WKV_Turbinen_2010_EN-rev1

7/30/2019 WKV_Turbinen_2010_EN-rev1

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Turbines Wor ldwide


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Why WKV of all companies?After all, there are bigger companies 4

Diesel and Gas pays back much quicker!But as it is well-known, who laughs last laughs best 6

Competence is not all-important.Quality also germinates from passion for data 8

Hydro power plants are unique.

We design according to your need 10If all good things come from (far) above.

WKV Pelton turbines 12

The all-in-one solution.WKV Francis turbines 14

Effectiveness over a wide range.WKV Turgo turbines 16

The economic solution.WKV Crossflow turbines 18

Energy converter on highest level.WKV alternators 20

Set out and manage.Switchgears and process controls 22

A reliable arrangement.WKV control systems 24

Not everything has to be brand-new.Restoration, renovation and modernizing existing powerplants 26

A partnership for life-time.Commissioning, maintenanceand service by the manufacturer 28

Your advantage.The best from tradition and modern age 30

Office building of the WKV AG Headquarters in Gutach


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A sustainable energy policy, based on renewable resources, will be crucial

to their future. Hydropower is one of the front-runners among such rene-

wable energies.

Wasserkraft Volk AG is one of the leading manufacturers of small and me-

dium-sized HEP systems in the world having made a significant contribution

towards a sustainable future.

In our 30 years of business activity, several hundred small and medium-sized

hydro power plants were manufactured, producing environmentally-friendly

energy in over 40 countries all over the world.

In May 2000, the State-of-the-Art Factory commenced operations. This is

the first large scale factory in Germany which is fully energy-self-sufficient

and operating without any CO2 emissions.

In view of the positive approach to the business development, where many

other business firms suspended their investment activities in the year 2008

due to the international financial crisis, Wasserkraft Volk AG put up a new

most modern and highly efficient production plant with a 4000 m 2 shop

floor.

As a medium size enterprise, our main focus is only Germany as the loca-tion for factories in view of our social responsibility and obligation towards

the country and future generations. Last but not least, a great portion of our

success comes from our highly motivated, dedicated, devoted and com-

mitted work force receiving consistent advance training, education and up-

dating in their respective fields in order to render a reliable and persistent

service to our customers.

We are only caretakers of the

world and its resources that

we pass on to our children.

(WKV's company slogan)

Green roof and solar panelslocated on the office buildings

In-house hydro powerplant in Gutach

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Why WKV of all companies?After all, there are bigger companies


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WKV AG is a medium-sized enterprise

located in Gutach/Breisgau. We are still

small enough to react flexibly to the

needs of markets and customers, but

on other hand large and experienced

enough to achieve something great!

At WKV, you get your complete power

plant, including turbines, controls,

alternators and switchboards, perfectly

adapted to each other, from one single

source.

And that is from A Z

Made in Germany!

Choose water for your

eco-friendly energy

source Choose

Wasserkraft Volk AG!

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Our principle all from one source allows to react extremely sensibly to the

requirements of our customers of you. Designing of your hydro power

station is performed by experienced engineers in the fields of hydraulics,

mechanical and electrical engineering and control technology. You will not

find another manufacturer in the market that can offer more comprehensive

knowledge and experience in the entire range of disciplines.

Our factory is structured to design and build the complete range of turbi-

nes, generators, switchboards and also electronic controls and accessories.

All manufacturing facilities are located in our plants in Gutach and Simons-

wald in Germany literally brining us to the same vicinity thus granting you

high flexibility, quick service and highest quality.

Last but not least: Where else will you receive such willing, eager and en-

thusiastic personal attention from the founder of the organization himself?


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Diesel and Gaspays back much quicker!

But as it is well-known, who laughs last laughs best ...


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... and tomorrows

generations will

be delighted if we

take care of our

environment today!

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Profitability and environmental compatibility dont have to be contradictory:

Hydro power plants are emission-free. No pollution, no CO2, no problems

with waste, low impact to the surrounding nature.

The long life-time of WKV hydro power plants produces eco friendly

electric energy for generations ahead.

