KAPLAN TURBINE WITH INNOVATIVE BLADE REGULATION SYSTEM AND NEWLY DEVELOPED GUIDE BEARING

Objective

The project consists of a Kaplan turbine installation for a head of 2,30 m and a max. discharge of 3,00 m3/s, resulting in Pmax = 54,7 and an expected output of 350 000 kWh per year. The installation will be equipped with two newly developed and innovative systems. (The patent application has already been submitted). The first innovation: improved hydraulic regulation system for the blades of the runner blades. Second innovation: new guide bearing allowing an easy remplacement. This avoids pollution of water by lubricants normally released with conventional techniques. A further new development are the turbines profiles derived by computer and giving improved efficiency.
All assemblies caused no problems and function satisfactorily. The bearing design ioncluding the sealing function satisfactorily. When the system was disassembled in December 1990 the shaft area of the seal was sprayed with ceramic hard facing to achieve extra hardness in this area. The means for adjusting the runner performed excellently and can be taken over without any change for new system. With the exception of the flow measurement means the measurement systems caused no problem. The flow measurement means are exceptionally sensitive to dirt in the river water and require repeated cleaning. Slight dirtying results in wrong measurements.
The objectives of the project in respect of the main innovative aspects were fully met. Improved hydraulic regulation system for the runner blades, innovative lower guide bearing consisting of a split self aligning roller bearing, newly developed turbine profiles by CAD giving improved efficiencies. Economic viability of project by short payback period of 8,69 years.
Total delay of the project : 7 month. Slight overruns of total project cost (10%).
The hydro scheme is located in Westendorf (Bavaria) and used to produce electricity to be fed into the public grid. The main activity is to rehabilitate an existing water power station by replacing the old Francis open flume turbine through an innovative Kaplan open flume turbine.
Technical Data :
Operational mode : Interconnected to the public grid
by induction generator
Number and type of turbine : 1 Kaplan open flume turbine
Design head : 2.30 m
Design flow : 3.00 m3/s
Turbine output capacity : 60.9 kW
Estimated annual energy output : 350,000 kWh
The bottom guide bearing of the turbine shaft is equipped with a split self aligning roller bearing. A new sealing system was developed, employing split felt rings. This system is continually lubricated with grease compatible with the environment to prevent wear and leakage. In the area of the seal had been sprayed ceramic hard facing.
A new heavy duty gearing steps up the turbine speed to the speed required by the AS generator. The adjusting gear was mounted on the gearing, i.e. runner adjustment outside of the gearing. By this new arrangement the adjustment gear is easily accessible.

Programme(s)

ENG-ENDEMO C - Programme (EEC) of demonstration projects and industrial pilot projects (EEC) in the energy field, 1985-1989

Topic(s)

Data not available

Call for proposal

Data not available

Funding Scheme

DEM - Demonstration contracts

Coordinator

SFL WASSERKRAFTANLAGEN GMBH

EU contribution

No data

Address

MUEHLSTRAßE 24
8851 WESTENDORF
Germany

Total cost