HYPOWER - HIGH POTENTIAL REPLACE OR REFURBISH? WHY SMALL HYDRO IS BIG NEWS - VOITH

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HYPOWER - HIGH POTENTIAL REPLACE OR REFURBISH? WHY SMALL HYDRO IS BIG NEWS - VOITH
MAGAZINE FOR HYDROPOWER TECHNOLOGY

HyPower
#28 | Autumn 2016

HYDROPOWER IN AFRICA

HIGH POTENTIAL
SUCCESSFUL PARTNERSHIPS

REPLACE OR REFURBISH?

FULL LINE SUPPLIER

WHY SMALL HYDRO IS BIG NEWS
HYPOWER - HIGH POTENTIAL REPLACE OR REFURBISH? WHY SMALL HYDRO IS BIG NEWS - VOITH
EDITORIAL

                                  IMPRINT

                                  Publisher:
                                  Voith GmbH
                                  St. Pöltener Str. 43
                                  89522 Heidenheim
                                  Germany

                                  Responsible for the publisher:
                                  Kristine Adams

                                  Editor-in-chief:
                                  Gudrun Köpf

                                  Editorial Board:
                                  Elke Kleinknecht, Susanne Speiser, Dr. Vesna Stirnadel

                                  In cooperation with:
                                  C3 Creative Code and Content GmbH,
                                  Heiligegeistkirchplatz 1, 10178 Berlin, Germany
                                  www.c3.co

                                  Paper:
                                  HyPower is printed on Respecta Silk. This paper
                                  was produced on a Voith paper machine.

                                  Copyright:
                                                                                                                                      UNLOCKING POWERFUL
                                  No part of this publication may be copied,
                                  reproduced or otherwise disseminated,
                                  nor may any of the content in it be used in
                                                                                                                                      POTENTIAL
                                  part or in whole in other works in any
                                  form whatsoever, without express written
                                                                                                                                      Diversity. Complexity. Potential. Three words          dance. We work closely with leading financial
                                  permission of the editor.                                                                           that sum up Africa pretty well in many different       institutions and insurers to help our African
                                                                                                                                      contexts – geographical, political, economic           customers spread the cost of building or reha-
                                                                                                                                      and social. They also apply to Africa’s energy-        bilitating hydropower facilities over realistic time
                                                                                                                                      generation infrastructure. While some African          frames. Our experts in Heidenheim and across
                                                                                                                                      countries have plentiful oil and gas reserves,         the world are ready and willing, not only to
                                                                                                                                      some have none. Some can rely on hydropow-             manufacture the equipment required, but to
                                                                                                                                      er for nearly all their power requirements, some       spend weeks and months on site, working
                                                                                                                                      need to import almost all their electricity from       closely with customers to transfer knowledge,
                                                                                                                                      outside their borders. And even if the resources       build skills and ensure that once a plant is com-
                                                                                                                                      exist, building an infrastructure that delivers        pleted, it can be run effectively by local people.
                                                                                                                                      power to homes and businesses reliably is an-          We are also investing in improving our local ser-
                                                                                                                                      other challenge altogether – especially in coun-       vicing capabilities to permanently improve ser-
                                                                                                                                      tries that have been ravaged by recent or cur-         vice for our customers.
                                                                                                                                      rent conflicts.                                              This new edition of HyPower showcases
Join us on:
                                        YOUR FEEDBACK: If you have any                                                                      As a result, there is one reality that applies   how customers and communities in Africa and
                                  comments or questions on this issue of                                                              to some areas of every African country: elec-          elsewhere are benefiting from maximizing their
                                  HyPower, please contact us: hypower@voith.com
                                                                                                                                      tricity supply is nowhere near sufficient to meet      hydropower potential, and leveraging the new-
https://twitter.com/voith_hydro
                                                                                                                                      demand. In fact, even in 2016, around three-           est technologies to do so. Enjoy!
                                                                                                                                      quarters of the African population do not have
                                  Photographs:
                                  Cover: Graeme Williams, Gauteng; Ryan Thomas /AerialShots, Johannesburg: 8, 9, 19; Christian        access to reliable, constant power. From a hy-         Yours sincerely,
https://www.linkedin.com/
company/voith-hydro               Wesser, Heidenheim: p. 16, 17, 18, 29, 35; Graeme Williams, Gauteng,: 10, 11, 12, 13, 14, 15, 20,   dropower perspective, Voith is at the forefront
                                  21, 22, 23; Dawin Meckel, Berlin: p. 26, 27, 28; Brian Gartside: p. 44, 45 Kent Kallberg Studios,   of efforts to change this.
                                  Vancouver: p. 39, 40; U3: Robert Caputo /Aurora / laif
                                                                                                                                            To harness Africa’s hydropower potential,
https://www.youtube.com/          All other photos are from Voith.                                                                    financing flexibility, expertise and commitment        Uwe Wehnhardt
c/Voith_Hydro                                                                                                                         are all essential. Voith has all three in abun-        President and CEO of Voith Hydro

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HYPOWER - HIGH POTENTIAL REPLACE OR REFURBISH? WHY SMALL HYDRO IS BIG NEWS - VOITH
CONTENTS                                                                                                                                                                                                                                   CONTENTS

                                                       8                                                            26                                                                                                                               39

                                            AGENDA SETTING                          FULL LINE SUPPLIER                       GLOBAL EXPERTISE                      39 THE BIG QUESTION:                           GUEST PERSPECTIVE
                                                                                                                                                                      REPLACE OR REFURBISH?
                                        8   ENERGIZING AFRICA                     26 SMALL PROJECTS,                      32 STOPPING THE FLOW                       Why it can pay dividends to              44 CREATING THE
                                            How significant hydropower projects      BIG RESULTS                             How an electronic control               overhaul old hydropower                     SAFE WATER BOOK™
                                            in South Africa and Angola are          In Asia, a larger number of smaller      mechanism for ring gates has            equipment, rather than retire it.            An exciting water filtering
                                            transforming economies and lives.       hydropower projects                      set new standards in precision.                                                      innovation could solve the problem
                                                                                    could be the key to improving                                                    INNOVATION                                   of dirty drinking water for millions.
                                        16 MANAGEMENT INTERVIEW                     rural power availability.             34 SERVICING AFRICA
                                            Voith Hydro's CMO and African                                                    When it comes to maintenance,         42 SAFE AND SOUND
                                            sales leader discuss the potential    28 MEETING THE LARGE HYDRO                 it's always better to have local        Why a new listening technology is        47 VOITH HYDRO PROJECTS
                                            of hydropower in Africa.                 CHALLENGE                               resources on hand. Voith Hydro is       the best way of monitoring plant             A visual summary of hydropower
Discover more about Voith through its                                               Hydropower projects so large that        investing in developing local           operation remotely.                          projects by Voith in Africa explored
other insightful publications.
                                        19 MODERNIZING                              they can take almost a decade            African expertise.                                                                   in this issue.
                                           MOUNT COFFEE                             to complete require a special set
                                            How Liberia's hydropower                of skills for success.                   SUCCESSFUL PARTNERSHIPS
                                            infrastructure is being                                                                                                      MOUNT COFFEE
                                            rebuilt to support rapid economic       FROM THE ARCHIVES                     35 24/7 MOBILE SERVICE
                                            development.                                                                     In Europe, the Voith HyService Bus
     REGULARS                                                                     30 TRUE SURVIVOR                           is ready to leap into action
                                        24 GLOBAL TRAINING,                         The rollercoaster history of the         whenever customers need it.
                                                                                                                                                                                             CAMBAMBE          TULILA
03   EDITORIAL                             LOCAL BENEFITS                           Cahora Bassa hydropower plant
06   WHAT’S NEW                             All over the world, Voith Hydro is      in Mozambique.                        36 THE POWER TO CHANGE LIVES                                                   CAHORA BASSA
07   ON TOPIC                               delivering training concepts                                                     How a convent in Tanzania and the
43   WORLD OF VOITH                         that meet the needs of individual                                                community it serves are benefitting                                BOKSBURG
                                                                                                                                                                                                               INGULA
46   5 QUESTIONS FOR …                      customers.                                                                       from Small Hydro.