At WKV, conservation of resources begins at the manufacturing stage itself.

Our in-house hydro power station produces electric energy required formanufacturing and also feeds the centrifuges on the heating system.

Electric Surplus energy is fed into the local mains.

Only about 22% of the technica l ly useable hydro

power potential on earth is currently uti l ized. Reap

the benefit from our knowledge and experience to

improve on this s ituation!

Generating sets based on fossil fuels are available at low cost, resulting short

term benefits. However, just considering economic aspects, small hydro

power plants are unbeatable in the long run:

WKV Hydro power plants are not only designed for years but for many

many years under continuous operation, thus granting high profitability

for many decades beyond the payback period.

Water always flows downwards resulting in minimum operating costs.

No friction means no wear and tear leading to low maintenance needs.

Energy price hikes do not bother us.


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Competence is not all-important.Quality also germinates from passion for data


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Continued education and professional training and updating ensure the

latest know how being imparted to the present employees as well as new

recruits providing necessary motivational inputs as well.

All this makes WKV AG your partner of choice for design and production

of your next hydro power plant.

Dont settle for the next best!

Expertise so far is an attribute which can be assumed for a company suc-

cessfully serving the international markets for decades. The consistent

evaluation of performance on the operating power plants has directly

contributed towards this competence.

WKV products are beyond the very best you can get for your money; i.ethe passion for detail that has lived at WKV, leading to a quality assurance

starting in the early planning stage up to the commissioning stage.

Over a period of 30 years, WKV AG has again and again proved beyond

doubt that industrial production and passion are thoroughly complemen-

ting. Hundreds of satisfied customers from all over the world will bear

testimony to this.

Knowledge can be acquired

+ Experience is attained by practice

= Expertise is generated by consequent integrationof theoretical knowledge into experience


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050607

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00001000100101 00003000020006000400030002007005004003002070605040302

1500

2000

Francis turbine

Onrequest

On request

Flow rate Q [l/s]

Turgo turbine

Crossflow turbine

Pelton turbine

Net head H [m]

Onrequest

20000kW

15000kW

10000kW

5000kW

2000kW

1000kW

500kW200kW

100kW

50kW

20kW

10kW

Hydro power plants are unique.We design according to your need


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Natural conditions of water courses is significantly different. Therefore,

every order demands an exclusive solution. WKV uses four different tur-

bine types to transform hydraulic force into electrical energy:

WKV Pelton turbines

WKV Francis turbines

WKV Turgo turbines

WKV Crossflow turbines.

Each of these turbine types is suitable for a specific operation area: Different

output ratings, various head values, highly unsteady watercourses or high

content of floating refuse. In addition, you get WKV speed controllers, WKV

water level controllers and WKV switchboards. Everything with well-proven

technology made by WKV AG.

WKV offers much more than the adaptation of turbine and alternator to the

site conditions. For example, a complete range of specific runner speeds

allows a perfect alignment to synchronous alternator speeds.

Common for all products: The first-class quality. In our test laboratory, we

have proved this beyond doubt and so far achieved highest efficiencies.

Since the company was founded, a big part of our profit has been re-inves-

ted into research and development. This makes us the forerunner in the

global minihydro industry. We keep our technological lead only by con-

tinuous development.

Do not buy your turbine plant at

a discounter trust in the specialist!

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If all good thingscome from (far) above.

WKV Pelton turbines


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Head range from 30 m up to more than 1500 m

Capacity up to about 20 MW

Single- double-, four-, five- or six-jet designs available

Horizontal or vertical shaft arrangementsJet deflectors for outstanding dynamic performance

2 or 4 bearing gen-set arrangements

Well suited to sites with significant fluctuations

in the water flow

Characteristics of

WKV Pelton turbines:

Developed for use in demanding applications with

water containing debris

Optimized jet and runner designs for highest efficiencies

Nozzle control either electrically or hydraulically

Runner cast from high grade, extremely wear resistant,

stainless steel

Maintenance free shaft seal design


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The all-in-one solution.WKV Francis turbines


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Characteristics of

WKV Francis turbines:

Head range up to more than 300 m

Capacity up to about 20 MW

Excellent peak efficiency

High efficiency also at partial water flowCompact design and low maintenance requirements by rigorous

selection of best suited materials and proper design

2 or 4 bearing gen-set arrangements

Bearings rated moderately for more than 100 000 hours of operation

Guide vane controls electrically or hydraulically

Runner made of Chrome steel


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Effectiveness over a wide range.WKV Turgo turbines


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Characteristics of

WKV Turgo turbines:

Head range 30 ... 300 m

Output up to approx. 7.500 kW

Single or double jet design

Jet deflectors for outstanding dynamic performance

(important on long pipelines)

Less sensitive to contamination than Francis turbines

Flat efficiency curve shows high efficiency also

at partial water flow

Geometry of stream and runner are optimized for

efficiency in WKVs own laboratory

The high specific speed allows using the Turgo

principle instead of multi-jet Pelton turbines or instead

of Francis turbines at lower partial load efficiencies

Guide vane control electrically or hydraulically

Runner made of extremely wear-resistant steel- orchrome steel casting not indestructible, but not far

from it!

Maintenance-free shaft sealing system


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The economic solution.WKV Crossflow turbines


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Characteristics of

WKV Crossflow turbines:

Head range 1.5 m up to approx. 150 m

Capacity up to 2 000 kW

A split vane construction allows an almost constant efficiency from 100% down to 17% of rated water discharge

Significant improvements achieved through targeted research and development in WKVs own test laboratories

Outstanding stiffness of runners

Cast or welded guide vanes with stainless steel shafts

Guide vanes controlled electrically or hydraulically

Easily accessible inspection ports and hatches

Proven bearing arrangement, designed by WKV, rated for more than 100 000 operating hours

Economic solution where other turbines prove to be too expensive


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Energy converter on highest level.WKV alternators


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Benefit from the

extensive experience

of our engineers in

building generators!

Characteristics of WKV synchronous alternators:

Rating: Matching the turbine output, up to 22.000 kVA

Power factor: cos phi 0,8, other values if required

Voltage: 400 V ...15 kV

Frequency: 50 Hz / 60 Hz

Degree of protection: IP 23, IP 44 or higher, adapted to operationsite and conditions

Design forms: Horizontal or vertical, for elastic coupling to the turbines

or with long shaft and re-inforced bearings for overhung mounting of

the turbine runner

Bearings: Antifriction or sleeve bearings, optimized for long life-time

and minimum maintenance need

Electromagnetic layout: Voltage and frequency range will be adapted

to Grid-Codes and/or to various local mains conditions. Concurrently

the machines are optimized for high efficiency in the most economical

operating range.

Operating principle, voltage control: The alternators are self-regulating

and self-excited, brushless and, except the bearings, practically

maintenance-free.

See also the separate leaflet

WKV Generators Worldwide

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Set out and manage.Switchgears and process controls


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WKV supplies a complete line of equipment from low voltage equipment

to the feeder at medium or high voltage level.

Conventional control panels

PLC based controls

Remote control (SCADA)

Annunciation and display equipment

Low voltage switchboards up to 3 500 A

Medium voltage switchboards up to 36 kV

High voltage switchboards

Transformers

Allocation metering towards mains operators

Complete wiring

Switchboards Made in Simonswald

WKV designs and manufactures the complete set of switchboards and con-

trols in-house, and thus provides a single-point overall responsibility. Each

unit is individually adapted to the clients standards and local regulations.

Your advantages:

Clear and precise arrangements, quick turnaround on design issues,

short deliveries

Factory testing and inspection of the complete switchboards and

control equipment in our own test facilities

Erection and commissioning by competent staff

Only first-class components are used


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A reliable arrangement.WKV control systems

Digital/analogue speed governor type SRE 2000:

This WKV development is unique in the world of controls as it combines the

advantages of both digital and analogue controls.

