Gilkes offers single source, water to wire solutions for a range of hydropower applications. From large utilities to small mini grids, our solutions are tailored to meet the needs of each individual project, uniquely designed to meet site conditions and operational needs and ensure efficiency and long-term performance.
A bespoke approach to every project
No two hydropower schemes are the same. Site conditions, water flow, and operational requirements influence every design. Our experienced team works closely with customers to develop tailored hydropower solutions that maximise efficiency and reliability.
A dedicated project team provides a single point of contact, ensuring clear communication and seamless project execution. Our engineers oversee hydraulic design, system integration, and commissioning, ensuring smooth development with minimal management required from the customer.
Seamless project delivery
Our multi-disciplinary team of engineers and designers brings extensive experience across the hydropower sector. Using tools such as SolidWorks and ANSYS to produce 3D designs, 2D layouts, CFD and FEA, we develop systems built for long-term performance and reliability.
Project execution includes:
- Turbine selection based on site conditions
- Energy calculations and surge analysis
- Precision design and specification
- Advanced hydropower manufacturing and assembly
- Sub-contracted equipment sourced from approved suppliers
- Rigorous quality control and factory testing
- Expert installation and commissioning
- Ongoing support and maintenance across the system lifecycle
This integrated approach supports efficient project delivery, with every system designed to perform reliably from day one.
A proven partner in hydropower
With over 170 years of experience, Gilkes is a trusted leader in small hydropower solutions worldwide. Our bespoke hydropower packages deliver dependable performance, providing customers with confidence in every investment.
By choosing a Gilkes hydropower package, customers gain a fully integrated, expertly managed solution built for efficiency, reliability, and long-term success.
Our in-house CFD team uses ANSYS Fluent and high-performance computing to support turbine design and development. With over 40 years of combined experience, we carry out detailed fluid flow analysis to optimise turbine performance.
CFD is applied across customer projects and internal R&D to improve efficiency, reliability and system integration.
Applications for customer projects include:
- Performance mapping at site-specific conditions
- Assessment losses of upstream and downstream pipework
- Structural analysis using hydrodynamic load data
Applications in research and development include:
- Runner blade design for Francis, Pelton and Turgo turbines
- Spiral case and manifold optimisation
- Nozzle and spear profile design for impulse turbines
- Pelton and Turgo case development
- Draft tube design for Francis turbines
This capability supports precision engineering and continuous improvement across our full turbine range.
Our latest investment in 5-axis machining enhances our in-house capability and increases productivity. The Mazak INTEGREX E-120V/8S allows us to fully machine turbine runners from a solid billet, improving accuracy and lead times.
We also use 3D scanning to support reverse engineering of hydropower components. With a handheld Creaform laser scanner, our engineers capture complex turbine geometry at resolutions up to 25 microns. The data is processed using surfacing software to generate precise CAD models, which form the basis for manufacturing replacement components that match the original design.
The original Turgo design
The Turgo impulse turbine was first developed by Gilkes in 1919 and remains a widely used hydropower solution. Designed as a side-entry impulse turbine, it typically operates at twice the speed of a Pelton turbine when working under the same head. This design was patented by Eric Crewdson, Grandfather of the current Gilkes chairman, and over a century later the Turgo continues to deliver reliable performance in a range of hydropower applications.
Design and performance
The Turgo turbine is designed for efficiency and reliability on medium head applications, making it well suited to a wide range of hydropower schemes. Its design allows for higher rotational speeds than a Pelton turbine, helping to reduce the size and cost of generators and potentially removing the need for a gearbox. The Turgo also maintains high efficiency across a wide flow range, making it a practical alternative to the Francis turbine in run-of-river installations where flow can vary.
Key features
- Covers the boundary between Francis and Pelton applications
- Limits over-pressure effect over the penstock
- Higher speed equals weight and cost reduction
- Maintains efficiency over a wide flow range
- Superior abrasion resistance
- Ease of operation and maintenance
Application areas
- Rural electrification
- Run-of-river hydropower
- Suitable for monsoon climates where there is high sediment load
- Good alternative to the Francis where over-pressure of the penstock is a concern, or on medium heads if the flow rates are variable
- Industrial and municipal power generation projects
Development and engineering enhancements
Gilkes continues to refine the Turgo turbine, incorporating advances in design and materials to improve performance and longevity. Current developments include:
- Optimised Turgo runner and injector designs
- Turgo runners fully machined from single forged block, or alternatively investment cast for superior dimensional accuracy
- Integration with modern control systems
The Turgo turbine remains a key component in small to medium-scale hydropower projects, offering a balance of efficiency, durability, and cost-effectiveness.