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WHAT’S NEW                                                                                                                                                                                                                                                 ON TOPIC

VOITH AT HYDROVISION 2016                                                                                                             DRIVING DEVELOPMENT
USA The StreamDiver was the focus of a presentation delivered at
 the recent 2016 HydroVision International event in Minneapolis,                                                                      In many parts of Africa, the lack of a reliable electricity infrastructure
 ­Minnesota. Presenter Philip Daus, a Small Hydro engineering project
                                                                                                                                      hinders economic development. Hydropower can play a big part in
  manager at Voith Hydro, said, “Hydropower is among the best solu-
 tions to energy market challenges, and we are using our technology                                                                   changing this picture.
  and expertise to achieve the best outcomes in economy and perfor-
  mance, both technically and environmentally.”
       Other important Voith innovation papers presented at the event
  covered: a rotor rim slot reshaping process for increasing generator
  longevity; a new analysis and replacement process for damaged               Klaus Schädler, Voith, at groundbreaking ceremony.
­turbine thrust collars, which improves monitoring, maintenance and                                                                   1   Power is patchy                                           2   Hydropower potential is enormous
  repair; a new forecasting method to increase accuracy and improve
  short-time pumped-storage balancing; and an overview of improved            BREAKING NEW GROUND
  online assessment processes for hydro-components.
                                                                               GERMANY One of the most exciting innovations
                                                                               being introduced at Voith Hydro in 2016 is the
                                                                                                                                                          645 million
                                                                                                                                                          Africans have no access to electricity.                   300  - 400 GW
                                                                               construction of a small hydropower plant (called                                                                                     Potential hydropower capacity in
                                                                              'Alte Bleiche') at the Heidenheim site, to act as a                                                                                   Europe and Africa is similar...
                                                                               demonstration facility for customers, employees
                                                                               and the public. The 35 kW plant will also feed
                                                                               electricity directly into the local grid – enough to             Power consumption per head
                                                                               power 100 homes. Construction work started                                                                                                          ...but Europe has an installed
                                                                                                                                            in Africa                    in Europe
                                                                               with a groundbreaking ceremony in April, and                                                                                                        capacity of 218 GW. Africa
 1
                                                                               the plant should be operational by year end.            181 kWh/y                 6,500 kWh/y                                                       has only 30 GW.
                                                                                    Voith apprentices are involved in the design
                                                                               and manufacturing, and are working to an eco-
                                                                               friendly design – created in cooperation with the
                                                                              Technical University of Munich – that eliminates
                                                                               the need for a new powerhouse. The plant will
                                                                               feature Voith’s new StreamDiver generator unit,
                                                                               recently showcased at a series of roadshows
                                                                               across Latin America. StreamDiver is designed
 2                                   3                                         for low-head river plants and deployed underwa-
                                                                               ter, eliminating noise emissions, minimizing local                         Africa produces 4%
1	Voith exhibition booth.
2  Customer event banquet.                                                     environmental impact and making small hydro-                                of the world’s total
3	Bob Gallo, Bill Malus and Martin Andrä at HydroVision 2016.                 power plants more cost-effective.                                          energy, but is home
                                                                                                                                                          to 13% of the global
                                                                                                                                                                                                                  218 GW                   30 GW
                                                                                                                                                                                                                    in Europe               in Africa

                                                                                                                                          4%                   population.

MORE POWER FOR UGANDA                                                                                                                                                                                                                  2015

UGANDA Voith Hydro has been awarded a contract for the            Berkeley Energy and customer ARPE Ltd. Commenting on
complete design, manufacturing, supply, installation and com-
missioning of the electromechanical equipment for the new
                                                                  the project, Head of Voith Hydro’s Small Hydro Business
                                                                  Klaus Schädler said, “We are happy to be part of the project
                                                                                                                                                                                                        2,174 MW
                                                                                                                                                                                                               across Africa
                                                                                                                                                                                                                                            Between 2010 and
                                                                                                                                                                                                                                            2015, 2,174 MW of
hydropower plant on the Achwa River in northern Uganda.           that supports reliable power production and sustainable eco-
                                                                                                                                      Frequent power outages are the norm in                                                                ­hydropower capacity
The plant features four vertical Francis turbines and vertical
synchronous generators with an installed capacity of 42 MW.
                                                                   nomic development in the region. We look ­forward to putting
                                                                  our ideas into practice, and to foster our collaboration for
                                                                                                                                      30 African countries.                                             2010                                was added across
                                                                                                                                                                                                                                           ­Africa.
The project will involve close collaboration between Voith, M/s   ­renewable energy in Uganda.”

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AGENDA SETTING                                                                                                                                         AGENDA SETTING

ENERGIZING                                                              AFRICA

                                                                                                                                A
                                                                       Successful installations at Ingula in South Africa and           reliable electricity supply brings
                                                                                                                                        light and heat (or relief from it)
                                                                       Cambambe in Angola illustrate how hydropower                     to homes and businesses, powers
                                                                       is transforming economies and lives across Africa.       machinery, and enables hospitals and
                                                                                                                                schools to function effectively. In a con-
                                                                                                                                tinent as large as Africa, with many
                                                                                                                                countries and political regimes, dis-
                                                                                                                                persed populations, variable transport
                                                                                                                                infrastructure and a wide range of cli-
                                                                                                                                mates and terrains, generating and dis-
                                                                                                                                tributing power effectively is a chal-
                                                                                                                                lenge.

                                        Hydropower in Ingula
                                                                                                                                Voith Hydro in Africa
                           Ingula       Installed capacity: 1,368 MW                                                            Voith Hydro supports many African na-
                                                                                                                                tions in making the most of their hydro-
                                                                                                                                power generation potential with a wide
                   Bramhoek Dam (lower dam) in winter.
                                                                       A view of the reservoir from the pumped storage          range of small and large projects in
                                                                       plant at Ingula in South Africa.

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AGENDA SETTING                                                                                                                                                                                                    AGENDA SETTING

   27 countries. Even so, less than 10%
of Africa’s potential hydropower genera-
tion capacity of an estimated 400 GW
has been exploited to date. Together
with its customers, Voith is addressing
this opportunity through: new state-of-
the-art plants; the repair, maintenance
and servicing of existing infrastructure;
and the transfer of knowledge to sup-
port African countries in running their
hydropower facilities self-sufficiently.
Two projects in particular, at Ingula in
South Africa, and Cambambe in Angola,
illustrate the benefits perfectly.
                                               1                                                                       3

