decision was made in favour of a combination of the two Austrian companies Schubert and Gugler. “The customer was ­ completely satisfied with this project and therefore swears by cooperation with Gugler/ Schubert”, engineer Christian Schwarzenbohler, division head of power generation at Schubert Elektroanlagen explains. The period for implementation was from May 2014 to commissioning in August 2016. The ­extensive order for Schubert called for the delivery of the entire electrotechnical equip-

The two Francis turbines from Gugler each have an output of 6,000 kW, while the two synchronous ­generators from INDAR have an output of 7,400 kV A (13.8 kV).

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ment for the power plant, for example, a ­medium ­voltage switching system, transformer, control/regulating system, electrical protection, guidance system (SCADA), ­power plant own requirements, installation, wiring and commissioning, as well as documentation. For more than 40 years now, the company from Ober-Grafendorf has been gathering experience in the electrotechnical equipping of power plants and can present a list of ­500 successfully constructed reference plants, ­including in other South American countries like Chile and Colombia. With this wealth of experience, Schubert is seen as the ideal partner for the provision of complete packages in the instrumentation and control engineering segment, such as electrical equipment, measurement engineering, control and regulating technology. Further technical involvement from Europe came with two Francis turbines of the Austrian company Gugler, each with 6,000 kW of power and two 7,400 kVA (13.8 kV) ­ ­synchronous ­generators from a Spanish manufacturer.

SOPHISTICATED TRANSPORT OVER THE ANDES: DELIVERY THROUGH A MOUNTAIN PASS In the case of the Carpapata III power plant, the complete delivery was undertaken by Gugler. The technical equipment was packed airtight by Schubert in crates, in seaworthy packaging suitable for withstanding the ­extreme stresses of wetness, heat, cold and the transfer of the goods, and ensuring that the sensitive goods arrive in one piece at their destination. The equipment, now stowed away in ship containers, was transported by sea from Italy to Lima. Here is where the ­difficult route through the Andes began. The 280 km long stretch from the Peruvian ­capital to Carpapata may sound like a short transport route, but this route packs a punch.

From its start in coastal Lima, which lies ­nearly at sea level, the Carreter Central road winds upwards to the Ticlio, a pass at 4,818 m above sea level, until it then descends 2,500 meters of elevation downwards to the location of the power plant (2,300 m above sea level). The entire transport of goods and persons between Lima and the central highlands, as well as to the neighbouring primeval forest areas takes place via the in some places very narrow Carreter Central. The transport of the electrotechnical plant parts proved to be even more difficult than is usually the case for the route through the mountain region: Delays occurred because the delivery had to take place during the rainy season and mudflows and rock avalanches interfered with transport.

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Carpapata III was originally intended as a cavern power plant, but the geological conditions didn‘t allow for this type of design.

Energy production thus takes place in the newly erected power plant building.

SPECIAL EXTINGUISHING SYSTEM FOR CONTROL CABINETS However, things were even more complicated: The power plant operator ordered an extinguishing system with nitrogen technology for the substation. “The transport of the components required for the trip circuit of the extinguishing system caused us difficulties with delivery”, Christian Schwarzenbohler tells.

“Because these involve hazardous goods, several hurdles needed to be overcome in order to successfully carry out delivery ”. But the problems didn‘t start only with the delivery of the control cabinets. First of all, a solution needed to be found for the called for integration of the extinguishing systems, with which server cabinets are usually equipped. The know-how of the fire protection company Wagner was drawn upon for this purpose. A system con-

cept was developed in cooperation with Schubert. “In order to ensure a smooth process, the extinguishing system was already installed and tested at our company by a fitter from the Wagner company”, Christian Schwarzenbohler explains. “Our personnel was also trained to install and commission the extinguishing system on location.”

ADVERSE CONDITIONS ON LOCATION Not only the technical suppliers Schubert and Gugler had their hands full with the ­difficult conditions on location. The customer UNACEM also faced major challenges during construction. In order to reach the power plant on the Huasahuasi River, a new road had to be built on the most inhospitable ground, as no access road to the power plant had previously been available. A tunnel also

The control technology from Schubert: thanks to its clearly structured user interface, the SCADA control system is the ideal aid for the power plant personnel in controlling and regulating the plant.

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The control cabinets were equipped with a special extinguishing system.

A concept for the special design was formulated by Schubert in cooperation with the fire protection specialists from Wagner and installed and tested while still in Austria.

had to be built for the waterways, which ­presented enormous challenges for the team on site.

SUPPORT FROM THE INSTALLATION TEAM FROM PERU Besides delivery, the order of Schubert also included construction supervision of the electro­technical installation. To this purpose, both Schubert and Gugler each had a super­ visor on location to head the installation. A supporting installation team was provided by “Hydro Power Andina”, a Peruvian company headed by a power plant technician who had once lived in Germany. “There were some ­advantages to having a Peruvian company on site during the execution of the project. For one thing, due to the language barrier (English was hardly spoken), as well as for acquisition of necessary materials, finally due to the mandatory safety regulations, which were quite estimable”, the division head of Schubert summarises.

The interior of the control cabinet with integrated extinguishing system.

SAFETY-RELATED REQUIREMENTS ENORMOUS IN PERU The occupational safety requirements were particularly formidable for installation. A report had to be submitted daily, indicating which work was to be carried out, what ­hazards might be expected, and how these could be avoided. This meant an enormous amount of work for the team on location. The con­struction site was also constantly monitored with regard to matters of safety. The ­reason for this is that Peru is very strongly influenced by American guidelines.

A great deal was also demanded of the team from Schubert in technical terms: one of the requirements was that the electrical data should be transferred from the power plant to the energy provider in real time by way of IEC protocols. The power plant also had to contribute to grid stability. That means that the generators had to increase or reduce output in accordance with the supply frequency.

Here too there were special specifications

from the power supply company that had to be observed and regularly tested. “The voltage level of the generators lies at 13.8 kV. These feed directly to the medium voltage substation delivered by us. From there a transfer transformer is supplied, which increases the voltage to 72.5 kV”, explains Christian Schwarzenbohler. The electrical power produced is fed into the national 72.5 kV grid (SEIN).

SUCCESSFUL COMPLETION SUBSEQUENT PROJECTS PLANNED After more than two years of project planning and construction, the Carpapata III power plant in the Andes was connected to the grid.

The project was successfully jointly implemented by the international team, and was in the process able to present itself so convincingly that the Schubert and Gugler companies were engaged in 2016 for two more major projects in Peru (HEPP Yarucaya with 2 x 11 MVA and HEPP Maranon with 3 x 8 MVA).

The turbine water was ­supplied through the interior of the mountain. A tunnel also had to be built for the waterways, which presented enormous challenges for the team on site.

Industriestraße 3 A-3200 Ober-Grafendorf Tel.: +43 2747 25 35 - 0 Fax: +43 2747 25 35 - 440 E-Mail: office@schubert.tech Schubert Elektroanlagen has been a leading provider of electrotechnical and mechanical plant equipment in the energy, environment and water segments for 50 years.

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RENEXPO INTERHYDRO SALZBURG BECOMING A CENTRAL HYDROELECTRIC ENERGY HUB If there are two meaningful indicators for the quality of a congress trade fair, then these must be the response from participants and the rebooking percentage. In the case of RENEXPO® INTERHYDRO in Salzburg, both parameters are convincing.

After around 2,000 visitors from throughout Europe passed through the turnstiles last year, we can once again count on a full house this year. On 29 to 30 November, the 9th edition of the RENEXPO® INTERHYDRO will take place in the trade fair centre in Salzburg. The focus will once more be on the most current themes of the industry, such as questions of economic efficiency and storage possibilities.

SURVIVING IN A DIFFICULT MARKET ENVIRONMENT Several focal themes characterise the event as in previous years. For one thing, the “Hydroelectric Energy & Energy Storage” will provide the theme of pump storage a lot of space in the 3rd edition. The storage of volatile forms of energy remains one of the central questions of the energy economy. In the pro-

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cess, aspects like technical innovations, matters of relevance for the grid and questions concerning the competition of pump storage with other forms of storage will be at the forefront. Alternative storage options for smaller and medium-sized operators will also be discussed in greater detail. Another important point in the programme will be the 9th International Small Hydroelectric Energy Conference: Presenting “Innovation and Economic Efficiency”. There is hardly anoIn the trade fair advisory council, intensive discussions are currently taking place as to in which areas the offering at the congress trade fair can be improved.

photo credit: Renexpo

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urope’s small hydroelectric energy industry is currently going through turbulent times. Wedged in the field of tension between increasing ecological requirements and market prices for green energy that are currently at an all time low, the main thing is to reposition and, above all else, once again find a solid perspective for the future.

To do this, profound analyses, effective communication and a strong network are required. RENEXPO® INTERHYDRO has in the meantime established itself as the ideal hub for the central agendas of the small and medium hydroelectric energy segments. It offers operators, planners, project developers, investors, municipalities, energy utility companies, but also politics, science, research institutions and industry a unique platform for presentation, knowledge transfer and exchanging experiences, as well as for establishing new contacts. Excursions with the aim of a practice-oriented exchange of know-how round off the event.

ther question of more importance to private operators today: What marketing possibilities does the market offer? Can I also participate in the control energy market? What are the most important prerequisites for surviving under the currently difficult marketing conditions? Particularly the small hydroelectric conference has developed into an extremely popular forum, in which a lively exchange of experience and knowledge takes place and new contacts are established.

Foto: zek

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photo credit: zek

Podium discussion at the Renexpo Interhydro 2016

photo credit: Renexpo

ECOLOGY AS AN ENDURING ISSUE Of course ecological thinking will once again receive its due at this year’s RENEXPO® INTERHYDRO. In the context of the 5th trade congress entitled “Aquatic ecology for reconcilable hydroelectric energy expansion”, experts will be present with their specialist knowledge. Which aspects need to be observed with regard to the renewed awarding of water rights, what requirements with regard to fish migration can operators anticipate, or what new legal basic conditions exist? In this context, all ecologically relevant questions are answered.

In connection with this, the fisheries associations should for the first time be more closely integrated into the communication this year.

Dialogue with the nature conservation will also be intensified. It remains an important

matter to also communicate the agendas of hydroelectric energy positively. This ultimately because it still bears the stigma of being perceived too negatively among the public and its importance underestimated.

PROMISING MARKET OF AFRICA Another central point in the context of this year’s congress trade fair is provided by the aspect of internationality. In addition to the two forums, the Eastern Europe Forum and the Western Europe Forum, the focus of attention this time is also on the Dark Continent: small and medium-sized hydroelectric energy in Africa will be the themes in the 1st Africa Hydroelectric Energy Forum. A very exciting thematic focus. Ultimately, Africa is considered one of the future markets for hydroelectric energy, even though African hy-

In this autumn as well, the city of Salzburg will become the epicentre of the hydroelectric energy industry. 2,000 visitors are once again expected at the Renexpo® Interhydro.

photo credit: Peter Gura_pixelio.de

Foto: zek

The trade fair advisory council after the first meeting in March 2017

droelectric energy projects are often confronted with considerable challenges. Regrettably, water measurements in some countries have not taken place since the 1980s and 1990s due to regional political conflicts. This is exacerbated by other challenges, such as questions of geology, feed possibilities, general connection possibilities, but also by questions of licensing rights or even something as simple as language barriers. Those who invest today in the African hydroelectric market can look forward to big opportunities with considerable risk. In the context of the 1st Africa Hydroelectric Energy Forum, the central key points should be thematised and an interesting overview of potential and options on the Dark Continent be offered.

“HYDROELECTRIC ENERGY MECCA” SALZBURG The RENEXPO® INTERHYDRO attracted around 2,000 guests to the Mozart city of Salzburg in 2016. 300 conference participants were also registered. No less than 110 exhibitors made use of the opportunity to present their products and services to a well-informed public. These figures alone impressively demonstrate the success of last year’s event.

It has been shown that the city of Salzburg, with regard to its geographical location, but also not least due to its attractiveness in tourism terms, has gradually become an ideal place for a congress trade fair for hydroelectric energy, which today is justifiably considered one of the most important hubs of the European hydroelectric energy industry.

From 29 to 30 November 2017, the RENEXPO® INTERHYDRO will once again open its doors in the trade fair centre in Salzburg. The RENEXPO® PV & Power Storage will take place simultaneously as a partner event. The preparations for this are already running at full speed.

May 2017

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photo credit: PROKON EKON Group

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Weir system of the new Vanazit hydroelectric power plant in northern Turkey. All electro-mechanical infrastructure and automatic plant control equipment supplied and installed by Ossberger.

