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VA TECH HYDRO

KAPLAN / PROPELLER TURBINES & GENERATORS

Water. Power. Kaplan.

We
how.
Weknow
know how.
sustainable solutions. for a better life.
www.vatech-hydro.com

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KAPLAN / PROPELLER TURBINES

& GENERATORS

General
Kaplan- and Propeller turbines are most
suitable for low head applications in the
range of 20 m to 70 m. The unit output today reaches the 200 MW range for the
largest applications. Runner diameters of
10 m and more are also standard today.

Up to approximately 30 m of head a concrete spiral casing is possible whereas for

higher heads full steel plate spiral cases
have to be used.
All types of regulation are possible today:
since the Austrian Victor Kaplan has invented this type of turbine in the beginning of the
20th century, a full Kaplan turbine has ad-

justable blades and adjustable wicket gates

to better perform according to the changing
water discharge. A Propeller turbine has
fixed runner blades and only adjustable
wicket gates for regulation and stopping the
machine. This is comparable to a classical
Francis turbine concept.
A much wider range of regulation can be
achieved by using adjustable blades and
fixed wicket gates - thus the stopping of the
machine has to be done by a gate. When
head and discharge are nearly constant over
104

KAPLAN
FIXED
100

related efficiency

The experience of VA TECH HYDRO regarding

Kaplan turbines is approx. 700 units and the
output installed is more than 18,000 MW
worldwide. Depending on the head range
there are Kaplan runners with 3 to 8 blades
used today. Beside the very low head applications of Bulb- and Pit turbines which have
a horizontal setting the general arrangement
of Kaplan- and Propeller turbines is a vertical shaft design.

PROPELLER
96

BLADE REGULATION
92

88
0.2

0.4

0.6

0.8

related unit discharge

1.2

1.4

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the entire operating range, a concept with

fixed wicket gates and fixed runner blades
is the most feasible solution.
Today the development of Kaplan turbines is
done by numerical analysis (CFD) as well
as finetuning by model testing.
Within VA TECH HYDRO this will be done
in the Hydraulic Laboratory in Linz, Austria.
All components of large Kaplan turbines are
designed using Unigraphics CAD-system
according to the latest design developments. Stress analysis of each component
is done by FE-methods.

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KAPLAN / PROPELLER TURBINES

& GENERATORS

Generator
VA TECH HYDRO generators are a synonym for state of the art design, high
efficiency and long lifetime. VA TECH
HYDRO has more than 110 years of experience in design and manufacturing
of all kinds of generators, from slow
speed to highest one, with air- or
direct water cooling, from several kVA
to more than 300 MVA. More than
33,000 MVA installed worldwide show
the impressive capability of VA TECH
HYDRO with many references for
vertical and horizontal hydro generators including bulb type units and
reversible speed motor-generators,
for turbo generators and for special
applications, like single phase machines.
For engineering of hydro generators the
most advanced computer based design
technologies like 3-D CAD, CFD for optimisation of cooling air circuits or FEM for
mechanical calculations are used together with own developed programs, representing the engineering experience accumulated in more than 110 years. Permanent improvement of the product is based
on own developments in cooperation with
universities. The possibility of manufacturing a complete generator in one workshop
allows shortest deliveries and grants high
quality standards. Additionally VA TECH
HYDRO has much experience in cooperation with local partners and subcontractors. A sophisticated quality assurance is
used to guarantee high reliability and long
life of the products. Modern tools are used
including 6-sigma methods for permanent
quality improvement.

