May 2003 ISSUE TONGBAI Page 4/5 COMPACT HYDRO in ...

May 2003 

ISSUE 

04 

sustainable solutions. for a better life. 

www.vatech-hydro.com 

TONGBAI Page 4/5 

COMPACT HYDRO in NORWAY Page 12/13 

ANKARA Page 20/21/22

Imprint 

2 

Customer magazine of VA TECH HYDRO 

Publisher & editor: VA TECH HYDRO GmbH&Co, 

A-1141 Vienna, Penzinger Strasse 76, Austria 

Phone +43/1 89100 - 2053, Fax 196 

Responsible for the content: Folker Bocksch, 

Pierre Duflon, Anna Kien, Rudolf Langer, Ursula Scheidl, 

Georg Schroeder, Susanne Schröder, Kurt Wolfartsberger; 

Copies: 19,000 

INTRODUCTION 

TECHNOLOGY 

TONGBAI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4/5 

KEY PROJECTS 

HIGHLIGHTS 

COMBINED CYCLE 

INFO 

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 

KAPRUN . . . . . . . . . . . . . . . . . . . . . 6/7 

CAPIM BRANCO II . . . . . . . . . 8 

DA PU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 

MILLARES II . . . . . . . . . . . . . . .10 

GRAND VERT . . . . . . . . . . . . . . . . . 11 

COMPACT HYDRO 

IN NORWAY . . . . . . . . . 12/13 

TALAVERA & PALOMAREJO 

PORTODEMOUROS . . . . . . . . . 14 

ECOBulb NEWS . . . . . . . . 15 

. . . . . . . . . . . . . . . . . . . . . . .16/17/18 

LINZ. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 

ANKARA . . . . . . . . . . . . . . . . . . . . . 20/21/22 

EVENTS / FAIRS 

KIRIS / TURKEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 

EDITORIAL 

The New Challenges 

The significance of traditional 

"mass marketing” as a factor of 

corporate success has decreased 

dramatically over the past few 

years. Sales divisions, which play 

a special role during times of economic 

difficulties, are also faced 

with new challenges. As a result of 

the liberalisation of the power markets 

this holds true in particular for 

our industry. 

Marketing concepts need to focus 

to a much greater extent on the 

concrete definition of customer 

benefits. We understand our customer 

magazine not only as a 

source of information but seek to 

provide customized communications. 

We strive to offer variety without 

being superficial. You should 

see VA TECH HYDRO with all our 

products and services not as an 

anonymous and obscure organisation 

but as a fully transparent 

group of companies with dynamic, 

flexible processes, run by competent 

people. 

We would like to know your requirements 

and expectations with respect 

to our customer magazine. 

For this reason, we appreciate 

your feedback in our effort to improve 

our magazine and to continuously 

refine individual customer 

ties. This knowledge will help us to 

realise target-oriented communications. 

Thank you very much in advance 

for your feedback. 

contact@vatech-hydro.com

Dear Readers, 

In this issue of Hydro News we examine the latest innovations and 

projects in hydropower. 

Despite the difficulties of last year’s 

market conditions, VA TECH HYDRO 

managed to attain its targets and 

strengthen its position as one of the 

leading players in the industry, securing 

a substantial number of orders 

in strategic divisions such as 

Large Hydro, Hydro Service, Combined 

Cycle and Compact Hydro. 

We have also reaffirmed our substantial 

role in the European market 

through our EPC activities for combined 

cycle power plants. 

Over the coming year the electricity 

market will continue to face challenges 

from the sector’s deregulation 

and commitment to Kyoto 

targets. Hydropower’s worldwide 

contribution to renewable energy is 

now approx. 95% and during the 

Johannesburg summit last year it 

was agreed that all hydropower, not 

just small hydro, is applicable for 

Kyoto accreditation in terms of renewable 

energy. 

At VA TECH HYDRO we will continue to 

promote the value of hydropower in 

reaching the Kyoto Agreement’s 

targets, emphasising the balance 

between a healthy economy and 

ecology. Over the next year we are 

committed to: 

• Develop new business opportunities 

approaches with emission 

trading certificates 

• Continue new products and services 

innovation for power plants 

and for the rehabilitation/servicing 

of older plants 

• Liaise with business partners for 

‘tailor-made’ solutions 

• Pursue involvement in the Hydropower 

Equipment Association 

(HEA) founded by VA TECH HYDRO, 

Voith Siemens and Alstom, in 2001 

and continue our collaboration 

with the International Hydropower 

Association (IHA). 

We would like to take this opportunity 

to thank all our business part- 

INTRODUCTION 

ners for contracts, close co-operation, 

performance feedback and for 

hydropower promotion, ensuring 

hydropower remains at the forefront 

of renewable energy. 

Best regards until the next issue, 

Christian Habegger 

Chairman of the Board 

Alfred Friedinger 

Member of the Board 

Franz Strohmer 

Member 

of the Board 

Helmuth Tschabuschnig 

Member of the Board 

3

TONGBAI 

4 

TECHNOLOGY 

Pump Turbine Model Development and Acceptance Tests 

Successfully Completed 

Having checked and verified the 

hydraulic design and resulting 

performance characteristics 

and data by means of witnessed 

model acceptance tests in the 

laboratory of VA TECH HYDRO in 

Zurich, in November 2002 the 

customer officially accepted 

and released the hydraulic profile 

for the final design of the 

prototype pump turbines. 

The contract for the new pumped 

storage power plant TONGBAI, 

comprising the complete electromechanical 

equipment for the 4 x 

334 MVA units including the control 

system, was awarded to VA TECH 

HYDRO in January 2002 (for more 

detailed information see HYDRO 

NEWS 03/2002). 

Based on the pre-design studies to 

support the bid data, the final 

hydraulic design and optimization 

of the pump turbine components 

were started early in 2002, using 

three-dimensional (3D) numerical 

tools for Computer Aided Design 

(CAD) of spiral casing, stay vanes, 

guide vanes, runner and draft tube. 

For simulation of the flow pattern in 

the stationary cascades during turbine 

and pump mode, 3D Navier 

Stokes computations were applied 

to minimize hydraulic losses and to 

optimize the profiles of stay vanes 

and guide vanes. Special attention 

was paid to the runner design to 

achieve cavitation free operation 

during normal pump operation. In 

view of smooth operation and a low 

level of pressure fluctuations, it was 

important to obtain a good flow interaction 

of the runner with the distributor 

and the draft tube. 

According to standard practice, 

simultaneously the mechanical design 

of the blade profiles was 

The pump turbine model installed on the test rig in Zurich 

checked to guarantee that the admissible 

limits of stresses and deformations 

were respected. This 

also goes for the guide vane profile 

and the location of its pivot, where 

it was essential to get torque characteristics 

with low maximum and 

minimum values. 

Early in 2002 also design and manufacturing 

of a homologous model 

pump turbine started, related to the 

prototype machine by a scale factor 

of 1:11.93, so that an outer model 

runner diameter of 402.5 mm resulted. 

First model test results were produced 

in June, and after a rather 

short period of runner fine-tuning, 

the model was ready to start contractual 

tests as per customer’s 

technical specification. Early in 

September the preliminary test report 

was submitted which included

the results of the following test series: 

hydraulic turbine and pump 

performance characteristics, 4quadrant 

characteristics including 

runaway and pump zero discharge, 

cavitation pattern, pressure fluctuations, 

guide vane torque, hydraulic 

thrust. From October 8 until Novem- 

Flow particles passing the guide vanes and the stay vanes, 3D view from runner side 

Pump turbine runner with streak lines of the flow 

ber 7, 2002 a customer delegation 

of 10 persons, supported by a consulting 

engineer from Lahmeyer 

International, spot-checked, verified 

and witnessed test results, calibration 

of instruments, data processing 

and geometry of the model components. 

