Problem: The Kaplan turbine with rotatory blade was built in 1948. The original unit structure was complex and the maintenance tasks were complicated. There was oil leakage in the hub, causing a frequent downstream oil contamination and logically; arousing the attention of the local government. At the same time, the turbines efficiencies were too low, and the output of the turbines were far below the design value.
The client needs the production capacity to be increased from 1600 kW to 2120 KW. As a historical and cultural heritage of the local government, this station equipment, appearance can’t be changed; in this sense, restrictions were imposed on the rehabilitation, greatly increasing the difficulty of upgrading.
Solution: GETAI performed on-site measurements and made a full flow passage CFD simulation analysis to optimize the blade profile. Due to fine-tuning the size of the unit, the over-current capacity of the runner was greatly increased and the cavitation performance of the runner was ensured. At the same time, the structure of the unit was optimized and the servomotor was placed on the top of the unit, leading to easier maintenance procedures of the unit.
Finally, the oil leakage problem of the unit was completely solved.