turbine turgo

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HYDROPOWER SYSTEMS

BY APPOINTMENT TO H.M. THE QUEEN

WATER TURBINE ENGINEERS,

GILBERT GILKES & GORDON LTD, KENDAL


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THE COMPANY 3

GILKES HYDROPOWER 5

GILKES PACKAGE 7

TURBINE SELECTION 10

PELTON TURBINES 11

FRANCIS TURBINES 13

TURGO TURBINES 15

SERVICE & REFURBISHMENT 17

CONTENTS

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Gilbert Gilkes & Gordon Ltd (Gilkes) is an internationally establishedmanufacturing company, based in Kendal, UK on the edge of theEnglish Lake District.

In 1856, Gilkes installed their rst hydroelectric scheme. Over 150 years later, itis still a world leader in small hydropower systems supplying over 6500 turbinesto over 80 countries during its history. With thousands of installations aroundthe world, Gilkes continue to demonstrate the ability to be sensitive to regionaldifferences and requirements and continually design, manufacture and installbespoke engineered solutions for their customers.

The companys head ofce is in Kendal, however other operations include adedicated hydro refurbishment unit in Fort William, Scotland and ofces inVancouver and Tokyo for the North American and Far East markets.

Gilkes also acts as the parent company to Gilkes Energy Ltd, which was formedin 2008 as our hydro project development business to help our clients developand nance hydro projects and focuses on Joint Ventures with landowners.

Other products designed and manufactured by the company include a rangeof sophisticated pumps for the cooling of diesel engines and plant, supplyingmany of the worlds major diesel engine manufacturers. Gilkes also producepumping solutions for the lubricating of oil or gas and steam turbines andsupply a range of industrial pumps for virtually any application. Gilkes Inc,based in Texas USA is our American facility, which focuses on the repair,remanufacture and sale of engine cooling pumps for our American customers.

AN INTRODUCTION TO

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GILKES HAS SUPPLIEDOVER 6500 TURBINESTO MORE THAN 80COUNTRIES

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WORLD LEADINGSERVICES FOR THEHYDROELECTRICINDUSTRY

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GILKESMANUFACTURE AND

SUPPLY HYDROELECTRICTURBINES AND ANCILLARY

EQUIPMENT IN THE OUTPUTPOWER RANGE FROM 50kWUP TO 20MW.

ACTIVITIES INCLUDE:4 Design4 Manufacture4 Installation4 Commissioning4 Testing4 Routine service and plant upgrade

GILKES PROCESS:4 Site visit and investigation4 Outline proposal and initial design4 Detailed proposal4 Design4 Project management4 Production4 Installation and commissioning4 After sales and servicing4 Operational support


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OUTLINE PROPOSAL AND INITIAL DESIGN

4 Advice and consultation during concept phase of project4 Equipment selection4 Annual energy maximisation

EQUIPMENT INERTIA AND SURGE ANALYSIS

For every project Gilkes carry out analysis of the inertiarequirements for the turbines and generator. For Francisunits this includes a surge analysis on the penstock tokeep the pressure rise on a trip from the grid networkwithin the pressure rating of the penstock.

CONTROL EQUIPMENT

All ancillary equipment is specically designed to beincluded into a fully integrated package. The controlequipment and ancillary equipment such as hydrauliccontrol modules are fully function tested simulatingsite conditions to minimise commissioning time.

TURBINE ISOLATING VALVES

All turbines are provided with a turbine isolating valvewhich automatically isolates the turbine / generator unitduring normal and emergency shutdown of the unit.

SPEED GOVERNORS

Gilkes can offer a range of speed control devicesdepending on the specic project requirements:4 Mechanical speed governors4 Digital electronic speed governors4 PLC speed control4 Electronic load governors (load ballast governors)

ELECTRICAL EQUIPMENT PACKAGE

The electrical equipment is designed specicallyfor each project. We provide solutions to meet therequirements of the surrounding infrastructure andthe capabilities of our customers personnel. Withmore emphasis on unmanned plants, automation andcontrol is essential. Gilkes offer complete packagesranging from basic manual systems to complex controlphilosophy for multi-turbine projects. All equipmentis fully factory tested, simulating conditions at site tominimise commissioning time.