Both the customer and the 

consulting engineer were very satisfied 

with the high performance 

achieved with the TONGBAI design 

as well as with the quality of model 

measurements. The TONGBAI development 

and model test activities 

were successfully completed in 

February 2003 with the submittal of 

the final version of the Final Model 

Test Report. 

Peter Bachmann 

Phone +41/1 278 2479 

peter.bachmann@vatech-hydro.ch 

Manfred Sallaberger 

Phone +41/1 278 2772 

manfred.sallaberger@vatech-hydro.ch 

Technical data: 

Output: 306 MW / 334 MVA 

Voltage: 18 kV 

Head: 287.6 m 

Speed: 300 rpm 

Runner diameter: 4,802 mm 

Stator diameter: 9,200 mm 

5

KAPRUN 

Kaprun, once the symbol of Austria’s 

reconstruction after the Second 

World War and one of the first hydropower 

plants put into operation, 

is currently under rehabilitation. 

Among other tasks, the four exposed 

penstocks are being replaced by one 

steel lined pressure tunnel – and 

VA TECH HYDRO is once again a major 

contractor. 

The first two penstocks were already 

built during the Second World War and 

were put into operation in 1944. The 

other two penstocks, for which a contract 

was awarded in 1949, were supplied 

by VÖEST Stahlbau, our predecessor 

company. These Kaprun 

penstocks were one of the first references 

our company gained in this field. 

Since age resistant materials were not 

available at the time of construction of 

the first two penstocks, operation of 

these is now limited to mid 2004 under 

condition of earliest replacement. For 

economic reasons but also to meet today’s 

environmental requirements the 

owner decided in favour of a steel lined 

pressure tunnel. This pressure tunnel is 

designed for a 25% higher discharge to 

serve also a future 5th turbine. In mid- 

2001, Verbund Austria Hydro Power 

awarded a contract for the supply and 

6 

KEY PROJECTS 

installation of the new steel tunnel lining 

and manifold to VA TECH HYDRO. 

VA TECH HYDRO´s scope of deliveries 

mainly comprises a 60 m upstream 

connecting branch between the existing 

pressure tunnel and a new valve 

chamber, a 1,015 m long and 45 de- 

grees inclined steel tunnel lining of a 

diameter of 2.6 m, a 265 m horizontal 

tunnel lining and the new manifold with 

connections to the existing four turbines, 

including one branch-off for a future 

5th turbine. Materials used in this 

project are thermomechanically rolled

steels with yield points from 355 to 550 

MPa and quenched and tempered 

S690Q steel. The total weight of 

VA TECH HYDRO’s scope of deliveries 

comes to some 2,012 tons. The whole 

construction time, including tunnel excavation, 

is only 33 months. During 

most of the time the power plant has to 

be kept operative, and it will be shut 

down for the last nine months of construction 

only. During this rather short 

time, all civil works, pipe installation 

and paint work necessary for connecting 

the new power conduit with the remaining 

structures, have to be completed 

– a real challenge for all parties 

involved in the project. Installation of 

the steel tunnel lining commenced in 

July 2002. It started with a section at 

the downstream end of the inclined 

shaft, followed by parallel work towards 

the upstream tunnel portal and the 

powerhouse. In the inclined shaft 12 m 

pipes are installed. For transport reasons, 

however, only 6 m pipes can be 

prefabricated. These sections are 

transported from the powerhouse to 

the upper valve chamber by means of a 

cable car, running parallel to the existing 

penstocks. In the area of the valve 

chamber, and directly on top of the upper 

tunnel portal, a temporary winterproof 

workshop has been installed. 

There, the 6 m pipes are assembled and 

welded to form erection units of a 

length of 12 m. For welding the field 

joints inside the tunnel once again the 

fully automatic TIG-HW welding technique 

is applied. This technology was 

adapted by VA TECH HYDRO for steel 

tunnel linings and was successfully 

used for the first time in the Goldisthal 

project in Germany. In the light of an accident, 

which recently occurred in a hydropower 

plant in Europe, highest attention 

is paid to material, welding and 

quality assurance. The client has 

placed special and very strict reguirements 

for welding and non-destructive 

testing. But there is no doubt that all 

these conditions are met to the full satisfaction 

of the client. VA TECH HYDRO 

subcontracted manufacture of the 

pipes to the Linz facility works of MCE 

VOEST, and, for capacity reasons, 

some parts to another MCE daughter 

company. MCE VOEST, our traditional 

partner in the field of hydromechanical 

equipment, is executing the installation 

under the overall responsibility of 

VA TECH HYDRO. All activities are well 

in time and the contractual completion 

in June 2004 is secured. With this contract, 

VA TECH HYDRO sets another 

milestone in its history of high-head 

penstock construction. 

Roland Starnberger 

Phone +43/70 6987 8805 

roland.starnberger@vatech-hydro.at 

7

CAPIM BRANCO II 

Three VA TECH HYDRO Kaplan Turbines for a New Hydropower Station in Brazil 

The twin project Capim Branco I&II, 

located in the western part of Minas 

Gerais, is part of Brazils current 

power development program, which 

covers the construction of several 

medium sized power stations 

through a well defined privatization 

process. VA TECH HYDRO has signed 

a contract for supplying, installing 

and testing turbines and generators 

for Capim Branco II as well as 

control systems and electrical auxiliary 

systems for both power stations. 

Despite current economic problems, 

the economy in Latin America´s largest 

country continues to perform in a relatively 

stable way compared to most 

other states in the region. Consequently, 

Brazil remains a target market for 

VA TECH HYDRO, the newly awarded 

contract for Capim Branco I&II represents 

an important step forward. The 

customer consortium is lead by Companhia 

Vale do Rio Doce (CVRD), an 

important mining company in Minas 

Gerais. Co-owners are the federal 

state´s local electric utility CEMIG as 

well as C.A. Paneiras and Companhia 

Mineira de Metais. CVRD is already well 

known to us as lead customer of the 

8 

CAPIM BRANCO 

KEY PROJECTS 

Candonga project which currently is 

under execution with VA TECH HYDRO 

as supplier of the complete electromechanical 

equipment. The project has 

gone through a public auction in November 

2000 based on previously performed 

basic studies. CVRD turned out 

to be the successful bidder for the concession. 

Two consortia were competing 

for the Engineer Procure Construct 

(EPC) contract, the successful one was 

lead by the Brazilian civil company Andrade 

Gutierrez, who joined with Odebrecht 

and Queiros Galvao. Within the 

E&M group, it has been agreed that the 

main equipment for Capim Branco I 

(three Francis groups) will be supplied 

by Voith Siemens and for Capim Branco 

II (three vertical Kaplan groups) by 

VA TECH HYDRO. During bidding and 

optimization, various alternatives have 

been studied, comparing different 

combinations of Kaplan and Francis 

turbines. The overall economic comparison 

resulted in the choice of three 

vertical Kaplan turbines for Capim 

Branco II, while Capim Branco I power 

plant remained with the originally 

planned Francis units. Further, the originally 

planned concept with one common 

penstock was replaced by individual 

penstocks, saving the huge 

trifurcator and the turbine inlet valves. 

The EPC contract was signed in October 

2002 and put into force in April 

2003. The plant is scheduled to gener- 

ate power in 2006. VA TECH HYDRO 

did model development and internal 

testing in their test laboratories specifically 

for this project prior to the contract 

start. The VA TECH HYDRO project 

team consists of team members in the 

Sao Paulo, Ravensburg and Vienna offices. 

As the scope share is mainly local 

with minimized import portion due to 

currency reasons, the overall lead is with 

the local project manager in Sao Paulo. 

Oscar Gonzalez 

Phone +49/751 83 3196 

oscar.gonzalez@vatew.de 


Output: 72 MW 

Voltage: 13.8 kV 

Head: 48 m 

Speed: 163.6 rpm 


Stator diameter: 6,800 mm

DA PU 

VA TECH HYDRO was awarded a 

new contract for the electromechanical 

equipment for the 

run-of-river power plant at Da Pu, 

Guangxi province. This continues 

a line of success for bulb turbines 

and generators including plant 

equipment in China. 

