HYDRAULIC OPTIMIZATION DATE: MAY 2025

+3.1% Efficiency Gain:
Post-Modernization

The Mission: A low-head Kaplan fleet struggled with efficiency loss post-refurbishment. Our objective: Identify hidden mechanical play and optimize the cam curve for maximum output.

MISSION STATUS:
MAXIMIZED
Peak Efficiency
91.3%

New Benchmark

Total Gain
+3.1%

Output Increase

ROI Period
14 MO

Payback Time

01 The Threat Vector

The client undertook a modernization of their 40-year-old Kaplan fleet, but conventional alignment and refurbishment methods failed to restore original hydraulic efficiency targets. Efficiency plateaued at 88%, well below the 91% design goal.

> RISK DETECTED: HYDRAULIC HUB WEAR
> CONSEQUENCE: DYNAMIC FLOW SEPARATION

02 Tactical Execution

We deployed the AnoHUB Optimization Protocol to restore precision:

  • Digital Twin CFD Ran high-fidelity CFD simulations to identify optimal blade angles and guide vane settings for current hydrological conditions, correcting outdated assumptions.
  • Hub Precision Check Used NDT to measure wear in control rods, leading to a micrometre-precision re-machining plan to eliminate mechanical play causing blade flutter.
  • LCC Procurement Audit Advised on upgrading to self-lubricating bushings to minimize future maintenance cycles and eliminate oil pollution risk, securing long-term savings.
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