WEIR AMERICAN HYDRO. Excellent Engineering Solutions

WEIR AMERICAN HYDRO Excellent Engineering Solutions

Weir Power & Industrial Division Sites Worldwide The Weir Group PLC Values Customer focus Listening to the voice of our external and internal customers in everything we do. Engineering excellence Adding value by meeting the changing needs of our customers. Integrity Consistency, openness and honesty applied across all our relationships, always meeting our promises. Self-determination Maintaining our freedom of action through prudent, highly professional financial and risk management throughout the business. Valuing people Trusting and respecting one another and supporting, challenging and developing each other to achieve our maximum potential personal contribution. Working together Working across boundaries to realize the full potential of Weir s global capabilities Leadership Harnessing the energy of our people to achieve our shared ambition for growing business success.

Weir American Hydro: High Performance Hydro Products & Services American Hydro Corporation was founded in 1986. In 2010, American Hydro became Weir American Hydro after being acquired by The Weir Group PLC. Employing over 11,000 people and operating in 42 countries around the world, The Weir Group PLC, headquartered in Scotland, is a global leader in the design, supply and ongoing service of engineering equipment and solutions for the Minerals, Oil & Gas and Power & Industrial sectors. A division of The Weir Group PLC, Weir Power & Industrial supplies valves, pumps, industrial steam turbines and hydro products to global power generation, industrial and oil & gas sectors. Our global network of service operations specializes in the maintenance, repair and upgrade of flow control and rotating equipment. Specifically in the hydro industry, Weir American Hydro is a leading supplier and installer of large equipment for the hydroelectric and water distribution industries, specializing in the design, manufacture, upgrade and servicing of high performance hydro-turbines and pumps. Weir American Hydro is a company steeped in a tradition of hydro power. We honor this tradition and we build on it. Our engineers are experienced and they know every nuance of the powerful equipment we build. Weir American Hydro has flourished, however, not just due to experienced engineers but by integrating state-of-theart technology in the design and manufacture of this equipment. Our engineers were the first in the industry to develop powerful three-dimensional finite element analysis and apply it to the structural design of some of the largest turbines in the world. Our engineers were first in adapting this same finite element technique to the analysis of fluid flow, revolutionizing the methods used to design new AMERICAN HYDRO runners. We have used these tools for more than twenty-five years. But what have we done lately? With this brochure we wish to tell you the story of our new technologies. It is the story of unique Francis turbine designs to achieve unparalleled levels of power, of new powerful draft tube analysis providing revolutionary means to improve performance, and of new methods to improve the aquatic environment surrounding our AMERICAN HYDRO turbines. It is a story of numerical manufacturing and robotics that provide the flexibility in design and precision in product necessary to achieve ultimate performance goals. It is a story from concept to commissioning. And why do we have such a single-minded goal of turbine improvement? Simply put, the revenues generated by hydro power originate from the turbine. Better turbines provide more revenue. This is the difference our technology will make for you. All of us at Weir American Hydro value the relationships we have with our clients, our suppliers, and our friends. If you are a customer, let us take this opportunity to thank you for your support. Let us also thank our suppliers whose dedication is so important to the products and services we provide. For those of you who do not know us, we look forward to meeting you, working with you, and welcoming you to the Weir American Hydro family. Weir American Hydro

Technology Weir American Hydro technology: Structural analysis and system dynamics The power of Weir American Hydro s structural analysis codes and the effectiveness of our engineering analysts have been established for many years. We work daily to be sure that our new AMERICAN HYDRO turbine components and your existing turbine can safely withstand the hydraulic and rotational loadings under extreme conditions. Recent advances in upgrading pump-turbines have led to new stay vane modifications which improve performance and significantly extend turbine life. This is not always accomplished by adding material, but also by reshaping the existing vanes, thereby leveling stresses throughout the structure, eliminating dangerous stress concentrations, and reducing hydraulic losses. While structural integrity based on constant loads is critical to turbine design, Weir American Hydro s ability to evaluate dynamic responses of all system components has been crucial for many of our successful projects. We have eliminated wicket gate vibration problems through careful contouring of the existing gates, and identified penstock frequencies which are avoided by proper selection of the number of runner blades. Transient turbine or pump operation, such as load rejection, can cause a pressure or speed rise which may damage the waterways or the equipment. Weir American Hydro s transient computer analysis accurately predicts this behavior. Our engineers use these tools to optimize turbine control system timing and avoid dangerous operation. Weir American Hydro