Generators driven by Kaplan turbines have

typically slow speeds resulting in large diameters. Stator bore diameters of more
than 10 meters are not unusual. Special
precautions are necessary to guarantee
stator roundness in cold and hot stage. Although the rated speed is slow, the runaway speed of these units is 3 times higher and the rotors must safely withstand
this possible failure operation. Typically
laminated yoke rims are used which usually are based on friction to obtain a permanent shape for reliable balance. For low
vibrations, rims do not float below load rejection speed. Long lasting experience
with tangential guidance provides low eccentricities at runaway speed.
Depending on the speed the generator has
one or two guide bearings. The thrust

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bearing, usually combined with a guide

bearing, is of segmental type with pivot
supports. The bearings are usually of self
lubricating type and motor driven pumps
are only used for high pressure oil relieve
during start up and shut down of the units.
The core components of each generator
are stator core, stator winding and field
poles. The stator winding is insulated by a
VPI (vacuum pressure impregnation) system of outstanding quality. It has an inner
potential grading and an outside corona
protection including end potential grading.
A modern elastic winding fitting (EWB)
system is used to fix the winding firmly,
safely and durably in the stator core. If requested, other proven methods can also
be applied. The stator core is built up of
low loss electrical steel sheets, insulated
on both sides. Pressing bolts of high
tensile steel allow high elongation
values and permanent pressing of the
core. Pole winding coils are made of
straight copper strips connected at the
corners by brazing. The coils are built up
accurately by use of a CNC automated
device. All insulation materials are flame
resistant and self extinguishing; therefore
a fire fighting system is not necessary.

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Highlights
1924 First Kaplan turbine supplied to Waldenburg in Germany with a runner diameter
of 2,100 mm and an output of 750 kW
1928 First large Kaplan turbine with a runner
diameter of 7 m and an output of
30,000 kW for Schwoerstadt, Germany
1947 Four Kaplan turbines supplied for Blondel
(Mondragon) with an unit output of 51.5 MW
1950 First Kaplan turbines with a runner
diameter of 7,200 mm supplied
for Birsfelden in Switzerland
1951 First highhead Kaplan turbine
for Barcis, Italy with a head
of 63.5 m
1953 Fourteen Kaplan turbines supplied for The Dalles Dam in USA
with 92.2 MW output and
7,112 mm runner diameter
1954 Five Kaplan turbines and generators supplied for Ybbs-Persenbeug in Austria with an runner
diameter of 7,400 mm and an
output of 34.4 MW each. First
stator bore diameter of 10 m
1960 Kaplan turbines with a runner
diameter 8,400 mm and an
output of 73 MW and generators
with a stator diameter of
13,000 mm for Aschach, Austria
1961 Twenty five Kaplan turbines
supplied for John Day, Lower
Monumental and Little Goose on
the Columbia River in the USA with a
runner diameter of 7,925 mm and an
output of 158.3 MW each
1974 Two Propeller turbines for Kainji, Nigeria
with 128.7 MW and 6,800 mm runner
diameter
1998 Refurbishment of six large Kaplan turbines
of the Iron Gate with a runner diameter of
9,500 mm and an output of 200 MW each

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KAPLAN / PROPELLER TURBINE

& GENERATOR EXPERIENCE

Aswan
Egypt
The Nile which is one of the longest
rivers in the world with an approximate
total length of 6,825 km has the oldest
and most extensive hydrological records.

For more than 7000 years the Egyptians

have tried to restrain the regular floods of
the Nile and therefore several dams were
erected along the river. One of these dams
is the Aswan Dam which was erected
between 1898 1902. In 1948 Escher Wyss
Zrich was awarded by the Upper Egypt
Power Authority with the contract to supply
the turbines for the new hydropower station
which was erected next to the existing
dam. The tailwater of the power station is
connected to the river behind the dam via
two large tunnels.
The power station is equipped with 7 vertical
5 blade Kaplan turbines for the main power
production. Additionally two small auxiliary
powerhouse turbines are installed to
enable a blackstart when the grid is down
and no power from outside can be supplied.

Later on the Nasser Dam upstream of the

Aswan Dam was constructed so that the
tailwater reservoir of the Nasser Dam is the
headwater reservoir of the Aswan Dam.
Due to that reason the design head of 32 m
will no longer be reached anymore and the
Aswan turbines will now be operated at a
head of approx. 22 m and a power output
of 38.6 MW.
Technical data:
Output:
Head:
Speed:
Runner diameter:

47.8
32
100
5,600

MW
m
rpm
mm

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Aschach
Austria
The Aschach Power Station was built as
second Austrian power station on the
river Danube in the years 1959 to 1964
and is located in Aschach approx. 20 km
northwest from Linz in Upper Austria.

