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Hydropower.
Energy for our future.
Our Kaplan turbines
Our product convinces by the compact and innovative design as well as the excellent material and processing quality.
KDP
Double regulated with permanent magnet synchronous generator
High-tech for high power: Kaplan turbine with permanent magnet generator
Our innovative Kaplan turbine type KDP (Kaplan turbine, double-regulated, with permanent generator) is the further development of our basic model KDR, which has proven itself for decades. In cooperation with an institute for electrical plants and machines, we have developed generators that are directly integrated into our Kaplan turbine without a transmission gearbox.
Important features
- • Use of a directly coupled permanent-magnet synchronous generator
- • Highest overall efficiency of the turbine unit with generator
- • Low-noise operation
- • Maintenance-free since belt maintenance and renewal of the flat belts is not necessary
- • Less space required in the machine room
- • Highest precision and excellent processing of the turbine components
- • Cavitation-resistant impeller material
- • Use of materials that are optimized for the highest stress levels
KDR
Double regulated with belt drive
Proven technology, rock-solid implementation: our basic KDR model with belt drive.
Our classic is the KDR type, the vertical-axis Kaplan turbine, double-regulated, with belt drive. Here, the generator is driven by a high-performance flat belt with a leather friction layer. There is no need to glue the high-performance flat belt together on site, as it can be installed in endless condition without dismantling the Kaplan turbine crosshead. The matching generator tensioning rocker arms for wall mounting or tensioning brackets for generators with a flange are optionally included in the scope of delivery. This proven turbine variant is significantly less expensive to purchase than our direct-drive models, which in return offer a higher efficiency of around 5% more annual yield.
Important features
- • Highest precision and excellent processing of the turbine components
- • Long-term and trouble-free operation
- • Maintenance-friendly design
- • Use of materials that are optimized for the highest stress levels
- • Corrosion protection according to DIN 19704-2
- • Fast and cost-effective installation
- • Low-noise belt drive
- • Cavitation-resistant impeller material
- • Proven classic at attractive price
KDD
Double regulated with direct coupled V1 generator
The strong compact solution: Kaplan turbine double-regulated, direct-coupled
Our vertical-axis direct-drive Kaplan turbine type KDD (Kaplan turbine, double-regulated, direct-coupled) is operated with a generator in V1 design.
Important features
- - Installation of a permanent magnet synchronous generator or separate-excited synchronous generator from various suppliers possible
- • Generator supports the axial load of the turbine
- • Generator shaft coupled directly with turbine shaft
- • Very compact design
- • Low noise operation
- • Cooling of the generator by built-in fan or water cooling system
- • Highest precision and excellent processing of the turbine components
- • Use of materials that are optimized for the highest stress levels
- • Cavitation-resistant impeller material
- • Corrosion protection according to DIN 19704-2
KSDP
Double regulated with permanent magnet synchronous generator and full spiral
Kaplan spiral turbine with permanent-magnet generator and full-spiral
Here, the difference to our innovative Kaplan turbine KDP (Kaplan turbine, double-regulated, with permanent generator) lies in the installation variant. With our Kaplan Spiral Turbine KSDP, a full spiral is used.
Important features
- • Steel sheet formwork with entry into the spiral chamber that is resistant to pressurized water
- • Possible connection on concrete or plastic pipes
- • Complete concrete cementation without additional forming
- • Optimal loading of the guide blades
- • Use in hydropower plants with pipe feed lines
Special solution Kaplan turbine
Special solutions for the installation of a WATEC-Hydro Kaplan turbine in the existing hydropower plant are of particular interest when the construction costs are significantly reduced.
WATEC-Hydro has successfully implemented several projects in the past by adapting the Kaplan turbine to existing wall ring flanges, existing concrete suction pipes, different geometries of old turbine chambers as well as ceiling penetrations with long turbine shafts for the customers.
Simply contact us if you are interested in special solutions.
Project planning
Between what is and what is to become lies the project planning phase with detailed planning. This ensures a smooth process and the achievement of the desired result. As your competent partner for the new construction and conversion of small hydropower plants by means of the installation of a Kaplan turbine, we are at your side with advice and support from the quotation to the commissioning.
An insight into the scope of project planning can be found in the following points 1-8.
Upon receipt of your inquiry, we will provide you with a detailed quotation including all relevant information such as design, material selection and all essential effect and performance data. All data are of course guaranteed by us according to IEC 041. In advance we check the local conditions and requirements. Detailed information from your side is also important for us. After that we define the ideal turbine size, the turbine type, the drive form, the generator and all auxiliary drives.After ordering you will receive a written order confirmation with all discussed details such as type and scope of the order of your Kaplan turbine, delivery dates and installation or commercial provisions.
Inventory
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.
Planning
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.