SYNCHRONOUS GENERATORS

Gilkes have successfully supplied customers withgenerators from a wide variety of manufacturers. Usingour knowledge and experience we can recommenda particular manufacturer for a given application. Thesynchronous generators are brushless machines,tted with rotating exciters and solid state AVRs.These features make a signicant contribution to

the reduction in routine maintenance required ongenerators. When appropriate, they can be offeredwith extended shafts. This enables the turbine runnerto be directly mounted onto the generator shaft,dispensing with the turbine shaft and bearing, withthe resulting reduction in maintenance. Gilkes canalso supply induction generators. All generators aremanufactured and factory tested fully in accordancewith International Standards.

PACKAGING / PACKING AND DELIVERY

Gilkes packing methods are customised to suit therequirements dictated by the project location andaccess to the project site. Equipment can be packedfor long periods of storage.

SITE WORK

Gilkes Engineers provide expert on-site installationand commissioning services. Our engineers providethe expertise to install, commission and start-up all ofthe components of the equipment package followingOperation and Maintenance procedures. Full training

on site or at the Gilkes factory can be provided.AFTER SALES SERVICE

Gilkes equipment packages are designed to minimiseor eliminate unscheduled down time. All criticalstrategic spares are identied in consultation with ourcustomers. All contract drawings and documentationare archived to provide spare and after sales servicethrough out the life of the project.

1. Bart Lake 6 Jet Pelton Turbine, Alaska2. Turbine monitoring3. Powerhouse at Logan Gill, in the English Lake District

THE GILKES PACKAGE

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In addition to the supply of the turbine, Gilkes can include in theproduct package:

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OUR ENGINEERSPROVIDE THEEXPERTISE TO INSTALL,COMMISSION ANDSTART UP ALL OF THECOMPONENTS


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GILKES HAS BUILT ONITS EXPERIENCE OVERLITERALLY THOUSANDSOF PROJECTS, WHICHALLOWS US TO OFFERAN INTEGRATEDPACKAGE OFEQUIPMENT


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Gilkes has built on its experience over literally thousands of projects, this allows us to offer a truly integratedpackage of equipment.

The optimum turbine selection for a given hydraulic duty and site application is dependent on many parameters,however the chart below provides a quick guide to the operating range of the main turbine types. It can be seenthat there is a substantial overlap of the duties covered by the different turbine types.

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TURBINE SELECTION

The water turbine is the key to any hydro project and requirescorrect interfacing with the electrical, mechanical, hydraulicand civil aspects of the project.

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H E A D ( m )

FLOW (M 3/S)

PELTON

TURGO

FRANCIS

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2 0 M W

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5 M W

2 M W

1 M W 5 0 0 k W 2 0 0 k W

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Pelton turbines are medium to high head free jetimpulse turbines. The jet(s) strike the splitter edgeof the double bucket and is turned through an angleof nearly 180% before falling under gravity into thedischarge channel or tailrace.

Gilkes Pelton turbines are supplied as horizontal singleand twin jet units or vertical 3, 4 or 6 jet units.

EFFICIENCY

Twin or multi-jet units are specied to increase theow range over which high turbine efciencies can beobtained. The efciency curves given here illustratethis point.

DESIGN FOR PURPOSE:

It is possible to use one size of Pelton bucket on arange of different mean diameters. By this meansthe turbine can be designed to operate at maximumpossible efciency for any given set of site conditions.

ADVANTAGES OF THE GILKES PELTON TURBINE:

4 It can operate on silt-laden water with the minimum of wear. When wear does occur the spear tip,

nozzle and deector plate can be easily repairedand after longer periods, welding can repair therunner. All working parts are easily accessiblethrough a detachable top cover.

4 Speed-load control is usually carried out by thedeector, which ensures no pipeline surge even onfull load rejection. When water economy isimportant, the deector speed control can be

augmented by follow-up closure of the spear.4 There is no danger of cavitation damage to the

runner or casing.

