Connecting The Worldwide Hydro Community September 2009

INGENUITY RESURRECTS
SMALL HYDRO PROJECT 18

AXIAL TURBINE FOR PIPES 36
TEXTBOOK TO THE RESCUE 42
HydroVision International
details pg. 51
GENUITY ING RESURRECTS
SMALL HYDRO PROJECT SM 18
AXIAL TURBINE FOR PIPES 36
TEXTBOOK TOTHE RESCUE 42
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Connecting The Worldwide Hydro Community September 2009
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www.hydroworld.com September 2009 / HRW 1
SEPTEMBER 2009
TURBINES AND MECHANICAL COMPONENTS
ARTICLES
18 Practical Development: The Story of 940-kW Onekaka
By Bryan W. Leyland, LCL Ltd.
Four small hydro enthusiasts applied ingenuity and practical thinking to bring the 940-kW Oneka-
ka hydro project in New Zealand abandoned in the 1950s back to working order.
28 Investigating Failures of Post-tensioned Anchors
By Malte O. Cederstrom, Vattenfall
When seven post-tensioned anchors along the intake canal
wall at the Alvkarleby hydroelectric station in Sweden failed,
dam safety engineers for owner Vattenfall AB conducted
an exhaustive investigation of the nature and causes of
the failure. The investigation gave the utility the
information needed to safely restabilize the dam.
DEPARTMENTS
ADVISORY BOARD
H. Irfan Aker
Dolsar Engineering
Limited, Turkey
Ian M. Cook
ICCL, United
Kingdom
Chris Head
Chris Head & Associates
United Kingdom
Leonard B. Kassana
East African Tea
Trade Association
Kenya
Peter Thomas Mulvihill
Pioneer Generation, Ltd.
New Zealand
Raghunath Gopal
(R.G.) Vartak
AFCONS Infrastructure
Limited, India
Emmanuel
Antwi-Darkwa
Volta River Authority
Ghana
Arturo Gil
Garcia
Iberdrola
Generation
Spain
Liu Heng
International Network on
Small Hydropower
(IN-SHP), People's
Republic of China
Carlos Alberto Knakiewicz
Itaipu Binacional
Brazil
Montri Suwanmontri, PhD
Dr. Montris & Associates
Thailand
Luis C. Vintimilla
Consulting Engineer
Ecuador
Zhang Boting
Chinese Society for
Hydropower Engineering
People's Republic of
China
Roger Gill
Hydro Focus
Pty. Ltd.
Australia
Zhang Jinsheng
China Yangtze
Three Gorges Project
People's Republic of
China
Dr. Terry Moss
Eskom Generation
South Africa
C.V.J. Varma
Council of Power Utilities
and The Dams Society
India
James Yang, PhD
Vattenfall Research
and Development AB
Sweden
2 Viewpoint:
The Quest for
Sustainable
Hydropower
4 Briengs
36 Tech Notes
40 New Hydro
42 Lessons Learned:
Keep That Book!
44 Small Hydro
50 Calendar
52 Index to
Advertisers
12 Equipment Innovations Improve
Operations, Decrease Costs
Owners of three hydro projects in
Europe save money and increase
operational effciency through
innovations in design and
selection of turbines and other
mechanical components.
28
Peer Reviewed
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We hear a lot about sustainability these days. Sustainable is a much-used
modifer, as in sustainable agriculture, sustainable cities, sustainable energy, sus-
tainable development and sustainable hydropower.
A dictionary defnition of sustainable is, capable of being sustained; of, relat-
ing to, or being a method of harvesting or using a resource so that the resource is
not depleted or permanently damaged. To most people in our industry, hydro-
power would seem to naturally ft this defnition. Yet, things are not so simple.
Thats because the quality of sustainability is not a matter of black or white.
Rather, it characterizes a pivot point between good and bad.
The debate over hydros sustainability arrived front and center after the
publication, in 2000, of the World Commission on Dams report, Dams and
Development. This report acknowledged that Dams have made an important
and signifcant contribution to human development . Yet, it also was criti-
cal in observing that In too many cases an unacceptable price has been
paid . The report went on to recommend practices to guide the future
development of dams. This drew strong reaction from the hydro industry,
owing to the conclusion that, however well-intended the recommendations
were, strict adherence would largely prevent even the most responsible future
development of large-scale hydro projects.
The International Hydropower Association (IHA) has been active in tackling
this issue and has pursued the development of tools and practices that can foster
increased responsibility and transparency in hydropower development. The as-
sociations efforts have resulted in the publication of Sustainability Guidelines
and the development of methods for assessing projects sustainability.
As part of IHAs focus on sustainability, the association recently held its 2009
World Congress in Iceland on the theme of Advancing Sustainable Hydro-
power. About 300 participants from 50 countries discussed issues relating to
improving hydros sustainability and acceptability as one of the worlds leading
sources of energy. At the conclusion of the Congress, IHA vice president Roger
Gill observed that, while delegates came to discuss the business of hydropower,
they discovered they were discussing the sustainability of the world.
IHA provides vital services to the hydro industry addressing sustainability
and other cutting-edge issues. The association deserves and has proven highly
worthy of your support!
Editor Emeritus
2 HRW / September 2009 www.hydroworld.com
Vi e wp o i nt
The Quest for
Sustainable Hydropower
Member: BPA International

Vol. 17, No. 4, September 2009
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4 HRW/ September 2009 www.hydroworld.com
Andritz to equip Austrias

20-MW Gossendorf, 20-MW Kalsdorf
Austria regional utility Energie Steiermark has awarded
a contract to Andritz Hydro to supply electromechanical
equipment for construction of the 20-MW Gossendorf
and 20-MW Kalsdorf hydroelectric projects on the Mur
River south of Graz.
Andritz said July 9, 2009, that it received orders total-
ing 28 million euros (US$39 million) to supply a total of
four bulb turbines with runner diameters of 3.6 meters,
plus generators, governors and excitation systems. The
units are to be designed for fows of 100 cms and heads
of 11.11 meters.
International hydro congress
focuses on sustainability
Sustainability became the key word for hydro industry
representatives from approximately 50 countries who at-
tended the International Hydropower Association (IHA)
World Congress in Iceland.
Nearly 300 people gathered June 23-26, 2009, for ses-
sions on energy and water policy, linkage between hydro-
power and climate change, hydro development, invest-
ment and fnance, and hydropower markets.
As chronicled by the International Institute for Sus-
tainable Development (IISD), the IHA Congress further
advanced IHAs Draft Hydropower Sustainability As-
sessment Protocol, a tool for assessment of sustainable
hydropower development.
Summing up the event, IISD quoted Roger Gill of Hydro
Focus Pty, who noted many people came to the Congress ex-
pecting to discuss the business of hydropower, but discovered
they wtre here to discuss the sustainability of the world.
Reporting on the work of the Hydropower Sustain-
ability Assessment Forum, a multisector collaboration to
advance the Hydropower Sustainability Assessment Pro-
tocol, Kristin Nyman of GTZ said participation of the
forums many stakeholders is refected in a new draft of
the protocol, making it more comprehensive.
Reginald Hernaus of the Netherlands Ministry of
Environment, suggested IHA increase its outreach ac-
tivities and promote the revised sustainability assessment
protocol. He told delegates the central challenge for the
hydropower sector is to convince the international com-
munity, especially climate change rules negotiators, that
hydropower is a sustainable energy source.
Paul Soffe of EcoSecurities said hydropower projects are
being demonized in climate policy arenas, with many buy-
ers shying away from hydro carbon credits. He said the hy-
dropower industry should lobby U.S. and European Union
governments to convince them of hydros sustainability.
President Luis Berga of the International Commis-
sion on Large Dams emphasized that water policy, en-
ergy policy, and hydropower development and operation
are interconnected. He called for adoption of integrated
water resource management policies, energy effciency
activities, and increased water infrastructure and stor-
age capacity to develop a holistic strategy for addressing
water and development.
A full report by the IISD on the IHA Congress may
be obtained via the IHA Internet site, www.hydropower.
org. Information on the Hydropower Sustainability As-
sessment Protocol is available at www.hydropower.org/
sustainable_hydropower/hsaf.html.
Vietnam utility names
supervisor of 156-MW Song Bung 4
The project manager for Electricity of Vietnam (EVN)
has named Mott MacDonald of the United Kingdom to
serve as implementation supervisor for construction of
the 156-MW Song Bung 4 hydroelectric project.
The frm is to administer and supervise procurement
and implementation of construction and equipment supply
contracts, and to ensure completion of the project in ac-
cordance with contracts and approved design. Mott Mac-
Donald said July 14, 2009, that it also is to review designs,
provide resettlement advice and monitoring, and perform
construction supervision and knowledge transfer.
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Argentina president ofciates
start of 132-MW Los Caracoles
Argentine President Cristina Fernandez de Kirchner presid-
ed over the start-up June 18, 2009, of the 132-MW Los Car-
acoles hydroelectric project on Argentinas San Juan River.
Fernandez issued the order to start one of the US$250
million projects two Francis turbine-generators in a video
conference link from the government house of San Juan
Province, about 60 kilometers from the hydro plant site.
Accompanied by San Juan Gov. Jose Luis Gioja, the
president said Los Caracoles is the most important work
realized in the history of San Juan and one of the great
energy works of the country.
The provinces electric utility, Energia Provincial So-
ciedad del Estado (EPSE), began mechanical testing of
the frst turbine-generator in April and recently completed
both mechanical and electrical testing of the equipment.
The second unit is expected to begin generating in July.
Los Caracoles 136-meter-tall dam was built by the
consortium Techint-Panedile, while Power Machines of
Russia supplied generating equipment.
Fernandez gave the order to close gates to begin flling
Los Caracoles reservoir in October 2008. However, low
water levels have delayed flling the impoundment.
India rm wins contract to
build Bhutans 114-MW Dagachhu
Dagachhu Hydro Power Corp. Ltd. has awarded a con-
tract to Indias HCC for civil construction of the 114-
MW Dagachhu hydroelectric project on Bhutans Da-
gachhu River.
The engineering and construction company said July 9,
2009, that it received a contract worth 3.875 billion rupees
(US$79.7 million) for construction of a diversion weir, chan-
nel and tunnel to desilter, shafts, powerhouse and transform-
er caverns, maintenance and control buildings, and tailrace
tunnel. The work is to be completed in 1,239 days.
RusHydro goal: Reestablish global
status of Russian hydro technology
The head of Russian hydropower giant RusHydro says
Russia has just fve years to reestablish itself as the sup-
plier of world-beating hydropower technology if it is not
to lose out to competitors in the developing world.
Acting Chairman Vasily Zubakin said RusHydro, the
worlds second largest hydropower generator, has a strate-
gic plan for Russia to once again be the dominant player in
hydropower plant design and construction.
We have a commitment to reestablish the reputation
of Russian technology to that of the Soviet days when
many countries hydropower facilities, including those of
China, were built with Russian expertise, Zubakin told
a London news conference. We must return to this po-
sition within fve years, otherwise the experience of the
aging workforce will be lost.
RusHydro is competing with international equipment
and service providers for contracts in developing coun-
tries. The utility operates 53 hydro power plants in Rus-
sia and has its own in-house research and development
facilities, design institute and engineering facilities.
Zubakins comments came July 6, 2009, the day the
frm launched the trading of global depository receipts
on the London Stock Exchange, aimed at broadening its
shareholder base and increasing liquidity.
Consortium to perform environmental study
The Inter-American Development Bank (IADB) has named
a U.S.-Canadian consortium to perform an environmental
impact study for the 630-MW El Diquis hydroelectric proj-
ect, proposed for Costa Ricas General Superior River.
IADB awarded a US$999,994 contract to a consortium of
the Louis Berger Group Inc. and Klohn Crippen Berger Ltd.,
which was chosen from among fve bidders for the work.
The consultants are to develop an environmental im-
pact study for submission to environmental regulator
Secretaria Tecnica Nacional Ambiental. The frms are
to identify positive and negative effects of the project and
formulate a risk management plan, emergency action
plan and an environmental management plan.
Utility seeks reputation
as clean energy company
RusHydro is also keen to brand itself as a clean energy
company and plans to invest heavily in a renewable energy
portfolio, which already includes wind, geothermal and
tidal projects. Zubakin said prospects for the company
would be affected by decisions to be made later this year in
Copenhagen at the Global Climate Change Conference.
