Powering a better future

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1 Powering a better future

2 A history of engineering excellence With over 180 years of engineering excellence, Wärtsilä is a global leader in advanced technologies and complete lifecycle solutions within the marine and energy market. With an emphasis on sustainable innovation and total efficiency, Wärtsilä aims to maximise the environmental and economic performance of installations for its customers. With widespread market experience, Wärtsilä has extensive engineering capabilities with a global customer base. This has enabled us to develop our expertise in the research, creation and development of custom solutions for renewable power generation and industrial applications. Our history in hydropower Wärtsilä Hydro Services specialise in the service, repair, overhaul and upgrade of existing hydroelectric installations, focusing on efficiency upgrades of medium to large hydroelectric turbines. Through our Services offering, we can support plant repairs, replacement and upgrades, conversions and rehabilitation of hydroelectric components, including runners, shaft seals, bearings and monitoring systems. We have specific expertise in rotating equipment, which allows us to solve inherent system issues and propose significant enhancement to operational efficiency and reliability. As an independent, full service provider for hydro applications worldwide, we have over 30 years experience of delivering service expertise in a safe, reliable and environmentally sound approach. This enables us to improve our performance, reduce adverse environmental impact and support complete lifecycle solutions for our customers. 2 3

3 Complete hydropower solutions With an integrated offering of products and services, we are well positioned to address the need for energy efficient, innovative and flexible solutions. Whether you are looking for enhanced product performance, refurbishment or total lifecycle services, Wärtsilä is here to help. Custom engineered solutions We have been specialising in the design and manufacture of hydro turbine components for over 30 years, with the capability of providing engineered solutions for the rehabilitation and upgrade of hydro power plant assets. By performing technical inspections on your key components, we can provide custom solutions to maximise the operational lifecycle of your hydro power plant. With extensive seals and bearings experience, our engineers and field support teams are capable of fully optimising your generating capacity by designing, manufacturing and installing new custom runners, turbine shaft seals, bearings and complementary equipment, including water quality systems. Our focus is to provide sustainable designs that maximise turbine capacity and efficiency, whilst eliminating cavitation to meet your needs. Upgrades and refurbishment Wärtsilä prides itself on providing turnkey upgrades and refurbishments of hydroelectric plants across the world. Upgrades and rehabilitation are unique opportunities to develop additional generation at a far lower cost than other sources of electric power. Our engineers are trained and experienced to fully optimise your generating capacity by designing, manufacturing and installing new custom designed runners, turbine shaft seals, bearings and other components, overhauling the remaining major components of your turbine. Through our global site service facilities, we can provide activities including shaft seal and bearing reconditioning, in-situ and workshop machining, re-babbiting and blade or cavitation repair. We take a specialised approach to every turbine upgrade with the goal of extending the life of your turbine and creating more capacity and efficiency within the layout of your hydro plant. 4 5

4 An unmatched portfolio Your global partner in engineered lifecycle solutions Any operational efficiencies you introduce will have a positive financial impact. By choosing Wärtsilä, hydro power plant operators can benefit from a comprehensive range of products and services, established from proven technology in the toughest and most demanding applications. We can provide a range of solutions that can be customised to meet your exact requirements. WÄRTSILÄ HYDRO PRODUCTS, SYSTEMS AND SERVICES Wärtsilä REsafe bearings The Wärtsilä REsafe bearing is a water lubricated and composite turbine shaft bearing, which provides low speed hydrodynamic operation, superior abrasion resistance and low noise generation. This encompasses an environmentally friendly and long lifecycle solution. These are available as bushes, shells or segments and also available as a package, retained in an existing or custom housing, tailored for easy installation. Housing options include standard spun cast aluminium bronze or Wärtsilä s lightweight and strong structural composite housing. By using our lightweight option, it reduces the weight of the housing by up to 75% without any detriment to strength, support and operation. This vastly improves the safety and operational elements of installation, commissioning and maintenance. Wärtsilä REguard seals The Wärtsilä REguard shaft seal is a high performance, low leakage solution for hydropower turbine applications. The seal utilises Wärtsilä s REvolution System, a Pressurised Interface Management System (PIMS), which enables an optimum operating system by constantly monitoring pressure and temperature. This allows the system to regulate the injection pressure of clean water between the interfaces, enhancing seal performance. Developed from years of research and development, the design combines spring force, hydraulic on-load and injected clean water supply to create a balanced, costeffective seal design, even under partial vacuum as seen on large pumps and water turbines. Increased operational uptime and reliability Real-time access, control and monitoring capabilities High abrasion resistance Total lifecycle shaft seal management Wärtsilä REguard A (REv) Seal and Wärtsilä REguard Restrictor Seal A popular choice for hydropower turbine applications, compatible with the Wärtsilä REvolution System Easy installation and maintenance minimises downtime Wärtsilä REvolution System Custom options available for a wide variety of applications Proven environmental performance The Wärtsilä REvolution system combines our Wärtsilä REguard shaft seal technology with a control and monitoring system which includes pressure, flow, temperature and wear sensors within the seal. Seal performance data is fed into a central high performance controller which allows the seal to maintain hydrodynamic operation through hydrostatic injection. By removing components such as shaft seals from your critical maintenance path, the system allows workload balancing, enabling focus on other key aspects of your hydro power plant s efficiency and output. With real-time data and intervention capabilities, we are able to provide total lifecycle management of your shaft seals. Wärtsilä Oil to Water Bearing Conversions A managed solution for the conversion of hydro power plants to water lubrication, including planning, approvals, equipment, installation supervision and project management. A typical onsite conversion involves shaft machining, removal of all oil lubricated seals, bearings, systems and pipework. Installation of our water lubricated bearings, seal and systems is then completed on site to ensure all components are installed correctly. In the move towards renewable energy, our conversions adhere to environmental legislation through the installation of water lubricated shaft seal and bearings. This provides zero risk of operational oil leakage and a longer service interval and lifecycle solution. Lightweight options available with reduced housing weight Easy to assemble with quick installation, minimises disruption Adheres to environmental legislation Zero risk of operational oil leakage Ideal for small hydropower and tidal power installations Environmentally compliant to meet changing regulations Reduced operational and maintenance costs 6 7

