Water Power and Dam Construction

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Lahmeyer International GmbH

i www.lahmeyer.de

•

Engineering and Consulting Services

nfo@lahmeyer.de

Naga Hammadi, Egypt

Aftout Essahili, Mauritania

Merowe HEP, Sudan

Mubarak Pumping Station, Egypt

Mujib Dam, Jordan

Three Gorges Shiplift, China

Vianden PSP, Luxembourg

Merowe HEP, Sudan

Basha HEP, Pakistan

Engineering Partner

for Hydropower

ADVERTISEMENT FEATURE

The largest of the four major hydroelectric power projects under

construction in northwestern Vietnam is the Son La generating

station. With a capacity of 10.2 billion KWh per year, it will also be

the largest in southeast Asia when it goes into operation in 2010.

GGB, formerly Glacier Garlock Bearings, has produced custom,

self-aligning spherical bearings for this project based on its DB

material, which is also available as cylindrical and flanged

bearings, thrust washers and sliding plates. The bearings are

installed in the cam rollers in heavy roller gates used for the

maintenance of radial gates that control the reservoir level through

discharge of water from the dam. Roller gates are typically used

where the openings are too large for slide gates, resulting in lower

operating loads and providing for gravity closure.

Hydropower gates open and close infrequently – at most once

or twice a year — but must function reliably and safely when they

do. The primary contributors to bearing failure in these gates are

dirt and corrosion. With this in mind, GGB Brazil designed custom

DB spherical bearings specifically for the application. With outside

diameters of 480mm (18.9 in.) and weighing about 400 kg (880

lbs.) each, they are constructed of a corrosion-resistant, stainless

steel inner ring and an axially split, seawater-resistant bronze outer

ring embedded with solid PTFE lubricant for easy installation.

Running-in film over the sliding surface assures instant full-load

capacity to minimize stick-slip effect.

This structure provides ultra-low friction, maximum wear

resistance, long service life and absolute corrosion resistance, even

in wet, dirty environments. And since they require no additional

lubrication, the new bearings are environmentally friendly and

totally maintenance-free.

Compare GGB’s new spherical bearings with standard offerings

that use non-corrosion-resistant bearings or carbon steel rings, with

only the sliding surface protected by thin chrome plating. The PTFE

sliding liner of these inferior bearings is glued to the outer ring,

allowing water to penetrate, corrode the ring and render the

bearing inoperable. As a result, these bearings require internal

grooves for the addition of potentially polluting lubricant to protect

against corrosion and intrusion of abrasive dirt.

When the roller gates open and close, the GGB DB spherical

bearings oscillate on a stationary, stainless steel shaft. For 32m of

the 85m round trip, they are subjected to loads of up to 4,342,900

N with a specific wear rate of 14 m/km. For the remaining 53m,

they are subjected to a lower guide load with a specific wear rate

of just 2 m/km.

Based on these wear rates, a specific load of 51.3 MPa,

oscillating speed of 0.02m/s and pU factor of 1.1, the estimated

service life of the bearings is calculated at more than 500 years.

In addition to its new spherical bearings, GGB recently

developed two self-lubricating, fiber/resin composite bearings,

HPF

and HPM

for bearings for Francis, Kaplan and Pelton

turbines, as well as gates and valves. These materials are

specifically designed to meet the demands of a wide range of

hydropower applications for high load capacity, low friction and

wear rate and long service life.

CONTACT: For more information contact GGB Canada,

25 Elgin Street, Grimsby, Ontario, Canada L3M 4G7,

tel: +1-905-309-9558, fax: +1-905-309-4901,

e-mail: hydro@ggbearings.com, Web:

www.ggbearings.com/hydro; or contact GGB Austria GmbH,

Gerhardusgasse 25, A-1200 Vienna, tel: +43-(0)1-332 49 92,

fax: +43-(0)332 91 60, e-mail: hydro@ggbearingsd.com,

Web: www.ggbearings.com/hydro.

Vietnam’s Son La project

benefits from maintenance-free,

environmentally friendly bearings

Note the solid PTFE inserts that provide low-friction and eliminate the

need for additional lubrication.