CFD analysis of full spiral case, including stay vanes and wicket gates Weir American Hydro

Weir American Hydro technology: Computational fluid dynamics (CFD) Complete CFD analysis of large (190 ) propeller turbine Technology is fundamental to every aspect of Weir American Hydro s projects. Our design and analysis technologies must accurately predict the performance of our AMERICAN HYDRO equipment before we begin to manufacture. The reliability and precision of our computational tools are critical to the success of your project. Building on our established expertise to refine runner design using finite element flow and performance analysis, Weir American Hydro has applied the latest Navier-Stokes computational fluid dynamic technology to calculate flows throughout the hydro turbine. We have concentrated our efforts to do what is needed and to do it well. We know that the diverging flows in draft tubes provide a daunting challenge to even the most advanced codes, yet this is exactly the turbine component that can dramatically impact performance. Our approach to this problem has paralleled what we have done for runner analysis. First, develop the best CFD analysis technique and then apply the analysis not to a few jobs, but to every job. Based on joint research with a major university, and more than fifteen years of program verification, Weir American Hydro is using the Navier-Stokes analysis with excellent results. Whether it is matching runner designs to difficult draft tubes, redesigning piers, designing new guide vanes, or calculating the increase in dissolved oxygen from Weir American Hydro s turbine aeration system, our draft tube analysis is providing tremendous improvements in optimizing the performance of our AMERICAN HYDRO turbine designs. Above: Intake velocity contours 4 Weir American Hydro

Three-dimensional cutaway rendering of a Francis turbine

The Weir American Hydro facility is designed from the ground up to provide a manufacturing environment that produces high quality hydromechanical components cost effectively and in less time than by conventional means. Making all of this possible is Weir American Hydro s expertise in computer and manufacturing integration. Engineered designs created with specialized software are input directly into work centers equipped with CNC milling or flame-plasma cutting machines for complete accuracy. This paperless production approach eliminates errors and improves quality. Over 123,000 square feet set on 38 acres 200 ton crane capacity Access by rail or road 6 Weir American Hydro

Manufacturing

Skoda* Vertical Boring Mill 500 ton, 52 ft. diameter table capacity Direct numerical control * Skoda is not a trademark of American Hydro Corporation. 2,800 Ton Press Horizontal Mill Weir American Hydro

Ingersoll* Horizontal Boring Mill 26 ft. vertical travel. 54 ft. horizontal travel. Direct numerical control of three axis and two axis rotary table. * Ingersoll is not a trademark of American Hydro Corporation. Dynamic Balancer Engine Lathe

Blast Room Size: 20 ft. x 20 ft. x 30 ft. Media: Carbon steel shot stainless steel shot and glass beads. Qualified for lead paint removal. Waldrich* Six Axis Machining Center Five axis simultaneous CNC control. 30 ft. horizontal travel. 14 ft. vertical travel. Head swivels +/-135. Blast Room Media Filtering Center * Waldrich is not a trademark of American Hydro Corporation. Welding Positioner

Toshiba* Vertical Boring Mill 28 ft. turning diameter. Live spindle for milling and boring operations. Direct numerical control. * Toshiba is not a trademark of American Hydro Corporation. Niles* Vertical Boring Mill * Niles is not a trademark of American Hydro Corporation. Weir American Hydro

Weir American Hydro: Manufacturing Weir American Hydro engineers are committed to the fabricated construction and fully computerized machining processes required to produce high precision rugged equipment. Our proven product quality and performance have validated this approach, and we never stop re-creating the techniques which keep Weir American Hydro at the forefront of the industry. When you visit our shop you will see new installations of large machine tools. These new tools help us grow our business and shift more manufacturing processes to numerical machining. Evidenced here is the continuing development of techniques which improve quality and cut costs. Numerical gas and plasma arc cutting in three dimensions has dramatically reduced machining time. Robotic grinding provides precise surfaces and eliminates tedious hand work. Fiber optic communications reduce spurious signals to machine tools. Modern shot blasting facilities remove hazardous lead-based paint in a manner which is safe for our employees and for the environment. Machining runner components Top, right top and bottom: Welding on runners 8 Weir American Hydro

