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International Conference on Hydropower for Sustainable Development
Feb 05-07, 2015, Dehradun
Andritz Green Kaplan Technology
Water Filled KaplanRunner Hub Design
Mr. Pankaj Agarwal
Head – Design & Engg.
Andritz Hydro Pvt. Ltd.
Village – 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

Max. output 86 MW
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TECHNOLGY LEADER IN
OIL FREE KAPLAN RUNNER TECHNOLGY
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
Blade seal: Hub water / river water
Lever ring
Composite bearing
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

Good ability for edge load

Own testing facility
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Oil Free Kaplan Runners – Material Grades
LIFE-LENGTH and RELIABILITY
Optimized design with high quality materials
Runner blades
Cast Stainless Steel
Lever ring
Cast Stainless Steel
Blade trunnion
Forged Stainless Steel
Links, pins, rod extension Forged Stainless Steel
Runner hub
Cross head
Piston/piston rod
Hub cone
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Cast steel
Cast alloy steel
Forged steel (SS overlay)
Fabricated carbon steel
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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THANK YOU
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