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.
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.
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.
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.
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.
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.
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.