MOST POWERFUL CROSS-FLOW TURBINE FOR TURKISH VANAZIT HYDROPOWER PLANT April 2016 saw the successful commissioning of the new Vanazit hydroelectric power station in the northern Turkish province of Giresun. The plant operated by ‘Proen Energy and Trade Inc.’ (Proen Enerji ve Ticaret A.Ş.) is located in the Kesap district, close to the Black Sea and exploits the potential energy of the Büyük water mass to generate electricity. OSSBERGER GmbH + Co. KG is based in southern Germany and was awarded the contracts for the provision of all the necessary electromechanical infrastructure for the new water diversion power station. The successful project bid means this internationally experienced company has been charged with the production of their most powerful cross-flow turbine at that date – with a maximum power output of 3.46 MW.

PLANT TO BE COMPLETELY REBUILT In order to construct the new water diversion plant, every single part of the power station needed to be completely rebuilt – from the powerhouse and weir system to the penstock. According to the specifications provided by the operating company, implementation would demand 18,000 m³ of concrete, 900 tonnes of reinforcing steel and 25,000 m² of casing material. The weir and powerhouse are both solid concrete structures.

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Many aspects of the planning and implementation of the project were carried out by the operating company, Proen Energy and Trade Inc., a member of the PROKON EKON Group, a corporation working mainly in the building, industrial and energy production sectors.

Ossberger deployed its own team of specialists to guarantee correct The cross-flow turbine has been designed to process a maximum of 3,500 l/s with a gross head value of 113 m.

The system can achieve a bottleneck output of 3.46 MW when flow supply conditions are at their best.

photo credit: Ossberger

O

ssberger GmbH + Co. KG is based in the Middle-Franconian town of Weißenburg and has already enjoyed recent commercial success in the Black Sea region. For example, the company provided the turbine infrastructure required by several thermic power stations on the Black Sea coast for energy recovery from the cooling water systems. Having been awarded the contract for the Vanazit power plant by the operating company, Proen Energy and Trade Inc., Ossberger is now responsible for the implementation of another purely hydroelectric project in this part of the world. Holger Franke is Ossberger’s sales and distribution specialist for the Turkish market and responsible for project implementation.

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XXL CROSS-FLOW TURBINE Diversion of the Büyük at the Vanazit plant is achieved with an available gross head of 113 m and a maximum flow volume of 3.5 m³/s. The system can generate a bottleneck output of 3.46 MW when flow supply conditions are at their best. “At the time of delivery this was the most powerful cross-flow turbine we had ever produced”, remarked Mr. Franke, who continued by explaining: “Despite the turbine’s power, its dimensions are relatively small, particularly in terms of its width. Due to the design of the machine, the steep drop made it necessary to realise a large rotor diameter of 1.25 m, while limiting the length of the rotor to less than 50 cm, which required the machine to be relatively narrow overall. The cross-flow turbine has a relatively low specific rotation rate. The

The successful bid for the Vanazit power plant project meant Ossberger would also be responsible for manufacturing their by then most powerful cross-flow turbine at their own production base.

optimum turbine rate for the Vanazit plant would be around 340 rpm. Hence, the decision to produce and install a power transmission gear system between the turbine and the generator, since a slow-rotation generator would be very expensive without being particularly efficient.”

COMPLETE OSSBERGER PACKAGE For the new power station, the scope of delivery encompassed the turbine, generator, gear system, an extremely heavy maintenance butterfly valve, and all the electrical and control-related hardware. The electro-technical infrastructure had to be adapted to suit the norms and safety directives in force in Turkey. The generator manufacturer had to adapt the short circuit ratio to comply with Turkish guidelines. The plant is run using the tried and trusted Ossberger SCADA online control system. Online remote access to control processes facilitates fully automatic and highly effective electricity production.

The overall package was rounded off with a medium voltage generator switching system and a transformer. The new Vanazit hy-

dro-electric plant finally went online in April 2016. The plant has been producing an ecologically sustainable power supply for the public mains grid since the trial period was completed successfully. The operators estimate the average annual power output to be around 10 GWh. Rear view of power plant control centre

photo credit: Ossberger

CROSS-FLOW TURBINE REPLACES TWO FRANCIS TURBINES The original call for bids in 2012 envisaged twin Francis turbines for the generation of electricity at the plant. However, due to the (in some cases) extreme fluctuation in the amount of water available at the plant site at different times of the year, a single Ossberger turbine was considered to be the more effective technical solution. Holger Franke explains: “The cross-flow turbine is very efficient the whole year round and can deliver at least as much power spread across the year. This is in contrast to the originally planned Francis turbines, whose strengths become evident working at full capacity. Furthermore, compared with the costs of purchasing two Francis turbines and the expenditure required for the associated technical infrastructure, the acquisition of an Ossberger turbine is significantly more affordable.”

photo credit: Ossberger

installation of the turbine, electrical and electronic infrastructure.

Technical Data • Flow Rate: 3,500 l/s

• Generator: Synchronous

• Gross head: 113 m

• Poles: 6

• Turbine: Crossflow

• Voltage: 3.300 V

• Runner Diameter: 1.25 m • Nominal Output: 3.125 MW • Runner Speed: 340 rpm

• Manufacturer: Marelli

• Output: 3.46 MW

• System Control: SCADA

• Manufacturer: Ossberger • Annual energy capacity: ca. 10 GWh

May 2017

43

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photo credits: Cotlan AG

With a new Kaplan SZ tubular turbine made by Kössler, the Cotlan power plant has entered into a new era. In comparison with the old stock, the installed capacity has increased eightfold.

THE MOST EFFICIENT POWER PLANT ON THE LINTH BECOMES OPERATIONAL The replacement for Cotlan AG’s traditional small hydroelectric station, a former textile factory in the Swiss canton of Glarus, was able to take shape thanks to a period of intensive construction work in recent months. The construction of the now entirely underground headrace in particular made this power plant project a real challenge. The powerful Kaplan-SZ turbine, which was provided by the Austrian hydroelectric power specialists Kössler, has been in operation in the new plant on the Linth river since last autumn. Designed to produce an output of 2.5 MW, in an average year the machine ensures around 12 GWh of clean energy from regional resources. As a result, this new low-pressure facility is the most efficient power plant on the Linth.

The ceremonial opening will take place in June this year.

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s­ tation in order to supply the cotton mill with electricity. That same mill was taken over by Cotlan Textilfabriken AG in 1979, which continued to operate the business. The factory just about made it into the new millenniA sight from the past: water used to flow through an open canal to the turbine.

um, although it was closed down shortly ­afterwards in 2002. The power plant that had undergone so many renovations throughout the decades was still running, but had long since reached the end of its technical lifetime. photo credits: Cotlan AG

Y

ou wouldn’t know it from looking at the romantic, sleepy Canton of Glarus, but it is nevertheless the most heavily industrialised canton in Switzerland – the very same canton in which the textile industry once burst onto the scene. The first textile factories that took the calculated decision to settle here did so principally because of the many streams and rivers in the area. These waterways allowed the machinery to be operated efficiently. By 1870, there were already around 22 textile printing plants and 24 spinning mills in Glarus. Around a third of the canton’s residents earned their living in these factories.

One of those old traditional factories was established in Rüti in 1847. Like so many others at that time, it was also reliant on water power from the Linth river. The hydropower station in Rüti formed the economic backbone of the textile company based there for many decades, initially providing mechanical drive and later producing hydroelectric power. In 1936, construction began on the Cotlan power

photo credits: Cotlan AG

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Pipe elements with a unit weight of 44 tons.

Pipe elements are pushed forward with a pressing weight of 1,500 tons.

HEADRACE DRAWN IN FROM UPSTREAM An important factor in the operator’s considerations was the fact that the power plant was built before 1918, and therefore that no new permits would be necessary for an expansion within the perimeter used at the time. With this in mind, it was decided that the new version of the power plant should make better use of the hydrological potential. To this end, a previously unused 400 m long watercourse segment to the upstream power station was incorporated into the plan. However, a new permit would have to be obtained for this stretch.

“A key point in the new planning strategy is to move turbine-driven works water from the upstream facility through an underground pressure channel to a completely new under­ ground pressure pipeline. This will allow us to use the already clean water from upstream a second time”, explained the project leader for Cotlan Wasserkraft AG, Friedrich Winkler.

This approach opens up a number of further advantages: since the water has already been cleaned of sediments, the old weir systems

photo credits: Berlinger

The works water now flows underground.

with rakes, rake cleaning machines and sand traps become obsolete, which is an important cost-saving factor. It moreover removes an obstacle that previously prevented fish from migrating along the river. The transition from a headrace channel to a pressure channel also allows for a more efficient energy yield. What’s more, the recultivated area can now be used once more for farming purposes. Finally, these measures will allow for the dismantling of the existing version, the diversion channel and, lastly, even the old power house to go ahead.

ELABORATE UNDERGROUND PIPE JACKING In terms of construction, the production of the 1,150 m long underground penstock ­poses the greatest and most complicated challenge for the building contractors and the contracted companies. One part was constructed in an opencast mine, but a 640 m long section was built using an elaborate technique known as pipe jacking. The subsoil turned out to be particularly difficult as it contained a high proportion of loose rock. This meant a large wear load for the drill head of the pipe jacking machine. “An additional challenge presented itself in the form of the high permeability of the subsoil. Due to the minimal blanket under­neath the Linth, which the tunnel ­crossed below, and because of the high groundwater levels, the support pressure had to be handled very precisely. As part of the pipe jacking, a curve radius of 500 m was d­ ­ rawn, the gradient of which measures ­between 0.5% and 6%” Friedrich Winkler ­explained. In total, the tunnel driving works required around 6 weeks, during which the drill head, which was roughly 3.8 m in dia­ meter, cut through the subsoil. The construction work for the project started back in 2014 after the operators had acquired the necessary permission. The breakthrough at the end of the tunnel was celebrated in September 2016 – a vital milestone for the power plant project.

The underground drilling process required very exact planning across the board. In the end, the path of the drill passed very close by Foto: Hydro-Solar

It was no longer economically feasible to operate and was even causing disruptions in the local distribution net. It became clear that renovation or re­placement had become inevitable.

the old vaulted tailraces of two other power plants that are still operational. However ­the­re was no viable alternative to the pipe ­jacking method. By using this method, there were very few problems in designing the ­construction of the pressure pipeline. The 44 ton pipe components were each compressed with a weight of up to 1,500 tons and then joined together.

TECHNOLOGY FROM LOWER AUSTRIA While the drilling machine was working under­ ground last summer, the machine ­assembly process in the facility was already on the home straight. The company contracted to produce the machinery, the Austrian hydro power specialists Kössler, had delivered the turbine in May 2016 and then started on the assembly process. The operators had decided to acquire a Kaplan-SZ turbine with a ­h­orizontal axis from the specialists at Kössler, who enjoy an excellent reputation far beyond the DACH countries. “During the bidding phase, we were able to win over our client’s decision makers with a technically sound ­design for a modern, 6-blade Kaplan turbine.

We were awarded the contract in July 2015.

As well as supplying the turbine, assembling it and making it operational, we also provided The old Francis turbine, over 80 years old, was designed for a 320 kW capacity

photo credits: Berlinger

A view of the tunnelling machine command centre.

photo: Cotlan AG

photo credits: Berlinger

Successful breakthrough after 6 weeks of intensive drilling.

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The turbine and generator are connected to each other directly via a shaft. The shaft run rotates on a three-point bearing.

the generator, the hydraulic turbine control system, the cooling water system as well as the entire electrical apparatus, which was developed in collaboration with Schubert Elektro­anlagen” explained the project leader at Kössler, Georg Neuber.

EFFICIENT 6-BLADE TURBINE WITH CUSTOMISED TECHNICAL SOLUTIONS The particular version of solid cavitation blade wheel with 6 blades met the requirements of the operators perfectly. Using this equipment allowed the installation height to be refined and for the project to do without deep foundations. This resulted in reductions in the building costs while retaining maximum efficiency. Turbines produced by the specialists at Kössler usually have a reputation of being at the forefront of hydropower engineering.

Customised solutions could therefore be ­developed, such as the incorporation of the blade wheel adjustment cylinder in the impeller hub, which is an unusual feature in Kaplan machines in small hydropower facilities.

More­over, a 3-bearing arrangement was chosen for the project, consisting of 2 generator bearings and 1 turbine bearing. The turbine guide bearing acts as a slide bearing with clean water lubrication. Georg Neuber: “Due to this

3-bearing arrangement, fitting and aligning the shaft assembly of the turbine and generator posed a difficult challenge for the technicians. The procedure called for considerable precision and, of course, plenty of experience.

In the end, it worked very well indeed.”

The control system specialists at Schubert Elektroanlagen were given very specific requirements in one particular detail. “Due to lack of space, the headwater reservoir had to be kept very small. This requirement proved to be very demanding in terms of the control system. Fortunately, the technicians at Schubert were able to overcome this challenge with an excellent solution” reported the project ­leader at Kössler.