We believe we have a strong potential for growth and
this will be infuenced by the depth of the decisions in
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Copenhagen, affecting the planets sustainable develop-
ment after Kyoto, Zubakin said.
RusHydro already has foreign interests including a joint
venture in India. Central Asia was singled out as a region
of interest with RusHydro looking to develop hydropower
projects in the upper reaches of Kyrgyzstans rivers.
Our preference is to work through joint ventures,
which better allow for management of local regulation
and environmental issues, Zubakin said.
The utility executive told reporters RusHydro plans to
invest more than US$9 billion in the Far East in the next
decade, increasing its generating capacity by more than
70 percent. He said more than 2,500 MW is on the draw-
ing boards in the region.
RusHydro signed an agreement in May with Mitsui & Co.
Ltd. and J-Power of Japan to study development of the 320-
MW Nizhne Bureyskaya (Lower Bureyskaya) hydroelectric
project in the Far Eastern Amurskaya Region. Additionally,
RusHydro said in June that its stalled 3,000-MW Boguch-
anskaya project appeared to be back on track in Siberia.
Alstom Hydro to equip Indias 500-MW Teesta 6
Developer Lanco Infra Tech Ltd. has awarded a contract to
Alstom Hydro of France to supply four turbine-generators
and other equipment for the 500-MW Teesta Stage 6 hydro-
electric project on the Teesta River in Indias Sikkim State.
Alstom said July 10, 2009, that the 40 million euro
(US$55.7 million) contract includes design, engineering,
installation, testing and commissioning of four 125-MW
Francis turbines, generators, main inlet valves, and con-
trol and protection systems. The work is to be performed
by Alstoms Vadodara, India facility.
Brazil bank signs its largest
loan, for 3,300-MW Jirau
Brazils national development bank gave fnal approval
to the largest loan in its history, 7.2 billion reais (US$3.5
billion) for construction of the 3,300-MW Jirau hydro-
electric project on Brazils Madeira River.
The action, announced by project partner GDF Suez
July 6, 2009, fnalizes the loan frst approved in Febru-
ary by Banco Nacional de Desenvolvimento Economico
e Social (BNDES).
BNDES funded 68.5 percent of the total investment.
It will directly grant 3.6 billion reais (US$1.78 billion). It
will grant an additional 3.5 billion reais (US$1.7 billion)
through the following banks: Banco do Brasil, Caixa
Economica Federal, Bradesco BBI, Itau-Unibanco, and
Banco do Nordeste do Brasil.
The fnancing was granted to Energia Sustentavel do
Brasil (ESBR), winner of a concession to build Jirau in
Brazils Amazon Region. Consortium members include
Suez Energy South America Participacoes Ltda.; Eletro-
sul Centrais Eletricas S/A; Companhia Hidro Eletrica do
Sao Francisco (CHESF); and Camargo Correa Investi-
mentos em Infra-Estrutura S/A.
Brazils environmental agency granted a license June
3 to the project, allowing stalled work to resume at the
construction site on the Madeira River. President Rober-
to Messias Franco of the federal environmental agency,
Instituto Brasileiro do Meio Ambiente (Ibama), signed a
license for Jirau containing 54 conditions.
The fnancing is even larger than the 6.1 billion reais
(US$3 billion) BNDES awarded in December 2008 to the
3,150-MW Santo Antonio hydroelectric project, Jiraus
sister project on the Madeira. At that time, BNDES said
Santo Antonio received the largest fnancing granted to a
single project in bank history.
Like Santo Antonio, Jirau is one of the most impor-
tant projects being developed under Brazils Growth Ac-
celeration Program (PAC), which provides more favor-
able fnancing to investors, BNDES said. It is expected
to generate 12,000 direct jobs and 30,000 indirect jobs
during construction, which is to be completed in 2014.
Test energy generated
by Laos 1,070-MW Nam Theun 2
Laos 1,070-MW Nam Theun 2 hydroelectric project
has delivered its frst test energy, a total of 60 MW to
Electricity Generating Authority of Thailand (EGAT).
The milestone came at the end of June with initial
synchronization of one of the turbines, the World Bank
announced July 3, 2009. Power was delivered through
the transformer bay and substation to the 500-kilowatt
transmission line that exports electricity to Thailand.
The project is expected to begin commercial operation
at the end of the year, exporting 995 MW to EGAT un-
der contract and supplying 75 MW to the Laotian grid.
The bank also reported the projects environmental
and social programs continue to make good progress
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despite challenges. In 2008, the Asian Development Bank
(ADB) approved US$400,000 to provide consultants for
safeguard monitoring of people affected by construction
of the project on Nam Theun River.
ADB included Nam Theun 2 in the recent favorable
assessment of its aid program to the energy sector in the
Greater Mekong Subregion of Southeast Asia.
Nam Theun 2 Power Co., a venture of EDF Interna-
tional, Italian-Thai Development, Electricity Generating
Plc. of Thailand, and Laos government-owned Electricite
du Laos, is building Nam Theun 2. The project includes
a 39-meter-tall dam, a 450-square-kilometer reservoir,
and a diversion of water from the Nam Theun to another
Mekong River tributary, the Xe Bang Fai River.
In 2005, the World Bank offcially decided to support
construction of Nam Theun 2. It is the largest public-pri-
vate hydro project built and one of the largest internationally
fnanced projects in Asia since the 1997 fnancial crisis.
Eurostudios-Ingetec wins award
El Salvador utility Comision Ejecutiva Hidroelectrica del
Rio Lempa (CEL) has awarded a contract for supervi-
sion of construction of the 67-MW El Chaparral hydro-
electric project on El Salvadors Torola River.
CEL announced the award to a consortium, Eurostu-
dios-Ingetec. It took bids for the work in early 2008.
The consortium is to supervise defnitive design, con-
struction, assembly, testing and commissioning of El
Chaparral, an El Chaparral substation, and extension of
a substation at the 99.4-MW Cinco de Noviembre hy-
droelectric project on the Rio Lempa.
U.K. utility proposes two
major pumped-storage projects
United Kingdom utility Scottish and Southern Energy
plc (SSE) proposes building two new pumped-storage
projects of 300 to 600 MW each on the Great Glen,
which bisects Scotland from Inverness to Fort William.
SSE said June 29, 2009, that it will seek a formal opin-
ion from the Scottish Government on the scope of the
environmental impact statement it will develop in sup-
port of planning applications it plans to submit in 2011.
In May, SSE announced it plans to construct a 60-
MW pumped-storage plant adjoining its 152-MW Sloy
hydroelectric project near Loch Lomond in Scotland.
Our goal is to maintain a diversifed portfolio of power
stations, with the fexibility to respond to customer demand
for electricity, while achieving a 50 percent reduction in
the carbon dioxide intensity of electricity produced, SSE
Chief Executive Ian Marchant said. Pumped storage can
help us achieve this goal and, after 30 years, I believe is a
technology whose time has come again.
Subject to fnal agreements and design, SSE envisions two
big pumped-storage plants that would be able to produce
more than 1,000 gigawatt-hours in a typical year to help meet
peak demand. It said in both cases, the projects would have
large upper reservoirs enabling generation for longer periods
without the need to pump water as soon from the loch below.
SSE said both projects would require construction of dams
to impound water for the upper reservoirs. However, pump-
ing and electric generating facilities are expected to be un-
derground, avoiding visual effects in the Great Glen itself.
They would be the frst pumped-storage schemes to
be developed in Great Britain since work began on the
1,728-MW Dinorwig project in 1974.
China builder to construct
Togos 147-MW Adjarala
Two-nation electric company Communaute Electrique
du Benin (CEB) has commissioned Chinese hydropower
construction company SinoHydro to build the 147-MW
Adjarala hydroelectric project between Togo and Benin
on Africas Mono River.
CEB signed a contract with SinoHydro in March for
construction of the 282 million euro (US$389 million)
project. Also signing the agreement were energy and wa-
ter ministers of Togo and Benin, which will own the proj-
ect upon completion.
Zurich Surety insures carbon
trade of Chiles 19.4-MW Lircay
Financial services provider Zurich has been hired to pro-
vide trade credit insurance to cover carbon emissions
credit transactions of the 19.4-MW Lircay hydroelectric
project on the Lircay River in Chiles Region VII.
Zurichs Surety, Credit, and Political Risk group was
commissioned by credit risk broker Alliant Emerging
Markets to mitigate political and counterparty default
risks for CQuest Capital, which is advancing funds to the
US$49 million Lircay, also called Hidromaule.
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POWER SOLUTIONS
MARELLI MOTORI S.p.A.
VIA SABBIONARA 1 - 36071 ARZIGNANO (VI) - ITALY
(T) +39 0444 479 711 - (F) +39 0444 479 888
www.marellimotori.com sales@marellimotori.com
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T
he turbine is one of many vital pieces of
equipment required to generate electricity
in a hydroelectric plant. At three hydro projects
in Europe, owners have applied innovations and
made modifcations designed to make the best use
of this valuable piece of equipment. Turbine and
mechanical component work featured in this arti-
cle includes: installing a turbine above the tailwater
level, modifying the nozzles for a Pelton turbine to
increase performance, and incorporating a smaller
turbine that rotates counter to the larger units at a
pumped-storage facility. These innovations in the
design and selection of turbines and other mechan-
ical components are saving money, improving unit
effciency, and allowing greater plant fexibility.
Installing a larger, higher unit
to save excavation costs
When rehabilitating the 2.8-MW Ludvika plant
on the Kolbacksan River in Sweden, owner Vast-
erbergslagens Kraft AB needed to replace the two
Francis units. These units, which began operat-
ing in 1930 and 1941, were taken out of operation
in January 2007 to prepare for plant rehabilita-
tion. At that time, Anlaggningsentreprenader
Hogtryck AB of Sweden received a US $3.8 mil-
lion contract for the civil work.
The company received proposals from two
vendors to install turbines with a runner diameter
of 1.6 meters to 1.7 meters and a small fywheel.
However, to avoid cavitation damage these units
would have to be set far lower than the 138-meter
tailwater level. This would entail extensive, and
expensive, excavation.
Another bidder a consortium of Koessler in
Austria and Lloyd Dynamowerke in Germany
proposed to use a Kaplan turbine with a diameter
of 2.12 meters. A larger unit would be more expen-
sive, in terms of manufacturing costs, the larger
generator with more poles, and a larger fywheel.
However, the design of this unit would allow it to
be installed at an elevation of 139 meters, 1 meter
above the maximum tailwater level. This would
save US$400,000 in excavation costs and con-
struction time. As a result, installation of the larger
Kaplan unit would be US$200,000 to US$300,000
less expensive than the smaller units. Vasterberg-
slagens Kraft chose this option. Koessler supplied
the Kaplan turbine and Lloyd Dynamowerke sup-
plied the synchronous generator.
The refurbished facility began operating in Oc-
tober 2007 with a single new 3.6-MW unit. The
plant now produces 13 gigawatt-hours (GWh)
of electricity each year, compared with 10 GWh
before the rehabilitation. The owner of the facility
anticipates a 12- to 14-year return on investment.
Information supplied by Tommy Hjort, Cer-
vus Power AB, formerly production manager at
Vasterbergslagens Kraft and project manager for the
Ludvika refurbishment
Technical experts Tommy
Hjort, Martin Nussmuller
and Jean-Pierre Taulan
contributed to this article.
Owners of three hydro projects in Europe are saving money and/or in-
creasing operational efciency through innovations in design and selec-
tion of turbines and other mechanical components.
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Model tests of the new nozzle design for the 510-MW
Lotru-Ciunget project veried the design improve-
ments made. Unit performance will increase by more
than 1 percent as a result of the new nozzle design.
Replacing Pelton nozzles to
improve operational performance
For Pelton turbines, nozzle design is a
key parameter to attain high performance
with respect to jet dispersion. Nozzle de-
sign can be optimized for both new units
and for rehabilitation of existing hydro
projects, as the nozzle is a component that
can easily be replaced in old turbines.