Weir American Hydro: Manufacturing The computer driven hot-forming and numerical machining techniques developed by Weir American Hydro engineers have resulted in cost-effective manufacturing to exacting tolerances. Turbine components heated in the furnace for hot-forming From the initial plate cutting to the final shaft fit up and dynamic balancing, your AMERICAN HYDRO turbine runners or pump impellers can be manufactured entirely in our shop. We control the schedule and the quality and you benefit from a successful project. 169 Kaplan runner Top: Robotic grinding Middle: Hot forming Bottom: Plasma cutting Weir American Hydro 9

Designed and manufactured products Weir American Hydro: New AMERICAN HYDRO Turbines Kaplan runner (5 MW) Rugged reliability. This is the foundation of our new AMERICAN HYDRO turbine design. Experienced engineers know the pitfalls and never compromise on structural integrity. Hydro turbines have to work and they have to last. Weir American Hydro can design you a new AMERICAN HYDRO turbine to improve fish passage or to reoxygenate the water. We can replace your old open flume turbine with a modern, custom AMERICAN HYDRO design to increase output significantly while eliminating nagging structural problems. We can replace your propeller unit with a full Kaplan runner to provide highly efficient operation over a wide range of heads and flows. Weir American Hydro starts from this foundation. It is precisely our comprehensive knowledge of turbine design which allows us to apply new technologies and innovate. We innovate to reduce your overall project costs and to improve your revenues, without sacrificing rugged reliability. Kaplan runners, propellers, Francis turbines, pumpturbines: Weir American Hydro can supply the turbine or the complete equipment package. Our technology enhances your revenues; our experience ensures your success. Three-dimensional cutaway illustration of draft tube assembly Draft tube assembly in Weir American Hydro s manufacturing facility Francis turbine 10 Weir American Hydro

127 Kaplan runner (6 MW) Weir American Hydro 11

Weir American Hydro: Seagull turbines Weir American Hydro s Seagull turbine is a perfect combination of advanced technology, innovative design and rugged construction. Working with our first Seagull turbine customer we developed a high performance, low maintenance unit which could replace antiquated quad-runner turbines. To be economically feasible the new turbine had to achieve high capacity with no change to the basic open-flume powerhouse layout. Although each new Seagull turbine is custom designed, every customer benefits from the design concepts of our first unit: Two bearings mounted immediately adjacent to the runners, a dry pit for all the wicket gate mechanisms, rugged single pedestal mounting, and all hydraulic passages designed using advanced Computational Fluid Dynamics. Our Seagull turbines have proven themselves as extremely robust, low maintenance units. They are workhorses which produce outstanding annual revenues. If your open flume unit is unreliable or you are looking to increase capacity, we would be pleased to size a Seagull turbine for you. Above: Installation of a Seagull turbine Three-dimensional cutaway rendering of Seagull turbine Above: Seagull turbine components in shop Seagull turbine Right: Structural analysis of draft tube 12 Weir American Hydro

Weir American Hydro: Rehabilitation and total plant upgrades Weir American Hydro welcomes the opportunity to provide turnkey upgrades for your power plant. Working with trusted partners, we will replace, rehabilitate and upgrade your entire electrical and mechanical systems. New electro-mechanical instrumentation and station controls can link with your operations center to facilitate remote operation. Turbine rehabilitation at Weir American Hydro is directed by experienced turbine engineers. Our approach is to use the existing parts if the design is sound, and to redesign and improve if modern technology will result in reduced maintenance and better availability. New bearing materials, better wicket gate linkage, and improved shafting systems can all contribute to reducing your operating costs. But what about revenues? Let us emphasize that the revenues generated all originate from the turbine. While capacity increases of 10-15% are relatively commonplace, Weir American Hydro s design and manufacturing technologies can often provide substantially more. A difference of 10% in capacity can mean increasing station revenue with no additional cost. This difference goes straight to your bottom line and may double your profits. We make a better turbine and you make more profit. It is that simple. Wicket gate linkage 176 Francis runner (60 MW) Weir American Hydro 13