GGB Bearings. 100 years of bearing experience and

superior performance for the hydropower industry.

At GGB (formerly Glacier Garlock Bearings) we know how important it is to preserve the environment as well as your

proﬁts. With GGB bearings you’ll be able to help the environment while also saving on maintenance and man-hours.

Self-lubricating GGB HPM

™

, HPF

™

and DB

™

bearings were speciﬁcally developed to meet hydropower applications

for high load capacity, low wear, low friction and a long service life. So when choosing a bearings supplier, choose

one with a history of superior performance. Choose GGB.

To learn more about GGB hydropower bearings, visit www.GGBearings.com/hydro

or e-mail us at hydro@GGBearings.com

GGB Canada • 25 Elgin Street, Grimsby, Ontario, Canada L3M 4G7 • Tel.: +1-905-309-9558 • Fax.: +1-905-309-4901 • hydro@GGBearings.com

GGB Austria GmbH • Gerhardusgasse 25 • A-1200 Wien • Tel.: +43-(0)1-332 49 92 • Fax: +43-(0)1-332 91 60 • hydro@GGBearings.com

We designed our

maintenance-free bearings

with more than just

your plant in mind.

ADVERTISEMENT FEATURE

Since 1950, Douce-Hydro designs and manufactures custom designed heavy

duty hydraulic cylinders and systems, which are recognized by our customers

for their high quality, advanced technology and service lives.

ouce-Hydro offers his advanced KERADOUCE® COATING on the rods of its

hydraulic cylinders. With over 18 years of experience, this innovative protective

coating has been tested extensively and continually improved. It has proven

extremely effective, particularly where CORROSION is a major concern.

Douce-Hydro brings customized advanced engineering solutions for our

clients’ wide range of applications, such as canals and waterways, radial gates,

intake gates, gangways and ramps, water adduction gates, locks doors, sluice

gates, ro-ro ramps, equipment for seaports, fluvial applications.

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BILLWERDER BUCHT Dam (Germany 2002)

16 DA hydraulic cylinders; 560 bore x 220 rod x 8400 mm stroke

Hydraulic Power Unit – BOGUCHANSKAYA Dam (Russia 2009)

Ser vomotor PUBUGOU Dam (China 2008)

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BOGUCHANSKAYA Dam (Russia 2009)

Douce-Hydro has designed, manufactured, and supplied for the Largest Hydro

Power Scheme under construction in Russia: 10 Hydraulic Cylinders

(Bore 710 mm x Rod 250 mm x Stroke 15000 mm) with Keradouce® Coating and

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Integrated Measuring System + Hydraulic Power Units and Control Panels.

SMALL HYDRO AWARD

WWW.WATERPOWERMAGAZINE.COM MAY 2009 55

• A dry transformer (without oil) was used eliminating the possi-

bility of an oil spill.

• This project has one of the most advanced monitoring systems of

plant operations and environmental variables such as rainfall, tem-

peratures and flows.

• Ongoing monitoring of fish stocks is providing for scientific evi-

dence of low flow requirement to sustain fish and other aquatic

populations.

• Improvements to hiking trails.

The basic characteristics of the project are summarized as follows:

CNAIR CREEK HYDROELECTRIC PROJECT

BRITISH COLUMBIA

CANADA

The McNair Creek hydroelectric project is a 9MW run of river pro-

ject located on British Columbia’s Sunshine Coas t, abou t 30km

northwest of Vancouver in the traditional territory of the Squamish

First Nation. The project was completed in 2005 and is owned and

operated by Renewable Power Corporation. It was constructed

under an EPC contract that guaranteed price, schedule and perfor-

mance with Peter Kiewit Sons Co as the prime contractor and Knight

Piésold Ltd as the lead design engineer. This EPC team was success-

ful in meeting or exceeding all the terms of the EPC contract, deliv-

ering the project on budget and ahead of schedule. Community

consultation, strict environmental management plans and monitor-

ing, project management, innovative design concepts, project opti-

mization and great team work all played a key part in the projects

success. These included:

• Web-based project management system

• Coanda (“shear-effect”) intake screens, which are self-cleaning and

eliminate sediment inclusion into the penstock at the intake.