5 An unmatched portfolio WÄRTSILÄ COMPLEMENTARY SYSTEMS AND COMPONENTS Wärtsilä Water Quality System Provides filtered water in line with operating and environmental standards for open and closed lubrication systems, increasing longevity of your components. A control panel oversees the safe operation and fully system monitoring for both pump failure and electrical supply redundancies. Wärtsilä Slide bearings Self-aligning generator bearings suitable for hydropower turbines. The housing is made of cast iron and centrifugally cast, tin-based white metal bearing surfaces. These can be fitted with complete remote monitoring for temperature and oil flow. Dual pumps for redundancy in the event of duty pump failure Cyclonic system automatically discharges particulate debris Full monitoring control panel Centrifugal pumps cannot over-pressurise the system, removing the need for safety valves Wärtsilä Thrust Pads Our thrust pads are manufactured internally, enduring a static casting process which creates a high bond strength between the cast iron body and white metal inner surface. The stability and strength of our thrust pads allows operation at high pressures as well as providing enhanced heat transfer through the white metal material. Wärtsilä interface components Wärtsilä hydraulic nuts Wärstilä hydraulic couplings Wärtsilä hydraulic bolts Reversed engineered components including seal interfaces. Wärtsilä provides its proprietary composite interface material, manufactured in-house, to be incorporated into other OEM seals or as replacement material for existing, older, installations. Supply is on a make to print basis with all intellectual property (IP) in the material retained by Wärtsilä. Manufactured from high quality materials, the hydraulic nuts are designed for use as an installation tool and a permanent nut. Simple and quick way to connect shafts, eliminating the need for keyways, tapers or thrust rings. Designed to ensure the easy connection of flanges while still being able to meet the requirement of high torque transmission. The high quality bolts keep the connections rigid under extreme operating conditions. They are easy to install, remove and reuse. 8 9

6 An unmatched portfolio SERVICES Rehabilitation and total plant upgrades Our experienced engineers are able to provide turnkey upgrades and refurbishments for your power plant. This covers a variety of components including runners, shaft seals and various bearing applications and monitoring systems. Working with trusted partners, we will replace, rehabilitate and upgrade your entire electrical and mechanical systems which can contribute towards reducing your operating costs through capacity and performance enhancements. Project engineering Our fully equipped field support teams can develop a project to cover disassembly to commissioning, including site machining of embedded components to ensure critical alignments and tolerances are achieved. We offer site surveys of existing plants and a range of maintenance options, including onsite rehabilitation of your components, made possible with our extensive machining systems and tools. Manufacturing and machining capabilities Our global manufacturing sites are designed to produce and refurbish high quality hydropower components efficiently through our expertise in computer and manufacturing integration. This enables us to produce engineered designs which are input directly into our work centres, which provide a range of manufacturing and machining capabilities. All of our facilities are certified to ISO 9001, ISO and OHSAS 18001, demonstrating our focus on the quality of refurbishment, safety and the environment. Our in-situ and workshop capabilities for hydropower equipment include: Full service machining - large capacity CNC to facilitate horizontal and vertical boring, milling and turning. Supported by quality control station with portable coordinate measuring systems Shaft/pump seals overhaul Guide/thrust bearings refurbishment, upgrades and re-babitting which can all contribute towards reducing your operating costs Runner repair Unit alignment, refurbishment and cavitation repair Blades Cavitation repair and restoration of blade profile Babbiting specialist bearing reconditioning Discharge ring extension and embedment Cavitation repair service Stay ring and guide vane modifications or replacement Wicket gate overhaul includes overhaul and installation of seal, bearings, washers and bushes. Cavitation and weld repair is also provided Valve/Pump/Actuator/Control Links overhaul Removal, refurbishment and re-installation services Oil to water conversions Shaft alignment services Welding and fabrication services Reverse engineering services NEXT GENERATION WHITE METAL TECHNOLOGY With over 30 years of experience in advanced white metal technology, we can repair and upgrade any specifications of white metal bearings and pads. With improved mechanical and tribological properties and our enhanced laser solutions, we make a real technological difference. Environmentally friendly and sustainable, this is technology that delivers improved performance on applications including bearings, thrust pads and gearboxes

7 Wärtsilä s total lifecycle solutions With over a century of engineering experience, Wärtsilä is ideally placed to help you with your hydropower needs. Our vast portfolio, global capabilities and servicing solutions offer cost-effective, environmentally friendly ways to harness the power of hydro. Contact For more information, please contact us on hydroandindustrialservices@wartsila.com Follow us on WÄRTSILÄ is a registered trademark. Copyright 2018 Wärtsilä Corporation. Specifications are subject to change without prior notice. Printed