As the global demand for renewable energy rises, the importance of maintaining and modernizing existing hydropower infrastructure becomes more apparent than ever. In Switzerland, a hydro power plant of the Kraftwerke Linth-Limmern AG in the canton of Glarus faced the task of carrying out a comprehensive revision of Pelton turbines that had been in operation since the 1960s. Although the units had undergone a major revision more than 20 years ago, it was time for another comprehensive modernization to ensure long-term operational reliability.
The plant operators entrusted Global Hydro with this task - and the revitalization of Machine Group 2 of the hydropower plant became a clear demonstration of what sets us apart: technical precision, flexibility, and a commitment to partnership built on trust. With these values, the team of experts successfully prepared the 60-year-old powerhouse for decades to come.
| Location: | Canton of Glarus, Switzerland |
| Turbines: | 2x horizontal Pelton Turbines, 23 MW |
| Net head: | 480.9 m |
| Flow per unit: | 5.5 m³/s |
| Timeline: | Machine Group 2: 2024-2025, Machine Group 1: 2025-2026 |
| Initial issue: | Total failure of nozzle #2: Unit operated in single-nozzle mode only. |
The hydropower facility houses two horizontal-axis, double-nozzle Pelton turbines, each with a capacity of 23 MW. Over time, both units began to show significant signs of wear - especially Machine Group 2 (MG2), which had been last overhauled 25 years ago and experienced substantial wear due to sand abrasion.
In recent years, one of MG2’s nozzles began failing to close reliably. By 2023, even opening the nozzle became problematic, forcing the turbine to run in single-nozzle mode. As the root cause of the malfunction remained unclear, a full-scale revitalization of the inlet, nozzle systems, and servomechanisms was initiated to restore full functionality and ensure long-term reliability.
At Global Hydro, we understand that every hydropower plant is unique. That's why we offer customized solutions tailored to each plant’s operational reality and long-term goals. For this Swiss project, our approach followed our proven revitalization process - from on-site disassembly to the final commissioning, backed by expert diagnostics, state-of-the-art technology, and transparent communication.
Following the completion of the revitalization work, Machine Group 2 entered trial operation and concluded testing in June 2025 - flawlessly and without any operational issues. Machine Group 1 is scheduled for an overhaul during the winter of 2025 and 2026.
Global Hydro was selected for this revitalization project due to a combination of key competencies. From the outset, the tender was submitted in a clear and meticulously prepared format, demonstrating both technical depth and dedication. The team responded to all inquiries promptly and professionally, reinforcing trust throughout the decision-making process. With the state-of-the-art innovation and manufacturing center in Austria and dedicated experts, we ensured quality and consistency every step of the way. Open communication and a collaborative project management approach contributed to the efficient execution of the work. Backed by revitalization references, Global Hydro delivered both confidence and capability. Even when unexpected challenges - such as undocumented design modifications - arose, our team reacted with agility and transparency, ensuring smooth project progress and customer confidence.
“We greatly appreciated the solution-oriented, partnership-based, and open collaboration with Global Hydro during the implementation of a project that was both technically and time-wise demanding, and we look forward to an equally successful completion of the second machine group.”
Global Hydro recognizes the urgent need to modernize the world’s aging hydropower infrastructure. Most plants still in operation today were built in the 20th century – and while many components were designed to last, others are now outdated or inefficient.
To address this, we have built a dedicated revitalization and service team with streamlined processes that ensure fast, efficient project execution. Our goal is twofold: to enable sustainable, modern hydropower solutions and to safeguard our customers’ investments. This dual commitment reflects our focus on both environmental responsibility and financial value protection.
As a trusted partner in hydropower modernization, Global Hydro combines cutting-edge technology, deep industry experience, and an unwavering commitment to quality. We understand that every component has its own lifecycle – from static turbine elements to fast-evolving control systems.
This Swiss project exemplifies how revitalization can extend the life of hydropower plants and ensure a secure energy supply and long-term sustainability.
A malfunctioning nozzle could no longer open or close reliably, forcing the turbine to run in single-nozzle mode. With the root cause unclear and efficiency declining, the operator faced growing performance losses and operational risk. A full revitalization was essential to restore functionality, secure output, and extend the unit’s lifetime.
Global Hydro implemented a tailored revitalization package that included the complete overhaul of inlet and nozzle systems, as well as the refurbishment of servomotors, sealings, and protective coatings. Thanks to in-house expertise, precise diagnostics, and transparent communication, the project was carried out with technical accuracy and reliability – even in the face of unforeseen challenges.
The revitalization restored full functionality of both nozzles, allowing the turbine to run again in dual-nozzle mode. This significantly improved energy output, operational efficiency, and stability. With refurbished components and modern sealing and coating systems, the plant is now set for long-term reliable performance and reduced maintenance requirements.
Whether you're facing aging components, reduced efficiency, or the need to modernize your systems - Global Hydro is your expert partner for tailored revitalization solutions. With decades of experience, in-house manufacturing, and a commitment to sustainable performance, we support you from first inspection to final commissioning, all around the world.
Let’s bring new energy to your existing infrastructure!
Roland Fleischmann
Senior Sales Manager Revitalization
+43 (7285) 514 0055
roland.fleischmann@global-hydro.eu Contact
