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Waterpower Week in Washington focuses on bringing together industry leaders, state and federal
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conventional hydro, pumped storage, and marine energy.
For more information on the conference program and sponsorship opportunities please visit
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VIEWPOINT:
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Volume 24. No. 5. September-October 2016
CONTENTS
10
FEATURES
10
International Guide to Hydro Innovations and

New Technology
By Gregory B. Poindexter
In this first-ever international product and technology guide, we

present data on how several companies are helping owners of hydro
plants and dams manage their facilities and maximize efficiency.
16
DEPARTMENTS
2 Viewpoint:
A Bright Future
4 World News
32 Index
to Advertisers
Solving High Intermittent Bearing Vibration after a

Modernization and Upgrade
By Enes Zulovic
The upper guide and thrust bearing assembly on Unit 1 at the

125 MW Tungatinah station experienced intermittent high
vibrations after an upgrade and modernization. The author developed
a novel integrated approach for vibration analysis to find the root
cause and propose an appropriate solution.
26
ADVISORY BOARD
Viewpoints from the Board Room: International Finance
Corporation
The International Finance Corp. (IFC) seeks to invest in responsibly

developed and operated hydropower projects to grant energy access
to impoverished people in developing nations. Morgan Landy
discusses IFCs involvement in sustainable hydro development.
H. Irfan Aker
Dolsar Engineering Co.,
Turkey
Emmanuel Antwi-Darkwa
ETAD Consult Ltd., Ghana
Enrique Cifres
eWATER Consultant SL,
Spain
Ian M. Cook
ICCL, United Kingdom
Jean-Louis Drommi
Electricite de France,
France
Maryse Francois-Xausa
Alstom Renewable Power
Hydro, France
Roger Gill
Sustena Partners,
Australia
16
www.hydroworld.com
1609HRW_1 1
26
Fernando de Menezes
e Silva
Itaipu Binacional, Brazil
Peter Mulvihill
Pioneer Generation,
New Zealand
Kanchit Ngamsanroaj
Electricity Generating
Authority of Thailand,
Thailand
Christian Dalosto Pase
Tractebel Energia, Brazil
Doan Ke Ruan
Power Engineering Consulting Company, Vietnam
Leon Tromp
Lesotho Highlands Water
Commission, Lesotho
Christine van Oldeneel
Hydro Equipment Association, Belgium
C.V.J. Varma
Council of Power Utilities
and The Dams Society,
India
Raghunath Gopal
(R.G.) Vartak
Consultant, India
Luis C. Vintimilla
Consulting Engineer,
Ecuador
James Yang, PhD
Vattenfall Research and
Development AB, Sweden
September-October 2016 / HRW 1
9/14/16 4:19 PM
VIEWPOINT
A Bright Future
Vice President, Group Publishing Director,

Hydro and Water Groups Marla Barnes
+1 918 832 9353 marlab@pennwell.com
Managing Editor Elizabeth Ingram
+1 918 831 9175 elizabethi@pennwell.com
Theories about where technology could take us have been a staple of the
entertainment industry for decades. Two examples that spring to mind

are the Star Trek movie and television show franchise (which is still
going strong) and the Jetsons television sitcom, both of which debuted
in the 1960s. In fact, did you know that Star Trek has been cited as an
inspiration for such technological breakthroughs as cell phones and

tablet computers?
Recently, hydroelectric power has captured the imagination of some
innovators, who are adapting this mature technology to achieve todays needs. A couple of
technologies that stood out for me are:
The Barsha pump, from aQysta in The Netherlands, uses the kinetic energy of moving water
to provide irrigation water for farmers (barsha means rain in Nepalese). The pump, a waterwheel
moored in a moving current, can be installed in a river, stream or canal and incorporates few
moving parts to simplify maintenance. It can pump water to a maximum vertical height of
20 m and a distance as long as 2 km. It can pump as much as 40,000 L per day, depending on
the speed and flow rate of the river and the height to which it is being pumped. The pump has
been installed in Indonesia, Nepal, Spain, Turkey and Zambia and provides an alternative to
pumps powered using kerosene or diesel.
Editor Michael Harris

+1 918 832 9363 michaelh@pennwell.com
Associate Editor Gregory B. Poindexter
+1 918 832 9330 gregp@pennwell.com
Production Manager Daniel Greene
+1 918 831 9401 danielg@pennwell.com
Graphic Designer Kermit Mulkins
+1 918 831 9554 kermitm@pennwell.com
Audience Development Manager Emily Martin
V.P. of Audience Development & Marketing June Griffin
Production Director Charlie Cole
www.pennwell.com
HRW Hydro Review Worldwide
PennWell Corp.
PennWell Global Energy Group
The Water Tower, Gunpowder Mill,
Powermill Lane, Waltham Abbey,
Essex, EN9 1BN, UK
Telephone: +44 1992 656 600
Fax: +44 1992 656 700
E-mail: hydroreview@pennwell.com
World Wide Web: http://www.hydroworld.com
Sales Manager:
Europe, Asia, Africa, Oceania Sophia Perry
+44 1992 656641 sophiap@pennwell.com
Sales Director: Americas Howard Lutzk
+1 913 402 7119 howardl@pennwell.com
The Estream, from Enomad in South Korea, is a lightweight hydropower generator with an
integrated lithium-ion battery that provides a capacity of up to 5 watts of electricity. The device,
which takes 4.5 hours to fully charge, is intended to produce power for outdoor adventurers
who might want to charge a USB-connected mobile device. The unit is 9.7 in by 2.5 in by
8.3 in and weighs less than 2 pounds. As of Aug. 31, this device was part of a Kickstarter
campaign that still had 11 days to go but had already raised $135,554 of its $80,000 goal.
Established companies in the hydropower and dams markets also are offering new technologies
and innovative applications of existing technology. Our article on page 10 features detailed
For assistance with marketing strategy or ad creation,

please contact:
PennWell Marketing Solutions Paul Andrews
240.595.2352 pandrews@pennwell.com
Chairman Robert F. Biolchini
Vice Chairman Frank T. Lauinger
President and Chief Executive Officer Mark C. Wilmoth
Executive Vice President,
Corporate Development and Strategy Jayne A. Gilsinger
Senior Vice President,
Finance and Chief Financial Officer Brian Conway
information on six such technologies applied around the world, one or more of which may help
you solve a problem at your hydro facility or dam.
In addition, further information on technology innovation and application is available under

the Technology/Equipment topic center at HydroWorld.com, updated daily.
Our current reality may not look much like what you saw on Star Trek or the Jetsons 50
years ago (no flying cars, yet), but technology is advancing rapidly, and the hydro and dams
industries are keeping pace.
Managing Editor
Subscriber Customer Service

PO Box 3264, Northbrook, IL 60065-3264, USA
Customer Service Phone: 1-847-559-7330
Fax: 847-763-9607
Email: hr@halldata.com
Reprints Rhonda Brown
+1 866 879 9144 pennwellreprints@fosterprinting.com
The views expressed by contributing authors are those of the individuals
concerned and do not necessarily reflect those of HRW or the publishers.
HRW (ISSN 1072-9542) is published six times in January, March, May, July,
September, and November by PennWell Global Energy Group, The Water
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1609HRW_2 2
Printed in the U.K.. GST NO. 12681 3153 RT0001

Publications Mail Agreement No. 40029359
9/14/16 4:19 PM
Dr. Jiri Koutnik, Managing Director of the international Voith Hydro Engineering Center, in a
conversation with Susanne Kathirvel, Product Manager, and Mauricio Kondo, Design Engineer.
As Managing Director of the international

Voith Hydro Engineering Center I deal
with lots of interesting and challenging
projects. After more than twelve years
with Voith I saw how we managed to
nd optimal solutions countless times.
What I like most is the interdisciplinary

character of the tasks, mostly touching
the complete power unit or even power
plant behavior. It is always interesting
to confront our theoretical approaches
with practical experiences and site measurements.
I am still fascinated by physical phenomena in hydraulic and electrical machines
and enjoy discussing them with my
1609HRW_3 3
colleagues. Together we invest all our

time and energy to meet customer
expectations and assert our competitive
position with state-of-the-art technology.
With a global R&D network, Voith Hydro

is always close to customers needs
and familiar with local conditions. As our
Engineering Centers are spread across
the globe we ensure a high-class international expert exchange and technological leadership.
International Experts
Ensuring Technological
Leadership
Dr. Jiri Koutnik