The run-of-river power plant Da Pu 

has an installed capacity of 93 MW 

and is located on the river Liu close 

to the city of Liu Zhou in the 

Guangxi Zhuang Autonomous Region 

in the south of China. Our customer 

is the Instrimpex Equipment 

Import and Export Corporation and 

the enduser is Guangxi Liuzhou 

Guiliu Hydropower. The contract 

was signed in Beijing on May 16, 

2001, and came into force on September 

13, 2002. VA TECH HYDRO 

had already followed this project 

since 1993 and final negotiation of 

the contract was concluded in 2001. 

During this rather long period the 

preliminary design was done and today 

civil construction is already at a 

very advanced stage. 

VA TECH HYDRO’s scope of supply 

consists of: 

• three horizontal shaft Kaplan bulb 

turbines including electronic 

speed governors of the digital type 

• three bulb generators 

• generator switchgear 

• excitation 

• protection 

• control and automation systems 

The design of the turbines and generators 

– both components of Austrian 

origin for financing reasons – 

as well as of the electrical balance 

of plant equipment is in full swing in 

Linz, Vienna, and Beijing. Liaison 

meetings with the responsible people 

of the Chinese partners coming 

from the Guangxi Water & Power 

Design Institute as well as from the 

client are taking place just now. 

Companies in China will manufacture 

the embedded steel components. 

The turbine governors as well 

KEY PROJECTS 

as control and automation systems 

are to be provided with the new 

NEPTUN technology developed by 

VA TECH HYDRO. 

Supply of the main equipment will 

start already in 2003 and the installation 

and commissioning of the entire 

plant is scheduled for 2004. By 

the end of the year 2004 the power 

station has to be on line. That’s a 

big challenge because meeting the 

short time schedule will need a lot 

of coordination and flexibility of all 

parties involved. 

This hydropower station will not only 

supply necessary electricity to the local 

power grid, it will also improve the 

flood protection of the entire region. 

This project will also contribute substantially 

to the irrigation of the surrounding 

agricultural area as well as 

improvement of navigation on the Liu 

river. 

Gottfried Seisenbacher 

Phone +43/70 6987 2842 

gottfried.seisenbacher@vatech-hydro.at 


Output: 30.7 MW / 32.6 MVA 


Head: 10.8 m 




9

MILLARES II 

The Most Important Project in Spain Commissioned in 2002, for the Most Important 

Spanish Hydro Utility - IBERDROLA 

Millares II hydropower plant was 

recently successfully finalized 

and commissioned in the summer 

of 2002. 

The most important hydroelectric 

project carried out in Spain in the 

past years, Millares II was built by 

Iberdrola in the eastern region of 

Spain, province of Valencia. Iberdrola 

is one of the Global Key Accounts 

of the VA TECH group, not 

only for its importance as the leading 

utility in the hydro electrical field 

in Spain and also in Europe, with 

50% of the installed power in hydro, 

but also as an active investor 

abroad, especially in Latin America. 

Their 8,000 MW installed power 

(200 stations, 400 units) represent 

50% of the total installed hydro capacity 

in Spain and 10% of the total 

in the European Union. 

VA TECH HYDRO in Madrid has 

been a traditional supplier of Iberdrola 

for years, for new plants and 

service work, always keeping an excellent 

relationship with this client 

and having collaborated in many 

other important projects in the past. 

As a result of Iberdrola´s confidence 

in the reliability of our company, 

VA TECH HYDRO was awarded a 

10 

KEY PROJECTS 

contract for the supply of all 

electromechanical equipment for 

Millares II including: 

• 2 vertical Francis turbines 

• 2 butterfly valves 

• 2 governor systems 

• 2 downstream gates 

• 2 penstocks ( Ø 2,500 mm ) 

VA TECH HYDRO in Spain provided 

the entire engineering for this scope 

of supply and the turbines were 

completely manufactured at the 

workshop in Madrid, with excellent 

results in all shop tests carried out 

by the inspection service teams from 

Iberdrola. The two penstock linings, 

with vertical portion, elbows, transition 

pieces and conical sections 

and the downstream gates were designed 

by VA TECH HYDRO in Spain 

and then approved by Iberdrola Engineering 

and manufactured by in 

subsuppliers at their workshops with 

quality control inspection by us. The 

butterfly valves were also designed, 

manufactured and shop tested by 

VA TECH HYDRO in Spain. They 

have a special double seal system 

(service and maintenance seal) as 

requested by the client. 

Finally, VA TECH was responsible for 

the supervision of site installation 

and the final commissioning of all 

equipment, successfully completed 

in the summer of 2002. 

Alejandro Santamaría 

Phone +34/91 425 10 19 

alejandro.santamaria@vatech-hydro.net 


Output: 31 MW 

Head: 223 m 


Runner diameter: 1,750 mm

GRAND VERT 

The improvement of operational 

efficiency and the benefit of 

Green Certificates as decisive 

factors for the rehabilitation of 

existing plants. 

The HPP Grand Vert, which is 

equipped with two vertical Kaplan 

units, is part of the SOCIETA’ 

IDROELETTRICA DI DONNAZ and is 

located in the beautiful valley of the 

Italian region of Valle d’Aosta. Since 

1940 it has been using the water of 

the Dora river to produce about 

44 GWh/year of energy. During its 

lifetime it has suffered damage by 

several floods, the last of which occurred 

in the winter of 2001 when 

the plant was totally flooded. 

Taking into consideration the effects 

of these injurious events, the 

client has decided to launch a rehabilitation 

project not only with the 

aim of extending the technical life of 

the equipment and improving safety 

aspects, but also with the target of 

raising profitability through better 

performance and higher availability. 

The necessity to improve the environmental 

impact was also a very 

important consideration in this 

beautiful area. 

At the beginning of 2002 the client 

awarded VA TECH HYDRO in Schio 

a contract for the total rehabilitation 

of the two Kaplan turbines including 

new governing systems and electrical 

equipment for the units. 

In the meantime, in March 2002, 

the Italian regulations concerning 

Green Certificates provided new assessment 

criteria, with interesting 

economical benefits with respect to 

energy tariffs in the case of a total 

renovation of the turbine-generator 

units. 

This opened up a new scenario in 

the investment evaluation of the 

Grand Vert project, which led the 

client to extend the project to 

KEY PROJECTS 

How to achieve additional profitability from a 60 year-old power plant through a 

suitable rehab intervention 

include the replacement of the turbines 

and the generators. Together 

with the client it was examined how 

this should be performed without losing 

the already ongoing rehabilitation 

work. 

In order to minimize plant downtime 

and to improve the profitability of 

the investment, the client asked us 

to draw up a very challenging 

timetable for the site work. It was 

decided to carry out the dismantling, 

erection and commissioning 

of the two units simultaneously 

with some civil works on the upstream 

channel in the winter of 

2003-2004. It is planned that the 

two renewed units will be operational 

by the end of March 2004. 

Aldo Cateni 

Phone +39/0445 678238 

aldo.cateni@vatew.it 


Output: 3.8 MW / 4.8 MVA 

Voltage: 6 kV 

Head: 11.86 m 




11

12 

KEY PROJECTS 

Compact Hydro in Norway 

After a long period of very low 

project activity, Norway’s small 

hydro market started to boom 

around the year 2000. Since 

then, more and more projects 

have become reality. A growing 

demand for electricity as well 

as rising energy prices make 

many of the sites feasible even 

though subsidies are not available 

for small hydro as in many 

other European countries. 

With a population of about 4.5 million 

people, Norway is facing a very 

difficult infrastructure: the very low 

population density combined with 

steep mountains of extremely hard 

rock and fjords reaching deep into 

the land seems to make the supply 

of electricity quite difficult. In addition 

to a few larger energy firms, 

there are about 200 small utilities 

distributed over the scattered settlements 

of this stretched country. 

