A detailed project planning is what lies between what exists and what it should become. The planning aims to ensure that the entire process runs smoothly and that the desired results are achieved. As your competent partner for construction and conversion of small hydropower plants, we are always at your disposal and eager to assist in both word and deed – all the way from order placement up to the commissioning.
We offer you comprehensive know-how around the topic of hydropower. We have a dedicated team with several decades of experience and creativity in this field. Our record shows over 200 successful projects, most of which were in Germany, Switzerland, Italy, Austria, and France.
Upon receiving your request, we will provide you with a detailed quote containing all the relevant information such as design, choice of materials, and all the relevant performance data. All the information is guaranteed in compliance with IEC 041. We first check the local conditions and requirements in advance, taking account your input, and are always glad when you provide us with as many details as possible. We then define the ideal turbine size, turbine type, drive type, generator, and all auxiliary drives. Once you place your order, you will receive a written order confirmation with all previously discussed details such as type and scope of the order, delivery dates, installation, and commercial agreements.
In the case of conversions, reactivations, and turbine replacement, we do not rely on existing as-built drawings. Nonetheless, these drawings can be used to create conversion drawings. We therefore ask you to provide them to us, if available. During the on-site assessment, we first check for any deviations so that we can structure the planning in detail. We also apply our expertise in water level and water management. In the case of new constructions with a new license, we plan based on the survey points of the engineering office that applied for the water permit and made it available to us.
We only trust our own experts (hydraulic engineers) to compile power plant and installation drawings. The drawings we create serve as a template for further planning and construction. For construction requests that are subject to approval, the implementation plans must be examined separately, signed, and reinforcement plans prepared by an authorized planner or structural engineer. During the on-site construction, good cooperation between us, the construction company, and the planning office is imperative. We find it crucial that the construction company provides our project managers with regular updates on the project progress. We conduct occasional meetings and visits to the construction site based on necessity and urgency. We recommend choosing a construction company that is experienced in the field of civil engineering, concrete engineering, and hydraulic engineering. There are companies that specialize in hydropower plant construction and therefore bring in excellent know-how acquired from numerous, successful projects, some of which were the installation of our turbines. If required, we will be happy to provide you with corresponding contact details.
Once all technical and commercial requirements have been met, the individual parts of the turbine as well as other components, such as hydraulics, control units, and sensors, are ordered. The turbine components are manufactured exclusively by selected specialist companies equipped with CNC production systems. This ensures that all turbine components are produced with utmost precision for long-term use. Short logistics routes help us review the production process and ensure fast response times. That is why we only work with suppliers from our region – made in Germany.
All supplied turbine components must be checked for material quality, processing, and dimensional accuracy. After the tests, your Kaplan turbine is assembled in accordance with our inhouse installation guidelines. Once the different components have been completed, such as impeller and distributor, they are checked for leaks, proper functionality, and coating. The individual components are assembled and your Kaplan turbine tested anew. After the test, it receives a CE mark and is ready for delivery. Our turbines are preassembled largely ready for connection in order to shorten the installation time required on site.
Kaplan turbines with impeller diameters of up to 1410 mm are delivered completely ready for installation. If it is not possible to lift the turbine for structural reasons, the individual components are pre-assembled and put together during the installation in the powerhouse. We will supply you with all the components required for installation, such as manifold formwork, intake manifold cone, etc., at the beginning of the construction work. All assembly work is carried out by our team of experts.
Once the turbine has been put in place and encased in concrete, the entire project is prepared for commissioning. In the case of a directly coupled version, the wiring takes place directly from the switch cabinet to the turbine, to the generator, and to the piping of the hydraulics. For belt-driven machines, smaller generators are mounted separately using a 3D clamping device, whereas a generator console is used for larger generators. A high-performance flat belt transmits power from the Kaplan turbine to the generator. The construction of a Kaplan turbine allows an endless assembly of the flat belt. The feeder connection and the metering device are installed by the local electrician, who is also responsible for submitting the application to the energy supplier in advance. Your new WATEC-Hydro Kaplan turbine is now ready for operation.
he turbine chamber is flooded gradually once all parameters have been configured and after extensive functional tests in dry operation. Additional tests and adjustments before switching on the plant ensure a safe and long-term operation. After the system has been switched on, the water levels, controls, and the emergency shutdowns are then tested. Your hydroelectric power plant is then handed over to you after detailed instructions, and you can now put it into operation. A detailed and extensive documentation with operating and maintenance instructions is also handed over or delivered to you.