• Elimination of anchor block requirements along the pipeline and

penstock.

• Optimization of installed capacity ensuring the best possible return

on investment for the Owners.

• Construction of fisheries habitat enhancement and spawning chan-

nels downstream of the powerhouse tailrace. This was further

developed into a park like setting for the local community with 22

Chum Salmon returning to spawn in these channels the first year

after construction.

Best of the best in small hydro

Over the next few issues of the magazine we’re including details on some of the best small

hydro projects (<50MW) in the world. Once details of all shortlisted projects have been

published, you’ll be given the opportunity to vote for one of these projects to be presented

with IWP&DC’s ‘Best Small Hydro Project’ award. This first instalment includes details

on the 9MW McNair Creek hydroelectric project and the 49MW Rutherford Creek

development in Canada, the 4MW Khudi project in Nepal, and the 3.6MW Ludvika

station in Sweden

The Coanda screen intake and headpond at McNair Creek

Owner & Operator Renewable Power Corporation

Prime Contractor Peter Kiewit Sons Co.

Lead Designer Knight Piésold Consulting

Nameplate Capacity 9MW

Average Annual Energy 35GWh

Gross Head 338m

Design Flow 3.3m

/sec

Diversion Weir A reinforced concrete structure comprising a

& Intake free over flow spillway incorporating a Coanda

screen (Aqua-shear scr een), a bypass

sluiceway and penstock isolation gate

Intake Sluice channel, screens, trash rake, vortex

desander and penstock isolation gate

Tributary Intakes Two tributary intakes with a maximum

combined capacity of 0.6m

/sec divert water

into the main intake headpond

Powerhouse Concrete substructure and pre-fabricated steel

super structure, with removable roof panels to

allow for extraction of the turbine generator set

with the use of a mobile crane

Turbine One 5-Jet Ver tical Axis Pelton unit

Generator Direct coupled synchronous generator,

generating at 4.16kV

Switchyard 4.16kV to 25kV

Transmission & 25kV

Interconnection

Fisheries Enhancement 200m long with both rearing pond and

Channel spawning channel habitat

56 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

SMALL HYDRO AWARD

• Large diameter Weholite (HDPE) pipe

• Whitewater kayak channel built into the powerhouse tailrace

The basic characteristics of the project are summarized as follows:

During the development phase there was extensive consultation with

the local community, stakeholders and First Nations groups that

helped to shape the final configuration of the project. This resulted

in the inclusion of one of the longest and most extreme artificial

whitewater kayaking parks in the world, as well as improved access

and parking for snowmobilers that use the access road past the intake

to access the Pemberton Icefields. There was also on-the-job training

for the local First Nations and at the height of construction about

1/3rd of the workforce was First Nation. The Prime Contractor

During the development phase there was extensive consultation with

the local community, s takeholders and First Nat ions groups that

helped to shape the final configuration of the project. This resulted

in the inclusion of the fisheries enhancement channel and improved

hiking trails, including a timber bridge over the powerhouse tailrace

channel with minimum disturbance to the riparian vegetation along

the banks of McNair Creek. There is joint use of the penstock with

the Sunshine Coast Regional District, saving them the cost of build-

ing their own infrastructure for drinking water and fire hydrants.

The project also resulted in Partial ownership and employment for

First Nation s and the penstock was buried for greater resi-

dent/wildlife access.

As with all projects developed in BC, the McNair Creek Project

ad to go through a rigorous environmental assessment and per-

mitting phase in order t o secure all the Provincial and Federal

approvals and licences. A typical run-of-r iver project i n BC will

require more than 50 permits, licences, approvals and reviews from

14 regulatory bodies, including federal, provincial, local and First

Nations. The project is now EcoLogo certified in Canada.

The innovative design concepts developed by Knight Piésold and

Kiewit resulted in significant cost and schedule benefits. A Coanda

screen intake design provides a low maintenance, self cleaning solu-

tion that eliminates the need for an expensive desandi ng basin,

resulting in significant cost and schedule savings.