- Power output: up to 10MW
- Head range: 50–250m
- Configuration: horizontal - single and twin jets
- Over 1000 installations worldwide
- Installations in 65 countries
Downloads
View a full Turgo hydro assembly
Deflector Actuator Mechanism
Generator
Bifurcation
Inlet Pipe
Inlet Pipe
Spear Rod Actuator
Branch Pipe
Spear Rod
Spear Tip
Nozzle
Deflector Plate
Runner
Turbine Case
Foundation Bolts
Pelton impulse turbine
High-efficiency turbine for high-head applications
The Pelton impulse turbine is suited to sites with high head and low flow. It operates by directing high-velocity water jets onto the runner, converting water energy into rotational force. Available in single or multi-jet configurations, with horizontal or vertical arrangements, the Pelton is designed to deliver high energy transfer and efficient performance.
Design and performance
The Pelton turbine maintains high efficiency across a wide range of flows. When multiple jets are used, this range is further extended, optimising annual energy production. Each Gilkes Pelton turbine is selected and configured based on site-specific conditions to maximise power generation and system performance.
Key features
- High efficiency at varying flow conditions ensures stable power generation
- Low wear and maintenance reducing long-term operational costs
- Runners fully machined from single forged block for durability
- Being an impulse turbine, easy to govern for islanded operation
- Limits over-pressure effect over the penstock
Application areas
- Rural electrification
- Run-of-river hydropower
- Energy recovery in water systems
- Industrial and municipal power generation projects
Streamline range – Pelton turbines
For smaller hydropower applications, Gilkes has developed the Streamline range, designed specifically for sub-1MW projects. These turbines are built for simplicity, durability, and ease of installation. The design simplifies the civil engineering requirements typically associated with hydro schemes, making deployment more cost-effective and improving serviceability.
Development and engineering enhancements
Gilkes continues to refine Pelton turbine technology, incorporating modern materials and control systems to enhance performance and longevity. Advances in Computational Fluid Dynamics (CFD) modelling and precision manufacturing ensure each turbine is optimised for its specific site conditions.
The Pelton impulse turbine remains a key solution for high-head hydropower projects, delivering consistent performance, efficiency, and reliability.
- Power output: up to 20MW
- Head range: 100-1000m
- Configuration: horizontal – single and twin jets
vertical – up to 6 Jets - Over 1000 installations worldwide
- Installations in 57 countries
View a full Pelton hydro assembly
Generator
Flexible Coupling
Bearings
Runner
Spear Tip
Spear Rod Actuator
MIV Bypass
Main Inlet Valve
Branch Tip
Branch Tip
Deflector Plate
Deflector Actuator Mechanism
Bearings
Turbine Case
Foundation Bolts
Francis reaction turbine
Versatile and efficient turbine for medium head applications
The Francis turbine is suited to sites with low to medium head and high flow. Water enters through a pressurised spiral casing and is directed by adjustable guide vanes onto the runner blades. The resulting water pressure drives rotation, delivering efficient power generation across a broad operating range.
Design and performance
Gilkes offers Francis turbines in both horizontal and vertical configurations, ensuring adaptability to site conditions. Flow control is managed by electric or hydraulic actuators, which adjust the guide vanes for optimal efficiency. The turbines can operate in standalone mode with a speed governor or be controlled via PLC systems for integration with distribution grids.
Key features
- High efficiency at full flow condition
- Relatively small footprint
- Has a draft tube outlet to utilise the maximum available head
- Runners fully machined from single forged block for durability
- Option to have a pressurized outlet if required
Application areas
- Run-of-river hydropower
- Generation from reservoirs & dams
- Energy recovery in water systems
- Industrial and municipal power generation projects
- Grid-connected and off-grid systems
Francis turbine in the water industry
The Francis turbine is widely utilised in water treatment facilities and municipal water systems to recover energy from pressurised pipelines. Instead of dissipating excess pressure through a pressure-reducing valve (PRV), a Francis turbine can be integrated to generate renewable electricity while maintaining system stability.
