Cylinder for bottom outlet gate
- Traction force: up to 5,000 kN (500 t)
- Rated pressure: 250 bar
- Stroke: up to 20.000 mm
- Complete with manifolds, sensors, and pipework
- Various coating systems
- Integrated position sensor systems
Hydraulic Cylinders for Hydropower industries
With the Power of Water
Hydraulic Masterpieces in Hydropower
The hydropower industry generally deals with movable steel structures in dams, ship locks, or movable bridges. For the drive of these components, Montanhydraulik has been one of the leading suppliers of hydraulic cylinders with complete drive and control systems as well as turnkey plants for decades.
In the last 10 years, hydraulic cylinders with complete drive and control systems for hydromechanical projects have evolved from a niche product to a strategically important product line in our company. Hydropower is essential for energy supply, especially in densely populated regions in Asia, to expand the energy supply in these countries. For industrialized countries, it is increasingly becoming a renewable energy source.
Montanhydraulik specialises in the manufacture and commissioning of hydraulic cylinders with diameters of up to 720 mm, strokes of up to 18 m and the associated hydraulic power units and control systems for the operation of butterfly valves.
In addition to the manufacture and supply of hydraulic cylinders and power units, Montanhydraulik also offers a complete worldwide service for pipework, installation and subsequent commissioning by Montanhydraulik employees.
An Application Example from Montanhydraulik India
The Indira Sagar Dam in central India, with a reservoir area of 913 km², a dam height of 92 m, and a length of 653 m, is the largest in India. It serves both power generation with a total output of 1,000 MW and the irrigation of 150,000 hectares of farmland. Between 1998 and 2006, Montanhydraulik supplied and installed the components for eight intake gates and 20 radial gates.
References + Customers
Staudamm Son La, Vietnam
Technical data:
- 6 hydraulic aggregates
- 12 hydraulic cylinders
Piston diameter: 720 mm
Stroke: 12,000 mm
The significance of water power as the major energy supply in Vietnam increases with the construction of what is so far the longest barrage in Southeast Asia. Both the generating station with six 400 MW turbines and the Son La barrage on the Da river were constructed from 2005 onwards.
Each turbine inlet channel is equipped with two inlet gates which are moved by individual hydraulic cylinders. Montanhydraulik is responsible for the complete hydraulic system for these gates.
The twelve hydraulic cylinders with a piston diameter of 710 mm are able to move a load force of more than 7,000 kN over a stroke of 11,800 mm. To protect against corrosion the piston rods, with a diameter of 250 mm, are manufactured from stainless steel and have been double-chromed.
The gates of the 138 m high dam are closed through their own dead weight, and this is controlled hydraulically. The Montanhydraulik engineers designed the hydraulic aggregates which supply pressure to the drive cylinders especially to cope with the varying loadings when moving the gates.
While Montanhydraulik in Germany supplied the cylinders, aggregates, and control systems, employees from Montanhydraulik India together with German colleagues supported the onsite assembly, installation, and commissioning of the complete systems.
Cua Dat dam, Vietnam
For the segment gates of the Cua Dat-dam in Vietnam, Montanhydraulik manufactured the hydraulic drive cylinders, the hydraulic aggregates, and the electrical control system. In addition, our engineers developed a special cardan mounting in order to optimise the movement of the powered segment gates.
Technical data:
- Piston diameter: 420 mm
- Rod diameter: 200 mm
- Stroke: 11,255 mm
Indira Sagar dam, India
With a dammed water surface of 913 km2, a dam wall height of 92 m, and a length of 653 m, the Indira-Sagar dam in central India is the largest barrage in India. With an electrical power of 1,000 MW, the reservoir is used on the one hand for power generation, and on the other hand for the irrigation of 150,000 hectares of farm land.
From 1998 to 2006 Montanhydraulik took on the project management for the complete hydraulics, from creating the drawings to the final onsite acceptance of the hydraulic equipment in its entirety.
For eight vertical intake gates as well as 20 segment gates (radial gates), our group of companies supplied the necessary components, including cylinders, aggregates, and control systems. For this, the ARMAC system developed by Montanhydraulik India was successfully deployed for the first time as a completely automatic monitoring and control system.
Technical data:
- 20 hydraulic aggregates
- Automatic Reservoir Monitoring and Control System (ARMAC)
- 40 hydraulic cylinders
Piston diameter: 500 mm
rod diameter: 240 mm
Stroke: 13,200 mm
Xayaburi Run-of-river generation station, Laos
For the Xayaburi project on the Mekong River in Laos, the largest run-of-river generating station under construction in Asia, the Montanhydraulik group provides the complete drive and control technology for the oil hydraulics of the moving steel components, such as segment gates, intake gates, and mitred gates for shipping locks. In addition, Montanhydraulik takes on the complete installation, piping, and commissioning by internationally experienced site managers and employees from within its own group.
The project is coordinated cross-border between the countries of Thailand and Laos. Upon completion, the hydroelectric power station is intended to supply the two countries with a total of 1285 MW, and is a reference project in Southeast Asia.
Montanhydraulik’s delivery programme:
- More than 100 hydraulic cylinders
- More than 50 hydraulic aggregates
- Control cabinets
- Hardware and software for the centralised control of the shipping lock system
- Electromechanical components for the safety systems of the shipping lock system
- Installation and commissioning service
- etc.
“Iron Gates” lock, Romania
The “Iron Gates” are located between the Serbian Carpathians and the Banat mountains on the border between Romania and Serbia. They are considered to be one of the most impressive gorges in Europe. Between 2006 and 2008, with our assistance our customer implemented a two-stage set of locks which compensates a height difference of 35 m.
