HYPOWER - HIGH POTENTIAL REPLACE OR REFURBISH? WHY SMALL HYDRO IS BIG NEWS - VOITH
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MAGAZINE FOR HYDROPOWER TECHNOLOGY HyPower #28 | Autumn 2016 HYDROPOWER IN AFRICA HIGH POTENTIAL SUCCESSFUL PARTNERSHIPS REPLACE OR REFURBISH? FULL LINE SUPPLIER WHY SMALL HYDRO IS BIG NEWS
EDITORIAL IMPRINT Publisher: Voith GmbH St. Pöltener Str. 43 89522 Heidenheim Germany Responsible for the publisher: Kristine Adams Editor-in-chief: Gudrun Köpf Editorial Board: Elke Kleinknecht, Susanne Speiser, Dr. Vesna Stirnadel In cooperation with: C3 Creative Code and Content GmbH, Heiligegeistkirchplatz 1, 10178 Berlin, Germany www.c3.co Paper: HyPower is printed on Respecta Silk. This paper was produced on a Voith paper machine. Copyright: UNLOCKING POWERFUL No part of this publication may be copied, reproduced or otherwise disseminated, nor may any of the content in it be used in POTENTIAL part or in whole in other works in any form whatsoever, without express written Diversity. Complexity. Potential. Three words dance. We work closely with leading financial permission of the editor. that sum up Africa pretty well in many different institutions and insurers to help our African contexts – geographical, political, economic customers spread the cost of building or reha- and social. They also apply to Africa’s energy- bilitating hydropower facilities over realistic time generation infrastructure. While some African frames. Our experts in Heidenheim and across countries have plentiful oil and gas reserves, the world are ready and willing, not only to some have none. Some can rely on hydropow- manufacture the equipment required, but to er for nearly all their power requirements, some spend weeks and months on site, working need to import almost all their electricity from closely with customers to transfer knowledge, outside their borders. And even if the resources build skills and ensure that once a plant is com- exist, building an infrastructure that delivers pleted, it can be run effectively by local people. power to homes and businesses reliably is an- We are also investing in improving our local ser- other challenge altogether – especially in coun- vicing capabilities to permanently improve ser- tries that have been ravaged by recent or cur- vice for our customers. rent conflicts. This new edition of HyPower showcases Join us on: YOUR FEEDBACK: If you have any As a result, there is one reality that applies how customers and communities in Africa and comments or questions on this issue of to some areas of every African country: elec- elsewhere are benefiting from maximizing their HyPower, please contact us: hypower@voith.com tricity supply is nowhere near sufficient to meet hydropower potential, and leveraging the new- https://twitter.com/voith_hydro demand. In fact, even in 2016, around three- est technologies to do so. Enjoy! quarters of the African population do not have Photographs: Cover: Graeme Williams, Gauteng; Ryan Thomas /AerialShots, Johannesburg: 8, 9, 19; Christian access to reliable, constant power. From a hy- Yours sincerely, https://www.linkedin.com/ company/voith-hydro Wesser, Heidenheim: p. 16, 17, 18, 29, 35; Graeme Williams, Gauteng,: 10, 11, 12, 13, 14, 15, 20, dropower perspective, Voith is at the forefront 21, 22, 23; Dawin Meckel, Berlin: p. 26, 27, 28; Brian Gartside: p. 44, 45 Kent Kallberg Studios, of efforts to change this. Vancouver: p. 39, 40; U3: Robert Caputo /Aurora / laif To harness Africa’s hydropower potential, https://www.youtube.com/ All other photos are from Voith. financing flexibility, expertise and commitment Uwe Wehnhardt c/Voith_Hydro are all essential. Voith has all three in abun- President and CEO of Voith Hydro HyPower 2016 | 3
CONTENTS CONTENTS 8 26 39 AGENDA SETTING FULL LINE SUPPLIER GLOBAL EXPERTISE 39 THE BIG QUESTION: GUEST PERSPECTIVE REPLACE OR REFURBISH? 8 ENERGIZING AFRICA 26 SMALL PROJECTS, 32 STOPPING THE FLOW Why it can pay dividends to 44 CREATING THE How significant hydropower projects BIG RESULTS How an electronic control overhaul old hydropower SAFE WATER BOOK™ in South Africa and Angola are In Asia, a larger number of smaller mechanism for ring gates has equipment, rather than retire it. An exciting water filtering transforming economies and lives. hydropower projects set new standards in precision. innovation could solve the problem could be the key to improving INNOVATION of dirty drinking water for millions. 16 MANAGEMENT INTERVIEW rural power availability. 34 SERVICING AFRICA Voith Hydro's CMO and African When it comes to maintenance, 42 SAFE AND SOUND sales leader discuss the potential 28 MEETING THE LARGE HYDRO it's always better to have local Why a new listening technology is 47 VOITH HYDRO PROJECTS of hydropower in Africa. CHALLENGE resources on hand. Voith Hydro is the best way of monitoring plant A visual summary of hydropower Discover more about Voith through its Hydropower projects so large that investing in developing local operation remotely. projects by Voith in Africa explored other insightful publications. 19 MODERNIZING they can take almost a decade African expertise. in this issue. MOUNT COFFEE to complete require a special set How Liberia's hydropower of skills for success. SUCCESSFUL PARTNERSHIPS infrastructure is being MOUNT COFFEE rebuilt to support rapid economic FROM THE ARCHIVES 35 24/7 MOBILE SERVICE development. In Europe, the Voith HyService Bus REGULARS 30 TRUE SURVIVOR is ready to leap into action 24 GLOBAL TRAINING, The rollercoaster history of the whenever customers need it. CAMBAMBE TULILA 03 EDITORIAL LOCAL BENEFITS Cahora Bassa hydropower plant 06 WHAT’S NEW All over the world, Voith Hydro is in Mozambique. 36 THE POWER TO CHANGE LIVES CAHORA BASSA 07 ON TOPIC delivering training concepts How a convent in Tanzania and the 43 WORLD OF VOITH that meet the needs of individual community it serves are benefitting BOKSBURG INGULA 46 5 QUESTIONS FOR … customers. from Small Hydro. 4 | HyPower 2016 HyPower 2016 | 5
WHAT’S NEW ON TOPIC VOITH AT HYDROVISION 2016 DRIVING DEVELOPMENT USA The StreamDiver was the focus of a presentation delivered at the recent 2016 HydroVision International event in Minneapolis, In many parts of Africa, the lack of a reliable electricity infrastructure Minnesota. Presenter Philip Daus, a Small Hydro engineering project hinders economic development. Hydropower can play a big part in manager at Voith Hydro, said, “Hydropower is among the best solu- tions to energy market challenges, and we are using our technology changing this picture. and expertise to achieve the best outcomes in economy and perfor- mance, both technically and environmentally.” Other important Voith innovation papers presented at the event covered: a rotor rim slot reshaping process for increasing generator longevity; a new analysis and replacement process for damaged Klaus Schädler, Voith, at groundbreaking ceremony. turbine thrust collars, which improves monitoring, maintenance and 1 Power is patchy 2 Hydropower potential is enormous repair; a new forecasting method to increase accuracy and improve short-time pumped-storage balancing; and an overview of improved BREAKING NEW GROUND online assessment processes for hydro-components. GERMANY One of the most exciting innovations being introduced at Voith Hydro in 2016 is the 645 million Africans have no access to electricity. 