For example, as part of the rehabili-
tation of the 510-MW Lotru-Ciunget
project on the Lotru River in Romania,
owner Hidroelectrica S.A. is replacing
the nozzles on all units. This powerhouse
contains three units that began operat-
ing between 1972 and 1975. Because of
the age of the units, Hidroelectrica de-
termined rehabilitation was needed.
Voith Hydro (formerly Voith Siemens
Hydro Power Generation) is performing
and nozzle. Before the rehabilitation, the
Lotru-Ciunget plant produced 1,150,000
megawatt-hours (MWh) of electricity each
year; with the modifcation, this is predict-
ed to increase by about 10,000 MWh.
The rehabilitation work at Lotru-
Ciunget is part of a larger program to
integrate national energy systems of
refurbishment work on the Lotru-Ciunget
project, under a US$101.7 million contract
awarded in January 2007. This work in-
volves rehabilitating all three turbine-gen-
erator units and auxiliary equipment. The
work is expected to be complete in 2011.
In determining the scope of the rehab
work needed, in 2007 Hidroelectrica com-
missioned Voith Hydro to perform fully
homologous model testing and measure-
ments of both the existing nozzle design
and potential design changes to the nozzles
for the three units. Results of this test-
ing indicated that changing the hydraulic
profle of the nozzles would result in a per-
formance increase of more than 1 percent.
This improvement was a result of optimiz-
ing several parameters: fow conditions
in the turbine housing, nozzle geometry,
and the transition between the manifold
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___________________________
THE HYDROPOWER
LEADER
S T R AT E G Y

MA N AG E ME N T

CO N S ULT I N G

E N G I N E E R I N G

CO N S T R UC T I O N
mwhglobal.com

312.831.3515
MWH, the wet infrastructure leader, builds, improves and
retrofts hydropower projects to provide clean, renewable
energy. By maximizing available sources of clean energy,
we help clients optimize the use of natural resources with
sustainable techniques. Our focus: conservation and
control of the worlds irreplaceable resource water.
Our goal: Building A Better World.
A R O U N D T H E WO R L D
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avaahc.
The small counter-rotation Pelton units installed in
the 360-MW Ronco Valgrande pumped-storage plant
allow owner Enel to take an individual unit from tur-
bine to pumping mode in less than 11 minutes.
southeastern Europe into the European
Union energy market.
Information supplied by Martin
Nussmuller, Voith Hydro
Using a counter-rotation Pelton
to slow pump-turbines
For pumped-storage hydro facilities, the
speed at which a unit can change from
pumping to generating mode and vice ver-
sa is very important. This speed and fex-
ibility allows the plant to act as a storage
facility, by storing water during periods of
low demand and releasing it for generation
during periods of high demand.
In northwest Italy, power utility Enel
operates the 360-MW Ronco Valgrande
pumped-storage plant near Lake Mag-
giore. The plant, built in 1971, contains
four pump-turbine units featuring Pelton
turbine, as required, to balance the vari-
ability of wind production. In 2008, Italy
was the worlds sixth largest producer of
wind power, with installed capacity of
3,736,000 MW, according to the Global
Wind Energy Council.
Information supplied by Jean-Pierre
Taulan, CHLOErets
runners. Immediately below each of the
Pelton runners, on the shaft, is a smaller
Pelton unit that was incorporated in the
design when the plant was built. This
unit rotates in the opposite direction of
the main unit and is powered using water
from the main penstock that is supplied
by a small Y-branch manifold.
Using the smaller Pelton unit, plant
personnel can take an individual unit
from turbine to pumping mode in less
than 11 minutes when going directly
from turbine to pumping operation and
in less than 15 minutes when frst bring-
ing the unit to a standstill.
In addition, each unit features a spe-
cial mechanical clutch system to rapidly
couple or uncouple the pump and turbine
on the same shaft at standstill. This al-
lows Enel to operate either the pump or
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1ogether we oan offer investors oomplete solutions ranging from
the development and design to the delivery of hydroeleotrio
power plant equipment on a turnkey basis.
6WURQJHU WRJHWKHU
(XURSHDQ UHOLDELOLW\ :RUOGZLGH H[LELOLW\
ZZZOLWRVWURMSRZHUHX
Ll1031R01 P0wLR - Litostroj Power
Litostrojska oesta 50
1000 Ljubljana
3lovenia
1el: +386 1 5824 115
lax: +386 1 5824 127
L-mail: infolitostrojpower.eu
www.litostrojpower.eu
Ll1031R01 P0wLR - Litostroj ydro lno.
45, Paoitque Lst
Bromont (uebeo)
Canada, 12L 1 14
1el: +1450 534 2929
lax: + 1450 534 0136
L-mail: infolitohydro.oa
Ll1031R01 P0wLR - CKU Blansko Lngineering
Capkova 2357/5
678 01 Blansko
1he Czeoh Republio
1el: +420 533 309 560
lax: +420 533 309 557
L-mail: infoobeng.oz
www.obe.eu
Ll1031R01 P0wLR ydraulio Researoh Center Blansko
orni Lhota 149
678 01 Blansko
1he Czeoh Republio
1el.: +420 515 538 580
lax: +420 515 538 598
L-mail: radomir.havlioekhroblansko.oz
knowledge is power
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So should you.
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_______________
__________________
________ ____
Bryan Leyland, MSc, is a
consulting engineer with
LCL Ltd. in New Zealand.
By Bryan W. Leyland
J
im Baird is a hydro enthusiast. In 1980, the
resident of Golden Bay, New Zealand, began
developing a plan to revitalize a 250-kW hydro
scheme on the Onekaka River. The plant was
built in the 1920s to supply electricity to the
Onekaka Ironworks. After the Ironworks shut
down in the late 1930s, the old station kept run-
ning. However, in the 1950s, it was abandoned.
Around 1995, Baird joined with a local civil
engineer to investigate rebuilding Onekaka.
With electricity shortages in 2001 and the re-
sulting higher prices, revitalization of the plant
began to look economical. Two other people
(including the author) joined Baird in 2001.
Together, we set out to rebuild the plant.
The new Onekaka facility, which began oper-
ating in November 2003, uses the existing con-
crete dam, a new penstock on the same route,
and a new powerhouse 200 yards downstream
from the original powerhouse. The new plant
has a capacity of 940 kW and annual produc-
tion of 3.5 gigawatt-hours. The power is sold
on the New Zealand electricity market at the
spot price.
This story of a hydro redevelopment shows
what can be achieved through the application of
ingenuity and practical thinking. With proper
planning and development, abandoned hydro
plants can again become producers of valuable
renewable electricity. However, if the authori-
ties impose signifcant restrictions for environ-
mental reasons, the cost of construction and
operation can negatively affect the economics
of the project. In New Zealand, this is a major
risk for any investor in small hydro.
Construction issues
The old penstock was made of riveted steel plate,
most of which was rusted through. The major
construction problem for this project was instal-
lation of a new penstock, following the same route
as the old penstock. The penstock route led up a
steep ridge to a surge pipe. From there, 600-mil-
limeter-diameter pipe traversed a steep and un-
stable slope about 400 meters to the dam. The
pipe was buried for the length of its route.
After the old penstock was removed and be-
fore the new penstock was installed, we used the
bench formed for the pipeline to access the dam.
This allowed us to dig out the silt and debris that
had completely flled the reservoir. We had to dig
this out using an excavator and cart it away at
considerable expense.
We chose an A frame design for the new pow-
erhouse because it suited the use of a single monorail
hoist for installation and maintenance. The power-
house has curved beams in the ceiling to minimize
the foor area and improve the appearance.
Equipment acquisition
For the powerhouse equipment, we salvaged two
500-kW turbine-generator sets. These initially
were used to generate electricity used during con-
struction of Tuai, a 90-MW station built in the
1920s. They then provided the station auxiliary
power, until they were no longer needed. Each Pel-
ton turbine drove a direct current (DC) generator
and a 400-volt alternating current (AC) generator
on the same cast iron foundation. At Tuai, the DC
generator provided power for the station crane and
acted as a spare exciter for the main machines.
Practical Development:
The Story of 940-kW Onekaka
Four small hydro enthusiasts applied ingenuity and practical thinking to bring the 940-kW
Onekaka hydro project in New Zealand abandoned in the 1950s back to working order.
S mal l Hy dr o
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The manufacturer of these turbines
had claimed effciency of about 82 per-
cent. However, judging by the shape and
size of the buckets, it was probably nearer
to 80 percent. We hired Mhylab in Swit-
zerland, a hydraulic laboratory special-
izing in small hydropower schemes, to
design a new runner for one of the units.
We did not replace the runner in the
second machine because it would only
operate 20 to 30 percent of the time.
Mhylab provided excellent service.
The company provided all the drawings
and data fles needed to have the runner
buckets cast in New Zealand from high-
tensile bronze and then machined under
computer control. In this way, we are
absolutely sure that the bucket shape is
exactly as it should be and that the eff-
ciency matches the 89.2 percent verifed
by model tests. Casting, machining, and
assembly of the runner was carried out
by a New Zealand frm. The company
weighed and assembled the individual
buckets to balance out the difference in
individual weights.
The turbine runs smoother than the
unit did with the original runner. An in-
spection and crack testing after fve years
of operation showed that the new bronze
buckets were in perfect condition.
The turbines originally had belt-driven
governors and low-pressure hydraulic
servo motors driving the jet defector and
needle. The inlet valve was manually oper-
ated. We purchased a new high-pressure
hydraulic power pack, together with hy-
draulic rams to operate the jet defector,
needle, and inlet valve. This has proved to
be quite a successful arrangement. How-
ever, in hindsight, it would have been bet-
ter to have used the lower cost alternative
of electrical actuators. These would have
made position control easier and would
have eliminated the potential environmen-
tal problems associated with having about
60 liters of oil in the powerhouse.
The new electrical system is designed
to be as simple as possible. The two gen-
erators are switched at 400 volts using
air circuit breakers. They are direct con-
nected to the step-up transformer.
We purchased second-hand cables and
a 1 megavolt ampere (MVa) transformer
from an old paper mill. These cost less
In spite of their age, the generators
were in good condition and only needed
to be cleaned and have the windings var-
nished. The original excitation system
was replaced with solid-state excitation
to take advantage of reduced mainte-
nance and better overall effciency. The
DC generators were scrapped.
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_______________________
Thanks to a recent revitalization, the 940-kW Onekaka hydro facility is generating
3.8 gigawatt-hours of renewable electricity a year for New Zealand power users.
than half the price of new equipment.
We connected a voltage transformer to
the 33-kilovolt (kV) line to detect earth
faults. The conventional alternative of a
transformer with a delta 400 volt and star
33 kV winding would have been much
The metering equipment operates
at 400 volts. Every month it transmits
half-hour readings of active and reactive
generation to the electricity market ad-
ministrator by cellular telephone.
Operation of the plant
The Onekaka station is automatically
controlled. It operates on water level con-
trol from the head pond, and it can use
the storage in the pond to increase out-
put during peak demand periods when
the prices are usually highest. A radio
transmitter at the head pond sends the
water level to the PLC every ten minutes.
The station operating program ensures
that the pond is full by about 6 a.m. At
7 a.m., the plant output increases by 100
kW to provide extra power during the
morning peak period. At the end of the
more expensive.
The control
system for the
Onekaka plant
uses programma-
ble logic controller
(PLC) equipment
from Unitronics in
Israel. This proved
to be an excellent
choice. The equip-
ment combines
unusually low cost
(about US$5,000)
with excellent versatility. A feature of
the equipment is the ability to send and
receive text messages over the cellular
telephone system. (For more on operat-
ing the plant using a cell phone, see Op-
eration of the plant, below.)
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_______________________________
peak period (about 9 a.m.), the control
system holds the water level constant
until the evening peak, when it again
increases output by 125 kW and draws
the head pond level down further (un-
til 7 p.m.). Then, until about 1 a.m., the
operating program runs the plant at an
output that will hold the water level con-
stant. The output is then backed off to
allow the pond to refll before 6 a.m.
Through the use of text messaging,
it is possible to monitor the status of
the Onekaka station. The PLC is pro-
grammed to respond to text instructions.
We can send it instructions to change the
peaking duration and output and shut it
down remotely in the event of an emer-
gency. For example, if an S is sent, the
PLC responds with the station output,
pond level, etc. As far as we know, con-
trolling a power station like this by a cell
phone is a worlds frst.
