zek HYDRO 2019 by zek Magazin

Verlagspostamt: 4820 Bad Ischl · P.b.b. „03Z035382 M“ – 17. Jahrgang

zek HYDRO 2019

2019 INTERNATIONAL HYDRO

FUTURE TECHNOLOGY

HYDRO HYDRO

YOUR GLOBAL PARTNE R FOR HYDRO SOLUTIONS

customer’s needs and requirements. Utility companies from all over the world value our know-how and commitment, and trust in the safety and reliability of our tailor-made energy generation solutions.

Successful Premiere for Hydro Power Containers in Iran How Power Plant Infrastructure can disappear inside a Mountain New Hydro Power Plant ensures Regional Grid Security in Honduras Upper Austrian Turbine Company extends its leading Role in Indonesia

“FROM WATER-TO-WIRE“

HYDROPOWER GENERATION ANDRITZ Hydro is a global leader of electro-mechanical equipment and services (“from water-to-wire”) for hydropower plants. With over 175 years of experience and more than 31,600 turbines installed, we are constantly striving to create up-to-date technological innovations to meet our

Two New Hydro Power Plants for Transcaucasia

for new, turnkey hydropower plants of all sizes to the refurbishing and overhaul of existing installations to comprehensive automation solutions. ANDRITZ Hydro - your global partner for hydropower generation.

Our comprehensive product and service portfolio ranges from equipment

Svaneti Hydro

ANDRITZ HYDRO GmbH ⁄ www.andritz.com/hydro

Ad_Image_AH_216x297_en_0001.indd 1

Umschlag zek International 2019.indd 1

www.zek.at

27.03.2019 09:03:33

14.05.2019 14:44:23

Surprisingly sustainable.

We need more sustainable power in the renewables mix Amiblu hydropower pipe systems Complete solution for maximum output • Excellent hydraulic flow • High surge pressure allowance • Resistance against corrosion, abrasion and UV light • Light weight, easy handling • Ideal penstock routing without bends • Lifetime of over 150 years

www.amiblu.com Umschlag zek International 2019.indd 2

Get in touch with our Amiblu sales team or our partners for Austria and Switzerland: www.apr-schweiz.ch

www.etertec.at

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

14.05.2019 14:44:23

HYDRO

HYDROPOWER HAS A LOBBYING PROBLEM

arly this year, the European think tanks Agora Energiewende and Sandbag published their Energy Turnaround analysis for 2018. According to the study, Europe has achieved a further reduction in CO2 emissions in electricity production. At the same time, energy production from fossil sources went down, while the share of renewable energy sources has reached an all-time high of 32.3 per cent. This is really remarkable, and it provides fresh hope that the looming climate breakdown can be averted yet. However, to make the turnaround happen the EU’s industrial nations and many others will have to lower their annual greenhouse gas emissions by five per cent. This should be achievable, actually. That said, it should be mentioned that the energy sector is responsible for only around one quarter of CO2 emissions. How much can hydropower contribute to the intended energy turnaround? Which role is it likely to play in combination with other renewable energy sources in the future? Which role is it going to play with respect to our power grids? So far, discussions of questions like these have not made it to the public arena. But these kind of questions are unavoidable, and they deserve some strong limelight. After all, science is already providing solid answers to these questions: Where compensating and regulating power are concerned, hydro will be indispensable. As for supply security, the answer is the same. As for grid security – the same again. As for black-start capacity – the same yet again. As for storage technology – ditto. The list could go on. All these issues have been proven scientifically for a long time and corroborated by countless figures, data, charts and diagrams. And yet, it seems, the political advocates for hydropower are few and far between. It’s obvious: the most long-standing, most efficient form of renewable energy has a lobbying problem. Political supporters of hydropower are a rare breed indeed. In case political decision-makers need further arguments for the protection and extension of small-scale hydropower, they may be referred to the new study published by the Bergische Universität Wuppertal. According to this report, small-scale hydropower is an essential contributor to grid stability that helps to reduce the costs for grid extension. In the case of Germany, small hydropower plants currently achieve savings of around EUR 1 billion in grid-related costs. If small-scale hydropower were to disappear, Germany would currently need the equivalent of three times the energy provided by wind energy, or even five times the solar energy, to ensure grid stability. The authors of the study consider the hypothetical case of replacing hydropower with solar or wind energy. In that case, grid expansion would have to be stepped up considerably, at costs of EUR 550 per kilowatt of hydropower taken off the grid. According to the study, this scenario would run up a bill of EUR 750 million for grid expansion. Besides, say the authors, another around EUR 250 million would be lost due to the lack of grid services from hydropower. Among other things, this includes the geographic proximity of Germany’s more than 7,000 hydropower plants to energy consumers. This way, transmission loss is kept to a minimum. In other words, small hydropower plants typically generate energy where it is consumed. All these are reasons enough to protect the most effective, most long-standing form of renewable energy against market distortions and to finally begin to appreciate their great value for our transfer grids. 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

Editorial_zek_Int_2019.indd 3

May 2019

14.05.2019 14:42:49

ideas4you

HYDRO

www.schubert.tech April 2016

Editorial_zek_Int_2019.indd 4

14.05.2019 14:42:50

HYDRO

MAXIMISE PLANT AVAILABILITY WITH SCHUBERT IT SECURITY: From professional risk analysis to optimum system protection - no task is too challenging for the experts of our IT security department. Benefit from tailor-made security solutions and maximise your plant availability from a single source: www.schubert.tech

Editorial_zek_Int_2019.indd 5

April 2016

14.05.2019 14:42:50

HYDRO

PP TANJUNG TIRTA (IDN)

27 PP ST. ANTON (IT)

32 PP RUZIEH (IR)

40 PP MESTIACHALA (GE)

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

03 Editorial 06 Table of content 08 Masthead

20 WFD causing drought for european small hydropower? [ EREF STATEMENT ]

36 11th RENEXPO Interhydro Hydro power trade fair in Salzburg [ EVENT / AUSTRIA ]

21 Upper Austrian company extends its leading role in Indonesia [ INDONESIA ]

37 First anniversary for underground power station Gletsch-Oberwald [ SWITZERLAND ]

24 Pencaligue power plant ensures regional grid stability [ HONDURAS ]

40 Austrian hydropower technology masters challenges in Caucasia [ GEORGIA ]

27 How power plant infrastructure can disappear inside a mountain [ ITALY ]

44 Two stage HPP generates energy for 4,000 households [ SWITZERLAND ]

32 Successful premiere for Tyrolean hydropower containers [ IRAN ]

48 Power plant operator supplies own facilities in Styria [ AUSTRIA ]

May 2019

Content_zek_Int-19.indd 4

14.05.2019 14:50:47

GE)

HYDRO

PP HEIDADORF (CH)

GRIZZLY (IT)

PP CARMEN AMALIA (GT)

Advertisers

PP DEÇAN (RKS)

zek HYDRO 2019

52 Leap in quality thanks to innovative coating technology [ PIPE TECHNOLOGY ]

64 Kelag implements a 4-stage cascade at the Balkans [ KOSOVO ]

Schubert Opener Amiblu U2 Troyer U3 Andritz U4

56 Trash rack cleaning machines from Vorarlberg in global demand [ TRASH RACK CLEANING ]

70 App for smart actuator setup and diagnostics [ TECHNOLOGY ]

59 For power plant operators the Grizzly comes from South Tyrol [ COANDA TECHNOLOGY ]

71 Steelwork engineering specialist expands its hydro segment [ TECHNOLOGY ]

62 Finca produces coffee and green electricity [ GUATEMALA ]

74 Professional know-how in all aspects of Seal production [ TECHNOLOGY ]

auma 14 BHM-Ing. 18 Braun 16 Elin 15 EREF 20 Geotrade-Superlit 51 Geppert 35 Gugler Waterturbines 23 Hitzinger 47 Koncar 69 Kössler 9 Künz 57 Muhr 11 Ossberger 63 Pelfa 73 Polish Hydropower 70 Pro Integris 34 Renexpo Interhydro Salzburg 36 Seal Maker 64 Siemens 17 TRM 55 Wild Metal 61 WKV 13

Content_zek_Int-19.indd 5

May 2019

14.05.2019 14:50:50

08_short cuts.indd 8

photo credits: zek Archive

As one of the world’s most important renewable energy sources, SHP is fifth in development, with large hydropower having the highest installed capacity to date, followed by wind and solar power.

photo: berggeist007_pixelio.de

22 MILLION GWH OF PUMPED HYDRO ENERGY STORAGE POTENTIAL WORLDWIDE There are approx. 530,000 potentially feasible pumped hydro energy storage sites worldwide, with a total storage potential of about 22 million GWh. These stupendous numbers have been published in a report recently released by Professor Andrew Blakers and colleagues with Australian National University’s RE100 Group. Today pumped hydro already constitutes 97 percent of electricity storage worldwide due to its low cost, ANU says, and the proportion of wind and solar photovoltaics in the electrical grid is extending considerably. This means “additional long-distance high voltage transmission, demand management and local storage is required for stability.” ANU researchers identified the potential sites and their potential using geographic information system (GIS) analysis. The massive storage potential of about 22 million GWh “is about one hundred times greater than required to support a 100 percent global renewable electricity system,” ANU says. An approximate guide to storage requirements for 100 percent renewable electricity, based on analysis for Australia, is 1 GW of power per million people with 20 hours of storage, which amounts to 20 GWh per million people. The identified sites are outside national parks and are mostly closed-loop (not river-based). [source: Smart Energy International]

SHP represents 1.9 percent of the world’s total power capacity, 7 percent of the total renewable energy capacity and 6.5 percent (< 10 MW) of the total hydropower capacity (including pumped storage).

There are about 530,000 potentially feasible pumped hydro energy storage sites worldwide, with a total storage potential of approximately 22 million GWh. Picture of the storage reservoir Emosson situated 1,930 m above sea level in the Montblanc area.

photo credits: zek

CHINA'S LEADING ROLE IN SMALL HYDRO DEVELOPMENT China continues to dominate the SHP landscape. 51 percent of the world’s total installed capacity (definition of below 10 MW) is located in China. It has more than 3 times the SHP installed capacity of Italy, Japan, Norway and the United States combined. Largely due to the dominance of China in SHP, Asia has the highest share of installed SHP capacity, with 51,919 MW, constituting approx. 65 percent of the total share. Oceania, on the other hand, has the lowest share, with less than one percent of the total global installed SHP capacity. The Latin America and Africa have the fourth and fifth-highest installed capacity and potential of all five regions. SHP in Africa can be characterized as having a relatively low level of installed capacity but with considerable potential for development. Together, the top five countries – China, Italy, Japan, Norway and the USA account for 67 percent of the world’s total installed capacity. The globally installed SHP capacity is estimated at 80 GW in 2017, with an average growth rate of 3 percent from 2013. In the coming years, the market will reach 90 GW in 2023 with CAGR about 2.12 percent. [source: Orbis Research]

photo credits: Elke Barbara Bachler_pixelio.de

HYDRO

Pumped hydro already constitutes 97 percent of electricity storage worldwide. Picture: PSPP Diessbach/Austria

May 2019

14.05.2019 14:52:01

HYDRO

Expertise in small hydro Kössler turns water into power Competent, efficient, economical: Our innovative solutions in Small Hydro guarantee high profitability and excellent performance at optimized costs. With standardized products, latest technologies and made-to-measure concepts we consequently meet our customers’ requirements: high availability, interruption-free operation, low operating costs and quick amortization – maximum reliability right from the start. A Voith Company

koessler.com

08_short cuts.indd 9

14.05.2019 14:52:01

HYDRO

photo credits: Amiblu

photo credits: BOKU Wien

The new hydraulic engineering laboratory in Vienna will offer globally unique research possibilities.

Amiblu supplied the 880 m long penstock built of Flowtite GRP pressure pipes DN 2200 for the new Kyambura Power Station.

photo credits: ILF

View from the planned upper reservoir towards the lower reservoir with the powerhouse of the Cultana project, and the Spencer Gulf in the background.

photo credits: UAS Technikum Vienna

Connectathon test laboratory at the UAS Technikum Wien

NEW HYDRAULIC ENGINEERING LABORATORY IN VIENNA At the end of June 2018, the ground-breaking ceremony was held for the hydraulic engineering laboratory planned at the University of Natural Resources and Life Sciences (BOKU) in Vienna in the presence of the Governor of Lower Austria Johanna Mikl-Leitner, Government Minister Heinz Faßmann and the Mayor of Vienna Michael Ludwig. The new hydraulic engineering laboratory will offer globally unique research possibilities to study questions relating to flood protection, hydropower and waterways, river-bed degradation and river research. What is known as BOKU’s “research channel” has been located at the Brigittenau spur, where the Danube Canal branches off from the River Danube, since 2015. A link was dug between the two waterways with a difference in level of 3 m. The channel, which is roughly 30 m long and 5 m wide, was utilised previously as an artificial river for hydraulic engineering experiments. AMIBLU GRP PENSTOCK FOR HYDROPOWER PLANT IN UGANDA Kyambura Power Station is a 7.6 MW run-of-river hydropower station currently under construction at the Kyambura River, in Kiruggu subcounty, Rubirizi district in Western Uganda. Amiblu supplied the 880 m long penstock built of Flowtite GRP pressure pipes DN 2200, PN 10, and DN 2100, PN 12 (440 m each), as well as flanges, bends, reducers and a flanged tee. The GRP penstock connects the forebay with the power station, which will be equipped with two Francis turbines. Kyambura Power Station will be ready to start producing electricity by the end of 2018 and have an annual production of 36.7 GWh. The original design had the main intake via a "headrace tunnel". In the new design, that has been replaced by a "headrace canal". This has reduced project costs and construction time. The budgeted cost of construction is US $ 24 million. ILF VENTURES INTO AUSTRALIA'S HYDROPOWER MARKET At the end of 2018, the ILF Group, which operates internationally, was commissioned by EnergyAustralia to carry out an independent review of the Cultana seawater pumped hydropower storage project near Port Augusta in South Australia. The power plant is designed to have a power output of 225 MW and an energy storage capacity of approximately eight hours. This is equivalent to constructing 126,000 domestic battery storage systems, with the associated costs amounting to just a third. In addition to the upper and lower reservoirs, the Cultana project will also comprise two penstocks, a powerhouse containing two Francis pump turbines, a tailwater channel, a seawater inlet and outlet structure and a connection to an existing 275 kV grid and auxiliary facilities. The storage reservoirs will be supplied with water from the Spencer Gulf. CONNECTATHON ENERGY 2019 IN AUSTRIA FOR THE FIRST TIME The first Connectathon Energy test laboratory in Austria opened its doors on 28 January 2019 in the ENERGYbase at UAS Technikum Wien. “As part of the three-year research project entitled ‘Integrating the Energy System’, it was possible to develop an interoperability process which makes it possible to adopt an integrated methodology for standardised application of standards for the energy system. What we have created here is a flagship international project,” explains Stefan Sauermann, key researcher for interoperability and standards at UAS Technikum Wien. New requirements placed on the energy networks and the energy market make it necessary for data to be capable of being exchanged between different systems easily, securely and cost-effectively. With the IES Austria research project and the Connectathon test laboratory at UAS Technikum Wien, Austria is an international pioneer when it comes to the interoperability of ICT systems.

May 2019

10_11_short cuts.indd 10

14.05.2019 14:53:31

HYDRO

photo credits: Bilfinger UK

The Ffestiniog power station in North Wales was the first major pumped storage plant to be built in the UK.

The Ffestiniog power station provides electricity for more than half a million people living in the region.

BILFINGER WINS MULTI-MILLION-POUND MECHANICAL AND ELECTRICAL PROJECT FOR WELSH POWER STATION REFURBISHMENT Warrington-based leading engineering and services provider Bilfinger UK has won a multi-million-pound contract with German hydropower specialists Voith Hydro to deliver a range of mechanical, electrical, maintenance and installation services at the Ffestiniog power station in North Wales. The deal forms part of significant restoration project set to be completed by 2020, which will involve the refurbishment of two generating units. The power station, commissioned in 1963, was the first major pumped storage system to be built in the UK and provides electricity for more than half a million people living in the region. Bilfinger UK will remove the plant’s existing vertical generator, turbine unit and mechanical control systems and replace electrical infrastructure, including the protection system and transformer control boards, as part of the contract. The company will also blast and paint the turbine spiral casing and pump internals. Phill Maurer, Managing Director for Bilfinger UK, said: “The Ffestiniog power station plays a critical role in powering North Wales and providing a response to changes in grid supply and demand, as such, delivering a smooth and efficient renewal will be key to ensuring the plant continues to provide the level of response for the future stability of the grid system. Our extensive experience in mechanical and electrical engineering, together with our wider service provision, means we are well placed to deliver this significant scheme.” Bilfinger UK provides its partners with unified, multidisciplinary support across the asset lifecycle to drive new efficiencies and reduce costs, with services including design and build, automated control and electrical systems, installation, commissioning, and operations and maintenance. Bilfinger UK is part of German engineering and service group, Bilfinger SE.

TRASH RACK CLEANING SYSTEMS HYDROMECHANICAL EQUIPMENT COOLING- & PROCESS WATER TREATMENT FISH PROTECTION TECHNOLOGIES

CATRONIC SH monorail screening system, Germany

HYDROCON sliding gate, France

HYDRONIC M multifunctional trash rack cleaner, Germany

ERHARD MUHR GMBH

10_11_short cuts.indd 11

83098 BRANNENBURG GERMANY ☏ +49 8034 90 72 0

INFO@MUHR.COM WWW.MUHR.COM

May 2019

14.05.2019 14:53:32

photo credit: ANDRITZ Hydro

HYDRO

photo credit: Wikimedia/ Man77

The Carinthian energy supplier Kelag has demonstrated its innovative spi rit: It used an innovative prototype with an internal spiral and horizontally split casing for the renewal of the Oschenik 1 storage pump. The innovati on was developed by ANDRITZ Hydro the specialist in hydroelectric power.

Dam wall of Charvak Reservoir in Uzbekistan, Tashkent Region

photo credit: Wikimedia / Giorgio_Galeotti

The main town of the Val di Sole, Malè, uses its renew able resources and relies on hydropower. Meanwhile, the community is considered energy self-sufficient.

photo credit: Hydroses.comm2

The Lower Sesan II hydropower plant with Cambodia’s largest dam has been connected to the grid since December 2018.

RENEWAL OF OSCHENIK 1 WITH TECHNICAL INNOVATION In September 2014, the Supervisory Board of the Carinthian energy supplier Kelag made the decision to invest in a new storage pump for Oschenik 1 – an integral part of the pumped-storage power station Innerfragant. More than two years were to elapse before the new pump could start trial operation at the end of January 2017. The 6-stage Niro storage pump with an internal spiral and a horizontally split housing was developed over several years by engineers at ANDRITZ Hydro. The appeal of this alternative solution was evident, among other things, in the simple assembly and dis assembly of the runner – both during initial assembly and during subsequent inspection. After all, a shorter stoppage time for the pump is an important economic argument. After more than a year in regular operation, it has now been established: The new pump has proven its worth in everyday use. All the performance requirements with regard to efficiency, flow rate and smooth running were met and even exceeded. It impresses with an increase in efficiency of 7.3 percent when compared to the old equipment. UZBEKISTAN WANTS TO MAKE GREATER USE OF HYDROPOWER POTENTIAL The Central Asian country of Uzbekistan has plans to construct a total of 20 hydropower plants between 2020 and 2024, according to a recent report by the online portal “Eurasian Press”. The development programme for the Uzbek hydropower plant sector, which is being adopted by the Government of Uzbekistan, envisages the construction of four large and 16 smaller hydropower plants. In addition, over this period the maintenance and refurbishment of 21 existing power plants is also planned. The total costs of these construction projects will amount to roughly 2.6 billion dollars. Overall, the construction of the hydropower plants is intended to generate around 2.8 billion kWh of electricity. In Uzbekistan, currently roughly 30 percent of the existing hydropower potential is utilised, and the annual generation capacity is 27.5 billion kWh. At the moment a considerable proportion of the demand for energy in the country is still met by thermal power plants. VAL DI SOLE ACHIEVES SELF-SUFFICIENCY IN ENERGY The municipality of Malè in Val di Sole in Trentino has been relying on hydroelectric power for several years. Between 2014 and 2016, a consortium of users from the region developed four hydroelectric power stations on the Rabbies, the local mountain river, which were mostly rebuilt, renewed and renovated. The completion of this cascade formed the Rabbies 4 power station, which was officially commissioned in August 2016. The small hydroelectric power station was equipped with two identical vertical Francis turbines from Tschurtschenthaler. Today, the turbine duo generates around 2.2 million kilowatt hours. This means an increase in power generation of around 30 percent according to the operators. A real milestone achievement for Malè, the capital of Val di Sole. After all, the municipality is now able to claim complete self-sufficiency in energy. LARGEST DAM IN CAMBODIA IS NOW PRODUCING ELECTRICITY During an official ceremony in December 2018, Cambodia’s Prime Minister Hun Sen opened the 400 MW Lower Sesan II hydropower plant in the north-eastern province of Stung Treng. Lower Sesan II was constructed over a period of four years. According to the Ministry of Mines and Energy, the mega-power plant covers around 20 percent of the country‘s annual energy demand. Cambodia is embarking on a wide range of different projects in an attempt to increase its capacities for industrial expansion. The stakeholders involved in the joint venture project, which is worth 816 million US dollars, are “Hydrolancang International Energy” from China with a stake of 51 percent, the Cambodian “Royal Group” with a stake of 39 percent, and “EVN International” from Vietnam with a 10 percent holding. This means that in Cambodia there are seven commercial hydropow er plants in operation, delivering a total output of around 1,328 MW.

May 2019

Projekt Kurzmeldungen 12_15 zek Hydro Internat 2019.indd 12

14.05.2019 15:48:14

HYDRO

Generators for Generations!

n High efficiency generators up to 40 MVA n Perfect solutions for all hydro turbines n Voltage up to 15 kV n Warranty up to 5 years n Worldwide after-sales-service n Really made in Germany

Wasserkraft Volk AG

Projekt Kurzmeldungen 12_15 zek Hydro Internat 2019.indd 13

sales.geno@wkv-ag.de

+49(0) 7685 9106-0

www.wkv-ag.com May 2019

14.05.2019 15:48:14

HYDRO

photo credit: zek

All electric car drivers could be certain of filling up with 100 percent green electricity and saving grid costs. In this way, the overall benefit of electric mobility could also be enhanced in a decisive, cost-effective way.

HARNESSING HYDROPOWER PLANTS AS CHARGING INFRASTRUCTURE “Small-scale hydropower in Austria can and will make its contribution to the measures and developments that are needed in the mobility sector. And not just in the form of electricity production,” says Austria Small-Scale Hydropower Managing Director Paul Ablinger. But regulatory adjustments are also required for this. For example, slight adaptations to the flat fee for green electricity could spark the construction of a large number of charging stations. Many of the more than 3,500 small-scale hydropower plants in Austria have good transport links and could quickly be equipped with charging stations. The flat fee for green electricity is almost 15,000 euros a year as soon as a power plant at level 5 changes from a full feeder to a surplus feeder. In this form, this flat fee for green electricity prevents the obvious and sensible construction of charging stations at small-scale hydropower plants.

AUTOMATION WITHOUT OIL

Many onlookers could not resist the opportunity to see this rare spectacle at Itaipú power plant.

For power supply, electric actuators just require an electric cable - low-maintenance, easy to install and free of potential oil leakage. All components of AUMA’s electric actuators are located within a single housing. Designed as standard in highest enclosure protection IP68. The version for continuous underwater use (UW) is capable of continuous immersion to a depth of 15 m and in enhanced version optionally to 60 m head of water. AUMA actuators can be used for any application above or below water level. Electric AUMA actuators meet the requirements of the highest corrosivity categories C5-M and C5-I in compliance with EN ISO 12944-2. Electric actuators ensure reliable operation over many years demanding minimum maintenance. Discover our auto mation solutions. www.auma.com

photo credit: Itaipu Binacional

Electric actuators for valve automation of weir penstocks, screens and valves in hydropower plants

ITAIPÚ MEGA-POWER PLANT OPENED FLOODGATES On 27 October, the Itaipú power plant, located in the border region between Brazil and Paraguay, opened all the floodgates and since then up to 1,400 m³ of water per second have been flowing down into the Rio Paraná. The joint project between Paraguay and Brazil was completed between 1974 and 1991. The plant was extended in 2004 to include two more turbines from Voith. The 20 turbines in total deliver an output of around 14,000 MW. With the amount of water available averaging 10,500 m³/s, Itaipú power plant delivers a standard capacity of 95 TWh per year. This makes the mega-power plant on the Rio Paraná one of the most powerful hydropower plants in the world. In contrast to previous situations, there is no longer any risk of flooding for the neighbouring district of San Rafael in Ciudad del Este.