300 - 400 GW construction of a small hydropower plant (called Potential hydropower capacity in 'Alte Bleiche') at the Heidenheim site, to act as a Europe and Africa is similar... demonstration facility for customers, employees and the public. The 35 kW plant will also feed electricity directly into the local grid – enough to Power consumption per head power 100 homes. Construction work started ...but Europe has an installed in Africa in Europe with a groundbreaking ceremony in April, and capacity of 218 GW. Africa 1 the plant should be operational by year end. 181 kWh/y 6,500 kWh/y has only 30 GW. Voith apprentices are involved in the design and manufacturing, and are working to an eco- friendly design – created in cooperation with the Technical University of Munich – that eliminates the need for a new powerhouse. The plant will feature Voith’s new StreamDiver generator unit, recently showcased at a series of roadshows across Latin America. StreamDiver is designed 2 3 for low-head river plants and deployed underwa- ter, eliminating noise emissions, minimizing local Africa produces 4% 1 Voith exhibition booth. 2 Customer event banquet. environmental impact and making small hydro- of the world’s total 3 Bob Gallo, Bill Malus and Martin Andrä at HydroVision 2016. power plants more cost-effective. energy, but is home to 13% of the global 218 GW 30 GW in Europe in Africa 4% population. MORE POWER FOR UGANDA 2015 UGANDA Voith Hydro has been awarded a contract for the Berkeley Energy and customer ARPE Ltd. Commenting on complete design, manufacturing, supply, installation and com- missioning of the electromechanical equipment for the new the project, Head of Voith Hydro’s Small Hydro Business Klaus Schädler said, “We are happy to be part of the project 2,174 MW across Africa Between 2010 and 2015, 2,174 MW of hydropower plant on the Achwa River in northern Uganda. that supports reliable power production and sustainable eco- Frequent power outages are the norm in hydropower capacity The plant features four vertical Francis turbines and vertical synchronous generators with an installed capacity of 42 MW. nomic development in the region. We look forward to putting our ideas into practice, and to foster our collaboration for 30 African countries. 2010 was added across Africa. The project will involve close collaboration between Voith, M/s renewable energy in Uganda.” 6 | HyPower 2016 HyPower 2016 | 7
AGENDA SETTING AGENDA SETTING ENERGIZING AFRICA A Successful installations at Ingula in South Africa and reliable electricity supply brings light and heat (or relief from it) Cambambe in Angola illustrate how hydropower to homes and businesses, powers is transforming economies and lives across Africa. machinery, and enables hospitals and schools to function effectively. In a con- tinent as large as Africa, with many countries and political regimes, dis- persed populations, variable transport infrastructure and a wide range of cli- mates and terrains, generating and dis- tributing power effectively is a chal- lenge. Hydropower in Ingula Voith Hydro in Africa Ingula Installed capacity: 1,368 MW Voith Hydro supports many African na- tions in making the most of their hydro- power generation potential with a wide Bramhoek Dam (lower dam) in winter. A view of the reservoir from the pumped storage range of small and large projects in plant at Ingula in South Africa. 8 | HyPower 2016 HyPower 2016 | 9
AGENDA SETTING AGENDA SETTING 27 countries. Even so, less than 10% of Africa’s potential hydropower genera- tion capacity of an estimated 400 GW has been exploited to date. Together with its customers, Voith is addressing this opportunity through: new state-of- the-art plants; the repair, maintenance and servicing of existing infrastructure; and the transfer of knowledge to sup- port African countries in running their hydropower facilities self-sufficiently. Two projects in particular, at Ingula in South Africa, and Cambambe in Angola, illustrate the benefits perfectly. 1 3 Ingula pumped storage plant, 2 South Africa Situated in the hills of KwaZulu-Natal in eastern South Africa near the town of 1 Intake structure at Bedford Dam Fuji in Japan. The first of the four tur- as he explains: “The project has involved Ladysmith, the pumped storage plant at (upper dam). bines was handed over to the customer in employing and training local staff to run 2 An operator adjusts the oil filtration Ingula is the largest of its kind in Africa. system. mid-June 2016. The next two turbines the plant once it is completed, which is a Its four underground pump turbines 3 Machine Hall Unit 1 and 2 side, were due for handover in August, and the key part of the service we provide. An- have a total installed capacity of 1,368 installation of machine hall ceiling. last by the end of 2016. other important element was our partic- MW. Following the tender process ipation in the Accelerated and Shared launched by South African state energy Keeping the plant cool Growth Initiative for South Africa (As- company Eskom in 2007, Voith Hydro In parallel, Voith has fulfilled the terms giSA). This program is designed to en- was awarded the contract for the provi- of a second contract, awarded in 2011, sure foreign firms invest to help grow sion of the pump turbines, motor gen- for various supplementary systems in- the local economy by sourcing products erators, the main inlet valve, and key cluding cooling water pipes, fire protec- and services from local providers. In ad- systems in September 2008, some 30 tion, fire prevention and an air ventila- dition, we oversaw the construction of years after the government first started tion system for the plant. The latter is new infrastructure, such as good quality planning the project. And it has a key particularly important, as Markus Mül- roads that enabled us to transport mate- role to play in South Africa’s energy ler explains: “Once they are fully opera- rials and people from Durban harbor to supply, as project manager Markus Mül- tional, the four turbines will generate a the plant site.” Not only that, the area ler explains: “Like most countries on the lot of heat, and because they are under- surrounding the site, which includes continent, South Africa suffers from en- ground, that heat has nowhere to go if sensitive wetlands and which has been ergy shortages which hamper its eco- there is no system in place to remove it. used to house the people working on the nomic growth. Ingula is particularly im- We are installing the system, but it will project, will be returned to its original portant because it will begin making its take longer to complete because the state as part of the project. contribution to the county’s power grid in 2016.” “The project has involved employing and four turbines have to be running before it can be fully tested.” Nevertheless, power generation is of course the ultimate goal and here, Mül- Site activities began in March 2012 training local staff to run the plant once ler has one final unique detail to add. and Voith’s international operations col- Customer and community benefits “What is very special about the Ingula laborated to deliver the required ma- it is completed, which is a key part of the Now that the project is nearing comple- site is that all the machines have already chinery. While the turbines were de- service we provide.” tion, Müller can reflect on its success, been producing energy before handover signed by Voith Hydro in Germany, the Markus Müller and the fact that it has delivered many in parallel with the commissioning. As motor generators were supplied by Voith Voith Hydro Project Manager for Ingula benefits beyond pure power production, the demand for power in South Africa 10 | HyPower 2016 HyPower 2016 | 11