With the building of this station, a 40 km

stretch of the Danube between Jochenstein
and Aschach has been opened for power
generation and navigation has been improved in this very narrow part of the river
valley. Power generation efficiency is
enhanced by the large head and the high
winter percentage of annual energy. The
powerhouse is of the semi-outdoor type,
equipped with a 220 t capacity gantry crane

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travelling on the crest across the whole

structure. Situated between the locks and
weir, it is connected to the switchyard and
operational building by bridges above the
tailwater. Four vertical shaft Kaplan turbines
with a rated output of 73 MW each are
coupled to generators of 85 MVA.

The turbine runners are 8.4 m in diameter

and have been the largest in Western Europe
a t t h e t i m e o f d e l i v e r y i n 1 9 6 3 a n d a re
situated 3.50 m below mean tailwater level.
Also the outerdiameter of the generatorstator with 13 m is the largest diameter of a
VA TECH HYDRO generator. Beside turbines
and generators, the scope of supply includes also the main transformers, everything designed, manufactured and commissioned by VA TECH HYDRO.
Technical data:
Output:
Voltage:
Head:
Speed:
Runner diameter:
Stator diameter:

73 MW / 85
10.5
17
68.2
8,400
13,000

MVA
kV
m
rpm
mm
mm

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KAPLAN / PROPELLER TURBINE

& GENERATOR EXPERIENCE

John Day, Lower Monumental, Little Goose/ USA

The John Day Dam is located at the
head of Lake Celilo, about 330 km upstream from the mouth of the Columbia
river. The dam crosses the river near
Rufus, Oregon about 40 km upstream
from The Dalles, just below the mouth of
the John Day river.

The project consists of a navigation lock,

spillway, powerhouse and fish-passage
facilities on both shores. Construction began
in 1958, the first of the 16 main units began
operation in 1968, the last in 1971. Completion of John Day Dam marked the
final step in harnessing the waters of the
Lower Columbia River. At peak production
the powerhouse is capable of producing
2,500 MW, enough to meet the electrical
needs of two cities the size of Seattle.

VA TECH HYDRO has supplied all together

for the three power plants John Day, Lower
Monumental and Little Goose 25 units of
Kaplan turbines of the same size and output. The turbines were manufactured by
Baldwin-Lima-Hamilton from Philadelphia
at that time.
Technical data:
Output:
Head:
Speed:
Runner diameter:

158.3
28.7
90
7,925

MW
m
rpm
mm

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Jupia
Brazil
The Power Station Jupia is located at
the Parana river in the state of Sao
Paulo in Brazil approximately 600 km
upstream of Itaipu. Jupia is operated by
the Companhia Energtica de Sao Paulo
(CESP) just like the Ilha Solteira Power
Station.
In the years 1963 to 1969 VA TECH
HYDRO as a consortium partner delivered
all Kaplan turbines which were equipped
with 5 blade runners. In total 14 turbines
are installed, each with 110.8 MW power
output. At that time it was one of the largest
hydropower stations ever built.
In a Kaplan runner blade the concentration
of the stresses has its peak at the intersection between blade and blade disc.
To reduce these stress peaks, so called
undercuts are milled at these sections.
The blades for Jupia were the first ones to
be designed and manufactured in this way
according to a global patent.
Today these undercuts are a worldwide
standard. Additionally these blades were
one of the first ones with anti cavitation lips.
These anti cavitation lips are used to protect
the base material and to reduce cavitation
at the hydraulic important surfaces.
Therefore, it can be stated that the turbines
were at that time not only within the largest
of their type, they were also the first ones
where the newest and most advanced technology of VA TECH HYDRO was employed.