Development and engineering enhancements
Gilkes continues to refine Francis turbine technology, incorporating advanced materials and computational fluid dynamics (CFD) modelling to enhance efficiency and longevity. These innovations ensure that the Francis turbine remains a key solution for hydropower projects.
- Power output: up to 20MW
- Head range: 30-400m
- Configuration: horizontal and vertical
- Over 1400 installations worldwide
- Installations in 66 countries
View a full Francis hydro assembly
Generator
Bearing House
Guide Vane Operating Mechanism
Spiral Case
Runner
Discharge Pipe
Inlet Pipe
Main Inlet Value
Guide Vane Linkage Assembly
Foundation Bolts
Compact turbine range
Reliable and efficient turbines for sub-150kw applications
The Gilkes compact turbine range consists of Pelton and Turgo turbines, engineered specifically for sub-150kW hydropower applications. These turbines feature a compact case design, electric actuation, and precision-engineered runners and spear valves, ensuring a cost-effective, durable, and efficient solution for a broad range of hydraulic conditions. Designed for easy integration, the compact range offers flexibility while maintaining high performance.
Technical specifications
- Power output: Up to 150kW
- Design: Compact case with precision runners
- Actuation: Electric (instead of hydraulic)
- Optimised footprint: Reduced installation costs and space requirements
Design and performance
The compact turbine range is built for reliable performance across varied operating conditions. Electric actuation replaces hydraulic systems, resulting in cleaner operation and reduced maintenance. With a simplified design, these turbines offer a cost-effective and adaptable solution for small-scale hydropower schemes.
Key features
- Electric actuation avoids the complexity of hydraulics and reduces maintenance
- Compact and lightweight design minimises installation complexity
- Cost-effective solution designed to optimise efficiency at lower operational costs
- Adaptability across hydraulic duties suitable for a variety of flow conditions
Gilkes compact turbine control system
The Gilkes compact turbine control system is a fully automated solution, capable of managing both grid-connected and islanded installations. Designed to work with both induction and synchronous generators, it ensures smooth and efficient operation.
Standard control system features
- Cost effective Micro PLC control panel providing intelligent automation and real-time monitoring
- Touch screen HMI enhances user interface and system interaction
- Secure remote connection – for remote monitoring and control
- Head level control to maintain steady power generation
- Optional vibration monitoring to detect early signs of mechanical wear
- Bearing temperature monitoring ensures longevity of turbine and generator components
- G99 protection relay to maintain grid compliance
- Power factor correction when using induction generators
Additional options
- Larger touch screen HMI with customisable interfacefor advanced control
- Remote monitoring provides real-time data access
- Email alerts for automated system performancenotifications
Integration and maintenance
The compact turbine is a core component of hydropower projects, requiring seamless integration with electrical, mechanical, hydraulic, and civil systems. With experience gained from thousands of projects, Gilkes delivers a fully integrated equipment package, ensuring that each turbine is optimised for its specific hydraulic duty and site conditions.
Hydropower control systems and electrical integration
Gilkes provides integrated hydro control systems that connect turbines safely to the grid, matching voltage and frequency requirements. Each system typically includes a PLC control panel with synchronising relays and metering, alongside a main breaker panel. Protection relays are included to meet G99 and G100 grid codes, voltage control standards and international safety regulations. We offer system design, installation, testing, inspection and modernisation, with flexible packages suited to both new installations and existing sites.
Our control systems are designed to manage and protect hydropower schemes while maintaining dependable generation. They manage turbine operations, track performance, and support safe grid connection. Key functions include water to wire integration, black start capability, grid or island mode transition, multi-turbine management, and remote access. Systems can link with SCADA and be upgraded with new panels, generator updates, and AVR changes.
Each package is tailored to the site’s technical needs and the operating team’s experience. From basic manual setups to automated systems for multi-site control, all solutions are assembled and tested in-house, replicating site conditions to reduce commissioning time and support a reliable handover.
HydroView
Smart, secure hydropower monitoring
- Smart, secure hydropower monitoring
- Secure remote access – monitor multiple sites from one portal
- Advanced diagnostics – identify faults before they escalate
- 24/7 alerts – stay informed and act fast
We’re with you for every step of the way
Talk to a hydropower expert today to protect your assets for future generations.