www.voith.com
A Voith and Siemens Company
9/14/16 4:19 PM
NEW DEVELOPMENT
Chia-aig River, at the eastern end of Loch
available, but the GIS should be installed and
Pakistan announces agreement signed
Arkaig. According to RWE, it received consent
ready for operation by 2018, Siemens says.
for 870 MW Suki Kinari project
from the Scottish government in June 2010.
Rogun Dam has a planned height of
The government of the province of Khyber
The Scottish Environment Protection Agency
1,099 ft and is located on the Vakhsh River
Pakhtunkhwa, Pakistan, has signed an agree-
under the Controlled Activities Regulations
in Pamir.
ment with SK Hydro Private and Industrial
granted a water license for the project.
Siemens said it is supplying:
and Commercial Bank of China to develop
An intake weir directs water to a
8DQ1 switchgear, which covers voltage
and construct the 870 MW Suki Kinari
3.2 km-long buried pipeline, into a power-
ranges of up to 550 kV and has 21 circuit
hydro project.
house that contains two vertical five-nozzle
Under the agreement, the hydro project
would be built on the Kunhar River in the
Pelton turbines, one each at 1.01 MW and
1.99 MW.
breakers;
8DN9 switchgear, which covers up to
220 kV and has four circuit breakers; and
Mansehra district of Khyber Pakhtunkhwa at
Paul Wheelhouse MSP, minister for
Online monitoring devices on the GIS to
a cost of US$1.9 billion and is expected to be
Business, Innovation and Energy, together
enable automatic remote diagnosis and
completed by 2021. The electricity produced
with Hans Bunting, chief operating officer
self-monitoring.
would be transferred to Pakistans national
for Renewables of RWE, were onsite for the
A total of six turbines at 600 MW should,
grid for distribution to the entire country.
plants inauguration.
according to Seimens, annually generate
13.3 billion kWh.
According to a press release, the parties
Bnting said, We value the skilled supply
have agreed to a 30-year power purchase
chain that Scotland can offer and when devel-
agreement, after which the government of
oping our renewables projects, it is important
KP would assume operation and ownership
to us that we are able to work with local
More Technology & Equipment news

is available on HydroWorld.com:
of the facility and receive all income from the
companies and to maximize the economic
IHA expands knowledge networks to eight
sale of electricity.
benefits to the local economy.

After the commissioning of the Cia Aig
More New Development news is

available on HydroWorld.com:
scheme, RWE now operates 15 hydroelectric
in Myanmar
Final unit at Brazils 220 MW Cachoeira
Caldeirao enters commercial operation
SMALL HYDRO
3 MW Cia Aig hydropower project
dissolution
power stations in Scotland.
MARINE HYDROKINETICS
Presidential order reinstates study for
proposed 6,000 MW Myitsone project
hydropower topics
Hydro Equipment Association announces
More Small Hydro news is

2 MW tidal energy test project
Hedcor to upgrade Bineng small hydro
A consortium led by Kyuden Mirai Energy Co.
plants, more than triple capacity
coming to Japan
plans to test a tidal energy project near Goto
Peterborough Utilities commissions
in Japans southwestern Nagasaki Prefecture. It
expanded 9.8 MW London Street small
is expected to have a capacity of about 2 MW
hydro station
when it begins operation in 2019.
Kyuden Mirai a subsidiary of Japans
commissioned in Scotland
Forestry Commission Scotland and Loch Eil
TECHNOLOGY/EQUIPMENT
Kyusuhu Electric Power Corp. is joined
Estates, in partnership with RWE Npower
Siemens providing GIS to
in the effort by Nippon Steel & Sumikin
Renewables, commissioned the run-of-river
3,600 MW Rogun plant in Tajikistan
Engineering, Nagasaki University, the
US$15.9 million 3 MW Cia Aig small hydro-
Germany-based Siemens AG is supplying two
Nagasaki Marine Industry Cluster Promotion
power scheme in August, after more than a total
gas-insulated high-voltage switchgear (GIS)
Association (NaMICPA) and OpenHydro.
of six years of development and construction.
for the 3,600 MW Rogun plant in Tajikistan.
OpenHydro said site surveys are expected
The project is located on the Abhainn
The amount of the award is not immediately
to begin this year, with procurement,
1609HRW_4 4
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9/14/16 4:19 PM
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WORLD NEWS
fabrication and cable laying set to begin in
used in the seismic design, analysis and safety
cap prices for an upcoming power auction that
2017. The Scottish manufacturer will build
evaluation of new or existing dams and their
includes more than 130 small hydro plants.
the projects generating unit in France before
appurtenant structures, as well as promote
According to a statement issued by the
shipping it to be anchored on a subsea base
consistency in handling the earthquake aspects
agency in mid-August, there was to be a
built by Nippon Steel & Sumikin Engineering.
of dam performance evaluation among owners,
US$77 per MWh cap in the Sept. 23 reserve

power auction.
This 16-metre turbine will be the first
designers and various organizations involved
commercial-scale tidal device to be deployed
in the planning, design, construction, opera-
in Japanese waters, OpenHydro Chief
tion, maintenance and regulation of dams.
In Brazil, power purchase agreements are

awarded to developers who submit the lowest
Executive Officer James Ives said. Through
Bulletin 157, Small Dams: Design,
bids for the price of power to be sold from
this demonstration project, we will work with
Surveillance and Rehabilitation, was prepared
their plants, with the government buying
our consortium partners to foster local skills
as a guide for small dam owners, engineer-
capacity using a reserve model to protect
and expertise.
ing, government agencies, developers and
against a future supply deficit.
Once installed, the pilot turbine will
contractors who are in charge of the design,
The cumulative capacity from the upcom-
undergo a year of tests that will, developers
construction, operation, maintenance and
ing auction is about 990 MW, Aneel said, with
hope, lead to the development for larger
safety of small dams. The bulletin says, Design
PPAs to be awarded in 30-year deals.
installations around Japan.
criteria and typical features for small dams are
The auction was scheduled for late July
generally different from those for high dams,
but rescheduled. Aneel plans to hold another
More Marine Hydrokinetics news

because the construction methods focus upon
reserve auction for renewables later this year.
Tidal energy company tests prototype in
recommendations to ensure that the dams will
Canadian archipelago, Haida Gwaii

MHK turbines possible for Indias power
infrastructure
economy. This bulletin presents the main

behave appropriately and with minimum cost.
More Business & Finance news is

Bulletin 166, Inspection of Dams follow-
Green Fuel needs $300 million to build
ing Earthquake Guidelines, is a revision of
Condo Dam, 200 MW hydro powerhouse
previous bulletin 62A, published in 1988.
in Zimbabwe
DAMS/CIVIL STRUCTURES
Inspection of dams following earthquakes
China loans Argentina US$25 billion for
ICOLD releases four new
is an important aspect in the integral safety
energy projects, including hydroelectric
technical bulletins on dams
concept of dams, ICOLD says. Since 1988,
The International Commission on Large
earthquakes have occurred that have caused
ENVIRONMENTAL
Dams has released four new technical bulletins
damage to dams. Large dams should be able
Brazilian regulator rejects environmental
related to various aspects of dams.
to resist the effects of the strongest ground
license for 8,000 MW Sao Luiz do Tapajos
Bulletin 146, Dams and Resettlement
shaking to be expected at the dam site.
Brazils Institute of the Environment and
Lessons Learnt and Recommendations,
However, major damage is accepted as long
Natural Resources, Ibama, will not award an
is intended to be an information source for
as there is no catastrophic release of water
environmental license for the Sao Luiz do
policy makers and implementers. It highlights
from the reservoir, the bulletin says.
Tapajos plant, effectively ending development
the latest policies, criteria and resettlement
The bulletins can be purchased at www.
measures adopted, their implementation
icold-cigb.org/GB/Publications/bulletin.asp.
of the 8,000 MW project.
The federal regulatory agency announced

its decision in early August following reports
aspects and the performance or effectiveness of
by public prosecutors that the project would
living standards and quality of life of the relo-
More Dams & Civil Structures news

cation. The bulletin deals with issues implied
BC Hydro responds to concerns about
Indians near Itaituba in Brazils Para state.
the mitigation measures taken to improve the
by resettlement, explains case histories and

lessons learned, and recommends strategies.
Bulletin 148, Selecting Seismic Parameters
fracking and dam safety
The land, known as Sawre Muybu, was
Pennsylvania announces $25.7 million in
officially acknowledged by indigenous pop-
funding for dam safety improvements
ulation authority Funai earlier this year. The
designation gives the land protection from
for Large Dams Guidelines, is a revision
of previous Bulletin 72, with the same name
destroy traditional lands of the Munduruku
BUSINESS & FINANCE
potentially invasive developments.

The US$8.6 billion plant was being devel-
and published in 1989. This bulletin takes
Aneel sets cap price for upcoming
into account current practice in a number
Brazilian hydroelectric power auction
oped by state-run utility Eletrobras and was one
of countries, with a view toward providing
Brazilian power regulator Agencia Nacional
of more than 250 hydroelectric plants and dams
a guide for the selection of parameters to be
de Energia Eletrica (Aneel) has set wholesale
publicly opposed by hundreds of members from
1609HRW_6 6
www.hydroworld.com
9/14/16 4:19 PM
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1609HRW_7 7
9/14/16 4:19 PM
WORLD NEWS
four Amazonian tribes in May 2015.
two power stations, this scheme will ideally
A concession auction for the projects
complement the volatile electricity generation
development was also previously revoked in
from wind power, which has been growing
September 2014 after Brazils Ministry of
significantly in recent years.
Phase two of rehabilitation and upgrade

beginning at 40 MW Matala in Angola
Tractebel awarded contract to modernize
Perus 1,008 MW Mantaro plant
Mines and Energy determined that the proposal did not meet a number of environmental
and social criteria.
Sao Luiz do Tapajos is the largest component of the proposed12,000 MW Tapajos

complexon the Tapajos and Jamanxim rivers
in northern Brazil. The complex also is to
EC approves Czech Republic hydroelectric
Plans announced for 300 MW
power support scheme
pumped-storage project in Scotland

Duke receives 30-year FERC license for
868-MW Keowee-Toxaway project
802 MW Cachoeira do Cai projects.
The European Commission has found that a

scheme which supports hydroelectric power
production in the Czech Republic to be con-
gruent with European Union state aid rules,
include the 2,300 MW Jatoba, 528 MW
Cachoeira dos Patos, 881 MW Jamanxin and
REGULATION & POLICY
More Pumped Storage news is

REHAB & UPGRADE

Final upgrade testing begins at Statkrafts
the organization said earlier today.