Ingula pumped storage plant,                                     2

South Africa
Situated in the hills of KwaZulu-Natal
in eastern South Africa near the town of                                                          1	Intake structure at Bedford Dam          Fuji in Japan. The first of the four tur-    as he explains: “The project has involved
Ladysmith, the pumped storage plant at                                                               (upper dam).                             bines was handed over to the customer in     employing and training local staff to run
                                                                                                  2	An operator adjusts the oil filtration
Ingula is the largest of its kind in Africa.                                                         system.                                  mid-June 2016. The next two turbines         the plant once it is completed, which is a
Its four underground pump turbines                                                                3	Machine Hall Unit 1 and 2 side,          were due for handover in August, and the     key part of the service we provide. An-
have a total installed capacity of 1,368                                                             ­installation of machine hall ceiling.   last by the end of 2016.                     other important element was our partic-
MW. Following the tender process                                                                                                                                                           ipation in the Accelerated and Shared
launched by South African state energy                                                                                                        Keeping the plant cool                       Growth Initiative for South Africa (As-
company Eskom in 2007, Voith Hydro                                                                                                            In parallel, Voith has fulfilled the terms   giSA). This program is designed to en-
was awarded the contract for the provi-                                                                                                       of a second contract, awarded in 2011,       sure foreign firms invest to help grow
sion of the pump turbines, motor gen-                                                                                                         for various supplementary systems in-        the local economy by sourcing products
erators, the main inlet valve, and key                                                                                                        cluding cooling water pipes, fire protec-    and services from local providers. In ad-
systems in September 2008, some 30                                                                                                            tion, fire prevention and an air ventila-    dition, we oversaw the construction of
years after the government first started                                                                                                      tion system for the plant. The latter is     new infrastructure, such as good quality
planning the project. And it has a key                                                                                                        particularly important, as Markus Mül-       roads that enabled us to transport mate-
role to play in South Africa’s energy                                                                                                         ler explains: “Once they are fully opera-    rials and people from Durban harbor to
supply, as project manager Markus Mül-                                                                                                        tional, the four turbines will generate a    the plant site.” Not only that, the area
ler explains: “Like most countries on the                                                                                                     lot of heat, and because they are under-     surrounding the site, which includes
continent, South Africa suffers from en-                                                                                                      ground, that heat has nowhere to go if       sensitive wetlands and which has been
ergy shortages which hamper its eco-                                                                                                          there is no system in place to remove it.    used to house the people working on the
nomic growth. Ingula is particularly im-                                                                                                      We are installing the system, but it will    project, will be returned to its original
portant because it will begin making its                                                                                                      take longer to complete because the          state as part of the project.
contribution to the county’s power grid
in 2016.”
                                                   “The project has involved employing and                                                    four turbines have to be running before
                                                                                                                                              it can be fully tested.”
                                                                                                                                                                                                Nevertheless, power generation is of
                                                                                                                                                                                           course the ultimate goal and here, Mül-
     Site activities began in March 2012            training local staff to run the plant once                                                                                             ler has one final unique detail to add.
and Voith’s international operations col-                                                                                                     Customer and community benefits              “What is very special about the Ingula
laborated to deliver the required ma-
                                                    it is completed, which is a key part of the                                               Now that the project is nearing comple-      site is that all the machines have already
chinery. While the turbines were de-                service we provide.”                                                                      tion, Müller can reflect on its success,     been producing energy before handover
signed by Voith Hydro in Germany, the              Markus Müller                                                                              and the fact that it has delivered many      in parallel with the commissioning. As
motor generators were supplied by Voith            Voith Hydro Project Manager for Ingula                                                     benefits beyond pure power production,       the demand for power in South Africa

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AGENDA SETTING                                                                                                                                                                                                                                        AGENDA SETTING

                                            is so great, that this was a key require-   and extend the life of the plant for de-
                                         ment from our customer Eskom. It’s             cades. The state-owned electricity sup-
                                         highly unusual, but I’m delighted that we      plier ENE selected Voith as a key player
                                         have been able to meet the customer’s          in an international consortium to take
                                         needs.”                                        on the project. Voith’s remit: to supply
                                                                                        the electromechanical equipment and
                                         Cambambe I and II, Angola                      systems, including four 67 MW Francis
                                         The contrast between the Ingola project        turbines and all the required disman-
                                         and the Cambambe I and II sites in An-         tling of old equipment and new installa-
                                         gola couldn’t be bigger. In the mid-           tions.
                                         2000s, following three decades of civil
                                         war, the existing Cambambe I hydro-            Modern technology for maximum
                                         power plant, located 180 kilometers east       performance
                                         of Luanda and originally commissioned          To ensure the best possible results, the
                                         in 1963, was in urgent need of rehabili-       decision was taken to design a state-of-
                                         tation. Although two of the original four      the-art hydraulic system for the Francis
                                         turbine units were still operating, one        turbines, combined with digital and hy-                                                                                                                                         1
                                         was being overhauled, and one wasn’t           draulics governors from Voith. To en-                                                                                                                                           2
                                         working at all. The decision was taken         sure the local area could be supplied
Workers measure a generator pit in the   to replace all four, in order to increase      with electricity throughout construc-
powerhouse of Cambambe II.               power generation capacity to 268 MW,           tion, the turbines were installed sequen-
                                                                                        tially. Combined with the control pack-
                                                                                        age featuring the digital governor, oil                     Cambambe
                                                                                        supply and pumping groups, pressure                                         Hydropower in Cambambe
                                                                                        tanks, main oil supply valves, regulating                                   Installed capacity: 960 MW
                                                                                        valves and hydraulic elements, Voith
                                                                                        was able to prove the value of its status               The Cambambe site is located 180 kilometers east
                                                                                        as full line supplier beyond any doubt.                 of Luanda, the capital of Angola.
                                                                                        And when the new plant equipment be-
                                                                                        came operational – with an even higher
                                                                                        performance than was contracted – the
                                                                                        customer was delighted. So delighted in         bambe II is so important for the future      ment of our commitments were also ex-        1	The Cambambe II powerhouse under
                                                                                        fact, that in 2012, they commissioned           of the country.” The new run-of-river        tremely important.” The first unit was          construction. 	
                                                                                                                                                                                                                                  2  A new generator being installed.
                                                                                        Voith to supply equipment for the Cam-          plant with an additional four turbines       commissioned at Cambambe II in July
                                                                                        bambe II project.                               adds 700 MW of installed capacity,           2016, despite an extremely tough time-
                                                                                                                                        bringing the sum total of capacity of        line, and the plant with all four units is
                                                                                        Expansion that will transform                   Cambambe I and II to 960 MW. As              foreseen to be fully commissioned in
                                                                                        a country                                       such, it is a key part of the Angolan’s      December 2016. As the client says:
                                                                                        Despite the advances that have been             strategy to increase power production        “From the day Unit 1 started commer-
                                                                                        made since the end of the civil war in          capacity to 6,000 MW by 2017.                cial operation, the power cuts in Luanda
                                                                                        2002, Angola still faces huge political,                                                     disappeared. This led to a considerable
                                                                                        economic and social challenges, as Pro­         Tailored financing package                   improvement of the ecological balance
                                                                                        ject Manager Patric Kiehlmann has               and training                                 due to the reduction of the use of diesel
                                                                                        learnt: “Angola is rich in natural sourc-       Speaking about the reasons behind the        generators.”
                                                                                        es, including oil, but the recent lull in oil   selection of Voith as the key supplier,
                                                                                        prices has had a big impact on the econ-        Kiehlmann comments, “Our one face to
                                                                                        omy – the government’s income has fall-         the customer strategy, and the excellent    “Our one face to the customer strategy, as well
                                                                                        en by 50%. Private enterprise is very           relationship we had built with ENE
                                                                                        limited, and healthcare is very poor.           during the Cambambe I project were
                                                                                                                                                                                     as a tailored financing package, were extremely
                                                                                        Economic development, and the jobs              key factors. An attractive, tailored fi-     important to becoming the key supplier.”
                                                                                        and increase in living standards it brings,     nancing package and the soundness of         Patric Kiehlmann
                                                                                        are needed urgently. That’s why Cam-            our technological approach and fulfill-      Voith Hydro Project Manager for Cambambe

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AGENDA SETTING                                                                                                                                                     AGENDA SETTING