Compact axial turbine at site assembly. Although Norway’s hydro generation is dominated 

by Francis turbines, the eastern utilities call for axial turbines. 

Nevertheless, Norway’s welfare is 

based on its tremendous resources 

of oil and gas - and hydropower. 

To be successful in the Compact 

Hydro business in Norway local 

presence is required. Today we can 

already look back to the co-operation 

with our Norwegian affiliates. It 

was Sulzer Hydro of Kriens that 

started a strategic alliance with 

Møller Energi in the year 1995, in the 

field of service and rehab. With a 

staff of some 90 employees, Møller 

Energi in Jevnaker had locally been 

well known in the field of hydro turbines 

and steelworks. This co-operation 

soon proved successful and 

was finally turned into an ownership: 

today this company is named 

VA TECH HYDRO AS. 

For more than two years, a co-operation has 

been maintained in the Compact 

Hydro segment between VA TECH HYDRO 

in Ravensburg and VA TECH HYDRO, 

Jevnaker. At the beginning the two 

parties had to find out how to divide 

the range of products and services 

most efficiently between them as 

Norwegian customers request 

turnkey “Water to Wire” deliveries. 

Usually, Ravensburg supplies turbines, 

valves, generators, turbine 

and generator control, and commissioning. 

Jevnaker completes the 

scope with penstocks and gates, 

cooling water systems, transformers, 

MV switchgear, balance of 

plant, project co-ordination, and 

erection. According to Jevnaker’s 

previous references, they sometimes 

also provide turbines designed 

in-house. 

Besides local presence there are of 

course some more factors essential 

in winning a project. Speaking of 

rules and ethics of tender evaluation, 

Norwegians are the most cor-

ect people you can imagine. For 

that reason it is definitely the bid 

that counts. After bid submission 

there is very little room for correction 

of performance, scope and 

prices. Client and consulting engineer 

usually select one or two companies 

within a very short time. The 

supplier will either find himself on 

the negotiation table very soon or 

won’t hear anything at all... 

The co-operation in the field of 

Compact Hydro is now increasingly 

bearing fruit. 

During 2002, VA TECH HYDRO Jevnaker 

could secure three orders in 

Norway with Compact Francis Turbines: 

Kolfossen, Stølsvann and 

Vikeså. For two further projects, a 

Letter of Intent was awarded: 

Kongsfoss and Bersåvatn. 

Lindland hydropower plant, awarded 

as a complete M+E project in 

Visualisation with comfortable touch screen 

operation: our latest turbine control generation 

2001, was commissioned this year. 

The two compact Francis turbines 

with a total output of 10 MW are operating 

to the full satisfaction of the 

owner Dalane Energi. After Lindland, 

Dalane Energi has ordered two 

more Compact units (Stølsvann and 

Vikeså). 

For all the above plants the new SAT 

turbine governor TC 1703 has been 

sold or already commissioned. With 

Lindland power plant: after commissioning in the cavern 

its visualisation software and touch 

screen operation we can provide 

maximum comfort at maximum 

plant safety. Also, communication 

to various types of remote control 

systems have to be performed with 

this new system. 

VA TECH HYDRO Jevnaker also operates 

a branch in Sweden. Despite 

relatively low project activity we 

could sell one compact Kaplan turbine 

that will go in operation early in 

autumn 2003. 

Ralph Poschenrieder 

Phone +49/751 83 2832 

ralph.poschenrieder@vatew.de 

Technical data Lindland: 

Unit: 1 2 

Output: 3.4 / 5.6 MW 

Net head: 98 / 98 m 

Speed: 1,000 / 750 rpm 

Runner diameter: 720 / 921 mm 

Technical data Kolfossen: 

Output: 2.8 MW 


Net head: 44 m 



Technical data Stölsvann: 




Speed: 1,000 rpm 

Runner diameter: 475 mm 

Technical data Vikesa: 






Technical data Kongsfoss: 



Net head: 14.7 m 



Technical data Johannisholm: 



Net head: 6.3 m 



13

KEY PROJECTS 

TALAVERA AND PALOMAREJO 

VA TECH HYDRO Madrid was awarded 

a contract for the complete supply 

(design, manufacture, erection, 

and commissioning) of four Semikaplan 

turbines with a runner diameter 

of 2.85 m by the Iberdrola group. 

Cienersa, a company belonging to the 

Iberdrola group, and dedicated to 

renewable energies and minihydro, is 

building two new power stations, Talavera 

and Palomarejo, both located in a 

city 120 km away from Madrid. Iberdrola 

is a Global Key Account of VA TECH 

HYDRO, and the leading utility in 

installed hydropower in Spain. The 

permanent collaboration of VA TECH 

HYDRO in Spain with Iberdrola and 

their daughter companies this time has 

PORTODEMOUROS 

VA TECH HYDRO in Spain has signed 

a contract with a subsidiary company 

of Union Fenosa for the supply of the 

electromechanical equipment for the 

extension of Portodemouros plant. 

Energias Especiales, Union Fenosa´s 

daughter company, dedicated to the renewable 

energies business, decided to 

install an additional hydraulic turbine at 

its Portodemouros power plant, to use 

the tidal flow. Initially, this plant was 

equipped with two large vertical Francis 

turbines, but this flow was by-passed 

when these large turbines were out of service, 

with the consequent loss of energy. 

The design submitted by VA TECH HYDRO 

in Spain obtained the contract for the 

electromechanical equipment for this 

project. The plant is located in Galicia, 

14 

resulted in an order for the supply of 

four Semikaplan vertical turbines, 

including the turbine itself, control 

equipment, speed accelerator, 

generator, inlet gates, and stop-logs. 

The same type of Semikaplan turbines 

specially developed by VA TECH 

HYDRO in Spain has been 

delivered before to the same client for 

other plants with satisfactory results. 

Taking advantage of the similar head 

and flow conditions of the two stations, 

the northwestern region of Spain - recently 

known worldwide due to the 

Prestige accident - where Union 

Fenosa is the most important utility. The 

engineering and management of this 

project was entrusted to Soluziona 

Ingenieria, Union Fenosa´s engineering 

company, which has taken turnkey responsibility. 

The project presents specific 

difficulties, since the erection work, 

and mainly the civil works and connection 

to the existing penstock, have to be 

made with the plant in service and 

therefore, the duration and scheduling 

of downtimes are of vital importance to 

the customer. Following these criteria, 

the proposal designed by VA TECH HYDRO 

in Spain is based on minimizing these 

downtimes and reducing the head loss 

at the connection to the new branch 

with the existing penstock, using a design 

which shortens erection time and a 

project management which assures the 

coordination of the delivery dates of the 

different components to have them 

available just at the time they are required 

on site. Both approaches, de- 

located on the same river, the 

turbine design has been the same for 

all units, and the construction itself is 

carried out almost simultaneously, in a 

record time, as requested by the client. 

Alejandro Santamaría 

Phone +34/91 425 10 19 

alejandro.santamaria@vatech-hydro.net 

Technical data Talavera: 

Output: 1,610 kW 

Head: 5.18 m 



Technical data Palomarejo: 


Head: 3.58 m 



sign and coordination, are possible due 

to the close cooperation of Soluziona 

Ingeniería, the VA TECH HYDRO engineering 

department in Madrid, the 

VA TECH HYDRO facility in Algete, the 

generator supplier -Indar- and the 

VA TECH HYDRO project manager. The 

scope of supply includes an 11 MW 

vertical Francis turbine, a synchronous 

generator, an ND 1700 butterfly valve, a 

penstock of 12 m in length, an outlet 

tube in concrete from the draft tube to 

the downstream level with an ND 2000 

insulation valve just at the draft tube 

outlet, an oil pressure system, a digital 

speed governor, a cooling system, 

erection, and commissioning. 