May 2019

anzeige_halbe_seite_zek_hydro_en.indd 1

Projekt Kurzmeldungen 12_15 zek Hydro Internat 2019.indd 14

05.04.2019 11:08:00

14.05.2019 15:48:14

HYDRO

photo credit /Animation: EWA

With an installed power output of 11.5 MW in a normal year, the Erstfeldertal power plant will generate around 32 GWh of clean electricity.

photo credit: Andritz

The construction of the new Inga 3 mega-dam is set to create an additional power capacity of 11,000 MW.

14-BILLION-DOLLAR DAM PROJECT ON THE CONGO At the end of 2018, several online portals reported that the Democratic Republic of Congo (DRC) had concluded a preliminary contract with two international consortia to construct a huge dam costing around 14 billion dollars. The project to build a dam on the River Congo, known as “Inga 3”, is intended to allow up to 11,000 MW of electricity to be produced. The Inga 1 and 2 dams were built on the Congo in the 1970s. The contract was secured by a Chinese group including the China Three Gorges Corporation, which is the state operator of the dam over the Yangtze River. The second consortium consists of the Spanish utility companies Grupo Cobra and AEE Holdings. The project in the west of the Central African country has been many years in the planning. Securing the funding for the project will be a major challenge for the DRC – one of the world’s poorest and most corrupt countries.

ERSTFELDERTAL PP – FROM THE VISION TO TANGIBLE REALITY Erstfeldertal power plant in the canton of Uri has made a decisive step forward. The power plant was given its licence at the beginning of October and on 19 November it received the building permit too. The corporation was officially founded on Wednesday, 21 November 2018. The construction works for the power plant are set to commence in June 2019, and the winter turbine is scheduled to be commissioned in December 2020. “We are investing 36 million Swiss francs in the Erstfeldertal power plant,” explained Board President Werner Jauch. “When in operation, it will supply electricity for around 7,200 households. The energy strategy of the canton of Uri is this year celebrating its 10th anniversary. The expansion of hydropower is a central thrust of this policy. Erstfeldertal power plant together with the other new Bristen, Gurtnellen, Schächen and Palanggenbach power plants support this strategy and also the energy strategy of the federal government. ”

Long term operation of plants requires careful consideration of interfaces.

At ELIN Motoren, lifecycle partnership means taking care of products throughout the entire product lifecycle as well as the generation of high added value: from consulting, throughout development and manufacturing up to on-site service. We are your lifecycle partner for rotating electrical machines and solutions, working for the best companies around the world.

WE KEEP THE WORLD IN MOTION. www.elinmotoren.at

Projekt Kurzmeldungen 12_15 zek Hydro Internat 2019.indd 15

May 2019

14.05.2019 15:48:15

HYDRO

KRAFTWERKE OBERHASLI AG BUILDS A REPLACEMENT DAM ON THE GRIMSEL RIVER Construction is to commence at the Grimsel site in the Bernese Oberland at the beginning of June 2019. The Spitallamm dam, one of two walls damming the Grimselsee, is to be rebuilt. The Supervisory Board of Kraftwerke Oberhasli AG recently passed the resolution approving the construction. The KWO estimates the replacement construction of the Spitallamm wall to cost 125 million Swiss Francs. The old 114 metre high Spitallamm dam on the Grimsel was built between 1925 and 1932. The Spitallamm dam wall has however shown irreversible deformation for quite some time. Detailed investigations by the KWO have determined that new construction is the most economically and technically sensible solution, better than partial demolition and renovation of the existing wall. The current Spitallamm dam is to remain in place and later submerged. A tunnel next to the old wall ensures hydraulic compensation of the water level. It is of central importance for the Oberhasli power plants that it is possible to use the water from Lake Grimsel, at the heart of the power plant system, for electricity production without restriction for the entire duration of the construction work. The construction work is expected to take six years. The Alpinhotel Grimsel Hospiz will be closed for guests in summer 2019.

The 4-nozzle Pelton turbine from Troyer AG is the optimum solution for frequent load fluctuations during regular operation. It has a capacity of around 4.3 MW which is about a third more powerful than the turbine in the former system.

photo credits: zek

Foto: Archive

photo credits: KWO

Foto: Archive

The usage of water to produce electricity in the Grimsel and Susten area started in 1925, with the foundation of the Oberhasli Hydroelectric Company KWO. An impressive network of eight reservoirs and thirteen power plants was built within several phases and is nowadays used to produce energy for a good million Swiss residents. Forschung und Entwicklung werden künftig in der neu gegründeten D-Sediment GmbH gebündelt. Alleine und in Kooperation mit mehreren Hochschulen entwickelt das Unternehmen Verfahren und technische Anlagen für Sedimentlösungen „Made in Germany“.

NEW ENGINEERING TECHNOLOGY INCREASES SAFETY IN ZERMATT The Zermatt hydroelectric power company, which operates three hydroelectric power stations in the famous Valais resort, discovered cracks in the shaft of the machine set in one of its installations a few years ago during a regular inspection. When faced with the choice of repairing the more than 40-year-old machines at KW Findelnbach or effecting a complete replacement, the operators decided to have the entire electromechanical equipment replaced by Troyer AG the South Tyrolean hydroelectric power specialist. The new four-nozzle Pelton turbine, which went into operation almost a year ago, now has a capacity of approx. 4.3 MW, about one third more than the existing capacity, also not least owing to a slightly higher flow rate. At the same time, noise abatement played a major role in the conversion. For this reason a comprehensive noise abatement concept was developed. The core of this concept was, on the one hand, to completely decouple the foundation of the machinery set from the building and, on the other hand, to design the interior of the building as soundproof as possible. The machinery unit was placed on isomer mats, which reduce the transmission of structural noise to a minimum. The operators invested around CHF 3.4 million in the conversion and refitting of the traditional hydroelectric power station.

Innovations for waterpower all over the world.

Trash Rack Cleaning Systems Hydro Mechanical Equipment

Foto: ETH Zürich

BRAUN Maschinenfabrik Ges.m.b.H.

Gmundner Str. 76 4840 Vöcklabruck / AUSTRIA E-Mail:office@braun.at

MASCHINENFABRIK

www.braun.at

May 2019

16_18 Kurznews Int.indd 16

14.05.2019 15:17:21

A proven solution for any challenge in hydropower automation Siemens Small Hydro Solution Sipocon-H – Control and Governor System As an integral element of the hydro power plant system, the Sipocon-H digital governor system combines flexible and modular architecture to meet tailor-made customer requirements. Furthermore, the system serves a huge variety of hydro plant systems ensuring availability and proven performance. The Task The hydroelectric power plant operation and its performance are largely dependent on the turbine governor system. Irrespective of hardware properties, the system ensures a safe and stable operation, maximum availability as well as precise functionality. Our Solution The Sipocon-H is the core element of our integrated and customized hydro power solution. It is based on universally available PLC/DCS systems, such as the globally established industrial standard of the SIMATIC family or the SICAM 1703 family. The system meets the highest demanding requirements and is easy to adapt and parameterize without any kind of programming. Sipocon-H hydro governor control structure (schematic overview)

Software and user interfaces (local and remote) can be provided in a variety of platforms, such as SIMATIC S7, PCS 7, SPPA-T3000, SICAM, WinCC, Zenon etc., which all have modular architecture and graphic interfaces in various designs. Operation and visualization is done via local and/or remote visualization systems. These systems provide long-term data storage and related reporting features, for continuous analysis and evaluation.

Typical additional applications

Due to its modular architecture and the standardized interfaces, the turbine governor Sipocon-H can be extended to a complete plant automation system.

More than 100 years experience

Additionally, the system supports a comprehensive range of communication solutions such as Profinet, Profibus DP, Modbus TCP, OPC, IEC 60870 and IEC 61850 amongst others.

• Plant control: Optimized controller for more than one parallel energy production line • Demand side management controller • Primary and secondary control Standard operation modes • Manual operation • Automatic operation • Remote operation • Island mode The hydro-specific functions, operation and diagnostic tools are always individually tailored for different turbine types and systems. Our extensive experience and more than 700 units installed help us to understand our customer requirements in both new and modernization plants.

Standard controller functions and features

Your Benefits

• Speed control • Power control • Flow control • Level control • Open control

• Modular governor architecture for tailor-made plant design • Easy parameterizing without engineering tools • Standardized interfaces, communication and arbitrary redundancy concepts for a smooth integration • Expandable to a complete plant automation system and scalable to all different unit sizes and unit combinations • Meets all relevant international standards for a global use • Performance and process optimization based on improvement modules

www.siemens.com/hydro energy.smallhydro.at@siemens.com

16_18 Kurznews Int.indd 17

14.05.2019 15:17:21

HYDRO

Gudauri in the Caucasus, an up-and-coming ski resort in Georgia, is focusing on the expansion of hydropower. Now the second small hydroelectric power station with Austrian hydroelectric technology has been put into operation.

Industry

Power Plants

Transportation

Special Topics Public Sector

photo credits: Wikipedia

Overall enGineerinG & cO n s u lt i n G s e r v i c e s

photo credits: Snowy Hydro

HIGH-MOUNTAIN POWER STATION IN THE CAUCASUS BEGINS OPERATION In December 2018, the new small hydroelectric power station Aragvi 2 commenced operation not far from the Gudauri ski region of northern Georgia in the Caucasus. A new power station was built within two construction seasons, at an altitude of more than 1,800 metres. Equipped with state-of-the-art hydroelectric technology, it generates around 12 to 14 GWh of clean electricity per year. The new high-mountain power station is the upper-level power station for the Aragvi 1 station, which was commissioned in 2014 with electrical equipment from Kössler, a subsidiary of the Voith technology group. Four years later, the Lower Austrian turbine specialist again supplied the mechanical heart of the new power station: a Francis spiral turbine, which was specially designed and manufactured for the difficult operating conditions at the site. The turbine installation achieves a nominal output of 1,950 kW at a discharge flow rate of 2 m3/s. When combined with Aragvi 1, the entire cascade exceeds 60 GWh, enough to supply more than 60,000 Georgian households.

Hydro Power Thermal Power Biomass Special services

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

feldkirch • linz • Graz schaan • PraGue

Australia is not only fully self-sufficient, the country has the opportunity to meet 100 percent of its energy needs with renewable energy. Currently, wind, solar and hydropower represent 17 percent of Australia's total electricity generation. To further increase energy production from regenerative sources and at the same time to ensure grid stabilization, the country relies heavily on pumped storage technology.

VOITH HYDRO RECEIVES MAJOR ORDER FOR AUSTRALIAN PUMPED STORAGE POWER PLANT Voith has been awarded a contract to equip the Australian pumped storage power station Snowy 2.0, one of the largest pumped storage basins worldwide, with electrical and mechanical power plant components. The Future Generation Joint Venture (a Joint Venture between Salini Impregilo, Clough and Lane) and the Heidenheim-based technology group signed the contract at beginning of April. Operator of the plant is Snowy Hydro Ltd. The order includes the supply of six reversible pump turbines, each with a rated output of 333 megawatts, three of which are variable-speed. In addition, the order includes six motor generators, the auxiliary systems and the complete power plant automation. With the six units, Snowy 2.0 will achieve a total output of 2,000 megawatts and provide the national electricity market with 175 hours of continuous large-scale storage. In the almost two-year tendering process, Voith Hydro successfully prevailed thanks to its know-how in pumped storage technology. At the heart of the innovative pumped storage technology is a special asynchronous motor-generator, the doubly fed induction machine. Compared to a conventional synchronous machine, it decouples the mechanical speed from the constant frequency and can vary. The project can thus make a significant contribution, both to grid stabilization and to the further expansion of power generation from renewable energy.

May 2019

ZEK_D+E_58x262_4C.indd 1 16_18 Kurznews Int.indd 18

05.02.2019 12:44:03 14.05.2019 15:17:23

HYDRO

Two hydro projects are about to be realized in Fjærland with the penstocks made of Amiblu GRP pipes.

INNOVATIVE MATRIX PUMP TECHNOLOGY FOR AUSTRIAN HPP End of last year’s October, the modernised Dießbach hydro power plant in Salzburg was ceremoniously opened. After a construction period of 1.5 years, the operator Salzburg AG was able to officially restart operating the plant. As part of the reconstruction, the plant, which was originally constructed in the 1960s as a storage power plant, was expanded with matrix pump technology and a lower reservoir and thus adapted to create a pumped-storage power plant. The matrix pump is a combination of 24 individual pumps which individually and jointly enable extremely precise regulation. Each of the 24 individual units has an output of 1.23 MW. The pumps are driven by 24 low-voltage motors which have a nominal output of 1,235 kW each and are made by ELIN Motoren GmbH, the globally renowned manufacturer of generators and motors. Thanks to its new electromechanical equipment, the plant is now not only able to generate electricity but can also store energy.

Dießbach power plant was made more flexible by constructing a lower reservoir and a matrix pump. This consists of 24 individual pumps which can be interconnected.

ANDRITZ TO DELIVER NEW LOW-HEAD HPP TO VIETNAM International technology Group ANDRITZ has received an order from Pac Ma Hydropower Joint-Stock Company for the supply, supervision, and commissioning of electro-mechanical equipment for the Pac Ma hydropower plant in Vietnam. Commissioning and start of commercial operation is scheduled for 2020. The ANDRITZ scope of supply comprises the complete electro-mechanical equipment for the hydropower plant, including four bulb turbine units (35 MW each), the electric power systems, and auxiliary mechanical and electrical equipment. With a total installed capacity of 140 MW and annual energy production of about 530 GWh, the Pac Ma hydropower plant will supply renewable electrical energy to the Vietnamese national grid. Award of this contract is further proof of ANDRITZ’s leading position for low-head technology in the important region of South East Asia.

photo credits: Vattenfall

The contract value amounts to around 40 million euros.

Sand catchment system

19_short cuts.indd 19

photo credits: Amiblu photo credits: zek

photo credits: Bilfinger UK

Vattenfall's hydro power plants are gaining greater flexibility in balancing more solar and wind power. Picture: Stornorrfors HPP.

photo credits: ANDRITZ

VATTENFALL'S HYDRO POWER PLANTS ARE BEING UPGRADED Vattenfall invests SEK 1 billion per year in hydro power maintenance. A major project has been under way since 2015 to upgrade the power plants and raise their output and flexibility. By 2023, hydro power will have been expanded by 600 MW without a single new dam being built. This is equivalent to the output of half a nuclear power plant, or roughly 100 modern wind turbines, and is a significant contribution to Sweden's climate goals and Vattenfall's goal of enabling fossil-free living within one generation. However, the primary purpose is to improve the ability to respond faster to changes in the need for generation, rather than to generate more electrical power. Around 20 power plants have already been upgraded in various ways, increasing the available output by around 450 MW. Vattenfall owns around 100 HPP in Sweden, with a total output of approximately 8,700 MW.

photo credits: Bilfinger UK

HYDRO-POWERFUL NORWAY BOOSTED BY AMIBLU GRP Two remarkable hydropower projects are being realized in the Norwegian region of Fjærland with penstocks made of Flowtite GRP pipes by Amiblu: For Project 1, Skeidsflåten kraftverk in Sogndal municipality (output 5 MW, production 19.5 GWh/year), 2500 m GRP pressure pipes DN 1800 and DN 1600 were supplied. The Francis turbines will utilize a height of 83 meters and will have a nominal performance of 1,750 kVA and 3,500 kVA, respectively. The power plant will be commissioned in winter 2020. Project 2, Tverrdalselvi kraftverk (output 5.7 MW, production 18 GWh/year) will feature an 1150 m Flowtite penstock DN 1100. The 6-nozzle Pelton turbine will utilize a 225 meter drop height and will have a rated output of 6,711 kVA. The annual electricity production will be approximately 18 GWh. The power plant will be commissioned in autumn 2019. Both projects are implemented by Jostein Sunde AS.

May 2019

14.05.2019 15:27:49

HYDRO

WATER FRAMEWORK DIRECTIVE CAUSING DROUGHT FOR EUROPEAN SMALL HYDROPOWER?

photo: Andritz Hydro

photo credits: zek

Directive 2000/60/EC or the Water Framework Directive (WFD) is meant to ensure the ‘Good Ecological Status’ (GES) of European waters. It requires from those who use water for economic or other purposes, the achievement of a set of conditions to meet such status. However, in many cases, the WFD unintentionally obstructs the development of hydropower.

he WFD allows for exemptions from achieving GES on an economic basis (if the cost of a measure to achieve GES is considered as disproportionately costly, then slightly less strict conditions apply). A cost-benefit analysis (CBA) is the method of choice to balance environmental costs and benefits but the WFD does not specify which parameters should be used in such an analysis. Costs are usually overestimated and non-quantifiable benefits tend to not be included. Defining the area of influence of a project has also proven difficult. In some cases, the value of benefits are multiplied by the number of nearby inhabitants, which is problematic for small hydropower plants which are usually located near scarcely populated areas. In some cases, CBA considers only the costs of construction of fish passages, ignoring the loss of revenue from energy generation due to the discharge in to the fish passage as well as the management and maintenance costs of such. WFD WITHOUT EU FUNDING The WFD is also incoherent with other EU policy. The costs of some environmental mitigation measures required to achieve GES are unfeasibly high for small hydropower operators which is a financial death sentence when one considers that the WFD has no dedicated EU funding for its implementation. The LIFE financing programme for environment and climate amounts to EUR 3.4 Bil whereas in contrast, the EU’s Regional Funds and the CAP amount to EUR 350 Bil and EUR 290 Bil respectively. Additionally, in 2015 entered the Paris Agreement and revamped its energy policy for the next decade in order to decarbonise its energy supply, reduce its dependency on energy imports and ensure its security of energy supply. The development of hydropower would serve these objectives but the WFD blocks this development.

EREF2019.indd 20

Small hydropower specifically has a key role to play in the transformation of the EU’s energy system: As the energy system transitions from a centrally based system, with large fossil fuel utilities producing a large volume of electricity and transmitting to a large number of consumers, to a more decentralised system with scattered independent renewable energy producers, small hydropower has a key role in maintaining the stability of an electricity grid powered entirely by intermittent renewable sources. With the WFD currently being checked for whether it is fit for purpose by the European Commission, now is a crucial time for the EU legislator to recognise and prioritise the benefits offered by small hydropower in the fight against climate change.

WORKSHOPS IN SALZBURG IN FALL The European Commission has finished its information gathering process for the fitness check of the WFD and is currently digesting it while it is working to produce a report which should be released near to autumn which will conclude whether or not the WFD is to be revised or not. The European Renewable Energies Federation’s Small Hydropower Chapter which represents the interests of Small Hydropower at EU-level and unites Small Hydropower stakeholders from 14 Member States, will organise workshops on this at RENEXPO INTERHYDRO in Salzburg in November later this year. Author: Rodrigo Mesquita EREF Policy Advisor

May 2019

14.05.2019 15:29:18

HYDRO

UPPER AUSTRIAN COMPANY EXTENDS LEADING ROLE IN INDONESIAN SMALL-SCALE HYDROPOWER SECTOR

easured in terms of population size, the 255 million people living in the South-East Asian island nation of Indonesia make it the fourth-largest country in the world. Roughly half of the population is spread across the main island of Java, with the Jakarta metropolitan area alone accounting for around 10 million inhabitants. Although around a quarter of the population lives below the poverty line, economic growth has recently been experiencing an increase by between five and six per cent every year, making the Indonesian economy one of the world’s fastest growing. This is also reflected in the considerable investments in infrastructure projects that have been made by the state and private sector in the last few years. In order to improve the power supply across the country, it is essential to exploit untapped hydropower potential. This trend is also reflected in the order books of GUGLER Water Turbines GmbH – an all-round hydropower provider from Upper Austria. At the end of 2017, the industry experts at GUGLER, who are highly active on the international stage, demonstrated their leading position in the Indonesian small-scale hydropower sector by

The Tanjung Tirta plant in the central area of the Indonesian island of Java was kitted out with all the electromechanical equipment by the turbine manufacturer GUGLER Water Turbines GmbH from Upper Austria.

photo credits: GUGLER

In 2017, GUGLER Water Turbines GmbH, which hails from Upper Austria, demonstrated its leading position in the Indonesian small-scale hydro power sector by taking on a range of projects. Shortly before the turn of the year, an additional reference facility in South-East Asia commenced operations, namely the Tanjung Tirta hydropower plant operated by the company PT Maji Biru Pusaka. GUGLER supplied all of the electromechanical, instrumentation and control equipment for this new construction in the central area of the island of Java with an estimated average annual production of around 63 GWh. Two highly efficient Francis spiral turbines with a bottle neck output of 5 MW each are employed as central power generators; the design of the turbines ensures high levels of efficiency even with varying inflow conditions. All of the power produced is fed into the public grid, which represents yet another vital part for improving the local power supply.

taking on a total of eight small-scale hydropower projects.

maris Hydro commissioned the turbine manufacturers with another project at the northern tip of the country in the same year. Following its acquisition by Tamaris Hydro, plans were made to expand the Krueng Isep power plant, which was equipped with a complete package of equipment from GUGLER when it was newly constructed in 2015, to include a third turbine. “The two Pelton turbines at the plant together with the new Pelton turbine will now generate a bottleneck output of more than 25 MW. By contrast, the Tanjung Tirta power plant was to be equipped with two horizontal Francis spiral turbines for electricity production during its

INDONESIA AS A VITAL MARKET One recently completed project is the Tanjung Tirta power plant located in the centre of Java in the province of Java Tengah, says GUGLER Project Manager Stefan Haderer. At the start of 2017, the operating company PT Maji Biru Pusaka awarded GUGLER the contract to supply all of the electromechanical equipment. This subsidiary belongs to PT Tamaris Hydro, a large private Indonesian utility company, specialised in generating electricity from hydropower. In addition, Ta-

Animation of one of the two Francis spiral turbines with an identical design.

Projekt KW Tanjung Tirta zek Hydro Internat 2019 Englisch NEU.indd 21

May 2019

14.05.2019 15:30:29

HYDRO

With an extraction water quantity of 6 m3/s each, each turbine ideally achieves a bottleneck output of 5 MW. The hydraulic design of the units ensures the most effective power generation possible even with varying inflow conditions.

original construction,” explains Project Manager Haderer. INITIAL COMMISSIONING IN AUTUMN 2018 In terms of its basic design, the Tanjung Tirta plant is a classic diversion power plant. In the Tanjung Tirta region, a local body of water is captured via a side weir and the works water is diverted in an open weir channel that is around 4 km long. At the end of the discharge channel there is a sand trap laid out in several trapezoidal stages, in which fine sediments are collected and washed back into the river through a purging device. Downstream from the open discharge channel is the inlet basin equipped with a fine trash rack, and immediately after this the DN2000 penstock begins. The penstock, which is around 400 m long and also runs above ground, is made from welded steel pipes routed to run in as straight a line as possible. Shortly before the transfer to the powerhouse, the penstock is split into

two DN1300 pipes by a Y-branch pipe. The powerhouse was designed with an appropriate concrete-steel structure, and an indoor crane installed in advance proved very useful for installing the components weighing several tonnes. “In April 2018, the turbines along with the electrical equipment set off from the Port of Trieste on their approximately six-week journey to Indonesia. The generators supplied by Siemens Gamesa and the transformers provided by ABB were also shipped. The assembly work, which began in June with the installation of the turbine spirals, was performed by the supervisors from GUGLER, the partner companies and local workers. Once the electrical installation work was completed, the power plant was put into operation for the first time in October,” states Haderer. 5 MW BOTTLENECK OUTPUT PER TURBINE For electricity production, the turbines designed with a horizontal shaft have a net head

Installation of a runner milled from a monobloc.

of 92.3 m and an extraction water quantity of 6 m³/s. The rotors of the turbines were milled from individual stainless steel monoblocs, and the special ZINGA coating was applied for corrosion protection instead of hot-dip galvanising in the steelwork for the spiral casing and draft tube. The hydraulic design of the Francis turbines, each with an absorption capacity of 6 m³/s and has proven itself to be efficient in numerous application across the globe, enables optimum levels of power generation at both full load and partial load. The guide vanes are adjusted by hydraulic actuators, with the corresponding hydraulic piping made entirely from stainless steel. With the full volume of water available, the units rotating at 750 rpm each deliver a bottleneck output of 5 MW, which is transferred via the turbine shaft to the directly coupled synchronous generators. The air-cooled generators were configured with an exhaust air duct at the

Technical Data • Flow rate: 12 m3/s • Net head: 92,3 m • Turbines: 2 x Francis spiral • Nominal Speed: 2 x 750 rpm • Runner Ø: 2 x 850 mm • Output: 2 x 5 MW • Manufacturer: GUGLER Water Turbines GmbH • Generators: 2 x Synchronous • Output: 2 x 6 MVA The control system provides a detailed overview of the individual components at the power plant.