At the plant intake, a simple chain-
and-rake-type screen cleaner removes
leaves and similar debris from the screen.
We designed the cleaner, which was built
by a local engineering company. The
cleaner is driven by the drive mechanism
from a 12-volt winch, of the type used
on recreational vehicles. A simple dif-
ferential pressure detector at the head
pond monitors the water level upstream
and downstream of the intake screen and
starts the screen cleaner if the differential
is above about 200 millimeters. Another
detector measures the differential across
the penstock guard valve. If the differ-
ential is greater than 900 millimeters,
the PLC closes the guard valve and trips
the station. This precaution is necessary,
in case the cause of the high differential
is a burst penstock. A small PLC at the
intake monitors alarms and opens a mo-
tor-driven scour valve every time there
is a large food. This allows silty water
to pass through the dam, rather than ac-
cumulating in the head pond.
of the PLC and radio transmitter. We
have supplemented the solar cell with a
micro hydro unit provided by EcoInno-
vation in New Zealand. The unit com-
prises a two-jet Pelton turbine driving
a generator made from the permanent
magnet low-speed drive motor from a
Originally, we used a 120-watt solar
cell and a 24-volt battery to supply sta-
tion service power at the dam, at a cost
of more than $2,000. This arrangement
cost about $1 per kilowatt-hour (kWh).
However, in the winter, the solar cell was
unable to supply the 6-watt standing load
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______________
The new powerhouse for the 940-kW Onekaka facility contains two 500-kW tur-
bine-generator sets. These units initially were used to provide power during con-
struction of a 60-MW power station in the 1920s and, later, for station service.
Ruskin Dam Safety
Spillway Assessment
Comprehensive Dam Safety Review
in accordance with Section 2 of the
Canadian Dam Association, Dam
Safety Guidelines
Designers: 1070MW Nam Theun 2 Project, Laos
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simplicity, efficiency, reliability.
Smart Drive washing machine. The
turbine cost $1,200 and gives a steady
output of more than 90 watts.
For environmental reasons, we release
a nominal 20 liters per second from the
our revised water right. Tributary fow
between the dam and the measuring weir
provides 10 liters per second.
As a result of this arrangement, we
release more water than under the origi-
nal water right during a dry period and
less fow when the tributary fows just
downstream from the dam are high. If
the station trips off line, all four valves
open automatically to increase fow
downstream from the station.
Commissioning the plant
Commissioning the Onekaka facility took
several weeks. Getting the machines to
synchronize successfully was quite dif-
fcult because the hydraulic system was
unable to position the needle with suf-
fcient accuracy. We solved this problem
by opening the needle a small amount
dam to maintain
the fow in the
1-mile section of
the river between
the dam and pow-
erhouse. Because
there is no suitable
measuring site in
the rapids and wa-
terfalls just down-
stream of the dam,
we monitor the fow
just upstream of the
power station. Flow
measurements are
transmitted to the station by radio, and
the PLC sends a signal to the dam, where
four valves are opened and closed as
needed to ensure that fow is maintained
at 30 liters per second, as required by
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_________
and then using the jet defector to control
speed by moving it either in or out.
This means that the unit speed cycles
above and below synchronous speed and
the auto synchronizer eventually fnds
a situation when the speed and phase
match, allowing synchronization. The
process is rather interesting to watch, but
it never fails to synchronize successfully.
The station originally was connected
to the local 11-kV distribution system via
a 3-kilometer transmission line from the
main road to the power station. The con-
nection point is about 10 kilometers from
a 66-kV substation. When the frst unit
went on line and we increased output to
about 400 kW, we discovered we were
pushing the local voltage from about 10.7
kV to above 11.5 kV. Over the next few
days, we discovered that we could export
Maximum station output is 940 kW.
Since the conversion to 33 kV, the station
has run very reliably with few problems.
The station has now been in opera-
tion for six years. The average price we
receive from the spot market is about
US$0.05 per kWh. We do not receive any
greenhouse credits or other subsidies.
Costs
As with most projects of this type, the f-
nal cost of US$1.8 million was well above
the original estimate of US$1 million.
The penstock installation and civil works
were the main source of the additional
costs because the original estimates were
old and, in hindsight, should have been
re-evaluated by the civil engineers. Never-
theless, I am convinced that following the
now-fashionable route of a turnkey design
about 400 kW when the farmers in the
district were milking their cows, but we
were restricted to about 250 kW for the
rest of the time. To limit the voltage rise,
we did everything we could to run under-
excited to the extent that the unit often
pole slipped and tripped on overcurrent.
This is not something that I had experi-
enced before! The lesson here is that even
small distributed generators can upset a
typical rural distribution system.
We operated in this mode for about
fve months, until the transmission line
company completed a conversion to 33
kV. From then on, we could operate up
to full power without restriction. Tests
showed that the new turbine had an
output of 520 kW when operating on its
own, whereas the unit with the old run-
ner could only achieve about 470 kW.
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and build contract would have made the
scheme completely uneconomical. Based
on my experience with other turnkey hy-
dropower developments, disputes also
would have arisen and the associated legal
costs and costs for unforeseen circum-
stances would have been very high.
As mentioned above, complying with
requirements imposed on us under New
Zealands Resource Management Act
was very expensive. These included:
Compilation of a heritage in-
ventory that involved scheduling and
sketching every one of the rusty old riv-
eted penstocks lying around in the bush;
Development of a report on the
history of the Ironworks;
Requirements for costly studies
of the fsh and other life in the stream,
which have to be repeated every year.
Monitoring, recording, and reporting
costs are ongoing and amount to more
than $10,000 per year.
During construction, very strict re-
quirements were imposed on us under
the Resource Management Act. These
included limits to the number of trees
we could to chop down for access dur-
ing penstock installation. There are half
a dozen saplings of a prolifc second
growth tree no more than 100 millimeters
in diameter that we were not allowed to
remove. This probably cost us more than
$US8,000, by making it very diffcult to
excavate and lay the penstock. Without
this requirement, we probably would
have laid the penstock above ground.
In addition, the start of construction
was delayed because it took so long to ob-
tain a multitude of consents and approvals.
These studies showed that foods were
the major factor in the quantity of marine
life. Because the Onekaka scheme has no
effect on foods, it has no measurable ef-
fect on fsh and other life in the stream;
Compilation of an expensive dam
safety report, for a dam that was built 70
years ago and, but for us, would still be
holding back thousands of tons of silt and
debris, with no one responsible for it;
Renewal of our water rights for 35
years. This involved lawyers, environ-
mental scientists, and consultants and
cost us about $80,000; and
Various delays waiting for envi-
ronmental approvals under the Resource
Management Act and complications in
the construction process that slowed
construction and probably cost us
$100,000 overall.
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Ingenuity on the part of a small group of hydro en-
thusiasts allowed the revitalization of an abandoned
facility in New Zealand, providing valuable renew-
able electricity for the country.
As a result, we fnished up doing a lot of
work in winter, which is the wet season in
New Zealand.
Overall, the above requirements prob-
ably added US$300,000 to the cost of the
project. In my view, maybe 5 percent of
the sum actually provided a real beneft to
the environment. If, instead, we had put
US$50,000 toward fencing off the river
downstream from cattle and providing
cattle crossings, I am sure the environ-
ment would have been far better off.
Lessons learned
If we could do it again, what would we
do differently? Firstly, we would install
a single new vertical four-jet Pelton tur-
bine instead of the two old single-jet hor-
izontal units. Although the two second-
hand units cost us less than $US15,000
blocks, would have saved even more
money because it eliminates the need
for a large number of expensive anchor
blocks and expansion joints.
to purchase, the costs to prepare them
for installation in the new powerhouse
were unexpectedly high. This included a
new runner and new turbine shafts, and
the hydraulic system for control of the
turbines. In addition, using two units in-
stead of one led to a much larger power-
house, additional switchgear, and addi-
tional complexity in the control system. I
am sure that the lowest cost option would
have been to commission Mhylab to de-
sign a new turbine, then manufacture all
the components in New Zealand.
As already mentioned, we probably
would have been better off if we had not
had to bury the penstock. Supporting
the penstock above ground as though it
were a steam or oil pipe, instead of the
conventional civil engineering solution
of expansion joints and massive anchor
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Malte Cederstrom is a senior
civil engineer in Vattenfalls
hydropower division. He was
responsible for directing the
investigations of the failed
anchors and developing
recommendations for
their replacement.
By Malte O. Cederstrom V
attenfall AB, Swedens largest power produc-
er and Europes ffth largest, operates 53 large
hydropower plants in Sweden. The 33 terawatt-
hours of hydroelectricity generated by these plants,
along with Vattenfalls nuclear power, account for
about half of the countrys power production. Vat-
tenfall places great importance on its dam safety
activities, which include research, emergency pre-
paredness, surveillance, safety evaluations, and
system-wide programs of safety upgrades.
Several of Vattenfalls concrete dams are stabi-
lized with post-tensioned anchors. Surveillance of
these dams includes a regular check on the func-
tionality of the anchors. In 2002, a load test of
anchors at the 120-MW Alvkarleby hydro project
on the Dalalven River, 170 kilometers north of
Stockholm, revealed that seven of the 78 anchors
in the intake canal wall had ruptured. Diagnosing
the cause of the failures proved to be a lengthy
process involving the design engineer, the manu-
facturer, the installer, and laboratory specialists
performing chemical and metallurgical analysis.
As a result of the investigation, Vattenfall installed
a different type of anchor throughout the facility
and no longer relies on the remaining anchors.
Installing the anchors at Alvkarleby
The Alvkarleby plant was constructed in the be-
ginning of the 20th century and began producing
power in 1915. The original plant had fve gener-
ating units and a total capacity of 70 MW. The
development included a 200-meter-long intake
canal partially blasted in rock and partially lined
with concrete walls. The concrete walls were cast
in 10- to-15-meter-wide monoliths ranging in
height from 3 to 16 meters. Drainage pipes were
installed in the walls, and the expansion joints
were sealed to prevent leakage.
In the late 1980s, Vattenfall added a new 50-MW
unit and refurbished the old units. To accommodate
the increased turbine fow, the intake walls were
raised and reinforced. Design loads considered in
raising the walls included water pressure, uplift, ice,
and load rejection. The left wall was raised about 0.6
meter, and a 0.3-meter thickness of concrete was cast
on the inside of the wall, with reinforcement bars con-
necting the new concrete, old concrete, and rock.
To further stabilize the wall, Vattenfall contracted
with a construction company to install 78 36-milli-
meter post-tensioned anchors in holes drilled through
the old concrete and 6 to 8 meters of the underlying
rock (see Figure 1). The holes were tested for wa-
tertightness before installation of the anchors and, if
leaks were detected, were pressure-flled with grout
and redrilled. After reflling the holes with grout, the
contractor fxed the anchors in the holes, grouted
the 5-meter anchoring zone, and allowed the grout
to cure. The upper anchor plate was then grouted
into place and allowed to cure, and the anchor was
tensioned to a force of 720 kiloNewtons. The ten-
sion force applied to the anchors was 66 percent of
the nominal yield strength and 58 percent of the
nominal ultimate strength for the anchor material.
During installation, the anchors elongation was
also measured at various loads and compared with
expected values. Before the installation, the anchors
Investigating Failures of
Post-Tensioned Anchors
When seven post-tensioned anchors along the intake canal wall at the Alvkarleby hydroelec-
tric station in Sweden failed, dam safety engineers for owner Vattenfall AB conducted an
exhaustive investigation of the nature and causes of the failure. The investigation gave the
utility the information needed to safely restabilize the dam.
Da m S a f e t y
This article has been evaluated
and edited in accordance with
reviews conducted by two or
more professionals who have
relevant expertise. These peer
reviewers judge manuscripts for
technical accuracy, usefulness,
and overall importance within
the hydroelectric industry.
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The Alvkarleby hydroelectric plant has been in service since 1915. The intake canal wall in which the anchor
failures occurred is behind the bridge.
were wrapped in a corrosion-protecting
band that would allow some movement
inside the concrete. This would enable Vat-
tenfalls dam safety engineers to measure
the actual force in each anchor in the fu-
ture. Finally, the hole was grouted and the
top of the anchor was treated for corrosion
protection and capped.