AGENDA SETTING AGENDA SETTING is so great, that this was a key require- and extend the life of the plant for de- ment from our customer Eskom. It’s cades. The state-owned electricity sup- highly unusual, but I’m delighted that we plier ENE selected Voith as a key player have been able to meet the customer’s in an international consortium to take needs.” on the project. Voith’s remit: to supply the electromechanical equipment and Cambambe I and II, Angola systems, including four 67 MW Francis The contrast between the Ingola project turbines and all the required disman- and the Cambambe I and II sites in An- tling of old equipment and new installa- gola couldn’t be bigger. In the mid- tions. 2000s, following three decades of civil war, the existing Cambambe I hydro- Modern technology for maximum power plant, located 180 kilometers east performance of Luanda and originally commissioned To ensure the best possible results, the in 1963, was in urgent need of rehabili- decision was taken to design a state-of- tation. Although two of the original four the-art hydraulic system for the Francis turbine units were still operating, one turbines, combined with digital and hy- 1 was being overhauled, and one wasn’t draulics governors from Voith. To en- 2 working at all. The decision was taken sure the local area could be supplied Workers measure a generator pit in the to replace all four, in order to increase with electricity throughout construc- powerhouse of Cambambe II. power generation capacity to 268 MW, tion, the turbines were installed sequen- tially. Combined with the control pack- age featuring the digital governor, oil Cambambe supply and pumping groups, pressure Hydropower in Cambambe tanks, main oil supply valves, regulating Installed capacity: 960 MW valves and hydraulic elements, Voith was able to prove the value of its status The Cambambe site is located 180 kilometers east as full line supplier beyond any doubt. of Luanda, the capital of Angola. And when the new plant equipment be- came operational – with an even higher performance than was contracted – the customer was delighted. So delighted in bambe II is so important for the future ment of our commitments were also ex- 1 The Cambambe II powerhouse under fact, that in 2012, they commissioned of the country.” The new run-of-river tremely important.” The first unit was construction. 2 A new generator being installed. Voith to supply equipment for the Cam- plant with an additional four turbines commissioned at Cambambe II in July bambe II project. adds 700 MW of installed capacity, 2016, despite an extremely tough time- bringing the sum total of capacity of line, and the plant with all four units is Expansion that will transform Cambambe I and II to 960 MW. As foreseen to be fully commissioned in a country such, it is a key part of the Angolan’s December 2016. As the client says: Despite the advances that have been strategy to increase power production “From the day Unit 1 started commer- made since the end of the civil war in capacity to 6,000 MW by 2017. cial operation, the power cuts in Luanda 2002, Angola still faces huge political, disappeared. This led to a considerable economic and social challenges, as Pro Tailored financing package improvement of the ecological balance ject Manager Patric Kiehlmann has and training due to the reduction of the use of diesel learnt: “Angola is rich in natural sourc- Speaking about the reasons behind the generators.” es, including oil, but the recent lull in oil selection of Voith as the key supplier, prices has had a big impact on the econ- Kiehlmann comments, “Our one face to omy – the government’s income has fall- the customer strategy, and the excellent “Our one face to the customer strategy, as well en by 50%. Private enterprise is very relationship we had built with ENE limited, and healthcare is very poor. during the Cambambe I project were as a tailored financing package, were extremely Economic development, and the jobs key factors. An attractive, tailored fi- important to becoming the key supplier.” and increase in living standards it brings, nancing package and the soundness of Patric Kiehlmann are needed urgently. That’s why Cam- our technological approach and fulfill- Voith Hydro Project Manager for Cambambe 12 | HyPower 2016 HyPower 2016 | 13
AGENDA SETTING AGENDA SETTING Just like the Ingula plant, the project “The reliable and stable supply of energy to the population. The even better news is is very much an international affair, with that this will likely not be the end of the the generator being supplied from Swe- the population and industrial sector is a story. Angola has the potential to gener- den, including a four-part stator that was fundamental prerequisite for improving living ate up to 18 GW of hydroelectric pow- put together on site. And just like Ingu- er, most of which remains untapped. la, the project has had its fair share of standards. Renewable energy is crucial for us.” challenges to overcome. Kiehlmann High-level political engagement Ellen Johnson Sirleaf says, “Importing the materials alone President of Liberia In recent years, several high-level dele- took three months, ensuring they were gations from Ethiopia, Liberia and able to handle the tropical conditions, other nations have visited Voith in and the bureaucracy involved in orga- Heidenheim to learn about relevant nizing visas for expat employees pre- training center is also planned. As Kiehl- technologies and best practices. On her sented tough challenges. But together mann emphasizes, “Our commitment to visit to Germany in 2015, Liberian with the customer, we overcame these.” Angola is a long term one. Through President and Nobel Peace Prize winner The extension of the Cambambe site training in particular, we will ensure that Ellen Johnson Sirleaf commented, “For is vital for the future of Angola. The con- the benefits of the project are sustainable Liberia as well as many other African struction phase is providing much need- for decades to come.” countries, the issue of energy supply is ed jobs and training and a permanent Despite all the challenges it has an essential item in the national growth faced since the end of the civil war, eco- strategy. The reliable and stable supply 1 nomic growth in Angola has been strong of energy to the population and indus- 2 – over 11% per year up until 2010. The trial sector is a fundamental prerequisite Cambambe II plant will play a signifi- for