Start of production
Once all technical and commercial requirements have been met, the individual parts of the Kaplan turbine and other components such as hydraulics, controls and sensors are ordered. The production of the Kaplan turbine parts is carried out exclusively in selected specialist companies with CNC production facilities. This ensures that all parts of the Kaplan turbine have the required precision for long-term use. Short logistics routes simplify the inspection of the production by our company and ensure fast response times. Therefore, we work exclusively with suppliers from our region - made in Germany.
Factory assembly
All turbine parts delivered are subjected to a factory inspection for material quality, workmanship and dimensional accuracy. The factory assembly of your ordered Kaplan turbine then begins. This is carried out exactly in accordance with our in-house assembly guidelines. Finished components of the Kaplan turbine, such as the runner or the guide vane, are tested for density, function and coating, followed by the actual final assembly. Here, the individual components are assembled into a functional Kaplan turbine and tested again. Finally, the Kaplan turbine receives not only the sensor system but also the CE mark and is ready for delivery. Our turbines are largely pre-assembled ready for connection in order to keep on-site assembly time to a minimum.
Delivery
Our Kaplan turbines are delivered completely ready for installation up to a runner diameter of 1410 mm. If it is not possible to lift in the turbine for structural reasons, the individual components of the Kaplan turbine are pre-assembled and only put together after they have been placed in the powerhouse. The components necessary for the start of construction work, such as the intake manifold formwork, the intake manifold cone, etc., are of course delivered to the construction site in advance. All assembly work is carried out by our team of experts.
Final assembly
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.
Commissioning
The 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.
For maximum precision
Measurement
So that everything fits exactly in the end:
With the Leica TS16 total station, WATEC-Hydro can precisely measure all types of power plant structures for accurate planning. This laser measuring device makes it possible to scan even more complex geometries, such as intake manifolds and turbine chamber curves, using targeted laser points for later processing in the CAD system. This allows us to offer independent power plant dimensions from a turbine expert's point of view - important for any preliminary study for rebuilding or turbine replacement of a hydropower plant.
Making things run smoothly
Our automation solution
Everything under control and in view: Control and regulation technology
State-of-the-art control and regulation technology ensures reliable and optimally tuned operation of the entire hydropower plant with fully automatic control of the Kaplan turbine, the turbine hydraulics and the hydraulic steelwork. Remote access and monitoring of the plant as well as visualisation of the plant data are possible.
Our offer includes:
Service and
Maintenance
By using high-quality materials, we take care to keep the turbine control system low-maintenance and trouble-free.
In the course of time, it may nevertheless be necessary for certain plant components to be serviced or replaced.
With many systems, it is also possible that faults and adjustments to the software can also be rectified via remote access.
Our services
- Maintenance via remote access
- Repair and replacement of defective equipment
New construction & modernization
From turbine control to hydraulic steel structures, our control system guarantees reliable operation of your entire small hydropower plant.
Powerful and user-friendly!
HyCon RemoteControl
The modern way of remote access
- Web-based technology
- Access via any HTML-5 enabled device (smartphone, tablet, computer)
- No setup required on the device
- Available as an app via the bookmark function
- SSL- Encrypted transmission of image and inputs
- Constant updating through security patches
- Protected by an IPS firewall
- Password management at the customer
Simple and safe, everywhere!
Making things run smoothly
Hydraulic steel structures
So that everything runs as it should: Hydraulic steel structures
Various hydraulic steel components are required to operate a hydroelectric power plant with turbine, which we can supply from a single source on request. If you need individual components, we will design them for you and have them manufactured by our suppliers. However, you can also work directly with our partners in hydraulic steel construction. We will be happy to put you in touch with them.
Required hydraulic steelwork components
- - Inlet gates
- - Weir gates
- - Trashracks
- - Trashrack cleaners
- - Overflow flushing channels
Making things run smoothly
Formwork construction
Formwork construction includes the draft tube elbows as well as complete draft tubes of the turbine, furthermore half and full spiral formwork and concrete cones of the turbine chambers as well as various special formwork such as transitions from circular cross-sections of pipelines to rectangular cross-sections, e.g. of turbine chambers.
Formwork construction
Preparation
Our timber construction specialists can look back on almost thirty years of experience in this industry. The draft tube elbows are built in accordance with modern geometry using frame construction and wooden planking. The surface in the hydraulically critical area of the manifold is always covered with a stable (mesh-reinforced) filler and sanded smooth. Before concreting, the formwork parts are treated with formwork oil. This ensures that all curves are later free of burrs and have a streamlined finish.
Installation
The installation of a draft tube formwork in the power plant is usually the first on-site task of WATEC-Hydro. Prior to this, a base plate is concreted on site in the area of the outlet. Our mechanics place the draft tube formwork along with the vertical steel diffusor (cone) on this base plate. After aligning the formwork and the diffusor and checking the height at the flange of the steel diffusor, the formwork is secured against uplift and lateral thrust before further concrete stages are carried out on site.
We also carry out the assembly of, for example, the half-spiral walls in the turbine chambers during the subsequent construction stages.