Future Production AS (FP) has recently delivered an innovative, bespoke handling and maintenance unit for the hydropower industry – the FP PeltoLift.
Since 1999, FP has designed and delivered a wide range of tailor-made handling systems to the international energy market, with a consistent focus on safety and efficiency. With extensive experience from the offshore energy sector, FP is recognized as a high-quality supplier by international blue-chip clients.
The FP PeltoLift is based on proven design principles and operational experience from previously delivered handling systems to offshore oil and gas installations, adapted to meet the specific requirements of hydropower facilities.
For this project, a Norwegian renewable power producer required a modular machine capable of safely handling one of the most critical components of a Pelton turbine system: the injector units. These units are heavy yet delicate, weighing between 5 and 11 metric tons, and are located inside a confined turbine chamber within the hydropower station.
Client experience and operational requirements
Traditionally, servicing and repairing Pelton turbine injectors involves securing the area with temporary flooring, building scaffolding for access, and using chain tuggers to dismantle and assemble the injector units. Due to tight handling tolerances, significant weight, and the fact that components are suspended above the working area, this method represents a high-risk operation, both in terms of personnel safety and potential damage to sensitive equipment.
The FP PeltoLift was developed in close cooperation with the client’s operators and maintenance personnel. The system is designed to handle and secure Pelton turbine injectors hands-free, allowing personnel to operate at a safe distance using wireless control.
The unit is designed to run on the existing rails inside the turbine chamber and is assembled within the confined space by sequentially mounting three modular sections. This modular approach enables efficient installation without the need for extensive structural modifications.
The photos below are taken during Factory Acceptance Testing (FAT) with the client, including overload testing of the system.
Operational Benefits of the FP PeltoLift
- Significant improvement to working environment safety
- Designed and delivered with relevant CE marking for European installations
- Working platforms can be easily established and assembled in sections as required
- Contributes to reduced Non-Productive Time (NPT) during maintenance operations
- Field-proven design with modular configuration to suit both smaller and larger hydropower stations
- Multiple alignment functions allow precise positioning during removal and reinstallation of injector units
- Quick installation and removal, utilizing existing chamber rails and enabling relocation between stations
- Tailored, robust design suited for hydropower environmental conditions
- Compact solution with extended reach (360°) and high lifting capacity
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Versatile and Compact – Customizable for Safety and Efficiency
The FP PeltoLift presented has a lifting capacity of up to 11 metric tons at full extension, with 360-degree operational reach. The system’s design, dimensions, and capacity can be customized to suit other hydropower stations with Pelton turbine installations, ensuring an optimal fit for varying site-specific requirements.
The image below shows the system in operation inside the turbine chamber.
Summary
The FP PeltoLift is a bespoke handling and maintenance solution designed to significantly improve safety for both personnel and equipment, while reducing Non-Productive Time (NPT) during planned or unplanned maintenance activities.
With an inherent focus on robustness, operational simplicity, and hands-free operation, FP products are synonymous with reliable and efficient performance. The FP PeltoLift system represents a highly attractive safety- and efficiency-enhancing investment for hydropower stations operating Pelton turbine systems.
Learn more about Future Production’s approach to tailor-made handling solutions.