improving living standards. Renew- cant role in helping the country grow its able energy is crucial for us.” Proof, if economy just as rapidly in the future. any were needed, that hydropower will But perhaps most importantly of all, it play a key role in African economic de- will also help improve the daily lives of velopment for many years to come. // FINANCING PROGRESS Hydropower plants such as the ones at Ingula and Cambambe are a capital-inten- sive investment. Financial solutions ease the immediate financial burden by spreading the cost over a long period – especially in developing economies. Voith’s Financial Services subsidiary creates tailored financing concepts in cooperation with private commercial banks and state-backed export credit insurers, which are usually based in the home country of the project’s main supplier. Indeed, Long- term excellent relationships and cooperations with Euler Hermes Kreditversicher- 3 ungs AG in Germany, the Oesterreichische Kontrollbank AG in Austria, and the 4 Nippon Export and Investment Insurance company in Japan, among others, are 1 In the Cambambe II powerhouse: generator covers of the installed the basis for this successful financing support. machines 1 and 2. 2 Installing a turbine shaft in Bernd Rieck, Head of Export and Project Finance, explains: “Our goal is to find the Cambambe II. optimal financing solution for every customer that wants to use Voith as a supplier. 3 Damjan Vucko, Head of Every concept is customized to specific customer needs, based on local variables, Operations at Voith Hydro, project details, the customer’s financial situation, and the so-called Voith Sourcing at Cambambe II 4 Installing the intermediate shaft Matrix, which analyzes the supply chain.” at Cambambe II with view of the thrust bearing and distributor Customer benefits underneath. • Additional financing sources. • Long payback periods. • Attractive financial conditions at advantageous interest rates. • Planning security for financing across the complete project timeline. 14 | HyPower 2016 HyPower 2016 | 15
AGENDA SETTING “We are developing our new Africa concept because we are positive that the African continent has tremendous development potential.” Heike Bergmann Senior Vice President Sales Africa How did a renewed push to develop power plants. The following compari- sales in the African market become son illustrates what we are talking part of your agenda? about. The hydroelectric capacity cur- Martin Andrä: We are implementing rently installed on the entire continent is this new strategic drive because we are equivalent to the installed capacity of convinced that Africa has very good fu- Norway. However, we think another as- Heike Bergmann and Martin Andrä in discussion. ture prospects and we need to tap into pect is also interesting: In Africa, we are these opportunities. In Sub-Saharan seeing a trend in which countries skip Africa, many countries have economic over the fossil fuel-based and nuclear growth rates of five percent and higher. power generation phases that are typi- Heike Bergmann, Senior Vice President Sales Africa, These countries need to be supplied cal of the industrialization process, and Voith Hydro with reliable power so they can further enter directly into electricity production OPPORTUNITY pursue their social and economic devel- from renewable energy sources. The opment. opportunities to make that happen are in place. Right now, Africa’s untapped Heike Bergmann: I want to re-empha- potential for hydroelectric power plants size that. We are developing our new amounts to between 300 and 400 KNOCKS Africa concept because we are positive Gigawatts. that the African continent has tremen- dous development potential. One also Does Voith have anything to offer to has to consider that in some African this market? countries, only 20 to 25 percent of the Bergmann: Yes, absolutely. On my dele population has access to electricity, gation visits, I keep seeing that power and power outages occur on a regular plants built in Africa by European com- basis. The latter presents an impedi- panies are held in high regard. Euro- ment to all industrial companies and pean technology can serve as the Voith is investing in its sales programs in Africa. Martin Andrä, Chief thus also to economic development. backbone of the African economy, and Marketing Officer, and Heike Bergmann, Senior Vice President Sales Africa, that includes Voith, whose hydropower discuss Voith Hydro's future strategy across the continent. Can you give us a rough estimate of technology has been used on the conti- the demand for power plants? nent for about 100 years. Africans value Andrä: There is a huge demand for new the quality and longevity of our prod- 16 | HyPower 2016 HyPower 2016 | 17
AGENDA SETTING AGENDA SETTING “To win projects in Africa, it’s impor- tant to offer financing solutions.” Martin Andrä Chief Marketing Officer ucts. They want our technology, but few. Our footprint literally extends over need support in financing it. the entire continent. MODERNIZING What does that mean for a technology What do you attribute that to? supplier? Bergmann: It’s based on the excellent Andrä: To win projects in Africa, it’s im- quality of our products and services, as Martin Andrä, portant to offer financing concepts and well as the fact that we keep working Chief Marketing Officer, Voith Hydro solutions. One of Voith’s advantages with our customers after a plant is com- that benefits our customers is that we missioned. We provide extensive train- MOUNT COFFEE can offer tailored financing solutions for ing for power plant operators and we projects. That’s why we work with pri- have our own network consisting of vate commercial banks and govern- maintenance facilities. mental export credit insurance compa- nies throughout the world. Andrä: We have always offered training programs and courses with our plants, Where can one find Voith Hydro tech- and that has helped us establish a very A significant hydropower plant T nology in Africa? good reputation in Africa. Now, we want modernization project is helping he digital age is finally reaching Liberia’s Mount Coffee Bergmann: There is a long list of Afri- to use our new concept to generate hydropower plant, thanks to Voith and its pivotal role in to improve Liberia’s power can hydropower stations equipped with added value for customers by providing this historic project, together with other international Voith technology. Installations extend solutions customized to their respective infrastructure following years companies. Built in the 1960s, this plant on the Saint Paul R iver from Aswan in Egypt to Drakensberg in needs. We have a global network and of civil war. was the West African nation’s largest at the time, but sustained South Africa. For example, Voith tech- are able to combine system compo- extensive damage during the civil war (1989-2003). And the nology is installed at Gilgel Gibe (Ethio- nents from Europe, Brazil, India, and path to ruin continued when looting ravaged the electrical and pia), Inga (Democratic Republic of Con- China with corresponding financing so- mechanical components, leaving only parts of the dam and the go), and Cahora Bassa (Mozambique). lutions. In this way, we can create the steel penstock intact. This proved to be a huge setback to the New projects include those at Cam- right package of technology, training, country’s economic and social progress, leaving Liberia’s capital bambe (Angola), Mount Coffee (Liberia), service, and fi nancing for any operator, city Monrovia reliant on costly, non-renewable diesel-power and the pumped storage power station regardless of their location and the size am wall under construction on the Saint Paul River, D generation to meet its energy needs from 2006 onwards. in Ingula (South Africa), to name just a of the hydropower station. // with the powerhouse on the right. 18 | HyPower 2016 HyPower 2016 | 19