THE MOST EFFICIENT POWER PLANT ON THE LINTH RIVER The dual-control Kaplan turbine is connected firmly to the generator and powers it with a nominal speed of 375 rpm. The Kössler turbine is designed for a net head of 18.74 m and

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May 2017

a design flow of 15 m3/s. Under full load, the machine therefore achieves a nominal output of 2,537 kW. In comparison with the output of the old system, which could produced 320 kW, the new Cotlan power plant has almost eight times the amount of installed capacity.

As a result, the facility is now the most efficient and powerful small hydropower plant on the Linth. “In an average year, we would expect an annual production of around 12 GWh. That’s enough to supply around 2,600 homes in Glarus with clean, locally-produced electricity” said Friedrich Winkler.

The operators invested around 22.5 million Swiss francs in the new power plant, which opens a new chapter in the region’s long history of using hydroelectric power from the ­Linth river. The facility became operational in January 2017, and successfully came through its first few months of trials. With the ceremonial opening of the new power plant at the end of June 2017, it will finally also re­ceive its official inauguration.

The Kössler company’s technical conception of a Kaplan turbine with double regulation and 6-blade runner convinced the operators. Now the power plant generates around 12 GWh in an average year.

photo credits: Kössler

Technical Data • Flow Rate: 15 m3/s • Net Head: 18.74 m • Turbines: Kaplan Bulb Turbine • Axis: horizontal • Number of Blades: 6 • Manufacturer: Kössler • Output: 2,537 kW • Generator: Synchronous • Penstock: Length: 1,170 m • Diameter Ø DN3000 • Total Average Capacity: 12 GWh

photo credits: Kössler

photo credits: Cotlan AG

This whole hydroelectric apparatus was realised

by Kössler, the Austrian hydro power specialists.

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GREEN ELECTRICITY PRODUCTION IN THE STYRIAN ZIRBENLAND SPITES FROSTY CONDITIONS

T

he so-called “Zirbenland” in the area of the upper Murtal, with its varied hiking options in a natural mountain land­ scape, is a popular destination for those seeking leisurely relaxation and athletic challenges. The heavily forested region is known for its high quality products made of wood and the aromatic cones of the Zirben pine. Not least, the landscape with its many streams offers optimal conditions for hydroelectricity.

This potential was also recognised by Verena Pichler, who began examining initial concrete ideas for the construction of a diversion plant on the Lavant. “While the first construction applications were rejected in 2013, following an aquatic ecology revaluation of the Lavant carried out in the following year, the responsible authorities finally gave a green light in 2015 for the planned power plant”, says Verena Pichler.

PROVEN STYRIAN COMPANY UP AT BAT The Guster Gottfried GmbH was commissioned with the entire structural and civil ­engineering, as well as with the manufacture of the pressure pipeline. At the local inspection in mid-January with temperatures eight degrees below zero, the managing director appeared to be very satisfied with the project completed a few months ago. “Nobody is really surprised when a power plant fails to

photo credit: zek

Wolfgang (l) and Verena Pichler celebrate together with builder Gottfried Guster the effective energy production of the “Lavant” power plant realised in a visually and technically extraordinary manner in the Styrian “Zirbenland” .

operate under such icy conditions, but power production continues uninterrupted here”, builder Guster praised the power plant, which commenced operations for the first time in September.

WEIR WITH SIDE EXTRACTION The water catchment of the Lavant power plant basically consists of a classic diversion structure with side water extraction. A 4 m wide and 1.6 m high back-up flap with a ­hydraulic drive is used to dam the water. The infeed guard at the end of the fish ladder, as

well as the flushing gates and gatehouse g­ uards are also moved hydraulically. Coarse and fine screens including an automatic ­telescopic screen cleaner ensure an optimal flow prior to the start of the penstock, while a subterranean desanding basin serves to discharge the fine sediment.

CAST PIPELINE A total of 1,749 m of cast-iron pipes of the JINDAL SERTUBI brand with a clear width of DN600 were laid for the production of the pipeline. Due to the route along complex

photo credit: Guster

The newly built small hydroelectric power plant “Lavant” of Verena and Wolfgang Pichler has been generating clean energy in the Styrian “Zirbenland” for more than half a year now. The operators are completely satisfied with the plant, which was realised both technically and visually in an exemplary fashion, and can annually generate around 2 GWh of green power. A 3-nozzle Pelton turbine of the manufacturer ANDRITZ Hydro with a maximum output of around 450 kW is used as an energy supplier. In the interest of the value creation chain, the know-how of regional companies was relied upon to a great extent for the construction of the project. In addition to the aspect of effective current production, the operators attached great importance to a structural realisation of the control centre and the weir in a manner as natural as possible that was also adapted to the landscape.

Thanks to the naturally implemented basin pass, the fish can easily pass the lateral structure into the headwater.

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The penstock was designed at a length of around 1,750 m entirely with castiron pipes with a dimension of DN600. The very durable pipes were delivered by the Upper Austrian sales pro Geotrade.

photo credit: zek

photo credit: Pichler

The 3-nozzle Pelton turbine from the manufacturer ANDRITZ Hydro can achieve a bottleneck output of 449 kW with the full extraction water quantity of 450 l/s.

The machine set also remains constantly on grid even with a significantly reduced water quantity as the result of deep winter conditions.

terrain, the operators decided in ­favour of the proven robust material. The ­extremely durable pipe system, with its user-friendly socket system, stands for the best laying conditions and also convinces with its robust material properties with a long service life and pressure resistance. The high quality pipes were delivered by the Upper Austrian sales specialists Geotrade from Ried in the Riedmark.

CONSTANT ENERGY PRODUCTION IN THE DEEPEST WINTER When choosing the electromechanical equipment for its new power plant, the Pichler family decided in favour of a highly efficient 3-nozzle Pelton Turbine of the ANDRITZ Hydro brand. When the complete extraction water quantity of 450 l/s is available to the turbine equipped with electrically regulated drive nozzles at the commencement of the snow thaw in spring, this can achieve a maximum output of 449 kW with a gross drop of approx. 120 m. A synchronous generator from the manufacturer Hitzinger coupled directly with the turbine shaft serves as a current transformer. Analogously with the turbi-

ne, this turns at exactly 750 rpm and has a rated apparent power of 500 kVA. The on-­ site appointment of zek Hydro proved that the turbine also reliably generates power even with a considerably reduced flow and significant icing of the upper water layer. Despite temperatures well below the freezing point and a fraction of the extraction water quantity, the machine set was consistently on the grid with an output of nearly 80 kW. The operators anticipate energy production of around 2,000,000 kWh in an average year.

The generated current is fed entirely into the public power grid.

ELECTRICAL TECHNOLOGY FROM THE PROS Another Austrian company, the MBK Energietechnik GmbH, was also able to distinguish itself with the delivery and proper installation of the entire electrotechnical equipment to the powerhouse and weir. The scope of services of MBK also includes the commissioning of the energy distributor and the programming of the fully automated plant control system. The machine was synchronised with the grid for the first time on 29th September 2016 and has since then pro-

vided energy for the public grid. Except for a few grid disruptions in the course of the winter, there were no production interruptions – not even the dry autumn and the quite frosty winter could have a significant effect on the plant.

RESIDENTS PROFIT FROM CONSTRUCTION WORKS A highly welcome auxiliary effect for the residents of a small settlement near the power plant was the creation of the new, subterranean power route for energy diversion. “As a result of these in any case necessary construction measures, the residents received a reliable connection to the public power grid. Failure due to storms or line damage as a consequence of snow load are thus no longer a problem”, says Verena Pichler. In order to also optimally mediate the practical implementation of local green energy production on location to passing hikers, the operators want to erect an illustrative information panel explaining the function of the power plant prior to the start of the tourism season.

The project realised in an exemplary fashion deserves this attention, plant operator and builder agree.

photo credit: zek

Since its initial commissioning at the end of September 2016, the Lavant power plant has produced green energy uninterruptedly since the initial commissioning at the end of September 2016. The annual core capacity lies at a range of around 2 GWh.

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Technical Data • Flow rate: 450 l/s

• Generator: Synchronous

• Gross head: 120,05 m

• Nominal output: 500 kVA

• Turbine: 3-nozzle Pelton

• Manufacturer: Hitzinger

• Output: 449 kW

• Penstock: 1,749 m DN600, cast iron

• Runner speed: 750 rpm

• Manufacturer: JINDAL SERTUBI

• Manufacturer: ANDRITZ Hydro

• average energy capacity: ca. 2 GWh

P

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Pipe systems for water power plants GRP-Pipes DN300 - DN4000 • • • • • • •

high break resistance lightness high abrasion resistance hydraulic losses are avoided excellent chemical resistance high static load capacity are manufactured in the spinning and winding process • ONR checked

and

Cast Iron Pipes DN80 - DN2000 • high pressure resistance • easy installation • suitable for difficult installation conditions • fast and safe installation • are manufactured in the spinning process • restrained socket joint

- Partners in Austria, Switzerland and Germany -

Handelsges.m.b.H

May 2017 49 • Hochstraß 84 • 4312 Ried in der Riedmark • TEL +43 (0) 7236 31 402 • EMAIL office@geotrade.at

In only 17 months, the community of St. Leonhard in Pitztal has realised its own hydroelectric power station. The installation now generates clean electricity to supply 4,000 homes.

photo credits: photofactory.cc

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TYROLEAN TOURISM REGION GETS SERIOUS ABOUT ENERGY INDEPENDENCE Community officials in the Pitztal valley in Tyrol, Austria, put their faith in hydroelectric power. Recently, the new St. Leonhard power station was completed. In co-operation with their partners, the community in the upper Pitztal valley was able to finalise the project within 17 months. In average years, the new showcase plant will generate nearly 18 GWh of clean electricity from the region for the region. It is equipped with two cutting-edge machine sets rated at 2.4 MW each. A pleasant detail is that the 13 million Euros estimated cost was reduced by about 2 million Euros in the end.

I

t was about six years ago that people in the 1,500-strong community of St. Leonhard in Pitztal, Austria, first came up with plans for a new hydroelectric power station. At that time it was far from certain that the Pitze River actually has the conditions required for economical power plant operation. In 2011, civil engineers Eberl Ziviltechniker GmbH in Innsbruck were commissioned to conduct a feasibility study. “The hydrological situation at the Pitze obviously posed a central challenge. For its protection, a minimum flow similar to natural conditions had to be taken into account.”

Following the positive assessment of the ­study, preparations substantiated and starting in 2012, the project was pursued with some vigour. Implementation nevertheless took

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May 2017

another three years. In March, 2015, the authorities gave the project their go-ahead. A few weeks later, local politicians broke the ground for the new power station.

EUROPE’S LARGEST COANDA SYSTEM The St. Leonhard hydroelectric power station is a diversion plant. Its quality results from the finely tuned technical layout with regard to the difficult hydraulic conditions on the one hand and from the high material and design quality of its technical equipment on the other. The concept is classically simple: The works water is retrieved through a lateral intake and then led through a 3.8 km penstock to the power station located at an altitude 139 meters lower.

There, it is processed in two identical machine sets and then led back to the Pitze’s bed.

It is a matter of course that a lot of experience and knowhow went into each part of the system and that the technical finesses are in the details. The path of the works water starts at the baffle preventing coarse debris from entering the intake. After passing the coarse screen, the water is conducted across a Coanda screen that is indeed unparalleled. 20 Grizzly Optimus modules made by Wild Metal, an industry specialist from South Tyrol, were lined up to be able to collect and filter the entire nominal discharge amounting to 4,000 litres per second. This makes that ­Coanda screen the largest in all of Europe.

This is confirmed by Franco Schlegel from HTW Chur technical and economic university who has been dealing with the subject of optimising Coanda screens as part of his rese-

photo credits: ZT Eberl

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20 Grizzly Optimus modules from Wild Metal combine to form the largest Coanda screen in all of Europe. Its intake capacity is 4,000 liters per second.

Transition piece / inlet pipe with pipe break flap

arch activities. It is, however, not so much the size that matters but the system’s functionality. Coanda screens from Wild Metal are among the most well-established on the market for years. Even in difficult conditions such as sharp winter frost, they are guaranteed to effectively filter solid matter out of the water.

For the new power station in St. Leonhard, the narrowest gap width was selected, a mere 0.3 millimeters, for very good reasons. The Pitze River carries traces of glacial sediment.

The narrow gap width also prevents microorganisms effectively from being drawn in. The Wild Metal Coanda screen renders the use of a sand trap obsolete. This is fundamentally a low maintenance system. For cases requiring interventions, two specifically designed maintenance accesses have been installed.

