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Andritz Green Kaplan Technology
Basics of Water Filled Runner Design
Mr. Pankaj Agarwal
Head – Design & Engg.
Andritz Hydro Pvt. Ltd.
Village
g – Prithla,, Dist-Palwal
Haryana 121102, India
Oil Free Kaplan Runners - References
References:
> 100 Units above 5 MW
 Majority in Scandinavia
 First runner Bruksfallet 1993
 Max. runner dia. 7.525 m
 Max. head 57.8 m
TECHNOLGY LEADER IN
OIL FREE KAPLAN RUNNER TECHNOLGY
 Max. output 86 MW
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Oil Free Kaplan Runners – Water Filled Hub
ENVIRONMENTALLY SAFE
No risk of oil leakage into the river water
Hub filled with water + corrosion inhibitor (lemon acid)
Blade seal arrangement prevents water exchange
Volume compensation
River water
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Hub
Water
Oil Free Kaplan Runners – Concepts
Servomotor positon (standard operating pressure 150 bar)
next to shaft coupling – inside runner hub – at the top of generator
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Oil Free Kaplan Runners – Design Example
Pressure oil
Runner hub
Piston
Lever ring
Blade seal: Hub water / river water
Composite bearings
Piston rod
SS overlay
Trunnion
Link
Water + anticorrosion additive
Piston rod seals: Oil / Hub water
Cross head
Link pins
Hub cone
Rod extension seals: hub water / river water
Piston rod extension
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Oil Free Kaplan Runners – Blade Bearings
COMPOSITE BEARING MATERIAL
 Low friction
 High load capability
 Low wear
y for edge
g load
 Good ability
 Own testing facility
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Oil Free Kaplan Runners – Material Grades
LIFE-LENGTH and RELIABILITY
Optimized design with high quality materials
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 Runner blades
 Lever ring
 Blade trunnion
 Links, pins, rod extension
Cast Stainless Steel
Cast Stainless Steel
Forged Stainless Steel
Forged Stainless Steel
 Runner hub
 Cross head
 Piston/piston rod
 Hub cone
Cast steel
Cast alloy steel
Forged steel (SS overlay)
Fabricated carbon steel
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Oil Free Kaplan Runners – Simulation
DESIGN OPTIMIZATON
Finite Element Analysis of complete runner
 Stresses / Rigidity / Bearing pressures / Vibrations /
Servomotor safety margin
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Oil Free Kaplan Runners – References
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