The announcement stems to September
350 MW Nedre Rossaga plant
2015, when the Czech Republic notified
More Environmental news is

A three-month test period for a new unit at
the EU of its plan to provide the opera-
Norways Nedre Rossaga hydroelectric plant
tors of hydropower projects up to 10 MW
US$7.3 million Tibble Fork Dam rehabil-
is under way, utility Statkraft announced. The
in capacity with support totaling up to
itation project temporarily ceases reservoir
225 MW unit is located in a new powerhouse
US$9 million.
drainage
built by Statkraft over the past three years and
Under environmental protection and
will replace three of the facilitys original six
energy guidelines established by the EC in
units once the test period ends.
2014, member states can support the produc-
Strategies used at 18 MW Rwegura
hydroelectric facility in Burundi to deal

with low water levels
The company said the remaining three

units in Nedre Rossagas old station have
tion of energy from renewable sources under

certain conditions.
PUMPED STORAGE
already been upgraded, giving the upgraded
According to the guidelines, hydro
Andritz awarded supply contract for
project a total installed capacity of 350 MW
installations with a capacity below 500 kW
880 MW Gouvaes pumped-storage plant
following the installation of the new unit.
will receive support in the form of a market
Equipment supplier Andritz Hydro GmbH
The plants cumulative capacity was 100 MW.
premium paid on top of the market price,
has been awarded a contract by utility
HydroWorld.com reported in March 2013
while those below will receive a feed-in tariff.
Iberdrola Generacion to supply electrome-
that the contract to supply the equipment
The EC said this, alongside a similar plan
chanical equipment and a penstock for the 880
was awarded to Voith Hydro as part of a
for the Czech Republics biogas sector, will
MW Gouvaes pumped-storage hydropower
US$12.9 million package that also included
minimize the potential distortion of competi-
plant in Portugal.
turbines for Statkrafts Oevera Roessaga and
tion brought about by the public financing by
Vessingfoss plants.
ensuring that these payments do not exceed
The order, worth about US$156 million,
includes the design, manufacture and instal-
By increasing the tunnel capacity and the
lation supervision for four 220 MW turbines
efficiency of the new equipment, the total
that will operate with a net head of 660 m.
power output of Nedre Rossaga will increase
Both initiatives are part of the Czech
The penstock will have a total weight of about
by 200 GWh per year, Statkraft said. In
Republics effort to increase its target of
12,000 tons, an average diameter of 5.4 m and
total, the annual generation of the power plant
making renewable sources account for 14%
a length of 2.5 km.
will reach 2,100 GWh, or 2.1 billion kWh of
of its total image consumed by 2020.
Andritz said Gouvaes will be the heart
the minimum level necessary to achieve the

schemes objectives.
renewable energy.
of a new 1,200 MW complex on the Tamega
The upgrade was part of a $165.5 million
River in northern Portugal. A pair of smaller
project announced by Statkraft in March 2010.
More Regulation & Policy news is

conventional hydroelectric plants will also
Construction began in January 2013 and also
Slovenske Elektrarne to petition
eventually be constructed.
included more than 19 km of tunnels and
Constitutional Court of the Slovak
environmental improvements.
Republic
Gouvaes will cover the need for peak-load
Group suing Portland General Electric
energy and provide fast-responding regulating

power, Andritz said in a release. Together
with this base load generation from the other

1609HRW_8 8
More Rehabilitation & Upgrade news

over operation of its Pelton Round Butte

project
www.hydroworld.com
9/14/16 4:19 PM
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T E C H N O L O GY A N D I N N O VAT I O N
International Guide to Hydro Innovations and

New Technology
In this first-ever international product and technology guide, we present
data on how several companies are helping owners of hydro plants and
dams manage their facilities and maximize efficiency.
By Gregory B. Poindexter
ydropower represents about 80% of
product and information on case studies and
the worlds installed renewable power
practical applications.
generation capacity, according to the
The monitoring system consists of a set of
robust high-frequency sensors and amplifiers,

a high-speed data acquisition and signal pro-
International Energy Outlook 2016. As
Cavitation monitoring software
such, the power source is a key ingredient in
Voith Hydros HyConMD cavitation moni-
the worlds commitment for developed and
toring module has been tested in Switzerland,
developing countries to reduce greenhouse gas
Norway, Canada and Germany in seven
Based on the measured acoustic emissions
emissions in the coming decades.
hydropower plants that include 210 MW
and commonly available machine data such
cessing unit, and an analysis software module.

The sensors can be attached from the
outside to the turbine.
A variety of methods are needed to
Wallsee-Mitterkirchen owned and operated
as rotational speed, the software module
efficiently manage and expand uses of this
by Verbund Hydro Power GmbH, according
calculates a characteristic value classifying
incredible resource. New software develop-
to Voith.
the state of cavitation (no, acceptable, strong,
ment for hydropower control and monitoring
Two recently completed case studies from
severe). A key advantage of the method is
applications is essential for this industry, as
operational hydropower facilities and turbine
the fact that no individual calibration of the
well as hardware that is applied at projects in
prototypes indicate the HyConMD cavitation
system is necessary. This allows the user to
innovative ways.
monitoring module provides reliable online
assess the cavitation in different machines
HRW-Hydro Review Worldwide has
information about the cavitation behavior of
independent of machine size and speed and,
identified new technologies; hardware that
a hydraulic machine. Cavitation potentially
most importantly, without prior knowledge
is in development, testing or deployment; and
limits the operational range of hydraulic tur-
of machine characteristics.
innovative applications for existing methods.
bines. It causes noise and vibrations and can
Both long-term and short-term obser-
What follows are short descriptions of each
even erode the surface of turbine components.
vations are possible, each giving important

insights into the machine behavior and
providing directions for the operation of the

machine. The instantaneous or short-term
data can be used for an optimization of the

operating range, while a long-term evaluation
of the signal supports an individual, condition
based adjustment of the revision intervals.

Seal management system
Wartsilas REvolution digital management
system can revolutionize sealing technology
for hydropower customers. It incorporates

machine learning, predictive modelling and
The HyConMD cavitation module monitoring system can help prevent runner erosion.
1609HRW_10 10
model predictive control (MPC) techniques

www.hydroworld.com
9/14/16 4:19 PM
to provide hydropower plant owners and
operators with intelligent, real-time active

management of the sealing interface fluid film
(pressurized water interface), minimizing wear
and removing the turbine sealing components
from the maintenance schedule critical path,

the company says.
The application of advanced control
techniques enables modern mechanical face

seals to overcome operational issues such as
excessive leakage and degradation of wearing

components. Both are caused when the offdesign-point operation of the seal occurs. This
can be transiently, such as during start up or
shut down conditions when the hydrodynamic

lubricating film of a traditional mechanical
face seal degrades and asperity (abrasive)
contact occurs, or it can be a result of debris
The REvolution system collects performance data, including seal interface wear and pressure.
or abrasives entering or possibly occluding

the interface.
The adaptation of a balanced mechanical
face seal to incorporate an optimally con-
conditions enables real time predictive wear
types of dams that include: roller-compacted
forecasting, which enables optimal mainte-
concrete, concrete faced rockfill, rockfill,
nance routines.
earthfill, thin arch, multiple arch, buttress,

and gravity.
trolled injection of clean lubricating water

directly into the sealing interface mitigates
Dam facing geomembrane
excessive interface wear, eliminates abrasive
Carpi Tech B.V., established in 1963, works
performed in dry conditions and underwater,
contamination and optimally manages leak-
with geomembrane scientists and formulators
when dewatering is not an option.
age. An adaptive MPC is used to manage
to deploy watertight, flexible polyvinylchloride
A case study indicates an innovative use
the pressure and flow of the injection fluid.
(PVC) geomembrane for specific site applica-
of the system in waterproofing the upstream
The analysis and predictive control action
tion. Carpi watertight geomembranes provide
face of the Nam Ou 4 Dam in Laos. The study,
yields optimal sealing performance and can
waterproofing and protection of all types of
Nam Ou VI: Geomembrane Face Rockfill
balance costs associated with leakage, wear
hydraulic, civil, underground and environment
Dam in Laos, was presented at the 2015
and maintenance.
protection structures.
Australian National Committee on Large
Carpi geomembrane installation can be
The REvolution system combines the
Typically, Carpi uses its patented geomem-
Wartsila REguard (a pump guard) mechan-
brane mechanical anchorage system and acts
The system is being constructed as part
ical shaft seal technology with a control and
as a specialty contractor to install exposed
of the 1,156 MW Nam Ou River basin
monitoring system package that includes
PVC geomembrane on the upstream face
project. The entire river basin project will
pressure, flow, temperature and wear sensors
of a dam.
feature seven dams and powerhouses with
within the seal.
Dams conference.
Since 2006, Carpi has performed extensive
projected installed capacity of 1,156 MW
Seal performance data are fed into a central
research to adapt geomembrane systems for
and annual generation of 5,017 GWh. The
controller running proprietary data analysis
new installation and rehabilitation for several
project is in the provinces of Phongsaly and
and control software. This enables the modification of the seal interface injection pressure in
real-time. Data are accessed via a supervisory
control and data acquisition system that can