The project now provides clean renewable energy to BC Hydro

under a long term contract, helping BC meets its goal of energy self

sufficiency by 2016 with 90% of its electricity coming from renew-

able sources.

For further information contact:

Sam Mottram, Manager – Power Services, Knight Piésold,

Vancouver. Email: smottram@knightpiesold.com

Peter Schober, Owner, Renewable Power Corp.

www.renewablepowercorp.com

UTHERFORD CREEK HYDROELECTRIC PROJECT

BRITISH COLUMBIA

CANADA

The Rutherford Creek hydroelectric project is a 49MW run of river

project locat ed in British Colu mbia’s Coastal Mountains a bout

20km nort h of the Whistler ski reso rt in the traditional territory

of the Lil’ wat Fir st Nati on. The project was complete d in June

2004 and is owned and operated by Innergex Power Income Fund.

Like the McNair Creek scheme, it was constructed under an EPC

contract t hat guar anteed price, schedule and performance with

Peter Kiewit Sons as the prime contractor and Kn ight Piésold as

the lead design engineer. The project faced nume rous challenges

during construction, including a major flood event, and work hour

limitations due to forest fire risk, but the civil works were still com-

pleted on sc hedule. The project includes many innovat ive design

features, including:

• Inflatable rubber diversion weir

• Combined vortex desander and environmental flow bypass

McNair Creek tailrace and hiking trail

Owner & Operator Innergex Power Income Fund

Prime Contractor Peter Kiewit Sons Co.

Lead Designer Knight Piésold Consulting

Nameplate Capacity 49MW

Average Annual Energy 180GWh

Gross Head 378.5m

Design Flow 17.2m

/sec

Diversion Weir 2m high concrete sill with 3m high inflatable

rubber weir

Intake Sluice channel, screens, trash rake, vortex

desander and penstock isolation gate

Penstock Total of 9km long, including 3km of 3m

diameter Weholite (HDPE) pipe and 6km of

welded steel pipe, buried over its entire length

Powerhouse Concrete substructure and pre-fabricated

steel super structure

Turbine Generator Units Two 6-Jet Vertical Axis Pelton units

Switchyard 13.8 kV to 230 kV

Transmission & Interconnection 170m long 230kV transmission line

Whitewater Kayaking Park 650m long with design flow range of

5.0 to 17.2m

/sec

Weir and intake at Rutherford Creek

ADVERTORIAL

The Kaplan turbine was invented in the Czech Republic by Victor

Kaplan in 1912 – 1914; the Francis turbine was invented in Lowell,

MA by the British-American engineer James Francis; and, the

Pelton turbine was invented by Lester Allen Pelton in the late

1800’s during the California gold rush.

These turbines, which have been utilized for nearly 100 years,

still account for most of the hydropower generated in the world –

qual to about 20% of all electricity consumed globally.

Mavel is grateful to be part of the rich history and promising

future of the hydroelectric power industry having now installed

nearly 350 turbines and approximately 250 sites around the

world since shipment of its first turbine in 1993 to a small

site in the former East Germany.

Mavel’s latest shipment was mechanical equipment for

the Upper Clowhom hydroelectric power project being

developed by ENMAX in British Columbia with project

management by Canadian Projects Ltd. Commissioning is

slated for this fall. And, Mavel’s latest contract is for a small

aplan turbine for Holyoke Gas & Electric’s Boatlock No. 1

project in Holyoke, MA where Mavel is a supplier to Waterline

Industries, Inc. This 704 kW rehabilitation project should be

commissioned in 2010.

MAVEL, A.S. congratulates International Water Power and Dam Construction on

its 60th Anniversary of providing information to the hydroelectric power industry

121 Mount Vernon Street

Suite 25-W

Boston, MA 02108 USA

T: +617 242 2204

F: +617 242 2205

E: jeanne@mavel.cz

Turbine and deliveries for the Upper Clowhom HPP 11.3 MW Project, British Columbia, Canada

58 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

SMALL HYDRO AWARD

(Kiewit) and the Lil’wat First Nation also formed an ongoing joint

venture after the construction was complete and built a pre-fabrica-

tion business for concrete products such as freeway barriers.