AGENDA SETTING AGENDA SETTING “At the customer’s request, Voith took on the challenging task of opening the spillway gates without causing any damage to the civil structure and components. All ten gates were reopened ahead of schedule.” Harry Kathirvel 1 Project Manager Voith Hydro 2 3 4 Mutual trust is the prerequisite Kathirvel: “At the customer’s request, Voith took on the chal- Trust in Voith’s long-standing presence and vast experience on lenging task of opening the spillway gates without causing any the African continent was key to its selection by the Liberian damage to the civil structure and components. All ten gates Electricity Corporation (LEC) to rehabilitate the run-of-river were reopened ahead of schedule.” plant in 2013. Now, the huge task of successively installing Poor road conditions between the site and the Port of four new Francis turbines and generators equipped with con- Monrovia, which is about 25 kilometres away, posed a chal- trol technology, a 95-ton overhead crane, as well as the auxil- lenge to the transportation of sensitive equipment. Not only iary electrical and mechanical plant equipment is nearing com- that, the heavy rain from April to October further disrupted pletion. The plant is scheduled to commence operations in late operations. This meant that for certain plant systems, Voith 2016. had to commence with the design and manufacturing phases Financed by the Liberian and Norwegian governments, early enough to complete local transportation during the dry 1 Reservoir at the Mount Coffee hydropower plant in Liberia. the European Investment Bank, Germany’s KfW Bank, and season. The thorough and detailed work plan that addressed 2 The local community will benefit significantly. the Millennium Challenge Corporation of the US govern- all these challenges resulted in a flawless execution of the en- 3 Installation work at the Mount Coffee ment, the modernized units are forecast to raise power output tire supply chain, without a hitch. powerhouse. 4 Julia Holder, Field Service Engineer, to 88 MW, a 33 percent increase on the plant’s capacity in the Voith Hydro. 1960s. As a result, Monrovia’s population of over one million Road survey and simulation run for powerhouse crane will have access to reliable, clean and renewable energy. transportation One of the major hurdles that had to be factored in during the Acknowledgement by the President Overcoming significant challenges local transportation of the 95-ton powerhouse crane was a Bai- Voith’s long working tradition in Africa dates back to the However, the path towards rehabilitation has had its fair share ley bridge. Given its rusty condition, doubts arose about its 1950s, a factor that helped build up trust at the start of the of obstacles, such as the condition of ten spillway gates that structural integrity, and whether the bridge could withstand project. Together with the customer, LEC, a cohesive, vital, Mount Coffee were destroyed during the civil war. The operating mecha- such a heavy load. Furthermore, using an existing alternative one-team approach has been adopted. nisms to open the gates had been destroyed, leaving the pow- bridge that was being renovated was out of the question. To Moreover, not even unpredictable events such as the Hydropower in Mount Coffee erhouse flooded. Keeping the powerhouse dry became impera- prevent any risk to the powerhouse crane equipment, Voith spread of the Ebola virus in 2014, and a high incidence of ma- Installed capacity: 88 MW tive, and that meant reopening the gates so that a cofferdam carried out a thorough road survey and simulated transporta- laria in the team later on have thwarted the rehabilitation could be built to prevent water flowing into the powerhouse. tion over the bridge using dummy cargo. Based on the simula- works, which are on schedule, as Franz Bayrle, Site Manager, The Mount Coffee site is situated near the This daunting task was a major milestone in the reconstruction tion results, significant measures were implemented to ensure explains: “This year, we have had 35 cases of malaria in my Liberian capital, Monrovia. of the Mount Coffee power plant, says Project Manager Harry the bridge was up to the task. team alone. But work within the culturally diverse team who 20 | HyPower 2016 HyPower 2016 | 21
AGENDA SETTING AGENDA SETTING “Voith is supporting Liberia with an important step in the fight for the CONTINUOUS development of the Liberian COLLABORATION economy.” GIZ supports the German government and Ellen Johnson Sirleaf President of Liberia other organizations in executing energy generation projects in Africa and around the world. hail from Liberia, Pakistan, Indonesia, Germany, Norway The energy department of the German Association for International and Sweden, is going well. I’m very pleased with them. They Cooperation (GIZ) supports the German Federal Ministry for Economic have all fitted well into the work schedule.” Their performance Cooperation and Development and other organizations in identifying, 1 was even acknowledged by the President of Liberia, Ellen financing and executing new energy generation projects in over 120 rap- Johnson Sirleaf. When visiting the Voith headquarters in 2 3 idly developing countries. Projects using renewable energy sources such Heidenheim last year, President Sirleaf, who is also Liberia’s as hydropower are very much in focus, as Jens Burgtorf, Head of Nobel Peace Laureate, said: “I am delighted that Voith and Technology C ooperation for the Energy Sector at GIZ, explains. LEC have found a secure and pragmatic way for the further development of the project, despite the recently overcome Eb- How have energy projects in developing countries changed in ola epidemic. With this, Voith is supporting Liberia with an recent years? important step in the fight for the development of the Liberian “Today, our clients want integrated energy generation concepts that are economy and combating national poverty: with the repair of CO neutral. That’s a significant and very positive change but it also brings ² the Mount Coffee power plant, one of the key facilities in the challenges. Specifically, power supplied from some renewable sources Liberian energy supply network is being reconstructed.” such as solar and wind power is unpredictable. If the sun doesn’t shine, Another interesting aspect of the project is the contribu- or the wind doesn’t blow, power can’t be produced.” tion of the project’s female engineers, in