Discovery and initial
investigations of failures
After installation, Vattenfall established
a program to sample the anchors per-
formance at fve-year intervals. Tests
consisted of measuring the force needed
to just release the nut. In 2002, the test
revealed seven broken anchors. At the
same time, the engineers realized that the
anchors had been installed with plastic
caps, which needed to be replaced with
contacted the design consultant, contractor
who delivered and installed the anchors, and
supplier. The installation contractor sent
two of the failed anchors to an independent
metallurgical laboratory, where they were
examined microscopically and subjected
to strength tests. The fracture surfaces
were corroded, making visual assessment
steel. They also noted that the top cor-
rosion protection seemed to be of poor
quality. Over the following two years,
three more anchors ruptured; two dur-
ing a test. All of the fractures developed
less than 2 meters from the anchors top,
and most less than 1 meter from it.
After the initial discovery, Vattenfall
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diffcult. The laboratory reported that the
fracture surface appeared both ductile and
trans-crystalline and that the fracture ap-
peared to have been instantaneous. On one
surface, a crescent-shaped initiation point
was evident. The yield point and rupture
strength in the material were 3 to 5 percent
suggested a sudden water level increase
as a possible cause, along with ice load-
ing, bending of the anchor at the plate,
and material weakness in the anchor bar.
Finally, the anchor supplier mentioned
that welding often leads to ruptures in
this type of high-strength material.
Pursuing a better explanation
After reviewing the initial reports, Vatten-
falls dam safety engineers decided a more
detailed investigation was needed in order
to prevent similar incidents in the future.
The team of four engineers assigned to the
investigation brought expertise in metal-
lurgy, concrete, design, and dam safety.
In conducting the investigation, they used
Vattenfalls metallurgical and concrete
laboratories in Alvkarleby, as well as other
laboratories. The investigations included
chemical and metallographic analyses,
magnetic particle testing, penetrant test-
ing, ultrasonic inspection, impact testing,
and grease analysis.
Chemical and metallographic analyses
Ruptured anchors were subjected to a
chemical analysis using optical emission
spectroscopy. The analysis indicated that
the constituent elements in the steel fell
within published industry standards, with
the exception of a slightly lower-than-
standard manganese content. The micro-
structure of one of the anchors also was
studied under an optical microscope and
was consistent with the chemical analysis.
Vattenfalls laboratory staff also per-
formed nondestructive testing on the
ruptured anchors, including ultrasonic
testing of the end of the bars and dye
penetration tests and magnetic particle
inspection of the surface of the ruptured
anchors. None of these tests revealed
cracks in the anchors. At the same time,
laboratory staff performed a separate
test of the ultrasonic method on an in-
tentionally cracked bar. The test showed
lower than the European standard values of
1,080 megapascals and 1,230 megapascals,
respectively. The laboratory report indicat-
ed that the probable cause of failure was an
overload, such as a sudden high water level.
The design consultant, who was not
aware of the laboratorys fndings, also
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that the method did not have the sensi-
tivity to detect faws of the size believed
to have initiated the ruptures.
To evaluate the brittleness of the steel
and the transition temperature, the labora-
tory also performed a notched-bar impact
test on samples from one of the anchors at
temperatures from -10 degrees Celsius (C)
to 25 degrees C. The resulting test values
were 2 to 3 Joules, much lower than the
expected value of at least 30 Joules for com-
mon construction steel alloys. The low test
values indicate a high degree of brittleness.
Grease analysis
During installation, the anchors were
covered by a special anti-corrosive grease
and wrapping, in addition to the corrosion
protection provided by the grout. Oxi-
dation of the grease would increase the
fractures. On at least one of the samples,
a crescent-shaped initiation zone, similar
to the in situ fractures, was visible.
Investigating a fracture
surface in detail
The anchor having the fracture surface
least affected by corrosion was chosen for
detailed microscopic investigation. A ste-
reomicroscope photograph clearly showed
the crescent-shaped. 3.2-millimeter by
0.8-millimeter initiation zone, as well as
rust stains. The initiation zone showed
signs of oxidation and was sharply delin-
eated from the remainder of the fracture
surface. The sharp difference between the
initiation zone and the remaining area al-
lowed the investigators to rule out fatigue,
which would have resulted in crack propa-
gation lines. Failure due to overloading
amount of free acid present. Grease sam-
ples from three failed anchors were ana-
lyzed and found to be more acidic than a
sample of unused grease provided by the
supplier. However, the test values were
not consistent enough or high enough to
support the theory of embrittlement due
to deterioration of the grease.
Load tests
To verify the strength tests made on small
specimens in the initial phase of the in-
vestigation, a laboratory was engaged to
perform uniaxial load tests on two of the
ruptured anchors. Rupture occurred at
1,159 and 1,136 kiloNewtons, or 7 and
10 percent lower than the European stan-
dard. The characteristics of the fracture
surfaces produced during the tests were
similar to those observed on the in situ
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would have been marked by deformation,
which was not detectable in the sample in-
vestigated. Finally, the absence of visible
grain boundaries in the area of the frac-
ture showed that coating by brittle phases
in the grain boundaries, such as cementite
or sulphide of iron, was not the cause.
precipitation from a liquid or gas phase.
These crystals could not have been
formed during the steel manufacture
process, because the subsequent hot-
rolling of the bar would destroy them.
The investigators concluded that the
crystals were the result of water entering
the crack, and therefore that the crack
formed after the anchor came into use.
Reviewing possible
sources of failure
The various professionals queried about
the failures raised several possible expla-
nations, including ice loading, transient
water pressures due to a plant trip, bend-
ing, and damage during welding. Vatten-
falls investigative team considered each
of these but did not fnd a persuasive case
for any of them, based on the laboratory
results and other project data. Overloads,
due to either ice pressure or plant tripping,
should have left evidence in the form of
deformation in the fracture surfaces. Vat-
tenfall also had performed calculations for
ice loading and physical model and full-
scale tests for loading during a plant trip
and found that the resulting loads did not
A more detailed microscopic view
showed signifcant details of the bound-
ary between the initiation zone and the
remainder of the fracture surface. A
structure just inside the initial fracture
zone contained needle-shaped separated
crystals, such as would be formed by
When the Alvkarleby plant was upgraded in the
late 1980s, post-tensioned anchors were installed
in the left intake wall. The anchors extended
5 meters into bedrock and were tensioned
to 720 kiloNewtons.
Figure 1 Post-Tensioned
Anchors at Alvkarleby
Anchor Free
length
Anchor
length
in rock
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exceed the actual force of the tensioned
anchors. Regarding ice loads, at least
some of the ruptures occurred during
ice-free periods. Ice formation is normally
prevented in the intake canal, although no
records existed to confrm this for the pe-
riod of outage for refurbishment.
Anchor bars also may be subject to
bending, caused for example by an an-
chor plate that is installed at an incorrect
angle. However, the spherical surface
of the nuts used should have prevented
bending by this mechanism. In addition,
the ruptures were too far from the nuts
to support this explanation.
Welding damage also was considered
an unlikely explanation, since there was
no record of welding at the time of instal-
lation. The protective wrapping should
also have protected the anchors against
tally assisted cracking. Environmentally
assisted cracking could be brought about
by either hydrogen-induced brittleness or
stress corrosion. The hydrogen theory was
based on the fact that, over time, additives
to the concrete grout develop free hydro-
gen, which has a high rate of diffusion
into concrete and steel. Increased hydro-
gen content in a high-carbon steel could
cause the steel to rupture. The time to
rupture would depend on the kind of steel,
hydrogen content, and stresses. However,
the grease analysis had not shown sig-
nifcantly elevated levels of free hydrogen.
Therefore, the investigators believed that
the anchors had not undergone prolonged
exposure to free hydrogen. Furthermore,
hydrogen embrittlement would not have
been limited to the top 2 meters of the an-
chors, where all of the ruptures occurred.
welding sparks, and the fractured sur-
faces showed no sign of welding damage.
It was apparent that the ruptures had
occurred well after the installation and
tensioning of the anchors. Generally, ex-
planations for this type of failure could
be either fatigue or environmentally
induced cracking of the material under
stress. The investigative team rejected
the fatigue hypothesis because the loads
acting on the anchors did not vary signif-
icantly over time and because of the ab-
sence of stop lines on the crack surface.
Pinpointing the cause
As a result of the investigations, par-
ticularly the investigation of the fracture
surface under a scanning electron micro-
scope, the team concluded that the most
likely cause of the failure was environmen-
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The explanation for the ruptures f-
nally adopted by the investigative team
was stress-induced corrosion, in combi-
nation with the high degree of brittleness
of the steel. The visible oxidation in the
initiation area pointed to corrosion, and
the brittleness and relatively low steel
strength explained the materials low re-
sistance to stress corrosion. The anchors
initially had been installed with a plastic
cap to keep grease in and water out. How-
ever, the caps proved to provide inad-
equate corrosion protection. Inadequate
protection at the top of the anchors might
explain the location of the ruptures in the
top 2 meters of each anchor.
Lessons learned
from the investigations
As a result of the anchor failures and sub-
method could not detect some small but
potentially serious fractures. Vattenfall
has joined a research effort with CEATI
Dam Safety Interest Group to fnd new
and better methods for anchor testing.
Correcting the situation
At the conclusion of the investigations,
Vattenfalls dam safety engineers recog-
nized that the ruptured anchors should
not be replaced in kind and the remain-
ing anchors should not be relied upon for
stability. Three main alternatives were
considered for meeting safety criteria:
installing new anchors and strengthen-
ing the existing concrete; constructing
supporting walls; and complete replace-
ment of the dam. Although there was a
strong interest within the company in
alternatives that did not involve anchors,
sequent investigations, Vattenfall installed
steel cables to replace all the anchors at
Alvkarleby. The remaining anchors were
left in place but were assumed ineffective
in stability calculations. Vattenfall now
checks the few anchors of the same type
installed in its other dams by pulling with
a jack until the nut is just released.
The investigations also brought new
insights about methods of testing anchors
in dams. When the ruptures were discov-
ered, Vattenfall was testing anchors by
measuring the actual load in a sample of
anchors with a hydraulic jack. A solution
used at some other plants was to install
additional test anchors in the dam, which
were used for testing but not considered in
stability evaluations or design. Vattenfall
also experimented with ultrasonic testing
but found in the Alvkarleby tests that the
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the frst option was clearly the most
economical. The supporting walls were
aesthetically undesirable, particularly
because the Alvkarleby plant is a tour-
ist attraction and is known as a facility
with few negative environmental effects.
There was also little space for such sup-
ports. The cost of a complete dam re-
placement was much higher than that of
the other alternatives, especially consid-
ering the cost of lost generation.
Concrete test results from the investi-
gation showed that the existing concrete
in the dam was in poor to very poor
condition. The situation provided an
opportunity to apply the results of one
of Vattenfalls recent research efforts.
This research project had focused on us-
ing concrete grout injections to increase
the life of aging structures. The grout
were flled with grout and the tendons
lowered into the grout. After the grout
had cured, the anchors were tensioned
to 1,500 kiloNewtons.
The ruptured anchors were replaced
in 2004, and the remaining new cables
were installed in 2005. Vattenfall plans
to select a sample group of anchors for
testing at fve-year intervals. The ex-
pected life of the new anchors is about 50
years, and there is ample space to install
new ones when needed.
Reference
Cederstrom, Malte, Per-Erik Thorsall, Bengt
Hildenwall, and Stig-Bjorn Westberg, In-
cident with Loss of Seven Post-Tensioned
72 Ton Anchors in a Dam, Dam Safety
2005 Proceedings, Association of State Dam
Safety Offcials, Lexington, Ky., 2005.
composition and the specifc installation
techniques used at Alvkarleby were based
on lessons learned through the research.
Grout was injected into holes drilled at
1-meter intervals along the dam. After
completing the grouting, the contractor
drilled holes for the new anchors and
the drill cores were saved for analysis.
The analysis of the cores showed that
the grout injection had substantially im-
proved the condition of the concrete.