                        Just like the Ingula plant, the project   “The reliable and stable supply of energy to                              the population. The even better news is
                    is very much an international affair, with                                                                              that this will likely not be the end of the
                    the generator being supplied from Swe-         the population and industrial sector is a                                story. Angola has the potential to gener-
                    den, including a four-part stator that was     fundamental prerequisite for improving living                            ate up to 18 GW of hydroelectric pow-
                    put together on site. And just like Ingu-                                                                               er, most of which remains untapped.
                    la, the project has had its fair share of      standards. Renewable energy is crucial for us.”
                    challenges to overcome. Kiehlmann                                                                                       High-level political engagement
                                                                  Ellen Johnson Sirleaf
                    says, “Importing the materials alone          President of Liberia                                                      In recent years, several high-level dele-
                    took three months, ensuring they were                                                                                   gations from Ethiopia, Liberia and
                    able to handle the tropical conditions,                                                                                 other nations have visited Voith in
                                                                                                                                            ­
                    and the bureaucracy involved in orga-                                                                                   Heidenheim to learn about relevant
                    nizing visas for expat employees pre-                                     training center is also planned. As Kiehl-    technologies and best practices. On her
                    sented tough challenges. But together                                     mann emphasizes, “Our commitment to           visit to Germany in 2015, Liberian
                    with the customer, we overcame these.”                                    Angola is a long term one. Through            President and Nobel Peace Prize winner
                          The extension of the Cambambe site                                  training in particular, we will ensure that   Ellen Johnson Sirleaf commented, “For
                    is vital for the future of Angola. The con-                               the benefits of the project are sustainable   Liberia as well as many other African
                    struction phase is providing much need-                                   for decades to come.”                         countries, the issue of energy supply is
                    ed jobs and training and a permanent                                           Despite all the challenges it has        an essential item in the national growth
                                                                                              faced since the end of the civil war, eco-    strategy. The reliable and stable supply
 1
                                                                                              nomic growth in Angola has been strong        of energy to the population and indus-
 2                                                                                            – over 11% per year up until 2010. The        trial sector is a fundamental prerequisite
                                                                                              Cambambe II plant will play a signifi-        for improving living standards. Renew-
                                                                                              cant role in helping the country grow its     able energy is crucial for us.” Proof, if
                                                                                              economy just as rapidly in the future.        any were needed, that hydropower will
                                                                                              But perhaps most importantly of all, it       play a key role in African economic de-
                                                                                              will also help improve the daily lives of     velopment for many years to come. //

                                                                                              FINANCING PROGRESS
                                                                                              Hydropower plants such as the ones at Ingula and Cambambe are a capital-inten-
                                                                                              sive investment. Financial solutions ease the immediate financial burden by
                                                                                              spreading the cost over a long period – especially in developing economies. Voith’s
                                                                                              Financial Services subsidiary creates tailored financing concepts in cooperation
                                                                                              with private commercial banks and state-backed export credit insurers, which are
                                                                                              usually based in the home country of the project’s main supplier. Indeed, Long-
                                                                                              term excellent relationships and cooperations with Euler Hermes Kreditversicher-
                                                                                          3
                                                                                              ungs AG in Germany, the Oesterreichische Kontrollbank AG in Austria, and the
                                                                                          4   Nippon Export and Investment Insurance company in Japan, among others, are
                    1	In the Cambambe II powerhouse:
                       generator covers of the installed                                      the basis for this successful financing support.
                       machines 1 and 2.
                    2	Installing a turbine shaft in                                          Bernd Rieck, Head of Export and Project Finance, explains: “Our goal is to find the
                       Cambambe II.                                                           ­optimal financing solution for every customer that wants to use Voith as a supplier.
                    3	Damjan Vucko, Head of                                                   Every concept is customized to specific customer needs, based on local variables,
                       ­Operations at Voith Hydro,                                             project details, the customer’s financial situation, and the so-called Voith Sourcing
                        at Cambambe II
                    4   Installing the intermediate shaft
                                                                                               Matrix, which analyzes the supply chain.”
                        at Cambambe II with view of
                        the thrust bearing and distributor                                    Customer benefits
                        underneath.                                                           • Additional financing sources.
                                                                                              • Long payback periods.
                                                                                              • Attractive financial conditions at advantageous interest rates.
                                                                                              • Planning security for financing across the complete project timeline.

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AGENDA SETTING

                                                                             “We are developing our new Africa
                                                                              concept because we are positive that
                                                                              the African continent has tremendous
                                                                              development potential.”
                                                                             Heike Bergmann
                                                                             Senior Vice President Sales Africa

                                                                             How did a renewed push to develop           power plants. The following compari-
                                                                             sales in the African market become          son illustrates what we are talking
                                                                             part of your agenda?                        about. The hydroelectric capacity cur-
                                                                             Martin Andrä: We are implementing           rently installed on the entire continent is
                                                                             this new strategic drive because we are     equivalent to the installed capacity of
                                                                             convinced that Africa has very good fu-     Norway. However, we think another as-
Heike Bergmann and Martin Andrä in discussion.
                                                                             ture prospects and we need to tap into      pect is also interesting: In Africa, we are
                                                                             these opportunities. In Sub-Saharan         seeing a trend in which countries skip
                                                                             ­Africa, many countries have economic       over the fossil fuel-based and nuclear
                                                                              growth rates of five percent and higher.   power generation phases that are typi-        Heike Bergmann,
                                                                                                                                                                        Senior Vice President Sales Africa,
                                                                              These countries need to be supplied        cal of the industrialization process, and      Voith Hydro
                                                                              with reliable power so they can further    enter ­directly into electricity production

OPPORTUNITY
                                                                              pursue their social and economic devel-    from renewable energy sources. The
                                                                              opment.                                    opportunities to make that happen are
                                                                                                                         in place. Right now, Africa’s untapped
                                                                             Heike Bergmann: I want to re-empha-         potential for hydroelectric power plants
                                                                             size that. We are developing our new        amounts to between 300 and 400

KNOCKS
                                                                             Africa concept because we are positive      Gigawatts.
                                                                             that the African continent has tremen-
                                                                             dous development potential. One also        Does Voith have anything to offer to
                                                                             has to consider that in some African        this market?
                                                                             countries, only 20 to 25 percent of the     Bergmann: Yes, absolutely. On my dele­
                                                                             population has access to electricity,       gation visits, I keep seeing that power
                                                                             and power outages occur on a regular        plants built in Africa by European com-
                                                                             basis. The latter presents an impedi-       panies are held in high regard. Euro-
                                                                             ment to all industrial companies and        pean technology can serve as the
Voith is investing in its sales programs in Africa. Martin Andrä, Chief      thus also to economic development.          backbone of the African economy, and
Marketing Officer, and Heike Bergmann, Senior Vice President Sales Africa,                                               that includes Voith, whose hydropower
discuss Voith Hydro's future strategy across the continent.                  Can you give us a rough estimate of         technology has been used on the conti-
                                                                             the demand for power plants?                nent for about 100 years. Africans value
                                                                             Andrä: There is a huge demand for new       the quality and longevity of our prod-

16 | HyPower 2016                                                                                                                                                                                      HyPower 2016 | 17
HYPOWER - HIGH POTENTIAL REPLACE OR REFURBISH? WHY SMALL HYDRO IS BIG NEWS - VOITH
AGENDA SETTING                                                                                                                                                                                                                          AGENDA SETTING

                                        “To win projects in Africa, it’s impor-
                                         tant to offer financing solutions.”
                                        Martin Andrä
                                        Chief Marketing Officer

                                        ucts. They want our technology, but          few. Our footprint literally extends over
                                        need support in financing it.                the entire continent.

                                                                                                                                  MODERNIZING
                                        What does that mean for a technology         What do you attribute that to?
                                        supplier?                                    Bergmann: It’s based on the excellent
                                        Andrä: To win projects in Africa, it’s im-   quality of our products and services, as
Martin Andrä,
                                        portant to offer financing concepts and      well as the fact that we keep working
 Chief Marketing Officer, Voith Hydro   solutions. One of Voith’s advantages         with our customers after a plant is com-
                                        that benefits our customers is that we       missioned. We provide extensive train-

                                                                                                                                  MOUNT COFFEE
                                        can offer tailored financing solutions for   ing for power plant operators and we
                                        projects. That’s why we work with pri-       have our own network consisting of
                                        vate commercial banks and govern-            maintenance facilities.
                                        mental export credit insurance compa-
                                        nies throughout the world.                   Andrä: We have always offered training
                                                                                     programs and courses with our plants,
                                        Where can one find Voith Hydro tech-         and that has helped us establish a very      A significant hydropower plant