HYDRAULIC STEELWORK DESIGN FACILITATES HARMONIOUS INTEGRATION Generally, all of the hydraulic steelwork equipment of the power station was made and installed by Wild Metal. The most striking

Hoisting the weir wicket with a view of the steel armour and the flap end piece.

feature is the weir shutter. 16 meters wide and 2.5 meters tall, it was shipped from the factory in Ratschings, South Tyrol, Italy, in two equally-sized parts and installed using a mobile crane. The steel colossus weighing 18 tons withstanding enormous forces can be opened and closed using two laterally mounted high-performance hydraulic cylinders. The weir system was designed to withstand floods with magnitudes expected to occur only once in a century.

A significant aspect in the planning of the water catchment was the attempt to harmoniously integrate the traverse structure with the scenery of the upper Pitztal valley. “We tried to stay as close to the foundation level as possible. During construction, the construction pit at the catchment was nine metres deep, ranging down to the foundation excavation.

The entire catchment structure is not protruding much at all. This is not least owed to the hydraulic steelwork equipment design. Wild Metal has been investing much energy in its continuous improvement”, says Stefan Tho-

maset. For planners and developer, the ecological approach of the concept was also central.

This is why the catchment was situated so that another stream feeding the Pitze was not integrated. It flows into the river bed immediately downstream from the catchment, enriching the natural residual water.

COMPLEX ROUTE PLANNING All in all, some 2,600 m3 concrete was used to build the water catchment, with an excavation volume of about 10,000 m3. From start to finish, construction work took more than 17 months. Naturally the most complex task was the installation of the penstock. Due to the uncommonly narrow valley bottom, several tributary streams, landslide zones, existing installations such as avalanche protection ­ structures and geologically problematic areas required profound route planning for the 3.8 kilometer penstock. The developers selected FLOWTITE DN1400 GRP pipes from ­Amiantit. They were supplied by Amiantit’s Austrian representative, Etertec.

Wild Metal GmbH • Handwerkerzone Mareit Nr. 6 I-39040 Ratschings (BZ) • Italy

Foto: Hydro-Solar

Wild Metal GmbH • Hydraulic steel constructions • Patented Coanda-system GRIZZLY • Trash rack cleaner • Gate • Security valve • Water intake rake • Complete water intake systems made of steel

Tel. +39 0472 759023 Fax +39 0472 759263

www.wild-metal.com info@wild-metal.com

We clean water May 2017

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HYDRO HYDRO Water cooled Hitzinger generator with auxiliary heating.

photo credits: photofactory.cc

Downstream view of the vertical slot fish pass.

A power cable and fiber-optic cables were installed to run parallel to the penstock. “This will put the community of St. Leonhard in the position to supply communal buildings or infrastructures with electricity if needed. For the time being, however, all of the generated electricity is fed to the public network”, says Thomaset.

TURBINE TECHNOLOGY OUT OF TYROL In view of the 3.8 kilometer length of the penstock, pressure shock resistance was an important consideration in the planning work. Geppert based in Hall, Austria, made and supplied the turbines. Consequently, they also performed these simulations calculating the control cycles required at the pipe break flap and at the inlet nozzles to absorb a 2.6 bar maximum pressure shock.

The experienced hydroelectric power generation specialists based in Hall won the contract to supply the entire electromechanical equipment of the power station. The operators had selected two identical vertical six-jet Pelton turbines to form the heart of the installation.

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The turbines have been designed for a 128 meter net head height and a nominal discharge capacity of 2 cubic meters per second each.

They rotate at 500 rpm. A strong point of the 2.4 MW turbines is that they can remain on grid even in low part load operation. Each turbine can be operated to a 69 liters per second minimum. Between them, the turbines provide a 4.34 MW bottleneck performance.

TOP GENERATOR EFFICIENCY The St. Leonhard community representatives were aware of the fact that current electricity prices caused considerable pressure on the budget. They nevertheless had no plans to compromise the equipment’s quality by cutting costs in the wrong places. As with the turbines, they shortlisted nothing but top quality when selecting the generators. They decided in favour of the tried and tested technology supplied by generator specialist Hitzinger based in Linz, Austria. Vertical synchronous generators specifically designed and dimensioned for the location’s requirements were installed. These generators are not only equipped with cutting edge water cooling but

also feature auxiliary heating facilitating a fast and problem-free system start following possible standstills during the frosty months.

Furthermore, the generators are equipped with generator brakes and high-grade sleeve bearings. “Hitzinger has taken our specific requirements into account in every detail. This resulted in practically fully customised machines that reach an efficiency factor of 97,8 percent under full load”, says Stefan Thomaset.

ROBUSTNESS A HALLMARK The synchronous generators weigh 21 tons each. Their apparent power rating is 2,700 kVA. They are part of the biggest Hitzinger generator model series. For some years now, the Upper Austrian manufacturer has expanded its three-phase machine portfolio at its upper end. Hitzinger has been supplementing its tried and tested range of smaller machine types by synchronous generators with power ratings ranging all the way to 6 MVA. Hitzinger design engineers managed to transfer the numerous quality benefits of the smaller models to the more powerful series as well. These

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generators excel not only with their high smoothness, speed stability and efficiency but are also known to be extremely robust. Hitzinger engineers say that they were able to give the generators this property because of the many things they have learned from the extreme conditions under which marine and off-shore generators are operated. They also dimension the electromagnetic aspects of the generators very conservatively so that there is still a wide margin left to prevent Hitzinger generators from overheating. What made the two generators for the St. Leonhard power station special is a test scenario the industry leader does not often encounter. “We had the opportunity to perform alternating tests with two absolutely identical machines from our big series and from the same batch on the test bed, effectively testing them against each other. This has provided us with some very interesting insights and at the same time confirmed the quality we are committed to”, says Hitzinger’s Dr. Daniel Huber. The test results also provide convincing evidence that this Austrian generator manufacturer can now also supply top-quality vertical sleeve-bearing generators. This is new.

COMPLEX WEIR WATER SYSTEM In order to comply with the quality objective ordinance on site, a comparatively high amount of weir water was required. From April to November, it amounts to 440 liters per second as a low water base. This is supplemented by requirements that need to be met precisely for weir water quantities of 26 to 55 percent of the arriving water flow as a dynamic weir water volume. The largest portion of the basic amount of the weir water is led through the fish pass. Another part is led through a DN300 doting duct at the entrance to the fish pass providing the attraction current for the fish. At the irrigation channel, water is constantly fed to the Pitze’s bed at 40

The power house at night.

liters per second. This was necessary as in this area fish can swim downstream, landing soft and without injuries in a water cushion.

17 PERCENT LOWER COSTS Following first dry tests of the turbines in July, 2016, Geppert engineers officially turned on the turbines with Pitze water three months later in mid-October. All work on the new power station was finally concluded within 17 months. The community’s representatives were particularly delighted to learn that the project’s 13 million Euros estimated costs were reduced by about 2 million Euros.

Particularly in times of rock bottom electrici-

ty prices, this proves the economic responsibility of the community. “During the first years, we do not expect the installation to generate profits. I am convinced, though, that coming generations will profit and appreciate our decision”, says St. Leonhard mayor, Elmar Haid, adding “The new power station also contributes to reducing our valley’s dependency on energy imports.” All in all, the power station is expected to generate some 17.6 GWh of clean electricity in average years. This is sufficient to at least statistically make the Pitztal winter sport and hiking region energy independent for the coming decades.

The two vertical Pelton turbines have a 2.4 MW power rating and drive a directly coupled Hitzinger synchronous generator each. These machines are dimensioned for a nominal power of 2.7 MVA.

Technical Data • • • • • • • • • • • • • • •

Flow Rate: 4 m3/s Net Head: 127.61 m Dam: Flap 18 x 2.50 m (Wild Metal) Sedimentation: Coanda Type: Grizzly Optimus (Wild Metal) Turbines: 6-nozzled Pelton Turbines (2 pc.)

Manufacturer: Geppert l Nominal Speed: 500 rpm Output: 2,426 kW each l Total Output: 4,338 kW Runner Size Ø: 960 mm l Bowl Width: 300 mm Generatores: Synchronous (2 pc.)

Manufacturer: Hitzinger l Nominal Speed: 500 Upm Overspeed: 900 Upm l Weight: 21 t Nominal Output: 2,7 MVA l Voltage: 6300/3637 V l Length: 3,860 m Penstock: l Diameter Ø DN1400 Material: GF-UP Total Average Capacity: 17.6 GWh

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photo credits: Kuenz

A new hydroelectric power station is under construction in the city of Graz. It is expected to commence operations in 2019. As in the Gössendorf plant shown in the image, all hydro-mechanical equipment will be supplied by Vorarlberg based company Kuenz.

PROVEN HYDRO-MECHANICAL EQUIPMENT TO PROVIDE SAFETY AT MUR RIVER POWER STATION As of 2019, a new hydroelectric power station on the Mur River will supply 20,000 homes in Graz, Austria, with green electricity. This new power plant will generate 82 million kilowatt-hours per year, saving up to 60,000 tons of carbon dioxide. Energy suppliers Energie Steiermark, Energie Graz and Verbund are the contracting authorities. The plant will be built in Graz. All of its hydro-mechanical equipment will be constructed by Kuenz. This manufacturer from Vorarlberg has equipped all hydroelectric stations on the Mur River for the past 25 years. The plant is expected to commence operations in mid-2019.

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here are built 25 hydroelectric power plants on the Mur River already. In early 2019 there will be added another station in Puntigam district of Styria capital Graz. It will be built upstream from Puntigam Bridge.

The projected two-year construction phase will provide employment for 1,800 workers.

90 percent of the contracts will be awarded to regional companies based within the ­state. The overall investment will be 80 million Euros. These costs will be borne by local energy supplier Energie Graz, regional energy supplier Energie Steiermark and Verbund. In February 2017 Austria‘s biggest

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national energy provider Verbund announced its participation in the project. The city of Graz is attempting to reduce its dependency from energy imports. Plans for the new power station are met by approval particularly from the regional industry.

“The Styrian Industrialist‘s Federation endorses the expansion of regional hydropower. The Graz power plant on the Mur River is an important step towards a CO2-reduced regional electricity generation, particularly for the Styrian Industry”, says Georg Knill, president of the Styrian Industrialist‘s Federation. Currently the share of renewable energies in Styria is about 30 percent.

GÖSSENDORF AND KALSDORF AS MODELS During four years, more than 50 evaluators and environmental experts, the Austrian ­federal senate on environmental affairs and the High Administrative Court evaluated all ecological aspects of the project. In spite of fierce protests from regional residents that even led to an early election of the Graz municipal council, construction work commenced in January 2017. Technical optimisation and electricity generation will be adapted to the location as nature-conforming as possible.

The power house is meant to blend in harmonically with its environment, which is why the architecture received much attention.

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As for the Gössendorf and Kalsdorf hydro­ electric power stations before, Hans Künz GmbH, a manufacturer based in the Austrian state of Vorarlberg, was awarded the contract to supply all of the hydro-mechanical equipment for the plant. The contract was performed by the company’s specialists at their Styrian branch in Groß St. Florian. Construction of the new Graz power plant generally follows the model of earlier plants in Gössendorf and Kalsdorf. For Kuenz the biggest challenge posed by the Graz plant is the limited time frame. Kuenz project manager Walter Schönecker regards streamlined installation operations as crucial for the fast and flawless implementation of the project. Due to space restrictions on site, storage is very limited so components need to be supplied to the construction site “just in time”.

As the company is already familiar with the customer’s requirements from Kalsdorf and Gössendorf, its engineers nevertheless expect a successful implementation.

KUENZ OPTIMIZES TECHNOLOGY FOR GRAZ PUNTIGAM The Kuenz scope of supply includes three radial gates with hydraulic flaps on top as well as steel lining for the spillways. These armours will be directly connected to the upstream bulkhead steel lining. Like in Gössendorf, a latest generation trash rack cleaning machine will be used in Puntigam as well. The TRCM-H1000 is a reliable high-performance product that is constantly improved. “Using feedback provided by our customers, we were able through the years to optimize the TRCM-H1000 and to align it with changing requirements”, says Schönecker. The equipment features a three-part cleaning rake with a

Installation of a radial gate at Gössendorf plant

synthetic wear strip. It removes debris floating on the water surface such as industrial waste, plastics and wood from the river. This debris is then conveyed to a concrete pit. During debris dumping uniform filling of the pit is monitored. When the maximum fill level is reached, the operators will empty the pit. The main arm of the cleaning machine can be fitted with a chain hoist used to unload the turbine intake bulkheads from the lorries and to transfer them to the trash rack cleaning machine‘s inlet.