Alfonso Madera 

Phone +34/91 425 1038 

alfonso.madera@vatech-hydro.net 


Output: 11 MW 

Head: 81.40 m 


Runner diameter: 1,280 mm

ECOBulb News 

First Industrial Unit in Operation at Aubas (France) 

The first industrial unit of 

VA TECH HYDRO’s ECOBulbTM turbine 

generator was successfully 

put into commercial operation in 

Aubas, central France, on October 

31, 2002. The private customer 

Mr. Farges is enthusiastic about his 

new unit and has already received 

several visits by interested private 

energy producers. 

This first project consisted in replacing 

a damaged asynchronous generator in 

a forty-year old unit with a modern permanent 

magnetic rotor and a new 

stator. No changes were made on 

the hydraulics, providing a unique 

opportunity to measure the increase in 

generator efficiency. Other minor modifications 

in the water tightness concept 

and in the synchronizing of the unit 

were also made in order to increase reliability 

and minimize maintenance requirements. 

All of ECOBulbTM ‘s electrical 

and mechanical features like power 

output, power factor, and quality of 

power currently equate to VA TECH 

HYDRO’s calculations. This gives a 

sound basis for further development of 

the ECOBulbTM range. 

New order for one 2.5 MW unit for 

Casamozza (Corsica, France) 

By the end of 2002, the private 

company Société Hydro éléctrique 

du Golo in Corsica (France) awarded 

VA TECH HYDRO in France an engi- 

neering and manufacturing contract for 

one 2.5 MW ECOBulbTM unit to be installed 

on the river Golo, just south of 

Bastia. The decisive arguments in favor 

of the ECOBulbTM technical solutions 

were the absence of step-up gear, 

the high overall efficiency and the 

low-maintenance design. Optimum 

integration in the narrow gorge as well 

as the danger of submersion of the 

turbo generator in case of floods supported 

the other features. During the 

engineering phase, VA TECH HYDRO 

also performed several optimization 

steps with respect to the water passages 

and improved the flow pattern at 

the entrance of the unit while using CFD 

calculations. 

Additional project under development 

In Canada, Innergex II has awarded 

VA TECH HYDRO in Canada an engineering 

contract for two single 

regulated ECOBulbTM units of approx. 

4 MW each a project named Sonoco. The 

engineering work has been completed 

and manufacturing will start soon. 

KEY PROJECTS 

During the industrialization phase, additional 

projects with typical features 

will be selected to develop the ECO- 

BulbTM range from 1 to 4 MW and for 

heads from 3 to 15 m head. Additionally, 

at the beginning of 2003 VA TECH 

HYDRO in France was awarded an engineering 

contract for two single regulated 

ECOBulb units of 1 MW each 

for heads of less than 3 m and 

2,600 mm in runner diameter, for 

the Paullo power plant in Italy. 

Pierre Duflon 

Phone +33/476 85 95 25 

pierre.duflon@bouvierhydro.fr 

Technical data Aubas: 

Output: 310 kW 

Voltage: 380 V 

Head: 3.20 m 



Air gap diameter: 1,320 mm 

Technical data Casamozza: 


Voltage: 3,300 V 

Head: 9.20 m 




Technical data Sonoco: 


Voltage: 3,300 V 

Head: 6.29 m 




15

USA 

JAYBIRD 

SACRAMENTO MUNICIPAL UTILI- 

TY DISTRICT (SMUD) signed a contract 

with VA TECH HYDRO USA in 

October 2002 for the design and 

supply of two Pelton – replacement 

runners, manufactured in reliable 

HIWELD technology in Linz. 

The HIWELD technology uses runner 

disks and runner buckets made of 

high-quality forged stainless steel, 

welded together in areas of low and 

safe stress levels. Thus areas of the 

buckets subjected to high stress are 

made of top quality forged materials. 

Finally these characteristics were the 

decision basis of SMUD for placing the 

order with VA TECH HYDRO against 

conventional cast runners. The Jaybird 

power station, located east of Sacramento 

in California, which includes 

two vertical Pelton turbines with six 

nozzles, will receive delivery of the first 

runner within one year and the second 

will follow two weeks later. 

Mike Byrne 

Phone +41/704 943 4343 

mbyrne@vatechhydro.com 

SPAIN 

HIGHLIGHTS 



Head: 456.6 m 



O NOVO PINDO 

Ferroatlantica has awarded 

VA TECH HYDRO in Spain a contract 

for the supply of an 11 MW 

Francis turbine for its O Novo 

Pindo facility. 

The contract follows a preliminary 

project jointly carried out by 

VA TECH HYDRO in Spain and Elecnor, 

based on the Ferroatlantica 

idea of installing an 11 MW Francis 

turbine, using the building of the old 

Pindo power plant, discontinued 

many years ago. VA TECH HYDRO´s 

partner in this project, Elecnor, is 

an electrical supplier, with whom 

VA TECH HYDRO has had a close 

16 

relationship for a long time ago 

as partner and as supplier in 

Spanish projects. The scope of 

supply includes an 11 MW Francis 

turbine, a synchronous generator, 

an ND 1250 butterfly valve, a 

digital speed governor, a 70 m 

penstock, erection, and commissioning. 


Output: 11 MW 

Head: 202 m 



Alfonso Madera 

Phone +34/91 425 10 38 

alfonso.madera@vatech-hydro.net 

MEXICO 

AGUA PRIETA 

VA TECH HYDRO in Switzerland has 

received an order for the supply of 

two additional MicroGuss replacement 

runners for Comisión Federal 

de Electricidad (CFE) in Mexico. 

CFE has an installed capacity of 

9,400 MW in hydropower and supplies 

more than 90 % of the Mexicans 

with energy. MicroGuss is a fabrication 

method for Pelton runners employing 

forged materials in highstress 

zones. Resistance to corrosion 

fatigue is significantly higher than of 

conventional castings and prevents 

cracking in bucket roots. 

MicroGuss runners feature increased 

lifetime, plant output, safety, 

and availability as well as reduced 

maintenance expenses. The new Pelton 

runners, with a weight of more 

than 20 t each, will be delivered in Mai 

2004 and June 2004, respectively. 


Output: 120 MW 

Head: 508 m 



Christoph Bütikofer 

Phone +41/41 329 53 72 

christoph.buetikofer@vatech–hydro.ch 

NORWAY 

ØVRE OTTA 

In December 2002 Norge Opplandskraft 

DA awarded a contract 

to VA TECH HYDRO for 

the design, manufacture, supply, 

installation, and commissioning 

of four synchronous generators. 

Øvre Otta is a group of power 

plants located in the western part 

of Norway consisting of two independent 

powerhouses operating 

underground: Framruste and 

Øyberget. 

Framruste utilizes a net head of 

approximately 325 m between 

Raudalsvatnet and Pollvatnet and 

Øyberget has a net head of approximately 

150 m between 

Heggebottvatnet and Dønfossen. 

The first unit is scheduled to be 

back on line in June 2005. 

Technical data Framruste: 

Output: 85 MVA 


Head: 325 m 



Technical data Oyberget: 

Output: 10/29/67 MVA 

Voltage: 11/10.5/10.5 kV 

Head: 150 m 

Speed: 750/500/333.3 rpm 

Stator diameter:2,700/4,700/5,700 mm 

Franz Cirnfus 

Phone +43/1 89100 2666 

franz.cirnfus@vatech-hydro.at 

NORWAY 

LYSEBOTN 

VA TECH HYDRO has secured a 

contract with Norway-based Lyse 

Produksjon AS for the delivery of 

12 new MicroGuss (MG) Pelton 

runners for the Lysebotn plant, 

near Stavanger.

The runners will be manufactured at 

our workshop in Switzerland within 

12 months. 

