Tu r b i n e s Wo r l d w i d e
Office building of the WKV AG
Headquarters in Gutach
Why WKV of all companies? After all, there are bigger companies
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Diesel and Gas pays back much quicker! But as it is well-known, who laughs last laughs best ‌
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Competence is not all-important. Quality also germinates from passion for data
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Hydro power plants are unique. We design according to your need
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If all good things come from (far) above. WKV Pelton turbines
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The all-in-one solution. WKV Francis turbines
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Effectiveness over a wide range. WKV Turgo turbines
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The economic solution. WKV Crossflow turbines
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Energy converter on highest level. WKV alternators
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Set out and manage. Switchgears and process controls
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A reliable arrangement. WKV control systems
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Not everything has to be brand-new. Restoration, renovation and modernizing existing power plants 26 A partnership for life-time. Commissioning, maintenance and service by the manufacturer 28 Your advantage. The best from tradition and modern age 2
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We are only caretakers of the world and its resources that we pass on to our children. (WKV's company slogan)
In-house hydro power plant in Gutach
A sustainable energy policy, based on renewable resources, will be crucial to their future. Hydropower is one of the front-runners among such renewable energies. Wasserkraft Volk AG is one of the leading manufacturers of small and medium-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.
Green roof and solar panels located on the office buildings
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 m2 shop floor. As a medium size enterprise, our main focus is only Germany as the location 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 committed work force receiving consistent advance training, education and updating in their respective fields in order to render a reliable and persistent service to our customers.
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Why WKV of all companies? After all, there are bigger companies 4
Choose water for your eco-friendly energy source – Choose Wasserkraft Volk AG!
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!
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.
At WKV, you get your complete power plant, including turbines, controls, alternators and switchboards, perfectly adapted to each other, from one single source.
Our factory is structured to design and build the complete range of turbines, generators, switchboards and also electronic controls and accessories. All manufacturing facilities are located in our plants in Gutach and Simonswald in Germany literally brining us to the same vicinity thus granting you high flexibility, quick service and highest quality.
And that is from A – Z ”Made in Germany”!
Last but not least: Where else will you receive such willing, eager and enthusiastic personal attention from the founder of the organization himself? 5
Diesel and Gas pays back much quicker! But as it is well-known, who laughs last laughs best ... 6
... and tomorrow’s generations will be delighted if we take care of our
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.
environment today!
No friction means no wear and tear – leading to low maintenance needs. Energy price hikes do not bother us. Profitability and environmental compatibility don’t 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 for manufacturing and also feeds the centrifuges on the heating system. Electric Surplus energy is fed into the local mains.
Only about 22 % of the technically useable hydro power potential on earth is currently utilized. Reap the benefit from our knowledge and experience to improve on this situation! 7
Competence is not all-important. Quality also germinates from passion for data 8
Knowledge + Experience = Expertise
can be acquired is attained by practice
is generated by consequent integration of theoretical knowledge into experience
Expertise so far is an attribute which can be assumed for a company successfully 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.e the passion for detail that has lived at WKV, leading to a quality assurance starting in the early planning stage up to the commissioning stage.
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.
D o n ’t s e t t l e f o r t h e n e x t b e s t !
Over a period of 30 years, WKV AG has again and again proved beyond doubt that industrial production and passion are thoroughly complementing. Hundreds of satisfied customers from all over the world will bear testimony to this.
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Hydro power plants are unique. We design according to your need 10
Natural conditions of water courses is significantly different. Therefore, every order demands an exclusive solution. WKV uses four different turbine 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-invested into research and development. This makes us the forerunner in the global minihydro industry. We keep our technological lead only by continuous development.
Do not buy your turbine plant at a discounter – trust in the specialist!
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If all good things come from (far) above. WKV Pelton turbines 12
Characteristics of WKV Pelton turbines:
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 arrangements Jet deflectors for outstanding dynamic performance 2 or 4 bearing gen-set arrangements
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
Well suited to sites with significant fluctuations in the water flow
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The all-in-one solution. WKV Francis turbines 14
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 flow Compact 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 15
Effectiveness over a wide range. WKV Turgo turbines 16
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
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- or chrome steel casting – not indestructible, but not far from it! Maintenance-free shaft sealing system
Geometry of stream and runner are optimized for efficiency in WKV’s own laboratory
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The economic solution. WKV Crossflow turbines 18
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 WKV’s 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 19
Energy converter on highest level. WKV alternators 20
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 operation site 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 22
Switchboards ”Made in Simonswald“ WKV designs and manufactures the complete set of switchboards and controls in-house, and thus provides a single-point overall responsibility. Each unit is individually adapted to the client’s 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
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
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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!
A reliable arrangement. WKV control systems 24
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 extreme ambient 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 25
Not everything has to be brand-new. Restoration, renovation and modernizing of existing power plants 26
If maintenance or modernization – WKV AG makes your power plant fit for the coming decades!
Usually hydro power plants are operated for many decades until the ravages 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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A partnership for life-time. Commissioning, maintenance and service by the manufacturer 28
Our promise to you: ”Impossible“ isn’t a part of our vocabulary!
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.
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Your advantage. The very best from tradition and modern age 30
To work at a place where others are doing vacation – also this is a motivation for our colleagues!
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 manufacturing 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 capacity makes us largely independent from sub-suppliers which allows us to react flexibly and to realize short project and lead times.
Wasserkraft Volk AG – the partner you can rely on 31
You will find our power plants in more than 40 countries all over the globe.
Edition 12/2010-EN. Pictures: Krieg Fotodesign/Archiv
Wasserkraft Volk AG Am Stollen 13 D-79261 Gutach Tel.: + 49 (0) 7685 9106 - 0 Fax: + 49 (0) 7685 9106 -10 E-Mail: sales@wkv-ag.com Internet: www.wkv-ag.com