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Actuation Test Equipment Co.
3393 Eddie Road
Winnebago, Illinois 61088  
Doug Albright
DudleyDevices@Aol.com
(815) 335-1143  
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 About ATECo   PT-Interface  ITB Test History   Glossary  Fish  Lee Sheldon
Constant Head and Blade Constant Head and Gate Constant Head and Power JRRT CEM Salmon_Story

The most cost-effective way to add power to the electrical grid is to tune-up and optimize the hydroelectric resources already in place and on-line.
Index Testing and Optimization of Kaplan Turbines is a very green technology.
Electric Car Trouble is headed our way, and we must do something now to prepare for and head-off another crisis.  Analysis of Energy Information Administration (EIA) data forecasts increase demand from burgeoning populations and governments pushing electric cars while environmental and public-safety concerns strive to curtail supplies of electrical power. Both are heading us toward shortages of electricity, which by the laws of supply and demand will make electricity prices "necessarily skyrocket."  
The new Index Test Box will help maximize operating efficiency of Kaplan turbines while reducing their environmental impact.
Click here: Why Electricity is Getting More Expensive
The best return on investment in any power generation activity is by improvement of equipment that is already in-place generating power. This is especially true for Kaplan turbines.

Index testing and optimization of Kaplan turbine 3-D cam data surface profiles corrects the efficiency-robbing blade to head and gate misalignment that increases turbidity and shear forces in the water flowing through the turbines.

Turbulence promotes vibration and noise, increases wear-and-tear on load bearing surfaces and exacerbates  mortality rates of downstream migrant aquatic life. Of greatest concern are anadromous fish and eels.

Benefits of optimizing Kaplan turbine 3-D cam surfaces include:
  • Increased generated power and revenue
  • Reduced turbidity, noise and runner surface erosion
  • minimized vibration and wear and tear on load bearing surfaces
  • Lessens the hazard presented to downstream migrant aquatic life 
Steady State Scan
Acquiring suitable data is the most tedious, time consuming and expensive part of index testing and optimizing Kaplan turbines.
In order to be usable for cam surface optimization, this data must be steady-state. The noisy environment of hydroelectric turbines makes this difficult and tedious.
The labor and cost of acquiring this essential data is no longer a deterrent to proper turbine optimization.
The SteadyState algorithm in ATECo Index Test Box gleans steady-state data points from the continuous streaming data.
A modern hydroelectric power plant already has all the instrumentation and recording equipment needed to index test and optimize a Kaplan turbine.  What is lacking is a means to extract the steady-state data from the noise.

ITB SteadyState Analysis Introduction This video explains the Index Test Box form, fit and function. 
Offering_of_Index_Test_Box_and_Joint_Load_Optimizer.htm
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Click on page for larger view and audio narration. Click on PDF Download of Flyer link to get printable copy.
Flyer page 1 Flyer Page 2
                       Click Here: ITB Flyer Page 1                                                            Click Here: ITB Flyer Page 2                                            
PDF Download of Flyer
Simerics Kaplan Image Blade Motion
 ITB Test History

Peru Gains Spreadsheet
This is a spreadsheet that shows cost/benefits of turbine optimization with 4-ea 1.8MW Kaplan bulb turbines.

Clergue Gains Spreadsheet
This is a spreadsheet that shows cost/benefits of turbine optimization with 3-ea 18MW Kaplan bulb turbines.

Spreadsheet to Predict Gains
This is a generic spreadsheet.
Turbine Survival Articles

New Limits Method U1_ConstBld

ITB Input Data Specimen

ITB Setup Procedures

ITB U1 ConstBlade Output File
ITB U2 ConstBlade Output File
ITB U3 ConstBlade Output File

ITB U1 ConstBlade Analysis File
ITB U2 ConstBlade Analysis File
ITB U3 ConstBlade Analysis File


ITB U1 ConstGate Output File
ITB U2 ConstGate Output File
ITB U3 ConstGate Output File

ITB U1 ConstGate Analysis File
ITB U2 ConstGate Analysis File
ITB U3 ConstGate Analysis File

ITB U1 ConstPower Output File
ITB U2 ConstPower Output File
ITB U3 ConstPower Output File

ITB U1 ConstPower Analysis File
ITB U2 ConstPower Analysis File
ITB U3 ConstPower Analysis File

Excel Spreadsheet to Predict Clergue Gains

Pressure Transducer

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