The runners will boost the lifetime of 

the plant’s six existing double Pelton 

units and increase electricity 

output in the Stavanger area. This 

contract confirms the strong position 

of VA TECH HYDRO in Norway, 

a country which is second only to 

Switzerland in commissioning MG 

Pelton runners. 


Output: 37.8 / 44.6 MW 

Head: 610 m 



Reidar Hjelleset 

Phone +47/61 31 52 16 

reidar.hjelleset@vatech.no 

NORWAY 

FAGERLI, REKVATN, EIDET I, 

SJONA, SIMA, TAFJORD 

VA TECH HYDRO is currently handling 

several turbine refurbishment 

and upgrading contracts. 

The refurbishment of Fagerli power station, 

Rekvatn power station and Eidet I 

power station has been completed and 

work is going on for Sjona power station. 

For Sima power station, one of the 

largest power stations in Norway, 

VA TECH HYDRO has delivered two 

new governors and will deliver the 

other two units during 2003. At Tafjord 

power station two spherical valve 

control systems have been installed 

and we have as many as 

fourteen new spherical valve control 

systems in our order book for delivery 

over the next two years. Additionally, we 

are working on the remodeling and 

repair of old Pelton runners for several 

customers at our workshop in Jevnaker. 

Erik Pike 

Phone +47/61 31 52 08 

erik.pike@vatech.no 

TINNOSET 

NORWAY 

Øst Telemarkens Brugseierforening 

has awarded VA TECH HYDRO a contract 

for delivering four sector gates. 

Three sector gates will be 16.35 m 

wide and 5.65 m high. A smaller one 

of the same width will only be 4.20 m 

high. Two of the gates have now been 

successfully delivered and soon we 

will start production of the remaining 

two gates that will be delivered in 

2003 during springtime. 



Head: 473.85 m 



Erik Pike 

Phone +47/61 31 52 08 


NORWAY 

TYIN 

VA TECH HYDRO has been awarded 

a supply contract for the 

penstock for Tyin power station 

owned by Norsk Hydro. We are a 

subsupplier to the main contractor, 

Selmer Skanska. 

The penstock is embedded in concrete 

and consists of a main part 

with a diameter of 2,900 mm and a 

bifurcation piece to two penstocks 

with a diameter of 2,200 mm leading 

to the power units. The design pressure 

is 1,147 m water column and the 

entire scope of supply consists of 

approx 600 tons of steel. The construction 

phase has been finished 

and we will soon start production. 

The erection has been scheduled for 

September 2003. 

Erik Pike 

Phone +47/61 31 52 08 


HIGHLIGHTS 

SWITZERLAND 

CHATELÔT 

10% Output increase on 50year 

old power units 

VA TECH HYDRO in Switzerland 

has signed a contract with Société 

des Forces Motrices du 

Châtelot (SFMC) for the upgrading 

and modernization of two 50year 

old Francis turbines at 

Chatelôt power station. This 

power station is located on the 

Doubs river, at the border between 

France and Switzerland. 

The scope of work comprises the 

replacement of the turbine runners, 

wicket gates, stationary 

wear rings and labyrinth rings, 

turbine main shaft, and adjacent 

components. The coupling system 

will be changed from a classic 

coupling with adjusted bolts 

to a so-called SKF-system with a 

lean coupling cone and sleeve. It 

was a challenge for our hydraulic 

engineers to come up with new 

runner blade and wicket gate 

profiles, which guarantee the increased 

output while reducing 

cavitation effects to a maximum. 

To avoid local cavitation due to 

slight deviations of the runner 

blade profiles, about 90% of 

these will be machined on a fiveaxis 

milling machine. 



Head: 94.45 m 



Pedro López 

Phone +41/21 925 77 13 

pedro.lopez@vatech-hydro.ch 

17

18 

HIGHLIGHTS 

SWITZERLAND 

RECKINGEN 

Kriens-based VA TECH HYDRO was 

awarded a contract by the operators 

of Reckingen power plant to upgrade 

and modernize one of their Kaplan 

turbines. 

Built 65 years ago, the station is situated 

10 km to the east of Waldshut on the 

Rhine. The scope of supplies includes a 

set of new runner blades, a guide wheel 

ring, discharge ring, and draft tube cone 

to allow for an increase of the runner 

diameter from 6,200 mm to 6,450 mm. 

Furthermore, the existing turbine controller 

will be replaced by a digital TC 

1703 governor of the NEPTUN series. 

This upgrading project is designed to 

boost the annual energy production of 

the refurbished turbine No. 1 by 3 %. A 

subsequent upgrading of turbine No. 2 

would result in a 5.7 % increase in overall 

annual energy production. Reconstruction 

and modernisation work is 

scheduled to start in January 2004. 


Output: 22 MW 

Head: 9 m 

Speed: 75 rpm 


Herbert Mignoli 

Phone +41/41 329 53 09 

herbert.mignoli@vatech-hydro.ch 

BOSNIA 

JABLANICA 

VA TECH HYDRO has signed a 

follow-up contract for the modernization 

of unit 2 of Jablanica 

hydropower station, located in 

Bosnia-Herzegovina, 80km south 

of Sarajevo. 

This contract follows the successful 

refurbishment of three other units over 

the past three years for Elektroprivreda 

Bosne I Hercegovine, Bosnia’s largest 

electricity provider. 

VA TECH HYDRO will supply the 

Jablanica plant, which dates back to 

1954, with various components including 

a new runner, distributor, turbine 

shaft, governor and corresponding 

oil hydraulic unit as well as three 

butterfly valves for units 1 to 3. Deliv- 

ery will take place within eleven months 

and VA TECH HYDRO will supervise the 

installation of the equipment. Within 

less than 20 months the plant will be fully 

operational. Refurbishment will increase 

the plant’s peak power by 22% 

and peak efficiency by 7%. Once all five 

units have been modernized, the additional 

annual energy production of more 

than 50,000 MWh will supply 100,000 

households with clean energy. 



Head: 99 m 



Jacques Bonifay 

Phone +41/21 925 77 75 

jacques.bonifay@vatech-hydro.ch 

INDIA 

MUNIRABAD 

VA TECH HYDRO in India has executed 

an order for the modernization 

of 40-year old Munirabad hydropower 

plant for VVNL (former KEB) in 

the state of Karnataka, realizing a 

significant improvement in plant performance. 

The contract was signed in December 

2000 and all the three Kaplan units have 

been successfully commissioned in the 

year 2002. In addition to other overhauling 

activities, the major scope of work 

consisted in the replacement of the existing 

hydromechanical governors with digital 

electronic governors and the existing 

excitation system with a microprocessorbased 

static excitation system. The order 

is of special significance since it is the 

third consecutive order in the state of Karnataka 

placed by the same customer. 


Output: 9 / 10 MW 


Head: 20 m 



Yogesh Bahadur 

Phone +91/129 527 4319 

contact@vatewf.com 

INDIA 

NERIAMANGALAM 

20 % output increase by modernization 

The contract for the upgrading of 

three Francis turbines and governing 

systems came into force in 

October 2002. Rehabilitation of this 

power plant, located in the south of 

India, will allow our customer, 

KSEB, to improve energy production 

and services. Financing will be 

assured by a Swiss mixed credit. 



Head: 192 m 



Florence Gaubil 

Phone +41/21 925 77 71 

florence.gaubil@vatech-hydro.ch 

THAILAND 

KLONG THUNG PHEN 

VA TECH HYDRO has achieved the 

first sales success with compact turbines 

in Thailand. 

In December 2002, a contract for 

the delivery of two compact Francis 

turbines including synchronous generators, 

inlet valves, and turbine control 

cubicles was signed with the Thai Company 

ST POWER ENGINEERING 

CORPORATION Ltd. The scope of supply 

for VA TECH HYDRO will be incorporated 

in a general drinking water supply 

project for the province of 

Chantaburi (approx. 200 km southeast 

of Bangkok), which consists of a dam, 

head water channel, surge tank, steel 

penstock, the powerhouse with adjacent 

tail water channel and reservoir. 

