Pelton Turbines

DynaVec AS offers innovative solutions for Pelton turbines exposed to water with high sediment content. All areas with high water speeds will be fully protected with hard-coating (HVOF - Wolfram Carbide). This includes the nozzles, needles, and the patented runner described below.

Introduction

The DynaVec Pelton runner consists of a separate disk and the optimal number of replaceable buckets connected to the disk, each by only one bolt. This allows for easier access to fully apply hard coating (HVOF) on the wetted surfaces and the possibility of easily exchanging the buckets as spare parts.

Pelton Runner with Exchangeable Buckets

Pelton Monsoon® Runner

The ability to replace and hard-coat individual buckets provides a tailored approach to turbine upkeep, allowing plant operators to maximize their efficiency while minimizing operational interruptions. With DynaVec’s design, maintaining the performance and integrity of the runner becomes a straightforward process, supporting the long-term success of hydropower projects.

Pelton Monsoon Runner

Flow Analysis

The bucket design is performed by an in-house program for the layout of the bucket, both inside and outside. After the layout, the performance is evaluated by a two-phase transient CFD calculation. The design elements, such as angles at the inflow, outflow, depth, and width of the bucket, are adjusted to achieve the best performance over the entire operation range.

Finite Element Analysis

The runner will be analyzed using modern Finite Element Analysis (FEA) to ensure safe operation. The worst conditions at maximum torque and early/late interaction of the water jet on the bucket and support are analyzed to keep dynamic stresses below the design criteria. Additionally, the centrifugal forces at both nominal and runaway speeds are evaluated.

Assembly and Disassembly

The bolted Pelton runner from DynaVec can easily be assembled and disassembled using standard hand tools. This can be performed on-site if a lifting arrangement is present. A customized assembly procedure will follow each delivery.

Coating

As the buckets can be removed, all wetted surfaces can easily be HVOF coated. The thermal spray coating (HVOF - High Velocity OXY-Fuel) is applied with robots. Typical coating thickness will be between 0.2 – 0.3 mm.

Maintenance

There are two types of maintenance for the bolted Pelton runner. The most efficient is preventive maintenance, where sandblasting and recoating are performed before the coating surface is broken. Alternatively, the geometry can be reshaped if damaged before coating, as typically planned in a maintenance schedule. Since the bolted runner can easily be disassembled, this simplifies maintenance and repair compared to a welded runner.

Pelton Turbine Assembly

Value Proposition