an industry where women are under-represented. Julia Holder, Field Service En- How important is hydropower in this context? gineer, comments, “There is definitely a collaborative working “Hydropower's advantage is that it is stable. Pumped storage plants are atmosphere at Mount Coffee, and all the staff are friendly and particularly important because they can store energy that can be used to helpful. The fact that myself, two Norwegian engineers and fill the gaps when solar and wind resources fall short. In other words, many of the local staff are women is not really an issue. We hydropower can form a core, stable power supply that can then be have a good team spirit and always support each other.” extended through solar and wind-based power.” The final steps to success How does this relate to Africa in particular, and what are the challenges? On completion, the modernized plant will be fitted with “Hydropower is very significant in Africa because the continent is so large, Voith’s automation system, including a digital governor and and the grid infrastructure is so patchy, especially in rural areas. In every state-of-the-art control system. The training of skilled person- 1 Mount Coffee powerhouse under project, protecting and enhancing the livelihoods of the communities construction. nel is already underway and the first team of new LEC em- 2 A lathe machine operator inside Voith's on- affected, and ensuring enough water is available for multiple purposes are ployees being trained for eventual operation and maintenance site workshop. paramount. We work closely with all the parties involved to ensure that.” of the plant will arrive in Heidenheim in fall 2016 for further 3 Final adjustments being made to the generator. instruction. This is where they will become familiar with the What is the future for hydropower in Africa in your view? design software, and gain in-depth exposure to the scope of the “Small, localized hydropower projects that bring energy to people outside Mount Coffee plant, its machinery and workings, while the the large population centers and which use existing infrastructure will play finishing touches are being applied to this mammoth project an important part because they minimize the capital investment required. on site. Thanks to Voith and its project partners, it will fulfil They can also be completed faster, so people benefit from the power they President Sirleaf’s mission to improve the reliability and scope generate more quickly.” of Liberia’s electricity supply. // 22 | HyPower 2016 HyPower 2016 | 23
AGENDA SETTING AGENDA SETTING GLOBAL neers might notice signs of operational errors affecting the components they are replacing, and suggest some extra courses to get on-site engineers up to speed. In the case of a completely new TRAINING, plant designed and installed from scratch, Voith can offer more detailed and intensive training. This covers each technology, how it works and how it is integrated into the plant as a whole, then moves on to how to look after and LOCAL maintain the components correctly. Many organizations opt for extra train- ing to ensure they’re getting the best value and most reliable service out of their installation. BENEFITS Market maturity levels define needs Aside from the technical aspects, Voith HydroSchool training is structured dif- ferently depending on market maturity. North America and Europe are mature markets, where refurbishment of very Voith is committed to the transfer of in-depth old plants is key, and where the im- technological knowledge and skills to local pending retirement of baby-boomer employees, thereby securing the successful engineers makes knowledge transfer important. These markets are served operation of hydropower plants for generations well with public courses where several to come – in Africa and around the world. customers attend the same course. The Chinese market is younger – with 25-year-old hydropower plants where Customer staff members in a training Liberian capital, Monrovia. However, it from hydropower in combination with the “original” engineers are still working session at the Cambambe II hydropower was damaged during the course of two skilled engineers on site can really plant, Angola. and are actively training younger staff. civil wars. Liberia had been dependent strengthen the economic and social Here, operators can book seminars for on expensive diesel-generated power fabric of countries like Liberia.” staff with Voith’s subject experts to top since 2006, and Voith was tasked with up their knowledge. In contrast, Africa is renovating the plant, which is due to be More African projects underway a greenfield market with a lack of skilled put into service at the end of 2016. The Voith HydroSchool will also provide engineers. “In these cases, our training Voith developed special courses that training services following the implemen- With less than one in three Africans ity in the long run, which is a decisive fac- program can ensure a skilled work- Liberian engineers will complete before tation of the Cambambe II project in having access to electricity, it’s clear that tor for economic and social development. force,” comments Cherie Ferrari, Man- the plant is commissioned, an aspect Angola, and the Inga I installation in the there’s an urgent need for efficient pow- ager of Customer Education and Train- that proved to be of great interest to Democratic Republic of the Congo. er plants across the continent. But even Flexible approach to accelerate ing at Voith. “We often design Liberian President Ellen Johnson Sirleaf Cherie Ferrari adds: “Along with techni- the most modern hydropower plants progress completely customized courses tailored and her energy minister, Patrick Sendolo, cal training, we can also deliver mentor- can’t simply run themselves – they need Every project is different – in Africa, as it to the plant operator, staff, project and when they visited Voith headquarters in ing. At a recent pole replacement project teams of skilled people to manage and is everywhere else. That’s why the Voith even the actual equipment in use.” May 2015. “We’re looking forward to in Mozambique, we simply ‘shadowed’ maintain them. That's why Voith pro- HydroSchool offers a wide range of welcoming Mount Coffee engineers local engineers and helped them with vides training to the African companies training options. Hydropower plant op- Mount Coffee: challenges overcome to the HydroSchool training center some tips and tricks. That’s the main and governments who own and operate erators can order a selection of training The Mount Coffee project in Liberia is a in Heidenheim this fall,” notes Cherie point about the HydroSchool – training is the plants. Voith’s HydroSchool contrib- modules as part of their installation or case in point. This hydropower plant, F errari. “This project is an excellent always exactly what each individual cus- utes to the reliable production of electric- refurbishment project. Or Voith engi- built in the 1960s, is located close to the example of how reliable electrification tomer needs. One size doesn’t fit all!” // 24 | HyPower 2016 HyPower 2016 | 25
