Hydromechanical engineering

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.

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.

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.

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.

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.

• 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

“Automatic Reservoir Monitoring and Control” has been specifically developed for the challenges of barrages, and so it facilitates automatic monitoring and control of the water level. For this, geographical and climatic data is continually evaluated through the use of current and already collected data to determine the optimum water level. In addition, several systems can be networked together using ARMAC, in order to regulate the water level optimally along the entire course of the river.

Overview of ARMAC:

• Exact monitoring and control of the water flow and level
• Individual control and simulation of individual weirs
• Selection between manual and automatic control of the weirs is possible
• Fault indication by visual and audible signals
• Generation and visualisation of extensive data (e.g. water quantity, flow, level, weir position, etc.)
• Use of open communication protocols such as Modbus/Profibus/Ethernet in combination with OFCs and redundant ring networks
• Flexible programming possible using PC-based systems; this can also be modified online
• Real time data transfer by means of OFC, VSAT or GPRS

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

• 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