• Manufacturer: Siemens Gamesa • Total annual average capacity: ca. 63 GWh

May 2019

Projekt KW Tanjung Tirta zek Hydro Internat 2019 Englisch NEU.indd 22

14.05.2019 15:30:30

HYDRO

The turbines started operating just a few months after the installation works began in October of last year.

The generated power is fed into the public grid and thus makes a further contribution to stabilising the country‘s national grid.

bottom and are each designed for a rated apparent power of 6 MVA. Separate water-cooled lubrication units for the sleeve bearings of the generators ensure optimum operating temperatures. From the generator terminals, the power generated is conducted to the two externally stationed transformers and then to the medium-voltage switchgear. The electricity makes its way to the feed-in point to the public grid via a ground cable. INDONESIA REMAINS A VITAL MARKET The level-controlled electricity production at the power plant works fully automatical-

ly, reflecting the state of the art. GUGLER commissioned the Croatian automation specialist Sintaksa as a partner for executing the electrical engineering and control technology, with which the Upper Austrian company has already implemented a whole host of projects around the world. The power plant control system, which is visualised in a user-friendly manner, provides authorised users detailed information on the plant status and enables comprehensive adjustments to the various power plant components. The power plant can be monitored around the clock and maintained remotely

via a secure online connection. The new Tanjung Tirta power plant finally commenced normal operation just before the end of last year. On average, the operators expect to achieve annual production of around 63 GWh, all of which will be fed into the public power grid. With the completion of this project, GUGLER can add another showpiece plant to its reference list for South-East Asia. However, resting on their laurels is out of the question for the turbine manufacturers, because further projects in Indonesia are already well advanced or under development.

• Worldwide active • Upgrading and modernization • Financing and AfterSales-Service • Water-to-wire solutions • Highest European quality and efficiency • Operator know-how • Long-time experience

Kaplan Turbines Pelton Turbines Francis Turbines up to 25MW

info@gugler.com www.gugler.com

Liquid Energy - Solid Engineering

Projekt KW Tanjung Tirta zek Hydro Internat 2019 Englisch NEU.indd 23

May 2019

14.05.2019 15:30:30

photo credits: GUGLER

HYDRO

The Austrian experts in their sectors, GUGLER Water Turbines GmbH and Schubert Elektroanlagen GmbH, supplied and installed the entire electromechanical and control technology for the Pencaligue power plant in Honduras.

PENCALIGUE POWER PLANT IN HONDURAS ENSURES REGIONAL GRID STABILITY In the past few years, in order to sustainably improve electricity supply grid stability in Honduras, one of the poorest countries in Central America, energy providers have increasingly focused on expanding previously unexploited hydroelectric power potential. In the summer of 2018, in the department of Santa Bárbara in the north-western part of the country – the 18 MW Pencaligue power plant went online to provide a small town nearby with electricity. The operators, Hidroeléctricas de Occidente S. de R.L., implemented the project successfully with a significant contribution having been made by Austrian industry expertise. Working as a subcontractor, Schubert Elektroanlagen GmbH of Lower Austria delivered and installed the entire portfolio of electric and control technology for the power plant. The overall contract for electromechanical infrastructure, including two Pelton turbines with a maximum capacity of 7 MW and one 3 MW Pelton turbine, was awarded to GUGLER Water Turbines GmbH of Upper Austria.

longside Haiti, Honduras is one of the poorest countries in Central America and over 70 percent of the country’s almost nine million inhabitants live below the poverty line. Outdated and lacking infrastructure and power plants mean that power failures are a common occurrence in many regions of the country. In order to improve the response to these bottlenecks, emphasis has been shifted to the expansion of regenerative energy sources – particularly toward hydroelectrics. The unreliability of the power supply in the town of Atima in the department of Santa Bárbara in north-western Honduras was the starting point for the Pencaligue hydropower project. The construction of the power plant was based around the idea of re-

directing a local body of water which would first flow through the mountain via a grade

tunnel before being guided by a penstock to the turbines. Named after the region itself,

Front view of the power plant centre in Departamento Santa Bárbara.

May 2019

Projekt KW Pencaligue zek Hydro Internat 2019.indd 24

14.05.2019 15:31:12

HYDRO

Construction work on the head dam and the intake structure.

OPERATORS RELY ON AUSTRIAN EXPERTISE Hidroeléctricas de Occidente awarded the Austrian hydropower allrounders at GUGLER Water Turbines GmbH the contract to provide all the electro-mechanical equipment for the project in December 2016. The Upper Austrian business had already installed two Pelton turbines for the same customer in 2015 for the 10 MW Mezapa power plant in Honduras, thus recommending itself for further projects in the country. GUGLER chose Schubert Elektroanlagen GmbH from Ober-Grafendorf in Lower Austria company to serve as their subcontractor and supplier of electrotechnical and control infrastructure. In 2016 their highly and internationally experienced specialists had

already cooperated to complete the 12.9 MW Carpapata III project in Peru. In 2017 they worked together again on another Peruvian project – Marañón – to achieve 19.7 MW of bottleneck capacity. Nevertheless, the Pencaligue contract was the first joint project in Central America. Due to the high levels of crime in the country a special camp was built at the plant headquarters to accommodate the construction staff and engineers, and was protected by armed guards around the clock. PENSTOCK FOLLOWS GRADE TUNNEL The water collection basin at the power plant was fitted with a head dam gate, with a side arm flow release of up to 2.9 m³/s for the generation of electricity. After release, the flowing water is fed into a voluminous desanding basin to allow the fine sedimentary particles to settle out from the water. A hydraulically operated flush gate ensures the sand and sediment are returned to the natural flow of the water. The cleaned water is then directed down a threekilometre grade tunnel blasted into the mountain. Having completed its underground passage, the water enters a level-regulation pool,

Technical Data • Flow rate Turbines 1 & 2: 2 m3/s • Net head: 413 m • Turbines: 2 x Pelton horizontal • Ø Runner: 1.365 mm • Output: 2 x 7,334 kW • Manufacturer: GUGLER Water Turbines • Generator: Synchronous • Manufacturer: Hyundai Ideal Electric

• Flow rate turbine 3: 0,9 m3/s • Net head: 413 m • Turbine: Pelton horizontal • Ø Runner: 910 mm • Output: 3,299 kW • Manufacturer: GUGLER • Generator: Synchronous • Manufacturer: Marelli

Total average capacity: approx. 100 GWh

TURBINES SERVE BROAD RANGE OF PURPOSES GUGLER’s Project Manager Roland Fleischmann explained that when designing the machine, the main focus of the designers was on maximising efficiency for a system working at partial capacity. The volume of water made available during the rainy season between October and May can fluctuate immensely, so three Pelton turbines were installed – two larger and one smaller machine – to optimise efficiency. On a technical level, the turbines were designed and manufactured as very easily-regulated 2-jet versions with horizontal shafts. The original project developers had already planned for the integration of a fourth turbine in the power house, but at the time the over-optimistic forecasts regarding available water volumes

Each of the two larger, identically constructed turbines provides a bottleneck capacity of 7,334 kW. The smaller turbine achieves a maximum output of 3,299 kW.

Projekt KW Pencaligue zek Hydro Internat 2019.indd 25

after which it is channelled down a penstock approximately 3.8 km in length. An unavoidable topological rise in the pipeline between the steel DN1700 and DN1500 sections necessitated the building of a surge chamber to release pressure at the highest point. To reach the purpose-built powerhouse the works water climbs to a gross head of 413 m.

Animation: GUGLER

the project had already been authorised in 2010, and some earth engineering had already taken place. However, work was halted and the project postponed for several years due to a lack of financial backing. In 2016 the project was taken over by the energy providers at Hidroeléctricas de Occidente S. de R.L. and construction work on the implementation of the plan recommenced the following year.

May 2019

14.05.2019 15:31:13

The power generated at the plant passes along overhead powerlines to the nearest distributor station.

Screenshot: Schubert

HYDRO

Rendering of the plant control infrastructure programmed by Schubert Elektroanlagen.

meant it was never installed. While the larger turbines produce a bottleneck output of 7,334 kW for an additional flow of 2 m³/s per turbine, the third unit can ensure a bottleneck output of 3,299 kW at a maximum flow volume of 900 l/s. Synchronised generators coupled directly with the turbine shafts serve as energy converters. On taking over the project the current operators also took ownership of the generators purchased by the original project developers – which had remained in storage for several years. Hence, the larger turbines had to be adapted for a perfect fit. The smaller unit was provided in its entirety by the Upper Austrian specialists, and also included a Marelli- manufactured generator. GRID OPERATOR TAKES CONTROL Lukas Rudolf, Schubert’s commissioning inspection technician, explained that – in terms of electrotechnics – it became essential for the Honduran grid operators to ensure they could control the plant remotely. “Fairly late in the day the grid operators added the condition that they had to be able to set the active and reactive power of the system at any time. Ultimately, it was only possible to clarify and deliver on these demands shortly before the plant officially went online, when the responsible parties were

finally able to deliver the specifics.” Basically, the grid operator is provided with all the key readings for the power plant. These form the basis for increasing and decreasing output in order to improve the facility’s capacity to counteract power supply fluctuation in the region.

480 V to 24 V low-voltage components were also installed in specially planned control cabinets. An emergency power diesel generator was provided as an additional operational safety measure in case of complete power outages.

ELECTRICS AND CONTROL TECHNOLOGY Schubert’s consignment included a SCADA system programmed to WinCC and the full portfolio of electrotechnical equipment – and also entailed provision of a 36-kV gas-insulated medium-voltage switch system for grid feed and power metering purposes. Three turbine power transformers (2 x 8.75 MVA and 1 x 3.75 MVA) guarantee that the voltage of the energy produced is adapted correctly before it is fed onto the public grid. A separate 200 kVA auxiliary power transformer was also provided. The components regulating the control of the three turbine units were installed in purpose-built control cabinets. Along side the PLC turbine controls the cabinet also contains the excitation power components and the plant’s electrical protection parts. The

PLANT ONLINE FOR NEARLY A WHOLE YEAR Once final installation work had been completed and the entire system approved by the grid operator, the power plant went into operation in the summer of 2018. Subsequently, trials were carried out for a range of operating conditions and requirements, and fine-tuning was done to maximise power generation efficiency. Independently of each another, following the transition from trial status to normal operation, the project managers at both GUGLER and Schubert gave a positive summary of the project and their first joint operation in Honduras. In only a few months the plant will be celebrating its first full year online. The operating company has estimated average annual power output of 100 GWh.

A special cooling water processing plant was installed to cool the generators.

May 2019

Projekt KW Pencaligue zek Hydro Internat 2019.indd 26

14.05.2019 15:31:13

HYDRO

What is currently becoming Italy’s largest power plant project is proceeding almost invisibly. Ultimately, the new St. Anton power plant is being constructed in the depths of Hörtenberg, Bozen’s local mountain to the north of the capital of South Tyrol. The private entrepreneurs of the project, Karl Pichler and Hellmuth Frasnelli, are investing around 55 million euros to place the power plant concept for the facility, which has existed since 1951, on an entirely new footing. The key aspect of this construction project is to eliminate the surges in the Talfer River, which have so far claimed the lives of 21 people since the existing power plant has been commissioned. In addition, the efficiency of the plant will increase and the installed machine output will rise from the previous level of 72 MW to 90 MW. All of the electromechanical equipment for this project is made in South Tyrol. The renowned hydropower specialist Troyer AG from Sterzing is supplying the equipment ready to use, and these are the largest turbines the company has ever delivered. The units have just been switched on for the first time and they have been generating power since early May.

s one of the most important local sites for recreation in the Bolzano municipal area, the meadows along the banks of the Talfer have always attracted large numbers of people, particularly in summer. “This is understandable. When the Talfer carries only 1 m3/s of water, people like to go in the river and enjoy sitting on the rocks. Unfortunately, in the past barely a month went by without people being rescued from the torrential Talfer because suddenly a surge of 16 m3/s dashes down,” says Karl Pichler from Eisackwerk GmbH outlining the wellknown, established problem with St. Anton power plant. In its history, since it began operating in 1951, 21 people have lost their lives in the Talfer. The reason: the surge which transformed the small stream into a torrential river in just 40 seconds. It is also obvious that such fluctuations in the flow of water have a

photo credits: Troyer AG

HOW POWER PLANT INFRASTRUCTURE CAN DISAPPEAR INSIDE A MOUNTAIN Three identical turbines made by Troyer AG have been installed. In total they deliver a power output of 90 MW.

devastating effect on the fish population and the fauna in the bed of the stream. But this downside to St. Anton power plant will be a thing of the past, as Karl Pichler explains. For this purpose, the new operators from Eisackwerk GmbH constructed a large underground equalizing basin in the turbine outflow which will ensure a continuous outflow from the power plant in the future. A cubic volume of 150,000 m3 has been blasted into the mountain to create the new demodulation basin. The basin, which is 900 m long and 13-15 m wide, can hold around 95,000 m3 of water. The construction works for it have already been completed. ENVIRONMENTAL IMPACTS ELIMINATED However, the project's leaders Karl Pichler and Hellmuth Frasnelli established the most important milestone in the new construction

KW St Anton_EN.indd 27

project back in February 2015. After a legal dispute lasting more than four years, Eisackwerk GmbH was officially declared the winner of the tender offer for St. Anton power plant. A short time later, the private company was able to acquire the power plant from SE Hydropower. With an installed power output of 72 MW and a standard capacity of 270 GWh, the plant was and still is the fifth largest hydropower plant in South Tyrol. But there is still room for improvement. Pichler and Frasnelli have set a target of increasing the yield by 10 per cent. The focus in redesigning the plant was on boosting efficiency, higher environmental compatibility and operational safety. “We are nullifying all environmental impacts by moving the whole power plant into the mountain to a depth of 300 m”, explains Karl Pichler, adding: “We have already gained a great deal of experience on how this May 2019

14.05.2019 15:32:15

HYDRO

The 6 m wide access tunnel leads 300 m into the mountain to get to the new machine cavern.

can be done in construction terms from Mühlbach power plant.” The Mühlbach HPP officially began operating in 2012 and all of its infrastructure is likewise housed inside a mountain. It is still regarded today as a truly pioneering feat of power plant construction, and it has delivered many benefits for the community of Mühlbach and its residents. SPECIAL RECOGNITION The positive response to the new construction of the traditional St. Anton power plant has in fact been even stronger, as Karl Pichler confirms: “The project was recognised by the President of Italy, Sergio Mattarella, as one of the ten most environmentally friendly projects in Italy. It is a first in Italy for a hydropower project to receive such recognition.” This of course is no coincidence. There probably is no other power plant in Europe where such an effort has been made to eliminate the negative effects of hydropeaking. It is no wonder then that the St. Anton project has also received the highest praise from fishermen, who are often obviously sceptical towards power plant projects. FAVOURABLE CONSTRUCTION PROCESS The majority of the excavation and concrete works on the equalizing basin, the machine cavern and the access tunnels were completed back in the middle of last year. “Thanks to the favourable progress of the construction, we were able to meet our timetable precisely,” Karl Pichler outlines with delight. The underground construction works were facilitated by

the general geological conditions. The Bozener porphyry rock is as hard and stable as granite, moving forward through blasting therefore works smoothly. At the height of the excavation works, the team advanced through the rock up to 12 m per day while approximately 1,800 kilograms of dynamite were exploded daily and more than 1,500 m3 of excavated material were transported out of the mountain. In total, up to 270,000 m3 of rock have been removed. The geological stability means that even the large caverns require hardly additional reinforcing concrete arches for stabilisation. Prior to these works, the reservoir situated on the plateau above was also emptied and cleaned up. The entrepreneurs also relied on an innovative method for this operation. “A specialized company that we commissioned flew floating platforms onto the reservoir by helicopter. Powerful pumps were attached to them using suction pipes to convey mud and water onto the floating platforms where the mixture of mud and water was passed through a Coanda screen to remove coarse debris. Du-

ring the water abstraction, the water containing the fine sediment was released through the turbines before the catchment and thus channelled through the turbines. We found a sediment load in the works water of no more than 3%, which is fine. During storms, the works water is contaminated with much higher loads of suspended solids. Using this environmentally friendly method, we have cleared up the whole area in the water catchment in the reservoir. The coarse-grain sediments have been deposited safely away from the water catchment,” says Karl Pichler. The reservoir holds around 350,000 m3, 320,000 m3 of which can be utilised to produce hydropower. VERTICALLY THROUGH THE MOUNTAIN The excavation of the shaft for the vertical penstock also proceeded on schedule using a raise boring method. This involves first drilling a pilot bore from top to bottom, in case of St. Anton power plant over a vertical distance of 523 m. The hole was then widened to a diameter of three metres from the bottom

Italy’s Minister of Economic Affairs made the following comment on his Twitter account in relation to this photo: "This team is completing incredible work. It is the most innovative hydropower plant in Europe and will soon be talked about in the rest of the world.”

photo credits: Eisackwerk GmbH

photo credits: Troyer AG

The new St. Anton hydro power plant has been constructed in the depth of Hörtenberg, Bozen's local mountain in the north of the capitol.

May 2019

KW St Anton_EN.indd 28

14.05.2019 15:32:17

HYDRO

The Troyer AG has also been responsible for the complete electrical equipment.

photo credits: Troyer AG

The pressure test for the penstock has been carried out successfully in the second half of April.

upwards – a proven and efficient method. The pipe shaft was excavated by the end of July last year. The rest of the procedure, in which the penstock has been installed in the shaft, proved to be particularly challenging. As with the construction of the vertical penstock at Mühlbach power plant, the steel penstock was lowered into the shaft from above as well. The 12 to 13 m long pipe sections were welded onto the piece of pipe below, the welded seam was checked and treated with protection against corrosion – and then lowered further down. This

process was continued until the pipeline had reached the level of the demodulation basin. “For this purpose, a stable tower that can support the biggest loads has been built at the top end of the shaft. In the end a mass of around 800 tonnes hung on this tower. There are huge forces at work at the plant,” explains Karl Pichler. From the beginning of February to the beginning of April, the pipeline was cast in concrete in the vertical shaft. The pressure test was carried out successfully in the second half of April.

With an output of 30 MW, these are the biggest and most powerful turbines that the experienced hydropower specialist Troyer AG has so far manufactured in its history.

photo credits: Troyer AG

LIMITS REACHED For the medium-sized family enterprise, the project does of course represent a major challenge. “In terms of design, there were fundamentally no big differences compared to small-scale hydropower for us. But the situation is definitely different as far as the internal logistics and manufacturing technology are concerned. Due to the significant dimensions of the individual components, we encountered a few limits – particularly in relation to gates or the handling of the large parts,” explains Thomas Fiechter, Troyer AG's project manager. The three turbine housings were completely preassembled at the Troyer AG factory in Sterzing and delivered to the construction site along with the ring line and the shut-off valve. By August 2018, all three turbine housings had been delivered to the St. Anton cavern.

KW St Anton_EN.indd 29

LARGEST TURBINES IN THE COMPANY’S HISTORY While the excavation works for the pipe shaft were still well underway, the machine installation work had begun last year's summer. At a depth of 300 metres inside the mountain, three identical turbines were installed which deliver a power output of 90 MW totally. The contract to supply all the electromechanical equipment at the power plant was secured by a company that is based not far from the power plant construction site: Troyer AG from Sterzing, which previously supplied the machines for Mühlbach power plant. With an output of 30 MW each, these are the biggest and most powerful turbines that the experienced hydropower specialist has so far manufactured in its history as a company. “Never change a winning team,” says Karl Pichler, referring to the “very good experiences gained in Mühlbach”. “We have seen that Troyer is in essence more than a match for the very big players in the industry – and also delivers the added benefit of implementing the plant so that it is fully ready for use, including transformers and generators.”

May 2019

14.05.2019 15:32:20

HYDRO

photo credits: Troyer AG

In total, 186 medium-voltage end terminals were implemented with more than 16 km of medium-voltage cables.

The runner design was made for highest efficency.

They were followed by the generators in midSeptember, which have been transported from Dresden to South Tyrol. The medium-voltage installations were then delivered and mounted. They are designed for short-circuit protection for currents of up to 63,000 A. The cabling for the installation proved to be a particular challenge. Thomas Fiechter says: “In total, 186 medium-voltage end terminals were implemented with more than 16 km of medium- voltage cables. Moreover we supplied and provided the cabling for all the control and automation cabinets.” In addition, two high- voltage transformers were supplied, fitted and wired up along with all the control, automation and protective fields. DESIGNED TO MEET THE HIGHEST REQUIREMENTS The installed turbines are specifically 4-nozzle, vertical-axis Pelton turbines with brake jets. Nozzle mounting: An unusually large amount of space for the fitter inside the turbine housing.

Rotating inside the turbine housing are rotors with an external diameter of 2,080 mm on which a total of 19 buckets have been fitted. The rotors were milled from a monobloc of highly alloyed steel and naturally configured in terms of their hydraulic design to cater for the high demands and requirements in the optimum way. The works water does at any rate overcome a drop of around 595 m from the reservoir down to the machine cavern. This means that normally a pressure of around 60 bar acts on the shutoff valve and turbines and the water leaves the nozzle needle at a speed of around 385 km/h. In this way, the rotor drives the directly coupled 3-phase synchronous generator via a free-flying shaft at 600 rpm. Each of the turbines is designed for an absorption capacity of 6 m3/s. These are high-end machines, both in terms of their robustness and availability and as far as efficiency is concerned

reflected the cutting edge of today's hydropower technology. “We did of course carry out numerical studies and analyses beforehand. We reckon the maximum turbine efficiency level is 0.915,” says Thomas Fiechter. IMPROVEMENTS TO ALL COMPONENTS The machine shut-off valves in use are spherical valves with a mobile operating and inspection seal of dimension DN1000 and pressure class PN80. They were designed and optimised for operation at the new St. Anton power plant by Troyer AG's engineers, likewise conducting numerical calculations. This is also true incidentally for the ring line and the pipe distributor. In each of these components, flow-related losses can of course occur if they are not optimally adapted. As the water level in the demodulation basin rises with a fill level of 8.10 metres, the turbi-

Technical Data • Flow Rate: 18.0 m3/s • Head: 595 m • Turbines: 4-nozzle Pelton-Turbines (3 pcs.) • Manufacturer: Troyer AG • Runner speed: 600 Upm • Runner pitch diameter: 2'080 mm • Number of buckets: 19 • Nominal output: 30 MW

photo credits: Meraner & Hauser

• Total output: 90 MW

• Generator: synchronous generators

(3 pcs.)