Technical data:
Output:
Head:
Speed:
Runner diameter:

110.8
23
78.3
8,400

MW
m
rpm
mm

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KAPLAN / PROPELLER TURBINE

& GENERATOR EXPERIENCE

Wallsee
Austria
Located approx. 45 km downstream of
Linz, the Wallsee Power Station was built
in an oxbow of the Danube, where the
river crosses the border between Upper and
Lower Austria, in the years 1965 to 1968.

Upstream of Wallsee the Danube bends

extremely, featuring sand banks and blind
corners, which used to be a serious obstacle for shipping. The power plant was
constructed with the so called dry construction-method in the dry area and a new
riverbed was dug for the Danube. This
method was used for the first time in
Austria. VA TECH HYDROs scope of supply
includes 6 vertical shaft Kaplan turbines
and 6 generators as well as the excitation &
automation system.

10

Technical data:
Output:
Voltage:
Head:
Speed:
Runner diameter:
Stator diameter:

37.9 MW / 42.5
8
11
65.2
7,800
12,250

MVA
kV
m
rpm
mm
mm

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Kainji
Nigeria
In 1962, the Federal Government of
Nigeria decided to base the main supply
of electricity on hydropower technology.
This led to the decision to construct
Kainji, the first large hydropower station
in Nigeria.

Kainji Dam and Power Station are located on

the River Niger in Niger State, some 350 km
west of the Nigerian capital Abuja. The
reservoir has a width of up to 20 kilometers
and stretches back some 180 kilometers,
almost reaching the border of neighbouring
country Niger. Construction work at Kainji
started in 1964.
In 1972, National Electric Power Authority
(NEPA) awarded a contract to VOEST-ALPINE,
one of the predecessors of VA TECH
HYDRO, to design, manufacture and install
two vertical Kaplan turbines of 108 MW maximum output. Before these two units
number 11 and 12 - were commissioned in
1974, NEPA ordered two more turbines
units 5 and 6. These two units of 128 MW
output each are designed as fixed blade
propeller turbines. The design challenge on
all four turbines was the limitation in size: the
existing turbine blocks were designed for

90 MW units only, the new units had to fit

in these narrow unit bays.
Along with the six 95 MW turbines at Jebba
and the four 150 MW turbines at Shiroro,
VA TECH HYDRO has supplied the turbines
for more than 80% of Nigerias hydro electric capacity.
Technical data:
Output:
Head:
Speed:
Runner diameter:

11/12 Kaplan
108.1 MW
38.1 m
115 rpm
6,500 mm

Technical data:
Output:
Head:
Speed:
Runner diameter:

5/6 Propeller
128.7 MW
38.1 m
107.1 rpm
6,800 mm

11

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KAPLAN / PROPELLER TURBINE

& GENERATOR EXPERIENCE

Jebba
Nigeria
The Jebba Power Station is located at
the Niger in the center of Nigeria
approximately a five hours drive west
from the capital Abuja.

In 1978 VA TECH HYDRO in Ravensburg

was awarded with the contract to supply the 6 turbines for the power station by
the Nigeria Electric Power Authority (NEPA).
Montreal Engineering from Canada was the
consulting company employed by the client
to supervise the works at the power station.
The turbines were designed as 5 blade
Propeller turbines and the speciality of these
turbines is, that the blades are clamped into
the hub and are not fixed with any kind of
screw connection.

12

Due to the high manufacturing quality of the

spiral case, with a diameter of more than
10 m, it was not required to press out the
spiral case. The power station has no shut
off device. Therefore the turbine will only be
stopped by closing the wicket gates.
During commissioning in 1982 / 1983
Montreal Engineering and NEPA observed
immediately that the wicket gates were very
tight since no noise from the leakage water
could be heard. This extreme tightness was
archived with the conical machined prestressed wicket gates.
Technical data:
Output:
Head:
Speed:
Runner diameter:

102.7
29.3
93.75
7,100

MW
m
rpm
mm

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Kotapanjang
Indonesia
Located right at the equator in the Riau
province in Central Sumatra / Indonesia,
the Kotapanjang Power Plant was built
for the client PT. PLN (Persero). The generated power is required for the further
industrial development in the Pekanbaru
area. Since the crises in Southeast Asia
the Kotapanjang project is one of the
key projects in the grid system for the
Riau and West Sumatra Areas.