PELTON CONSTRUCTION:

CASING

The turbine casing is manufactured in two parts andmade of fabricated steel. The lower part is specically

designed to allow free discharge of water from therunner and include arrangements for secure groutinginto concrete foundations. The upper part is easilyremoved for access to the runner and maintenance ofthe unit.

RUNNERThe Pelton runner is machined from solid to improvereliability and efciency. Materials vary depending onoperating conditions but are usually chrome nickelstainless steel. In certain circumstances depending onthe head and water quality aluminum bronze runnerscan be supplied. The runner can be mounted on itsown turbine shaft or overhung on the generator shaft.

SHAFTThe turbine shaft of carbon steel is either machinedfrom bar or forged. On larger units the designincorporates a forged half coupling.

BEARINGSOn high power turbines, tilting pad, oil lubricated,thrust or journal type bearings are used, while greaselubricated ball or roller bearings are used for lowerpower turbines. Where required, lubricating oil andcooling water systems are included.

SPEAR VALVE (NEEDLE VALVE) / BRANCH PIPEIs manufactured from fabricated steel in a variety ofpressure ratings up to PN 100.

SPEAR TIP AND NOZZLEAre manufactured from stainless steel, both items areeasily renewable.

SPEAR RODIs manufactured from stainless steel and is supportedby a bronze guide which also corrects the ow as itapproaches the nozzle, ensuring a clean efcient jet.Operation can be electrical, manual or hydraulic.

JET DEFLECTORThe deector plate is of stainless steel and can beeasily replaced if worn.

PELTON TURBINES

HEAD RANGE UP TO: 1000mPOWER OUTPUT UP TO: 20MW

The Pelton Wheel maintains a high efciency over a wide ow range. Whenever possible twoor more jets are specied. This increases the high efciency ow range. Every Gilkes turbine isdesigned to optimise your site conditions providing the best annual energy production gures.

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PERCENT OF FULL FLOW

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SINGLE JET TURBINE


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EVERY GILKES TURBINEIS DESIGNED ANDOPTIMISED TO PROVIDETHE BEST ANNUALENERGY PRODUCTIONFIGURES


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FRANCIS TURBINESARE DEVELOPED FROMLABORATORY-TESTEDMODELS AND RETURNEFFICIENCIES OF UP TO94% AT THE TURBINESHAFT


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Gilkes Francis turbines are available as either horizontalor vertical units. The water enters the spiral, or scrollcase, and is directed by a series of moveable guidevanes, or wicket gates, to the turbine runner. As thewater passes through the runner it rotates and the waterpressure drops. Water is then discharged through a draft

tube into the tailrace. Flow control is affected by openingor closing the guide vanes, which is carried out by anactuator, which, is itself controlled by either a speedgovernor, for stand-alone duty, or, PLC control for paralleloperation with the distribution grid.

EFFICIENCY

Gilkes Francis turbines are developed from laboratory-tested models and return efciencies of up to 94% atthe turbine shaft. Gilkes use modern Computational FluidDynamics (CFD) analysis techniques to continually improverunner design.

DESIGN FOR PURPOSE

Gilkes Francis model range includes eight differentspecic speed designs. The Hydro team at Gilkes canadvise on the best solution for your project.

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FRANCIS TURBINES


1. Gilkes hydro installation in Sri Lanka2. CFD analysis of Francis runner3. A recent project leaving ready for installation by our team

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As a Gilkes patented design, the rst ever Turgo turbinewas installed in Scotland in 1919. Since then, turbinesof Gilkes originated design have been operating inover 80 countries worldwide and many of the originalunits are still in operation.

Gilkes are now replacing, completely or in part, copiesof our Turgo Impulse turbines with the original Gilkesdesigned machine and providing the owners andoperators with improved output.

The Turgo range of machines covers the boundarybetween Pelton and Francis machines and they havebeen proven to deal extremely well with dirty waterwithout any detriment to performance.