• Penstock length: 1'450 m • Vertical penstock: 525 m • Diameter: DN2200 Material: steel • Spherical valve: PN80

DN1000 (Troyer AG)

• Electrical Equipment: Troyer AG • Annual production: 300 GWh

May 2019

KW St Anton_EN.indd 30

14.05.2019 15:32:22

HYDRO

photo credits: Troyer AG

The key aspect of this project was to eliminate the surges in the Talfer River, which have so far claimed the lifes of 21 people.

nes must also be positioned higher. “There is another drop in height as a result of the 362 m long return channel. Despite this, through careful planning we succeeded in limiting the loss in the drop compared to the old structure to 4.96 m,” says Karl Pichler, explaining how the target for an increase in efficiency of 10 per cent should still be achieved: “Thanks to the new equalizing basin, the new power plant will be able to process 18 m3/s rather than the previous figure of 15 m3/s. It is also possible to reduce friction losses thanks to the new penstock. Compared to the old structure with DN1700/1600, the new penstock now has a clear width of DN2200. What is more, we now have more efficient and powerful turbines and will be able to reduce the downtimes to a minimum. And not to forget: The drop at the equalizing basin is also utilised by two Kaplan turbines from Troyer AG. All these measures combined we will achieve a 10 per cent increase in yield that we are looking for. We are in fact secretly hoping for an increase in production of up to 20 per cent.” With an electrical bottleneck capacity of 90 MW, in an average year the new St. Anton power plant will in future generate around 300 GWh of clean electricity from the River Talfer.

tricity which is generated is brought out of the mountain at a medium- voltage level of 13,800 volts and then increased up to 220 kV. The importance of the fifth-largest hydropower plant in South Tyrol for the stability of the grid cannot be overestimated. Particularly in relation to the sharp rise in volatile sources of electricity, such as photovoltaics and wind power, there is a need for powerful facilities which can, when required, deliver the necessary balance at the frequency band of the supply network. But a new era will also shortly be dawning as far as operational safety is concerned. The water level in the River Talfer may of course still vary a little in the future – specifically at a ratio of no more than 1:4, with the rise and fall in the level taking place gradually. But this will be quite harmless compared to the previous hydropeaking ratio of 1:16. This means that the power plant will not only be safer for nature lovers along the River Talfer, but will also be more beneficial ecologically for all of its residents. The first electricity was generated in early May 2019.

photo credits: Troyer AG

POWER PLANT AS GRID STABILISER The new cavern power plant in the north of Bozen is designed as a peak-load power plant and is also intended to be operated as such. Thomas Fiechter says: “This fact does of course place the biggest demands on the generator and the medium-voltage installation. Both have been designed for repeated start-up and phasing out of the turbines – generally up to five times a day – is guaranteed without any problems.” The elec-

The shut-off valves are spherical valves with a mobile operating and inspection seal of dimension DN1000 and pressure class PN80.

The generated electricity is brought out of the mountain at a medium-voltage level of 13,800 volts and then increased up to 220 kV.

KW St Anton_EN.indd 31

May 2019

31 14.05.2019 15:32:26

HYDRO

photo credits: Geppert

The Geppert GmbH engineers built five small-sized Pelton turbine sets in specially modified industrial containers for the Ruzieh project in Iran.

SUCCESSFUL PREMIERE FOR TYROLEAN HYDROPOWER CONTAINERS IN THE MIDDLE EAST The hydropower allrounder Geppert has successfully concluded a further project in the Middle East, this time in the form of five small-scale power plants, each pre-assembled in its own container for use in the drinking water supply of the Iranian city of Semnan. Counting from the receipt of the order confirmation in March 2018 to acceptance by the customer at the end of June, the ready for connection turbine sets including generators and hydraulic units had to be designed and manufactured from scratch within a period of less than four months. These container-mounted plug and play solutions (a first for Geppert) represented a challenge for the company, not least because of the very tight schedule. Electric power is generated by five ultra-compact Pelton turbines with vertical shafts, some equipped with 5 nozzles and others with 4. These powerful small-scale power plants combine to generate a bottleneck capacity of more than 3 MW, all of which the operators feed directly into the public grid throughout the year. The containers were rapidly connected and commissioned on schedule after their arrival on site. Geppert now plans to expand sales of this versatile and inexpensive container system in the future.

he Tyrolean turbine manufacturer had already supplied a turn-key system for drinking water power generation back in 2017 to Roshd Sanat, an Iranian Group active in the fields of energy, construction and manufacturing industry. A power plant with a Francis spiral turbine with a bottleneck capacity of just under 3.5 MW was constructed in the existing drinking water pipeline close to Qom, a city with a million inhabitants in the north of the country. The Ruzieh project (named after the Ruzieh Springs drinking water source and constructed in record time) was

also planned to take advantage of the previously untapped energy potential of an existing drinking water pipeline to generate electricity. Unlike the Qom power plant, this project, located close to the city of Semnan about a further 270 km to the north-east, included the simultaneous manufacture of five turbine units pre-installed in containers. In a contract concluded between Roshd Sanat and the Semnan water supply utility, these hydropower containers were to be installed in several different locations along a primary drinking water pipeline.

ORDER WITH A TIGHT SCHEDULE The plan was to install each of the containers next to existing intermediate reservoirs for the drinking water pipeline. The highest power plant, called “Station 1” was located 2,146 m above sea level, while the lowest one was at a height of 1,316 m. All the turbine sets except for Station 4, where the customer had installed a pump turbine, were supplied by Geppert. Looking back over the contract, Geppert’s Project Manager, Ulrich Ruggenthaler, recalled that the schedule represented the greatest challenge. “As a result of the customer’s

May 2019

Projekt KW Ruzieh zek Hydro Internat 2019.indd 32

14.05.2019 15:33:42

HYDRO

delivery requirement of the end of June, we had less than four months to complete the design, manufacture and pre-assembly after receiving the order in March 2018. It was also the first time for us that the turbine sets had to be constructed inside containers.â&#x20AC;? Ruggenthaler added that as their suppliers had full order books the on-time supply of bought-in components such as generators and hydraulic equipment could not be taken for granted. COMPACT EQUIPMENT INSTALLED IN CONTAINERS A number of key conditions had to be met when constructing the hydropower units in containers originally intended to transport goods. The turbine cases, which could not be made with the usual ring mains because of the lack of space, had to be manufactured as ultra-compact units. Computer-supported flow analyses completed before manufacture commenced confirmed that optimal functionality and efficiency levels could be achieved even with the constricted turbine cases. The design which was selected also enabled each of the five turbines to have an identical case, the modifications for the individual turbines being limited in the main to components such as nozzle needles or the corresponding orifices. Turbine components in contact with the water such as the Pelton rotors which were machined from monoblocks were all completely manufactured from food quality-certified stainless steel. The turbine sets were constructed on rigid frames so that they could be in an optimal position to resist the forces induced during operation. A special structure was also fabricated for installing the base plate. During installation on site the assembly frames and the floor structure of the containers were em-

Installation of a hydropower container

Installation of Station 1 at a height of over 2,100 m above sea level. The hydropower containers use the previously unexploited energy source of a main drinking water pipeline for the city of Semnan in the north of the country.

bedded in concrete foundations. The designers also devoted particular attention to the exchange of air and heat dispersion inside the metal containers. This was achieved by fitting all generators with their own exhaust air shafts which conveyed the hot air from the generator directly into the open air. Two separate ventilation slots in the container walls supplied fresh air to evaporate the condensate which inevitably formed on the turbine cases. BOTTLENECK CAPACITY UP TO 745 KW Except for the number of nozzles (two turbines were supplied with 5 nozzles and three turbines with 4) the machines were to all in-

Stations 2, 5 and 6 ready for delivery. The plug-and-play solutions make quick and easy on site installation possible.

Projekt KW Ruzieh zek Hydro Internat 2019.indd 33

tents and purposes identical in construction. Because of the cramped conditions inside the containers the designers had opted for a space-saving hydraulic/mechanical combination to control the nozzles. The nozzle needles are precisely controlled by a hydraulic cylinder acting on a rigid rod. The cylinder is connected to a hydraulic system also housed in the container and controls the plantâ&#x20AC;&#x2122;s deflectors and the emergency shut-off valves at the same time. Each turbine has a nominal discharge of 500 l/s for power generation at its disposal, with the usable heads varying between 147 and 189 m. The turbines with 5 nozzles rotate at 750 rpm and the ones with 4 heads rotate

May 2019

14.05.2019 15:33:43

HYDRO

Pelton turbines, directly coupled synchronous generators and hydraulic equipment for five sets were accommodated in containers. Turbine controls, low voltage equipment and transformers are located in separate buildings.

at 1000 rpm. At peak water availability the turbines generate bottleneck capacities between 499 kW and 745 kW. Five vertical synchronous generators are coupled directly to the turbine shafts and act as energy converters. The generators rotate at exactly the same speed as the turbines and each was manufactured with a connection voltage of 400 V. The generators coupled with the turbines with 5 nozzles achieve a rated apparent power of 560 kVA each, and two of the generators powered by the turbines with 4 nozzles achieve 800

www.prointegris.hr

kVA while the third generates 630 kVA. The technical equipment inside the containers is supplemented by the hydraulic units. The turbine control systems, low tension equipment and transformers are accommodated in separate buildings. PROBLEM-FREE INSTALLATION After acceptance of the hydropower containers by the client in the factory, delivery to site was completed in July 2018 as agreed in the contract. The “Made in Tyrol” hydropower containers were delivered to the Middle East in an overland journey of several thousand kilometres. Their arrival in Semnan was delayed for several days by complications experienced during customs clearance. According to Project Manager Ruggenthaler who supervised the installation and commissioning on site between the end of August and the beginning of September, the container design proved to be extremely practical. “Unlike a large machine hall with several different pieces of equipment, the hydropower containers constitute just a single unit which has to be watched during installation. The result was that it was possible to complete the installation, which needed up to 40 persons at the same time, within a very short period. All the units had started work when I left on 7th September.” THE CONTAINER SOLUTION HAS A FUTURE As in the Qom drinking water power plant, the turbine control units and all the control engineering equipment for the Ruzieh project were manufactures by Pro Integris, a Croatian company specialising in the automation of hydropower plants. The controls for the plants are based on a SCADA system and enable the stations to be operated either manually or completely automatically. “The challenge for the control system was that both the power generation of the hydropower plants and the supply of drinking water had

Visualisation of the control system supplied by Pro Integris.

to be maintained without interruption. As a matter of principle, of course, the drinking water supply took precedence with the result that only the amount of water permitted by the water levels in the various reservoirs could be used for power generation. If any of the individual stations had to come to a complete standstill, the relevant bypass systems spring into action in a second, thus guaranteeing the drinking water supply every time. An on-line connection makes the remote monitoring and control of the power plants possible, and the control panels installed in the secondary buildings also enable the equipment to be controlled on site. Because of the good experience with the Ruzieh project, Geppert is very confident about the future of the hydropower containers. The turbine manufacturers are convinced that the low-cost power generation units can be used in increasing numbers to supply remote regions with electricity.

Technical Data • Flow rate: 500 l/s • Gross heads: 147 m - 189 m • Turbines: 3 x 4-nozzle & 2 x 5-nozzle Pelton • Runner speed: 2 x 750 & 3 x 1,000 rpm • Output Station 1: 499 kW • Output Station 2: 745 kW • Output Station 3: 517 kW • Output Station 5: 716 kW • Output Station 6: 586 kW • Manufacturer: Geppert GmbH • Generators: 5 x Synchronous • Voltage: 5 x 400 V • Output: 2 x 800, 2 x 560, 1 x 630 kVA

May 2019

Projekt KW Ruzieh zek Hydro Internat 2019.indd 34

14.05.2019 15:33:45

HYDRO

The revolutionary mobile power station

Your declaration of independence

www.geppert.at

Projekt KW Ruzieh zek Hydro Internat 2019.indd 35

May 2019

14.05.2019 15:33:45

HYDRO

11TH RENEXPO INTERHYDRO HYDROPOWER TRADE FAIR IN SALZBURG photo credits: Mike Vogl

Under the motto “Hydropower needs politics needs hydropower”, RENEXPO INTERHYDRO will be taking place at Salzburg Exhibition Centre on 28 and 29 November 2019. This trade fair, which is open to the public, has become established over 11 years as a very good platform for networking and the mutual exchange of information.

p until the beginning of the 20th cen tury, water power was utilised mainly in mills. The fact that today hydro power is making a significant contribution to delivering a safe, sustainable and climate-neu tral energy supply is the subject of the Euro pean hydropower fair with affiliated congress. The patron of the event is the State of Salz burg with the Deputy State Governor Dr. Heinrich Schellhorn. KNOWLEDGE TRANSFER AND NETWORKING The trade fair is aimed primarily at people from business and industry, authorities and local municipalities, politics and science from right across Europe who are involved directly with hydropower. Interested visitors and experts will be given an overview of all essential aspects that make hydropower an efficient, reliable and capable form of energy. Well-known companies will present the full hydropower value chain at the trade fair. This will range from manufacturers of Kaplan, Francis and Pelton turbines, generators, seals, pipes and other plant components, power plant control systems, plant construction, maintenance and optimisation through to measurement and control technology, electri city trading, electric service stations and di rect marketing – from long-established fa

RENEXPO INTERHYDRO held at Salzburg Exhibition Centre has established itself in recent years as a hub for the international hydropower industry.

mily businesses through to international companies. The topics of this year’s congress on the Thursday and Friday alongside the exhibition will be the latest practical experiences and projects as well as energy storage, small-scale hydropower as electric service stations and hydropower expansion that is compatible with water ecology. Once again this year, in ternational markets will be presented with the 3rd Eastern Europe Hydropower Forum and the 3rd “Hydropower in Africa” seminar. This year’s partner country for the trade fair is Italy. Italian exhibitors will present their pro ducts and provide information about new technologies and current challenges. The trade fair and congress will provide a comprehensive overview of new technolo gies, the political framework in Europe and the future of hydropower.

A designated networking location is the In ternational Hydropower Associations Stand in the Hydro Lounge. This is where associa tions will provide information about their activities and innovations – a meeting place at which you will be able to discuss the ener gy supply of the future and find tomorrow’s answers. At the 4th European Association Meeting, the associations will also exchange views on the current political situation with the aim of combining their interests better and strengthening the hydropower sector across Europe. On both days, the Hydroforum in Hall 10 will offer visitors to the trade fair an interes ting and varied programme with talks and discussion panels on current topics in the in dustry. Further information can be found at: www.renexpo-hydro.eu Impressions from RENEXPO INTERHYDRO 2018

May 2019

Projekt Renexpo Vorbericht Internat 2019.indd 36

14.05.2019 15:34:36

HYDRO

FIRST ANNIVERSARY FOR UNDERGROUND POWER STATION GLETSCH-OBERWALD IN THE UPPER VALAIS REGION

he fact that there was considerable hydropower potential along the upstream stretch of the Rhône near the Valaisian municipality of Obergoms, between the districts of Gletsch and Oberwald, had been known for many decades. In a current article published in the Swiss trade journal “Wasser Energie Luft” (“Water, Energy, Air”) Raoul Albrecht, Member of the Board and Head of Production at FMV SA in Sion, notes that various concepts for exploiting the hydropower potential in the project area in the Upper Valais region had been under consideration since the 1970s. Among others, these included the construction of a 100-million cubic metre reservoir in Gletsch, as well as various pumped-storage concepts. However, due to the growing public sensitivity with respect to environmental and landscape protection in the 1980s, and in view of changing economic conditions, the plans for the construction of

Installation of the electromechanical equipment in the cavern was completed by ANDRITZ Hydro in 2017, with regular operation commencing already in early 2018. In an average year, hydropower plant Gletsch-Oberwald generates around 41 GWh of energy.

photo credits: FMV

The newly constructed Gletsch-Oberwald power station in the Upper Valais region of Switzerland has been producing clean energy since early 2018, making efficient use of the energy potential of the upper Rhône river at the foot of the Furka pass. Financing for the logistically complex CHF 67 million project was provided by Sion-based energy supplier FMV SA. From the turbine house and 2.2 km pressure tunnel to the integrated desilter, most of the facility is installed underground. The plant’s three-year implementation phase included extensive rock blasting work and the use of a tunnel boring machine with a 3.9 m diameter to excavate around 90,000 cubic metres of rock. In view of the impressive performance of the finished plant, however, it is safe to say that the effort was well worth it. With full water resources available, the two identical Pelton turbines provided by ANDRITZ Hydro achieve a total of more than 14 MW. In normal years, this high-tech facility supplies the power for around 9,000 Upper Valais households. To comply with the environmental regulations for power stations, amelioration measures had to be implemented in an extensive riparian area.

a large hydropower facility were subsequently put on ice. However, the introduction of the “Compensatory Feed-in Remuneration” (CFR) in 2009 as a means of subsidising energy from renewable resources, marked a turnabout in the economic situation for Swiss energy providers. Energy provider FMV SA had had the foresight to prepare a feasibility study for a regional power station project already in 2007, and one year after the introduction of the CFR was able to submit a license application for the construction of a hydropower station in the area under consideration.

The entire construction and rock blasting work, including the excavation of the 2,150 m headrace tunnel with a tunnel boring machine, was carried out by Strabag AG.

Projekt KW Gletsch-Oberwald zek Hydro Internat 2019.indd 37

ECOLOGIC PACKAGE OF MEASURES An operating license for a period of 80 years was granted to FMV by the Valais cantonal authorities in 2013. This was possible only because a settlement could be agreed with the regional environmental agencies, which had initially objected to granting the requested license. Intense negotiations between all affected parties led to a package of several measures, the most crucial of which called for comprehensive ecological amelioration measures in the riparian “Sand” area near Oberwald. Additionally, the plans included to flood protection measures for the community, and va-

May 2019

14.05.2019 15:35:10

HYDRO

Due to the confined space, the construction of the desilter cavern was a logistic as well as an engineering challenge.

rious touristic aspects. For example, additional tributary streams of the Rhône in the riparian area were to be opened, a footbridge was to be installed, and hiking paths were to be prepared. Once the license was granted, the planning approval application could be submitted in late 2013, which also marked the start of the tendering process. Actual construction work commenced in spring 2015. LOGISTIC CHALLENGE Commenting the on-site inspection by zek Hydro of the latest-generation underground turbine house, Raoul Albrecht names the organisational and logistic aspects of the project as the greatest challenge during the construction phase: “As usual with large-scale projects in the Alpine regions, we were faced with a lot of logistic challenges. We had worked out a basic concept that would allow construction work to continue all year round. However, work at the forebay in Gletsch was possible only during the summer and autumn months, as access via the Furka pass road was closed for around seven months due to the avalanche risk there. That made the completion of the Oberwald tunnel all the more urgent as the

only was to enable year-round access to the construction site at the forebay.” Moreover, despite the limited spatial conditions inside the mountain and at the gallery access points, the engineers had to prepare the space required for the transport of material and equipment, along with a suitable location for preparing the concrete. As far as coordination planning was concerned, it was necessary to organise the work into multiple shifts with around 40 staff to work them. Detailed planning for the individual sub-installations was provided by four contracted engineering offices. TUNNEL BORING MACHINE CUTS HEADRACE TUNNEL Internationally successful underground construction specialist Strabag AG won the contract for the entire drilling, rock blasting and concrete placement work. April 2015 marked the simultaneous kick-off to the blasting work for the two access galleries in Gletsch and Oberwald. In Oberwald, the first 300 metre stretch of the access gallery leading up to the turbine house was excavated exclusively by blasting. The gallery was also used for getting

Inside view of the Pelton turbine with the rotor, which was milled from a monobloc.

the 120 m long tunnel boring machine in pace so the construction of the headrace tunnel could go ahead. Measuring 3.9 m in diameter, the boring head began its work in October, cutting its way through the rocky crag of the Grimsel massif. Excavation work for the underground turbine house and the tailrace tunnel, through which the processed motive water is returned to the Rhône river, was also begun in autumn 2015. About half of the 90,000 cubic metres of excavated material that was blasted out of the mountain was directly recycled and used as concrete and gravel material for construction. Thanks to the favourable geological conditions and the perfect collaboration among the various firms involved in the project, the tunnel breakthrough to Gletsch was achieved by April 2016, after just six months. With the gallery complete, the water intake in Gletsch was now accessible all year round for the entire rest of the construction period. GRP MATERIAL REDUCES INSTALLATION TIME In the area in front of the transit to the underground turbine house, the final section of the penstock (approximately 60 m) was imple-

Technical Data • Flow rate: 5,7 m3/s • Gross head: 288 m • Headrace tunnel: 2,150 m • Turbines: 2 x 6-nozzle Pelton • Runner Speed: 2 x 600 rpm • Runner Ø: 2 x 1,150 mm • Output: 7,500 kW • Manufacturer: ANDRITZ Hydro • Generators: 2 x Synchronous • Output: 2 x 8,100 kVA The pipework was backfilled with concrete along the entire penstock run.

• annual standard capacity: approx. 41 GWh

May 2019

Projekt KW Gletsch-Oberwald zek Hydro Internat 2019.indd 38

14.05.2019 15:35:11

HYDRO

mented in the form of a solid steel construction. In the bottom third of the gallery, this followed by an approximately 700 m run of GRP pipework. As the pipe elements had already been lined with concrete at the factory, they could be installed using the rails that had been installed for the tunnel boring machine. Once the pipe elements – each measuring 6 m and weighing 15 tonnes – were installed, they were backfilled with concrete along the entire run. This method, says Albrecht, was much faster than using steel armour plating. Thanks to the excellent condition of the rock, the subsequent 1.3 km penstock run leading to the desilter at the forebay could be completed using concrete lining without the need for any additional reinforcement. In total, the headrace tunnel with its steady 13-degree gradient measures 2,150 m in length and includes an almost 90-degree bend. FOREBAY AND DESILTER The construction of the forebay in the form of a bed intake, along with interior work on the desilter cavern, were completed during the summer and autumn months of 2015 to 2017. A temporary diversion of the Rhône with its flow capacity of 20 m³/s provided a dry working area with added protection in case of high water levels. As Albrecht points out, completing the interior construction for the entirely rock-blasted desilter cavern came with its own set of challenges. In an extremely confined space and in very short time, strong concrete walls 10 m high were put up while the hydraulic steelwork was put into place. In its finished state, the desilter consists basically of two high-volume reservoirs, each measuring 45 m in length, where fine-grained debris from the glacier and the sediments from the Rhône waters can slowly settle. Thanks to the well-coordinated collaboration of the executing contractors, the work on the forebay and close-by desilter cavern were completed on schedule in autumn 2017. CUTTING-EDGE UNDERGROUND TECHNOLOGY Starting with the installation of the two turbine casings, work on the technical equipment for the cavern in Oberwald commenced in spring 2017. The delivery included the electromechanical equipment and the automation and control system – an all-in-one package provided by internationally active all-around hydropower specialist ANDRITZ Hydro. With the electrical engineering work complete, the facility was taken into trial operation in November 2017. Two 6-nozzzle high-efficiency Pelton turbines are used to ensure maximum utilisation of the Rhône’s energy potential both at full and reduced flow rates. The

The forebay was positioned in immediate proximity to the railway line in Gletsch, next to the desilter, which is also located in an underground cavern.

two vertically aligned turbines have a total design flow rate of 5.7 m³/s as well as a gross head of 288 m to put to optimum use. When the full water volume is available, each of the machines with hydraulic nozzle control can achieve a bottleneck capacity of 7,500 kW. Each of the 1,150 mm turbine rotors was milled from a stainless steel monobloc and rotates at 600 rpm. The directly coupled vertical synchronous generators are operated at precisely the same rotational speed. Water cooling in the generators’ casing ensures optimum operating conditions during heat-intensive full-load operation. A previously installed indoor crane proved extremely useful in installing the generators, each weighing 35 tonnes and generating a rated apparent power of 8,100 kVA. The power generated this way is fed into the medium-voltage switchgear and then stepped-up to 16 kV by two transformers inside the cavern. At this voltage the electrical energy is transported via underground cables to the “Pfarrwerk” sub-station and on to the nearby (65 kV) Ulrichen sub-station, from where it is finally fed into the next-higher grid level. ANDRITZ Hydro’s control and automation system also provides fully automated regulation of the energy production process. The system is operated via control cabinets with the help of large touch screen panels.

The processed motive water is returned to the Rhône river.

FMV TRUSTS IN HYDROPOWER POTENTIAL The Gletsch-Oberwald power station commenced regular operation already more than a year ago, in January 2018. In late August 2018, the facility was formally inaugurated in an official ceremony. “Despite tight energy markets, FMV decided in 2015 to implement the construction of the new Gletsch-Ober-

Projekt KW Gletsch-Oberwald zek Hydro Internat 2019.indd 39

wald hydropower plant on their own account and as the sole building owner. This is in line with the cantonal and corporate strategy of putting the hydropower potential of the Valaisian municipalities to efficient use,” commented FMV’s Managing Director, Paul Michellod in an official press release. Project manager Albrecht is highly satisfied with the energy production of the FMV’s new hydopower plant after its first year in operation, and he commends all firms that helped to implement the project. With its annual standard capacity of 41 GWh, the power station satisfies the annual energy requirements of 9,000 average households.

