Large-scale capability
Components greater than 10 tons and 3 m diameter.
Shaping the future of turbine runner manufacturing: Global Hydro leads the way in high-performance runner production – with unmatched precision, durability, and time savings for our clients.
In today’s energy landscape, hydropower is more vital than ever. As the world transitions toward sustainable energy systems, hydroelectric plants provide stable, renewable baseload power. But as these facilities age, so do their components. The need for high-quality, efficient replacement runners is growing - and with it, the demand for advanced, reliable manufacturing technologies. We have redefined how runners are made. By combining welding automation, deep hydropower know-how, and forward-thinking R&D. Global Hydro delivers runners that meet today’s performance expectations - and tomorrow’s sustainability goals.
Welding technology at Global Hydro is not just an upgrade – it’s a complete transformation of how runners are built. Our robotic welding system was developed in-house, tailored for turbine components especially runners, and guided by decades of experience in hydropower. This robotic system handles even the largest runner sizes – greater than 10 tons in weight and 3 m in diameter. Every part of the production process takes place at our headquarters: hydraulic profile development, engineering, milling, welding, polishing, balancing, testing, and the FAT. That means full control over quality, from start to finish. This is especially important for replacement runners, where precision and delivery time matter most — particularly in unplanned situations like turbine failure, where every day of downtime counts. Thanks to our fully automated process, we reduce production time and guarantee consistent results – helping operators keep their plants running with minimal downtime.
At Global Hydro, innovation doesn’t stop with automation. What truly sets us apart is our unique welding design, developed specifically to meet the demands of modern hydropower. While many manufacturers still rely on conventional methods — placing weld seams directly in high-stress areas — we take a fundamentally smarter approach.
Through expertly engineered runner geometry and intelligent planning, our welds are strategically positioned away from the most heavily loaded zones. This avoids peak stress, prevents weak points, avoids premature wear, and ensures maximum strength exactly where it’s needed.
This design philosophy is a direct result of our decades of hydropower expertise and deep understanding of the forces and stress levels inside components of turbines. Every weld, every joint, every surface follows a clear goal: longer component life, flawless performance, and less downtime for the operator.
In short: while others simply weld – we design for durability.
Cold Metal Transfer (CMT) – a modern arc welding process that offers better control and much less heat than traditional welding. The welding wire moves back and forth up to 170 times per second to precisely control each droplet of molten metal. This leads to stronger, cleaner welds, with fewer distortions and better fatigue resistance. Components last longer, because lower heat input results in less internal stress.
Homogeneous weld seams – Continuous welds without flaws increase fatigue strength
Minimal heat input – Reduces the heat-affected zone (HAZ), avoiding material distortion and ensuring better structural integrity
Error-free results – Eliminates human mistakes and guarantees consistent, repeatable quality
High corrosion resistance – Controlled temperature prevents chromium depletion in stainless steel
Better working conditions – Welders are no longer exposed to 100 °C preheated components
Reduced material waste – Optimized filler usage and minimized rework
In hydropower, components like runner blades, buckets, and other hydraulically active surfaces are exposed to continuous mechanical stress, abrasive particles, and high-velocity water flows. These forces can wear down even the strongest materials over time. To counteract this, we offer advanced cladding solutions tailored to specific operational demands. Using our in-house robotic welding systems, we can apply stainless steel overlays to critical areas, providing robust protection against wear and corrosion. This automated process ensures consistent quality and precision, even on complex geometries. For applications subjected to extreme wear, we provide cladding with Stellite - a cobalt-chromium alloy renowned for its exceptional resistance to erosion, corrosion, and high temperatures. This material is particularly effective for reinforcing the leading and trailing edges of Pelton turbine buckets, where it helps maintain optimal efficiency by preserving the critical hydraulic profiles over time. By integrating these cladding techniques, operators can significantly extend the service life of their components, reduce maintenance intervals, and ensure sustained performance under challenging conditions.
The result: components that last longer, perform more reliably, and reduce unplanned downtime and replacement cycles. Cladding at Global Hydro is not just a finishing step – it’s long-term protection engineered from the start.
Turning worn into better - efficient, precise, and sustainable.
Using advanced 3D scanning, digital geometry optimization, and multi-layered cladding, we restore worn turbine parts to as-new condition. Our automated process delivers perfect fit, improved flow dynamics, and significant cost savings compared to new part production – a smart investment in performance and longevity.
Pelton Bucket Repair - Learn more
We don’t settle for what’s already possible. We constantly question the status quo and push ourselves to go beyond. Together with leading research partners like TU Wien (Vienna University of Technology), we are shaping the future of hydropower manufacturing through bold ideas and technical creativity.
One of our key initiatives is the A4M project (Additive for Manufacturing) – an ambitious concept that combines 3D sand printing, robotic wire arc additive manufacturing (WAAM), and advanced digitalization into one integrated process. The goal? A smarter, faster, and more flexible production system that sets new standards for quality and efficiency in runner manufacturing. Another exciting project is Green-Turbine, which focuses on restoring worn Pelton runners instead of producing new ones. Using innovative cladding and additive techniques, we can repair and strengthen existing components, saving valuable raw materials and reducing energy consumption. This approach not only saves costs and shortens delivery times, but also supports a more sustainable hydropower future.
With every project, we prove: innovation isn’t just something we do – it’s how we think.
Hydropower operators face growing pressure to keep their plants running efficiently while extending the lifespan of critical components like turbine runners. Downtime, premature wear, and performance losses due to outdated weld designs or poor quality add to the problem. And when it comes to making the right investment, plant operators need solutions that match their technical, operational, and economic requirements.
Our advanced welding automation is built specifically for hydropower. With robotic precision, Cold Metal Transfer, and a smart weld design that avoids stress zones, we create highly durable runners with minimal distortion. Optional cladding adds targeted protection. All steps are handled in-house for full quality control and fast turnaround.
You extend the life of your runners, reduce downtime, and lower long-term maintenance costs. With advanced welding technology and optimized seam design, you keep your plant running efficiently and make a smart investment that meets your technical and economic goals.
Discover how Global Hydro’s advanced welding automation and hybrid manufacturing can extend the life of your components while bringing true cost efficiency to your plant. Whether you need replacement runners, are planning a repair, or want to future-proof your process — we’re here to support you with cutting-edge technology.
Get in touch with our experts and take the next step toward smarter runner production. Let’s shape the future of hydropower — together.
Thierry Burckhart
Director Revitalization
+1 (970) 710 1285
thierry.burckhart@global-hydro.eu İletişim