Weir American Hydro: Rehabilitation and total plant upgrades Hydro plant upgrades are unique opportunities to provide valuable new sources of electrical capacity and energy. The additional generation developed through a plant upgrade can be realized at a far lower cost than other sources of new power. Environmental impacts of plant upgrades are minimal, and in some cases upgrades can improve the local ecosystem. The new generation created from a hydro plant upgrade consumes no scarce resources, produces no greenhouse gases, and leaves no dangerous waste products behind. Weir American Hydro s experience and technology will help you unlock the unused potential of your hydro plant. Right: 205 Francis runner (12 MW) Far left: 152 Propeller runner (5 MW) Top right: Retrofit of an individual servomotor gate mechanism Middle right: 70 double discharge Francis runner (23 MW) Bottom right: Adjustable water-lubricated bearing 14 Weir American Hydro

Middle: 72 Propeller runner (4 MW) Far right: Distributor assembly Weir American Hydro 15

Weir American Hydro: Pump-turbines and pumps 212, 190,000 HP (140 MW) pump-turbine For new and upgraded pump-turbines, Weir American Hydro has made dramatic improvements in turbine power at the crucial lower heads while not requiring more motor power for the pump. These improvements, achieved through integration of stay vane, wicket gate and runner designs, have resulted in significant capacity increases. Cycle efficiency increases of 10% are not uncommon. The startling increases in station revenue are further enhanced by elimination of vibration, fatigue cracking, cavitation and excessive noise and by reductions in pump back and start-up times. Pump-turbines installed between 1960 and 1990 represented a relatively new technology. Initially, designers adapted pump impellers for use as pumpturbine runners. Francis turbine wheelcase designs were improved to accommodate the more rigorous pump-turbine environment. These machines have served our industry well, but now provide valuable opportunities for improved reliability and increased revenues. Today s technology provides true pumpturbine designs and equipment that optimizes hydraulic performance while strengthening the entire machine. Top left: Pump-turbine ready to ship (84 MW) Middle left: 261 pump-turbine (220 MW) on CNC horizontal boring mill in Weir American Hydro s shop Bottom left: Model runner built for hydraulic laboratory testing Right: Installation of 225 pumpturbine (370 MW) 16 Weir American Hydro

206 pump-turbine (270 MW) Weir American Hydro has applied the technology developed for pump-turbines to achieve impressive increases in pump efficiency and capacity. For cooling water pumps at fossil or nuclear plants the increased pump capacity may be leveraged into a significant increase in total plant capacity and energy production. The economics of these pump upgrades can compare quite favorably with improvements to the primary generators. The upgrade of large pumps used for water distribution and irrigation can increase flow while reducing maintenance and operating costs. Weir American Hydro pump upgrades have eliminated cavitation, solved chronic vibration problems, and dramatically improved bearing life. New AMERICAN HYDRO pump impellers, designed and manufactured to our exacting standards, provide smooth, high efficiency operation that may eliminate bearing problems that plague many condenser cooling water pumping plants. As an added benefit, the new AMERICAN HYDRO impellers can operate at the lower intake river levels that can occur in the summer months when the full capacity of the fossil plant is most needed in hotter climates. Above: Condenser cooling water pump designed for seawater application Right: Pumped storage facility Weir American Hydro 17

Services 18 Weir American Hydro

Weir American Hydro: Engineering & project analysis Weir American Hydro offers a broad range of engineering analyses to the hydro turbine industry. Primary to our business are studies to determine rehabilitation and upgrade options for hydro stations and hydro equipment. We have completed hundreds of these studies and are able to evaluate your hydro plant quickly and accurately. However, our engineering analysis is much more... Turbine Aeration and Dissolved Oxygen Enhancements Engineered Using Two Phase Navier-Stokes Calculations Hydraulic System Transient Analysis 8 Year Project Analysis Three Unit Upgrade One Unit 25% Load Rejection Life Evaluation through Fatigue and Fracture Mechanics Analysis Energy Production and Financial Impact Based on River System Analysis Structural Redesign Using Static and Dynamic Finite Element Analysis Weir American Hydro 19

