Turbines & generators | Testing times Voith has been testing equipment provided for hydropower projects in Australia and New Zealand
Above: Roxburgh hydropower station in New Zealand has recently been upgraded
ALMOST SIMULTANEOUSLY AND SPREAD across two continents, earlier this year Voith successfully completed two major factory acceptance tests (FATs) for Australia’s Snowy 2.0 pumped storage project. Both were completed on schedule with positive feedback. In Voith’s Shanghai workshop, the FATs focused on critical generator parts - the rotor poles for Unit 4 and stator bars for Unit 2. Meeting all technical specifications, the rotor poles demonstrated uniform magnetic flux density, high-quality lamination, and precise winding, while the stator bars showed consistent insulation thickness, good partial discharge values, and precise bar end shaping. The complete FAT process – from raw material inspection to final testing was conducted under a structured, traceable quality framework. At Voith’s Heidenheim location, the automation team conducted integrated FATs for Units 5 (asynchronous) and 6 (synchronous). These tests included both the digital and hydraulic governors, assembled and tested in their final cabinet configuration with live connections to the control system. The FATs marked the first implementation of bus-controlled proportional valves on an Allen-Bradley PLC platform. After initial system calibration, all functions ran as
intended. Opening and closing times of the hydraulic system were optimised in preparation for faster commissioning at site. The emergency shutdown sequence, including asynchronous valve closure, was executed in accordance with the project’s specifications. More than 30 engineers and technicians from the
automation team participated, using the FATs to build hands-on experience that will support upcoming field activities in Australia. Voith said this process contributed to internal knowledge transfer and improved readiness for on-site commissioning. “Snowy 2.0 will underpin the future of clean energy in Australia – and we are proud to contribute key technologies and expertise to make it a success,” says Bill Armstrong, Senior Vice President Global Large
Projects of Voith Hydro. These parallel FATs, he added, demonstrate how collaboration, digital innovation and hands-on skills can be delivered across borders.
New Zealand upgrade Voith has also successfully commissioned the second
upgraded turbine unit at New Zealand’s Roxburgh Hydropower Station, advancing modernisation of this 1950s-era facility. Owned by Contact Energy, four out of the eight original 40MW units are undergoing phased replacement, with the project over halfway through the upgrade process. The newly commissioned unit, following rigorous
testing and a ten-day endurance run, was handed over to the customer for commercial operation in mid- August 2025. Leveraging insights gained from the first turbine upgrade completed in December 2024, Voith – supported by its New Zealand-based subcontractors – successfully reduced the on-site implementation time by over a month. Efficiency tests in January 2025 confirmed that the first unit met all contractual performance guarantees. “The upgraded turbines deliver higher output with the same water flow due to the significant increase in efficiency,” stated Contact Energy’s Project Delivery Manager, Kirk Pritchard. “Our collaboration with Voith and its subcontractors has been instrumental in such a successful project. With two units operational, we’re on track to modernise this iconic piece of infrastructure that has powered New Zealand for over half a century.” The third turbine, manufactured at Voith’s facility in India, arrived at Port Chalmers, New Zealand, on 31 August 2025 and was to be installed following dismantling of the existing unit. Each of the new stainless-steel runners weigh 28.5 tonnes and measure 3.9m in diameter.
As Raj Vidyarthi, Managing Director and CEO of
Voith Hydro India, says, collaboration with Contact Energy and subcontractors was key for successful project completion.
Above: The original 1950s turbine (top) has been replaced by a new Voith turbine (bottom) at Roxburgh hydropower station in New Zealand
Right: Celebrating successfully integrated factory acceptance tests for Snowy 2.0’s Units 5 and 6 governors at Voith’s Heidenheim workshop
28 | December 2025 |
www.waterpowermagazine.com
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