The new anchors comprised 40 steel
tendons, each consisting of 12 12-milli-
meter-diameter wires. The wires were
split apart in the lowest 5 meters to im-
prove the anchoring. Above the anchor
zone, the wires were coated in protec-
tive grease and placed inside plastic
pipes that would allow the wire to move
freely when tensioned. The anchor holes
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___________________
Tech Notes
ICOLD Forum: New committee
releases work plan
A new International
Commission on Large
Dams (ICOLD) com-
mittee has released its
work plan and intends
to publish a position
paper later in 2009. The ICOLD Com-
mittee on Engineering Activities Associ-
ated with the Planning Process for Wa-
ter Resources Projects was established in
2007; seven countries are represented on
the committee. Arthur H. Walz Jr., P.E.,
former ICOLD vice president, is chair-
man of the new committee.
The position paper has fve purposes,
Walz says.
Focus on the development and
management of water resources using
integrated water resources management
in the watershed;
Summarize the current basic
planning process being used for water
resources projects;
Articulate the need to improve the
process in order to plan realistic and
sustainable water resources projects with
accurate cost estimates;
Present and discuss enhancements
needed to the process to ensure the se-
lection of better and more cost-effective
alternatives; and
Present what ICOLD will recom-
mend as a new strategy and process,
which includes initial guidance from the
decision-makers, input from all techni-
cal disciplines, collaboration with stake-
holders and the public, and an external
review, if needed. This new strategy and
planning process, Comprehensive Vision
Based Planning, is based on a systematic
and holistic or watershed approach to
both comprehensive planning and inte-
grated water resources management.
The position paper is scheduled to
be published in the fall of 2009, and the
committees next step is to publish guide-
lines. Walz says the guidelines likely will
be available in 2010.
ICOLD is a nongovernmental or-
ganization that provides a forum for the
exchange of knowledge and experience in
dam engineering. The organization leads
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the profession in ensuring that dams are
built safety, efficiently, and economically,
and without detrimental effects on the en-
vironment. To learn more about ICOLD
activities, contact Michel De Vivo, Secre-
tary-General, ICOLD 151, Bd Haussman,
Paris 75008 France; (33) 1-40426824; E-
mail: secretaire.general@icold-cigb.org.
Voith Hydro updates
German laboratory
Voith Hydro recently updated its Brun-
nenmuehle laboratory in Heidenheim,
Germany. This work, which cost more
than 20 million euros (US$25.9 mil-
lion), included doubling the capacities of
the test rigs, installing super-computers
for more precise simulations, and con-
structing a new offce building.
Friedrich Voith, son of company
founder Johann Matthaeus Voith,
founded this hydroelectric turbine test-
ing laboratory in 1908. The location
had been a mill. To power the turbines,
Friedrich Voith used a water storage tank
above the facility to construct the frst
pumped-storage plant in Germany.
The Bruennenmuehle laboratory
offers research and development ser-
vices for all Voith Hydro operating units
worldwide. In addition to being a model
testing facility, the laboratory is a devel-
opment center for complete hydro units,
including generators, excitation and
control systems, and components (such
as butterfy and spherical valves).
EPRI seeks funding of
generator repair research
EPRI is seeking $180,000 in funding
from the hydroelectric industry to sup-
port research on how to restore safe op-
eration of a generator after failure of one
or more coils in the stator winding.
The institute seeks supporters who
will provide $30,000 each. Companies
that fund any EPRI program can take
advantage of tailored collaboration funds
for up to half of their contribution, says
Jan Stein, senior project manager.
After failure of a stator winding, proj-
ect personnel can isolate, or cut out, the
failed coil from the rest of the winding and
quickly return the units to service, Stein
says. In addition, one or more healthy coils
may need to be cut out from the electrical
circuit to ensure the electric current dis-
tribution in the remaining winding does
not cause thermal damage to the insula-
tion. Use of temporary repair procedures
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______________________________
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such as this can keep a machine in service
until it can be permanently repaired or
replaced, providing substantial economic
beneft, Stein says.
This research project updates work
described in EPRI report EL-4983,
Synchronous Machine Operation with
Cutout Coils, published in 1987. Work on
this project, which is estimated to take 18
months, will begin as soon as all partici-
pants are identifed.
The objectives of this project are to:
Update and expand calculations
about how many and which coils can be
safely cut out;
Provide guidance for performing
parallel circuit current measurements to
validate stator winding operation within
its thermal limits;
Learn more about the effect of the
winding with cut-out coils on vertical
shaft run out; and
Document worldwide experience
and practices.
For more information about funding
this research, contact Jan Stein at (1) 650-
855-2390; E-mail: jstein@epri.com.
Brazil university begins study
of sh passage at dams
Research is needed to determine how
to preserve the about 4,500 species of
migratory fsh in South America and
to build and monitor fsh passage de-
vices at dams, says Dr. Paulo dos San-
tos Pompeu, department of biology at
the Universidade Federal de Lavras
in Brazil.
To provide more information on pro-
tecting fsh species in South America,
researchers at the university are launch-
ing several studies. Dr. Pompeu says the
studies include:
Baseline biological studies before
dams are built. These studies are vital to
provide information on migratory move-
ments and determine if fsh passage is
necessary or would be benefcial.
Determination of critical habitats
for each life stage of the various spe-
cies and the effects of fragmentation of
those habitats by dams and impound-
ments. This research is needed to de-
termine if a river section that will be
fooded by a reservoir associated with
a hydro project is a critical habitat for
certain fsh species.
Long-term monitoring to assess
the effcacy of fsh passage and its rela-
tive benefts to biological communities
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Our services
Engineering
Assembly work / Site erection
Production in own workshops
Preventive wear protection
Your partner for hydropower
Refurbishment
Modernization
Automation / Control systems
Hydraulic steelwork
Internet www.stellba-hydro.ch
E-Mail info@stellba-hydro.ch
Stellba Hydro AG
Langgas 2
CH-5244 Birrhard
Switzerland
Telefon
Telefax
+41 (0)56 201 45 20
+41 (0)56 201 45 21
Internet www.stellba.de
E-Mail info@stellba.de
Stellba Hydro GmbH + Co KG
Badenbergstrasse 30
D-89520 Heidenheim
Germany
Telefon
Telefax
+49 (0)7321 96 92 0
+49 (0)7321 6 20 73
Hydro
both upstream and downstream of
dams. This will provide longer-term
information, as most studies are com-
pleted two years after the reservoir is
formed and many fsh passage devices
are not monitored.
Development of technologies for
passing bottom-dwelling species. This
will help improve passage of bottom-
dwelling fsh, such as large migratory
catfsh, which may not be passed eff-
ciently by traditional passage facilities at
dams in South America.
Assessment of passage needs for
non-migratory fsh. This study is in-
tended to determine whether passage
over dams is important for non-migrato-
ry fsh species, to maintain genetic fow
between populations in the river.
Development and implementation
of downstream passage technologies for
eggs, larvae, and juveniles. Developing
passage technologies for all stages is
crucial to allow eggs and larvae to reach
areas where they can develop and to al-
low for dispersion of juvenile fsh.
HydroVision International
announces call for
technical abstracts
PennWell Cor-
poration, or-
ganizer of the
HydroVision International conference
and exhibition, is accepting abstracts
for the Technical Papers program. The
conference will be held July 27-30, 2010,
in Charlotte, N.C, United States.
Abstracts are requested on all topics
of interest to technical professionals in
the hydropower feld. Preference will be
given to abstracts that focus on innova-
tive, practical, and proven technologies
and methods.
Abstracts that describe the focus and
content of proposed papers (maximum
of 400 words) are due October 30, 2009.
Submit abstracts through the Internet at:
www.hydroevent.com.
All abstracts submitted will be re-
viewed by the conference Technical
Committee. If accepted, authors will
be invited to submit a paper by April
30, 2010, for inclusion in the offcial
conference publication (in CD-Rom
format) that will be distributed to all
conference delegates.
For more information, contact (1)
918-831-9736 or E-mail: hvconference@
pennwell.com.
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New Hydro
South Korea starts up, to
expand 1-MW Jindo Uldolmok
The 1-MW Jindo Uldolmok tidal energy
project is operating in South Korea, and
government and research offcials plan
to expand it to 90 MW by 2013.
South Koreas Ministry of Land,
Transport, and Maritime Affairs said
the initial 1-MW project was completed
in May 2009, becoming the countrys
frst operating tidal plant. The min-
istry emphasized that all the projects
related technologies were developed in
Korea, a country 97 percent dependent
on foreign energy.
The project was initiated in 2005 in Ul-
dolmok Strait, off Uldolmok, Jindo Island,
in South Jeolla Province. The project is to
produce 2.4 gigawatt-hours annually.
Korea East West Power Co. and South
Jeolla Province signed an investment
agreement in 2006 to develop a tidal
plant in Jindo. Hyundai Construction &
Engineering was chosen to construct a
test power plant, Hyundai Heavy Indus-
tries was named to develop generators,
and Iljin Electric was chosen to manu-
facture mechanical equipment.
Ecofys completes installation
of 30-kW unit in Holland
Ecofys in Holland completed installa-
tion of a 30-kW Wave Rotor demon-
stration unit in the Westerschelde in
the south of Holland. The unit began
trial operations in July 2009, says Peter
Scheijgrond with Ecofys. The company
plans to start analyzing the data gath-
ered in September 2009, he says.
Ecofys chose this location in the
North Sea because it has high tidal fows
up to 2 meters per second close to the
shore. Waves in the area are as high as
1.5 meters several times a day. Testing
at this site is intended to investigate the
performance of the Wave Rotor and all
components in the ocean environment.
The Wave Rotor unit consists of a ro-
tor containing both slanted and horizon-
tal blades. The vertical and horizontal
motions of ocean waves generate lift over
the blades. This lift turns the rotor, which
is attached to a generator via a gearbox.
The rotor is the only moving part in the
water; all other parts are about 10 meters
above the water level.
J P Kenny develops new
Offshore Renewables Division
J P Kenny, a pipeline and subsea en-
gineering and management contrac-
tor based in the United Kingdom, has
formed an Offshore Renewables Divi-
sion. Personnel in this division will work
on delivery of the companys existing re-
newable projects and expand to seek to
capture a large share of the market for
engineering and project management.
J P Kennys renewable energy proj-
ects include: the Wave Hub development
off the coast of Cornwall in southwest
England and support of wave energy
projects being developed by Oceanlinx
Ltd. of Australia.
J P Kenny has seven offces worldwide
and operates within the Engineering &
Production Facilities Division of Wood
Group. Tim OSullivan was appointed
operations director of the new division
of J P Kenny. Before joining J P Kenny,
OSullivan led MCS in Aberdeen, Scot-
land, a subsea technology company
owned by Wood Group.
Wood Group is an international en-
ergy services company that operates in
46 countries.
Feasibility study beginning
for Solway Firth project
A consortium led by Halcrow Group
Ltd. is studying the feasibility of a tidal
power project on Solway Firth in the
United Kingdom.
Northwest Regional Development
Agency, Scottish Enterprise, and the
U.K.s Nuclear Decommissioning Au-
thority announced in July 2009 that they
agreed to commission the 100,000 pound
(US$164,000) feasibility study. The goal
of the study is to evaluate options for har-
nessing tidal power at Solway Firth, on
the border of England and Scotland.
The concept of a Solway Energy Gate-
way is being promoted in the form of a
tidal barrage at the site of a former railway
viaduct that spanned the frth from Bow-
ness in England to Annan in Scotland.
The study is being supported by nb21c
(social enterprise) Ltd., the organization
responsible for conceiving, developing,
and promoting the community-based
proposal. A Solway Energy Gateway
Steering Group is being formed with rep-
resentation from both sides of the border,
as well as funders and interested parties
from the public and private sectors.
New Zealand rm to
nance 200-MW project
New Zealand-based World Energy Re-
search is fnancing development of a
200-MW tidal power project by Blue
Energy Canada.
In July 2009, World Energy Research
agreed to fnance Vancouver-based Blue
Energys frst big commercial tidal proj-
ect, at a location to be announced, at a
cost of about US$500 million.
Blue Energy Canadas vertical axis
turbine is designed to be effciently lift
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driven, much like modern wind turbines.
The turbine is composed of vertical
hydrofoils attached to a central shaft
transmitting torque to a generator. The
turbine is to be housed in a thin concrete
caisson that channels water fow to the
unit and houses the generator and elec-
trical components above the water sur-
face. The modular units are designed to
be stacked to serve as a bridge between
two land masses.
