A An Innovative, Exciting and Competitive Hydro Solutions Company

HydroWorks

• Extensive list of Reference sites & Projects

• New Build up to 12MW

• Refurbishment up to 30 MW

• Very experienced professional team

• End to end contract management, turbines, valves, gates, bifurcations, pipe jacking trolleys, screen cleaners, controls and protection.

• Solving difficult issues with Innovative solutions our specialty

Manufacturing capabilities

Machine shop

Metrology

On site machining

Fabrication shop

Non ferrous

foundry

Machine shop

Vertical turning capacity: 5.5 m diameter x 2.2 m high

Work-piece capacity 20 tonnes

Tekapo B Francis runner, 80MW

Tekapo A Kaplan runner, 33 MW

Hydro Runner Replacement

Mangorei 1.8 MW

Aluminium Bronze

Runner

Mangorei 1.8 MW

CA6NM

Stainless Steel

Runner

Cobb 4 MW

CA6NM

Stainless Steel

Pelton

Hydro Refurbishment Projects

Tekapo ‘B’ 82 MW

Francis

Refurbished seal ring

Tekapo ‘A’ 33 MW

Kaplan

Refurbished hub

and blade seal and

bearing surfaces

Manapouri 100 MW

Head cover

refurbishment

New Hydro Projects

Motakawa 500 KW

In-Race Kaplan

Turbine

Deep Stream

2 x 3 MW Francis

Turbines

Mace hydro experience

• Waitaki G3

• Benmore – On Site machining

• Tekapo B - Overhaul

• Tekapo A - Kaplan Refurbishment

• Manapouri (via Transfield)

Technical Skills

• CAD Modelling – Siemens NX (4 seats) and SolidWorks (6 seats)

• Advanced CFD – Huntsman Code

• Advanced FEA

• Vibration analysis

• Transient analysis

• Efficiency testing

• Mechanical Design

CFD

CFD for analysis Use commercial CFD package….e.g. Ansys CFX or Star CD

Can only analyse…….….NOT design

Highbank - Bifurcation

• Bifurcation required to pump water back up into RDR

• 3m Diameter

• Design & manufacturing support

CFD

CFD for design Exclusive licence of the “Huntsman” CFD code for turbine design and 20 years experience in developing and using this code

New HydroWorks

designed blade

Original blade

Runner

Francis turbine

Who has this capability?

1st tier manufacturers such as Andritz, Toshiba, Alstom....

………and HydroWorks

Transients analysis

• Key Element of safe Hydro design and operation

• Underpins design of Turbine, Penstock and controls

• Hydraulic transients and governing simulation • (in house and commercial code)

• Design and commissioning experience across extensive range of sites

• Recently identified a serious safety concern at an existing customer site

Model Testing

Hydraulic Model Testing

• HydroWorks have our own Pelton test rig

• Measures to within +/- 0.05% for efficiency

• Fully complies with international test codes and instrument test certification.

• Validates innovative designs before delivery

• New Build

• Refurbishment

• Consultancy services

• Maintenance contracts

• Climate Defender range of products – Irrigation

– Municipal

Hydro Solutions

Climate Defender InRace

Cobb - TrustPower

• 2 x 12 MW Pelton turbine refurbishment • Effectively new turbines

• Integration with original embedded components

• 600 m head (highest in NZ)

• Model testing on our Hydraulic Test Facility

• Full mechanical analysis including FEA

•Design life Runner lifetime of 1010 cycles

• Thermodynamic Testing – – Efficiency gain of 2.5% at the operating point.

• The first 6-jet Pelton in New Zealand – 7.7MW

• 418m Head (2nd highest in NZ behind Cobb)

• Uses deflector governing to maintain grid stability

• From the Westpower website; – “This turbine was designed and constructed in New Zealand and is

of a very high quality with efficiency figures as good as anything

available in the world today…”

Amethyst - Westpower

• Tasmanian Irrigation – Scheme Owner

• 6 MW 4 Jet Pelton (650m Head)

• 33 km long penstock, has to operate in islanded mode. – Deflector governing

• Conveyance of Irrigation water is the priority

– Fitted with a bypass system and a device to dissipate 6MW of energy.

Midlands Hydro Scheme - Tasmania

• Private Scheme

• 1.5 MW - 2 Jet Pelton

• Design, Manufacture, Install and Commission

• Started Generating Dec ‘15

Inchbonnie – West Coast NZ

Fraser Dam – Pioneer Generation

• Refurbishment project – Central Otago •245m head, 1.8m3/s flow

• New Pelton Turbine & Generator (3.3MW) •Another example of ‘end to end’ service capability (mechanical)

•Design, manufacture, supply, install & comm

Marama Nui - Tahiti

Titavaari 1A - Refurbishment

• New Shaft, base-plate and Bearing arrangement

• Old design – resulting in premature bearing failure and through shaft arrangement resulting in poor efficiency

• Design Study up front

• Manufacture contract

• Installed and commissioned late 2015

• Currently manufacturing for Vaihiria 1

Waipori 1A

A good example of our Innovation and Point of Difference

• 10 MW Kaplan in Otago

• Critical failure required immediate response

• Manufacturing supported by professional engineering

• Designed a stand to facilitate rapid but safe repair – Recognized the urgency

– Earthquake risk

• Technically challenging disassembly

• Responsive Design – Original plan was to replace “like for like”

– Late decision made to redesign crank arms

Somerset Dam Brisbane

• SEQ Water, QLD – Water Authority, SOE

– Core function is water and wastewater

• Flood damaged station –Out of service since Jan 2011

• Contract executed in Sep 2015

• Effectively new turbine (~4MW), new generator, new controls & protection, transmission connection and minor civil work.

• Principle/Lead Contractor - Design, Manufacture, Supply, Installation, commission

• Managing international sub-contractors

Melbourne Water – Mini Hydro’s

• Design, Manufacture, Install and Commission.

• 5 Separate sites (65-300kW) – 3 PaT’s

– 1 Francis

– 1 Pelton

• Fully containerized solutions

• Tight noise limits

• Contract signed in Dec, 18 month program

If you think we can assist you or your company with any of

your current hydro equipment challenges or have any

interest in knowing more please contact me in the first

instance :

Ian Mc Innes – ian.mcinnes@hydroworks.co.nz