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2029’ project. Around 200 guests attended as VERBUND hydropower management representatives Michael Amerer and Karl Heinz Gruber, along with tunnel patron Kathrin Aberger-Dick and ARGE representatives Jürgen Raschendorfer (COO Porr AG) and Bernd Raderbauer (Marti Tunnel AG), initiated the TBM’s cutterhead rotation. The new headrace is expected to be completed by the end of 2027, ensuring the continued safe and efficient transport of water from the Wasserfallboden reservoir to the power plant. The TBM being used for this project was
previously deployed in the Limberg II and Limberg III projects. Key components, including the 100-tonne cutterhead with a 6.90m diameter, have been replaced and adapted. The entire TBM measures 190m in length and weighs 1,200 tonnes. Transporting its components required 90 separate deliveries to the assembly cavern, where it was put together over eight weeks. VERBUND Hydro Power Managing Director Michael Amerer emphasized the historical significance of the project, stating: “We are continuing on the path taken by the heroes of Kaprun after the Second World War for the reconstruction of Austria. Today, we have driven the first metres of the new pressure tunnel – an important moment for VERBUND. This pressure tunnel is the centrepiece of our project, which will upgrade the entire power plant to the latest state of the art by 2029, so that we can continue to supply all of Austria with green electricity and efficient flexibility from hydropower in the future.” Project Manager Maria Leo noted the careful
planning that preceded the tunnel boring process. “A launch celebration is always something very special. We are pleased that the preparatory work has gone so well and that it is now starting. The geological conditions for the advance are well known and the tunnel boring machine and the team are already familiar with our mountains from previous projects. Almost all of the work will be carried out underground. This means that the impact of the construction work is reduced to a minimum.” Tunnel patron Kathrin Aberger-Dick spoke about her personal connection to the region. “I have close ties with the mountains in Kaprun and grew up with the high-altitude reservoirs. It is therefore a special honour for me to accompany the construction phase as the earthly representative of Saint Barbara, the patron saint of tunnel builders and miners. I hope that the underground work remains free of accidents and that the tunnel boring machine reaches its destination as smoothly as possible.” The TBM will advance at an average rate of about 15m per day, reaching its destination at the new surge tank in about a year. The pressure tunnel will have an incline of 0.50% and a 6.90-metre excavation diameter. The excavation process requires managing
approximately 200,000 cubic meters of removed material. The rock is broken into small
6 | April 2025 |
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pieces by the cutters and transported out of the tunnel via conveyor belts to a transfer station at the Limberg valve chamber. From there, it is moved through the existing tunnel system to a disposal site in the valley. This system helps minimize construction-related traffic and reduces the impact on the surrounding area. VERBUND is investing approximately €370 million in the ‘Kaprun 2029’ project, which aims to upgrade the power plant with modern technology to ensure reliable and sustainable energy production for the future.
US Lake Creek hydroelectric plant successfully commissioned The Lake Creek hydroelectric plant, located in Troy, Montana, US, officially came online in October 2024 following a successful retrofit. The project, undertaken by Canyon Hydro for owner and operator Northern Lights, involved the installation of advanced hydroelectric components designed to enhance performance and reliability. According to Canyon Hydro, the plant’s startup proceeded smoothly. “The unit is online and the customer has accepted it,” the company stated. A key feature of the retrofit was the integration
of Vesconite Hilube components, known for their no-swell, self-lubricating properties. These components play a critical role in the plant’s operation, ensuring efficiency and reducing maintenance requirements. The installation included a range of parts essential for the plant’s function, such as wicket gate bushings, wear pads, thrust washers, and bearing inserts. These high-performance components contribute to the smooth operation of the plant, which supplies approximately 10% of Northern Lights’ power. The use of grease-free Vesconite Hilube components also offers an environmentally friendly advantage by preventing oil or grease contamination in this run-of-river hydroelectric application. “Vesconite Bearings has a longstanding
reputation as a trusted supplier for hydroelectric projects, and we are excited to be part of the Lake Creek Project,” said Vesconite Bearings application engineer Louis Gouws. “Our self-lubricating, no-swell Vesconite Hilube components are designed to enhance the longevity and reliability of equipment, and the Lake Creek installation demonstrates their effectiveness in real-world applications.”
Finland Valmet to upgrade automation system at Verla 2 hydro plant Valmet has announced it will modernise the automation system at KSS Energia’s Verla 2 hydropower plant in Kouvola, Finland. The upgrade will replace an outdated third-party system with the Valmet DNA Hydro Turbine
Automation, aiming to improve operational reliability. “We have developed a long-term partnership
with Valmet across our other hydropower plants. As Valmet has successfully retrofitted hydro turbine automation with Valmet DNA at our Siikakoski hydropower plant, we aimed to implement a similar solution for the Verla plant, too. A unified automation system across all sites, including engineering tools and data collection, ensures that only one system requires future upgrades,” said Jukka Rämä, Senior Vice President, Asset Management, KSS Energia. “This hydro turbine automation delivery marks another significant step for Valmet in strengthening its position in Finland’s hydropower market. The previous projects between KSS Energia and Valmet have been highly successful, and the new case is expected to be another valuable step in our cooperation,” added Tom Bäckman, Sales Manager, Automation Systems business line, Valmet. The Verla hydropower plant, originally built
to support the local wood processing industry, consists of two units, Verla 1 and Verla 2. It generates approximately 15,000MWh of electricity annually, enough to power about 3,000 average households. The Valmet DNA Hydro Turbine Automation
system will be connected to the Hinkismäki power station. All KSS Energia hydropower plants are centrally operated from a control room managed by Norwegian technology supplier Volue.
Canada
OPG’s Niagara stations set new generation record
Ontario Power Generation’s (OPG) five hydroelectric stations in Niagara set a new electricity generation record in 2024, surpassing a previous milestone set in 1979. The stations collectively produced 13.75TWh of electricity, enough to power approximately one million homes for a year. This figure exceeded the 1979 record by 0.17TWh, helping meet the province’s growing electricity demands. OPG’s Niagara Operations include the Sir Adam Beck I and II Generating Stations (GS), Sir Adam Beck Pump GS, and DeCew I and II GS. Together, these facilities provide about 10% of Ontario’s energy needs annually. “While the record is for 2024, it was achieved on many years of building on our successes and ensuring we are always learning and striving to improve,” said Eric Jury, Director of Plant Operations for OPG’s Niagara Operations. The Sir Adam Beck stations played a key role in setting the new record, generating 13.0 TWh and surpassing their own station-specific record from 1979. In addition to increased generation, OPG’s Niagara employees exceeded targets for work protection, health, and safety in 2024. Reliability and project performance for the Niagara fleet also surpassed expectations, contributing to
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