World Energy Research is an Auck-
land-based energy research, exploration,
management, and operating company that
specializes in development and commer-
cialization of green energy technology.
Australia state approves
wave energy pilot projects
The government of South Australia
State has approved two wave energy pi-
lot projects that will utilize the exten-
sive energy generated by the Southern
Ocean off Australia.
The state approved one project, by Wave
Rider Energy Pty Ltd., in May 2009 and
one, by Carnegie Corp., in April 2009.
A wave power assessment of the
southern Australia coast last year found
170,000 MW of potential near-shore
wave energy potential. The independent
report, commissioned by wave energy de-
veloper Carnegie, estimated a conserva-
tive 10 percent of that amount 17,000
MW is economically extractable.
Wave Riders project is planned for
installation off Elliston on the Eyre
Peninsula. The company plans an ini-
tial investment of A$5 million (US$3.9
million). Premiere Mike Rann said Wave
Riders frst Wave Energy Converter will
be deployed on a seabed lease.
The Carnegie project will be located
at a test site along the Limestone Coast
near Port MacDonnell.
Briey
Chile and the United States are coop-
erating to advance high-priority energy
issues, such as energy effciency tech-
nologies and developing renewable en-
ergy sources including ocean power.
Equipment manufacturer Alstom Hydro
signed a technology licensing agreement
with Clean Current Power Systems
Inc., a Canadian developer of hydrokinet-
ic tidal energy technology. The agreement
includes an exclusive worldwide license
for ocean and tidal stream applications for
Clean Currents patented technology.
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Lessons Learned
Keep That Book!
A hydro utility with more than 1,000
MW of capacity bought an 80-year-old
hydro plant with a capacity of 8 MW. An
inspection of its acquisition revealed the
steel surge tank was severely rusted. The
utility hired a local consultant with small
hydro experience to design a new tank.
The consultant proposed to replace the
Johnson-type differential tank with a
restricted-orifce surge tank with a di-
ameter about 0.5 meter smaller, which
would be less expensive.
During commissioning of the new
tank, Paul, the plant operator, started
testing of load rejections at 25 percent
generator load. At the second test, for a 50
percent generator load rejection, the surge
tank overfowed, to everyones surprise.
Paul called George, another consultant,
who obtained the drawings for the new
tank, as well as copies of the plans and
profles for the old pipeline and penstock.
George determined that the orifce on
the new surge tank was too large, at 64
percent of the pipeline diameter. For a
restricted-orifce tank, the rule of thumb
is that the orifce diameter should be 45 to
55 percent of the pipeline diameter.
Paul asked the consultant to review
the hydraulic design of the new tank.
At the same time, George warned Paul
that with the smaller orifce diameter, the
penstock pressure rise on load rejection
would be larger. This meant the penstock
waterhammer should be determined with
the new surge tank because it could affect
the design of the penstock.
The consultant had written an Excel
program for the hydraulic design of the
new surge tank, and he had obtained
the discharge coeffcient for the orifce
from a chart. Upon reviewing the chart,
George noticed it was for multi-orifce
pressure-reducing plates used at in-
dustrial plants, not for a single-orifce
condition. Based on this feedback, the
consultant increased the discharge co-
effcient to 0.62 from 0.25 and ran the
program for various orifce sizes, in the
region of 40 percent to 60 percent of
pipeline diameter. Based on advice from
the consultant, the utility installed an
orifce with a diameter of 46 percent of
the pipeline diameter. Once this change
was made, commissioning of the surge
tank was completed successfully.
George then tried to determine the ef-
fect of the smaller orifce on the penstock
waterhammer and turbine speed rise.
Paul informed him that governor time at
this facility was about 10 seconds to close
from full load opening. With this long
interval, George determined the turbine
would reach runaway (maximum turbine
rotational speed) on any shutdown great-
er than about 60 percent generator load.
Even with a faster governor time calculat-
ed to produce a 45 percent waterhammer
(the normal maximum for a penstock),
the speed rise would be to runaway.
George now focused on the generator
inertia because a higher inertia would re-
duce speed rise. The inertia value George
initially found was from a table for modern
generators. However, generator rotors built
before about 1940 are large and heavy due
to the extra spacing between poles required
to accommodate the thick insulation. This
meant data for modern generators is not
applicable to this older unit.
Finally, in looking through his library
of hydro books for an inertia value for
the unit, George found a table listing the
inertias of Westinghouse vertical water-
wheel generators. The book, Hydro-electric
Handbook, was dated 1927. From this table,
George was able to produce a formula for
inertia of this particular unit as a function
of kilovolt-amperes (kVa) and speed. This
calculation resulted in a higher inertia than
those supplied for modern units. Using this
higher inertia, George determined that
speed rise on full load rejection would be
less than 50 percent with a governor time
of 2.8 seconds. In addition, waterhammer
would be less than 50 percent, an accept-
able design for an isolated power plant.
However, the current governor close
time was about 10 seconds. Should the
utility shorten it to about 3 seconds?
After deliberation, Paul decided to re-
tain the slow closing time. His intention
was to keep penstock waterhammer as low
as possible, in view of the fact that the steel
penstock was quite deteriorated. Because
this plant was connected to a large grid,
fast governing times were not a neces-
sity. Also, the well-built old Westinghouse
generator had demonstrated that runaway
speeds were not a problem.
Lessons learned
First, always test a new computer surge
tank design program on an existing
tank, to determine whether it reproduces
the range of water surge levels observed
within the tank.
Second, if tank diameter is being
decreased, it is important to assess the
effect on the penstock, as the range of
surge pressures will change.
Third, retaining information for old
units often is diffcult. Such esoteric data
as generator inertia often is lost. In this
case, resort must be made to old refer-
ences. So dont throw out that old book!
By James L. Gordon, B.Sc., hydro-
power consultant
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Synchronous Generators
up to 15 MVA
www.tes.cz
Asynchronous Generators
up to 1.5 MW
90 Years of Power Engineering
Worldwide Generator Exporter
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__________
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Small Hydro
Austrian rm named to develop
16 Macedonia small hydros
Austrian company Energie Zotter Bau
signed contracts to build 16 small hydro-
power plants in Macedonia representing
a total investment of 15 million euros
(US$21 million).
Macedonia Vice President Vladimir Pe-
sevski participated in the signing of agree-
ments in July with Energie Zotter Bau,
marking Macedonias frst award of small
hydro concessions stemming from three
public solicitations that began in 2007.
Upon completion by June 2012, the 16
hydro plants are to have total installed ca-
pacity of 6.62 MW and estimated annual
generation of 26.48 gigawatt-hours.
For details on the plant names, sizes,
and locations, go to www.hydroworld.
com and search for Energie Zotter Bau.
Macedonias Ministry of Economy said
a fourth concession auction is planned
offering up to 40 small projects.
Association to develop
European hydro database
With backing from the European Union,
the European Small Hydropower Asso-
ciation (ESHA) is to develop a database
of European hydropower as well as recom-
mendations on future hydro development.
The Streammap project is to run three
years from its launch in June at a meeting
at the Renewable Energy House in Brus-
sels. ESHA said the program is partially
funded by the European Union under the
Intelligent Energy Europe (IEE) Pro-
gram conducted by the European Agency
for Competitiveness and Innovation.
ESHA is to coordinate and set up a
central database called HYDI, including
complete information on the hydropow-
er sector for each of the 27 EU member
states. Information is to range from basic
data on the number of plants to invest-
ment and economic variables. It also is to
cover policy and legislative frameworks.
The association said the second pur-
pose of the program is to defne a road
map for the small hydropower sector,
including recommendations on future
development to be delivered to national
and local policymakers in view of plans
to increase use of renewable energy.
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___
________________ www. r i zzoassoc. com
DESIGN ANALYSIS INSPECTIONS CONSTRUCTION MANAGEMENT
CORPORATE HEADQUARTERS :: PITTSBURGH, PENNSYLVANIA, USA
PHONE :: 001.412.856.9700 FAX :: 001.412.856.9749
Proudly building on 25 years of RCC and Dam
Construction Experience.
ESHA is to coordinate Streammap
with a consortium of France-Hydro-
Electricite, British Hydropower Asso-
ciation, Lithuanian Hydropower Asso-
ciation, Italian Association of Renewable
Energy, Slovenian Small Hydropower
Association, Swedish Renewable En-
ergy Association, Romanian Institute
for Hydro and Design, Portuguese
Renewable Energy Association, Polish
Hydropower Association, and Belgium
Renewable Energy Federation.
ESHA also studies mini-
hydro, wind in mountains
In another IEE-funded project, ESHA
and six partners from mountainous
and rural European Union territories
are conducting a two-year project that
involves mapping and analyses of local
hydropower and wind potential.
The six partners are Agency for En-
ergy and Environment in the Province of
Teramo (AGENA) of Italy; the Associa-
tion of North Bohemian Municipalities,
Czech Republic; Diputacion provincial
de Huelva, Spain; Energikontor Sydest,
Sweden; Energy Centre of Western Thes-
saly, Greece; and Sun Valley, Romania.
Energy potential from mini-hydro-
electric and mini-wind installations will
be mapped in the six regions participat-
ing in the rural renewable energy sources
(RURAL-RES) project. Mapping will
be done from existing information and
through collection of missing data.
From a previous mapping exercise,
three to fve sites for hydropower are to be
selected in each region for a pre-feasibility
study and an impact assessment. A con-
sultation process with stakeholders then
will be initiated. The program is expected
to encourage agreements to perform full
business plans and to invest in at least one
hydro plant per partner, corresponding to
an overall power of 10 MW.
Participants launched RURAL-RES
in 2008 to promote renewable electric-
ity production by supporting local de-
velopment of grid-connected mini-hydro
plants and off-grid mini-wind installa-
tions in mountainous areas. It is expected
to demonstrate exploitation of hydro and
wind resources on a small scale can re-
spect the environment and be compatible
with other activities such as tourism.
Information developed in the project
will be disseminated for replication. Cas-
es studies are to be identifed across the
EU in both mini-hydro and mini-wind
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________________
Continuous
automated
monitoring system
for greenhouse gas
concentrations in
freshwater
environments
See us at:
Hydro 2009 in Lyon,
France, October 26-28
sectors, ESHA said. Plans also call for
publication of a guide, 15 good practices
on grid-connected mini-hydro power
plants, for decision-makers, investors,
and opinion leaders.
Czech rm to equip Finlands
1.76-MW Kuokkastenkoski
Mavel a.s. of the Czech Republic is sup-
plying two 880-kW Kaplan turbines to
the 1.76-MW Kuokkastenkoski hydro-
electric project in Finland.
Kuokkastenkoski is owned by Pohjois-
Karjalan Sahko Oy at a site 120 kilome-
ters north of Kuopio. It has a net head of
10 meters and a fow of 20 cubic meters
per second.
Mavel said it is to supply two KVK/
D1450K5 double-regulated vertical Ka-
plan turbines with runner diameter of
1,450 millimeters and fve runner blades.
It also is to supply generators, draft tube,
hydraulic system, lubrication, and cool-
ing system. Vaasa Engineering Oy is
supplying electrical equipment.
Mavel said the contract was signed in
February 2009, with completion sched-
uled for December 2010.
Other Mavel orders in Europe include:
Supplying a turbine for refurbish-
ment of the 862-kW Finnholm hydroelec-
tric project on the Ahtavanojoki River; and
Supplying four 662-kW turbines
and related equipment for the 2.65-MW
Lovosice-Pistany 1 hydroelectric project
in the Czech Republic.
Bosnia utility to build
17 small hydro plants
The utility serving Bosnias Muslim-
Croat federation, Elektroprivreda BiH
(EPBiH), plans to invest 67.5 million
marka (US$44.3 million) to build 17
small hydropower plants under a conces-
sion from the town of Konjic.
The plants, with total installed capac-
ity of 22 MW, will be built on the Nere-
tvica River in southeastern Bosnia and
produce 83.5 gigawatt-hours of electric-
ity per year, EPBiH said.
Konjic awarded a 30-year concession to
EPBiH on condition that it employs up to
70 percent locals in construction work and
respects environmental requirements.
U.K. to develop 25 projects
on historic canal system
British Waterways and its partner Small
Hydro Co. Ltd., a developer, are pursuing
25 small hydroelectric projects proposed
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for the United Kingdom. British Water-
ways, a public corporation, owns and
maintains 3,500-kilometers of U.K. wa-
terways, including rivers and 200-year-
old canals.