                                                                                                                                                                                          T
                                        nology in Africa?                            good reputation in Africa. Now, we want      modernization project is helping                               he digital age is finally reaching Liberia’s Mount Coffee
                                        Bergmann: There is a long list of Afri-      to use our new concept to generate                                                                          hydropower plant, thanks to Voith and its pivotal role in
                                                                                                                                  to improve Liberia’s power
                                        can hydropower stations equipped with        added value for customers by providing                                                                      this historic project, together with other international
                                        Voith technology. Installations extend       solutions customized to their respective     infrastructure following years                          companies. Built in the 1960s, this plant on the Saint Paul R
                                                                                                                                                                                                                                                      ­ iver
                                        from Aswan in Egypt to Drakensberg in        needs. We have a global network and          of civil war.                                           was the West African nation’s largest at the time, but sustained
                                        South Africa. For example, Voith tech-       are able to combine system compo-                                                                    extensive damage during the civil war (1989-2003). And the
                                        nology is installed at Gilgel Gibe (Ethio-   nents from Europe, Brazil, India, and                                                                path to ruin continued when looting ravaged the electrical and
                                        pia), Inga (Democratic Republic of Con-      China with corresponding financing so-                                                               mechanical components, leaving only parts of the dam and the
                                        go), and Cahora Bassa (Mozambique).          lutions. In this way, we can create the                                                              steel penstock intact. This proved to be a huge setback to the
                                        New projects include those at Cam-           right package of technology, training,                                                               country’s economic and social progress, leaving Liberia’s capital
                                        bambe (Angola), Mount Coffee (Liberia),      service, and fi­ nancing for any operator,                                                           city Monrovia reliant on costly, non-renewable diesel-power
                                        and the pumped storage power station         regardless of their location and the size     am wall under construction on the Saint Paul River,
                                                                                                                                  D                                                       generation to meet its energy needs from 2006 onwards.
                                        in Ingula (South Africa), to name just a     of the ­hydropower station. //               with the powerhouse on the right.

18 | HyPower 2016                                                                                                                                                                                                                            HyPower 2016 | 19
AGENDA SETTING                                                                                                                                                                                                                            AGENDA SETTING

                                                                                                                           “At the customer’s request, Voith
                                                                                                                            took on the challenging task of
                                                                                                                            opening the spillway gates without
                                                                                                                            causing any damage to the civil
                                                                                                                            structure and components. All ten
                                                                                                                            gates were reopened ahead of
                                                                                                                            schedule.”
                                                                                                                           Harry Kathirvel
 1
                                                                                                                           Project Manager Voith Hydro
 2

                                                                                                                                                                                               3

                                                                                                                                                                                               4

                                                            Mutual trust is the prerequisite                               Kathirvel: “At the customer’s request, Voith took on the chal-
                                                         Trust in Voith’s long-standing presence and vast experience on    lenging task of opening the spillway gates without causing any
                                                         the African continent was key to its selection by the Liberian    damage to the civil structure and components. All ten gates
                                                         Electricity Corporation (LEC) to rehabilitate the run-of-river    were reopened ahead of schedule.”
                                                         plant in 2013. Now, the huge task of successively installing           Poor road conditions between the site and the Port of
                                                         four new Francis turbines and generators equipped with con-       Monrovia, which is about 25 kilometres away, posed a chal-
                                                         trol technology, a 95-ton overhead crane, as well as the auxil-   lenge to the transportation of sensitive equipment. Not only
                                                         iary electrical and mechanical plant equipment is nearing com-    that, the heavy rain from April to October further disrupted
                                                         pletion. The plant is scheduled to commence operations in late    operations. This meant that for certain plant systems, Voith
                                                         2016.                                                             had to commence with the design and manufacturing phases
                                                              Financed by the Liberian and Norwegian governments,          early enough to complete local transportation during the dry
1	Reservoir at the Mount Coffee hydropower
   plant in Liberia.
                                                         the European Investment Bank, Germany’s KfW Bank, and             season. The thorough and detailed work plan that addressed
2	The local community will benefit significantly.       the Millennium Challenge Corporation of the US govern-            all these challenges resulted in a flawless execution of the en-
3	Installation work at the Mount Coffee                 ment, the modernized units are forecast to raise power output     tire supply chain, without a hitch.
   powerhouse.
4	Julia Holder, Field Service Engineer,
                                                         to 88 MW, a 33 percent increase on the plant’s capacity in the
   Voith Hydro.                                          1960s. As a result, Monrovia’s population of over one million     Road survey and simulation run for powerhouse crane
                                                         will have access to reliable, clean and renewable energy.         transportation
                                                                                                                           One of the major hurdles that had to be factored in during the     Acknowledgement by the President
                                                         Overcoming significant challenges                                 local transportation of the 95-ton powerhouse crane was a Bai-     Voith’s long working tradition in Africa dates back to the
                                                         However, the path towards rehabilitation has had its fair share   ley bridge. Given its rusty condition, doubts arose about its      1950s, a factor that helped build up trust at the start of the
                                                         of obstacles, such as the condition of ten spillway gates that    structural integrity, and whether the bridge could withstand       project. Together with the customer, LEC, a cohesive, vital,
  Mount Coffee
                                                         were destroyed during the civil war. The operating mecha-         such a heavy load. Furthermore, using an existing alternative      one-team approach has been adopted.
                                                         nisms to open the gates had been destroyed, leaving the pow-      bridge that was being renovated was out of the question. To             Moreover, not even unpredictable events such as the
                            Hydropower in Mount Coffee   erhouse flooded. Keeping the powerhouse dry became impera-        prevent any risk to the powerhouse crane equipment, Voith          spread of the Ebola virus in 2014, and a high incidence of ma-
                            Installed capacity: 88 MW    tive, and that meant reopening the gates so that a cofferdam      carried out a thorough road survey and simulated transporta-       laria in the team later on have thwarted the rehabilitation
                                                         could be built to prevent water flowing into the powerhouse.      tion over the bridge using dummy cargo. Based on the simula-       works, which are on schedule, as Franz Bayrle, Site Manager,
      The Mount Coffee site is situated near the         This daunting task was a major milestone in the reconstruction    tion results, significant measures were implemented to ensure      explains: “This year, we have had 35 cases of malaria in my
      Liberian capital, Monrovia.                        of the Mount Coffee power plant, says Project Manager Harry       the bridge was up to the task.                                     team alone. But work within the culturally diverse team who

20 | HyPower 2016                                                                                                                                                                                                                             HyPower 2016 | 21
AGENDA SETTING                                                                                                                                                                     AGENDA SETTING

“Voith is supporting Liberia with an
 important step in the fight for the
                                                                                                                         CONTINUOUS
 development of the Liberian                                                                                             COLLABORATION
 economy.”
                                                                                                                         GIZ supports the German government and
Ellen Johnson Sirleaf
President of Liberia                                                                                                     other organizations in executing energy generation
                                                                                                                         projects in Africa and around the world.

   hail from Liberia, Pakistan, Indonesia, Germany, Norway                                                               The energy department of the German Association for International
and Sweden, is going well. I’m very pleased with them. They                                                              ­Cooperation (GIZ) supports the German Federal Ministry for Economic
have all fitted well into the work schedule.” Their performance                                                           Cooperation and Development and other organizations in identifying,
                                                                     1
was even acknowledged by the President of Liberia, Ellen                                                                  ­financing and executing new energy generation projects in over 120 rap-
Johnson Sirleaf. When visiting the Voith headquarters in             2                                               3     idly developing countries. Projects using renewable energy sources such
Heidenheim last year, President Sirleaf, who is also Liberia’s                                                             as hydropower are very much in focus, as Jens Burgtorf, Head of
Nobel Peace Laureate, said: “I am delighted that Voith and                                                                 ­Technology C
                                                                                                                                       ­ ooperation for the Energy Sector at GIZ, explains.
LEC have found a secure and pragmatic way for the further
development of the project, despite the recently overcome Eb-                                                            How have energy projects in developing countries changed in
ola epidemic. With this, Voith is supporting Liberia with an                                                             recent years?
important step in the fight for the development of the Liberian                                                          “Today, our clients want integrated energy generation concepts that are
economy and combating national poverty: with the repair of                                                               CO neutral. That’s a significant and very positive change but it also brings
                                                                                                                             ²
the Mount Coffee power plant, one of the key facilities in the                                                           challenges. Specifically, power supplied from some renewable sources
Liberian energy supply network is being reconstructed.”                                                                  such as solar and wind power is unpredictable. If the sun doesn’t shine,
    Another interesting aspect of the project is the contribu-                                                           or the wind doesn’t blow, power can’t be produced.”
tion of the project’s female engineers, in an industry where
women are under-represented. Julia Holder, Field Service En-                                                             How important is hydropower in this context?
gineer, comments, “There is definitely a collaborative working                                                           “Hydropower's advantage is that it is stable. Pumped storage plants are
atmosphere at Mount Coffee, and all the staff are friendly and                                                           particularly important because they can store energy that can be used to
helpful. The fact that myself, two Norwegian engineers and                                                               fill the gaps when solar and wind resources fall short. In other words,
many of the local staff are women is not really an issue. We                                                             hydropower can form a core, stable power supply that can then be
have a good team spirit and always support each other.”                                                                  extended through solar and wind-based power.”

