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Litostroj - Kaplan Turbines
Design principle and range of use: Kaplan turbine is a double-regulated turbine. It is equipped with a Kaplan runner with variable-pitch blades that is hydraulically optimized for a wide range of discharge and a relatively wide range of head and is combined with regulated guide vanes, which makes a Kaplan turbine suitable for a wide range of discharge and head. The governor enables optimizing the CAM relationship between the distributor and runner opening; this unique function enables Kaplan turbines to efficiently operate under versatile hydrological conditions. Kaplan turbines are appropriate for use of water energy under different heads; typically, the head ranges from 5 m to 75 m.
General description & our setup
Litostroj Power has a long experience in design and manufacture of Kaplan turbines worldwide in various setup options. We apply the state-of-the-art technologies and the highest environmental standards, therefore we offer a great variety of hydraulic design considering the specific requirements and operating conditions of a unit with Kaplan turbine and offer comprehensive solutions tailored for each customer.
Typically the water is fed from the storage reservoir created by the dam to the spiral case. The spiral case is designed either as a concrete semi-spiral in case of a lower head (up to 35 m) or as a welded steel spiral for a head above 30 m.
As the Kaplan turbine operates with low speed, the static and rotating parts are heavy, with a high moment of inertia, and so very suitable for electric grid stabilization.
The unit is usually isolated by guide vanes only, but at a higher head, normally above 40 m, it can be also equipped with a main inlet valve. For units with a long intake channel we have references for design and installation of effective pressure relief systems which mitigate the transient surges.
Throughout the decades, Litostroj Power has supplied or upgraded more than 350 Kaplan turbines, with a total output of 8 GW.
Special solutions
Eco-friendly Kaplan runner is a highly-demanded solution on the markets with the most strict environmental standards. Its main advantage is in the absence of oil in the hub, which means no oil leaking into the river and environmental contamination whatsoever. We have experience in supplying either water-filled or empty (dry) eco-friendly Kaplan runners.
Refurbished Kaplan units - numerous Kaplan units around the globe have been in operation for more than 50 years and need to be refurbished. Litostroj Power offers various scopes of refurbishment, depending on the customer’s requirements. We offer improved hydraulic shape of the runner, new design and replacement of crucial components, such as replacement of grease or oil-lubricated bearings with self-lubricating bearings.
The refurbishment makes the unit operation more reliable, flexible, effective and environmentally acceptable. Refurbishment is executed at site in a short timeframe so as to shorten the interruption in unit operation to the minimum.
Propeller-type Kaplan turbine is a fixed-blade Kaplan turbine, which can be installed where small variation of flow through the turbine is expected and, in particular, on hydropower plants equipped with 4 or more units of the same type.
Semi-Kaplan turbine is a Kaplan-type turbine with fixed guide vanes. The single regulation – regulation of the runner blades - enables a flatter efficiency curve compared to that of the propeller type. Such setup requires controlled intake or draft tube gate to cut off the flow when the unit is to be stopped.
Main features
- Heads from 5 m up to 75 m
- Wide range of heads and discharges
- Outputs up to 110 MW
- Runner diameters up to 9,3 m