May 2019

14.05.2019 15:35:12

Foto: Braun

In total five machine units with a bottleneck capacity of more than 50 MW have been installed in the new double hydro power plants Mestiachala 1 & 2 in Georgia.

Photo credits: Svaneti Hydro

HYDRO

AUSTRIAN HYDROPOWER TECHNOLOGY MASTERS ALL CHALLENGES IN TRANSCAUCASIA Two powerful new diversion-type hydropower plants have been built along the Mestiachala river in the well-known Svaneti region of Georgia for a total investment volume of around 65 million US dollars. The two-plant joint venture, financed by the Georgia Capital Group and Austria’s RP Global Investment, has now almost been completed. The consortium put together a team of expert businesses to ensure optimum implementation throughout the entire project. The Austrian hydropower specialists at Kössler were selected for their expertise in turbine technology. In addition, the know-how of the people at the Braun Maschinenfabrik, also an Austrian company, was brought on board for hydropower steel infrastructure engineering. Shortly, both plants will be going online and are expected to feed 176 GWh of clean power into the Georgian electricity grid on an annual basis.

n order to reduce dependence on foreign energy imports the government of Georgia decided to take advantage of one of the country’s greatest natural assets – water power. Today, Georgia’s water power provides around 80% of all the electricity consumed in the country. At the end of 2015 the country in the Caucasus region boasted around 70 hydroelectric power stations with a total operative power output of 2730 MW. The area’s mountainous topography and abundance of water makes Georgia a typical hydropower country. There are, of course, disadvantages associated. Although excess electricity can be sold to neighbouring countries in the summer months, low water levels in the winter mean the country is still dependant upon foreign

fossil-fuel energy. Georgia has been investing time and money in the expansion of its hydropower resources for several years in order to improve the country’s degree of self-sufficiency. After 2004, a new political course was set, which now also permits foreign investment in the expansion of hydropower infrastructure in the Caucasus. The double-plant project, Mestiachala 1 & 2, upon which work commenced in the summer of 2017, is a perfect example of this – Mestiachala 2 is already in operation, Mestiachala 1 will follow soon. STRATEGIC EXPANSION OF HYDROPOWER At the ground breaking ceremony at the beginning of July 2017, Georgia’s Energy Minister Kakha Kaladze announced: “This is

another step along the road to energy self-sufficiency”. In the speech he also spoke of the expansion of local infrastructure and the creation of jobs on the power plant site for the people in the region. The project was developed by Svaneti Hydro, a Georgia Capital Group joint venture holding 65% of the shares - and RP Global Investment, in possession of the remaining 35%. The Georgia Capital Group is an investment platform trading on the London Stock Exchange. RP Global Investment is an international strategic investor, project developer and operator from Austria with over 30 years of experience in renewable energy. The two partners have worked out a strategic approach to increase the use of regenerative energy sources in Georgia. Around 500 MW

May 2019

KW Mestiachala_EN.indd 40

14.05.2019 15:36:17

HYDRO

All shut-off devices have been delivered by Kössler as well.

50 MW FROM 5 TURBINES Specifically, the two power plants, Mestiachala 1 & 2, are diversion type stations on the Mestiachala river in the Mestia area. The

red the deployment of 3800m of GRP pipes, plus 3460m of steel piping - for a total piping distance of 7260m. CHALLENGING DELIVERY DEADLINE Kössler is a renowned Austrian hydropower technology manufacturer and had already supplied turbines for a Georgian hydroelectric power station, thus being a logical choice as a supplier of electromechanical equipment. The delivery contract was signed for the turbines, the generators, the entire electrotechnical infrastructure, and the medium-voltage system in June 2017. To ensure the electrical

Thanks to the close cooperation with the parent company Voith Hydro runners made by Kössler feature an ultra-modern and highly efficient design.

photo credits: Kössler

Water from 6 nozzles drive the turbine runner, which is 1350 mm in diameter.

207m (+/-) net head will be exploited by two identical 6-nozzled Pelton turbines at the Mestiachala 1 plant. Both have been set up for a flow rate of 6 m³/s and provide a bottleneck capacity of about 23.7 MW. The net head at the Mestiachala 2 station is very similar at 231m. However, the additional water collection channel along the Chalaati river allows the system to take in an extra 6m³/s of flowing water. This enables the three Pelton turbines, each designed for 6m³/s of flow rate, to achieve an overall bottleneck capacity of around 30 MW. In total, the two plants utilize three collection channels, two compensation basins and two power houses. The pipeline system is particularly impressive. Steel pipes were laid along a 1900m above-ground channel and the underground infrastructure requiphoto credits: Kössler

should be accounted for by solar, wind and hydropower. The joint venture acquired the requisite water rights for the double-plant project in an international call for bids. In 2014 and 2015 a declaration of intent was signed with the Georgian government for the implementation of each of the hydropower projects in the Svaneti region. “We received a great deal of assistance from the Georgian Ministry of Energy, underlining their commitment to the expansion of Georgia’s immense energy production potential”, explained Gerhard Matzinger, CEO of RP Global.

photo credits: Svaneti Hydro

Photo credits: Svaneti Hydro

Power house of Mestiachala 1 in the Svaneti region of Georgia.

KW Mestiachala_EN.indd 41

May 2019

14.05.2019 15:36:20

HYDRO

quirements placed on modern hydropower operations. “The size of the plant and the weight of the generator made it necessary to build turbines with interior-facing nozzles and to use concrete-embedded distribution pipelines. This also provides better protection from earthquakes; something that can never be ruled out in the Caucuses”, argued Karl Henninger. Kössler turbines are known for their robustness and excellent efficiency. The latter can be attributed in no small measure to the close cooperation enjoyed with the parent company Voith Hydro, and the provision of continually enhanced, ultra-modern runner designs. Kössler’s runners are considered to be among the most sophisticated designs on the market.

photo credits: Braun

The individual components for the weir gates were sent on a 3000 km journey on a low-loader all the way from Vöcklabruck.

bridge ahead of the site made it necessary to split up the turbine housings and dismantle the generators for the drive, and to reassemble everything on site. “Because we had already inspected the access routes before compiling our bid, we were aware of – and accounted for – the requisite measures very early on. Resultantly, the actual transportation of infrastructure was completed without any major restrictions”, reported Karl Henninger. Assembly work also went smoothly and was completed according to schedule, not least due to the excellent cooperation with the other companies on site. ROBUST AND EFFICIENT In technical terms there was no need to customise any of the 5 turbines. In principle, since Kössler turbines meet very high technical standards in general, they already fulfil all the rephoto credits: Braun

technology was installed flawlessly, Kössler chose a proven project partner in Schubert Elektroanlagen. The generators were provided by Nidec/Leroy Somer. The notable similarity of the operating conditions made it possible to send 5 identical turbine sets to the South Caucasus. The scheduling was extremely ambitious, as Kössler’s responsible area sales manager Karl Henninger confirms: “The delivery deadline posed a great challenge. However, flooding and an extreme winter caused construction delays that forced the restrictive timetable to be revised slightly.” The turbine housing, the corresponding distribution piping and the closing devices all left the Kössler works in Lower Austria last June. In total, delivery of all the parts to the power station site in the South Caucasus required 52 heavy good vehicle trips. A bottleneck on the road to Mestia and a 60-ton weight limit on a

250 TONS OF STEEL COMPONENTS Of course, a hydropower project of this magnitude is heavily reliant on robust steel infrastructure. Braun Maschinenfabrik was chosen by the responsible decision-makers as a company that has had a good reputation within the industry for producing supreme quality steel waterwork structures for decades – all over the world. “We were awarded the contract in July 2016 and completed the final designs for all of the components between autumn 2016 and May 2017. We produced all of the components at our workshop within about a year up to last April”, recounted Michael Habring, the Braun Maschinenfabrik project manager. In total, the Vöcklabruck company provided the entire package of mechanical steel structure for the three weir plants, the two storage basins and the powerhouses, including all the hydraulics, electrics and controls. Overall 250 tons of steel structure were sent from Upper Austria to the South Caucasus region. Habring explained: “Around 20 heavy good vehicles made

Technical Data KW Mestiachala I •

Flow rate: 12 m3/s

KW Mestiachala II • Flow rate: 18 m3/s

• Rated gross head: 207.50 m

• Rated gross head: 231.53 m

• Rated net head: 197.20 m

• Rated net head: 196.80 m

• Output capacity: 23.7 MW

• Output capacity: 30.9 MW

• Turbine type: pelton turbine 2 pcs

• Turbine type: pelton turbine 3pcs

• Runner speed: 428.6 rpm

• Number of nozzles: 6

• Runner pitch diameter: 1.350 mm

• Manufacturer: Kössler

• Penstock length: 1'800 m

• Penstock length: 7'260 m

• Hydromechanical equipment: Braun Maschinenfabrik

• Flap dimension: 19 x 3 x 2,8 m

• Flap dimension 1: 19 x 3 x 2,8 m • Flap dimension 2: 10,5 x 3 x 2,8 m

The backwater gates were delivered as separate components and welded together on site under the supervision of the Braun assembly team.

• Total average capacity: approx. 176 GWh • Commissioning: spring 2019

May 2019

KW Mestiachala_EN.indd 42

14.05.2019 15:36:22

HYDRO

BACKWATER GATES HALVED FOR TRANSPORT Last autumn the main components were installed, such as 19m x 3m weir gates, under the supervision of Braun Maschinenfabrik. The gates were cut down the middle for transportation, due to the lack of space on site, and were re-welded after installation. “We began the overall installation process in July 2018. A number of schedule changes led to some small delays. Nevertheless, we were able to complete the project on time”, stated Habring. The entire fortification and protective side plates were installed before the onset of winter – as were the hydraulics and control infrastructure in the late autumn. To this end a second specialist installation engineer was sent from Vöcklabruck to Mestia to complete the electrics and prepare

photo credits: Braun

ALL-INCLUSIVE CUSTOMISED SOLUTIONS Braun Maschinenfabrik’s scope of delivery was considerable. As well as the 19m-broad weir gates for both water collection channels on the Mestiachala river, the contract also included an additional steel weir gate with a width of 10.5 m on the Chalaati river. It also comprised several sections of stop log fortification, bottom outlets, three large debris rakes for the three channels, and a fine debris rake for each of the storage basins. Braun Maschinenfabrik also fitted each compensation basin with a deicing system and with a cable rake cleaning machine for the grate. Because they are so efficient at cleaning deep water fine-debris rakes, these machines have set the standards for decades and enjoy an excellent reputation. The steel infrastructure package for the weirs was rounded off by supplying the hydraulics, the corresponding electrotechnology and the control units. What makes Braun’s hydro-plant steel engineering so special is the fact that it is the product of immense know-how, and often involves custom-built solutions for specific requirements. Instead of installing conventional intake regulation gates to control flow to the intermediate storage basin, special gates were mounted for both power plants on the Mestiachala river. “The advantage is that they can be closed by a counterweight and protect the storage basin from flooding. If there’s a power outage the gates close automatically, without an external power supply”, explained Braun’s project manager.

Two steel weir gates, each 19m in width, were installed in the two water collection channels of the double hydropower plant project Mestiachala 1 & 2. As with all of the steel engineering, they were produced by the Austrian hydropower steel structure specialists at Braun Maschinenfabrik.

the infrastructure for commissioning. The weir systems were successfully pre-commissioned at the end of November. CONTRACT SHOWCASE IN GEORGIA Not only does this contract in the north-western part of Georgia provide proof of the expertise Braun Maschinenfabrik can offer on an international level, it is also the company’s first order from this Caucasian country. The responsible executives for the Upper Austrian specialists are justifiably proud that this hydropower project was an excellent opportunity to put on a broad-based showcase of the company’s immense expertise and consummate quality. Georgia is still considered an emerging market in the hydroelectric industry. Both power

The two hydro power plants at Mestiachala River are already connected and operating (M1 in test mode). .

KW Mestiachala_EN.indd 43

plants are connected to the grid already, and with a potential power output of 176 GWh they can be expected to make a significant contribution to Georgia’s energy production strategy. It is understandable that a project of this scale was of great importance, even to established hydropower specialists like Kössler. The Lower Austrian company had already provided turbines for two Georgian power plants, Gudauri in 2012 and Aragvi 2 in 2018, and has now installed a total of 8 turbines in Georgia. Successful completion of the two-plant project on the Mastiachala River by Kössler and Braun Maschinenfabrik has ensured they have left an impressive reference work for other potential customers to admire.

Photo credits: Svaneti Hydro

the long trip of around 3300km in total.” The first consignment arrived in June 2017 and altogether included around 15 tons of anchor plates for the two power plants. Subsequently, the steel infrastructure components for the power plant construction site were all delivered last July.

May 2019

14.05.2019 15:36:23

HYDRO

photo credits: zek

Multi-stage hydropower plant Heidadorf in the Visperterminen community in the Swiss canton of Valais took around eighteen months to construct. The ANDRITZ Hydro four-nozzle Pelton turbine at the turbine house in Chrizji, which is equipped with a directly coupled synchronous generator by Hitzinger. The machine is designed for 3.35 MVA.

TWO-STAGE HYDROPOWER PLANT IN VALAIS GENERATES ENERGY FOR 4,000 HOUSEHOLDS Taking only eighteen months to construct, the newly erected hydropower plant Heidadorf in the Swiss community of Visperterminen was officially inaugurated in October 2018. The two-stage facility with a pair of independent turbine houses utilises the energy potential of the nearby brook Gamsa with an impressive total head of almost 1,000 m. As a positive side effect of the CHF 16.5m project, a considerable portion of the drained water is reused to irrigate the surrounding farmland along the pipe route. The legal framework was established with the foundation of hydropower plant Heidadorf AG, in which the community of Brig-Glis and operator EnBAG AG each hold a 40 per cent share. A further 18-per cent share is held by the community of Visperterminen, with local energy supplier EW Riedbach holding the remaining two per cent. Both plants were equipped with powerful latest-generation technology. The two four-jet turbines for the turbine houses in Chrizji and Stundhüs were provided by Andritz Hydro, whereas Austrian generator manufacturer Hitzinger was contracted for the design and delivery of the two synchronous generators. In a normal year, the new two-stage hydropower plant in Heidadorf generates a total of around 16 GWh of clean electrical energy.

ituated at the entrance of the Visper valley in the canton of Valais, the mountain village of Visperterminen is known for its popular “Heida” variety of white wine. It is to this fact that the village owes its informal second name of “Heidadorf ”. The sun-kissed rows of vines in this community with a population of around 1350 grow at an altitude of between 600 and 1200 metres above sea level. This and the ambient topography together provide ideal conditions for generating hydropower. First steps in this direction were already

taken in the early 1900s with the construction of an irrigation tunnel for the dairy farms in the higher Alpine regions. It took almost 20 years to complete the 2.65 km conduit, which is still transporting the waters of the Gamsa stream through the mountainous rock. Shortly after the conduit breakthrough in 1916, hydropower plant Riedji was taken into operation. This marked the first point where the water was utilised before being drawn again and fed to the turbine of hydropower plant Ackersand further downhill.

NEW CONSTRUCTION WITH TWO TURBINE HOUSES Once the operating licence for hydropower plant Riedj ran out, initial planning for a replacement of the old facility after more than 90 years of operation began in 2009. Energy provider EnBAG from Brig-Glis was entrusted with overall responsibility for the entire Heidadorf power plant project, from planning to final implementation. As for the construction of the new facility, the future owners agreed on an adapted utilisation concept consisting of a surge chamber and two inde-

May 2019

Heidadorf_en.indd 32

14.05.2019 15:37:22

photo credits: Wild Armaturen

photo credits: zek

HYDRO

The penstock, consisting of ductile cast iron pipes, was laid over a total length of 3.8 km. They have been supplied by Swiss specialist Wild Armaturen AG.

pendent turbine houses. The first turbine house was constructed uphill in the small village of Chrizji, the one further downhill in the valley was installed on a dedicated site in the district of Stundhüs. EnBAG’s project manager, Jonas Kalbermatten, says the approval process was rather uncomplicated: “We were able to find satisfactory solutions for everyone affected by the project, including the landowners on whose properties the penstock will be installed. Generally speaking, the citizens and municipal government have been very supportive of the project. And since the construction also improves the irrigation along the outflow reach, the environmental agencies also waived their veto right.” Several work teams were set up to implement the project. Six construction firms provided the professional building construction and civil engineering work.

The uphill turbine house of hydropower plant Heidadorf is situated in the Chrizji region.

Finally, the silt is returned in a steady stream to the natural watercourse through a flushing gate. Thanks to the two separate reservoirs, the power generation process is entirely unaffected by the flushing. After desilting, the water is transported straight to the non-pressure tunnel through a stretch of GRP pipework. A surge chamber was installed behind the non-pressure tunnel to enable proper regulation of the machine unit at the Chrizji facility. Of the total design flow rate of 875 l/s, up to 225 l/s are diverted to irrigate the surrounding Nanz valley farmland. An additional self-cleaning Coanda trash rack was installed at the forebay to remove the frequently accuMayor Rainer Studer, Norbert Stoffel of EW Riedbach, President of the Board Renato Kronig and the Mayor of Brig-Glis, Louis Ursprung (l. t. r.) at the official inauguration ceremony on October 3rd, 2018.

KICK-OFF TO CONSTRUCTION IN SUMMER 2016 Summer 2016 marked the kick-off to the construction work, starting with the complete refurbishment of the forebay in the Nanz valley. A hydraulically controlled weir baffle is used to dam up the waters of the Gamsa, with the motive water discharged through a Tyrolean weir. To ensure ecological consistency, a water bypass was installed by the weir, which provides a constant year-round discharge volume of 78 l/s. Immediately after passing through the Tyrolean weir, the water is transported to an open desilter consisting of two reservoirs, where any sediments carried along by the mountain stream are allowed to settle.

photo credits: EnBAG

The forebay in the Nanz valley has been completely refurbished.

Heidadorf_en.indd 33

May 2019

14.05.2019 15:37:23

HYDRO

RELIABILITY IN THE SHAPE OF MACHINES ANDRITZ Hydro was able to win the contract for the complete electromechanical and secondary equipment for both turbine houses. Each of them was equipped with a four-nozzle 1,000 rpm vertical Pelton turbine. The uphill Chrizji turbine house has a design flow rate of 650 l/s and a net head of 532 m that can be utilised for hydropower generation. When the full water volume is available, each of the machines can achieve a maximum bottleneck capacity of 3,110 kW. In the event that the Chrizji turbine needs to be shut down for technical reasons, a bypass system kicks in within seconds to divert the motive water. The turbine at the downhill turbine house in Stundhüs can utilise a 600l/s design flow rate with a net head of 450,2 m. Under ideal conditions, this machine has a bottleneck capacity of 2,430 kW. The jets of both machines are controlled hydraulically, with their free-standing housings ensuring optimum accessibility for maintenance purposes. In keeping with the technical state of the art, energy production at both turbine houses is fully automated.

photo credits: zek

CUSTOM TAILORED GENERATORS FROM LINZ Where the generators are concerned, the operators’ demands were just as exacting as with the turbines. Austrian-based industry specialist Hitzinger was an obvious choice as supplier. For more than 60 years the

Up to 225 l/s of water are provided by the surge chamber for irrigation purposes.

Foto: EnBAG

mulating larch needles and driftwood. The forebay also marks the starting point of the 3.8 km underground penstock. Due to the challenging geological conditions along the pipe route, the power drop was implemented in the form of ductile cast-iron pipes throughout.

Linz-based generator manufacturer has been providing technically refined three-phase hydropower generators that have won top ratings in the industry the world over. This is due, for the main part, to the bespoke design and the extensive know-how that goes into the construction of the machines. No Hitzinger generator leaves the production facilities in Linz without an individual customer number. This means that each and every generator is fully custom tailored to its purpose, location and individual customer requirements. As a result, the entire machine design is fine-tuned as needed, from its magnetic characteristics to the insulation system and the proper iron-to-copper ratio. One key advantage is the ability to cooperate closely with the steel conglomerate VOEST, which also happens to be headquartered in Linz. This allows Hitzinger to make use of the latest-generation high-performance steels, which ensure less attrition and greater robustness than other metals. The specific types of steel that Hitzinger uses for its generators are resistant against extremely high temperatures. Two additional points in favour of Hitzinger generators are their outstanding ability to sustain high rotational speeds, and their extreme running smoothness, which typically keeps vibrations to an absolute minimum. This is where customers benefit from Hitzinger’s experience in ship generator engineering – a business segment where low-vibration qualities are crucial. HIGHLY EFFICIENT ENERGY TRANSFORMER During the engineering stage, special care was taken to maximise the efficiency of the synchronous generators for the Heidadorf hydropower plant project. Both machines run at a rotational speed of precisely 1,000 rpm. The turbine runner was mounted directly onto the generator shaft, and each of the machines was fitted with highly stress-re-

Technical Data Chrizji HPP

Upper Austrian electrical engineering specialist Hitzinger supplied the efficiecyoptimised synchronous generators. It was only a few years ago that the Linz-based firm began manufacturing generators in this performance class, which are every bit as efficient and high in build quality as their smaller-sized counterparts.

Stundhüs HPP

• Flow rate: 650 l/s

• Flow rate: 600 l/s

• Net head: 532 m

• Net head: 450,2 m

• Turbines: 4-nozzle Pelton

• Runner speed: 1.000 rpm

• Bottle neck capacity: 3,110 kW

• Bottle neck capacity: 2,430 kW

• Manufacturer: ANDRITZ Hydro

• Generator: synchronous

• Nominal output: 3,350 kVA

• Nominal output: 2,600 kVA

• Voltage: 6.000 V

• Manufacturer: Hitzinger

Annual production: approx. 16.5 GWh

May 2019

Heidadorf_en.indd 34

14.05.2019 15:37:23

HYDRO

ELECTRICAL ENERGY FOR 4,000 HOUSEHOLDS On June 20 last year the turbines of hydropower plant Heidadorf were spun up for the first time. The official inauguration was celebrated

The two generators are fitted with an air-to-water heat exchanger to ensure proper cooling.

photo credits: zek

sistant slide bearings. The generator at the turbine house in Chrizji was designed for a rated apparent power of 3,350 kVA and has a maximum output efficiency of more than 98 per cent under full load. The generator at the Stundhüs turbine house has a rated apparent power of 2,600 kVA and achieves an output efficiency of 97.36 per cent when operated under full load. To ensure optimum operating temperatures during the intensely heat generating energy production process, both generators are cooled by a water circulation system that uses an air-to-water heat exchanger. Both generators are from the larger-sized product line that Hitzinger has been marketing with great success for many years. Around ten years ago, Hitzinger was known primarily for its generators in the lower-performance category of up to 1 MVA. Today, however, the Linz-based industry specialist also offers generators with a performance of up to 4 MVA. Still, these ‘big boys’ come with all the quality features that their smaller siblings are known for. They are likewise precision tailored to their respective operational requirements.

only several months later, in late October. In their official speeches at the ceremony, Rainer Studer, Visperterminen’s President of the local Council, and Renato Kronig, President of Heidadorf AG’s Board of Directors, stressed their delight with the fact that the project was completed on time and without any accidents. In his interview with zek, Project Manager Kalbermatten offered a similarly positive summary: “Despite a very dry summer in Valais, we had extensive rainfall in the autumn. That made it possible to even exceed

the manufacturer’s expectations during the first six months of operation. By the beginning of December, the two turbine houses had already generated a total of around 10 GWh.” In a normal year, the power plant generates around 16 GWh of electrical energy, which is fed into the public grid. This way, hydropower plant Heidadorf covers the annual energy requirements of around 4,000 average households. In total, the Heidadorf AG invested around CHF 16.5m in the construction of the facility.

HYDRO POWER

YOU GOT THE POWER.

COMPACT RELIABLE

SUSTAINABLE SAFE

EFFICIENT FLEXIBLE

Maximum flexibility in design and high quality products are our top priority. We guarantee sustainable performance for renewable energy supply. Generators - designed and built for generations.

Heidadorf_en.indd 35

May 2019

14.05.2019 15:37:23

HYDRO

photo credits: Schweighofer

Operator Ernst Schweighofer at the water catchment for the Arbesbach small-scale power plant. The plant, which was constructed over a period of around five months, provides an independent power supply for a heating plant as well as several residential and commercial properties in Strallegg.