The client and operator of this hydropower 

plant is a department of the 

Thai Ministry of Energy, the Department 

of Energy Development and Efficiency 

(DEDE), based in Bangkok. Commissioning 

has been scheduled to take 

place early in the year 2004. 



Head: 190 m 

Speed: 1,000 rpm 


Hans Wolfhard 

Phone +49/751 83 3304 

hans.wolfhard@vatew.de

LINZ 

VA TECH HYDRO’s Combined 

Cycle Division, a renowned expert 

in the field of power plant technology, 

was awarded a contract 

for the construction of a turnkey 

gas-fuelled combined cycle plant 

at Linz Mitte by operator LINZ AG. 

The order includes engineering, delivery, 

installation, and commissioning 

of a combined gas/steam facility 

featuring an electrical output of 

approx. 100 MW, a district heating 

capacity of approx. 84 MW (peak 

load up to 150 MW), and a fuel efficiency 

factor of about 87%. Main 

components include a 70 MW General 

Electric gas turbine, a non-fuelled 

waste heat boiler with catalyst 

(DENOX), a backpressure steam turbine 

as well as a district heat accumulator 

and two district heat peak 

time boilers. Trial operation is 

scheduled to commence on October 

1, 2004. 

The gas-fuelled combined cycle 

technology is characterized by high 

efficiency factors primarily with respect 

to power/heat coupling, while 

capital expenditures and harmful 

emissions are kept at a minimum. 

As a result of these benefits, excel- 

lent global growth rates for gas-fuelled 

combined cycle plants are 

forecast for the deregulated power 

markets over the next few years. 

VA TECH HYDRO have impressively 

demonstrated their competence in 

this sector with previous projects – 

most recently a 400 MW gas-fuelled 

combined cycle plant for the municipal 

Stadtwerke München utility in 

Germany as well as another 400 MW 

facility of the same type in Coolkeeragh, 

Northern Ireland. 

As a long-standing partner of LINZ 

AG, VA TECH HYDRO may look 

back upon a successful cooperation 

with this customer. Following the renewal 

of gas turbines 1 & 2 of Linz 

Süd power station as well as gas 

turbine 3 of the same facility, the 

Linz Mitte order is already the third 

project, for which LINZ AG relies on 


VA TECH HYDRO to Renew Linz Mitte 

District Heating Plant 

the renowned Austrian company. 

Efficient utilisation of the space 

available as well as smooth integration 

of existing system resources 

represent a particular challenge 

during construction. After completion, 

the new Linz Mitte power station 

will ensure the supply of the 

majority of industrial and residential 

customers in Linz with district heat. 


Gas turbine: 

1 x 6 FA type, 73 MW output 

fuel: natural gas Dry Low NOx 

Steam turbine: 

1 x bleeding - back pressure 

steam turbine 

27 MW output 

Generator: 

1 x 105 MVA, 10.5 kV (for GT) 

1 x 36 MVA, 6.3 kV (for ST) 

HRSG: 

1 x with district heating (loop) 

Heating capacity: 

84 MW output 

Gerhard Klawatsch 

Phone +43/1 89100 2903 

gerhard.klawatsch@vatech-hydro.at 

19

ANKARA 


The Ankara Combined Cycle Power Plant Project 

Tractebel, the Belgian world leader 

in energy, signed an EPC contract 

(Engineering, Procurement, Construction) 

with VA TECH HYDRO 

on July 19, 2001. This contract was 

split on September 28, 2002 after 

the establishment of Baymina Enerji, 

the special purpose company 

for the Ankara CCPP project. 

85% of the contract value is to be 

executed by VA TECH HYDRO, 

Vienna, and 15% by Elin Elmak, 

Ankara / Turkey. The shareholders 

of Baymina are Tractebel (95%) 

and Mimag (5%). 

The project site is located approximately 

40 km to the south-west of 

Ankara close to the village of Maliköy 

and near the River Ankara and 

other essential infrastructures (the 

TEAS and BOTAS electricity and 

gas grids). 

The area of the main plant is approx. 

136,000 m2. The site for the water 

pre-treatment plant to provide additional 

water for the cooling system 

and the demineralisation plant is 

2.5 km away from the main plant 

next to the Ankara river. 

As a result of mountainous surroundings, 

Central Anatolia is subject 

mainly to terrestrial climate that 

20 

is characterized by cold winters and 

hot, dry summers. The site elevation 

is approximately 750 m above sea 

level. 

The main reason for proposing this 

plant within the provincial borders 

of Ankara is to meet the rapidly 

increasing energy demand of the 

region. 

Financial close took place on November 

26, 2002. ECA’s (Export 

Credit Agencies) involved are US 

Exim / USA, Hermes / Germany, 

OND / Belgium and ÖKB / Austria. 

Key Dates 

Date Activity / Milestone 

Jul 2001 Award of contract 

Sep 2001 Site mobilisation 

Nov 2001 Start of excavation 

Feb 2002 Foundation works 

Jun 2002 Commencement of 

mechanical erection 

Sep 2002 First gas turbine on site 

Oct 2002 First HRSG-modules 

on site 

Nov 2002 Steam turbine on site 

Dec 2002 Back energizing 

Feb 2003 Pressure test HRSG 1 

Mai 2003 First fire GT 1 

Mai 2003 First synchronisation 

GT 1 

Jun 2003 First fire GT 2 

Jul 2003 First steam to ST 

Sep 2003 Reliability and performance 

test 

Nov 2003 Temporary acceptance 

protocol 

Type of Power Plant 

The Ankara power plant is of the 

combined cycle type combining two 

gas turbines and one steam turbine 

delivering a total guaranteed net 

capacity of 763.1 MW and a guaranteed 

net heat rate of 6,470 kJ/kWh

(corresponding to 55.6% net 

efficiency). 

The reference conditions are: 

• Barometric pressure 926.5 mbara 

• Ambient temperature 11.8°C 

• Relative humidity 60% 

The power plant is designed for a 

lifetime of at least 25 years and will 

be built to recognised international 

standards and will also meet the local 

Turkish standards identified in 

the grid code (APK359) and other 

relevant local legislation. 

Combined Cycle (CC) is the technology 

of choice for new and 

replacement power plants. CC is 

forecast to account for over 30% of 

Europe's installed capacity by 

2020. 

Reasons include: 

• Low capital costs 

• High levels of generating efficiency 

(up to 56%) 

• Low emission levels 

• Short periods for erection and 

commissioning 

• Availability of low cost natural gas 

• Development of combined cycle 

systems suited to baseload 

applications 

What is “Combined Cycle” ? 

The basic principle of a combined 

cycle power plant is the following: 

Burning gas in a gas turbine (GT) 

produces not only power - which can 

be converted to electric power by a 

coupled generator - but also fairly 

hot exhaust gases. Routing these 

gases through a boiler produces 

steam, which can be turned into 

electric power with a coupled steam 

turbine and generator. 

This set-up of gas turbine, wasteheat 

recovery boiler, steam turbine 

and generator(s) is called a 

combined cycle. 

Gas Turbine (GT) 

All gas turbines operate on the principle 

of the Brayton cycle: 

Compressed air is mixed with fuel 

and burned under constant pressure 

conditions. The resulting hot 

gases are allowed to expand 

through a turbine to produce electricity 

with a coupled generator. 

Both gas turbines for Ankara CCPP 

are of the PG 9351 (FA++) type supplied 

by General Electric. 

At base load and ISO-conditions an 

air flow of 2,170 t/h is cleaned in a 

pulse type filter and compressed at 

a pressure ratio of 15 in an axial flow 

compressor (18 stages). 

Natural gas as fuel is added to the 

compressed air in the combustor 

and raises temperature to approx. 

1,290 C in a continuous combustion 

process. NOx-emissions are minimized 

by a Dry Low NOx combustor 

(DLN 2+). 