The Gilkes Turgo Impulse turbine has the followingmajor advantages relative to other Impulse and Reactionturbines over a wide range of head conditions:

4 Being of the Impulse pattern, no ne clearances areinvolved which means that the turbine can operateon silt laden water over long periods with theminimum of wear. When wear does occur, thespeartip and nozzle can be easily repaired, andafter longer periods welding can repair the runner.Turgo Impulse turbines are very popular at miningpower plants. They are able to provide a long lifewhen operating on mining tailings. The overallefciency is unaffected by normal wear.

4 All working parts, including the deector are easily accessible through the detachable top cover or

through the tailrace pit.

4 The jet deector usually carries out speed load control. This method of speed control ensures that

there is no penstock surge even on full loadrejection. Where water economy is of paramountimportance, the deector speed control can beaugmented by follow up closure of the spear, therate of closure being designed to be compatiblewith the penstock design rating. This gives theTurgo Impulse an advantage over medium to highhead Francis turbine installations that require higherpressure rated penstocks, surge facilities orrelief valves.

4 There is no danger of cavitation damage to therunner or the casing.

4 The performance curve is at giving high efciencyover wide ow and load variations. Despite thelower peak efciency, the Turgo Impulse whencompared to a Francis turbine may result in a higherannual energy production. This is particularly

important where the turbines are used on run ofriver sites subject to seasonal ow changes or inconjunction with water supply or irrigation schemes.

4 The large jet diameter relative to runner meaneffective diameter provides a compact machinecapable of passing large quantities of water. This isparticularly useful when the turbine is being used asa ow-regulating device in a water supply orirrigation scheme.

4 The high specic speed characteristic generallymeans that a more compact and cheaper generatorcan be used when compared with multi jet Peltons.

4 These features all indicate that the Gilkes TurgoImpulse turbine must be seriously considered whenone is looking for a medium to high head machine ofproven efciency, reliability and simple maintenance.

EFFICIENCY

Single or multi-jet units are specied to increase theow range over which high turbine efciencies can beobtained. The efciency curves given here illustratethis point.

TURGO TURBINES


Gilkes Turgo Impulse turbine design was developed to provide a simple Impulse type machinewith a higher specic speed than a Pelton. The design allows a larger jet of water to be directedat an angle onto the runner.

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TURBINES OF GILKESORIGINATED DESIGNHAVE BEEN OPERATINGIN OVER 80 COUNTRIESWORLDWIDE ANDMANY OF THE ORIGINALUNITS ARE STILL INOPERATION


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GILKES CAN MEET ALL YOUR MECHANICALAND ELECTRICALAFTER SALES NEEDS,WHETHER ITS ANINDEPENDENT 10kWTURBINE OR A 10MW

GRID CONNECTEDPLANT



SERVICE AND REFURBISHMENT

As long as we have been manufacturing hydro turbines and associated control systems, wehave also been delivering an after sales service throughout the world to meet our customersrequirements. Whether it is a privately owned standalone 10kW turbine or a 10MW gridconnected plant exporting power, Gilkes can meet all your mechanical and electrical aftersales needs. Gilkes also has a dedicated Service and Refurbishment team based at a facilityin Fort William, Scotland.

SERVICES:

4 Tailored long-term electro mechanical service contracts

4 Site surveys & condition assessment

4 Breakdown service

4 Control system upgrades & reprogramming which includes:

Conversion to digital load governing

Hydraulic & electric actuated upgrades

PLC control philosophy programming

SCADA systems for remote monitoring

4 Full hydroelectric plant refurbishment & optimisation

4 Replacement turbine components

4 Installation & commissioning

BENEFITS:

4 World-class engineering & design

4 Plant efciency improvements

4 Project management

4 Responsive to customer standards / preferences

4 BS EN ISO 9001:2001


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Gilbert Gilkes & Gordon Ltd,Canal Head North,Kendal, Cumbria, LA9 7BZ

Telephone: +44 (0) 1539 720028Fax: +44 (0) 1539 732110Email: [email protected]. gilkes.com

turbine turgo

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