also operate as a standalone system.
The application of advanced digital controls and data acquisition provide the capa-
bility of optimizing performance throughout

the seals entire operating envelope. The
collection and use of historical data collected
during operation through monitoring, local
analysis and logging of the seal operating

www.hydroworld.com
1609HRW_11 11
The longevity of this patented system is one a the main benefits of Carpi geomembranes.
9/14/16 4:19 PM
of Munich in Germany, and Italys Istituto Sperimentale Modelli E
Strutture, which many in dam safety and the hydropower industry

consider a top hydraulic research institute.
Ultrasonic flow measurement
Ultraflux has tackled accurate flow measurement at hydropower
facilities (i.e., better than 1% accuracy) in tough hydraulic conditions

(e.g., insufficient straight length). These applications used up to eight
ultrasonic chords, and in some cases required the installation of probes

inside pipe where external access for use of insertion probes was not
possible. The resulting precision flow measurement was used to calculate
Ultraflux is able to install probes for pipe diameters up to 10 m.
turbine capacity.
Luang Prabang, and the total cost is expected to be US$2.8 billion.
in France and all over the world, including: Brazil, South Africa,
According to Carpi, the Nam Ou 4 scheme includes an 88 m-high
Morocco, Georgia and in the UK. Ultraflux has been tasked with
geomembrane faced rockfill dam (GFRD), which will be the highest
installing multi-chord ultrasound flow meters on existing pipes that
GFRD in Laos. The only element providing watertightness to the dam
have 1,800 mm to 2,700 mm diameter and, in one case, pipes exceeding
is an exposed composite PVC geomembrane, installed according to
7,000 mm in diameter.
Ultraflux installed products for hydropower generation applications
an innovative design now being increasingly adopted to construct safe
rockfill dams at lower costs.
In the South African hydroelectric plant operation for four penstocks

at 7.4-m in diameter, the measurement system installed by Ultraflux
The liner is a composite geomembrane (geocomposite), SIBELON
uses clamp-on probes to regulate the plants flows and protect against
CNT, comprising a watertight PVC geomembrane that can withstand
the risk of flooding in the valley. The project combined an acoustic
elongation exceeding 250% of its original shape and an anti-puncture
transmission test using a portable flow meter and SE 1599 probes in
geotextile heat-bonded to the geomembrane during manufacture.
direct configuration that helped optimize system application.
Carpi geomembrane systems have been tested by the U.S. Army

Corps of Engineers, Hydro-Quebec in Canada, the Technical University
Ultrasonic flow measurement is one of the technologies that still

has the potential for improvement and growth.
Harness the power

from the water
At Ingeteam each project is addressed from the
concept of i+c, innovation to develop the best solutions
and commitment to provide the best service.
We provide comprehensive solutions for hydropower
plant electrical and control systems, integrating
proprietary technologies for automation, protection,
regulation and synchronisation.
Our independence, capability and experience in
renewable energy generating plants allows us to
offer protable solutions, with the highest levels of
availability, reliability and safety. Solutions tailored to
meet the specic needs of each and every customer.
The formula of the new energy
ISO 9001 / 14001 / OSHAS 18001
www.ingeteam.com
hydro.energy@ingeteam.com
Control, Protection
and Regulation Systems
Electrical Systems
Substations
READY FOR YOUR CHALLENGES
1609HRW_12 12
www.hydroworld.com
9/14/16 4:19 PM

--

-

1609HRW_13 13
9/14/16 4:20 PM
The floating bulkhead system is comprised of individual modular
components that are floated into place to enclose the area being
dewatered. The system Kuenz designed for Verbund Hydro was used
for operation at the spillways of the 12 m-high by 143 m-long Mixnitz
Dam and the 19 m-high by 53 m-long Moetschlach Dam, both located

on the Mur River in Bruck an der Mur, Styria, Austria.
In creating the technology for Verbund Hydro, Kuenz says it

now has the ability to develop multiple construction kits applicable
to address varied spans and heights of intakes, affording choice to
hydro project owners.
The Kuenz floating bulkhead system can be floated in for use.
The elements are lowered by a mobile crane upstream into water
before being floated in place in front of the gate bay. Once all bulkhead
The company says it is able to: offer system analyses and diagnostics
to customers on site; measure speed over several [pipe] sections so that
elements are mounted, the bay can be dewatered.

The floating bulkhead systems main advantages are:
the various flow speeds can be taken into account; provide controlled
Systems elements can be lifted directly from the shore into the
and reliable measurements to reduce uncertainty about flow dynamics;
reservoir because they are floatable, negating the need for relatively
mount probes under load; and allow for consistent repeatability of
large gantry-type cranes;
applications throughout entire projects.
Construction kit can cover several different types of intakes;

System is designed for temperatures between minus 20 degrees
Celsius and 40 C; and
Floating bulkhead
Hans Kuenz GmbH specifically developed its floating bulkhead tech-
Expected lifecycle of system components is more than 70 years,
nology for the needs of Verbund Hydro Power GmbH in Austria. The
according the European Standard DIN 19704.
power producer was seeking a system for some of its hydroelectric
Because it is not possible at the Mixnitz Dam spillway to remove
facilities that could be used to dewater spillway gate bays to allow
the bulkhead gates using a gantry crane, the floating bulkhead system
for inspection, without the need for major civil work rehabilitation
resulted in a dewatering mechanism of the gate bays with minimal
or new construction.
civil work modification, which helped reduce overall on-site costs.
Hydro-Mechanical Equipment
Gates, Flaps, Stop Logs, Screens, Trash Rack Cleaning Systems
Hans Kuenz GmbH | 6971 Hard - Austria
T +43 5574 6883 0 | sales@kuenz.com | www.kuenz.com
1609HRW_14 14
www.hydroworld.com
9/14/16 4:20 PM
Low-head turbine-generator
Verterra Energy is developing the Volturnus, a modular hydropower,
3 m-diameter, low-profile vertical-axis riverine turbine-generator that

has a capacity of 5 to 10 kW.
The company has received three U.S. utility patents and eight foreign
fillings, including within the European Union. The pioneering patent
issued for this technology was issued on July 16, 2013: Turbine System
and Method United States (U.S. 8,487,468 B2).
Volturnus uses the power of flowing water to generate electricity and
the company says its units have minimal impact on the environment.
The device has a patented vertical axis design that allows it to
operate in water at depths of less than 2 m. Its design includes the use
of a parapet a low protective wall along its upstream edge that
The low-profile Volturnus unit has a capacity of 5 to 10 kW.
allows the Volturnus to deflect and self-clear debris, which is ideal for
low-profile riverine turbine-generator component, which is significant.
reliable operation in man-made canals and rivers.

The company has designed, developed and built three generations
The device recorded nearly 32% efficiency in a 1.1 meters per second
of prototypes over the past five years. Verterra is in talks with four
(mps) flow with turbine rotation approaching 100 rpm. That velocity
cities in the U.S. and international project developers in Italy, Haiti
range of 0.5 to 1.1 mps for the scaled-prototype is the equivalent of a
and Tajikistan.
commercial scale turbine in flows of 1.5 to 2.5 mps.
In September 2015, the company tested a 0.5 m-diameter scale
Volturnus, V-PODS with a nameplate capacity of 50 kW each, will
prototype in the Crow River in Rockford, Minn., and a manmade
be deployed modularly scaling up to 1 MW with 20 V-PODS. This
canal. The testing was performed in multiple locations over the course
is analogous to the solar industry in which solar panels are deployed
of six weeks. The overall water depth ranged from 20 to 30 inches with
in arrays rather than as one large and costly unit.
the depth over the lip of the device varying between 3 to 7 inches.
Verterra saw between 29% and 50% coefficient of power depending
on water velocity, as calculated by the forward swept area of the
Gregory Poindexter is associate editor for HRW-Hydro Review Worldwide.
Standard and customized seals

for hydro power plants

and above

sealing materials

installation time

Sealing solutions from SKF

Gabelhoferstrae 25, A-8750 Judenburg
SKF Sealing Solutions Austria
GmbH
Phone:
+43 (0)3572 82555-0,
Gabelhoferstrae 25, 8750 Judenburg
Fax: +43 (0)3572 42520,
Phone: +43 3572 82555-0, machined.seals@skf.com
Fax: +43 3572 42520
skf.com/seals
machined.seals@skf.com, www.skf.com/seals
www.hydroworld.com
1609HRW_15 15
9/14/16 4:20 PM
BEARINGS
Solving High Intermittent Bearing Vibration after

