Multipliers, Not Just Gearboxes. Riduttori Italia For Kaplan-type Turbines.

At Riduttori Italia, historically positioned in the gearbox sector, we have taken on a new production challenge: designing and manufacturing multipliers for Kaplan-type turbines intended for hydroelectric plants.

We tackled the task with an innovative design and production approach: the solutions implemented and the results obtained demonstrate the adaptability and capacity for innovation that our company expresses in fields other than those for which it is known and appreciated in Italy and worldwide.

A Kaplan mechanical turbine gearbox must possess several fundamental qualities to guarantee efficient and reliable operation.

We have designed this series of gearboxes to specifications indicated by the customer, applying high standards that distinguish us in the production and revamping of gearboxes.

Robustness: As the gearbox operates under varying load conditions and mechanical stress, it must be constructed of durable materials that can withstand stress and abrasion. In particular, gears and bearings must guarantee a very long service life of the gearbox, for more than 100,000 hours of continuous operation.

Robustness also contributes to the longevity of the device.

Efficiency: Maximum efficiency is crucial to optimise the transmission of power from the turbine to the generator. A good multiplier must minimise mechanical losses, ensuring that a high percentage of the kinetic energy produced by the turbine is converted into electrical energy.

The lubrication of the internal mechanical moving parts - gears, bearings, shafts - is ensured by an external control unit prepared for the application of a heat exchanger if necessary.

Reliability: In hydroelectric plants, reliability is essential to ensure continuous operation and minimise downtime. High-quality components and proper design are essential to prevent failures. The case has been coated with water-resistant primers and paints, enamels that provide special protection against the action of continuous water flow on the external metal surfaces of the multiplier.

The hollow through-shaft is designed to house the Kaplan Turbine blade adjustment rod: an optimal solution that ensures constant turbine rotation even with variable flow rates.

Compactness: The size of the gearbox is also relevant for integration into the turbine system. A compact design can help optimise the use of available space while maintaining high performance.

Maintenance: Ease of maintenance is another important quality. A design that allows easy access to internal components facilitates inspection and repair work, reducing costs and downtime.

In these speed increasers we have combined efficiency, robustness, reliability, adjustability, ease of maintenance and compactness to ensure optimum performance and durability.

This is a new field of application in which experience, design capability and construction quality have combined to produce high quality and reliable products.