As with McNair Creek, the Rutherford Creek project had to go

through a rigorous environmental assessment and permitting phase

in order to secure all the Provincial and Federal approvals and licences.

The innovative design concepts developed by Knight Piésold and

Kiewit resulted in significant cost and schedule benefits. A physical

hydraulic model of 1:20 scale was built of the entire intake, includ-

ing rubber weir, screens, vortex desander and penstock isolation gate.

The final product performed so well that the need for an expensive

desanding basin was eliminated, resulting in significant cost and

schedule savings. The Rutherford Creek project was one of the first

to use large diameter Weholite (HDPE) pipe in a hydroelectric power

application. Although not much cheaper than steel pipe, the use of

Weholite resulted in significant schedule savings.

The project now provides clean renewable energy to BC Hydro

under a long term contract.

For further information contact:

Sam Mottram, Manager – Power Services, Knight Piésold,

Vancouver. Email: smottram@knightpiesold.com

Richard Blanchet, Vice President Western Region – Hydroelectric

Energy, Innergex Renewable Energy Inc., Vancouver.

HUDI POWER PROJECT

, N

EPAL

Khudi is a 4MW hydroelectric power plant built in a Nepali village

by BPR (GCSCP) for Khudi Hydropower Ltd. The project’s history

is as much a story of sustained efforts during the years, as the results

of individual savings accumulated penny by penny over 10 years, as

that of obtaining financing. Today, this perseverance has paid off:

the first project of its kind in the country to h ave remained on

budget, this project is now cited as a socially responsible develop-

ment model.

Context

Nepal is a country of 25 million inhabitants, but only 15% of them

benefit from electricity. Despite having a hydroelectric potential of

over 80,000MW, Nepal has developed less than 1% of this poten-

tial. Most people live in rural areas and they mainly resort to burn-

ing wood and residue for power and heat, creating environmental

problems of vast deforestation, pollution and health issues.

Towards the end of the 1990s, Quebec consulting engineers BPR

(then GCSCP), a company that specializes in small and medi um-

sized hydro power projects, obtained a mandate in Nepal. Engineer

Francois Vitez of BPR became consultant to Mr. Dikendra Kandel,

head of the Lamjung Electricity Development Company (LEDCO).

LEDCO is a community-based developer of renewable energy with

a socially responsible approach.

To design and build the Khudi plant, a consortium was created

known as Khudi Hydropower Limited. It consisted of LEDCO (15%);

Butwal Power Company (a Nepali hydro power consulting engineer-

ing company) (60%); and SCP Hydro International (25%). SCPHI is

Canadian Hydro Developer created by BPR (Then GCSCP). Khudi

Hydropower Limited will operate the plant for 25 years.

To get the project off the ground, the consortium had to find addi-

tional financing, but the Nepali bankers were sceptical of such pro-

jects as there was no previous similar experience. These projects

tended to leave very little benefits to the local communities and very

limited transfer of knowledge to Nepalese once the work was com-

pleted. However, eventually, five Nepali banks agreed to lend the

rest of the start-up funds.

Complexity and originality

From the start the challenge was to design, build and operate the

power plant at the lowest possible cost without compromising per-

formance. The dual relationship of being both colleagues and asso-

ciated investors in the project united the participants behind these

goals and allowed them to reach compromises. The second challenge

consisted in avoiding scaling down the technology from large hydro

to s mall hydro an d ensure fai l safe mech anism for suc h a remote

plant. The t hird chall enge was to build this project w ithout any

explosives as it was constructed during a civil war in Nepal when

all use of explosive substances was illegal and heavily punishable.

The final, and most complex, aspects of this project was river sedi-

mentation and bedload management.

The design team adapted technologies from other sectors, includ-

ing HYFRAN software from the National Institute of Scie ntific

Research, Canadian technology for control syst ems as well as

inversed siphon technology.

By simultaneously building both the power plant and transmis-

sion lines, normally under the responsibility of the State, the team

was able to reduce the completion time by at least one month. The

line was later handed over to the state owned utility.