Weir American Hydro: Hydro plant surveys, field testing, project management, field service & field machining Weir American Hydro provides engineered turnkey solutions for the rehabilitation and upgrade of your hydro power plant assets. Our fully equipped field crews can develop a program to cover all aspects of on-site mechanical, from disassembly to commissioning, including site machining of embedded components to ensure critical alignments and tolerances are achieved. Weir American Hydro s fleet of field machining equipment reduces project costs and outage times. Above: Installation of 110 Francis runner (15 MW) Left: Brake ring machining Right top: Installation of 174 Francis runner (40 MW) Right bottom: Field machining 20 Weir American Hydro

Weir American Hydro: Site service Weir American Hydro s experience in the management of mechanical projects in the hydro power industry is well established. Turnkey projects are supported by a network of partnerships for the supply of a wide range of hydro turbine upgrades, complete turbine and turbine generator sets, as well as balance of plant. We manage each of our projects by assigning a project manager as a single point of contact. Project managers follow our Integrated Project Methodology based on PMBOK* (Project Management Body of Knowledge) principles. Weir American Hydro s technical field advisors have many years of experience on all types of hydro equipment. This experience is backed by our team of hydro engineers in York, to support the unexpected. From mobilization to commissioning our hydro team is ready to support your needs. Weir American Hydro s extensive portable on-site machining and inspection tools can analyze and correct all alignment/tolerance issues. Our team of highly trained welders can repair all welding needs based on OEM best practice. We deliver innovative engineered solutions which enhance the performance and lifespan of equipment, thus improving the efficiency of our customers operation. Customer Benefits Safety & Environmental Custom safe work plans for specific projects OHSAS 18001 and ISO 14001 Certified Quality of refurbishment Premium engineering and design Global repair facilities and on-site machining Responsive to customers standards and preferences Complete mechanical overhauls ISO 9001 certified Timely execution Global resources - local support Local single point of contact PMI* (Project Management Institute) management structure IPMM (Integrated Project Management Methodology) PMP * (Project Management Professional) trained personnel On budget Over 140 years of experience provides excellent engineering expertise to consult and evaluate each project which ensures the project s success. Left: On-site labyrinth seal machining Above left: Stay vane modification Above right: Field machining * PMBOK, PMI and PMP are not trademarks of American Hydro Corporation. Weir American Hydro 21

Weir American Hydro: Maintenance, overhaul and refurbishment solutions Site services offered but not limited to: Site surveys of existing plants Complete disassembly and reassembly of hydro turbines In-place machining of all embedded components Turning, milling, grinding on site with our extensive fleet of portable precision machine tools FARO Laser Tracker surveys and complete unit alignment of stationary parts Extension and embedment of new discharge rings Stay ring and guide vane modifications or replacement Stator realignment Installation of oil lube systems as well as cooling systems Governor replacement Cavitation repair Performance testing Turbine field installation process 22 Weir American Hydro

As part of The Weir Group, Weir American Hydro is supported by a network of service facilities and has an enviable reputation of providing a quality service to meet the high demands of the hydro industry. (See page 28 for a map of locations.) Specialist service engineers aligned with the design and project management resource have the necessary capabilities and experience to ensure that the work is carried out to the highest possible standards. Our field service teams have extensive experience and are fully conversant with the health, safety and environmental requirements surrounding the industry. These services are complemented by site survey and test groups. From initial site survey, we provide a complete service of operations study and detailed specification of work. Below: Critical valve installation Field machining Above and left: Turbine installation Weir American Hydro 23