During regular operation of the power station, there will be two alternatives of fully automatic operation of the TRCM-H1000. During regular flow conditions, the so-called cyclic operation is selected. The cleaning machine will complete a cycle once a day or once a week. The cleaning frequency can be adjusThe two-span fine screen of the Gössendorf plant. The one for the new Graz plant will be almost identical.

ted in the machine‘s settings. Using the other option, a trash rack differential pressure is calculated using the water pressure upstream and downstream of the screen. When the screen loss reaches a pre-set value, the power station’s control system will initiate an automatic cleaning cycle.

PERFECT SYNERGY OF THE THREE MUR POWER STATIONS Synergies were generated in the area of the spillway design for the Gössendorf, Kalsdorf and Graz power plants. The clear span of the spillway bays is the same for all three power stations so the new Graz plant can be operated without additional bulkhead sets. Due to the proximity of the other hydroelectric power stations, neither new bulkheads nor storage

Technical characteristics • Engineering start 04/2017 • Commissioning 06/2019 • 3 weir segments with superimpsed cap, clear span 15.50 x clear height 8.7 m incl. armour • Hydraulic drive – power unit in the power house – piping across weir bridges • 3 upstream bulkheads, clear span 15.50 x clear height 8.7 m • 3 downstream bulkheads, clear span 15.50 x clear height 18.5 m • 2 turbine inlet screens, clear span 9.3 x clear height 12.24 m • 2 turbine inlet bulkheads, clear span 9.30 x clear height 12.24 m • 2 turbine outlet bulkheads, clear span 7.38 x clear height 16.70 m • 1 latest generation TRCM-H1000 with bulkhead hoister

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places for them are required on site in Puntigam. Benefits are cost and storage room savings. Two sets of bulkheads are sufficient for all three power stations. They can easily be transported between locations when needed.

REVITALISATION AS A HABITAT AND A GREAT PLACE TO BE At an altitude of 2,050 meters, the Mur River starts at a spring in the Hohe Tauern national park in Salzburg. Parts of its course form the borders between Austria, Slovenia, Croatia and Hungary. Until the end of the 1980es, the Mur ranged among the most polluted ­rivers in Austria. This was caused by wastewaters from local pulp and paper as well as steel industries. Meanwhile, hydroelectric power stations along the Mur are contributing substantially to the river’s ecological revaluation.

The hydroelectric Mur plants generate clean electricity to help reduce electricity imports from foreign nuclear energy sources.

Plans are to revitalise the Mur River in Puntigam following completion of the construction work to offer various recreation opportunities for residents. New nature discovery trails, promenades, Cafés and beaches will be created around the new plant. Cycling trails will be extended to a width of three meters.

The proven Kuenz trash rack cleaning machine.

Various water sports activities such as rowing, paddling and canoeing are meant to make the banks of the Mur a great place to be. It is not just the leisure aspect that is in focus there.

Additionally, 99 ecological measures will be taken. Among them are a fish ladder, shallow water zones, bat boxes and dice snake habitats. These measures are intended to protect and preserve natural habitats. Around the power station, seven hectares of lawns will be

planted. For any two bushes or trees that need to be cut down to build the power station, three will be planted. As in the Gössendorf and Kalsdorf projects, preserving and improving the local environment was paid great attention. An important aspect of environment protection is that the new Mur hydroelectric power station will save up to 60,000 tons of carbon dioxide per year. This corresponds to the pollution caused by 36,000 cars.

Hydro-Mechanical Equipment Gates, Flaps, Stop Logs, Screens, Trash Rack Cleaning Systems

Hans Kuenz GmbH | 6971 Hard - Austria T +43 5574 6883 0 | sales@kuenz.com | www.kuenz.com

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photo credit: WRH

The functional principle of the Steffturbine is based on the transport technology continuously developed by WRH Walter Reist Holding AG in past decades. The areas of usage of the innovative turbines are more than broad.

STEFFTURBINE CONVINCES WITH A VARIETY OF POSSIBLE USES AND ECONOMIC EFFICIENCY Based on more than 50 years of experience in the field of conveyor technology, the Swiss WRH Walter Reist Holding AG (WRH) developed the “Steffturbine”. In the process it adapted the familiar technical principle of waterwheels to modern chain technology, which has proven itself ideally in a number of industrial applications. Thanks to the compact and easy to install turbine system, even small drops and throughflows can be used efficiently, for example, for the energetic utilisation of residual water quantities.

Economical operation of the Steffturbine results automatically through the optimal price-performance ratio and the low installation expenses. An extensive tour through the “Steffworld” took place in May of last year in the course of a product introduction at the WRH company headquarters in Hinwil. In the process, in addition to the Steffturbine, the intelligent control system “Steffmaster” and the versatile fish ladder “Steffstep” were also presented in detail.

W

RH, together with its subsidiary companies Ferag AG, Denipro AG and WRH Marketing AG, have been developing, building and selling conveyor technology systems for more than five decades. The core competence of WRH thereby exists in further print processing for newspaper and magazine printers. The conveyor systems are used in printing businesses throughout the world. The foundation of the conveyor systems is the rolling conveyance principle, with which kinetic fiction is practically eliminated. This means that even heavy

loads can be conveyed over long transport routes in a manner that is gentle on the material and at the same time requires little use of energy. The functional principle of the Steffturbine originates from precisely the transport technology that has been consistently further developed and promoted by WRH in past decades.

MANY POSSIBLE APPLICATIONS The focus of the technical concept is on a chain run guided by two turning wheels to which paddles are attached and set in moti-

on by the gravity of the water. A permanent magnet generator integrated into the compact turbine housing ensures an electrical output of 12 kW. This makes it possible to generate up to 100,000 kWh in eco-energy even with a drop as of 2 m. Two different sized turbine models with an extraction water quantity of 400 l/s or 600 l/s can be chosen from.

The potential uses of the Steffturbine are there­ by extremely versatile. They can, for example, be used for drop steps of naturally flowing waters or commercial canals. However, the Steffturbine can also be used for generating May 2017

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STEFFTURBINE USED AROUND THE WORLD One of the first Steffturbines of the WRH Walter Reist Holding AG was installed in the so-called Tannertobel, a narrows of the river Jona in the Zurich Oberland, in 2015.

Favourable natural conditions for the use of hydroelectric energy have always been provided by the drop step with sliding retention reservoirs. Since the installation of the Steffturbine in the previous year, 70,000 kWh could already be generated for the operating association “Unternehmen Dürnten – Verein zur Förderung ökologisch nachhaltiger Ziele (Dürnten company – association for the promotion of ecologically sustainable objectives”.

In keeping with the motto of the association, photo credit: WRH

photo credit: WRH

electricity from process water when installed in sewage treatment plants or when used in industry and processing operations requiring the use of large amounts of water, such as paper or food processing.

Only two cradles need to be installed on the grounds for the installation of the Steffturbine. Additional interventions into the natural conditions of a flowing body of water are unnecessary. The turbine unit is delivered in a completely assembled condition and, thanks to placement above ground, prevents any impairment of water quality. Extremely positive from an ecological perspective is the aspect that the turbine is passable for fish, which arises from the flow direction.

Developer Heinz Füglister speaks about the special features of the control system “Steffmaster.”

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Biologist Eva Baier explains the functional principle of the “Steffstep” fish ladder to the visiting media representatives.

the installation of the environmentally friendly power generator took place without significant construction measures, and the water flow at the location was not impaired. Two additional Steffturbines are used in Swiss waste water treatment plants. The turbine of the sewage treatment plant La Saunerie near Colombier uses a drop of around 4 m and generates around 45,000 kWh annually. A second Steffturbine is found at the waste water treatment plant Buholz in Emmen, whereby the treated waste water is used to generate energy before being returned back to the flowing body of water. The installation of a Steffturbine in Italy at R ­ anica in Bergamo is ongoing.

WRH company spokesman Nick Mysicka ­explicitly points out in the context of the tour through the Steffworld that the principle of the Steffturbine is best suited for use in emerging and developing nations, both for island operation and for feeding into the grid, due to the comparatively low effort involved in installation. Two years ago, the Swiss company set a good example and delivered a Steffturbine for “Susanne’s African School”, also founded by the WRH in Tanzania. The school building in this economically underdeveloped region thus has its own entirely autarkic power supply.

STEFFMASTER COORDINATES AND OPTIMISES RENEWABLE ENERGY SOURCES Steffmaster is also a development of WRH with which the efficiency of renewable forms of energy can be optimised through the use of intelligent automation technology and environmentally friendly storage solutions.

The Steffmaster as a control device enables various regulating combinations with other renewable energy sources. In addition to the photo credit: WRH

photo credit: WRH

The fish ladder with the name “Steffstep“ from WRH at the Töss Kollbrunn location in Switzerland. The fish ladder was completely installed after only 7 hours.

Live interview with a Steffturbine client representative located at a sewage treatment plant in Buholz Emmen.

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based on the well-known technical principle of “vertical slot fish ladders” and is suitable for use on smaller to medium-sized bodies of water. In contrast with most “vertical slot fish ladders” built in concrete, the individual basins of the Steffstep are made of durable plastic.

Like the Steffturbine, the system stands for easy and quick installation, as well as for short planning and construction phases. The step form thus reduces the total construction length of the drop step to be overcome considerably.

Thanks to the horizontal installation position of the individual basins, the fish ladder also requires only a small quantity of water and at the same time enables a fish-friendly, moderate flow speed.

photo credit: zek

An excursion to a Steffturbine in practical use at the “Tannertobel” of the nearby Jona body of water was also part of the presentation of “Steffworld.“

the use of hydroelectric energy with the Steffturbine, this new development from WRH also links energy management with solar, wind and biogas power. The energy management of the Steffmaster thus creates an energy and economically efficient linking of power producers, such as the Steffturbine for the use of hydroelectric energy, with batteries and energy consumers.

The control system in this way masters the combination of continuous power generation with hydroelectric energy and stochastic production through photovoltaic and wind power systems, as well as with biogas and sewage gas applications. This makes it possible, thanks to optimised regulation, to generate a maximum of energy from hydroelectric energy, to store surplus energy during production peaks, and to release this energy again as needed. If power production is inadequate due to the time of day or weather conditions, stored electricity can be drawn upon from a battery and directed

to the respective consumer. The battery used for this procedure uses a saline solution as an electro­lyte and thus consists of environmentally friendly materials. This battery can be recharged, has low investment costs and thus enables a short payback period. By using a battery system, not only the storage of current is guaranteed, bus also an autarkic power supply, whether as an island solution or as an emergency power supply in the grid network mode.

STEFFSTEP OVERCOMES DROP STEPS The also newly developed fish ladder with the name “Steffstep” from WRH is the logical supplement for the Steffturbine. With this ladder with a modular design for aquatic life forms, river verges, crossing structures, weirs or dam walls can be overcome within a very small space. The potential for usage of the Steffstep can be found in Switzerland alone at several thousand artificial obstacles on various bodies of water. The construction of the Steffstep is thereby

STEFFWORLD IS DEDICATED TO ENVIRONMENTALLY FRIENDLY TECHNOLOGY “With regard to internationally agreed upon energy and climate targets, goals involving an environmentally sustainable development of power generation systems are also always named. WRH Walter Reist Holding AG also pledges itself to these goals and concentrates in the context of Steffworld on the creation of environmentally compatible systems”, comments company spokesman Nick Mysicka at the finish of the company tour and adds: “Steffturbine, Steffmaster and Steffstep, as elements of the Steffworld, are a clear commitment to energy and economic efficiency with integral environmental compatibility. In interaction with other renewable energy sources, photovoltaic, wind power and biomass systems, the energy management achievable with Steffmaster enables optimisation of production, storage and consumption. WRH Walter Reist Holding AG is setting a pioneering benchmark for the future of energy here and enables innovative concepts for energy producers on the basis of many years of technology know-how.”

photo credit: zek

Model of the Steffturbine at the company headquarters in Hinwil.

photo credit: WRH

The Steffturbine on the Jona river in the Zurich Oberland was installed in the previous year and energy production has since then amounted to about 70,000 kWh.

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PROVEN SCREEN CLEANING SOLUTION DEVELOPED BY BAVARIAN SPECIALIST In view of growing worldwide environmental awareness and reinforced environmental laws, the protection of fish is gaining in significance as an influencing factor in the hydropower licensing process. In the EU, for example, hydropower construction work is subject to the guidelines of the European Water Framework Directive, which applies to new constructions and refurbishment projects as well as to the renewal of water rights. As a result, current technical developments are coming into focus, including “fish-friendly turbines” and modified guard grating systems that provide a barrier in the intake area to keep aquatic animals away from the turbine. Where screen cleaning is concerned, Bavarian industry specialist “Erhard Muhr GmbH” already has a string of innovative, high-quality reference projects under its belt.