The final steps to success                                                                                               How does this relate to Africa in particular, and what are the challenges?
On completion, the modernized plant will be fitted with                                                                  “Hydropower is very significant in Africa because the continent is so large,
Voith’s automation system, including a digital governor and                                                              and the grid infrastructure is so patchy, especially in rural areas. In every
state-of-the-art control system. The training of skilled person-    1	Mount Coffee powerhouse under                     project, protecting and enhancing the livelihoods of the communities
                                                                       ­construction.
nel is already underway and the first team of new LEC em-           2	A lathe machine operator inside Voith's on-       ­affected, and ensuring enough water is available for multiple purposes are
ployees being trained for eventual operation and maintenance            site workshop.                                    paramount. We work closely with all the parties involved to ensure that.”
of the plant will arrive in Heidenheim in fall 2016 for further     3	Final adjustments being made to the
                                                                       ­generator.
instruction. This is where they will become familiar with the                                                            What is the future for hydropower in Africa in your view?
design software, and gain in-depth exposure to the scope of the                                                          “Small, localized hydropower projects that bring energy to people outside
Mount Coffee plant, its machinery and workings, while the                                                                the large population centers and which use existing infrastructure will play
finishing touches are being applied to this mammoth project                                                              an important part because they minimize the capital investment required.
on site. Thanks to Voith and its project partners, it will fulfil                                                        They can also be completed faster, so people benefit from the power they
President Sirleaf’s mission to improve the reliability and scope                                                         generate more quickly.”
of Liberia’s electricity supply. //

22 | HyPower 2016                                                                                                                                                                      HyPower 2016 | 23
AGENDA SETTING                                                                                                                                                                                                                                             AGENDA SETTING

GLOBAL
                                                                                                neers might notice signs of operational
                                                                                                errors affecting the components they
                                                                                                are replacing, and suggest some extra
                                                                                                courses to get on-site engineers up to
                                                                                                speed. In the case of a completely new

TRAINING,
                                                                                                plant designed and installed from
                                                                                                scratch, Voith can offer more detailed
                                                                                                and intensive training. This covers each
                                                                                                technology, how it works and how it is
                                                                                                integrated into the plant as a whole,
                                                                                                then moves on to how to look after and

LOCAL
                                                                                                maintain the components correctly.
                                                                                                Many organizations opt for extra train-
                                                                                                ing to ensure they’re getting the best
                                                                                                value and most reliable service out of
                                                                                                their installation.

BENEFITS
                                                                                                Market maturity levels define needs
                                                                                                Aside from the technical aspects, Voith
                                                                                                HydroSchool training is structured dif-
                                                                                                ferently depending on market maturity.
                                                                                                North America and Europe are mature
                                                                                                markets, where refurbishment of very
Voith is committed to the transfer of in-depth                                                  old plants is key, and where the im-
technological knowledge and skills to local                                                     pending retirement of baby-boomer
employees, thereby securing the successful                                                      engineers makes knowledge transfer
                                                                                                ­
                                                                                                important. These markets are served
operation of hydropower plants for generations                                                  well with public courses where several
to come – in Africa and around the world.                                                       customers attend the same course. The
                                                                                                Chinese market is younger – with
                                                                                                25-year-old hydropower plants where           Customer staff members in a training    Liberian capital, Monrovia. However, it       from hydropower in combination with
                                                                                                the “original” engineers are still working    session at the Cambambe II hydropower   was damaged during the course of two          skilled engineers on site can really
                                                                                                                                              plant, Angola.
                                                                                                and are actively training younger staff.                                              civil wars. Liberia had been dependent        strengthen the economic and social
                                                                                                Here, operators can book seminars for                                                 on expensive diesel-generated power           fabric of countries like Liberia.”
                                                                                                staff with Voith’s subject experts to top                                             since 2006, and Voith was tasked with
                                                                                                up their knowledge. In contrast, Africa is                                            renovating the plant, which is due to be      More African projects underway
                                                                                                a greenfield market with a lack of skilled                                            put into service at the end of 2016.          The Voith HydroSchool will also provide
                                                                                                engineers. “In these cases, our training                                              Voith developed special courses that          training services following the implemen-
With less than one in three Africans            ity in the long run, which is a decisive fac-   program can ensure a skilled work-                                                    ­Liberian engineers will complete before      tation of the Cambambe II project in
having access to electricity, it’s clear that   tor for economic and social development.        force,” comments Cherie Ferrari, Man-                                                  the plant is commissioned, an aspect         ­Angola, and the Inga I installation in the
there’s an urgent need for efficient pow-                                                       ager of Customer Education and Train-                                                  that proved to be of great interest to        Democratic Republic of the Congo.
er plants across the continent. But even        Flexible approach to accelerate                 ing at Voith. “We often design                                                         ­Liberian President Ellen Johnson Sirleaf     Cherie Ferrari adds: “Along with techni-
the most modern hydropower plants               progress                                        completely customized courses tailored                                                  and her energy minister, Patrick Sendolo,    cal training, we can also deliver mentor-
can’t simply run themselves – they need         Every project is different – in Africa, as it   to the plant operator, staff, project and                                               when they visited Voith headquarters in      ing. At a recent pole replacement project
teams of skilled people to manage and           is everywhere else. That’s why the Voith        even the actual equipment in use.”                                                      May 2015. “We’re looking forward to          in Mozambique, we simply ‘shadowed’
maintain them. That's why Voith pro-            HydroSchool offers a wide range of                                                                                                      welcoming Mount Coffee engineers             local engineers and helped them with
vides training to the African companies         training options. Hydropower plant op-          Mount Coffee: challenges overcome                                                       to the HydroSchool training center           some tips and tricks. That’s the main
and governments who own and operate             erators can order a selection of training       The Mount Coffee project in Liberia is a                                                in Heidenheim this fall,” notes Cherie       point about the HydroSchool – training is
the plants. Voith’s HydroSchool contrib-        modules as part of their installation or        case in point. This hydropower plant,                                                   F errari. “This project is an excellent
                                                                                                                                                                                        ­                                            always exactly what each individual cus-
utes to the reliable production of electric-    refurbishment project. Or Voith engi-           built in the 1960s, is located close to the                                             example of how reliable electrification
                                                                                                                                                                                        ­                                            tomer needs. One size doesn’t fit all!” //

24 | HyPower 2016                                                                                                                                                                                                                                               HyPower 2016 | 25
FULL-LINE SUPPLIER                                                                                                                                                                                                                                FULL-LINE SUPPLIER

SMALL PROJECTS,
                                                                                                                                                                                                            1	Manufacturing small hydro turbines
                                                                                                                                                                                                               in Vadodara, India.
                                                                                                                                                                                                            2	Local technician inspects turbine quality.

BIG RESULTS
Small hydropower installations are often the only
practical and economic option – but their impact
can still be significant.