Direct display of the main control parameters

Dynamic PID controls with the option for external noise application ensure

stability even in the case of long penstocks or unstable grids

Modular 19 rack design for easy implementation and replacement

of components

Protection against external faults, all I /O circuits are protected against

external short-circuiting and reverse polarity

Easy adjustment of all main parameters by use of a simple screw driver,

no programming, no software or terminal, no laptop required

Contact-free speed sensing

Designed for operation with PLC based controls or a remote control system

Suited for speed control, output control, discharge or level control,

as well as for double-regulated units (injector/deflector or guide

vanes/runner blades)

Durable and user-friendly design and technology

WKV offers a lifelong guarantee for supply of spare parts and services.

All control units are backwards-compatible!


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Hydraulic devices for speed control

and parallel operation with mains

WKV offers a complete range of hydraulic power units for control

applications. This includes simple actuators for operation on a grid (level

or discharge control) as well as the most complex applications involving

isolated network or parallel operation.

Designed for decades of continuous operation only the best components

are used

Low-pressure hydraulics for extended service life

Energy-saving designs

Typically no high-pressure accumulators that need severe maintenance

WKV manufactures the complete range of governors in-house another

benefit to you!

WKV level control for parallel operation

Designed to ensure best possible use of the available water flows and

most economical operation!

PLC controlled operation to achieve optimum efficiency for multi-jet

impulse turbines as well as for twin-cell Crossflow turbines

Indication of the intake water level

Surge-protected water-level sensors provide safe operation even under

adverse environmental conditions

User friendly adjustment of set points

Electronic load controller

Designed for small units up to 800 kW supplying isolated loads as well as

for the emergency power supply of grid-connected units.

Excellent frequency-accuracy even during load acceptance or rejection

Heavy duty industrial grade electronics especially designed for extremeambient conditions

Mechanical governors and their maintenance

For some applications mechanical governors may provide significant advantages.

WKV offers a full line of such governors manufactured in-house:

Robust and well-proven technology

Completely without electronics best suited for applications in remote

locations


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Not everything has to be brand-new.Restoration, renovation and modernizing of existing power plants


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Usually hydro power plants are operated for many decades until the rava-

ges of time will require a basic renovation. Accompanying the renovation,

mostly a reasonable improvement in system efficiency is requested.

Other power plants are damaged by natural disaster, systems have to be

partly or completely cleaned, repaired or replaced. Often, special building

conditions or monumental or archaeological protection rules that have to be

adhered to can significantly complicate the work at site.

Our special purpose machinery manufacture covers turbines including

control system, generators and switchboards. By far, WKV is experienced

and flexible enough to refurbish your power plant for a reliable operation

over the coming decades.

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If maintenance or

modernization

WKV AG makes your

power plant fit for

the coming decades!


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A partnership for life-time.Commissioning, maintenance and service by the manufacturer


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It is obvious that our commitment to you, our customer, does not end when

delivering a premium product. We offer you a broad worldwide service,

starting with erection and commissioning until regular maintenance of

your power plant.

Even the best system can get damaged due to external factors. Never Mind

if in the tropics or in the far North qualified WKV personnel are available

(not only) in case of emergency but any time to ensure best of service.

Our promise to

you: Impossible

isnt a part of

our vocabulary!

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Your advantage.The very best from tradition and modern age

T k t l h


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Craftsmanship has a long tradition

in our area. The idea of quality is

traditionally lived and realized with

passion for details. Solid education

and advanced training enable a high

level of creativity, what is immensely

important for any kind of manufactu-

ring of special machines.

We from WKV are combining these

characteristics with most modern

manufacturing technologies resulting

in a cost effective manufacture of our

premium products.

Our great in-house production capa-

city makes us largely independent

from sub-suppliers which allows us

to react flexibly and to realize short

project and lead times.

To work at a place where

others are doing vacation

also this is a motivation

for our colleagues!

Wasserkraft Volk AG

the partner you can rely on

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Wasserkraft Volk AG

Am Stollen 13

D-79261 Gutach

Tel.: +49(0)7685 9106-0

Fax: +49(0)7685 9106-10

E-Mail: [email protected]

Internet: www.wkv-ag.com

You will find our power plants in more than 40 countries all over the globe.

tion12/2010-EN.

Pictures:KriegFoto

design/Archiv

Documents

WKV_Turbinen_2010_EN-rev1