A Hydro Solutions Company that has solved some difficult challenges for existing and new Hydro Asset Managers

1. A An Innovative, Exciting and Competitive Hydro Solutions Company

2. 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

3. Manufacturing capabilities
Machine shop
Metrology
On site machining
Fabrication shop
Non ferrous
foundry

4. 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

5. 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

6. 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

7. New Hydro Projects
Motakawa 500 KW
In-Race Kaplan
Turbine
Deep Stream
2 x 3 MW Francis
Turbines

8. Mace hydro experience
• Waitaki G3
• Benmore – On Site machining
• Tekapo B - Overhaul
• Tekapo A - Kaplan Refurbishment
• Manapouri (via Transfield)

9. 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

10. CFD
CFD for analysis
Use commercial CFD package….e.g. Ansys CFX or Star CD
Can only analyse…….….NOT design

11. Highbank - Bifurcation
• Bifurcation required to pump water back
up into RDR
• 3m Diameter
• Design & manufacturing support

12. 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

13. 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

14. 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

15. • New Build
• Refurbishment
• Consultancy services
• Maintenance contracts
• Climate Defender range of products
– Irrigation
– Municipal
Hydro Solutions

16. Climate Defender InRace

17. 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.

18. • 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

19. • 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

20. • Private Scheme
• 1.5 MW - 2 Jet Pelton
• Design, Manufacture, Install and Commission
• Started Generating Dec ‘15
Inchbonnie – West Coast NZ

21. 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

24. 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

26. 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

29. 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

33. 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

35. 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