Water to wire environmentally and socially sustainable small hydro power plants in Zimbabwe Andy Eaton, Hydro Sales Engineer, Gilkes, UK Gianluca

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1 Water to wire environmentally and socially sustainable small hydro power plants in Zimbabwe Andy Eaton, Hydro Sales Engineer, Gilkes, UK Gianluca Stanic, Technical Director, Marelli Motori, Italy

2 Gilkes at a Glance Gilbert Gilkes & Gordon Ltd is an internationally established manufacturing company,based in Kendal, UK on the edge of the English Lake District. Gilkes is a world leader in small hydropower systems for the generation of electricity from water. Since the company's first hydro turbine installation in 1856, Gilkes has supplied over 6500 turbines for more than 80 countries. Contact: Andy Eaton - a.eaton@gilkes.com

3 Marelli Motori at a Glance Marelli Motori S.p.A. has a tradition dating back to 1891 when Ercole Marelli founded the Company. With over 100 years of manufacturing excellence and experience, Marelli Motori is recognised as a leading supplier to the Power Generation, Industrial, Petrochemical and Marine market sectors, offering a complete range of Generators and Electric Motors in low and high voltage from fractional kw to 9MVA in low, medium and high voltage. Worldwide presence (Service included) African subsidiary Company is based in South Africa Contact (Africa) Dean Pratt - dpratt@marelli.co.za

4 Background Information Pungwe & Duru are Hydro Projects both located in the Honde Valley, north western Zimbabwe. They are run-of-river power plants providing power into the national grid, though they both have the capability of running islanded if required. Honde Valley, Zimbabwe

5 Fundamentals of both Projects Duru Net Head, m Flow, lps Power, MW Speed, rpm Pungwe Both plants consist of a Gilkes twin jet Pelton Turbine coupled to a Marelli Generator. The generator produces its power at 6000V, and this is stepped up by transformer to the 33kV grid voltage.

6 Twin Jet Gilkes Pelton Turbine Water Inlet

7 General Arrangement Gilkes Turbine Marelli Generator

8 Infrastructural Activities Both sites have required grid extensions to evacuate the power, and access roads have had to be built in the rural hilly terrain. Each project was a brand new construction - diversion dam and intake, water pipelines, and powerhouses. Rigt: Duru Site

9 To Act as a Team but These projects were water-to-wire electromechanical contracts. Gilkes were responsible from the water inlet to the turbine, to the outgoing side of the power transformer at 33kV. The customer provided all the civil works, as well as the 33kV switchyard works and some of the grid protection.

10 in the Long Run for Local People The customer took a lot of care to employ local people for project construction as far as possible, so that they would feel benefitted by the project coming to their area. A school is also under construction for local children who otherwise have to travel a long way to find schooling.

11 Civil Works at Pungwe

12 While Marelli was making the Generators Runner installed onto the generator shaft Lateral rotor dynamics (overspeed) Bearings designed to manage water thrusts Lube Oil Unit Shaft Driven Mechanical Pump Flywheel to increase system inertia Extensive Factory Testing Capabilities Made in Italy with local presence in Africa

13 Marelli Generators 3D design

14 Marelli Generators Side View Terminal Box Thrust Bearing Flywheel & Shaft Driven Oil Pump

15 Marelli Generators FEM checks

16 Oil lubrication system Lube Oil Unit with Collection Tray

17 Performance Tests in Italy

18 ..Gilkes building the turbine (runner machining)

19 From Europe to Zimbabwe Note the packing suitable for sea freight and capable to preserve equipment during transportation handling.

20 Runner Installation on Site

21 Erection Works - Duru

22 Pungwe - Generator Installation

23 Erection Works - Duru Note the alternator (left) and turbine casing (right)

24 Erection Works - Duru Rear view of the generator: note the flywheel (yellow disc) and lube oil system (left side).

25 Erection Works - Duru Rear view of the generator: note the flywheel (yellow disc) and lube oil system (left side).

26 Pungwe Power House

27 Duru Connection to Lube Oil unit

28 Pungwe and Duru: Status Pungwe is running (Feb 2013) and is in commercial operation. Duru is still being commissioned.

29 To look after in years to come Customer Care and After Sales Service to include: Commissioning Spares Trouble shooting Maintenance Training Optimization Retrofit..locally Marelli South Africa

30 Pungwe & Duru: a Reference for the Future The customer is planning to build more Hydro plants in Zimbabwe, building on the experience gained on Pungwe and Duru. It is most likely that they may even consider building in other parts of this region in the future.

31 Africa-EU Energy Partnership(AEEP) The two continents share a commitment to a significant expansion of renewable energy in the energy mix in order to reduce dependency on fossil fuels, improve energy security, and form the backbone of a future low-carbon energy system AEEP targets on renewable energy to be reached by 2020: 10,000 MW of hydropower facilities. Africa has got natural resources to expolit!

32 Q&A