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VA TECH HYDROs delivery included

three vertical generators, the main transformers, generator switchgear and balance
of plant equipment (station service equipment including station service transformers,
emergency Diesel, batteries, chargers and
inverters, uninterrupted power supply and
the control system), fire fighting equipment,
telecommunication and grounding system.

Also included in the scope was the design,

manufacturing, transportation, erection,
commissioning as well as the training of
the operation staff. All three units are in
successful commercial operation since
November 1998.
Technical data:
Output:
Voltage:
Speed:
Stator diameter:

45
11
200
5,900

13

MVA
kV
rpm
mm

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KAPLAN / PROPELLER TURBINE

& GENERATOR EXPERIENCE

Zilina
Slovakia
The power plant of Zilina is located on
the river Vah approximately 200 km
north/east of Bratislava nearby the city
of Zilina in Slovakia. The plant will supply the local grid with 173 GWh of electricity and is regulated also for peak
load production.

Two vertical Kaplan turbines have been

installed utilizing 320 m 3/s of the river
discharge. It was on 28th of October
1994 when the consortium of ABBSAE-SADELMI and VA TECH HYDRO
signed the contract for the design, fabrication, supply and installation of the equipment.
This included the following:
- Two vertical shaft Kaplan turbines including digital type governors
- Hydromechanical steel structures including three large radial spillway gates, stoplogs, rakes and trashrach raking equipment
- Powerhouse crane
- Generators and electrical equipment
(supplied by ABB).

14

Start of construction was in October 1994

and four years later in January and April
1998 the two Kaplan turbines were successfully commisioned and handed over
to the client VODNE DIELO ZILINA (VDZ),
a subsidiary company of the Slovakian
Energy Supply Company VODNE
ELECTRARNE TRENCIN.
Technical data:
Output:
Head:
Speed:
Runner diameter:

38.1
25.8
150
4,800

MW
m
rpm
mm

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Candonga
Brazil
The Candonga Power Station is located
on the river Rio Doce in Minas Gerais
near Ponte Nova / Brazil and has a total
capacity of 142 MW.

as well as the auxiliaries and all the

engineering, design, manufacture, transport, erection and commissioning work
of the plant.

Located in the municipalities of Ponte Nove,

the turnkey engineering procurement and
construction (EPC) contract was won by a
consortium VA TECH HYDRO BRASIL being
a part of it. Work on this project is scheduled from 2001 till 2004 where the first of
these three units was set into operation at
the end of 2003.
For the private investors EPP and CVRD,
VA TECH HYDRO supplied the complete
electromechanical equipment including
three vertical Kaplan units, the hydromechanics, the three generators, substation
and transmission line, main transformers,
protection, excitation and control system

Technical data:
Output:
Voltage:
Head:
Speed:
Runner diameter:
Stator diameter:

47.6 MW / 53
13.8
48.6
225
2,840
6,500

15

MVA
kV
m
rpm
mm
mm

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VA TECH HYDRO worldwide

VA TECH HYDRO can point to more than 160 years of experience in hydraulic power generation and
is a competent partner for sustainable solutions.

VA TECH HYDRO
e-mail: [email protected]
Penzinger Strasse 76
A-1141 Vienna, Austria
Phone: (+43/1) 89 100 - 2963
Fax: (+43/1) 89 100 - 3821

sustainable solutions. for a better life.

www.vatech-hydro.com

Lunzerstrasse 78
A-4031 Linz, Austria
Phone: (+43/732) 6987 - 3451
Fax: (+43/732) 6980 - 2554

Escher-Wyss-Strasse 25
D-88212 Ravensburg, Germany
Phone: (+49/751) 83 - 2941
Fax: (+49/751) 83 - 3280

eHYD.LH.36.4000.C04

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United Kingdom, Ukraine, USA, Venezuela and Vietnam.