The power plant operates with a flow of 5m³/sec, generates 4MW

with a head of 96m, and produces 24.3GWh annually.

At present, the project is supplying electricity to Khudi, Besishahar,

Dumre, and the national grid. The reliability of the local electrical

distribution has been substantially improved.

Budget

The initial budget for the project was CDN$9M, this figure was fur-

ther revised to $10M at financial closure. However, upon comple-

tion of the project, the cost of the power plant turned out to be lower

than planned at $9.4 M.

Schedule

Construction was scheduled to be completed in March 2002.

However, Nepal at that time was faced with a period of great polit-

ical instability, culminating in 2001 with the Royal Family being

assassinated. Violence and fear then took over the entire country,

which in turn affected financing partners and Nepali investors.

In March 2004 , a revised schedule was produced. On 30

Construction of the penstock at the Rutherford Cr eek project

Penstock at Khudi

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reservoirs or canals.

Asphaltic concrete, with an appropriate mix-design, is impermeable for water up to

20 bar and more. It is a resilient and hard wearing material but at the same time, it is

flexible enough to absorb settlements up to 10%.

An asphaltic concrete barrier system has a layer composition of three different types

of bituminous material.

•

binder layer, serving as a sub base for the dense layer and as drainage and

ventilation layer

• dense layer, serving as the sealing element

• mastic layer, ser ving as a protection layer

The thickness of the layers depends on the demands of the project and on the standards

required. Generally the asphalt concrete layers have a thickness of between 6 cm and 10

cm, the mastic layer is a thin film of bitumen and filler, usually at a rate of about 2 kg/m

Two different laying methods can be used when placing asphalt on slopes; a horizontal

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High construction outputs ensure short construction time or rehabilitation time,

saving time and money.

Asphaltic concrete needs little maintenance for many years. If rehabilitation

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Using asphaltic concrete can provide a dam, reservoir or canal operator with the ability

to heighten or lift their facility in order to increase capacity or production, with little

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Dam and Landfill Construction

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Fax +41 44 740 31 40

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Asphalt Lining: Bituminous sealings for Dams, Reservoirs and Canals

Avce Pump Storage Scheme, Slovenia

Construction of Dense Asphalt Lining

Above: Asphalt lining above water surface

Above: Vertical lining system in action at the pump storage

scheme in Dlouhé Stráne

60 MAY 2009 INTERNATIONAL WATER POWER & DAM CONSTRUCTION

SMALL HYDRO AWARD

December 2006, 15 months after breaking ground, the power plant

was commissione d. Compliance with this timeline is particularly

remarkable as the work was carried out in a very mountainous

region where the road infrastructures complicated supply and no

explosives were used.

Social, economic and environmental impact

In embarking on such a project, the project team needed to satisfy

three dictates (economic, environmental and social) commanded a

priority by the competent Nepali authorities and supported jointly

with CIDA (Canadian International Development Agency).

With regard to the economic aspect, the project had to be viable.

The sale and distribution of energy would serve to reimburse the

oan and generate long-term profitability. In 10 years, the KHL prof-

itability threshold would be reached (15% of shareholders are small

local investors). This project is now hailed by the various financial

and governmental environments

With regard to the environmental aspect, one impact study carried

out before work began led to the elaboration of an environmental

management plan, whose implementation began in July 2007.

With regard to the social aspect, in cooperation with the CIDA

and LEDCO as well as a non-profit organization in the district of

Lamjung, COPPADES (Committee for the Promotion of Public

Awareness and Development Studies), BPR designed a mitigation

and social development plan which was both comprehensive and

varied. Activities of this program included assistance to 26 schools

in the area, construction of four new school buildings, micro-credit

group and cooperatives, tradesmen training, b iogas and t oilet

making training and implementation, health post creation, HIV-Aids

education, etc. The hydro power project was the entry point from

which these social enhance ment measures have been able to be

implemented and sustained. These programs are still operating after

commissioning of the project.

For further information, contact François Vitez, Ing.