MORE THAN THIRTY YEARS’ EXPERIENCE Erhard Muhr GmbH has been designing, manufacturing and installing hydraulic

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Headquartered in Brannenburg in Upper Bavaria, Erhard Muhr GmbH has several decades’ experience in manufacturing proven and innovative screen cleaning solutions for hydropower and industrial applications. The image shows Muhr’s RO-TEC drum screen system.

screen cleaners for hydropower stations since 1983. The company, which is headquartered in Brannenburg, Bavaria, delivered its first horizontally aligned screen cleaner in 1989.

“A lot of our previous experience in hydraulic vertical cleaning went into the development of our horizontal cleaners. In this ­particular design, the hydraulic controls en-

all photo credits: Muhr

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o it is no surprise, that particularly intake screens have seen a marked increase in demand for horizontal designs in recent years. This is because horizontally aligned bars are inherently more efficient than vertical designs in keeping fish away. As a result, horizontal screens are usually accepted by fish protection authorities with a wider bar spacing than vertical systems. For hydropower operators, this has the added advantage of higher flow rates and reduced cleaning expenses. „Of course, horizontal screens, like vertical ones, require proper equipment for efficient cleaning. Due to the different orientation of the cleaning motion there are distinct differences in terms of the technical ­ demands on the cleaning systems and their ­ resulting design,” explains Florian Kufner, a ­ ­trade journalist with specialist expertise in Muhr technology. It is obvious that horizontal cleaning systems have no commons with the traditional cable operated systems for vertical screens. But there are also significant differences compared to hydraulically operated vertical cleaning systems.

According to Kufner, especially the drive system and the hydraulic control require different solutions, whereas many mechanical parts are quite similar.

sure that the grab rake has an accurate, even contact pressure. This is a huge advantage in terms of operational stability,” says Kufner.

Whereas standardised machine configurations can be used in small-sized arrangements or facilities with relatively shallow cleaning depths of up to 3 m, larger-sized facilities and sites with greater cleaning

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depths require the equipment to be adjusted individually to constructional and locational conditions. Where debris filtering is concerned, there are various options. In practice, the choice depends on the answer to one central question: is it permissible to leave the floating debris in the river and simply dispose of it through a flushing gate, or are there reasons against leaving it in the watercourse?

“Muhr offers a variety of solutions, from simple arrangements with all-electric drives to large-scale systems with grab rakes and movable machines with slewing gears. Of course, Muhr also provides the ­required screens, valves and other hydro steel structures. This ensures that all components are perfectly compatible, and customers benefit from having to deal only with a single-source provider – this makes things much easier in terms of warranty and servicing, for example,” says Kufner.

HORIZONTAL SCREEN CLEANING SYSTEMS “MADE BY MUHR” Static systems are the most basic type of horizontal screen cleaners.

The name is not quite accurate, actually, as the rake does move across the entire length of the screen. But since the entire unit is firmly attached to the building, it is, by definition, a statically installed screen cleaning device. A reference product of this type, the HYDRONIC H-3500, is in use at hydropower plant Holenstein in Switzerland. As the name says, this particular machine moves horizontally to clean, at a cleaning depth of 2.3 m, a horizontal rack that measures approximately 21 m in length and 2 m in height.

CLEANING ON THE RIGHT TRACK “An alternative to static systems are movable ones. Equipped with a travel carriage, these machines move along the screen on rail tracks.

This type of system is suitable primarily for long screens and/or greater cleaning depths. In some cases, gear racks are used, depending on the forces that the system has to withstand,” says Kufner, referring to the Muhr HYDRONIC H-6500 V system at hydropower plant Raguhn in Eastern Germany as an example: “The machine there cleans a 28 m screen using a 4 1/2 m wide rack at a depth of 5 1/2 m. Considering the high flow velocity of 7 1/2 m/s, this arrangement required a really sturdy and powerful design. In this case, the screen cleaner is also fitted with a hydraulic gantry that has an orange-peel grab for removing larger-sized floating debris.”

Multi-purpose screen cleaner HYDRONIC H-9500 BDV at hydropower plant Keselstraße in the German state of Baden-Württemberg.

ber of drums in a row that can reach across even the widest of intake structures. However, as Kufner points out, there is one condition that intakes must meet to enable the use of screen drums: to ensure that Movable screen cleaner HYDRONIC H-6500 V at hydropower plant Raguhn in Eastern Germany. The machine is also equipped with a hydraulic gantry for removing large-sized floating debris.

MULTI-PURPOSE SCREEN CLEANERS Multi-purpose screen cleaners for horizontal screen cleaning are built by equipping a movable rig with slewing gears, a grab rake and controls. In addition to cleaning screens, systems of this type can also be used for grabbing the collected debris and depositing it at a designated location for disposal. A multi-purpose machine of this type, a HYDRONIC H-9500 BDV, is used at hydropower plant Keselstraße in Kempten in Baden-Württemberg, Germany. Equipped with a driver cabin, this machine is designed for the automated cleaning of a horizontal screen that measures around 23 m in length.

The grab rake has a cleaning depth of around 6 m and a cleaning width of 3.3 m.

AN INTELLIGENT ALTERNATIVE: SCREEN DRUM SYSTEMS With its RO-TEC screen drum units, Muhr offers a state-of-the-art alternative to the combination of horizontal racks and screen cleaners. A constant revolving motion generated by an integrated electric motor enables the drums to virtually ‘self-clean’, thus ensuring consistently high flow rates. Screen drums are suitable for intakes of any width. Solutions range from single-drum arrangements for small overflow or intake channels to arrangements consisting of any num-

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The RO-TEC screen drum system provides an innovative alternative to classic screen cleaning systems.

The ‘static’ horizontal screen cleaner at the Holenstein power plant in Switzerland is used for cleaning a fine-grated rack measuring around 21 m in length.

the collected debris can be properly flushed down the watercourse, the intake must run parallel – or, at the most, at a slight angle – to the direction of the water flow.

HYDRONIC M, Pakistan

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SCREEN DRUMS HAVE MANY BENEFITS The true highlights of this innovative ­guard grating system, says Kufner, are its unique ease of installation and maintenan-

CATRONIC SV, France

RO-TEC Screen Drums, Austria

ce. Each screen drum is completely pre-­ assembled at the factory. On-site installation consists merely of placing the drum onto the guide rails and connecting it to its power supply. The guide rails are the same as the ones that are used for stop logs. This provides the system’s second big advantage: Individual drum modules can be removed for inspection purposes and replaced by stop logs that can be placed on the guide rails. “This way, the removed modules can be inspected, cleaned and maintained properly on dry land. Normally this is necessary only in individual cases, as the drum units are designed to be maintenance-free and wear-resistant,” explains Kufner.“ As far as fish protection is concerned, the screen drums are considered to be the current benchmark. The specific flow conditions around the drums have a naturally ‘repellent’ effect on aquatic animals. Even in case a fish happens to be bold enough to approach the drum screens, there is no real danger, as the drums revolve very slowly, and there are no sharp edges or other harmful elements on the system.” Last but not least, the innovative technology is also easy on the eye, as the installed drums are almost invisible.

HYDROCON Roller Gate, Portugal

photo credits: TRM

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The ductile cast-iron pipe line from TRM was laid over a length of 600 m in immediate proximity with Lake Reschen.

LAKE RESCHEN POWER PLANT TRUSTS IN DUCTILE CAST-IRON PIPE SYSTEM

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nown as the topmost level for the run-of-river power plant Kastelbach, the hydroelectric power plant Guido Donegani is one of two power plants that are fed by the 116 million m³ Lake Reschen.

The sophisticated waterway system of the so-called “Reschen lakes concession” extends from the tributary valleys of the Vinsch­gau through Lake Reschen down to Schluders. The Etsch, with its inflow streams Arundabach, Meltzbach, Marienbergbach, Zerzerbach, Punibach and Saldurbach, plays a central role for the Lake Reschen reservoir. A considerable expanded flow rate of up to 22 m³/s is achieved for power plant operations. The works water falls from a ­waterfall drop of 586.2 m onto 2 horizontal twinned Pelton wheels. The power plant produces 248.74 GWh in an average standard year.

photo credits: TRM

The old hydroelectric power plant Guido Donegani in Glurns near the Reschen Pass is even today considered a technical ­masterpiece in power plant construction. Especially impressive is the extensive system of pressure lines and pressure tunnels, ­through which nearly every water resource of the region is directed into Lake Reschen. This power plant system has thus been drawing water from a total of seven bodies of water from both sides of the valley since its commissioning in 1949. For the ­power plant operator Hydros GmbH, the time had now come to renew a section of this feed water system and to trust completely in the know-how of the Tiroler Rohre GmbH in the process.

The ductile cast-iron pipe from TRM is exceptionally well-suited for this difficult terrain.

LAYING PIPES IN THE TUNNEL Following a pipe break on the right shore below Lake Reschen, the renovation of the old sheathed concrete line was already commenced with in 2015 and was renewed piece by piece. As with the first section previously, the operating company Hydros GmbH this year once again decided in f avour of ductile cast-iron pipes from Tiroler Rohre GmbH,

which are exceptionally well-suited for the rocky terrain thanks to their high compressive and fracture strength. Another advantage is provided by the BLS®/ VRS® T-connection, which guarantees rapid laying of pipe regard­ less of the weather. “Winter comes very early at 1,500 metres above sea level and the snow remains on the ground for a long time.

Every­thing has to happen fast”, says Christoph Obkircher, sales manager at TRM for Italy. This year around 600 metres of pressure lines were replaced. In the process, the situation for the routing through rocky ­ ground resembles that of the previous year.

However, the special feature here is the 180 metre long tunnel through which the old concrete pipe was also laid. “The difficulty was in the fact that the new pipe, in contrast with the old concrete pipe, was twice as heavy”, says Obkircher. This presented a real May 2017

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photo credits:: TRM

One steel cradle each is fastened to this vehicle.

And is pushed into the tunnel together with the pipe.

The vehicle for pipe installation designed specifically for this purpose.

challenge for the laying team. The local construction company had previously refurbished the tunnels for the most part, poured a concrete floor in the approximately 1.75 m high and approximately 1.75 m wide tunnel and then sealed its top side. This created the prerequisites for installing the pipe. Nonetheless, the handling of the 2,500 kg ­pipes proved to be difficult.

The pipes were laid on galvanised steel cradles in the tunnel itself. “A special vehicle was built for laying in the tunnel in order to lay pipe by pipe together with the steel cradles. The spatial conditions in the tunnel were just adequate for allowing one person each to the left and the right of the pipe to find space to connect the cast-iron pipes with the TRM plug-in sleeve system. “If the tunnel were any smaller, we would have had to dimension the pressure line differently”, Obkircher adds.

THE CONNECTION The quick and problem-free laying of the pipe is also made possible by the socket joint restrained against longitudinal forces. Whereby a weld bead at the narrow end of the cast-iron pipe ensures the mechanical shear and tensile strength and the interior of the coupling is designed according to the principle of the 2-chamber system. The TYTON® seal is inserted into the first chamber. Lubricant is then applied to the seal and the narrow end and the cast-iron pipes are pushed together with a 1.5t chain tackle block. The 14 locking seg-

ments planned for the DN1000 are then deployed. These are inserted by way of a so-called “window” and pushed around the entire coupling. It is also possible to loosen this connection at any time. This simple but clever socket joint can in any case withstand pressure of 16 bar and tolerates a maximum permitted tensile strength of 1,560 kN. This is appropriate for the area around Lake Reschen with a maximum operating pressure of 10 bar. When the narrow end and the pipe are properly connected, the line is still bendable to 1.5° even at DN1000, which offers considerable room to manoeuvre. Thanks to the sophisticated socket system, the exertion of force when pushing together is still many times less than with other manufacturers, even with large pipe diameters. Time-consuming follow-up work, such as welding, weld bead checks or the retroactive application of a surface treatment are also unnecessary. The trench can thus be closed again immediately after the laying of the pipe.

THE INSTALLATION OF THE PIPES The ductile cast-iron pipe from TRM, as the name suggests, is malleable. The malleability prevents the formation of cracks. Precisely this fulfils the difficult requirements in the steep Alpine terrain with its rocky substrate. “A shear and tensile strength-proof connection is thus imperative for this reason”, says Obkircher. The pipe itself is made of spheroidal iron, with a ferritic basic matrix, and is manufactured in a

The cast-iron pipe on the way to the installation site.