In the turbine work is extracted from 

the hot combustion gases as they 

expand to almost atmospheric pressure. 

This allows to drive a generator 

of 235 MW electrical output. 

The expanded gases are lead to the 

Heat Recovery Steam Generator 

(HRSG) at a temperature of approx. 

590°C. 

HRSG 

The waste heat available from the 

GT exhaust gases is utilized in two 

heat recovery steam generators 

(HRSG) of the drum type. 

For optimized efficiency steam is 

generated at three pressure levels: 

• High pressure (HP): 

120 bar / 565 °C, 320 t/h (each) 

• Intermediate pressure (IP): 

25 bar / 565 °C, 360 t/h (each) 

(with reheat) 

• Low pressure (LP): 

4.7 bar / 288 °C, 13 t/h (each) 

A supplementary firing system is installed 

to maximize the electrical 

output of the plant on demand. The 

temperature of the GT exhaust gases 

is further increased by means of 

gas-fired duct burners (52.5 MW). 

Steam Turbine 

The steam turbine is of the 4 casing 

(2 LP casings, 4 floods) type with reheat 

supplied by Alstom Power 

(Mannheim). In full condensing 

mode (condenser pressure 0.035 

bar abs) the generator produces an 

electrical output of 328 MW. 

The nominal live steam conditions 

are 120 bars, 565°C. 

Generators 

Gas turbine generator 

• 2 x 276 MVA 

• 15.75 kV 

• cos phi = 0.85 

Steam turbine generator 

• 1 x 386 MVA 

• 18 kV 

• cos phi = 0.85 

Cooling Towers 

Cooling water for the condenser is 

cooled by a mechanical draft cell 

cooling tower with 16 cells by partial 

evaporation. The wooden cooling 

tower is constructed in 2 rows, each 

150 m long. The circulating cooling 

water system is equipped with 3 

times 50% cooling water pumps. 

21

Water Pre-treatment 

Water for replacement of evaporation 

losses of the cooling tower and 

blow down of the HRSG’s is supplied 

from the Ankara river that 

passes at a distance of approx. 2.5 

km from the site. The poor quality of 

the water of the Ankara river re- 

quires advanced pre-treatment. The 

amount of water of approximately 

1.200 m3/h is screened, filtered, 

clarified and decarbonised and is 

pumped to the main plant through an 

underground pipe. 

Gas Connection 

The connection of the power plant 

to the main gas pipeline, passing at 

a distance of 4 km from the site is 

also part of the contract. The plant´s 

average requirement of natural gas 

is approximately 140,000 Nm3/h. Transmission Infrastructure 

The site is directly connected via 

three 154 kV transmission lines 

(~300m) to the 154 kV substation 

built by TEAS connected to the existing 

TEAS 380kV Temelli substation 

Project Team Head Office 

Project management, design, and 

22 

subcontractor co-ordination for the 

Ankara CCPP Project is handled by 

a team located at the Vienna headquarters. 

Project Team Site Office 

A permanent VA TECH site team is 

responsible for the supervision of 

erection and commissioning as well 

as performance testing. 

In December 2002, a total manpower 

of approx. 900 (including subcontractor’s 

personnel) was active on 

site, which is expected to increase 

to 1,200 persons during peak period 

of mechanical erection. 

Health, Safety and Environment 

The site team works in accordance 

with VA TECH’s health and safety 

regulations and an environmental 

plan. These plans are updated periodically. 

A monthly site inspection 

by the lender´s engineer takes 

place. The monthly comparison with 

international benchmarks for health 

and safety is favourable: 

• UK = 25 

• Turkey = 28 

• Ankara site = 8 

Major Subcontractors 

• General Electric, USA 

(2 PG 9351 FA gas turbines) 

• Alstom Power, Germany 

(1 steam turbine) 

• CMI, Belgium (2 HRSG’s) 

• Yüksel, Turkey (civil works) 

• Goema, Germany 

(water pre-treatment plant) 

• Marley, Germany (cooling towers) 

• Noske Kaeser, Germany 

(steam piping) 

• VA TECH Peebles, UK 

(transformers) 

• Metso, Austria 

(distributed control system) 

Execution of the Contract 

All deadlines started when the contract 

was signed in July 2001 without 

the usual Pre-NTP phase. The 

first engineering documents had to 

be submitted already 4 weeks after 

contract signing. 

Tractebel and Baymina (Project 

Management) are fully aware of the 

critical issues of this fast-track project 

and teamwork in all phases of 

the project is excellent. 

Monthly progress meetings with 

VA TECH HYDRO’s project team take 

place to ensure smooth execution. 

The monitoring of the project takes 

place as follows: 

- monthly project meetings 

- since ECA’s are involved, additional 

monthly meetings with the lender’s 

engineer take place on site 

- approval of engineering 

- monitoring of all site matters by 

the owner’s engineer 

- quarterly "Director’s Overview 

Meetings” on a higher management 

level with Tractebel / Baymina 

and VA TECH HYDRO 

Up to now all milestones could be 

reached despite the tight time 

schedule. On several occasions 

Tractebel have expressed their 

satisfaction regarding VA TECH 

HYDRO’s performance and have 

announced that further co-operation 

may be considered. 

Jan Federspiel 

Phone +43/1 89100-2059 

jan.federspiel@vatech-hydro.at

HYDRO 2002 in Kiris / Turkey 

HYDRO 2002 International Conference 

and Exhibition, a major 

event for worldwide development 

of hydropower was held in Kiris, 

Turkey, on November 4-7, 2002. 

The selection of Turkey was ideal 

as this country has a major commitment 

to hydropower. 

Participation in this event was remarkable 

as key developers coming 

from all parts of the world 

were present. From Turkey, DSI 

and EUAS delegates as well as 

developers from the private sector 

showed a strong interest in 

the exhibition and had the opportunity 

to discuss present and future 

projects with our delegates 

in a friendly and casual atmosphere. 

VA TECH HYDRO was one of the 

principal sponsors of HYDRO 

2002. During the barbecue party 

sponsored and organized by our 

company. Mr. Franz Strohmer of 

the VA TECH HYDRO Board, 

pointed out in his welcome 

speech, that VA TECH HYDRO has 

already delivered equipment representing 

a share of more than 80% of 

the total 11.000 MW operating 

hydropower plants to the country 

hosting this hydro conference. 

VA TECH HYDRO was present with 

an outstanding booth and its experts 

presented several papers: 

• H.Keck: 

New technologies in design and 

manufacturing of large Francis 

and pump turbine runners 

• C. Bissel: 

Pelton flow patterns with computational 

flow simulations 

• J.Fonkenell: 

Technical features of ECOBulb 

turbine-generator unit 

• J.Schönauer: 

Predesign process of hydroelectric 

generators on the application of 

EVENTS 

computational fluid dynamics, 

thermal and electromagnetic 

finite element methods. 

Maurice Michon 

Phone +90/312 466 3580 

michon@attglobal.net 

FAIRS & 

EVENTS 

ICOLD 

June 16–20, 2003 

Montreal, Canada 

WATERPOWER XIII 

July 29–31, 2003 

Buffalo, New York, USA 

VA TECH Customer Day 

August 28–29, 2003 

Kriens, Switzerland 

contact@vatech-hydro.ch 

HYDRO 2003 

November 3-6, 2003 

Dubrovnik, Croatia 

23


WHY 

Combined Cycle 

IS MORE THAN 

hot steam 

Combined Cycle, a business unit of VA TECH HYDRO, provides environment-friendly 

and energy saving turnkey combined cycle power plants in the range of 100 to 

800 MW based on General Electric gas turbine technology. 

Our main strenghts are economically convincing, 

tailor-made concepts fulfilling customer needs. 

sustainable solutions. for a better life. 

www.vatech-hydro.com 

eHYD.25.8000.W.B03 HYDRO News 4

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