Production Director, BPR Energy. Email: francois.vitez@bpr.ca

UDVIKA HYDRO POWER STATION

SWEDEN

During refurbishment of the Ludvika hydro power station on the

Kolbacksan river system in Sweden, emphasis was placed on making

the new installations as eco-friendly as possible within the bound-

aries set by nature and legal constraints.

The intrusion into the natural river of Kolbacksan took place sev-

eral centuries ago when locks were built for boat traffic and dams

were built for waterwheels to power mills, hammers etc. Harnessing

of hydroelectricity was a very late event. The refurbishment effort

proactively took aim to withdraw as much electricity as possible

from the intrusion thus justifying it to a large extent from an envi-

ronmental point of view.

Some of the refurbishment features included:

• The powerhouse was reused, preserving some industrial history of

the early 1900s.

• The peak efficiency of the new machine was put at the maximum

legally permissible d ischarge, makin g the most efficient use of

available water.

• An oil-free runner hub was chosen, with only a small amount of

lycol used for lubrication.

• The hydraulic power pack and oil-lubrication units were equipped

with tubs to contain any oil leakage.

• An oil separator was installed between the pump sump and recipient

• The hydraulic power pack was designed to have motors run-

ning only when needed to charge accumulators , limiting po wer

consumption.

• The machine is normally in operation from 6am – 10pm five days

a week, producing power only when demand is the highest.

• The generator was equipped with an extra heat exchanger to recov-

er losses into a large accumulator tank, which was then used to heat

the power house during the night and at weekends.

• The plumbing was conne cted to the community sewage system

instead of to the recipient.

The power station was first commissioned into a 40Hz plant in

1901. In 1930 and 1941 the previous Francis machines started ser-

vice at 50 Hz and operated until 8 January 2007. The new Kaplan

machine commenced operation on 19 October 2007.

Further key features of the refurbishment included:

• The 330m long race water slag-stone masonry tunnel was repaired.

• A new stainless steel intake and surge chamber gates were installed.

• A new painted carbon-steel penstock wa s used, buried close to

powerhouse.

• A new Kaplan turbine with synchronous generator was installed.

This is a Six-bladed horizo ntal Kaplan with ru nner Ø= 2.12m,

nom

= 17 m, Q

max

= 24m

/sec and P = 3.6 MW

Synchronous generator with rotating brush- less exciter, U =

10.5kV, f = 50 Hz, n = 273 rpm

• New motorized overhead traverse cranes were installed instead of

hand-operated ones.

• A new computerized control system featuring field bus and dis-

tributed I/O units was utilised.

• New medium voltage switchgear featuring vacuu m type circuit

breakers was also installed.

• A high-accuracy absolute efficiency test featuring the Accusonic

method for flow measurement (inaccuracy of < 0.7 %) was used.

The Ludvika station is owned and operated by Vasterbergslagens

Kraft AB, which has 47 dams and 11 hydro power stations, among

them the Hellsjon station which was part of the world’s first com-

mercial power scheme utilizing three-phase alternating current.

The refurbishment was made within the governing permit of 1916

and the established usage thus having the same maximum discharge

and regulating reservoir amplitude as before.

A consortium made up fr om turbine manufacturer Kossler of

Austria and generator manufactur er Lloyd Dynamowerk e of

Germany had the most favourable evaluated tender for the machine

including peripherals. Guaranteed efficiency was exceeded.

Project investment was US$8.5M, which included US$2M for the

complete turbin e-generator and US$60,0 00 for the absolute effi -

ciency test. It is estimated that the investment will be repaid after 13-

14 years. In an average year the new equipment will ge nerate

13.0GWh at 3.6MW compared to the previous 10.4GWh at

2.8MW. The very wet year of 2008 yielded 18.6GWh.

Green certificates will be granted for the entire production for 15

years making the refurbishment reasonably profitable.

For further information contact Tommy Hjort of Cervus Power AB.

Email: tommy.hjort@cervuspower.se

Don’t miss the June issue for details on further small

hydro schemes worldwide

New (buried) and previous

penstock entrances at Ludvika

IWP& DC

Water Power and Dam Construction - Issue May 2009

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