A coastal country on the Indochina                                                                                                                                                                                           in Quang Ngai province and southwest
Peninsula, Vietnam is one of Southeast                                                                                                                                                                                       of Quang Ngai City, the scope includes
Asia’s fastest-growing economies. The                                                                                                                                                                                        supplying a complete set of equipment
country’s numerous rivers are an impor-                                                                                                                                                                1                     for two powerhouses in cascade forma-
tant transportation route with over                                                                                                                                                                    2                     tion – Son Tra 1A and Son Tra 1B. The
17,700 kilometers of navigable water-                                                                                                                                                                                        30-4 Quang Ngai Joint Stock Company
ways – and they are also an important                                                                                                                                                                                        is developing the project.
source of renewable energy. Vietnam
has a theoretical hydropower potential                                                                                                                                                                                       Serving all of Asia
of approximately 300,000 GWh annual-                                                                                                                                                                                         Voith’s manufacturing facilities in Vado-
ly, 100,000 GWh of which is economi-        in the Tu Mo Rong District. The con-          PROJECT         CAPACITY                                                                                                           dara serve India, Nepal, Bhutan, Indo-
cally viable. Until recently, just 15,211   tract’s scope involves the supply of tur-     Dakpsi 2B       2 x 7 MW
                                                                                                                                                                                                                             nesia, Laos and the Philippines.
MW had been installed, leaving plenty       bine and generator, automation, E-BOP,                                                                                                                                                 For instance, in April 2016, Voith
                                                                                          Dak Ter-1       2 x 1.8 MW + 10 % COL
of room for growth.                         M-BOP and supervision of installation                                                                                                                                            commissioned the Kurhed project in
                                                                                          Dak Ter-2       2 x 1.7 MW + 10 % COL
                                            and commissioning the project. The                                                                                                                                               ­Himachal Pradesh, India; the installa-
                                                                                          Thanh Thuy-1    2 x 6 MW + 10 % COL
Small hydro success in Vietnam              system and component engineering of                                                                                                                                               tions at Behna and Gullu are slated for
                                                                                          Alin B1
As part of the new Renewable Energy         the turbine was undertaken by Voith’s                                                                                                                                             commissioning in late 2016.
                                                                                          hydroelectric
Development Strategy 2030, unveiled         local engineering center, and the tur-        project         2 x 23 MW + 10 % COL                                                                                                     Meanwhile, in the Philippines, the
in December 2015, the Vietnamese            bines were manufactured in Vadodara,          Son Tra 1A      2 x 18 MW                                                                                                           Lake Mainit project is being built on the
government has prioritized renewable        India. This was the first pilot project us-                                                                                                                                       northeastern section of the island of
                                                                                          Son Tra 1B      2 x 18 MW
energies and plans to increase hydro-       ing the cost-effective Standard Small                                                                                                                                             Mindanao. Voith has also supplied the
                                                                                          Kurhed          2 x 2.25 MW + 10 % COL
power generation from 56 TWh in 2015        Hydro Automation Scheme. This                                                                                                                                                     electromechanical equipment for Asiga,
                                                                                          Behna           2 x 2.5 MW + 10 % COL
to 90 TWh in 2020. Voith Hydro Private      scheme combines the functions of digi-                                                  menced in April 2014, and since com-           Voith was also chosen to work on           also located in Mindanao.
                                                                                          Gullu           2 x 12 MW + 10 % COL
Limited, based in Vadodara in north-        tal governor, control system, and exci-                                                 missioning in September 2015, both Dak     the Alin B1 hydroelectric project in                And in Indonesia, the supply of
                                                                                          Lake Mainit
west India, which launched in the Viet-     tation and protection system in one                                                     Ter-1 and Dak Ter-2 have been perform-     March 2016, following a tough bidding          equipment for the Semangka project is
                                                                                          project         3 x 8.333 MW + 10 % COL
namese market in 2011, is supporting        common panel, and delivers it within a                                                  ing to the customer’s full satisfaction.   process. Located in the A Luoi and             underway, as well as installation of the
                                                                                          Asiga           2 x 4 MW
the country in building and renewing its    compact solution. Both units in the                                                          A contract for Thanh Thuy-1 was       Phong Dien districts, this is the com-         turbine components. The project is due
                                                                                          Semangka        2 x 28.3 MW + 10 % COL
hydropower infrastructure, which fea-       project were handed over to the cus-                                                    signed in May 2015 with twin-jet Pelton    pany’s seventh successful Vietnamese           to be commissioned in 2017.
tures a large number of relatively small-   tomer in February 2015, leading to a                                                    turbine generating sets and complete       project, which is being developed in co-            Importantly, all of Voith’s activities
scale installations. This commitment is     third project, Dakpsi 2B, being recently                                                water-to-wire scope. Thanh Thuy-1          operation with Truong Phu Hydropower           in the region are driven by close cus-
reflected by numerous already commis-       awarded to Voith Hydro.                                                                 H ydropower Joint Stock Company
                                                                                                                                    ­                                          Joint Stock Company.                           tomer relationships, and regular face-
sioned projects and others which are             Meanwhile, the contract for Dak                                                    ­selected Voith to deliver all the power       And finally, another recent impor-         to-face meetings between customers
currently underway.                         Ter-2, which is in the cascade of the                                                    plant equipment at Haiphong port with-    tant milestone was the securing of a           and senior Voith managers. This dem-
     Dak Ter-1 was the first project com-   Dak Ter-1 project and on a similar scale,                                                in 14 months of the commencement          contract for the Son Tra 1 project in April    onstrates the company’s commitment
missioned by Voith in Vietnam, located      was signed in October 2013. Work com-                                                    date, followed by commissioning.          2016. Located on the Dak Se Lo River           to hydropower projects of all sizes. //

26 | HyPower 2016                                                                                                                                                                                                                                           HyPower 2016 | 27
FULL-LINE SUPPLIER                                                                                                                                                                                                      FULL-LINE SUPPLIER

                                                                                                Preparing a bid for a large hydro-                                                                   laboration,” adds Bulota. It was a real
                                                                                                power facility is a major project in its                                                             marathon, but it paid off in the end!”
                                                                                                own right. It requires patience, attention
                                                                                                to detail, and investment. According to                                                              A strong foundation for success
                                                                                                Björn Reeg, Voith Hydro’s Head of Pro­                                                               On the other side of the world, another
                                                                                                ject Management, constructing a scale                                                                large-scale project is taking shape that
                                                                                                prototype of the plant is often the first                                                            also relies on close collaboration. The
                                                                                                step. “The miniature version helps us to                                                             Wudongde hydropower station is the
                                                                                                optimize and to achieve the required                                                                 fourth largest in China and its turbine
                                                                                                performance and efficiency.” The team                                                                generator units will be amongst the
                                                                                                assesses the project’s technical feasi­                                                              largest worldwide in terms of power
                                                                                                bility and finds the right balance be­                                                               output. Zhang Min, project manager of
                                                                                                tween efficiency, longevity and perfor­                                                              Voith Hydro Shanghai for Wudongde,
                                                                                                mance.                                                                                               echoes the experience of Björn Reeg
                                                                                                      Working on a project that takes a                                                              and L­aurent Bulota. “We won this pro­
                                                                                                decade to complete is normal for Reeg
                                                                                                and his team. “The assessment pro­               “Outstanding change management skills and
                                                                                                cess takes time, because there are so
                                                                                                many factors – the country and its regu­          reacting quickly to unexpected events are vital,
                                                                                                lations, the plant’s location and logisti­        because unpredictability is a given.”
                                                                                                cal needs, and all the technical and
                                                                                                                                                 Björn Reeg
                                                                                                customer-related specifics. The longest          Head of Project Management, Voith Hydro
                                                                                                project I’ve worked on was Iberdrola’s
                                                                                                La Muela II installation in Spain – it took      Voith Hydro in Montreal. “Several of the            ject ­because we built a good relation­
                                                                                                eight years! Even after all that time,           customer’s criteria were soft factors like          ship with the customer and because we
 1
                                                                                                despite some delays outside of our
                                                                                                ­                                                customer references and methodologi­                had ­ access to global expertise from
                                           2                                                    control, the customer was delighted              cal details.” The team then performed               across the Voith Group,” he says.
                                                                                                with the project management. I’m very            several simulations to optimize the bal­                 In fact, the recipe for success in

