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kbonymarkOEM TECHNICAL RECOMMENDATION – HYDRAULIC SYSTEM, VALVES & PIPING
Client: Kenya Electricity Generating Company PLC (KenGen)
Location: Kiambere Hydropower Station, Embu, Kenya
Purpose: Supply, installation, and commissioning of refurbished hydraulic system with penstock valves,
piping network, and associated HPU systems.
prepared by;Pavicon limited
1. DESIGN BASIS
Parameter Value
Main Penstock Valve Size 4,000 mm (DN4000)
Maximum Water Flow Rate 60 m³/s
HPU Pump Delivery Head 35.84 meters
Actuator Force Requirement 60 kN
Accumulator System Pressure 200 bar
Valve Opening Time 250 seconds
Valve Closing Time 200 seconds
2. MAIN PENSTOCK VALVE (DN4000)
Recommended OEMs:
ANDRITZ Hydro – Engineered Spherical Valve
KSB – Mila DN4000 High-Pressure Butterfly Valve
Velan – Custom hydropower-grade shutoff valves
Technical Features:
Design: Spherical or butterfly configuration with axial flow alignment
Body: Welded carbon steel with internal epoxy coating (minimum 3-layer)
Seat: Replaceable stainless steel rings with elastomeric sealing
Nominal Diameter: DN4000
Pressure Rating: PN200 (test up to 1.5 × 200 bar)
Flow Capacity: ≥ 60 m³/s
Operation Mode: Hydraulic actuator with position control and feedback
Open/Close Timing: Smooth, damped motion to avoid water hammer (250s open / 200s close)
Testing:
Seat leak test, shell test at 1.5× pressure, and functional stroke test with simulated load.
3. HYDRAULIC ACTUATOR SYSTEM
Recommended OEMs:
Bosch Rexroth – HIC (Hydraulic Integrated Cylinder)
Moog – Servo-controlled actuator systems
Parker Hannifin – ISO-compliant custom hydraulic cylinders
Specifications:
Stroke Length: Matched to 1.6 m valve travel
Rated Force: 60 kN minimum
Pressure: 200 bar operating
Construction: Welded steel tube, chrome-plated rod, polyurethane or Viton seals
Mounting: Trunnion or clevis depending on site envelope
Feedback: LVDT integrated for precise position tracking
Damping System:
Integrated end-of-stroke cushioning
Speed control valves to modulate open/close times as per specification
4. HYDRAULIC POWER UNIT (HPU)
Recommended OEMs:
Bosch Rexroth – Standard HPU Skids
Parker Hannifin – Modular electro-hydraulic systems
Eaton – Hydrokraft HPU packages for hydro applications
Design Parameters:
Working Pressure: 200 bar
Pump Head: 35.84 meters
Delivery Rate: Sized to ensure 250s open / 200s close timings
Tank Size: 600–1000 L with baffle and level sensors
Pump Type: Variable displacement axial piston pump (e.g., Rexroth A10VO series)
Motor Power: 15 kW, IP55-rated, 400V/50Hz
Accumulator Charging Circuit: Gas-charged bladder or piston accumulator with automatic check and
dump valves
Controls & Safety:
PLC-based HPU control panel
Manual override
Redundant pressure relief valves (set at 210 bar)
Emergency shutoff solenoids
Filtration:
Return line filter: 10 micron absolute
Inline pressure filter: 3 micron
Offline filtration circuit optional (kidney loop system)
5. ACCUMULATOR SYSTEM
OEMs:
HYDAC, Parker Olaer, Bosch Rexroth
System Design:
Type: Bladder or piston accumulators
Rated Pressure: 200 bar
Pre-charge Pressure: ~80% of system pressure (i.e., 160 bar)
Discharge Volume: Sized to allow full stroke of actuator without active pumping
Mounting: Frame-mounted, with isolating valves and pressure gauges
Purpose:
Fail-safe actuation in case of power loss
Damped valve closing to prevent surge
6. HYDRAULIC PIPING SYSTEM
Recommended OEMs:
Parker Hannifin, Eaton Walterscheid, Manuli, Stauff
Specifications:
Material: Seamless carbon steel (ASTM A106 Gr. B or DIN 2391)
Pressure Rating: 250 bar min (for safety margin)
Pipe Sizes: ¾” to 2” depending on circuit (pressure, return, drain)
Hoses: High-pressure ISO 1436-compliant, braided or spiral hose for flexibility
Fittings: 24° flare, JIC, or SAE flanges (6000 psi rated)
Piping supported every 1.5 meters
Flexible joints with vibration dampers near HPU and actuator ports
Expansion joints where thermal movement is expected
7. SCADA & MONITORING INTERFACE
Remote monitoring of valve position, oil temperature, pressure, and motor status
Alarms for low oil level, high temperature, pressure drop, and filter clogging
Interface: Modbus RTU, Profibus, or Ethernet/IP compatible
8. DOCUMENTATION & COMMISSIONING DELIVERABLES
Complete set of drawings: GA, P&ID, Isometrics, Wiring Diagrams
As-built installation records
FAT & SAT reports (Factory/ Site Acceptance Tests)
O&M manuals
Warranty certificates (minimum 2 years)
Authorised by;
Eng Benedict langat
Technician Pavicon limited
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