POWER PLANT OPERATOR SUPPLIES OWN FACILITIES IN STRALLEGG, EASTERN STYRIA The construction of a small-scale hydropower plant in the community of Strallegg in eastern Styria made the operator Ernst Schweighofer largely independent of the public power grid. The plant, which was constructed largely independently, covers almost all the electricity demand for several residential and commercial properties and a heating plant which is likewise owned by the operator. The surplus power is fed into the grid operated by Energie Steiermark, from which power can also be sourced if the water level is low. The power plant, which was constructed in the space of five months in 2017, is based on the classic diversion principle. Via a Tyrolean weir, up to 130 l/s of water are collected from the River Arbesbach and directed via a penstock that is around 1.3 km long to a 3-nozzle Pelton turbine. All of the piping in the form of highly durable ductile cast-iron pipes was provided by the professional sales company Geotrade from Upper Austria. Thanks to the flexible socket system, it was p ossible to lay the entire pipeline without installing any pipe elbows. After being commissioned in March 2018, the plant celebrates its first anniversary of operation this spring.

rnst Schweighofer, who is today 21 years old and comes from Strallegg in the district of Weiz in eastern Styria, developed his interest in hydropower at an early age. It was back in 2009 that the then twelve-year-old drew his first designs for the construction of a hydropower plant on his parents’ property. However, the cost of constructing a plant with a maximum output of 5 kW was considered to be too high. Once the family had taken up the initiative to receive advice on small-scale hydropower plants in 2014, the plans for a hydropower plant of their own

The fish ponds next to the powerhouse are supplied with water through the residual water section.

May 2019

Projekt KW Arbesbach zek Hydro Internat 2019.indd 48

14.05.2019 15:38:00

HYDRO

The ductile cast-iron pipes from the Jindal SAW brand were supplied by the Upper Austrian pipe distributor Geotrade from Ried in der Riedmark.

were again fleshed out. As part of the advice provided, the potential to generate around 200,000 kWh a year was identified. But as the focus of the Schweighofer family was and still is on supplying energy for their own needs, the project was put back on ice. “This changed in 2015 when we started operating our own biomass plant. The large amount of electricity that the heating plant used meant that the construction of a hydropower plant once again made a lot of sense,” explains Ernst Schweighofer. POWER PLANT CONSTRUCTION APPROVED IN VERY SHORT TIME The application to construct a small-scale hydropower plant on the River Arbesbach was submitted to the relevant authorities in December 2015. The project was planned and developed by the engineering firm Mosbacher from Lower Austria, which specialises

The around 1.3 km long pipeline was laid completely underground.

in small-scale hydropower. Schweighofer stresses that the landowners, owners of fishing rights and public officials were involved in the project right from the start and it was possible to quickly reach an agreement with all the parties involved. This also explains the short approval phase, with the building permit being issued just a few months after it was submitted in May 2016. As an ecological counterbalance, one section of the body of water at the mouth of the river was made accessible to fish by installing low-water groynes. PENSTOCK MADE FROM DUCTILE CAST-IRON PIPES The actual construction works started with the excavation of the powerhouse at the beginning of June 2017, and the concrete structure of the building was hoisted into place in around three weeks. This was followed by the

laying of the around 1.3 km long penstock which, like the groundworks and the hydraulic steel construction works, was overseen by Schweighofer himself with assistance from fitters to help with the assembly work. The upper section of the penstock was laid with a dimension of DN350 and, following tapering, the remaining section of around 950 m towards the powerhouse had a DN300 design. Also laid at the same time were empty conduits for the power cables and fibre optic cables, each routed separately, for providing power to the water catchment. When it came to the material for the pipes, the operator opted for ductile cast-iron pipes from the manufacturer Jindal SAW which were supplied by the sales specialist Geotrade from Upper Austria. The high-quality pipes are renowned for their high compressive strength, resistance to harmful environmental effects, optimum flow conditions thanks to their ultra-smooth insi-

Technical Data • Flow rate: 130 l/s • Net head: 64 m • Penstock: ca. 1.3 km ductile cast-iron • Ø: DN350/DN300 • Turbine: 3-nozzle Pelton • Runner speed: 750 rpm • Nominal output: 70 kW • Manufacturer: Maschinenbau Unterlercher • Generator: Synchronous • Voltage: 410 V • Output: 80 kVA • Manufacturer: Hitzinger • Total average capacity: ca. 200,000 kWh

At full load, the Pelton turbine, which is designed for an extraction water quantity of 130 l/s and a gross drop of 64 m, produces a bottleneck capacity of 70 kW. In addition, the machine is able to display its strengths in full when operating at partial load thanks to three electrically regulated nozzles.

Projekt KW Arbesbach zek Hydro Internat 2019.indd 49

May 2019

14.05.2019 15:38:02

HYDRO

The self-manufactured Tyrolean trash rack can be opened up for cleaning using hinges.

Visualisation of the control technology on the touch display in the powerhouse.

de surfaces, and they are suitable for very tough installation conditions. In addition, the pipes can be laid without any additional bedding material in the ground. Thanks to the ability of the pipe joints to deviate within the connecting sockets, the system allows expansive changes of direction to be designed into the pipeline without using specific piping fittings. This was also the case with the penstock for the Arbesbach power plant, which was laid, including a river underpass, entirely without any pipe bends in around 1.5 months. PELTON TURBINE OPTIMISED FOR PARTIAL LOAD The water catchment was equipped by Schweighofer with a Tyrolean weir which he fabricated himself, and a slide valve integrated into the transverse structure is used for residual water discharge. In the weir cabin in which the electrical engineering components were housed, an additional fine trash rack can be used for winter inflow. Following entry, the works water is fed into a de-sanding basin, and the power descent begins immediately after this. “As the maximum extraction water quantity of 130 l/s was set relatively high, the turbine should be able to cover the widest possible operating volume. In addition, the level-controlled unit had to be adapted to a second-hand, refurbished synchronous generator from Hitzinger,” says Schweighofer. Maschinenbau Unterlercher GmbH from East Tyrol manufactured a 3-nozzle Pelton turbine with a horizontal shaft that was optimised for this intended use. The connection between the turbine and generator shafts is provided by a belt drive which is also used at the same time for speed transmission. With a gross drop of 64 m, the turbine produces a bottleneck capacity

of 70 kW. When the amount of water available reduces due to the different seasons, the three electrically regulated nozzles ensure a maximum level of efficiency. A powerhouse crane from the company Mayrhofer from Wenigzell makes it easier to carry out maintenance on the technical equipment. The fish ponds which were created next to the powerhouse before the plant was constructed source their supply of water from the residual water section. INDEPENDENT POWER SOURCE SINCE 2018 As well as providing a dedicated energy supply, the power plant’s ability to operate independently was also an important point for the operator. This requirement was safeguarded by the items supplied by SOWA-Control GmbH, which was responsible for the electrical engineering and control. The electrical engineering in the powerhouse and the power feed were likewise designed by Schweighofer himself. To connect the cogeneration plant and the properties spread around the local area to the dedicated supply grid, the operator laid around 4 km of power cables. If a sufficient amount of water is available, the properties are supplied with power completely independently; if the power plant stops operating, power is automatically sourced from the grid operated by Energie Steiermark. After the plant began operating normally in March of last year, Schweighofer is very happy with the production capacity that has been achieved to date: “Although the power plant was shut down for several months, around 80 percent of our own energy requirement was met in 2018. In addition, around half of the electricity produced was fed into the public grid.”

All changes in direction for the penstock were designed without any specific fittings thanks to the ability of the pipe joints to deviate slightly in the connecting sockets.

Despite the discharge channel for the small-scale power plant, the River Arbesbach still has plenty of water. The processed works water flows from the powerhouse back into the body of water via the black plastic pipe.

May 2019

Projekt KW Arbesbach zek Hydro Internat 2019.indd 50

14.05.2019 15:38:03

HYDRO

EXCLUSIVE PARTNER

Switzerland, Liechtenstein and Austria

for

Pipe systems for hydro power plants GRP-Pipes DN300 - DN4000 • are manufactured in the spinning and winding process • laminated EPDM-gasket for safe and

and

Cast Iron Pipes DN80 - DN2000 • restrained socket joint

easy installation

• ÖNORM tested • GRIS tested

• ÖNORM tested • ÖVGW tested

Handelsges.m.b.H • Hochstraß 84 • 4312 Ried in der Riedmark • TEL +43 (0) 7236 • May 31 2019402 51 EMAIL office@geotrade.at Projekt KW Arbesbach zek Hydro Internat 2019.indd 51

14.05.2019 15:38:03

photo & graphics credits: TRM

HYDRO

Together with a partner from the Austrian cement industry, TRM has developed an innovative fibre cement coating. The Tyrolean company is thus once again setting the standard when it comes to resilience and durability.

LEAP IN QUALITY FOR TRM CAST-IRON PIPES THANKS TO INNOVATIVE COATING TECHNOLOGY Tiroler Rohre GmbH, which is a traditional manufacturer of ductile cast-iron pipes from Tyrol, consistently relies on innovation and further development. Over a period of two years, the TRM research department worked alongside an Austrian cement manufacturer to produce a new type of fibre cement mortar for the outside coating of the pipes. Since the autumn of last year, two machines have been set up at the plant in Hall to enable the pipes to be wrapped with the new type of fibre cement mortar in an almost fully automatic fashion. The first pipes coated in this way are now being produced. Thanks to the new type of outer sheath, the pipe system offers not only a maximum level of chemical and mechanical protection, but also offers tangible economic benefits.

he fact that Tiroler Rohre GmbH has been able to maintain its high level of quality for more than 70 years is down not least to its consistent drive to champion innovation. In the past, the engineers at this traditional company have constantly managed to develop “their” product further and deliver new innovations to the market. Courage and a willingness to innovate have made TRM’s ductile cast-iron pipe what it is today: a pipe system that sets the benchmark when it comes to resilience, durability and economic efficiency. The most recent product of in-house development work is called “ZMU-Austria”: It represents a self-developed cement mortar coating which is applied to the pipe using an extrusi-

ADHESION WITHOUT GLUE Another challenge in developing the new cement mortar was to create the perfect adhesive strength for the material on the cast-iron

pipe. “It was very important for us to make the cement capable of adhering without using any adhesion promoters at all. First of all, an adhesive means the additional use of a chemical substance, and second the application of the adhesive in production means an additional stage in the process, and third it was also key to avoid excessive adhesion on the pipe because it also needs to be capable of being cut at the construction site and it must also be possible for the coating to be stripped away,” explains Christian Auer, referring to the specific roughness of the zinc surface on the pipes which is applied beforehand and which fundamentally provides a good foundation for the adhesion of the cement. The fact that the new pipes with the ZMU-Austria coating are The fibre cement sheath is applied in a thickness of 5 mm fully automatically using an extrusion method.

Foto: Bernhart

The roughness on the galvanised outer surface means that the new type of cement adheres very well to the pipe.

on method. “We devoted around two years of development work to this project, which was only possible thanks to the excellent cooperation with our long-standing cement technology partner. The objective here was to develop a cement mortar which on the one hand offers a maximum level of outer protection for the pipe and on the other hand is easy to apply in production. We managed to do this,” says engineer Christian Auer, Head of Quality Management at Tiroler Rohre GmbH, with great satisfaction.

May 2019

ZMU-Austria special_en.indd 52

14.05.2019 15:38:55

HYDRO

line composition which prevents any corrosion beyond a pH of 10. “The fibre cement mortar which we have developed also demonstrates very high sulphate resistance. This means that the new pipe system offers maximum protection in highly aggressive, contaminated and sulphate-containing soils,” explains Christof Mairinger. Thanks to its harmless electrochemical properties, the ZMU-Austria pipe can also be used within the sphere of stray currents. The marketing manager also points out a special property on the outermost surface of the cement shell: “As a result of the carbonation on contact with the surrounding environment, the cement hardens further on the surface and forms a sealed, resistant and water-repellent layer.”

Two winding machines, which were adapted in recent weeks so that they are best suited to the production processes, are capable of coating pipes from DN80 to DN1000.

COMPLEX STRUCTURE – SOLID PROTECTION If you look at the structure of the ductile castiron pipe with the new ZMU-Austria, you can talk about three layers surrounding the pipe. It is clad on the inside with a cementation comprising Portland, blast-furnace, alumina or plastic-modified cement. On the outsi-

de, the first layer comprises a fine zinc coating in a thickness of 200 g/m². The outermost protective layer is then the novel fibre cement coating, which is 5 mm thick. The spigot end and socket remain free of cement mortar and are instead provided with the tried-and-tested PUR or epoxy coating. “For the connection areas, we recommend using special rubber or shrink-on collars for fitting so that the whole pipeline boasts optimum protection,” explains Christof Mairinger, BA, MBA, marketing manager at TRM. It is obvious that theydid not want to limit one of the great strengths of the ductile cast-iron pipe – namely its flexibility – as a result of the cement coating. Depending on their diameter, the pipes still have a flexible ductility of 3 to 5 per cent even in the ZMU-Austria version. CHEMICAL RESISTANCE Another important property that is key for the new fibre cement mortar is its chemical resistance. Specifically, it involves a high alka-

For the application of the TRM tapping clamp, the cement mortar layer is partially removed.

Foto: zek

produced without any adhesion promoter at all has so far proved to be a unique selling point in the market. In production, the special cement mortar is extruded onto the pipe via a mesh bandage and smoothed at the same time. This production step is performed automatically. For this purpose, special machines were purchased last autumn and, in close collaboration between TRM and the Austrian machine manufacturer, they were adapted to suit the requirements of the production process. “Once we have eradicated the initial ‘teething problems’, production will be able to commence in the coming days,” says Christian Auer.

After it has been cut, the cement mortar layer can simply be removed with a hammer and a chisel.

ZMU-Austria special_en.indd 53

MECHANICAL PROTECTION But the pipe’s most obvious attribute is its mechanical protection. The 5 mm thick fibre cement mortar layer ensures that the pipe is not damaged during storage, transportation and of course also when being installed. The latter also plays a particular role when the pipe is installed without a trench as ultimately large loads occur on the pipe as it is being pulled into place. The ZMU surface protects against any damage. The multi-talented ZMU-Austria product is just made for use in alpine and high alpine terrain. Thanks to the great mechanical robustness, almost any excavated material can be used for backfilling, with rock inlays up to 100 mm in size being permitted. Christof Mairinger says: “The benefit of being able to use this pipe ideally in alpine terrain is down to the fact that no additional bedding or backfill material is required. In addition, there are also no costs for disposing of the excavated material that is produced because it can be reused. The economic benefit is obvious. But in this context the ecological benefit should also not go unmentioned: The repatriation of the original excavated material preserves the

May 2019

14.05.2019 15:39:02

HYDRO

The roots of the trees need to be provided with sufficient space in a coarse-grained substrate so that the areas can absorb increasing amounts of water, which incidentally will also deliver beneficial effects in coping with the increasingly heavier rainfall events that are occurring. The only drainage pipes that can be used here are of course those that are 100 per cent root-resistant – such as our new ZMU-Austria pipe,” says engineer Carina Kirchmair from TRM’s applications engineering department. A pilot project of this type is set to be launched very soon in a major city in Austria.

The high mechanical load capacity means that no special bedding material is required, and the excavated material can generally be used as backfill.

natural structure of the soil at the site. This is a point which repeatedly comes up with questions relevant to the environment.” Its outstanding suitability for use in alpine pipeline construction makes the ZMU-Austria the pipe of choice when it comes to penstocks for hydropower plants, but also for artificial snow-making facilities. URBAN APPLICATIONS However, the extreme resilience and the high level of durability are not only regarded as noticeably desirable benefits when constructing pipelines in alpine territory. “There is one thing you should bear in mind here: It is of course relevant whether clearances are required in a forested area when the pipeline needs to be replaced after just 20 years or maybe not until as many as 100 years have elapsed. However, the question is an even

more delicate one in heavily developed urban areas. You just have to envision the fact that simple plastic pipes in urban areas frequently need to be replaced after fewer than 20 years – with all the consequences this entails for traffic and the whole infrastructure. This is why the durability provided by the TRM pipe also plays an important role in this area,” argues Christof Mairinger. In urban areas, another very sensible possible application for the new pipes might present itself in the near future: Under the specialist term “sponge city”, design engineer Christoph Bennerscheidt, Managing Director of the European Association for Ductile Iron Pipe Systems, has developed a solution model for cooling in increasingly hotter urban centres. “To cool the city centres of the future in a natural way, the desire is increasingly to rely on green areas where trees will be planted.

ECOLOGICAL FOOTPRINT IMPROVED With all innovations at TRM, the questions of sustainability and the ecological footprint play a leading role. According to the marketing manager, this is a central concern of the management. It is no wonder then that the new ZMU-Austria pipe also sets the benchmark in this regard. “For our ductile cast-iron pipes, we generally only ever used recycled material that we obtain from the immediate vicinity. Another factor is that, thanks to our photovoltaic installation with a collector surface area of 9,000 m², the largest roof-top installation in Tyrol, we use the energy that is generated ourselves and thus make a substantial contribution to conserving the environment. In addition, any by-products that are produced are utilised: The best example of this is our waste heat, which is fed into the Hall district heating system. The ecological footprint of the ZMU pipe has of course been significantly minimised by the fact that the pipe no longer needs to be delivered to an external source for the coating to be applied. This is now all done by us at the factory.” SOLUTIONS TO PRACTICAL QUESTIONS This enables the traditional company to respond with even greater speed and flexibility to customer enquiries. Although TRM has a very well-stocked warehouse, in practice it is very often necessary to deal with special re-

In the case of installation without a trench, it is advisable to use a special sheet-metal cone to provide additional protection for the couplings.

May 2019

ZMU-Austria special_en.indd 54

14.05.2019 15:39:06

HYDRO

ZMU-Austria pipes can of course be secured just as easily using the tried-and-tested locking segments. The spigot end and coupling area remain free of the cement sheath.

quests quickly. “The two new coating facilities enable us to wrap the pipes in their coating within a few days. In theory, we can also recoat pipes that have already been coated on request,” explains Christian Auer. Christof Mairinger refers in this context to the great importance of the in-house applications engineering department, which repeatedly responds to practical requests and thus promotes the further development of the product. “Our great strength is our close links with the customer. Our sales representatives are engineers who can support the customer with advice and practical assistance. Their feedback frequently provides vital inspiration for developing the

pipes further. Our research department is therefore also consistently supported by the management in its drive for innovation.” ALL DIMENSIONS AVAILABLE The most recent result of this research and development work is thus the new type of ZMU-Austria pipe which, thanks to its resilience, is suitable for use in both pressurised and unpressurised areas. All the relevant certificates and approvals are also provided. “We did not invent the ZMU pipe, but we have almost perfected it,” reckons Christof Mairinger with a degree of pride. Today the factory in Hall has two coating facilities, one for the dimensions

DN300 – DN1000 and another for DN80 – DN600. By the middle of this year, all sizes of pipe within this range will be available with ZMU-Austria. What is also new is the improvement in traceability and process data recording. Today every single pipe that leaves the factory in Hall boasts its own QR code which enables it to be identified automatically. This ensures seamless documentation and traceability that provides information about when and in which series the pipe was produced. The ZMU-Austria pipe from Tiroler Rohre GmbH represents another milestone in the technical development of the cast-iron pipe in Austria.

ZMU-Austria

ductile iron solutions www.trm.at

ZMU-Austria special_en.indd 55

May 2019

14.05.2019 15:39:08

photo credits : Künz

HYDRO

“GE85” rope-type trash rack cleaning machine for the new large power plant on the Xayaburi Dam in Laos, South-East Asia.

TRASH RACK CLEANING MACHINES FROM VORARLBERG IN GLOBAL DEMAND There is a good reason why Künz GmbH, which was founded in 1932, is one of the leading companies in the engineering industry in Vorarlberg. Among other things, over recent decades the company has established itself as a reliable partner for manufacturing high-quality hydropower equipment around the globe. Its range of products comprises of complete hydraulic steelwork solutions for run-of-river and storage power plants, high-pressure gates, crane systems and trash rack cleaning machines. Künz provides customised solutions to suit the particular requirements of new construction projects, upgrade projects, replacement projects or remediation projects. In Künz recent history, the company has continued to expand globally with an influx of projects in North America and South-East Asia. The primary focus of these projects has been to proivde trash rack cleaning technology to large hydropower plants. Künz’s most powerful hydraulic trash rack cleaner to date is being supplied for the 195-megawatt “Forrest Kerr” power plant in Canada. Still very much present back home in Austria, Künz engineers are delivering their largest horizontal trash rack cleaning machine for the reconstruction of Traunleiten Power Plant in Upper Austria. With more than 50 years of experience in manufacturing reliable trash rack cleaning systems, Künz offers a technical solution that is always individually adapted for a wide range of different areas of application.

o ensure that a hydropower plant can operate as efficiently as possible, great importance is attached to making sure that the inflow works properly. Any floating debris that is washed up at the inflow area may considerably hamper the operation of the plant and the performance of the electromechanical equipment as a consequence. To

address this problem, Künz GmbH, which is based in the town of Hard in the Austrian state of Vorarlberg, provides an extensive range of semi-automatic or fully automatic trash rack cleaning solutions. With their technical sophistication and robust design, the hydraulic systems from Künz are ideally suited to removing bulky debris both from vertical and

inclined protective screens. They have a lifting capacity of up to 6 tons and are manufactured with a cleaning depth of up to 33 m. If necessary, the hydraulic systems can be expanded with additional equipment such as bulkhead lifting devices or grabbers. For dams where a restricted amount of space is available, Künz provides rope-type trash rack cleaning machi-

May 2019

Projekt Künz RRM zek Hydro Internat 2019 Englisch.indd 56

14.05.2019 15:41:00

HYDRO

nes that offer high precision and reliability. These machines are noted primarily for their low maintenance requirements, lifting capacities up to 8.5 tons and can clean up to depths of 100 m. In addition, the integrated loading crane enables carpets of floating debris to be removed from the surface of the water. In the case of new construction or even power plant revitilizations, fish and eco-friendly horizontal screens are increasingly installed. Künz also offers a trash rack cleaning solution for this situation, further catering to the needs of any potential client. Machines with this design have a thrust cleaning capacity of up to 3 tons and are suitable for cleaning to depths of up to 8 m. An integrated loading crane allows rapid removal of bulky floating debris such as large branches or tree trunks. With systems of this design, the floating debris is removed automatically via a flushing unit at the end of the trash rack array.

Hydraulic trash rack cleaner of the “H200” series at Halsey Afterbay Power Plant.

“MADE IN AUSTRIA” IN GLOBAL DEMAND “To be able to guarantee the highest quality standards, all trash rack cleaning machines from Künz are fully designed, manufactured, commissioned and rigorously tested in our three dedicated production facilities. Künz’s central hub for the hydro sector is its plant in Groß St. Florian in the Austrian state of Styria,” explains hydro product manager Samuel Wolfgang. In total, the major company employs around 500 workers at its five sites in Austria, Italy, Slovakia and the USA. In recent years, Künz has acquired an outstanding reputation both nationally and internationally with its reliable technical solutions. The products of the company from Western Austria are particularly popular on the North American continent, confirms Wolfgang: “In the last four years, the energy provider AltaGas, which operates in the USA and Canada, has ordered four trash rack cleaning machines, making it one of our most important customers in North America. For the current ‘Forrest

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

Kuenz GmbH | 6971 Hard - Austria sales@kuenz.com | www.kuenz.com

Projekt Künz RRM zek Hydro Internat 2019 Englisch.indd 57

May 2019

14.05.2019 15:41:00

HYDRO

The globally proven hydraulic trash rack cleaners by the engineering experts from Vorarlberg ensure optimum flow conditions and are also very adept at handling even bulky floating debris. The picture shows a trash rack cleaner from the “H4000” series in use in Arkansas.

“EK45” rope-type trash rack cleaner for the Vyasi Power Plant in India.

Kerr’ AltaGas project, a 195-megawatt plant located around 1,500 km north-west of Vancouver, Künz is supplying what is to date the heaviest and most powerful hydraulic machine of the ‘H4000’ type from its own production.” The Shoeshone Falls Power Plant, which is operated by Idaho Power in the North-West USA, also relies on quality “made in Austria”. In 2017, the operators placed an order for the supply of three hydraulic “H200” trash rack cleaners, a new machine type that arrived to market in 2016.

for the Forrest Kerr Power Plant in Canada: “With this plant, a difficult inlet geometry results in unfavourable inflow conditions and very special requirements placed on the trash rack cleaning system. Huge side currents of > 3 m/s at the hydraulic boom system represent a very unusual requirement and demand everything from the system. The extremely robust design of the steel structure and the bearings ensure that the large power plant operates smoothly, especially during the snow thaw in the spring.”