The lifting gate of the lock is lowered using two hydraulic cylinders, each of which has a lifting power of 4,500 kN. With a diameter of 600 mm and an overall length of 24 m, the piston rods are made of a single piece, and are protected against corrosion and damage by a ceramic coating.
For reasons of redundancy, each lifting gate cylinder is equipped with two position sensor systems integrated into the coating of the piston rod.
Lifting gate cylinders
- Piston diameter: 600 mm
- Rod diameter: 220 mm
- Stroke: 18,000 mm
Cylinders for rotary disc shutters
- Piston diameter: 500 mm
- Rod diameter: 200 mm
- Stroke: 6,000 mm
“Limberg II” pumped storage power station, Austria
Montanhydraulik supplied hydraulic cylinders to the “Limberg II” pumped storage power station. The power station has a total output of 833 MW.
In the new “Limberg II” pumped storage power station, a central underwater valve chamber gate is used as a redundant emergency closing mechanism for shutting off the underwater works water channel. The latter was equipped with cylinder technology from Montanhydraulik.
Montanhydraulik specially modified the cylinder, which has a piston diameter of 450 mm and a stroke of 6,950 mm, to the requirements for the sluice function: A hydraulic locking reliably holds the sluice board in the open position by acting directly on the cylinder’s piston rod; this thereby prevents uncontrolled lowering.
Hydraulic cylinders with special hydraulic locking for the underwater valve chamber gate:
- Piston diameter: 450 mm
- Stroke: 6,950 mm
SOME OF OUR PROJECTS
- Assiut, Egypt
- Baixo Sabor, Portugal
- Burfell, Island
- Cua Dat, Vietnam
- Danube River, Romania
- El Chaparral, El Salvador
- Foz Tua, Portugal
- INGA, Congo
- Lai Chau, Vietnam
- Nante de Drance, Switzerland
- Naga Hamadi, Egypt
- Polavaram, India
- Son La, Vietnam
- Xayaburi, Laos
- Yamasubaru, Japan
Products & Services
Cylinders for segment gates (radial gates) fitted with pivot bearings
- Traction force: up to 5,000 kN (500 t)
- Rated pressure: 250 bar
- Stroke: up to 20.000 mm
- Complete with manifolds, sensors, and pipework
- Various coating systems available
- Integrated position sensor systems
Cylinders for intake gates, with central flange and surge tank
- Traction force: up to 5,000 kN (500 t)
- Rated pressure: 250 bar
- Stroke: up to 20.000 mm
- Complete with manifolds, sensors, and pipework
- Various coating systems
- Integrated position sensor systems
Hydraulic aggregates
- Tank size: 10 to 10,000 l
- Material: Structural steel, stainless steel, etc.
- Design: mobile, stationary
- Construction: Weather-resistant or integrated into separately accessible cabin
- Flow rate: 5 to 700l/m
- Pump pressure: up to 300 bar
- Power: up to 300 kW
Control cabinets
- Layout and manufacture as per customer requirements
- With programmable logic controller (PLC)
- Also with remote control if desired
- Use of universal protocols such as Modbus, Profibus, OFC, and Ethernet
- Additional combination options using relay-based systems are possible
Connection between aggregate and cylinders
- Pipework made from stainless steel etc.
- Cabling for supply and signal voltages
Position sensors
- Magnetostrictive
- Cable pull system
- LPM position sensor system (incremental by means of grooves and via piston rod)
- Mechanical end switches
- Inductive proximity switches
Locking systems
- Axial
- Radial
- Purely mechanical
- Driven hydraulically
Rod coatings
- Hard chrome / nickel chrome
- Ceramic coating
- Chromium carbide
- Tungsten carbide
- Others
Systems & Services
System integration
System integration
Montanhydraulik provides comprehensive service in the area of oil hydraulics for the movement of hydromechanical gates in barrages, weirs, locks, and bridges.
In addition to system integration, Montanhydraulik also performs commissioning, installation, and maintenance worldwide.
System integration includes installation of the cylinders and aggregates, as well as their connection via the respective electrical and hydraulic circuits. The installed components are connected to each other via centralised and decentralised control units.
As part of commissioning, fine tuning is performed directly onsite by the Montanhydraulik personnel. It is performed by the same employees who were earlier responsible in the works for the assembly and testing of the systems. From the design and manufacture all the way to commissioning, the aim is to ensure a seamless transfer.
Overview of commissioning services:
- Before commissioning, local inspection of cabling and piping requirements in order to ensure problem-free commissioning
- Onsite management of materials and equipment
- Wiring of hydraulic aggregates and control panels for control current and power circuitry
- Local programming of the PLC
- Mechanical and electrical system integration while complying with strict operating and safety standards
- Commissioning testing of the installed components
- Employee training
Hydraulic Aggregates
Designed to the most varied customer requirements, and fulfilling the specifications of the classification companies, Montanhydraulik India manufactures fully piped and tested hydraulic aggregates.
Technical data:
- Tank size: 10 to 10,000 l
- Flow rate: 5 to 700 l/m
- Pump pressure: 100 to 300 bar
- Power capacity: up to 300 kW
- Working temperature: -30 to +80 °C
- Local and remote operation possible
- With or without pump motor redundancy
Control panels
- Robust and easily available manufacturer-independent components and protocols
- Communication using universal protocols such as Modbus, Profibus, OFC, and Ethernet
- Communication using redundant ring networks to protect against loss of control of cylinders or operating data
- Combination of relay-logic-based systems and programmable cylinder position displays in order to enable cylinder operation without the use of PCs
