Full restoration of the Sayano-Shushenskaya HPP is scheduled to be completed in 2014

From the HPP’s Central Control Board, Russian Federation Prime Minister Vladimir Putin launched hydro-unit № 6 into its production load. In addition to Mr. Putin, the ceremony was also attended by the following officials: Russian Federation Deputy Prime Minister Igor Sechin, Russian Federation Energy Minister Sergey Shmatko and Evgeny Dod, RusHydro’s Chairman of the Board, as well as by regional officials and representatives from numerous Russian governmental agencies. Representatives from project and construction organizations, scientific institutes and equipment-producing suppliers also attended the event.
Within the framework of the Russian Federation Prime Minister’s visit to the Sayano-Shushenskaya HPP, the course of restoration work at the HPP was discussed. It was noted that industrial operation of hydro-units № 6 and № 5 (scheduled for March 2010) means the introduction of 1,280 MW of capacity — effectively minimizing flooding risks and guaranteeing water supply to people and industrial and social objects that are located in the HPP’s lower reaches.
At hydro-units № 6 and № 5, full scale repairs of generator equipment, as well as work on main and auxiliary turbine equipment, were carried out. At hydro-unit № 6, generator switch equipment was replaced and a stationary vibration control system was put into operation. Equipment installation is continuing at hydro-unit № 5.
In addition, diagnostic work was performed on the power conduits at hydro-units № 6 and № 5. Specialists from JSC «VNIIG (named after B.E. Vedeneev)» monitored the spiral case drafting tubes and other construction elements. The inner metal coverings of the power conduits at hydro-units № 6 and № 5 were also inspected. As a result of this work, the scientific technical report «Examination of the power conduits at hydro-unit № 6 and hydro-unit № 5» was prepared, with conclusions about their condition. Results from the completed examination confirm the working capacity of the reinforced concrete constructions for hydro-units № 6 and № 5. From 2010 — 2014, all power conduits at the Sayano-Shushenskaya HPP will be examined as part of a special program.
To conduct testing and commissioning work at hydro-unit № 6, reconstruction of the supporting plates, building structures and metal constructions, the flow tube of the hydro-unit, auxiliary and common service equipment and the power circuit delivery tract were carried out. In addition, completely re-worked management, control, safety and automation systems were instituted. An equipment overview for the gas discharge chamber and the zero terminal chamber was conducted. A shield of aggregate auxiliaries was put into operation and a fire extinguisher system for the cable galleries was tested.
At present, hydro-unit № 5 is in a blank-run mode.
Hydro-units № 6 and № 5 started operating in a blank-run mode on December 30th, 2009. During the launch process, the parameters of the hydro turbine, regulator and oil pressure installations were checked. With the fulfillment of technical operations, structural vibrations were monitored by specialists at the NPO «TSKTI» (Central Committee for Heavy Industry) scientific research center. The measurements illustrated that the vibrating conditions of the hydro-units conformed to requirements found in the relevant normative technical documentation.
The launch of hydro-unit № 6 into the network load was preceded by start up and adjustment operations in all working regimes, including switching to the grid. The exploitation test program was coordinated with the plants that produce turbines and generators for JSC Power Machines Group. JSC Lengidroproekt, the general designer, confirmed equipment conformity with technical design specifications, as well as all technological systems and constructions for hydro-unit № 6 and the T3 transformer unit for the first start-up complex.
Work readiness for putting the hydro-units into operation in the network and under load was confirmed by JSC Lengidroproekt and JSC Power Machines (Minutes from the meeting of the operational staff of the Russian Ministry of Energy № 7 dated January 27th, 2010). The System Operator confirmed the basic work regime for the hydro-units.
The launch of hydro-unit № 6 into the network was carried out ahead of schedule and the launch of unit № 5 will take place in March 2010. Hydro-units № 3 and № 4 will be operational prior to the end of 2010. Following these launches, the Sayano-Shushenskaya HPP’s installed capacity will stand at 2,560 MW.
Furthermore, on June 1st, 2010, the first stage of the shore spillway will be operational — ensuring the additional passage of 2,000 cubic meters of water per second. The launch of these hydro-units and an operational shore spillway will ensure that the HPP can safely deal with the 2010 spring floods.
Additional organizational and technical measures have been undertaken to ensure industrial and fire safety while a large volume of restoration work is being carried out, at the same time as the initial start up of the object.
The fulfillment of all works is conducted in strict accordance with and under the supervision of operational personnel, as well as by the Sayano-Shushenskaya HPP’s reliability and occupational safety services. Employees of both outside contractors and the HPP are informed about the sequence of actions to carry out in contingency situations. In addition, a complex joint training session was held on how to address these contingency situations. A technological television system has also been installed that offers visual monitoring of key zones of hydro-units № 6 and № 5, technological corridors and power block premises, as well as the emergency control mechanisms, the repair water gate and near the watershed peer of the overfall. In total, 11 video cameras were installed to offer additional monitoring. In the turbine room, an alarm system was installed in case a contingency situation cropped up. Sound and light alarms, as well as telephone and/or radio connections, have been hooked up in all workspaces.
Full restoration of the Sayano-Shushenskaya HPP is scheduled to be completed in 2014.
On August 17th, 2009, due to the destruction of hydro-unit № 2 at the Sayano-Shushenksya HPP, there was an inflow of water from the turbine crater. Water flooded the machine hall and damaged power equipment, auxiliary equipment and the machine hall’s building constructions. All ten hydro- units were rendered inoperative. Seventy-five people died as a result of the accident.
The accident led to an irreversible change in safety standards at the hydro-electric power plant. Now, all new HPPs will have a life support system that can be serviced remotely (without requiring the presence of individuals).
Immediately following the accident, Russian authorities announced the need to restore the HPP to its full operational mode.
Today, full-scale restoration work — involving more than 2,500 people and over 90 vehicles — is being carried out at the Sayano-Shushenskaya HPP.
In November 2009, the Company concluded a contract with JSC «Power Machines» to supply equipment for the HPP. By 2014, the Company plans to replace all hydro-units at the site. The value of the contract is RUR 11.7 billion (excluding VAT). Production on the first hydro-unit (turbine and generator) is planned for January 2011. Subsequent production will be performed on two to two-and-a-half month intervals. In total, during 2011, 6 new hydro-units will be produced and the remaining equipment will be produced in 2012.