PRESTIGE PROJECT IN THE FAR EAST Künz is also developing a strong presence in South-East Asia, having recently installed a „GE85“ rope-type trash rack cleaning machine at the 1260-megawatt project on the Xayaburi Dam in Laos. According to Wolfgang, the construction of the mega-power plant on the Mekong River in NW Laos by the client Xayaburi Power Corporation, is currently one of the most prestigious hydropwoer projects throughout Asia. A few thousand kilometres further west, Künz proved to be stiff competition in India for the new customer “OM Metals” a rope-type trash rack cleaning machine of the “EK45” type shall be delivered for the Vyasi Power Plant. Künz has also secured a new customer in its home country with Wels Strom GmbH. For the reconstruction of Traunleiten Power Plant in Upper Austria, which will start operating at the end of 2019, Künz is manufacturing a horizontal trash rack cleaning machine. “Masses of rock lichen that accumulated on the trash rack installations made life difficult for the operator over many years. With the reconstruction of the power plant, Wels Strom is now also investing in a powerful trash rack cleaning facility with a patented drive system that in future will reliably guarantee a free flow through the installation,” states Wolfgang. INDIVIDUALLY ADAPTED TECHNOLOGY With more than 50 years of experience delivering unique trash rack cleaning machines around the globe, Künz can confidently provide solutions to any hydropower plant. Whether the plant exhibits tropical conditions like in South-East Asia, or harsh winters like northern Canada, Künz has a solution for you. “Künz trash rack cleaning systems generally always derive from a series that has been put to the test. But the basic machine is then always adapted precisely to cater for the needs of the customer. This ensures that operators receive solutions that are customised yet have already been tested over many years,” explains Wolfgang, citing as an example the “H4000” XXL trash rack cleaner

Horizontal Trash Rack Cleaning Machine at the Rüchlig Power Plant on the River Aare in Switzerland.

May 2019

Projekt Künz RRM zek Hydro Internat 2019 Englisch.indd 58

14.05.2019 15:41:01

HYDRO

photo credits: Wild Metal

In the last two decades, Coanda systems have also become established on the water catchments in the Alpine region. Models such as the Grizzly from Wild Metal are among the best-established and most successful.

FOR HYDRO POWER PLANT OPERATORS THE GRIZZLY COMES FROM SOUTH TYROL Whereas the technology of the Coanda rake has long been established in hydropower in the USA, but also in Canada and New Zealand, its benefits have only been appreciated in our part of the world in the last ten to 15 years. The Coanda rake has now established itself as an economically and ecologically sensible option for water catchments on mountain streams which are full of debris. This can also be attributed not least to the small number of manufacturers that today provide ÂCoanda systems in the Alpine region. The company Wild Metal from Ratschings, South Tyrol plays a particularly special role here. Hardly any other supplier has installed more Coanda rakes in recent years, and in South Tyrol it is the undisputed market leader with the Grizzly Power model. And the largest Coanda rake in Europe to date was also manufactured by Wild Metal â&#x20AC;&#x201C; it is installed at the St. Leonhard power plant in Austria's Pitz Valley with a width of 25 metres.

he majority of Coanda rakes were installed in recent years in South Tyrol, in Western Austria and in Switzerland. With the Coanda rake, the wall adhesion effect, known as the Coanda effect, is utilised when the works water flows evenly over a rounded weir body and in the process is deflected by the fine rake bars. In combination with what is known as the shearing effect of the profile bars, the water flows into the intake. At the same time, the Coanda rake prevents the penetration of sediments and small aquatic creatures into the works water system. A modern and efficient Coanda system, such as the Grizzly Power from Wild Metal, therefore combines its repellent function with ecological water conservation. In additi-

on, the Coanda rake is regarded as a largely self-cleaning system because all floating debris and foliage that comes to rest on top of it is carried along by the excess water. The Grizzly Coanda rake from the company Wild Metal is a patented system which is individually adjusted to suit the particular requirements and both hydrological and topographical conditions. There are currently roughly 350 Coanda systems of the Grizzly Power type in use in the Alpine region but also beyond. The feedback from operators has all been very positive. GRIZZLY INCREASES ECONOMIC EFFICIENCY The small gap width of the Coanda rakes limits the level of sand contamination to a mi-

Coanda-spec_EN.indd 59

nimum. This means that there is no need for any separation systems such as a trash rack cleaner and sand traps, if they are required at all, are much smaller than is the case with conventional intakes with a Tyrolean weir. This increases the economic efficiency because this advantage is reflected directly in lower construction costs. The Grizzly Power rake, which was developed and prepared for the market by the company Wild Metal, fundamentally consists of a robust, hot-dip galvanized steel grid and an underlying fine screen. The form of the upper protection bars is adjusted to the natural water flow. The construction method and the spaces between the bars are finally adjusted to the conditions on site. May 2019

14.05.2019 15:42:18

graphics: Wild Metal

HYDRO

Wild Metal essentially offers three basic types of its Grizzly Power: the Protec (left), designed for mountain streams which carry a large amount of debris with an efficient protective screen; the Optimus (middle), which is integrated into existing water catchments – such as a side extraction – and therefore does not require a coarse screen upstream, and the Titan (right), which was developed for fishing waters with large amounts of leaves. The Grizzly is generally noted for its good absorption capacity and high degree of separation.

Shypot SHPP– (UKR)

photo credits: Wild Metal

Fanes SHPP - South Tyrol (It)

A TRIO FOR ALL REQUIREMENTS As the requirements during operation and the conditions at the location of a water intake can often vary significantly, in the last few years the engineers from Wild Metal have developed three basic types of Grizzly Coanda rakes which can be adapted using a modular concept to suit all size requirements. The trio,

gap of from 30 mm to 50 mm, keep the debris away from the fine screen and thus protect it from any damage. In addition, they direct the water from the acceleration plate to the fine screen. Wedging of rocks and wood debris is largely prevented by the special arrangement of the rake rods. Depending on the gap width, fish and smaller aquatic crea-

Val Strem SHPP - Sedrun (CH)

Foto: AF-Iteco

photo credits: Wild Metal

Kienzer SHPP- (AT)

consisting of the Grizzly Power Protec, the Grizzly Power Titan and the Grizzly Power Optimus, covers the majority of the basic requirements in the Alpine region. For example, the Grizzly Power Protec was developed for mountain streams that carry a large amount of debris. Its flow-optimised extruded profile rods, which generally have a

May 2019

Coanda-spec_EN.indd 60

14.05.2019 15:42:23

HYDRO

Steineraa PP - Schwyz (CH): The absorption capacity of the Grizzly at Steineraa PP is 1,250 l/s. Thanks to the efficient Coanda system, the people responsible for the project were able to save on the construction of a sand trap.

photo credits: AF-Iteco

photo credits: Wild Metal

20 modules of the Grizzly Optimus lined up in series produces Europe’s biggest Coanda rake with a width of 25 m: at the St. Leonhard power plant in the Pitz Valley. (AT) The absorption capacity totals 4,000 l/s.

tures between 0.2 mm and 2 mm in size can easily get through the fine screen and are carried along by the current of the running water. The same also applies to foliage, twigs, moss and similar debris. Only particles that are smaller than 0.2 mm to 2 mm (depending on the gap width) can get into the works water. This means that the level of maintenance work on the systems is minimised. GRIZZLY TITAN AND GRIZZLY OPTIMUS The Grizzly Titan is deployed primarily in fishing waters with large amounts of leaves and on bodies of water where there is hardly any debris congestion in the catchment area. The best example of this is the outflow from a lake. Robust rounded steel ribs, which are fitted 19 cm apart, protect the fine screen from tree trunks, branches and rootstocks. In high water, the driftwood slips easily over the Grizzly Power Titan. The Grizzly Power ensemble range is completed with the Grizzly Optimus. This is an

efficient Coanda screen without any protective rake above it. The tried-and-tested Optimus is therefore obviously deployed wherever the fine screen is already protected by a coarse screen for the water catchment. This does primarily apply to water catchments with side extraction or alternatively following a Tiroler Wehr. But morever it is also used at sites where the water is relatively calm like at water treatment plants and fish farms. Basically the experts of Wild Metal take the decision on which type is brought to bear for every project specifically. Depending on the type, Wild Metal today offers gap widths of from 0.3 – 2.0 mm, with the sizes 0.6 and 1.0 mm being the most popular choice. The customer can now choose between different rod profile sizes. In addition, as well as a stronger profile wire, the South Tyrolean company now also offers an even harder-wearing material for the fine screen. The new material increases the useful life of the screens significantly.

BIGGEST COANDA RAKE IN EUROPE Wild Metal has caused a real stir in the hydropower industry with its innovative Grizzly Power. What is less surprising is that the hydraulic steel construction specialist from Ratschings in South Tyrol has also implemented Europe’s biggest Coanda system to date – in St. Leonhard in Tyrol’s Pitz Valley. In this case, 20 modules arranged in series for a Grizzly Optimus were used to allow the full extraction water quantity of 4,000 l/s to be handled. A very small gap width of 0.4 mm was very deliberately chosen in order to keep the highly abrasive glacier-polished rocks in the Pitz Valley away from the machines. During regular operation, the Grizzly Power models guarantee effective filtering of solid materials even under the toughest conditions, such as a hard winter frost. The Grizzly’s claws are currently among the most effective that Europe’s Coanda market has to offer.

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

Tel. +39 0472 759023 Fax +39 0472 759263

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

Coanda-spec_EN.indd 61

We clean water May 2019

61 14.05.2019 15:42:25

HYDRO

photo credits: Roberto Fernandez

The Carmen Amalia power plant in Departamento Quetzaltenango in the south-western part of Guatemala first went online in the spring of 2017. In an average year, the plant in the Finca region will produce around 2.8 GWh of electricity.

FINCA CARMEN AMALIA IN GUATEMALA PRODUCES COFFEE AND GREEN ELECTRICITY

In the spring of 2017, after a construction period of less than a year in the Finca Carmen Amalia area in south-western Guatemala the small-scale hydropower plant sharing the same name went online. The typical diversion-type plant is owned by the Fernandez family who have been growing coffee crops in the Finca for several generations. The ideal topography of the landscape is now also being exploited to produce green electricity. The first plans for the construction of a small power plant were drafted in 2014. Building work commenced in March 2016. A maximum volume of 1200 l/s is diverted for electricity generation and passes down a 1.5 km underground high-pressure pipeline to a surge tank. From there it flows along an above-ground steel pipeline into the power house for use in the turbines. All the electro-mechanical and control-related infrastructure for the central station was provided by Ossberger, the southern German specialists for small-scale hydropower plants with immense international experience. At maximum water capacity the benefits of the crossflow turbine come to the fore in partial-load operation, as it is capable of guaranteeing a bottleneck capacity of 689 kW. All of the electricity generated is fed onto the public mains grid. In an average year the plant produces around 2.8 GWh of power.

he fertile volcanic earth in the Departamento Quetzaltenango region in the south-western part of Guatemala is ideal for the cultivation of a whole range of crops, such as corn, wheat, various types of fruit and vegetable, as well as coffee and sugar cane. The vast Finca Carmen Amalia area is approximately 50 km south of the regional capital Quetzaltenango, and coffee has been grown there for several generations. “In order to utilise the ideal topography and hydrology of the Finca area for energy production, Manuel Fernandez González – the head of the family – devised a plan to build a hydroelectric power plant there”, explains his son, Roberto Fernandez España, who developed and implemented the plant with the project manager Carlos de Leon. Financial backing for the building of the power plant was provided during the planning phase by the ARECA in-

itiative (Accelerating Renewable Energy Investment). This body supports the implementation of renewable energy resource projects in Central America and Panama. Once nume-

rous issues had been dealt with, such as local hydrology, environmental impact, geotechnics and a planning phase – which also encompassed the market situation, the actual

A dam of 12 metres in width was built for drainage purposes, directing the water into an open two-chamber desander and on to a 1.5 km high-pressure pipeline.

May 2019

Projekt KW Carmen Amalia zek Hydro Internat 2019.indd 62

14.05.2019 15:43:06

HYDRO

main construction phase was initiated in March 2016 when excavation work commenced. BUILDING DURING THE RAINY SEASON Although the majority of the construction work was conducted during the rainy season between May and October, and despite the challenging geological conditions along the route of the pipeline, the project was implemented without any significant delays, states Roberto Fernandez. To prevent ground erosion, compensatory ecological measures included the planting of 12,000 trees and many deep-rooting plants alongside the diversion route. A concrete dam 12 m across was built for the main collection basin, from which the water flows into an open two-metre diversion channel. An open-air desanding basin with two separate chambers is also connected directly with the channel. Fitted with a sluice gate, the desander is located at the entry of the high-pressure pipeline. The initial 1.5 km underground section of the high-pressure tubes is made completely from plastic DN900 piping. The water is then fed through to a surge tank-type collection basin that serves to regulate the water level. From here the water flows along an above-ground DN800 steel pipeline on the final steep section to the power house turbines. MADE IN GERMANY: IN DEMAND IN GUATEMALA While the above and below-ground construc tion work was carried out by local businesses, the operators favoured a ‘Made in Germany’ label for the centre’s technical infrastructure. The entire contract for electrical machinery was ordered via JC Niemann, an expert trading company specialised in European industrialsector products and machines, and an estab lished and trusted dealer working in Guate mala on behalf of the Ossberger turbine manufacturers. In November 2016 the tur bines, generator and electrotechnical equip-

The entire electromechanical equipment and control technology was provided by Ossberger, the German specialists for small-scale hydropower plants. At full capacity the robust crossflow turbine can produce a bottleneck output of 689 kW.

ment embarked on the journey of several weeks from the port of Hamburg to Central America. On-site assembly and installation went very smoothly and were carried out by a local company contracted by JC Niemann. Ideally, when producing electricity, the crossflow turbine processes a maximum discharge of 1,200 l/s with a gross head of around 70 m, and offers a bottleneck output of 689 kW. Moreover, the robustly-built and hydraulically regulated machine is particularly good in part-capacity op eration when there is a limited volume of water available. The drum-shaped runner was built especially for the two-cell turbine and is ex tremely effective and efficient, even when the flow of available water fluctuates significantly. In addition, the turbine masters driftwood and floating waste with ease. Such flotsam is forced underwater by the runner within half a revolution. A Marelli 12-pole synchronised generator converts the energy of the turbine. The air-cooled machine is directly coupled horizontally with the turbine shaft, rotating – as does the turbine – at 600 rpm.

ANNUAL PRODUCTION OF APPROX. 2.8 GWH To ensure fully automated operation of the en tire plant, Ossberger provided an automation solution they have already implemented successfully a hundred times, right around the globe. Their control infrastructure and software for turbine regulation are based on universally implemented industry standards to facilitate easy programming for the operation of the power station – without requiring additional computer hardware. In March 2017, subsequent to the completion of all installation tasks, the Carmen Amalia power plant generated electricity for the grid for the very first time – and has since been in uninterrupted service for two years. In an average year the plant operators expect to produce around 2.8 GWh of power. Guatemala remains a promising market for Ossberger. Since the Carmen Amalia power plant went online, the southern German company already completed a further two projects within the country. In fact, news of another successful bid for a project in Guatemala was received just as the editorial deadline was reached for this issue.

Technical Data • Flow rate: 1,200 l/s

• Output: 689 kW

• Gross head: 70 m

• Manufacturer: Ossberger

• Net head: 68 m

• Generator: Synchronous

• Penstock: approx. 1,500 m

• Generator speed: 600 rpm

• Material: PVC & steel

• Voltage: 480 V

• Ø: DN900 / DN800

• Generator output: 728 kVA

• Turbine: crossflow

• Manufacturer: Marelli

• Runner speed: 600 rpm

• annual production: approx. 2.8 GWh

Projekt KW Carmen Amalia zek Hydro Internat 2019.indd 63

May 2019

14.05.2019 15:43:07

Seal Maker is a global manufacturer of highquality semi-finished products, CNC lathes and various kinds of seals for all types of industries. Beside extraordinary quality our strengths are flexibility in fulfilling individual customer requirements, fast processing times and an international active service team.

www.seal-maker.com /company/seal-maker

Seal Maker Produktions- und Vertriebs GmbH | Viktor-Kaplan-Allee 7 7023 Pรถttelsdorf | Austria

HYDRO

In 2009, KELAG acquired the traditional Lumbardhi 1 power plant in Deçan, Kosovo. Over the course of the following eight years, the plant was expanded to feature one upstream power plant and two downstream power plants. In a standard year, the entire cascade supplies around 105 GWh.

he community of Deçan is located in the west of Kosovo, not far from the borders with Montenegro and Albania. The small town, which is situated at an altitude of around 550 metres above sea level, enjoys international renown which it owes primarily to the monastery of the same name that is located in a narrow mountain valley roughly two kilometres west of the town. Deçan Monastery is a Serbian-Orthodox monastery dating from the Middle Ages – one of the last remaining in Kosovo. It is regarded not only as a place of pilgrimage and a sight that is famous internationally, but is also home to the only fully preserved medieval fresco murals showing Byzantine art. During the Kosovo War in 1999, the monastery provided Serbs, Roma but also Kosovo-Albanians who were fleeing the war with a roof over their heads. During these difficult times, the complex was spared destruction not least owing to the dedicated protection that was offered by KFOR troops. The monastery was declared a World Heritage Site by UNESCO in 2004, and the close protection provided by the KFOR units is maintained to the present day.

NEW LIFE FOR POWER PLANT THAT WAS DESTROYED Around 10 km away from the monastery, there has for decades been a state-owned, small hydropower plant which is situated on the banks of the Rivers Deçan and Lumbardh. However, the small power plant, which was built in 1957, was less fortunate than the monastery. It was partially destroyed in the chaos of war and stood idle for a number of years. New prospects for the plant only opened up in 2003 when a Kosovar living in America offered to repair and restore the power plant using US funding. As a consequence, the entire plant was revitalised, the turbines were restored and a new generator from the company Koncar was installed. Lumbardhi power plant (today known as Lumbardhi 1), which has a bottleneck output of 8.3 MW, began operating again in 2005. But three years later it was up for sale; the investor had begun looking for a buyer that was willing to take over the plant. He found great interest from KELAG, which was very quick to identify the great potential of this river course. KELAG bought the small power plant in 2009 and then immediately set about planning a cascade comprising three further power plants along the waterway. “For this purpose, we teamed up with a partner from Austria that had been active in Kosovo

for many years, has good contacts and is very familiar with the general legal conditions and local conventions. It acquired 10 per cent of the shares in the power plant company,” recounts qualified engineer Ingo Preiss, Managing Director of Kelag International and the man responsible for the whole project. DIFFICULT PRE-NEGOTIATIONS But the signs were not all that favourable. Before the first spade was put in the ground, it was necessary to overcome the hurdles of the official state procedures and successfully negotiate with the monastery. “In Kosovo, nobody had confidence that we would be able to reach agreement with the monastery. Ultimately, the monastery complex’s status as a World Heritage Site means that it is subject to strict safeguards, and a defined protection zone exists around the monastery. We were therefore aware that it would not be easy to gain the consent of the monastery. Another factor was that at this time Kosovo was still heavily under the influence of international agencies, and there were no norms and standards governing a power plant project of this type. We essentially set a precedent,” reflects Ingo Preiss, pointing out that ultimately the negotiations with the monastery proved to be less complicated than the official approval process. The environmental and natural conservation procedures in particular turned out to be very difficult. The project manager from Carinthia views the Environmental Impact Assessment that needed to be passed successfully to be similar to the type of EIA procedure that is known in Austria. In total, all the official procedures and pre-negotiations were set to stretch out over three years before the first diggers could move in. Foto: zek

With the completion of the few remaining tasks, the Carinthian energy provider KELAG was recently able to draw a line under a very challenging power plant project in the Republic of Kosovo. After acquiring an existing small-scale power plant in the community of Deçan back in 2009, two downstream plants and one upstream plant were constructed in addition to this in the years that followed. All four power plants, which were equipped with the very latest technology, are now in operation. In a standard year, the cascade generates roughly 105 GWh of clean electricity which is largely paid for via the state feed-in regime. The new power plant chain thus makes a significant contribution to increasing the stability of the network and the security of the supply of power.

photo credits: KELAG

KELAG IMPLEMENTS A 4-STAGE CASCADE IN KOSOVO

Kaskade Decan_EN.indd 65

May 2019

14.05.2019 15:44:22

HYDRO

GOOD CONDITIONS FOR A CASCADE The Carinthian energy provider is involved in Kosovo not least because of the favourable hydrological conditions in the region. The surrounding mountains extend up to 2,500 m above sea level. They present the first barrier for moist flows of air from the Mediterranean at which precipitation falls regularly. In winter, the snow in the mountains can easily pile up to four or five metres high. The snow thaw therefore lasts a long time, usually right into June. However, in summer there can occasionally also be dry periods. The plan for the cascade then envisaged constructing two plants downstream and one plant upstream of the existing Lumbardhi 1 power plant. The latter has three stream catchments and therefore three tributaries which discharge into a 25 million m3 equalising reservoir. Overall the cleverly designed tributary system consists of around 12 km of concrete channels, three smaller tunnels and the steep drop – so the penstock leading to the power plant. The first new plant to be implemented beneath Lumbardhi power plant was Belaje power plant with a bottleneck output of 8.2 MW, then the bottom stage was constructed in the form of Deçan power plant. It reaches 9.81 MW. Finally, the last project to be constructed was the upstream Lumbardhi 2 power plant. With an output of 6.2 MW, this is the smallest power plant in terms of performance.

View inside the powerhouse of Lumbardhi 1 power plant. The turbines were refurbished from 2003-2005 and both generators (Koncar) were replaced.

11 KILOMETRES OF GRP PIPE When it came to the type of pipe, the choice was not that difficult for the operators. They put all their fatih in GRP pipes, with roughly 11 km being laid in total for the three power plants. Whereas pipes from a Turkish manufacturer were used for Belaje and Deçan power plants, the operators opted for the grades of the GRP Flowtite pipe from Amiblu

CHALLENGES AT DEÇAN PP As part of implementing the first stage - for Deçan power plant - which was constructed between 2014 and 2016, an existing drinking water network was also replaced at the same time. This turned out to be complex and costly because the supply of drinking water to the small town of Deçan had to be maintained throughout.

photo credits: KELAG

Belaje power plant has two additional intakes.

Foto: Glanzer

Foto: Glanzer Belaje power plant is the first downstream power plant that takes the water from Lumbardhi 1 power plant directly. It is designed for a bottleneck output of 8.2 MW.

photo credits: KELAG

for Lumbardhi 2 power plant, which was the last to be constructed. The latter proved an excellent choice not just in terms of their handling during laying, but also during operation thanks to their exceptionally smooth inner surface. The team that laid the pipes had plenty to contend with from a technical point of view. There were no fewer than eight river crossings to design. “For Lumbardhi 2 power plant four culverts were built, three were constructed for Belaje power plant, and one was required for Deçan power plant. The companies that were commissioned to do the work came up with very good solutions to these technical challenges,” says Jörg Friedrich, the construction project manager from Kelag.

photo credits: KELAG

VERY BUSY ROADS The first construction works at Belaje power plant began after the snow thaw in 2013. The plant was able to start operating at the end of 2015. “The dry conditions in summer very much benefited the construction process, which meant we were able to make very good progress with the works. And yet executing the construction works was still the biggest challenge of the project,” says Ingo Preiss, referring to the fact that the pipe laying works, which were awarded to local companies, were particularly difficult owing to the large pipe dimensions of up to DN 2200. The pipeline runs largely in the road along the valley but in summer this road is very busy with tourist traffic – and it had to be kept open in all circumstances. Bypass routes were therefore created to prevent gridlock. A similar situation arose in the autumn when lots of wood is chopped down in the neighbouring forests and the route for the timber trucks had to be kept clear at all times. “This was no easy task,” as Ingo Preiss concedes. The fact that the checkpoints with the prescribed checks did not really make the situation any easier is obvious.