a Modernization and Upgrade
The Unit 1 upper guide and thrust bearings at 125 MW Tungatinah
experienced intermittent high vibration after an upgrade and
modernization. The author developed a novel integrated vibration
analysis approach to find the root cause and propose a solution.
By Enes Zulovic
he 125 MW Tungatinah Hydro Power Station in central
the oil thrower ring on the lower guide bearing found to have contacted
Tasmania has five vertical shaft generating sets commissioned
the stationary oil pot. Testing over three days showed improvement in
from 1953 to 1956, each comprising a 26.1 MW Francis turbine
all vibration levels and the machine was RTS.1
and a 31.25 MVA synchronous generator. From 2010 to 2014, Units
Five days later, a significant increase in bearing orbits and housing
5, 1 and 2 in that order underwent upgrade and modernization.
vibration was recorded. The vibration trends captured show significant
Unit 1 was returned to service (RTS) in January 2013 and almost
variation in amplitude for each machine start despite operating at
immediately experienced unpredictable, intermittent and unacceptably
consistent loads.
high vibration. A condition monitoring system is installed on this

unit, and a portable vibration system was used for commissioning. The
Novel integrated approach for vibration analysis
increase was recorded at all three bearings but was particularly noticeable
This article proposes a systematic, analytical approach to resolving
at the upper guide and thrust bearing assembly (see Figure 1 on page
vibration problems. Basic elements of the approach are:
20).1 Maximum shaft orbits increased for all three bearings and upper
System of logic
guide bearing housing vibration reached 3.8 mm/s (unacceptably high).
Integrated approach
The unit was inspected in March 2013, initially focusing on the
upper guide, lower guide and turbine guide bearings. Clearance on all
Definition of vibration as a ratio of the dynamic forces acting on a

machine to its support stiffnesses.2
was acceptable, with the upper guide bearing showing no damage and
System of logic
Ask: Why did this turbine fail and not the nearly identical turbine
next to it?3
Example: Unit 1 experienced high intermittent vibration but not Unit 5.

Idea: Compare the failure case and a case as similar as possible that
did not fail.
The Unit 5 concrete beams at the generator level were cut to allow
for spiral casing assembly and replaced with a heavy steel welded
structure that restored the foundation stiffness.
Integrated approach
Vibration analyses should include a review of the following:
Shaft alignment: Evaluate against major acceptance criteria hori-
zontal level <0.02 mm/m, shaft static runout at the journal of the turbine
This view of Unit 1 from the turbine floor, looking up, shows the two heavy
guide bearing as a percentage of bearing diametral clearance <35%,4
steel I-beams that replaced the removed concrete reinforced beams.
generator air gap stator eccentricity 3% and rotor eccentricity 1.5%.5
1609HRW_16 16
www.hydroworld.com
9/14/16 4:17 PM
Repair - Retrofit - Design - Align
Large Bearing
Specialists
www.hydrotech-inc.ca
Hydro Tech Inc., Sault Ste. Marie, Ontario, Canada
T +1 705 946 3182
info@hydrotech-inc.ca
1609HRW_17 17
9/14/16 4:17 PM
Balancing: ISO 1940-1 gives recommenda-
tions for maximum allowed unbalance, determined by rotating mass, rotational speed and
be 70% of bearing radial clearance.
Machining tolerances: Standard IEEE

3
810 to be applied for the shaft.
result of other root causes occurring. To prove

the relationship between vibration and stiffness, the following actions were conducted:
balancing grade. Balance quality grades (in mm/
Vibrations: According to some hydro
a) Concrete foundation vibration testing
sec) are designated according to the magnitude
industry experience and proven practice, ISO
using seismic accelerometers: The founda-
of eper, the distance of the mass center from the
7919-5 and ISO 10816-5 are not sufficiently
tion responded with vibration amplitudes
shaft axis. But it makes more sense to define
defined as vibration standards.
of 30%, exceeding the recommend values
balance quality grade in terms of eccentricity.
Stiffness: Vibration is a ratio of the
of 25% of the bearing housing vibrations.
We recommend precision dynamic runner
dynamic forces acting on the machine to its
Unit 4 is very sensitive to machine load and
workshop balancing and site rotor two-plane
stiffnesses. Viewed this way, the focus becomes,
the concrete foundation vibration increased
precision balancing be performed to a balance
What has changed in the machine, the forces
up to 2.5 mm/s root mean square (rms)
quality grade <Q1.6, or calculated eccentricity
acting on it or its stiffnesses?2 Vibration is a
when load exceeded 24 MW;

b) Turbine shaft bump test for natural fre-
quency: Shaft natural frequency is less than

calculated;
c) Stator frame bump test for natural frequency: Result not repeatable;
d) Trial by compactor of excitation of the
concrete foundation to determine its natural frequency: It was not possible to excite
the concrete foundation at the generator

level with the small compactor when speed
control was not variable;
e) Exciter shaft balancing: Exciter shaft resonant frequency is about 36 Hz, but due to
the low stiffness of the exciter support, it
was subject to high vibrations in dynamic
operating conditions;
f ) Adding two metal stiffeners to the concrete

foundations: This increased the foundation
stiffness, reduced overall machine vibration
and moved the shaft resonance far from
We embrace your vision

as our own.
the operating speed;
g) Adding eight radial stiffeners to the thrust

bracket: Vibration testing provided confi-
dence that the additional radial stiffeners
Your challenges are transforming the way you

do business. We understand that your needs
are changing rapidly and that you need a
partner who is proactive in identifying the larger,
long-term issues affecting your business.
Welcome to a new era. Together we can build
positive change.
were providing a stabilizing effect on the

thrust bracket assembly; and
h) Trim rotor balancing: This provides addi-
tional margin on the shaft critical speed

by reducing dynamic unbalanced forces.
Shaft critical speed

In traditional design processes, the only
needed check is calculating the shaft first
Contact us at hatch.com
natural frequency and assuring this is at

least 1.25 higher than the highest runaway
rotational speed. This frequency was calculated

under the assumption that the bearings are a
rigid support model, so that the calculated

natural frequency was always much larger
1609HRW_18 18
than the frequency experienced in operation.

www.hydroworld.com
9/14/16 4:17 PM
To calculate the shaft system natural fre-
Figure 1 shows that once the unit is steady
and generator floor. As left alignment was
quencies and machine steady state response, the
at 0 MW, it oscillates between a resonant
good, with a shaft plumb of 0.005 mm/m and
computational model for a hydro rotor should
and non-resonant condition, evident by the
the runner centralized in the wearing rings.
combine a finite element model (FEM) with
dramatic variation in vibration levels at the
However, as found shaft plumb was 0.029
varying guide bearing stiffnesses, foundation
upper guide bearing.
mm/m (acceptance <0.020 mm/m) and the
runner was about 0.500 mm offset in the seals.
stiffnesses, the gyroscopic effect, unbalanced
magnetic pull (generator air gap), and hydraulic
Foundation structure
and mechanical forces (shaft misalignment and
During work on Unit 1, sections of flooring
Station foundation vibrations
runner and rotor unbalance).
concrete were removed to install a new spiral
To understand the relationship between
The turbine generator shaft rotating system
casing down to the turbine floor. Enlargement
vibration and foundation stiffness, tests were
natural frequency of lateral vibrations varies
of the existing openings included removing a
conducted using seismic accelerometers from
with bearing stiffness and can be significantly
concrete floor beam and slab in the operating
PCB Piezotronics installed at the generator
less than calculated if this stiffness is insufficient.

Detailed investigation
Hydro Tasmania technical personnel conducted
root cause analyses from April to June 2013 to
help identify the cause of the unusual machine

condition. Tests of changing conditions, loads
and sequences on Unit 1 and the other machines
in service were performed. Results showed the

vibration was not speed (mechanical balance)
related but that increased vibrations of the
stator frame and stator core when excitation
(electrical force) was applied were evident.
Comprehensive inspection and partial strip
PRODUCTS
BUILT ON
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RELATIONSHIPS BUILT ON
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down of Unit 1 was performed, and a thorough
investigation of the surrounding structure.
When the unit operates at its resonant

frequency, it responds more strongly, which is
observed as higher vibration levels. If the unit
is operating close to its resonant frequency,

a small change in force or perturbation may
cause the resonance to be excited. Analyzing
a polar plot of the shaft displacement after
a Unit 1 overspeed test suggests a resonant
frequency exists close to synchronous speed.
Resonance is indicated by a 180 degree phase

shift in vibration and is displayed in polar
coordinates as a circle formed by changing
machine speed, with actual resonant frequency
Whatever your challenge, weve got the

people, skills and products to meet it
head on. Were a company steeped in
experience and rich in innovation. We are
American Hydro. Speak to our skilled team
and set a performance challenge for us.
being the furthest point on the circle.