Technical data • Manufacturer: Tiroler Gussrohre GmbH, Hall in Tyrol, Austria • Ductile cast-iron pipe for turbine lines • Pressure line: DN1000 • BLS® connection with socket joint restrained against longitudinal forces • Multiple coatings on both sides

photo credits:: TRM

• Locking segments: 14

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• Bendable to 1.5° • Maximum operating pressure: 16 bar (higher pressures upon request) • Max. permitted tensile load: 1,560 kN

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photo credits: zek

Once they are slidden over the entire sleeve by way of the so-called “window” in the outermost ring, the 14 locking elements are distributed along the entire circumference.

centrifugal process. Inside it is coated with grouting and a cement mortar sheath out­ side ensures the retention of mechanical properties. “The grain size of the bedding material can thus be very high, whereby it can in some cases even be dispensed with, which saves time and effort throughout the entire construction phase”, according to Obkircher. An experienced team manages about 8 pipes per day, which is around 48 metres. A total of 4 different bends can be chosen from, whereby the repertoire of TRM includes a complete series of piping fittings and components, suitable for any application.

COMPLETION IN SPRING 2017 The second section was now completed in the context of refurbishment for the connection of the Etsch with the tributaries Arundabach, Meltzbach, Marienbach and Zerzerbach. The second of three stages was thus realised. “The tunnel required many measures that made more rapid work progress impossible. The last section will be tackled in spring”, says Obkircher. After passing through the tunnel, the TRM cast-iron pipe ends in the old pump house above Lake Haider at 1,450 m above sea level. It is waiting to be connected in spring to the

Etsch, which is very rich in water resources.

In order that Lake Reschen can once again be supplied with valuable water, like in the past 58 years.

ductile irone piping systems for

hydroelectric turbines

ductile iron technologies www.trm.at

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photo credits: zek

Amiantit presented its Flowtite Grey, a new high impact GRP pressure pipe, at the IFAT 2016 in Munich.

FLOWTITE GREY - NEW EXTRA STRONG GRP PIPE SERIES The exhibitors at last year’s IFAT in Munich, the world’s leading trade fair for environmental technologies, once again presented the most innovative products in their portfolios. The pipe manufacturer Amiantit was no exception here, introducing its new pipe – the “Flowtite Grey” - from the Flowtite range. Light as plastic and strong as steel, the new pipe type is intended for use in particularly demanding terrain but without compromising on transport and installation comfort.

ADDITIONAL SAFETY To ensure that a power plant is as economi­ cal as possible, operators nowadays expect their pipes to have a particularly long life.

However, the operating parameters may alter over several decades so that pipe manufactu­ rers are required to warrant that their pipes can also withstand unforeseeable events.

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Standard pipes from Flowtite have a high ­safety factor so that they are usually able to withstand changes in pressure and the level of strain.

At last year’s IFAT in Munich, Amiantit ­presented a new Flowtite pipe – the Flowtite Grey – for particularly demanding terrain.

Grey is the result of a multiyear development programme in the areas of material, layer structure and production technology. The aim was to achieve even better pipe properties.

photo credits: Amiantit

G

RP pipes have many advantages and are therefore frequently the preferred solution for the creation of hydro­ power pressure pipe lines. In addition to the low-cost installation, Flowtite pipes are also very durable thanks to their high corrosion resistance and excellent flow properties.

Coarser backfill material can be used thanks to the higher impact resistance.

10 TIMES HIGHER IMPACT RESISTANCE Premature pipe defects are usually attributa­ ble to faults when installing the pipes or un­ expected strain. Flowtite Grey now offers a

photo credits: Amiantit

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of having to bring a plant to a standstill for inspections and therefore permits longer ope­ rating periods, something which is also reflec­ ted in a longer life of the pipe line.

WATER JETTING RESISTANCE Water jet cleaning is a method which is usual for sewers throughout the world. However, it is increasingly used for pressure pipe lines to guarantee optimum conditions of use. High cleaning pressures are used here and the pipes must be able to withstand these extreme clea­ ning conditions. Flowtite Grey is a highly ­resistant pipe in this respect.

AVAILABLE FROM DN 300 AND UP TO PN32 The Flowtite Grey product range comprises pipes with a diameter from 300 mm to 4000 mm, pressure resistance of up to 32 bars and any stiffness upwards of SN 2500. Flowtite Grey permits a backfill particle size of up to 100 mm with diameters greater than DN1100.

FLOWTITE COUPLINGS Flowtite Grey is designed for use with the stan­ dard range of Flowtite couplings and fittings.

This also applies to the laminates. Pipe cou­ plings are also produced and supplied in accor­ dance with the requirements for normal Flow­ tite pipe lines. Tried and tested pressure couplings are used for hydropower applica­ tions. Flowtite couplings for increased angular deflections permit an angle of up to 3 degrees.

photo credits: Amiantit

solution precisely for these two factors. The impact resistance of the pipes in this range is ten times higher compared with the standard pipes in the Flowtite range. Flowtite Grey has

Flowtite Grey is also suitable for high pressure water jet cleaning.

a new wall structure that makes the pipe less sensitive to, and more tolerant of, cracking due to higher impact. They are therefore ideally protected against transport and installation ­damage. More excavated material or coarser bedding material can also be used as backfill.

This saves money because finer backfill materi­ al is more expensive and more difficult to pro­ cure – also because it does not naturally occur on site. Flowtite Grey now permits particle ­sizes of up to 100 mm to be used as backfill material for the largest pipes. The higher impact resistance has been tested and con­ ­ firmed in an impact test.

HIGHER ABRASION RESISTANCE The abrasion resistance has also been increased considerably compared with the standard ­pipes in the Flowtite range and is 60 % - 100 % above the normal value. Abrasion resistance is important in all pipe installations in which wa­ ter carries sand, silt and gravel at high speed.

These particles in the water can cause abrasion and wear and endanger operational reliability in serious cases. They may also often make fre­ quent renewal measures necessary. The higher abrasion resistance also reduces the frequency

Amiantit Germany GmbH Am Fuchsloch 19 D-04720 Döbeln Germany Email: info@amiantit.eu/ www.amiantit.eu/de photo credits: Amiantit

Flowtite Grey is also simple to install and transport. Tried and tested Flowtite couplings can be used as usual.

Strong as steel and light as plastic – this was the message for the Amiantit Flowtite Grey presented at last year’s IFAT.

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Images: DIVE

FISH-FRIENDLY DESIGN OF POWER PLANTS

Example of a fish ladder in a hydro power plant in Germany with a DIVE-Turbine.

T

he DIVE-Turbine is a double regulated propeller turbine for capacities of 50kW – 2 000kW. The development and manufacturing of the DIVE Turbine are located in Amorbach, a small town in the North of Bavaria about one hour from Frankfurt (Main).

The DIVE-Turbine is regulated by the guide vanes and the runner speed, which is adapted for high efficiencies at any operation point.

The runner blades are fixed to the runner hub. Hydraulically, the ­adaption of the runner speed of the DIVE-Turbine has the same effect as the adaption of angle of the runner blades for a standard ­Kaplan-Turbine with fixed runner speed: the blades of a Kaplan-­ Turbine are closing when the flow is reduced. At a DIVE-Turbine, the runner speed is lowered. Due to the fixed runner blades of the ­DIVE-Turbine there is no gap between the runner blades and the runner hub. The gap between the runner blades and the outer vessel is very tiny, because the blades don’t need space to be turned. Moreover, the fixed connection between runner blades and runner hub doesn’t require an inside mechanism of the hub to move the blades. Therefore the number of runner blades of a DIVE-Turbine is not restrained by mechanics of joint.

Inclined fish friendly rake with openings for downstream migration.

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Worldwide, ecological aspects are an issue of growing attention in the ­authorization process of hydro power plants. In the area of the power plants downstream migrating fish need to find a safe way of passing the turbine chamber. Fish-friendly rake and bypass systems are the main component to guide the fish around the turbine chamber. Moreover, fish friendly turbines also enable a safe passage of the turbine itself for fish that can pass through the fine rake. By combining a fish friendly rake system with a fish friendly turbine an overall ecological power plant can be realized.

DIVE Turbinen GmbH & Co. KG has developed the DIVE-Turbine, a turbine that is highly efficient in terms of power generation and in the same time a very fish friendly system. The first emprirical studies on the DIVETurbine have been realized in 2016.

FISH FRIENDLINESS ON HYDRO POWER TURBINES The subject of fish friendly turbines is to minimize the risk to get stuck in gaps, the collision probability and collision velocity for a fish that would eventually pass the fine rake and make it to the turbine chamber. In most cases diadromous fish species like eel and salmon smolt are subject to fish friendliness examinations, as they are facing many hydro power plants on their way downstream to the sea. Empirical studies about the effect of Kaplan-Turbines on salmon smolts and eels have been carried out ever since the invention of Kaplan-­ Turbines. Based on these experiments, guidelines and calculation ­methods were developed to estimate the turbine mortality. In many aspects, the guidelines for fish friendly turbines are met by the ­DIVE-Turbine: > runner blades remain constantly open: low collision risk, low collision speed. > no gap between runner blades and runner hub: no risk to get stuck. > very small gap between runner hub and runner blades: no risk to get stuck. > reduced speed due to large-scale dimensioning of the turbine.

Experimental setting of empirical studies about the fish friendliness of the DIVE-Turbine in France, 2016.

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INCLINED VERTICAL RAKE WITH GUIDANCE AND DOWNSTREAM MIGRATION SYSTEM.

weir DIVE-Turbine trench for flushing and downstream migration openings for downstream migration incline flat-angle fine rake inclination < 45° for protection and guidance to the migration openings

EMPIRICAL RESEARCH ON THE DIVE-TURBINE DIVE Turbinen GmbH & Co. KG has started empirical studies on turbine mortality in 2016. The first tests took place at a DIVE-hydropower plant near Toulouse, southern France, at the river Ariége. Rainbow trouts in the size of salmon smolt (TL=18cm…25cm) were introduced directly into a turbine and recaught and examined behind the draft tube. The turbine had a runner diameter of 1,600 mm and 5 runner blades. The mortality rates after 48h were 15% at full load (Q=11m³/s), 2% at 80% part load and 1% at 60% part load. The size of trouts tested corresponds to a fine rake with max. 25mm rake bar distance. If the efficiency of the rake system itself is considered 75%, the overall mortality rate of the power plant (fish-friendly rake-and-bypasssystem & DIVE-Turbine) can be considered max. 1,5%. This mortality rate can still be lowered by reduction of number of runner blades (3 instead of 5 to reduce collision probability).

It is also possible to reduce the runner speed and therefore the collision risk for fish by amplifying the runner diameter. opening at the surface for downstream migration

DIVE-Turbine

EFFICIENT RAKE SYSTEMS Still, the design of the fine rake is the most important criterion for a fish friendly power plant, as the rake is both a physical and a hydraulic barrier for any downstream migrating animal. A fish friendly designed rake hydraulically guides the fish towards a bypass or any other safe downstream passage without the need of being also a physical barrier. Vertically very inclined rakes or horizontal rake-and-bypass-systems (EBEL, GLUCH & KEHL) are of very high efficiency considering safe downstream migration.

Moreover and most important, those rake systems also minimize the rake-induced hydraulic losses and operation cost compared to conventional inclined rakes.

In cooperation with fish biologists all over the world DIVE Turbinen GmbH & Co. KG has developed the turbine technology to realize fish friendly power plants in accordance with local demands. In the same time the DIVE-Turbine has proven to be an economic turbine solution of high efficiency.

One of the most fish friendly hydro power plants in Europe is currently under construction in Germany. It has a horizontal rakeand-bypass-system, a fish ladder and three flap gate for flushing with openings for downstream migration

DIVE-Turbines with 3 runner blades each.

The combination of the downstream and upstream migrating system and the DIVE-­ Turbine will set an example in terms of ecological hydro power worldwide. The power plant will be set into operation in 2017.

bypass channel for downstream migration

DIVE-Turbine during installation.

weir

DIVE-Turbine

horizontal fine rake for protection and guidance to the migration openings opening at the ground for downstream migration

guidance wall at the bottom of the rake for tracking the migration openings

HORIZONTAL RAKE (HORIZONTAL BARS) WITH GUIDANCE AND DOWNSTREAM MIGRATION SYSTEM.

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photo credits: AUMA

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AUMA actuators control the process water lake level at the northern Swedish Kiruna iron ore mine.

EXTREME SERVICE NORTH OF THE ARCTIC CIRCLE Swedish mining company LKAB relies on AUMA electric actuators to secure the outlet of a process water lake at its mine in Kiruna. The LKAB mine is the world’s largest underground iron ore mine and has an annual production capacity of more than 26 million tons of iron ore. The mine and the town of Kiruna are located at the northern edge of Sweden, some 140 km north of the Arctic Circle, where the sun does not rise above the horizon for two months in winter and w ­ here temperatures go down to – 40°C.

A

UMA supplied two of its latest-generation multi-turn actuators to automate two gates located at the outlet of a reservoir dam. The existing actuators on the gates were replaced with the sturdier and higher-performing SA 14.6 actuators with AC actuator controls to ensure sufficient torque to operate the gates safely when the water level is high. The heavy gates are 1300 mm wide and have a travel of 1760 mm. To open and close them, the actuators are equipped with rising stems more than 2 m long.