Weir American Hydro: Dedicated to safety in all we do Safety is of the utmost importance to Weir American Hydro whether in our shops or at a customer s site. Protecting the health and safety of employees, customers, guests, contractors and the environment is the primary goal of all of us at Weir American Hydro. This goal is met through the development of a comprehensive and effective environmental health and safety plan that endeavors to eliminate unsafe conditions and minimize the impact of hazardous situations. Our program benefits the company and the community by reducing illness and injury, preventing property damage, and preserving the environment. To meet this commitment, Weir American Hydro employees observe five key Safety Values: My colleagues and my own safety is paramount No task or activity is so important or urgent it cannot be undertaken safely I will only undertake tasks that I am trained, competent and properly prepared for I will never cut corners nor take shortcuts at the expense of safety I will stop the job if I believe it is unsafe to continue. 24 Weir American Hydro

Welding turbine components in the Weir American Hydro manufacturing facility Weir American Hydro 25

Customer and community relationships Weir American Hydro: Customer relationships Weir American Hydro has excellent relationships with many valued customers. We are pleased to respond to their specifications with comprehensive and competitive proposals. A number of our clients have chosen to work with us exclusively. In these cases we develop formal or informal partnering arrangements to best suit their needs. If you have not yet worked with Weir American Hydro, we believe you are in for a most pleasant surprise. Our sales and engineering staff welcome the opportunity to work with you to better develop the project scope and objectives before your procurement process begins. Once we have your confidence and project award, our philosophy is to supply what you ordered. We never begin a project expecting to increase scope. We want your project to be a complete success: meeting budget, exceeding performance guarantees and on time. This is the way Weir American Hydro builds its business. Eliminating the Unexpected Weir American Hydro will custom design all new equipment and engineer any refurbishment and installation services before we submit our quotation. Our approach is to understand all the project details before bidding and to inform you of those details in our proposal. Weir American Hydro works to eliminate all adders which might otherwise develop during the project. Our up front engineering allows us to make a most competitive bid and eliminates unwelcome surprises. Customer inspections of manufacturing at Weir American Hydro s facility Weir American Hydro customers overseeing turbine installation 26 Weir American Hydro

Weir American Hydro: In our community We re more than just advanced technology and massive precision manufacturing. Weir American Hydro is part of a larger community which has supported and nurtured our business. Each member of our Weir American Hydro family reaches out to support our York community. York College SAE Mini-Baja Competition, sponsored by Weir American Hydro York County School of Technology internship program apprentice Community Involvement York County School of Technology - Apprenticeship Program York Strand-Capitol Performing Arts Center York College of Pennsylvania - Engineering Co-op Program SE Pennsylvania Manufacturers Association Annual picnic and open house Youth Soccer sponsor Above: Photos from the Weir American Hydro family picnic Right: Youth league playing at the Weir American Hydro soccer field Weir American Hydro 27

The Weir Group PLC: Global resources, local support As part of The Weir Group, Weir American Hydro has access to an extended geographical facilities support base providing valuable in-country support. Weir American Hydro works with hydropower owners worldwide through the supply of more powerful and efficient AMERICAN HYDRO runners, turbine components, complete new turbines and water-towire equipment packages. Whether we manufacture all of the equipment in our facilities or partner with local manufacturers, we strive to achieve the maximum benefit for a most successful project. Weir American Hydro technology can be found around the world producing new capacity with high efficiency. Our new AMERICAN HYDRO turbines and more powerful AMERICAN HYDRO runners for existing turbines are in operation in Africa, Europe, Latin America, South America, Iceland, New Zealand and throughout North America. Our export of high technology equipment complies with U.S. Government objectives and qualifies for financial support programs. Handling the Unexpected If a problem does arise during the execution of your project Weir American Hydro will work without rest to engineer a solution. When your operating revenues are at stake we respond. Whether you choose to implement a solution yourself or through Weir American Hydro, we will work with you to limit costs and minimize the impact on schedule. At that time, when you really need help, we will help. 28 Weir American Hydro

Weir American Hydro 135 Stonewood Road Tel: + 1 717-755-5300 P.O. Box 3628 Fax: + 1 717-755-5522 York, PA 17402 www.weirpowerindustrial.com USA Excellent Engineering Solutions 8/30/2012 V1.1 Legal Information Copyright 2012, American Hydro Corporation. All rights reserved. AMERICAN HYDRO, Seagull and the AH logo are trademarks of American Hydro Corporation. WEIR is a trademark of Weir Engineering Services Limited (UK). Printed in the United States of America.