Evidence was seen of a resonant frequency
at the upper guide bearing around 608 rpm,

very close to the operating frequency of 600
rpm. With a resonant frequency so close
Call
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to the synchronous speed, the sudden step

changes in vibration may be explained by only
American Hydro
a small perturbation to the machine causing

the resonance to be excited. Likewise, a similar
perturbation could de-excite the resonance

and cause a step down in vibration.
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1609HRW_19 19
| +1 717 755 5300

| info@ahydro.com
A Wrtsil Company
EN G IN E ERI
ERINN G | P ERF ORMAN CE UP GRAD ES | RE HABI LI TATI ON | N EW UN
UNIT
IT S | FIE L D S E R V IC E
9/14/16 4:17 PM
low stiffness of the exciter housing combined
Figure 1 Vibration Data

5
with its shape as a cantilever beam extending

MW
from the operating floor caused it to vibrate
25
up to 12 mm/s rms on occasion as the foun20
UGB 90 degree
15
10
4 tuned in to the exciter housing at 36 Hz.
Stator design
The stator is assembled in two halves. The key
1
0
11:11
dation structural vibration initiated from Unit

MW
Amplitude
UGB US
3
5
0
11:21
UGB US
UGB 90
11:31
Time
LGB US
LGB 90
11:41
11:51
bars are welded into cut-outs in the frame and
shimmed dovetail strips are bolted to the inner

surface of the bars for stacking of the lamination
plates. The stator frame/core consists of 32 key

TGB US
TGB 90
Axial
MW
This vibration data captures the upper guide bearing housing step change in vibration
levels after excitation as measured on March 28, 2013.
bars welded to the frame diametrically around
the inner bore. A dovetail key is spaced from

the key bars using small sections of plate and
fastened by 11 countersunk 0.5-inch screws.
Based on stator core and frame vibrations
level on all five machines.6 Vibration analysis
Piezotronics were installed outside the Unit 1
increasing when excitation is applied, it
revealed the power station structure is suscep-
stator. Further analysis conducted during RTS
appeared Unit 1 was experiencing a loss of
tible to vibrations produced particularly by
testing revealed that as Unit 4 load fluctuates
core to frame connection. Specifically, the
Unit 4. With Unit 1 shut down, vibration up
above 24 MW, it would occasionally initiate
loss of the dovetail to keybar connection was
to 0.4 mm/s was recorded outside the Unit 1
structural vibration up to 1.4 mm/s in the
identified as the likely possible root cause
alternator enclosure (see Figure 2 on page 22).
station floors. Similarly, high vibration was
due to inherent flaws in the dovetail design
High sensitivity accelerometers from PCB
observed in the Unit 1 exciter housing. The
arrangement using screws.1,7
1609HRW_20 20
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9/14/16 4:17 PM
The core assembly shows the presence
of a split core design, which is inherent to
with the natural frequency too close to the
the perturbation on the machine, helping
operating frequency;
excite the resonance during operation;
occurrence of vibrations of 100 Hz. In the
Removing the concrete beams reduced unit
Station concrete structure is not rigid and
split design, the joints between the stator core
stiffness and shifted the natural frequency
is noticeably affected by the operation of
sections should be tight to reduce the core
at the upper guide bearing support assem-
vibrations amplitude due to the pole passing
bly closer to the operating frequency;
magnetic forces. If the joints become loose,
As the upgrade and modernization included
the vibration root cause on hydro gen-
high amplitude core vibrations at 100 Hz
the installation and concreting of a new
erating units. The integrated approach
metal spiral case, the changed shaft lean and
described in this article provided distinctly
shift in position is most likely due to settling
better results;
7,8,9
frequency could develop.
Unit 4 when above 24 MW;
There is no simple method for determining
Stator frame shims
of concrete components. This corresponding
Results presented here indicate the value
The Unit 1 stator frame was shimmed using
change in position at the turbine increased
of site testing for quantifying vibration,
10 mm-thick plates to correct axial alignment

of the rotor and stator, which was found to be
incorrect during the upgrade and modernization alignment. This contributed to a decrease
in stiffness of the stator supporting assembly.
Other issues
Other minor abnormalities discovered and
tests performed during the investigation are:
Stator frame weld cracks. During upgrade

and modernization of Unit 5, non-destruc-
tive testing (NDT) of the stator frame

revealed many weld cracks. Inspections of
the other four units revealed similar cracking. The investigation revealed the cracks
were welding defects from manufacture of
the frames and there is a low risk of failure
even with multiple failed joints.

Alternator concrete foundation. Samples of
the concrete inside the alternator enclosure

revealed it to be of poor quality and soaked
with oil after years of leaks from the lower

guide bearing.
Thrust bracket bolts. The thrust bracket

hold-down bolts had been over-torqued
during installation.
Bump tests. A bump test of the shaft was
conducted with the unit free on the thrust
bearing. The shaft at the turbine pit recorded

a distinct natural frequency of 3.9 Hz.
Discussion
Combining the vibration definition (dynamic

force/stiffness) with results of the detailed
analysis and inspections, the following was

discussed to identify the root cause of the Unit
1 high intermittent vibration and provide a
corrective action plan.

Unit experiences a resonant condition at
the upper guide bearing support assembly
www.hydroworld.com
1609HRW_21 21
9/14/16 4:17 PM
It was decided to: increase the stiffness of
Figure 2 Unit 1 Foundation Vibration Response
the upper guide bearing and shift the resonant
2.0
frequency away from the operating frequency

by re-installing the floor beams and adding
1.5
stiffening beams, realign the unit to the set-
Amplitude
tled position of the turbine components and

perform a trim balance of the rotor.
1.0
Corrective work
Work was carried out to increase overall
0.5
stiffness of the unit foundation and at the
upper guide bearing support and to reduce

0
07:29
the dynamic forces: alignment and rotor

07:39
Unit 1 Alt Axial

Unit 2 Alt Axial
07:49
07:59
Time
Unit 3 Alt Axial

Unit 4 Alt Axial
08:09
08:19
08:29
unbalance to control response of the unit
during operation, by shifting the resonant
Unit 5 Alt Axial

Unit 1 Alt Radial
Unit 4 Alt Radial

Unit 1 Op Axial
This figure shows the concrete foundations vibration response (green TU4load related
high levels of 1.38 mm/s rms, blue TU1- low level of 0.1 mm/s rms) of Unit 1 in June 2013,
after corrective work.
frequency from rated speed and reducing the

subsequent vibrations.
Stiffening metal beams: The concrete floor
beams were replaced with steel I-beams. To
provide additional stiffness to the upper guide
as the exciter/shaker testing, to obtain the
bearing assembly, eight more steel beams were
Additional stiffening of the supporting
natural frequency of the components, stiff-
installed at each upper guide bearing bracket
system reduces vibration below the accep-
ness calculations, and site verification tests
leg extending outwards to the alternator
tance by a big margin; and
by using a vibration diagnostic software such
enclosure wall attached to the reinforced top
as Veski (stiffness, shaft critical speed).8,10,11
concrete beam. The new beams were mounted
natural frequencies and stiffness,
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1609HRW_22 22
www.hydroworld.com
9/14/16 4:17 PM
with only light contact to allow for thermal
Unit 1 RTS
and dramatically lower than the previous high
expansion once the unit is online.
RTS testing was performed in June 2013.
vibration recorded in March 2013.
Alignment: The unit was realigned to the
The unit was subject to machine and station
Further evidence suggests the stiffening
settled turbine components and with the runner
conditions previously shown to induce the
beams have shifted the resonant frequency away
centralized to the wearing rings. The upper
resonant vibration, as well as other conditions
from the operating frequency (see Figure 3).
guide bearing was offset to achieve a shaft
common during normal operation. The unit
The machine is again decreasing in speed after
plumb of 0.011 mm/m. Besides shifting the
was subject to multiple starts and stops as
an overspeed test, but there is no indication
resonant frequency of the upper guide bear-
well as long term operation, and the previous
of a resonant frequency close to the operating
ing by improving the stiffness, the improved
resonant condition could not be excited.
frequency of 10 Hz (600 rpm) in the polar plot.
alignment will help minimize the machine
Overall, the shaft orbits and bearing hous-
Since the Unit 1 RTS, vibration levels have
perturbation exciting the resonant frequency.
ing vibration were much lower than during
remained well below the previous levels and
Balancing: During RTS testing of Unit 1,
commissioning in January to February 2013
the unit has continued unrestricted operation.
the balance grade of G1.0 achieved during

initial commissioning was again recorded.
Further minimizing the unit perturbation, the
rotor was successfully trim balanced to a grade

of G0.8 according to ISO 1940.12
Exciter shaft: The new exciter shaft installed

during the upgrade and modernization was
out of balance. The shaft was removed and

dynamically balanced in April to June 2013.
Unit 4 restriction: Structural vibration orig-
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was recorded to similar levels during the Unit
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concrete foundation and further minimize any

disturbance exciting the resonance on Unit 1, a
23 MW load restriction was placed on Unit 4.
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www.hydroworld.com
1609HRW_23 23
9/14/16 4:17 PM
Recommendations
Figure 3 Unit 1 Polar Plot