SAFE GATE OPERATION Jan Strandberg, who has more than 20 years’ experience as a service engineer for AUMA actuators, travelled all the way up to the northern tip of Sweden to install and commission the actuators. “The dam is located

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in absolute wilderness – my car twice got stuck in the snow on the way to the client’s site,” Strandberg says. “But the customer is very happy now that the gates can be operated safely, especially in spring when the ­water level in the lake rises with the snow melt. The customer also appreciates the AC diagnostics capabilities, as the applied torques can now be easily monitored to ­ ­ensure the gates and actuators do not get ­damaged by excessive torque.”

THE EXTRA MILE AUMA’s worldwide service network literally goes the extra mile to support customers even at the most remote locations. AUMA actuators are designed to withstand the harsh­est environmental conditions. They are available in extreme temperature versions, for example down to –60°C or up to +120°C.

AUMA SA 14.6 multi-turn actuators with AC integral controls provide the torque required to operate the heavy gates at the lake outlet.

AUMA Riester GmbH & Co. KG Aumastr. 1 79379 Müllheim Germany Tel +49 7631 809-0 info@auma.com/ www.auma.com

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AUSTRIAN STEELWORK SECURES NEW FLOOD CONTROL SYSTEM IN OMAN

F

loods and inundation are probably not the first thing people associate with the sultanate of Oman on the eastern side of the Arabian Peninsula. The country is actually located in a semi-arid region, which means protracted stretches of dry weather are periodically punctuated by phases in which more rain falls than evaporates. With this in mind, it is understandable that water is a precious commodity in a country like Oman. Hence, over the past decades the government has invested heavily in the construction of reservoirs and dams to allow rainwater to be direc-

The new Fulaij dam now protects the city of Sur in the eastern region of the sultanate of Oman from flooding.

photo credits: BRAUN

To ensure Sur in the sultanate of Oman can rely on better flood protection in the future, over the past few months one of the largest valley dams in the country – the Fulaij Dam – has been constructed just outside the city. From the beginning of 2014 STRABAG International GmbH implemented ­ this immense project on the Arabian Peninsula. The company brought in another renowned Austrian business, Braun Maschinenfabrik, as experts in the provision of hydrotechnical steel structures. Braun supplied the components for the dam required to control the run-off of stored water after flooding. The Fulaij Dam went into operation officially mid-April this year.

ted to – and stored in – dry valley ‘wadis’. In parallel, valley-mouth dams have been built to protect the cities from repeated flooding.

The main causes of such inundation are offshoot storms of monsoon rain that cross the Indian Ocean and meet the coastal mountains in Oman, where they cause voluminous precipitation and, consequently and not uncommonly, extreme flooding. In 2007 in particular, Oman was hit by devastating flooding caused by the arrival of cyclone ‘Gonu’ on land. Meteorologists ranked it as a onceevery-500-years flood. Not only did it cause

photo credits: BRAUN

The mammoth concrete construction is 230 m long and was built to facilitate a controlled release of water.

millions of dollars of damage, it also claimed several lives. This natural disaster, and cyclone ‘Phet’, which hit Oman in 2010, convinced the officials to invest even more mindpower, manpower, material and money in the realisation of flood protection projects.

COMPLEX PROTECTION SYSTEM The 70,000-inhabitant city of Sur, not far from the easternmost point of the sultanate, was severely affected by ‘Gonu’ in 2007. Back then, large areas of the city were completely inundated. Based on a viability study conducted in 2009 and 2010, the plan to build the new Fulaij dam in the location of a former ground water supplementation dam was developed to avoid suffering devastation on a similar scale in the future. According to details provided by Dr. Reinhard Schmid (Ing.) of STRABAG International, the concept foresaw a system of four (and later just three) upstream dams and the widening and strengthening of the riverbed in the city. This should lead to the volume of water flowing through the city being reduced from 1800 m³/s to around 800-900 m³/s – that is, by roughly a half. The Fulaij Dam is to be the largest and most powerful defence for the city of Sur, serving a catchment area of 684 km². Before the remaining dams are completed it will be able to protect the city from a once-in-200-years flood. Subsequently, the system should be able to deal with the scale of flooding that occurs once in 500 years. The solution was a 1.2 May 2017

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photos: BRAUN

It was above all the extreme temperatures that posed the greatest challenge for the Braun Maschinenfabrik construction team while installing the steel dam infrastructure.

photo credits: BRAUN

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CONCRETE STRUCTURE WITH STEEL GATES According to Dr. Reinhard Schmid (Ing.) the main structure consists of a 23 m high earthfill dam sealed with an inner tarmac core, a milled concrete diaphragm wall and water-side embankment reinforcements made of hydrotechnical armour stones. The earth-fill dam can be flooded via the concrete crown and the linked-up underwater gabion steps along around 700 m. It is estimated this infrastructure could even withstand the kind of flooding that occurs once every 10,000 years without being damaged.

The concrete structure is 230 m wide and was built on the left-hand side of the valley, where all the necessary plant control components can be found. The main part of the system is considered to be the stepped concrete floodwater discharge solution with a run-off section 140m across and designed to deal with a maximum flow volume of 3900 m³/s. The release gate structure has a key function. It is fitted with 4 hydraulically driven, wheel-mounted steel doors that are 4.6 m wide and 3.6 m high, as well as a dam base water discharge system with a further two

Technical Data • Catchment area: 684 km2

smaller slide-in protection units serving as shut-off valves. These components were ­manufactured in the Austria town of Vöckla­ bruck at the Braun Maschinenfabrik. They produced the entire hydrotechnical steelwork needed for the Fulaij Dam, the steel shut-off gates, above-the-surface and underwater protective plating, and all the hydraulics and controls. This was an exciting and challenging project for the Upper Austrian experts in steel building for dams, whose solid gates and tried and trusted steel hydrotechnical structures are in demand far beyond the ­Austrian borders. These Austrian steel builders have developed their reputation on their spirit of innovation and the provision of ­unsurpassed quality.

COMPONENTS FROM UPPER AUSTRIA Before components were installed on site they were sent to Artelia Consultants’ hydraulic test lab in Grenoble for physical testing to ­guarantee their functionality required for the solution planned. STRABAG’s plan proved to be both functional and efficient. Overall technical supervision of the project on site was the responsibility of Artelia Consultants.

“Artelia technicians also visited our factory

and took the opportunity to see the manufacturing process at close quarters. Braun Maschinenfabrik is now recognised by Artelia as a certified manufacturer”, Braun’s Head of Sales Thomas Oberanzmair said. As an experienced industry insider he is completely familiar with every challenge the contract poses, having been involved in the project from the very first discussions in 2013 to the moment the system commenced operation. Initially he made two advance trips to Oman to clarify technical and financial details. At the end of 2015, STRABAG Oman L.L.C. awarded the contract for the provision of dam steelwork to the Braun Maschinenfabrik.

“The components were built in our works in the spring and summer of last year, then transported to Oman on a freight ship. Our assembly team began work on the protective plating and reinforcements last autumn. Subsequently, the dam gates were delivered this February and installed over the period up to the end of March. The plant went online on the 11th April this year”, stated Thomas Oberanzmair. The assembly team showed its vast experience as installation work ran smoothly and was completed on schedule, despite the extremely hot and humid conditions. photo credits: BRAUN

km long earth-fill dam and a 230 m concrete structure for controlled water release. The mammoth project was awarded to STRABAG International GmbH and was implemented by their subsidiary in Oman.

• Dam Length: 1.2 km • Type: Earth-fill dam sealed with an inner tarmac core • Length of Concrete structure: 230 m • Hight of the main structure: 23 m • Construction: STRABAG Oman L.L.C. • Hydromechanical Equipment: Braun Maschinenfabrik • w heel-mounted gates: 4 pc 3600 x 4600 mm

(18 m water load) • Sliding Gates: 2 pc 1000 x 1500 mm (21 m water load) • Sliding Gates: 2 pc 1000 x 1000 mm (20 m water load) • Technical Superintendence: Artelia (Grenoble) • Commissioning: 2017-04-11

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The official representative of the ministry of regional municipalities and water resources is very pleased with progress on site.

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photo credits: BRAUN

It is vital for the sealing doors and regulating infrastructure to be 100% functional, even if they are idle for long periods of time. Special technical solutions were installed to this end.

CHALLENGE TO BE 100% READY-FOR-ACTION Guaranteeing 100% technical and operational availability for the hydro-plant steel structures made the task even more challenging – mostly due to the extreme weather conditions.

Temperatures around the city of Sur can vary between -10 and +60 degrees Celsius.

Sandstorms are a common hazard and the air is very salty, since Sur is located at the edge of the Gulf of Oman. Thomas Oberanzmair stated: “It’s important to realise that sometimes it doesn’t rain for three years, but when the rain does come the entire set-up must be in complete working order. Alternatively, it may be that the water gates need to be operated in short intervals.” For these reasons the components had to be specially designed and equip-

ped for the task. The wheel-mounted gates were fitted with a special irrigation system to ensure the sealings were dampened before being put into operation. The high temperatures outdoors necessitated the implementation of a special hydraulic oil cooling unit. The head of sales at Braun Maschinenfabrik also explained: “Ease of maintenance was another key goal for those responsible for the project, so a special maintenance room was integrated into the infrastructure.”

A MILESTONE FOR SUR STRABAG Oman L.L.C. worked on the implementation of this mammoth project from the beginning of 2014. According to Dr. Reinhard Schmid. (Ing.), the project required

Innovations for waterpower all over the world.

excellent communication and a large degree of flexibility in terms of construction work, particularly with a view to the risk of flooding during the building phase, but also due to the proximity of the building operation to existing buildings, machinery and local public infrastructure. The entire volume of excavation for the 1.2 km valley dam encompassed around 1.2 million m³ of loose earth and 300,000 m³ of rock. In total the project used up 180,000 m³ of concrete and 7,000 metric tons of steel. In order to broaden the riverbed in was necessary to excavate around 3 million m³ of loose earth and install gabion mattresses to secure the channel banks along 2.3 km ­through the heart of the city. The new Fulaij Dam and, most importantly, the 6 km of ­riverbed expansion through the city, required precisely detailed planning, immense flexibility and sophisticated, well-coordinated publicity.

The concrete required for the construction of the dam was produced in a concrete mixing plant situated just 300m from the site. “The coarse-grain concrete produced by the plant wasn’t easy to pump to the site, so it was mostly lifted to the sections in which concrete was needed using mobile cranes and large-­ scale concrete vessels. Because of the high daytime temperatures, it was necessary to pour the concrete into moulding structures at night”, explained Dr. Reinhard Schmid.

When the Fulaij Dam went online this April it was a moment of great significance for the city of Sur, which is now far better protected from the consequences of violent floods. The city’s inhabitants no longer need to be fearful of what could happen when torrential rain comes. From now on, cyclones of the category of Gonu will pose a far lesser threat than was previously the case.

Trash Rack Cleaning Systems Hydro Mechanical Equipment BRAUN Maschinenfabrik Ges.m.b.H. Gmundner Str. 76 4840 Vöcklabruck / AUSTRIA E-Mail:office@braun.at

www.braun.at

MASCHINENFABRIK

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The Instant Powerplant

smarT Proven technology combined with the compact construction guarantee a quick processing and short delivery times. The already in our workshop prefabricated and premounted Hydro Powerplant allows for an extremly simple mounting and commissioning at site.

Global Hydro Energy GmbH | www.global-hydro.eu 4085 Niederranna | +43 7285 514 10 | info@global-hydro.eu

Surprisingly sustainable.

GRP pipework systems for hydropower facilities Flowtite pipes are manufactured from glass-fibre reinforced polyester resin (or GRP for short). GRP has very low weight but is extremely durable and remarkably flexible.

Efficiency, quality and service life make them a convincing proposition. They complement traditional materials such as steel and cast iron for the construction of pressure pipelines.

Some key benefits of pipework systems made from GPR: • Variable diameter, from DN 100 to DN 4000 • High pressure resistance, up to 32 bar • Flexible length (standard lengths are 3, 6 and 12 m)

Germany / South East Europe / Benelux:

Amiantit Germany GmbH info-de@amiantit.eu www.amiantit.eu Austria:

ETERTEC GmbH & Co.KG office@etertec.at www.etertec.at Switzerland:

APR (Schweiz) AG info@apr-schweiz.ch www.apr-schweiz.ch Amiantit Germany GmbH · Am Fuchsloch 19 · 04720 Döbeln · Tel.: + 49 34 31 71 82 - 0 · info-de@amiantit.eu · www.amiantit.eu · Member of the AMIANTIT Group

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 sustainable way.

Troyer SpA info@troyer.it Tel. +39 0472 765 195