FULL-LINE SUPPLIER FULL-LINE SUPPLIER SMALL PROJECTS, 1 Manufacturing small hydro turbines in Vadodara, India. 2 Local technician inspects turbine quality. BIG RESULTS Small hydropower installations are often the only practical and economic option – but their impact can still be significant. A coastal country on the Indochina in Quang Ngai province and southwest Peninsula, Vietnam is one of Southeast of Quang Ngai City, the scope includes Asia’s fastest-growing economies. The supplying a complete set of equipment country’s numerous rivers are an impor- 1 for two powerhouses in cascade forma- tant transportation route with over 2 tion – Son Tra 1A and Son Tra 1B. The 17,700 kilometers of navigable water- 30-4 Quang Ngai Joint Stock Company ways – and they are also an important is developing the project. source of renewable energy. Vietnam has a theoretical hydropower potential Serving all of Asia of approximately 300,000 GWh annual- Voith’s manufacturing facilities in Vado- ly, 100,000 GWh of which is economi- in the Tu Mo Rong District. The con- PROJECT CAPACITY dara serve India, Nepal, Bhutan, Indo- cally viable. Until recently, just 15,211 tract’s scope involves the supply of tur- Dakpsi 2B 2 x 7 MW nesia, Laos and the Philippines. MW had been installed, leaving plenty bine and generator, automation, E-BOP, For instance, in April 2016, Voith Dak Ter-1 2 x 1.8 MW + 10 % COL of room for growth. M-BOP and supervision of installation commissioned the Kurhed project in Dak Ter-2 2 x 1.7 MW + 10 % COL and commissioning the project. The Himachal Pradesh, India; the installa- Thanh Thuy-1 2 x 6 MW + 10 % COL Small hydro success in Vietnam system and component engineering of tions at Behna and Gullu are slated for Alin B1 As part of the new Renewable Energy the turbine was undertaken by Voith’s commissioning in late 2016. hydroelectric Development Strategy 2030, unveiled local engineering center, and the tur- project 2 x 23 MW + 10 % COL Meanwhile, in the Philippines, the in December 2015, the Vietnamese bines were manufactured in Vadodara, Son Tra 1A 2 x 18 MW Lake Mainit project is being built on the government has prioritized renewable India. This was the first pilot project us- northeastern section of the island of Son Tra 1B 2 x 18 MW energies and plans to increase hydro- ing the cost-effective Standard Small Mindanao. Voith has also supplied the Kurhed 2 x 2.25 MW + 10 % COL power generation from 56 TWh in 2015 Hydro Automation Scheme. This electromechanical equipment for Asiga, Behna 2 x 2.5 MW + 10 % COL to 90 TWh in 2020. Voith Hydro Private scheme combines the functions of digi- menced in April 2014, and since com- Voith was also chosen to work on also located in Mindanao. Gullu 2 x 12 MW + 10 % COL Limited, based in Vadodara in north- tal governor, control system, and exci- missioning in September 2015, both Dak the Alin B1 hydroelectric project in And in Indonesia, the supply of Lake Mainit west India, which launched in the Viet- tation and protection system in one Ter-1 and Dak Ter-2 have been perform- March 2016, following a tough bidding equipment for the Semangka project is project 3 x 8.333 MW + 10 % COL namese market in 2011, is supporting common panel, and delivers it within a ing to the customer’s full satisfaction. process. Located in the A Luoi and underway, as well as installation of the Asiga 2 x 4 MW the country in building and renewing its compact solution. Both units in the A contract for Thanh Thuy-1 was Phong Dien districts, this is the com- turbine components. The project is due Semangka 2 x 28.3 MW + 10 % COL hydropower infrastructure, which fea- project were handed over to the cus- signed in May 2015 with twin-jet Pelton pany’s seventh successful Vietnamese to be commissioned in 2017. tures a large number of relatively small- tomer in February 2015, leading to a turbine generating sets and complete project, which is being developed in co- Importantly, all of Voith’s activities scale installations. This commitment is third project, Dakpsi 2B, being recently water-to-wire scope. Thanh Thuy-1 operation with Truong Phu Hydropower in the region are driven by close cus- reflected by numerous already commis- awarded to Voith Hydro. H ydropower Joint Stock Company Joint Stock Company. tomer relationships, and regular face- sioned projects and others which are Meanwhile, the contract for Dak selected Voith to deliver all the power And finally, another recent impor- to-face meetings between customers currently underway. Ter-2, which is in the cascade of the plant equipment at Haiphong port with- tant milestone was the securing of a and senior Voith managers. This dem- Dak Ter-1 was the first project com- Dak Ter-1 project and on a similar scale, in 14 months of the commencement contract for the Son Tra 1 project in April onstrates the company’s commitment missioned by Voith in Vietnam, located was signed in October 2013. Work com- date, followed by commissioning. 2016. Located on the Dak Se Lo River to hydropower projects of all sizes. // 26 | HyPower 2016 HyPower 2016 | 27
FULL-LINE SUPPLIER FULL-LINE SUPPLIER Preparing a bid for a large hydro- laboration,” adds Bulota. It was a real power facility is a major project in its marathon, but it paid off in the end!” own right. It requires patience, attention to detail, and investment. According to A strong foundation for success Björn Reeg, Voith Hydro’s Head of Pro On the other side of the world, another ject Management, constructing a scale large-scale project is taking shape that prototype of the plant is often the first also relies on close collaboration. The step. “The miniature version helps us to Wudongde hydropower station is the optimize and to achieve the required fourth largest in China and its turbine performance and efficiency.” The team generator units will be amongst the assesses the project’s technical feasi largest worldwide in terms of power bility and finds the right balance be output. Zhang Min, project manager of tween efficiency, longevity and perfor Voith Hydro Shanghai for Wudongde, mance. echoes the experience of Björn Reeg Working on a project that takes a and Laurent Bulota. “We won this pro decade to complete is normal for Reeg and his team. “The assessment pro “Outstanding change management skills and cess takes time, because there are so many factors – the country and its regu reacting quickly to unexpected events are vital, lations, the plant’s location and logisti because unpredictability is a given.” cal needs, and all the technical and Björn Reeg customer-related specifics. The longest Head of Project Management, Voith Hydro project I’ve worked on was Iberdrola’s La Muela II installation in Spain – it took Voith Hydro in Montreal. “Several of the ject because we built a good relation eight years! Even after all that time, customer’s criteria were soft factors like ship with the customer and because we 1 despite some delays outside of our customer references and methodologi had access to global expertise from 2 control, the customer was delighted cal details.” The team then performed across the Voith Group,” he says. with the project management. I’m very several simulations to optimize the bal In fact, the recipe for success in MEETING proud of