0
Experience on this project highlights the importance of the following

recommendations:
A hydro-generator rotor model shall combine a FEM with varying guide bearing stiffnesses, foundation stiffness, the gyroscopic
effect, unbalanced magnetic pull (generator air gap), hydraulic force
and mechanical forces (shaft misalignment and runner and rotor

unbalance) to calculate natural frequencies and machine steady state
vibration response.
270
90
Technical specifications shall include all the factors above and
vibration levels determined in conjunction with machining tolerances, runner workshop balance specified as eccentricity (not
residual weight), site shaft alignment tolerances, rotor site balancing,
sufficient stiffness of the support and concrete foundation to keep

the shaft critical speed 15% above overspeed and vibration levels
within acceptance.
An integrated approach to vibration analyses should be applied
180
that considers machining tolerances, installation tolerances, run-
This polar plot from Unit 1 shows the shaft displacement at the
upper guide bearing during a run down from overspeed after
the corrective work was performed.
ner workshop dynamic balancing, shaft alignment, rotor dynamic

balancing, stiffness, stresses, dynamic forces.
Install and monitor vibration equipment on each unit. Vibration
Following completion of the Unit 2 upgrade and modernization
information is crucial to timely identification and diagnosis of
project and installation of new metal support beams, which increased
machine problems. Use vibration software such as that from
the overall stiffness of the foundation at adjacent Unit 2, vibration
Veski that can produce such data as shaft orbits, shaft deflection,
levels at Unit 1 unit have been stabilized and reduced.
slow roll vector, guide bearing alignment, air gap, calculation of
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1609HRW_24 24
www.hydroworld.com
9/14/16 4:17 PM
shaft critical speed and stiffness of the
Notes
supporting structure.
Oreskovic, O., Implementation of Total Machine Condition
Zulovic, Enes, and J. Vandervelde, The Tungatinah Vibration
Monitoring System on Pump Storage Generator in PSPP
When conducting major work on a unit,
Station; Multiple Vibration Issues Requiring Unique
Avce (Slovenia), Proceedings of HydroVision International
consider its impact on unit stiffness, which
Solutions, Proceedings of 16th HPEE, Hobart, Tasmania,
directly affects vibration.
Australia, 2014.
During the rebuild of a unit, ensure the
Instructions on Measuring and Interpreting the Vibrations
Sabin, S., Understanding and Using Dynamic Stiffness A
alignment is within the design specifi-
cation, and allow time for unit balancing
2013, PennWell Corp., Tulsa, Okla., USA, 2013.

9
Tutorial, Bently Nevada, 2000.
on Machines, VDI 3839.

10
Keith, G.G., P. Loustau and M. Melin, Lloyds Register:
during RTS.
Tungatinah unit number 1, Hydro Tasmania, Hobart,
Tasmania, Australia, 2013.
Failure Analysis of Rotating Equipment using Root
Consider the acceptable levels of vibration
Cause Analysis Methods, Proceedings of POWER-GEN
within the power station concrete foun-
dation structure. There are no specific
11
Oreskovic, G., Computerised Diagnostic System, CoDis,
International 2011, PennWell, Tulsa, Okla., USA, 2011.

4
Hydroelectric Turbine-Generator Units Guide for Erection
Internal documentation prepared during testing of
Veski, Melbourne, Victoria, Australia.

12
API Standard Paragraphs Roto Dynamic Tutorial: Lateral
hydro machine standards addressing this,
Tolerances and Shaft System Alignment; Part V
Critical Speeds, Unbalance Response, Stability, Train
but other standards referencing rotating
Maintenance of Vertical Shaft Units (All Types of Turbines
Torsional, and Rotor Balancing, American Petroleum
machinery concrete foundation vibration
or Pump-Turbines) Limits for Key Parameters, Canadian
Institute 684, 2005.
state acceptable vibration is up to 25% to

30% of the bearing housing vibration.
Electricity Association.
5
Nasselgvist, M., R. Gustavsson, and J.-O. Aidanpaa, A
Reference
Due to the complexity of vibrations of
Methodology for Protective Monitoring of Hydropower
Zulovic, Enes, A Novel Approach Solving High Intermittent
vertical-shaft units, it is important to
Units Based on the Mechanical Properties, ASME Journal
Vibrations Following Modernisation and Upgrade
of Dynamic Measurements, March 2011.
Project, Proceedings of HydroVision International 2015,
periodically present advances in analytical

and diagnostic tools and methods and
Machinery Protection Systems, American Petroleum Institute
standards and any new knowledge and
experience (Unit 1 is a good example),
PennWell Corp., Tulsa, Okla., 2015.
670, 2003.
7
Vladislavlev, L.A., Vibration of Hydro Units in Hydroelectric
as well as to review prior knowledge and
Power Plants, (translated from Russian) Amering
Enes Zulovic, MIEAust, CPEng, is specialist hydro
concepts.
Publishing, New Delhi, India, 1979.
mechanical engineer with Acutel Consulting in Australia.
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1609HRW_25 25
9/14/16 4:17 PM
EXECUTIVE INTERVIEW
Viewpoints from the Board Room:

International Finance Corporation
The International Finance Corp. (IFC), part of the World Bank
Group, seeks to invest in responsibly developed and operated
hydropower projects worldwide to grant energy access to impoverished
people in developing nations. In this interview, Morgan Landy
discusses IFCs involvement in sustainable hydro development.
he World Bank Group was
example, in Africa, less than 10% of the
established in 1944 and provides
continents hydropower potential has
financial and technical assistance
been tapped.
to developing countries. Its mission is
IFC has a long track record of
straightforward: Fight poverty with
investing in the hydropower sector.
passion and professionalism, for lasting
Since the early 1990s, IFC has invested
results. To accomplish its mission, the
more than US$1 billion in 25 countries,
World Bank Group consists of five dis-
which include: Chile, Guatemala, Nepal,
tinct organizations:
India, the Philippines, Uganda, Turkey,
International Bank for Reconstruction
Georgia and Pakistan. IFC now has
and Development;
43 active hydropower projects in its
International Development Associ-
portfolio with a total installed capacity
ation;
of 9,942 MW.
International Finance Corporation;
IFC plays a key role in bringing hydro
Multilateral Investment Guarantee
projects to fruition, providing long ten-
Agency; and
ors to match the lives of the assets and
International Centre for Settlement

of Investment Disputes.
taking on risks that traditional banks are

Morgan Landy
reluctant to even contemplate. We offer

innovative ways of providing support to
HRW-Hydro Review Worldwide
hydropower companies, including early-stage
recently interviewed Morgan Landy, co-
risk capital to help projects get off the ground.
make hydropower more sustainable in Asia.
Q: Briefly outline the structure

of IFC and its principal role
in the hydropower sector.
Landy leads IFC in fulfilling its strategic
Landy: Lets first emphasize why IFC invests
debt and equity financing for companies in
commitments to sustainable development.
in sustainable hydropower development:
emerging economies worldwide. Our indus-
He also helps ensure IFC operational growth
Worldwide according to the World Bank
try experts provide clients with solutions to
is achieved through prudent environmental
Group, about 1.4 billion people lack access
strategic financing, blending investment with
and social governance risk management and
to electricity. Of these, 700 million are in Asia.
advice and resource mobilization.
fosters sustainable practices for improved per-
Hydroelectricity accounts for one-fifth of the
With the right approaches in place,
formance in key sectors, including hydropower.
worlds electricity supply but remains severely
hydropower can be sustainable. This is where
The following is a transcript of that
underexploited in many developing countries
IFC comes in. Our environmental and social
and regions with strong hydro potential. For
experts are based across the globe and provide
director of the Transactional Risk-solutions

Department for IFC, to learn about efforts to
interview.
1609HRW_26 26
As a member of the World Bank Group,

IFC is the largest multilateral source of
www.hydroworld.com
9/14/16 4:20 PM
hydropower clients with the tools they need to
Lai Electricity JSC helping to support
strengthen policies and regulations, we aim
make this happen. By investing in sustainable
renewable energy development to provide
to lay the foundation for better investments
operations upfront, our clients learn how to
critical power to the domestic market.
to enter the market.
improve their business outcomes.
Were working to untangle the environ-
Q: What role do institutional investors

play in the sustainable development
of hydropower in Asia? How has
this role changed over time?
mental and social challenges that IFC faces
Q: Could you highlight some

key activities in which IFC is
currently engaged within the
Asian hydropower sector?
Landy: In Asia, IFC is working in key hydropower markets that are challenging environments but also have the potential to have
the most development impact. Our active

portfolio includes a pipeline of five projects
in Nepal, followed by four in India, four in
when developing hydropower including

how to develop sector sustainability. This is
where IFC plays a unique role, especially when
IFC now has 43 active hydropower

