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Malta Hydroelectric Power Plant
Our last major project took place in an unusual place – in Tyrol. The site of the project was the Malta pumped-peak power plant installed in the Kölnbrein, on Lake Speicher Kölnbrein. Not only are the landscapes unheard of, the plant design is also remarkable. Kölnbrein Dam with Malta Hydroelectric Power Station and Observation Deck and Lake Speicher Kölnbrein; the dam is 200 m high (the highest in the country), a crown with a length of 626 m and a width of 7.6 m, at a base of 41 m and a volume >2,000,000 m3; dam tank: 200.000.000m3. Malta Oberstufe and its Galgenbichl power plant are a pumped-peak power plant located about 1933 m above sea level in the Carinthia Mountains of Austria. Equipped with two vertical pumps, construction began in 1974 and was completed in 1977. First put into operation in 1979, Malta Oberstufe includes a 200-metre double curved concrete dam. It is not only the tallest dam in Austria, but also one of the highest curved dams in Europe. At its peak capacity, the lake has a capacity of about 200 million m3. After almost forty years of operation, the power plant is now being modernised with new high-performance variable speed pump turbines. The existing turbines had a rated capacity of 62.8 MW each. In pump mode, the units had a rated power of 21 MW at 375 rpm and 58 MW at 500 rpm. ANDRITZ Hydro will replace existing units with 80 MW turbines each in pump and turbine mode. At the heart of this modernisation are the whole-forged and welded rotors of the pump turbine and the newly welded support ring, which uses existing cast spirals. The new pump turbines have a spiral in which a double rotor consisting of a Francis rotor and a radial pump rotor rotates. The direction of rotation is the same for turbine and pump operation, although hydraulically the turbine and pump parts are independent of each other. To cope with the significant lifting height fluctuations produced by the Kölnbrein tank, isogyre pump turbos have variable pole generators and two speed settings. Our scope is the removal – through mechanical processing – of literally many tons of old structures – wanes, upper and lower rings, as well as machining – preparation for welding and ready-to-use treatment after installation (and welding) of new, modernized components. For this purpose, the KWW525 machine is designed and built – more on it: https://wwtech.com.pl/en/hydro-2/the-machines/
The Hydro tab has appeared in the main menu of the website, where you can find information about our activities in the field of hydropower.
Automated external defibrillator
Once again, all WWtech employees take part in first aid courses organized by WENA Konsulting. The course program, in addition to standards (BLS – Basic Life Support), covers the following topics: • Wound management, • Cardiopulmonary resuscitation (CPR), • Using the Automated External Defibrillator (AED). Automated external defibrillator (AED) – a highly specialized, reliable, computerized device that, by voice and visual commands, guides both people with and without medical training through a safe defibrillation procedure in cardiac arrest. Cardiopulmonary resuscitation in combination with defibrillation within 3-5 minutes of loss of consciousness can allow effective resuscitation in 49-75% of cases, and every minute of defibrillation delay reduces the likelihood of survival by 10-12%. The automatic external defibrillator is intended for use by any person (preferably trained) who witnesses an event in which cardiopulmonary resuscitation is required. Wikipedia. Trained WWtech employees are easily recognizable in the workplace; on their helmets there is a sign of a white cross on a green background.
Regeneration of pump casings
Two casings for regeneration, which consisted in turning the internal diameter (about 300mm), and then mounting the stainless steel lining (bushings). An interesting fact is that the sleeves-linings were made of a typical pipe with a slightly larger diameter, by cutting an appropriate part of the pipe circumference along a radial line. This allowed the cladding to fit tightly inside the casings. Tooling was also made for assembly, which allowed to close the circumference of the cladding and push it inside the casing. The effect meets the customer’s expectations.
Modernisation of turboset in Turkey
At the power plant located on the Turkish Riviera, GE has modernized the turbosets, consisting in the complete replacement of high- and medium-pressure modules. The remaining elements of the turbine had to be adapted to the new modules. Our scope of work was relatively wide, including supervision of the work carried out by a local subcontractor. Milling the foundation for sliding plates Grooves of bearings 1 and 2 Installation of the insertion Supervision of the machining of the bottom parts of the bearing pedestals. Bearing grooves No. 3,4,5, and 6 Machining the casing for blade carriers
Modernization of the turbine casing screw connection Part 2
We are pleased to announce that the project described in the article:https://wwtech.com.pl/en/2020/10/23/modernization-of-the-turbine-casing-screw-connection/has been successfully completed! In addition to measurements, the analysis of the casing shape geometry and machining, WWtech also produced all fasteners: studs, bolts and cap nuts, including the design of new bolts replacing the existing studs.
Fully functional equipment is fundamental to company’s success. Every machine has precision elements, bearings and number of other parts, that enable its efficient operation. Those main elements, which ensure correct machine operation require specific solutions in case of a breakdown. Leaks, cracks and grooves are issues that have to be eliminated to ensure proper operation.
An industrial metrology
WWTECH Company provides its clients with a complex way of problems resolving, offering them three-dimensional coordinate measurements and a full 3D documentation. Due to accurate measuring devices FARO (Laser Tracker, Measuring Arm) WWTECH makes it is possible to carry out uniquely accurate, fast and non-contact measurements, results of which can be analyzed in a real time.
In all undertaken activities WWTECH gives priority to the safety. Our staff’s and the society’s health, respect for the environment are the factors which determine a whole tam activities, a place and other aspects of our work, such as transportation or cooperation with a third party.
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