that.” ance between the units’ performance, large hydropower projects is quite simi “I think there are four key criteria for the amount of rock to be excavated out lar wherever the site, as Zhang con ensuring the success of a large-scale of the river and the Amount of concrete cludes: “This project is already pro project,” says Reeg. “A good relation in the plant. The entire offer process gressing well and we are very focused THE LARGE ship with the customer is probably the took over three years, culminating in the on achieving the best result for the cus most important – without that, every contract signature in March 2016. tomer. Diligence, confidence and great thing else is more difficult. Outstanding “When BC Hydro awarded us the con teamwork: that’s the secret to succeed change management skills and re- tract, they thanked us for the close col ing in large projects.” // HYDRO acting quickly to unexpected events are also vital, because unpredictability is a given. Thirdly, leadership skills, espe cially the coordination and manage CHALLENGE ment of multinational and multicultural 1 The cavern of the world's third-largest hydropower plant at Xiluodu on the Jinsha teams. And of course, quality – our River, China. Voith delivered three of the reputation depends on it.” 18 machines for the site, which has a total capacity of 13.86 GW. 2 A Voith employee inspects the installation Close collaboration Today, major hydropower projects involve to ensure maximum quality. In Canada, a project for BC Hydro at Site C, a large-scale plant on the Peace combining components that arrive from River in British Columbia, provides a all over the world. Optimizing speed, good example of transferring this theory quality and cost-efficiency is a tough into practice. “We set up a project team Iberdrola’s La Muela II installation in Spain to work solely on this offer,” says took eight years to complete. balancing act. Laurent Bulota, Head of Proposals at 28 | HyPower 2016 HyPower 2016 | 29
FROM THE ARCHIVES FROM THE ARCHIVES TRUE plans for the construction of an irrigation system to serve technique was developed for this: high-voltage direct-current huge agricultural areas. A total of 15,000 km² was supposed to transmission. With this new technique, the engineers were able be harnessed for the cultivation of fruits for export. And the to cut the transmission costs in half. revenue generated from this was intended to boost economic SURVIVOR development. Independence without peace However, there were also dissenting voices and protests. In April 1974, the “Carnation Revolution” in Portugal ended The Mozambican freedom movement Frelimo, which had the Caetano dictatorship and also paved the way for the inde- been fighting for political freedom from Portugal since 1964, pendence of the colonies. Mozambique became independent criticized the project, as did various student movements across in 1975. Frelimo became the ruling party and began to support Europe. Their argument was that Cabora Bassa would only the construction of the power plant. The first expansion stage “Cabora Bassa” – a name that demands benefit the apartheid regime in South Africa and the dictator- with 1,224 MW capacity was completed as planned and the superlatives: a 164-meter-high dam wall ship in Portugal. During the construction and installation pe- hydropower plant began commercial operation on 26 March riod, civil war and violence dominated the country. The con- 1977. In June 1979, the last expansion stage was completed on the Zambezi River; a 250-kilometer- struction site and the camp, which housed more than 3,000 and Cabora Bassa was finished on schedule after 10 years of long reservoir lake; a 1,500-kilometer-long engineers and construction workers at the time, had to be se- construction. high-voltage line between Mozambique cured by the military. The political turmoils on the Zambezi, however, were not over yet. Now the guerrilla movement Renamo, supported by and South Africa; and a total power output Technical innovation lowers costs the South African apartheid regime, began fighting the Marxist- of 2,075 MW. In the meantime, the engineers were mastering technical chal- Leninist Frelimo government. What followed was a bloody, lenges. They erected a six-kilometer-long overhead line from 16-year-long civil war. Around 900,000 people died and 1.7 mil- the platform at the cavern surface to the Songo plateau 600 me- lion fled the country. Renamo also repeatedly attacked the infra- M ozambique was still a colony when the tender was ters above it, and connected it to a three-phase current substa- structure at Cabora Bassa, which became a ruin. Only in 1997, sent out for the construction of a hydropower plant tion and a converter station. Here, 220 kV three-phase current after the end of the civil war, was Cahora Bassa (as it is spelled on the Zambezi River in November 1967. The Por- was converted into 533 kV direct current for transport. A new today) repaired and returned to operation. // tuguese “Minister for overseas territories” was planning “Cab- ora Bassa” as the largest hydropower plant in southern Africa. 1 Manufacturing the turbines for Cabora Bassa Five turbines were meant to generate the electricity that was at the factory in Heidenheim. largely intended to be sold to South Africa. For electricity 2 The efforts of local workers were key to completing the plant on schedule. The spectacular dam on the Zambesi following transmission, a 1,500-kilometer-long high-voltage line was completion in the late 1970s, before it was ruined 3 New roads and tunnels were constructed to provide during the civil war. built between the site and Pretoria. easier access to the dam site during construction. In September 1969, roughly two years after the tendering process began, the contract for the underground hydropower plant was awarded to an international consortium that includ- TECHNICAL DATA ed Siemens, Voith, AEG, BBC and the construction company Hochtief – all German companies. Voith provided the five 5 Voith Francis turbines with 415 MW each; turbine runner diameter: 7 m Francis turbines for Cabora Bassa. While the turbines were being constructed in Heidenheim, robust roads and bridges Dam Wall: were built in Mozambique so that machines and equipment height: 164 m could be transported to the construction site. On the high 1 width at the base: 23 m plateau, a runway for propeller-driven aircraft was built, and 2 3 width at water level: 4 m the region was equipped with a new telecommunications and telex system. 103.5 METERS HEAD Ambitious goals versus critical voices 5 generators with 480 MVA each; The Cabora Bassa construction site was situated at the end of rotor diameter: 13 m a gorge that is 18 kilometers long, 250 meters wide and 700 meters deep. Ambitious goals were attached to the construc- Cavern: tion of the reservoir and power plant. The Zambezi had been length: 220 m made navigable over a length of 320 kilometers in order to al- height: 57 m low for the transport of natural resources such as coal, iron, width: 29 m titanium, manganese, chromium and bauxite. There were 30 | HyPower 2016 HyPower 2016 | 31
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