British Waterways said more than
120 million pounds (US$166 million) of
private capital will be invested over three
years to develop the projects. It said the
projects would generate 210,000 mega-
watt-hours of electricity from renewables
each year, create 150 construction jobs,
offset 110,000 tons of carbon dioxide
emissions, enhance waterway biodiver-
sity, and improve food mitigation.
Prospective sites for the hydro ven-
ture feature weirs, which act as barriers
to migratory fsh. Plans call for adding
fsh passage facilities at each site. The
hydro projects also would enable parties
to lower water levels ahead of increased
fows, offering better control of water.
The waterways originally were built
for transportation but they now are
mostly used mostly for recreational pur-
poses. Millions of people visit the water-
ways each year.
Climate Change Capital, an invest-
ment manager and adviser that manages
Ventus Funds, a large group of funds spe-
cifcally targeted at the U.K. renewable
energy sector, is supporting the program.
Small Hydro Co. and Climate Change
Capital said they intend to have the frst
projects developed under the scheme op-
erating in 2010 to meet the governments
renewables target of 10 percent.
Electricity generated by the projects
would be fed into the national grid or
provided to neighboring sites. British
Waterways said it intends to reinvest its
share of project revenue in the govern-
ments waterways network. Small Hydro
Co., Exon, England is raising funds and
providing expertise; it also expects to see
a return on investment.
Miner forms renewables unit
to expand Perus 1.2-MW Tingo
Canada-based mining company Trevali
Resources Corp. formed Trevali Renew-
able Energy Inc. to refurbish and expand
the 1.2-MW Tingo hydroelectric project
to power Trevalis Santander silver, lead,
and zinc project in Peru.
Trevali Renewable entered an agree-
ment with Peruvian bank Banco Inter-
nacional del Peru and corporate law frm
Estudio Echecopar to arrange long-term
credit facilities of about US$20 million.
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http://hrw.hotims.com RS #411 http://hrw.hotims.com RS #410 http://hrw.hotims.com RS #409
http://hrw.hotims.com RS #402 http://hrw.hotims.com RS #401 http://hrw.hotims.com RS #400
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PAN
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kontakt@pan-metall.com www.pan-metall.com
All Services for Complete Solutions
from concept to completion and operation
from projects to complex systems
from local to multinational schemes
for public and private developers
Lahmeyer International GmbH
Friedberger Strasse 173 D-61118 Bad Vilbel, Germany
Tel.: +49 (6101) 55-1164 Fax: +49 (6101) 55-1715
E-Mail: bernd.metzger@lahmeyer.de http://www.lahmeyer.de
Your Partner for
Water Resources and
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Professional Listings
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24-26 March 2010 | EXPOCENTR | Moscow | Russia
w w w . h y d r o v i s i o n - r u s s i a . c o m
call for abstracts
abstract deadline: 19 August 2009
Expanding the success of HydroVision International, North Americas
largest gathering of hydro professionals, HydroVision Russia seeks
to showcase the changing future of the Russian energy mix and
highlight the great potential of hydro power. We invite you to submit
your proposals for this exciting event.
Apply your strategies and technologies to the 2010 HydroVision
Russia conference by submitting an abstract for HydroVision Russia
and impart your knowledge alongside the technical and strategic
decision-makers in the Russian power industry.
Attendees to include:
Qualied senior management/executive decision makers who have
the authority to purchase, or inuence the purchase of world-class
products and services including public and municipal utility owners
& managers, government and regulatory executives, independent
power producers, and many more.
For additional information about submitting your abstract,
please contact:
Mathilde Sueur
Conference Manager
T: +44 (0) 1992 656 634
F: +44 (0) 1992 656 735
E: papershvr@pennwell.com
hydro power
HydroVision Russia is the premier conference and tradeshow for
hydro energy production, maintenance and technology. Co-located
with Russia Power, this event will provide an overview of energy
production methods, both traditional and renewable for current
needs and projects as well as future endeavors.
changing the future of energy.
co-located with: agship media sponsor:
owned & produced by:

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________________________________
UK: Gilbert Gilkes & Gordon Ltd,
Canal head North, Kendal,
Cumbria LA9 7BZ
hydro@gilkes.com
USA: Gilkes Inc
gilkes@gilkesinc.com
JAPAN: Gilbert Gilkes & Gordon Ltd
h-yamamo@rf6.so-net.ne.jp
HYDRO AND POWER SYSTEMS
Reliable and innovative solutions utilizing over
150 years continuous hydro electric
turbines, generators, controls, switchgear and

associated plant up to and around 20MW.
Calendar
Sept. 16-18. Benchmark Workshop on Nu-
merical Analysis of Dams sponsored by In-
ternational Commission on Large Dams.
Location: Paris, France. Contact: E-mail:
marie-louise.luissint@coyne-et-bellier.fr;
Internet: www.coyne-et-bellier.fr.
Sept. 21-24. African Hydro Symposium
2009 sponsored by NamPower. Loca-
tion: Windhoek, Namibia. Contact:
(260) 211-371007; E-mail: elna.erlank@
nampower.com.na; Internet: www.nam-
power.com.na.
Oct. 5-9. Hydropower Financing and Proj-
ect Economy sponsored by International
Centre for Hydropower. Location: Oslo,
Norway. Contact: (47) 73-590780; E-
mail: mail@ich.no; Internet: www.ich.no.
Oct. 7-9. Power-Gen Asia sponsored by
PennWell Corporation. Location: Bang-
kok, Thailand. Held in conjunction with
Renewable Energy World Asia. Contact:
(44) 1992-656610; E-mail: exhibitpga@
pennwell.com; Internet: www.powerge-
nasia.com.
Oct. 7-9. Renewable Energy World Asia
sponsored by PennWell Corporation.
Location: Bangkok, Thailand. Held
in conjunction with Power-Gen Asia.
Contact: (44) 1992-656632; E-mail:
exhibitrewa@pennwell.com; Internet:
www.renewableenergyworld-asia.com.
Oct. 12-13. Second International Con-
ference on Long Term Behavior of Dams
sponsored by Graz University of Tech-
nology. Location: Graz, Austria. Con-
tact: E-mail: ltbd09@tugraz.at; Internet:
www.ltbd09.tugraz.at.
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www. hydroevent. com
Environment/Social
Equipment and Technology
Market Trends and Strategies
Water Management and Movement
Project Management and Operations
Suggested Topics:
Topics of interest to the HydroVision International conference audience include, but are not limited to, the following:
HydroVision International Call for Abstracts:
HydroVision International is now accepting abstract submittals for the 2010 conference program.
Submit your abstract by October 30, 2009, and take advantage of the opportunity to share your insight with
more than 2,500 hydro colleagues and to become a prospective participant in this exciting conference!
Contact:
Jan Simpson
|
HydroVision Conference Manager
|
1421 S. Sheridan Road
|
Tulsa, OK 74112 USA
|
1.918.831.9736
|
hvconference@pennwell.com
STEP 3:
Submit your abstract online at www.hydroevent.com -
click on Online Abstract Submittal Form located
under Conference.
STEP 1:
Choose a topic from the list of suggestions,
or propose your own hydro-related topic.
STEP 2:
Develop a well-written, concise synopsis of
your proposed presentation that addresses
key points, approximately 200-400 words
in length.
OWNED & PRODUCED BY: FLAGSHIP MEDIA SPONSORS: SUPPORTING ASSOCIATIONS:
For additional information about submitting an abstract and the selection process, please go to www.hydroevent.com.
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Kap|ar, |rarr|s, Pe|ter tarb|res
www.zere.|t |rfe@zere.|t +JJ 115 &IJ15
!|e 4|ffererre |s |rs|4e.
Ad Index
RS# COMPANY PG#
14 Accusonic www.accusonic.com/hydro 21
3 ALSTOM www.power.alstom.com/hydro 5
1 American Hydro www.ahydro.com IFC
49
ANDRITZ HYDRO GmbH
www.andritz-hydro.com
OBC
42
Axys Technologies Inc.
www.axystechnologies.com
46
43
Bernard Bonnefond
www.bernardbonnefond.com
46
18 Dyrhoff www.dyrhoff.co.uk, www.dyrhoff.no 24
34
Elektroprojekt Consulting Engineers
www.elektroprojekt.hr
43
17 Gilbert Gilkes & Gordon Ltd. www.gilkes.com 23
38 Gugler www.gugler.com 44
25 Hans Knz GmbH www.kuenz.com 33
48
HCS Hydro Component Systems, LLC
www.hydrocomponentsystems.com
IBC
27 Huggenberger AG www.huggenberger.com 35
47
HydroVision Call For Papers
www.hydroevent.com
51
46
Hydrovision Russia Save The Date
www.hydrovision-russia.com
49
4 IMPSA www.impsa.com 7
RS# COMPANY PG#
2
INA Schaefer Group Industrial
www.schaefer.com
3
45 INSET www.inset.ru 47
7
James Walker & Co. Ltd.
www.jameswalker.biz
14
16 Klohn Crippen Berger www.klohn.com 22
32
Koncar Generators and Motors Inc.
www.koncar-gim.hr
39
21 Leroy-Somer www.leroy-somer.com 29
11 Litostroj Power www.litostrojpower.eu 17
30
Marco
a Continental Company
www.marcosolutions.net
38
6 Marelli Motori S.p.A www.marellimotori.com 11
41 Mavel www.mavel.cz 45
37 MC-monitoring SA www.mc-monitoring.com 43
15 MHyLAB www.mhylab.com 22
23 Muhr GmbH www.muhr.com 31
8 MWH www.mwhglobal.com 15
28
Norris Screen & Manufacturing
www.norrisscreen.com
36
19 PANOLIN AG www.panolin.com 25
39
PCR Paul C. Rizzo Associates, Inc.
www.rizzoassoc.com
44
RS# COMPANY PG#
12
Potencia Industrial S.A.
www.potenciaindustrial.com.mx
19
26 Rascor International Ltd. www.rascor.com 34
40
RST Instruments Ltd.
www.rstinstruments.com
45
13
Seals Unlimited Inc.
www.sealsunlimited.com
20
33
Sotek, Inc. and Belrix Industries, Inc.
www.sotek.com
41
31 Stellba Hydro www.stellba-hydro.ch 39
36 TES VSETIN A.S. www.tex.cz 43
5
Thordon Bearings Inc.
www.thordonbearings.com
9
10 3Tier www.3tier.com 17
9 TNO Diana BV www.tnodiana.com 16
35
Tyton Fematics Canada
www.fabgroups.com
43
44 Veski d.o.o. www.veski.hr 47
20 Voith Hydro www.voithhydro.com 26-27
24 Waukesha Bearings www.waukbearing.com 32
22
Worthington Products, Inc.
www.tuffboom.com
30
29
Yooil Engineering Co. Ltd.
www.rubberdam.co.kr
37
*IFC=Inside Front Cover, IBC=Inside Back Cover, and OBC=Outside Back Cover
Advertisers and advertising agencies assume liability for all contents (including text representation and illustrations) of advertisements printed, and also assume responsibility for any claims
arising therefrom made against the publisher. It is the advertisers or agencys responsibility to obtain appropriate releases on any items or individuals pictured in the advertisement.
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Water generally implies fascination
and inspiration. But to us at ANDRITZ
HYDRO it means even more: a constant
challenge to create up-to-date techno-
logical inventions. Utility companies
from al l over the worl d val ue our
know-how and commitment and trust
in the safety and reliability of our tailor-
made energy generation solutions: from
equipment for new, turnkey hydropower
plants to refurbishment and overhaul of
existing installations and comprehensive
automation solutions.
We focus on the best solution from
water to wire.
V
i
s
i
t
u
s
a
t
B
o
o
t
h
#
1
5
Ly
o
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-
F
r
a
n
c
e
Hydro Power.
Your partner for renewable and clean energy.
ANDRITZ HYDRO GmbH
Penzinger Strasse 76, A-1141 Vienna, Austria
Phone: +43.1.89100-2659, Fax: +43.1.8946046
contact@andritz-hydro.com
www.andritz-hydro.com http://hrw.hotims.com RS #49
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