MEETING
                                                                                                proud of that.”                                  ance between the units’ performance,                large hydropower projects is quite simi­
                                                                                                      “I think there are four key criteria for   the amount of rock to be excavated out              lar wherever the site, as Zhang con­
                                                                                                ­ensuring the success of a large-scale           of the river and the Amount of concrete             cludes: “This project is already pro­
                                                                                                 project,” says Reeg. “A good relation­          in the plant. The entire offer process              gressing well and we are very focused

THE LARGE
                                                                                                 ship with the customer is probably the          took over three years, culminating in the           on achieving the best result for the cus­
                                                                                                 most important – without that, every­           contract signature in March 2016.                   tomer. Diligence, confidence and great
                                                                                                 thing else is more difficult. Outstanding       “When BC Hydro awarded us the con­                  teamwork: that’s the secret to succeed­
                                                                                                 change management skills and re-                tract, they thanked us for the close col­           ing in large projects.” //

HYDRO
                                                                                                 acting quickly to unexpected events are
                                                                                                 also vital, because unpredictability is a
                                                                                                 given. Thirdly, leadership skills, espe­
                                                                                                 cially the coordination and manage­

CHALLENGE
                                                                                                 ment of multinational and multicultural
                                               1	The cavern of the world's third-largest
                                                  hydropower plant at Xiluodu on the Jinsha      teams. And of course, quality – our
                                                  River, China. Voith delivered three of the     ­reputation depends on it.”
                                                  18 machines for the site, which has a total
                                                  capacity of 13.86 GW.
                                               2	A Voith employee inspects the installation    Close collaboration
Today, major hydropower projects involve          to ensure maximum quality.                    In Canada, a project for BC Hydro at
                                                                                                Site C, a large-scale plant on the Peace
combining components that arrive from                                                           River in British Columbia, provides a
all over the world. Optimizing speed,                                                           good example of transferring this theory
quality and cost-efficiency is a tough                                                          into practice. “We set up a project team            Iberdrola’s La Muela II installation in Spain
                                                                                                to work solely on this offer,” says                  took eight years to complete.
balancing act.                                                                                  ­Laurent Bulota, Head of Proposals at

28 | HyPower 2016                                                                                                                                                                                                               HyPower 2016 | 29
FROM THE ARCHIVES                                                                                                                                                                                                                       FROM THE ARCHIVES

                                                     TRUE
                                                                                                                       plans for the construction of an irrigation system to serve            technique was developed for this: high-voltage direct-current
                                                                                                                       huge agricultural areas. A total of 15,000 km² was supposed to         transmission. With this new technique, the engineers were able
                                                                                                                       be harnessed for the cultivation of fruits for export. And the         to cut the transmission costs in half.
                                                                                                                       revenue generated from this was intended to boost economic

                                                     SURVIVOR
                                                                                                                       development.                                                           Independence without peace
                                                                                                                            However, there were also dissenting voices and protests.          In April 1974, the “Carnation Revolution” in Portugal ended
                                                                                                                       The Mozambican freedom movement Frelimo, which had                     the Caetano dictatorship and also paved the way for the inde-
                                                                                                                       been fighting for political freedom from Portugal since 1964,          pendence of the colonies. Mozambique became independent
                                                                                                                       criticized the project, as did various student movements across        in 1975. Frelimo became the ruling party and began to support
                                                                                                                       Europe. Their argument was that Cabora Bassa would only                the construction of the power plant. The first expansion stage
                                                     “Cabora Bassa” – a name that demands                              benefit the apartheid regime in South Africa and the dictator-         with 1,224 MW capacity was completed as planned and the
                                                     superlatives: a 164-meter-high dam wall                           ship in Portugal. During the construction and installation pe-         hydropower plant began commercial operation on 26 March
                                                                                                                       riod, civil war and violence dominated the country. The con-           1977. In June 1979, the last expansion stage was completed
                                                     on the Zambezi River; a 250-kilometer-
                                                                                                                       struction site and the camp, which housed more than 3,000              and Cabora Bassa was finished on schedule after 10 years of
                                                     long reservoir lake; a 1,500-kilometer-long                       engineers and construction workers at the time, had to be se-          construction.
                                                     high-voltage line between Mozambique                              cured by the military.                                                      The political turmoils on the Zambezi, however, were not
                                                                                                                                                                                              over yet. Now the guerrilla movement Renamo, supported by
                                                     and South Africa; and a total power output
                                                                                                                       Technical innovation lowers costs                                      the South African apartheid regime, began fighting the Marxist-
                                                     of 2,075 MW.                                                      In the meantime, the engineers were mastering technical chal-          Leninist Frelimo government. What followed was a bloody,
                                                                                                                       lenges. They erected a six-kilometer-long overhead line from           16-year-long civil war. Around 900,000 people died and 1.7 mil-
                                                                                                                       the platform at the cavern surface to the Songo plateau 600 me-        lion fled the country. Renamo also repeatedly attacked the infra-

                                                     M
                                                                ozambique was still a colony when the tender was       ters above it, and connected it to a three-phase current substa-       structure at Cabora Bassa, which became a ruin. Only in 1997,
                                                                sent out for the construction of a hydropower plant    tion and a converter station. Here, 220 kV three-phase current         after the end of the civil war, was Cahora Bassa (as it is spelled
                                                                on the Zambezi River in November 1967. The Por-        was converted into 533 kV direct current for transport. A new          today) repaired and returned to operation. //
                                                     tuguese “Minister for overseas territories” was planning “Cab-
                                                     ora Bassa” as the largest hydropower plant in southern Africa.
                                                                                                                                                                                              1	Manufacturing the turbines for Cabora Bassa
                                                     Five turbines were meant to generate the electricity that was                                                                               at the factory in Heidenheim.
                                                     largely intended to be sold to South Africa. For electricity                                                                             2	The efforts of local workers were key to
                                                                                                                                                                                                 completing the plant on schedule.
The spectacular dam on the Zambesi following         transmission, a 1,500-kilometer-long high-voltage line was
completion in the late 1970s, before it was ruined                                                                                                                                            3	New roads and tunnels were constructed to provide
during the civil war.
                                                     built between the site and Pretoria.                                                                                                        easier access to the dam site during construction.
                                                           In September 1969, roughly two years after the tendering
                                                     process began, the contract for the underground hydropower
                                                     plant was awarded to an international consortium that includ-
TECHNICAL DATA                                       ed ­Siemens, Voith, AEG, BBC and the construction company
                                                     Hochtief – all German companies. Voith provided the five
5 Voith Francis turbines with 415 MW each;
turbine runner diameter: 7 m                         Francis turbines for Cabora Bassa. While the turbines were
                                                     being constructed in Heidenheim, robust roads and bridges
Dam Wall:                                            were built in Mozambique so that machines and equipment
height: 164 m                                        could be transported to the construction site. On the high                                                                     1
width at the base: 23 m                              ­plateau, a runway for propeller-driven aircraft was built, and
                                                                                                                                                                                    2     3
width at water level: 4 m                             the region was equipped with a new telecommunications and
                                                      telex system.
103.5 METERS HEAD
                                                     Ambitious goals versus critical voices
5 generators with 480 MVA each;                      The Cabora Bassa construction site was situated at the end of
rotor diameter: 13 m                                 a gorge that is 18 kilometers long, 250 meters wide and 700
                                                     meters deep. Ambitious goals were attached to the construc-
Cavern:
                                                     tion of the reservoir and power plant. The Zambezi had been
length: 220 m
                                                     made navigable over a length of 320 kilometers in order to al-
height: 57 m
                                                     low for the transport of natural resources such as coal, iron,
width: 29 m
                                                     titanium, manganese, chromium and bauxite. There were

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