projects in its portfolio with a total
installed capacity of 9,942 MW.
Pakistan, three in China, two in Indonesia,
and two in Fiji.
IFC is also looking at opportunities to
working with governments. For example, in
Landy: Developing hydropower in Asia
develop small hydropower projects in Asia,
Myanmar, we are working with officials to
is especially challenging with regard to
including supporting platform companies for
prepare a countrywide strategic environmen-
cross-border projects. IFC often engages
small hydropower development in Indonesia
tal assessment for the hydropower sector. In
in markets with serious environmental and
and other markets where relevant. For exam-
Nepal, we are helping develop guidelines for
social issues, political sensitivity, financing
ple, IFC recently made its first investment
environmental impact assessments. In Lao
challenges and lack of government capacity to
in Vietnams largest private-sector indepen-
PDR, we are assisting with guidelines on
implement.IFC is tackling these challenges
dent small hydroelectric company Gia
cumulative impact assessments. By helping
but cant do this alone. We need to work with
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strategic sponsors and good EPC [engineer-
hydropower sector. In Asia, this begins with
in the near future to similar groups being set
ing-procurement-construction] contractors
intensive capacity-building to help officials
up in Myanmar, Pakistan and Nepal.
and ensure commitments address environmen-
gain an understanding of environmental
IFC, together with our clients, can influ-
tal and social challenges. We require the com-
and social risks in hydropower development
ence how stakeholders are engaged in the
panies we invest in and their sub-contractors
and how they can mitigate risks, followed
hydropower sector. Our continued experience
to adhere to IFCs Performance Standards,
by policy and regulatory development to lay
demonstrates that meaningful engagement
which are our guiding framework on achieving
the foundation to secure good investments.
is invaluable and central to a companys
environmental and social sustainability.
performance.
Q: How can IFC help address

cross-border resource-use issues?
encouraging the financing of new projects to
Q: How else can IFC positively

influence Asian hydropower
development, for example, through
advisory services, education, etc.?
help manage environmental and social risks.
Landy: If you want hydropower to be sustain-
cross-border hydropower projects can help
Vietnam, Indonesia and the Philippines have
able, you need to get the private sector into the
stabilize regional electricity grids and reduce
also adopted green credit policies. However, we
debate. In late 2013, IFC, with government
costs through coordination with thermal
have to continue to work with the state-owned
support from Australia and Japan, established
plants. While we believe in the benefits
enterprises as they invest abroad to ensure they
the Hydropower Developers Working Group
cross-border projects bring, they face many
follow both these policies, set up domestically,
in Lao PDR. Many of the members of this
challenges. Cross-border projects often have
and international standards.
group also develop small hydro projects, and
serious environmental and social issues,
Recently, banking regulators are taking more proactive roles. In China, they
have established green-lending guidelines,
Landy: From the energy perspective,
they provided the government with feedback
political sensitivities, and financing and
Q: How does IFC work with national

governments to establish support for
sustainable hydropower in Asia?
on the countrys then-draft regulations on
implementation challenges.
small hydropower development. This feedback
One example is the 185 MW Shuakhevi
was well received; it was the first time the Lao
hydroelectric plant in Georgia. Shuakhevi is
Landy: IFC advises government agencies on
PDR government involved the private sector
planned to meet electricity demand during the
environmental and social standards in the
in policy formulation. We are looking forward
winter, reduce dependence on imported fuel
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1609HRW_28 28
www.hydroworld.com
9/14/16 4:20 PM
and increase renewable energy output. It will
must ensure that we support projects in the
currently in place. By tapping hydropower
also foster cross-border electricity trading at
right manner, which includes applying IFCs
resources sustainably, we plan to deliver energy
other times of the year by exporting electricity
Performance Standards.
to the people who most need it in the region,
to Turkey through a transmission line financed
In Myanmar, were working to help clients
thus helping to alleviate poverty. We want to be
by the European Bank for Reconstruction
walk the talk and address complex environ-
able to look back 20 years from now and see a
and Development. The project demonstrates
mental and social issues. Complexities include
measurable surge created in access to electricity
that non-recourse cross-border financing is
managing river basins where multiple projects
thats affordable and generated in the cleanest
available for green projects in Georgia and
are planned; conserving biodiversity; and
and most renewable manner possible.
is an example of hydropower strengthening
stakeholder engagement. As our experience
regional cooperation.
elsewhere has shown us, stakeholder engage-
Another example of cross-border power
ment is key if we want to build a sustainable
IFC action notes
engagement closely tied to hydropower is in
hydropower sector in Myanmar. With this
IFC, a member of the World Bank
Nepal. In Nepal, IFC is supporting the first
in mind, we plan to engage through forums
Group, is the largest global development
real movement to harness potentials to export
and platforms where internal and external
institution focused on the private sector
power to India and Bangladesh.
stakeholders can exchange perspectives. The
in emerging markets. Working with
government is supporting our efforts and has
2,000 businesses worldwide, we use
a true commitment to learning, enabling our
our six decades of experience to create
experts to build officials knowledge.
opportunity where its needed most. In
Q: What are some of the key

challenges IFC faces in executing
its objectives with regard to
hydropower development in Asia?
Fiscal Year 2016, our long-term invest-
ments in developing countries rose to
right projects. This is one reason we pursue
Q: What is IFCs perspective on

future hydropower development
in the region and the future role of
IFC in achieving that vision?
sector-wide strategic environmental assess-
Landy: IFCs vision includes a more sustainable
and boost shared prosperity. For more
ments, for example, in Myanmar. Then, we
hydropower sector in Asia beyond what is
information, visit www.ifc.org.
Landy: The challenges we face are two-fold.

First, we must ensure that we choose the
1000
20
nearly US$19 billion, leveraging our
capital, expertise and influence to help

the private sector end extreme poverty
The Hydro Industrys

Proven Authority
Visit
4102
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1609HRW_29 29
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19
29
Andritz Hydro GmbH www.andritz.com
OBC
15
Canyon Hydro www.canyonhydro.com
21
23
Fugesco www.fugesco.com
27
GGB Bearing Technology www.ggbearings.com
20
Gilbert Gilkes & Gordon Ltd www.Gilkes.com
25
26
Gugler Water Turbines GmbH www.gugler.com
29
19
RST Instruments Ltd www.rstinstruments.com
24
Hans Kuenz GmbH www.kuenz.com
14
18
Seals Unlimited Inc www.sealsunlimited.com
24
12
Hatch Associates Consultants Inc www.hatch.ca
18
Siemens AG www.siemens.com
HCS Hydro Component Systems LLC

www.hydrocomponentsystems.com
IFC
10
SKF Sealing Solutions Austria GmbH

www.skf.com/seals
15
14
Hibbard Inshore LLC www.hibbardinshore.com
20
16
Sotek and Belrix Industries Inc www.Sotek.com
22
11
Hydro Tech Inc www.hydrotech-inc.ca
17
Thordon Bearings Inc www.ThordonBearings.com
27
HydroWorld.com www.hydroworld.com
29
25
Vesconite www.Vesconite.com
28
Ingeteam S A www.Ingeteam.com
12
Voith GmbH www.voith.com
28
International Hydropower Association

www.hydropower.org
IBC
Wasserkraft Volk AG www.wkv-ag.com
13
*IFC=Inside Front Cover, IBC=Inside Back Cover, and OBC=Outside Back Cover
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9/14/16 4:20 PM

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Waterpower Week in Washington | May 1-3, 2017 | Washington D.C.

Flagship Media Sponsor:

HOW SIX PRODUCTS HELPED SOLVE UNIQUE PROBLEMS

Easy isnt a benefit, ITS A REQUIREMENT.

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Rugged trash racks and rakers keep

Volume 24. No. 5. September-October 2016

International Guide to Hydro Innovations and

In this first-ever international product and technology guide, we

Solving High Intermittent Bearing Vibration after a

The upper guide and thrust bearing assembly on Unit 1 at the

The International Finance Corp. (IFC) seeks to invest in responsibly

September-October 2016 / HRW 1

Vice President, Group Publishing Director,

entertainment industry for decades. Two examples that spring to mind

inspiration for such technological breakthroughs as cell phones and

Editor Michael Harris

For assistance with marketing strategy or ad creation,

you solve a problem at your hydro facility or dam.

In addition, further information on technology innovation and application is available under

industries are keeping pace.

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Printed in the U.K.. GST NO. 12681 3153 RT0001

As Managing Director of the international

What I like most is the interdisciplinary

colleagues. Together we invest all our

With a global R&D network, Voith Hydro

Dr. Jiri Koutnik

Chia-aig River, at the eastern end of Loch

available, but the GIS should be installed and

Pakistan announces agreement signed

Arkaig. According to RWE, it received consent

ready for operation by 2018, Siemens says.

for 870 MW Suki Kinari project

from the Scottish government in June 2010.

Rogun Dam has a planned height of

The government of the province of Khyber

The Scottish Environment Protection Agency

1,099 ft and is located on the Vakhsh River

Pakhtunkhwa, Pakistan, has signed an agree-

under the Controlled Activities Regulations

ment with SK Hydro Private and Industrial

granted a water license for the project.

Siemens said it is supplying:

and Commercial Bank of China to develop

An intake weir directs water to a

8DQ1 switchgear, which covers voltage

and construct the 870 MW Suki Kinari

3.2 km-long buried pipeline, into a power-

ranges of up to 550 kV and has 21 circuit

house that contains two vertical five-nozzle

Under the agreement, the hydro project

would be built on the Kunhar River in the

Pelton turbines, one each at 1.01 MW and

Mansehra district of Khyber Pakhtunkhwa at

Paul Wheelhouse MSP, minister for

Online monitoring devices on the GIS to

a cost of US$1.9 billion and is expected to be

Business, Innovation and Energy, together

enable automatic remote diagnosis and