May 2019

Kaskade Decan_EN.indd 66

14.05.2019 15:44:25

photo credits: KELAG

HYDRO

photo credits: KELAG

Two Francis turbine sets made by Kössler are housed in the powerhouse at Belaje power plant. The machine dimensions were chosen to have a ratio of 1/3 to 2/3.

KNOW-HOW FROM AUSTRIA As with the previous projects in the Balkans, all of the planning work was done by the competence centre of the power plant department of KELAG itself, which was ultimately also responsible for supervising the construction work. In addition, with the technical trades in particular, the expertise of Austrian companies was used. The electromechanical equipment at the two downstream plants - Belaje and Deçan - was provided by the company Kössler from Lower Austria, which delivered two Francis turbines to Kosovo to be installed in each of the two power plants. To handle the seasonal fluctuation in the amount of water available in the best way possible, the turbines were chosen with a size ratio of from one third to two thirds. Whereas Belaje power plant achieves a bottleneck output of 8.2 MW with a drop of 123 m, Deçan power plant achieves a power output of 9.81 MW with a drop of 176 m.

pany Geppert from Hall in Tyrol supplied the modern turbine with a vertical axis that drives a generator via a directly coupled shaft. The 3-phase synchronous generator supplied by TES rotates at 600 rpm and is designed for a rated apparent power of 7,350 kVA and a voltage of 6,300 V. Drawn cup bearings were used due to the high demands from the radial forces of the Pelton turbine. To achieve a maximum output, a special rotor technology with an efficiency level of 98.25% (cos phi 1/100 load) was chosen. The generator was given a robust design and can withstand a short circuit with two and three phases. With this equipment, the upstream Lumbardhi 2 plant is able to produce a bottleneck output of 6.2 MW. The excavation for the construction pit at Deçan power plant extended down to a depth of up to 14 m. The water drainage was therefore complicated and costly.

photo credits: KELAG

“Delivering the Deçan power plant generally presented us with a number of challenges. In this context, the considerable depth of construction should primarily be mentioned. As the two Francis turbines have a negative suction head due to the drop – so the machine shaft is located below the tailwater level, the powerhouse had to be designed to be correspondingly low. So low that the level of the bottom of the machine hall is roughly 10 m below ground level. The excavation depth at the site of the powerhouse was up to 14 m, and the rear section of the building was incorporated into the steep slope behind it,” reports Jörg Friedrich. To support the excavation pit, a bored pile wall with 128 reinforced concrete pillars with a length of up to 17 m was constructed all the way round. According to Friedrich, the water drainage in the construction pit was just as complicated and costly.

To get the machines inside the powerhouse at Deçan power plant, the rails of the indoor crane were temporarily extended outside.

To support the excavation pit, 128 reinforced concrete pillars with a length of up to 17 m were used.

photo credits: KELAG

DIFFERENT LINKS IN THE CHAIN Around a third smaller than Deçan power plant is the upstream Lumbardhi 2 power plant, whose construction began after the snow thaw in the spring of 2017. It is also the power plant at the highest altitude – the water catchment was created around 1,400 m above sea level. “The 2017 construction season was very much defined by a dry period, which had a very beneficial effect on the progress of the construction work. We were able to complete trial operation back in December 2017 and transfer the plant to normal operation,” recounts Ingo Preiss. In contrast to the other power plants in the cascade, Lumbardhi 2 power plant was equipped with a single turbine, specifically with a 6-nozzle Pelton turbine. The operators once again placed their trust in the know-how of an experienced Austrian hydropower specialist: The com-

Kaskade Decan_EN.indd 67

May 2019

14.05.2019 15:44:26

HYDRO

Foto: KELAG photo credits: KELAG

photo credits: KELAG

Similarly to Belaje power plant, two turbine sets with a size ratio of 1/3 to 2/3 were also installed at Deçan power plant.

The bottom downstream Deçan power plant is also the most powerful plant with a bottleneck output of 9.81 MW.

As favourable as the weather conditions were for the construction works, the transportation of the machines as far as the powerhouse would prove to be a difficult task. It was necessary to transport them to their intended location along a 14 km long gravel road, which in places was very steep and featured some extremely tight bends. “To withstand the weight of the laden vehicle, we had to temporarily support the four bridges along the route using steel girders. Once it arrived at Deçan power plant, the generator weighing several tonnes was transferred onto a short vehicle using a 100t mobile crane, which is generally not easy to get hold of in Kosovo. Finally, a chain excavator had to support the 800 hp tractor unit to overcome the final incline before reaching the Lumbardhi II powerhouse. This was a real achievement!” IMPROVEMENT IN THE GRID SITUATION An important point in the overall cascade project involved the grid connection. “The existing Lumbardhi power plant was connected to a 12 km long, old 30 kV overhead transmission line. The capacity would not have been sufficient for the entire cascade. The connection to the 110 kV grid was thus essential – even though this was not straightforward. Although a 110 kV transformer station is located nearby, the integration with the 110 kV switch panel and in particular the required coordination with the grid operator were extremely complicated,” says

Dietmar Holzer, project manager for the entire grid connection, in summary. To make the connection to the grid, a 40 MVA transformer was installed and 6 km of power cables were laid from the bottom Deçan power plant up to the transformer station. The new grid situation in the valley, which is difficult to access, has resulted in significant improvements in respect of the stability of the grid and therefore the reliability of the power supply. Ultimately, grid outages and shutdowns, which often lasted for more than five hours, were a frequent occurrence. Blowdowns and heavy snowfall were the main causes of them. Thanks to the connection to the 110 kV grid, the number of outages has been reduced considerably. MONITORING FROM KLAGENFURT For regular operation of the new cascade, KELAG employs a team of ten local workers who oversee ongoing operation of the plants. However, all four power plants are essentially designed to be operated fully automatically. For this purpose, the process and control technology was designed as an essential part of the overall concept and put out to tender separately. In the case of the cascade power plant series in Kosovo, a thorough, Simatic-based control technology system was developed and implemented, and this provides KELAG with professional, comprehensive access to the plant from its base in Klagenfurt. For this purpose, fibre-optic

The intake for the upstream Lumbardhi 2 power plant was created at an altitude of around 1,400 m.

photo credits: KELAG

Lumbardhi 2 power plant is the smallest power plant in the cascade with a bottleneck output of 6.2 MW.

Technical Data Lumbardhi II HPP • • • • • •

Number of Turbines: 1 Turbine type: 6-nozzle Pelton Manufacturer: Geppert Nominal output: 6.2 MW Total annual capacity: 18.0 GWh Years of construction: 2016-2018

Lumbardhi I HPP • • • • • •

Number of Turbines: 2 Turbine type: 2-nozzle Pelton Manufacturer: Litostroj Nominal output: 8.3 MW Total annual capacity: 25.0 GWh Y. o. c.: 1957 (refurbished in 2005)

Belaje HPP • • • • • •

Number of Turbines: 2 Turbine type: Francis spiral turbine Manufacturer: Kössler Nominal output: 8.2 MW Total annual capacity: 24.0 GWh Years of construction: 2013-2015

Deçan HPP • • • • • •

Number of Turbines: 2 Turbine type: Francis spiral turbine Manufacturer: Kössler Nominal output: 9.81 MW Total annual capacity: 38.0 GWh Years of construction: 2014-2016

May 2019

Kaskade Decan_EN.indd 68

14.05.2019 15:44:28

photo credits: Wikipedia

photo credits: KELAG

Foto: KELAG

HYDRO

A 6-nozzle Pelton turbine manufactured by Geppert was installed in the upstream Lumbardhi 2 power plant. It is ideally designed to cater for the hydrological conditions at the site.

cables were also laid throughout for the new plants. “Monitoring the entire cascade is very important to us. Especially in summer when conditions are dry, at least a certain amount of hydropeaking using the balancing reservoir of Lumbardhi 1 power plant is possible. In such cases, the facility is shut down for roughly ten hours so that it can then be run through for six to seven hours again. But there are of course also times in summer when we automatically maintain gauge-controlled operation. However, you have to admit that in general the main periods of power generation are during the snow thaw,” says the project manager.

The medieval Serbian-Orthodox Deçan Monastery houses the only fully preserved medieval fresco murals showing Byzantine art. It is considered a place of pilgrimage and enjoys the status of a UNESCO World Heritage Site. The monastery complex is still guarded by KFOR units today.

105 GWH OF GREEN ELECTRICITY PER YEAR In retrospect, Ingo Preiss can reflect positively on the extremely complicated project in Kosovo. Not least owing to the great experience of power plant projects that KELAG International now boasts in the Balkans, the project was delivered highly professionally – even if not everything was quite so straightforward. Ingo Preiss says: “All deliveries to Kosovo were generally made without any problems. But it should of course not be forgotten that spare parts and small pieces of equipment are almost impossible to obtain in the region, and everything that is imported must also have

Kaskade Decan_EN.indd 69

duty paid on it.” It was only a few weeks ago that KELAG completed the final remaining tasks and improvement works so that the project can now be considered to be completed. For the region bordering Montenegro and Albania, the power plant today represents an important improvement to the electrical infrastructure. In a standard year, the new cascade supplies 105 GWh of clean electricity to the grid. The successful conclusion of the power plant project confirms KELAG’s commitment to Kosovo, a country that offers plenty of further potential for other power plant facilities.

May 2019

14.05.2019 15:44:29

ne im .

HYDRO

Foto: KWB

AUMA ASSISTANT APP FOR SMART ACTUATOR SETUP AND DIAGNOSTICS

graphics copyright: AUMA

Electric actuator manufacturer AUMA has released version 3.0 of the AUMA Assistant App.The app allows fast and easy configuration and diagnostics of AUMA actuators from a smartphone or tablet. All the actuator’s operating parameters can be set via the app, saving considerable time and cost during commissioning.

he app uses Bluetooth wireless communication to transfer data to and from the actuator. Parameter settings can also be prepared offline and transmitted to the actuator on site at a later point in time. Copying parameters from one actuator to another is also possible. A snapshot function facilitates maintenance and troubleshooting: All diagnostic and operational data stored in the actuator can be read out as snapshot files. These files can then be uploaded into the AUMA Cloud for detailed analysis and diagnostics. Snapshot data include, for example, run times, number of starts, and torque characteristics. AUMA ASSISTANT APP IS AVAILABLE FREE OF CHARGE Operators can send settings and diagnostic data directly from the app via e-mail to AUMA’s Service department, thus shortening the time for troubleshooting and remedial action. The AUMA Assistant App also allows the operator to download device-specific documentation such as operation instructions and technical datasheets to the smartphone or tablet simply by scanning a QR code on the actuator. The AUMA Assistant App is available for free download in the Google Play Store and the Apple App Store.

www.auma.com Polish Hydropower Conference

HYDROFORUM 2019 Solina (Poland), October 9-10th, 2019

The conference scope includes:

 Current problems of hydropower development in the Central-East and North European regions;  Best practices and experience in the field of planning, design, construction, maintenance and operation of hydropower installations and equipment;  Hydropower oriented research & development activities. The Conference venue will be located at the picturesque Solina Lake, in the South Eastern part of Poland, at the foothills of Bieszczady mountain range. Study visits at Solina Dam and Hydropower Plant (200 MW) are envisaged. Further details, call for papers and registration forms are already available from our websites www.tew.pl, www.imp.gda.pl and Conference Secretariat biuro@tew.pl.

May 2019

AUMA_Assistant_App.indd 70

14.05.2019 15:45:07

photo credits: PELFA Group

HYDRO

PELFA Group’s new machine shop was taken into operation last December. The resulting extended workshop floor space and additional machinery enable a more detailed implementation of customer requirements.

STEELWORK ENGINEERING SPECIALIST PELFA GROUP EXPANDS ITS HYDRO SEGMENT Steelwork engineering provider PELFA Group Srl., which has its headquarters in the Northern Italian town of Buia near Udine, last year inaugurated its new production hall. With this milestone event in its company history, PELFA has achieved a considerable expansion of its in-house manufacturing competence. Founded in the late 1970s, the tradition-steeped corporation today manufactures high-quality industrial components for the energy sector, railway operators, the military, hoisting technology providers, and the construction industry. For more than 10 years, PELFA Group has been a reliable partner of the hydropower industry and proven its competence with a series of international large-scale projects. High quality and material standards, as well as efficient project management and customer-focussed service have earned the industrial engineering firm an excellent reputation. It is no wonder, then, that a growing number of international manufacturers in the steelworks engineering industry trust in PELFA’s competence and have their high-quality hydropower components delivered from the PELFA facilities near Udine.

he pioneering spirit of PELFA’s founder Redento Fabbro is still palpable today throughout the firm’s manufacturing facilities. After all, it’s qualities like his drive for innovation, flexibility and openness to new developments that the firm still practices today. Since its foundation in 1979, the firm has grown to its current workforce of 150 staff. Over the years it was possible to preserve the traditions held dear in the family-owned business of back then. “Our employees are still our most valuable capital,” explains Ing. Forgiarini Andrea, who has been serving as PELFA Group’s CEO since 2004. This appreciative corporate culture not only promotes a positive social interaction among employees, it is also essential for ensuring smooth collaboration between the various departments. “This way, we can keep our internal employee

turnover on a very low level, which means valuable competence stays within the company. Of course, this policy also benefits our customers,” says Ing. Forgiarini Andrea, adding that “For us it’s essential that we stay flexible despite our constant growth and change. This allows us to respond quickly to all kinds of new situations, but that works only with seasoned, well experienced employees.” The various teams are used to working in close collaboration, which eliminates communication barriers between the individual professional groups involved. “Although we are a mid-sized industrial firm we actually practice the corporate culture of a small-sized business with its flat internal operational structures,” as Andrea explains. This means that engineers, welders, material engineers, varnishers, customer support staff, product, project

PELFA Group.indd 71

and quality managers, as well as technical editors and communicators are working hand in glove with each other at the local manufacturing facilities. What is more, says Ing. Forgiarini Andrea, “We even interlinked the offices visually with glass panels instead of walls.” This streamlined management structure allows a close focus on details to enable smooth project processes across the various different areas of competence. NEW INVESTMENT – NEW PERSPECTIVES The manufacturing processes can be tailored to individual requirements to cover the variety of components for individual contracts. New investments are undertaken every year to accommodate both current and future market developments. “It’s a constant process of adjusting to the market situation,” as Ing. ForMay 2019

14.05.2019 15:18:49

HYDRO

HIGH QUALITY STANDARD At PELFA, the quality of individual industrial components is not just spot tested. Instead, quality testing is incorporated already at the planning stage of the individual manufact ring concepts. Every day at least five seasoned

In the fitting shop, the often highly complex hydropower plant components are assembled and subjected to rigorous tests.

SERVICES AND POTENTIAL PELFA Group has been active in international markets for forty years, specialising in the manufacture of systems, machines, and mechanical and welded components for a variety of different industries. PELFA covers the entire production process, from order acquisition to the delivery of the finished turnkey product. All working steps can be performed on-site, including comprehensive contract management, engineering, materials purchasing, cutting of sheet metals and structural shapes, pressing, bending, calendering, welding, heat treatment, tooling, sand blasting and painting, as well as pre-assembly and mechanical final testing. The shops are equipped with cutting-edge technology such as CNC

PELFA Group Overview:

MANUFACTURE AND DELIVERY OF EQUIPMENT FOR:

• 150 specialist engineers, employees and workers • 25,000 m2 of factory halls and workshops • 100 t crane capacity, with 10 m hook elevation

STEELWORKS • Scrap metal chutes • Ladles • Minimill EAF • Electrode arms • Continuous casting • Oxygen lances • Ladle cars • Towing and straightening systems • Vacuum tanks and hatches

INTERNAL DEPARTMENTS • Oxy-Cutting, Welding, NDT Inspection, • Thermal Treatment, Machining, • Dimensional Inspection, Sand Blasting, Metallisation, • Assembly and Functional Testing CERTIFICATIONS: • UNI EN ISO 9001:2008 • UNI 1090 EXC4 • EN 15085 Class 1

FORGING TECHNOLOGY • Press body and manipulator parts

Installation of the turbine rotor with a diameter of around 2.2 m for Gugler’s HPP Bodorna project.

photo credits: PELFA Group

and highly qualified staff are busy ensuring the proper implementation of quality standards, subjecting the components to rigorous tests after each relevant manufacturing step. PELFA takes its quality testing very seriously, which has other advantages as well, as CEO Andrea explains. “Good quality management makes it easy to spot further optimisation potential.” As a result, quality assurance is an essential contributor to the firm’s further development.

After a careful final inspection the component is ready for shipping.

photo credits: PELFA Group

photo credits: zek

Foto: Rolf Marke

photo credits: zek

giarini Andrea explains. To keep up with changing market demands, a new machine shop was put up last year and taken into operation in December. With this extension, PELFA expanded its manufacturing floor space by 1,000 m² to a total of 25,000 m². Equipped with some new manufacturing equipment, it did not take long for this promising investment to prove its worth. “As far as our manufacturing processes, assembly work and just-in-time deliveries are concerned, they are now easier to plan, and they can be implemented more efficiently to boot. This means we are now able to suit our customer’s requirements even better, and we are able to respond more quickly and flexibly to belated changes,” says Andrea. To put this added value into practice, other departments were reorganised as well, with targeted optimisations in individual areas ranging from the delivery network to warehousing, logistics, and quality management.

photo credits: PELFA Group

The core element of PELFA’s new machine shop: a CNC-based plate boring and milling system. The state-of-the-art high-precision machine measures around 7 m in height and can process components weighing up to 100 tonnes.

A member of the quality assurance team performing material tests with an ultrasonic measuring device.

METAL-WORKING INDUSTRY • Nippers • Spreaders • Steel grid welders • Pusher-type furnaces • Roll housings • Ingot casting modules • Cooling beds ENERGY PRODUCTION • Components for hydropower plants • Water turbines (Kaplan, Francis, Pelton) • Hydrodynamic screws • Selected parts for penstock systems (branch pipes, T-pieces, armour plating)

May 2019

PELFA Group.indd 72

14.05.2019 15:18:52

HYDRO

photo credits: PELFA Group

Fotos: Bayerische Landeskraftwerke

Fotos: zek

Measuring 8 m in length and weighing 70 tonnes, the component is transported to its destination in Georgia. With a design flow rate of 35 m3/s, HPP Bodorna generates a rated output of 2.556 kW. Commissioning of the plant by Gugler Water Turbines GmbH is scheduled for next September.

photo credits: zek

and NC ([Computer] Numerical Control), but also with traditional machinery, to enable the manufacture of components for industries ranging from steelwork engineering to energy technology, mining, and various others. PELFA’s portfolio includes the construction of new facilities, overhauling and restoration of existing equipment, delivery of parts and components, and the installation of selected turnkey systems. These services include materials sourcing, oxygen cutting, welding and machining of parts up to a weight of 100 tonnes. Many years of experience in industrial metal engineering have allowed PELFA Group to acquire extensive knowledge in engineering, manufacture and delivery of products for the heavy industry. This comprehensive knowledge, as well as the firm’s reliability in terms of contract implementation and deliveries, have convinced a long list of hydropower businesses to choose PELFA Group as a proven project partner. “Each of our customers and partners is assigned a dedicated project leader, who acts as a contact that they can consult with on all relevant issues,” says Andrea. Each order is processed differently, depending on the individual customer’s requirements. “Over the last ten years we have acquired extensive knowledge concerning the manufacture of high-quality system components for hydropower projects. By now, we can provide almost the entire range of related competences as in-house services. That’s our strong suit today,” concludes Ing. Forgiarini Andrea. The share of hydropower projects in the firm’s annual turnover of around 25 million euros amounts to roughly 60 per cent. PELFA offers its customers a wide range of high-quality hydropower plant components such as draft tubes and housings, as well as fully-featured Kaplan, Francis, Pelton or hydrodynamic turbines. One of the largest parts ever manufactured by PELFA is currently on its way to the hydropower construction site of HPP Bodorna in Georgia.

Group photo in front of the 20 t pump impeller. (left to right) Giulia Alessia, Sales; Erich Feldtänzer, Regional Head of Sales for German-speaking countries; Ing. Forgiarini Andrea, CEO, PELFA; Alessandro Bertino, Head of Mechanical Manufacturing.

PELFA Group.indd 73

May 2019

14.05.2019 15:18:53

HYDRO

Seal Maker is a global manufacturer of high-quality plastic and elastomer semi-finished products, as well as CNC lathes and seals that are used in all types of industrial sectors. Successfully established in 1997 Seal Maker offers business solutions enabling its customers to meet individual sealing requirements. Currently the network of satisfied customers comprises partners in more than 70 countries all over the world, expanding each year.

esides the high-quality standards Seal Maker focuses on supporting customers with a perfectly aligned seal production system consisting of a wide and diversified range of semi-finished materials and efficient CNC-lathes. That enables seal producers to overcome challenges and fulfill increasing market requirements easily. Another aspect of Seal Maker’s service range is seal production itself. So, the company offers capacities of its inhouse machinery, producing seals up to 1,850 mm diameter. This special service supports partners to meet requirements from their clients. DOING WELL IN SPECIAL “INDUSTRY” SOLUTIONS As flexibility is common at Seal Maker it’s proud of offering manufacturing of unique seals and single pieces if necessary. Therefore, Seal Maker’s SML SystemSoftware provides more than 220 profiles as well as special solution profiles. So, great strengths lie in service for all matters of sealing technology, flexibility in manufacturing customized orders, fast processing times as well as reliability in order transactions. This also covers unique productions for special industries like hydropower, mining and cement industry. Most times seals manufactured for “special industries” partners require

The development, production and marketing of high quality semi-finished products in form of bars and tubes for the machining of sealing elements is an integral part of the core competence of Seal Maker Produktions-u. Vertriebs GmbH.

photo credits: Seal Maker

PROFESSIONAL KNOW-HOW IN ALL ASPECTS OF SEAL PRODUCTION

Seal Maker offers a world-wide advisory service for all matters relating to the sealing technology, both with their technical expertise, as well as with their assistance in advertising, respectively, marketing activities.

large diameters and professional welding know-how. As Seal Maker has met an increasing demand in this field of business within the last years, its experts are very familiar with state-of-the-art welding as well as individual challenges. Experienced technicians practice welding regularly and carry out seal welding and assembly work on customers site if required.

(m/f ) are solution- oriented and responsible, while demonstrating integrity, vision and team spirit in order to service customers with technical expertise and comprehensive advice. Would you like to find out more about the company and its products? Visit the website: www.seal-maker.com

EXTENDED LIMITS – NEW SML 750eplus As a leading manufacturer of CNC-lathes Seal Maker presented its new SML 750eplus machine recently. More than ten years of knowledge and profession have been integrated into this new machine which enables the production of seals with 750 mm diameter, optional even 850 mm. Equipped with an efficient 12-station disc turret with driven cutting tools and the user-friendly SML SystemSoftware it redefines the limits of what can be machined in one system. EMPLOYEES ARE THE BASIS OF SUCCESS The applications for the company´s product range are as diverse as the activities of its employees. Seal Maker‘s ambitious employees

Due to ultra-modern manufacturing technology the company is able to cover the whole spectrum of seal applications.

Machinery capacity up to 1,850 mm with SML 1800e.

Enlarged diameter and machining length capacities - combined with the included driven cutting tools facilitate the production of large seals up to 1,850 mm diameter as well as of complex plastic parts.

May 2019

Seal Maker EN.indd 74

14.05.2019 15:21:52

Surprisingly sustainable.

www.amiblu.com Umschlag zek International 2019.indd 2

Get in touch with our Amiblu sales team or our partners for Austria and Switzerland: www.apr-schweiz.ch

www.etertec.at

14.05.2019 14:44:23

Verlagspostamt: 4820 Bad Ischl · P.b.b. „03Z035382 M“ – 17. Jahrgang

zek HYDRO 2019

2019 INTERNATIONAL HYDRO

FUTURE TECHNOLOGY

HYDRO HYDRO

YOUR GLOBAL PARTNE R FOR HYDRO SOLUTIONS

“FROM WATER-TO-WIRE“

Two New Hydro Power Plants for Transcaucasia

Our comprehensive product and service portfolio ranges from equipment

Svaneti Hydro

ANDRITZ HYDRO GmbH ⁄ www.andritz.com/hydro

Ad_Image_AH_216x297_en_0001.indd 1

Umschlag zek International 2019.indd 1

www.zek.at

27.03.2019 09:03:33

14.05.2019 14:44:23