The Toktogul hydropower plant (HPP), with an installed capacity of 1.2GW, is the biggest power plant in Kyrgyzstan accounting for approximately 40% of the country’s power output. The plant generates approximately 6,000GWh of electricity a year using four vertical Francis turbines of 300MW each. A joint venture of GE Hydro (France) and GE Renewables (Switzerland) was awarded a turnkey contract worth $104m for the Toktogul hydropower plant rehabilitation project. Our participation in this project is the surfaces machining of the upper ring and the lower ring. Due to the location (5000 km), apart from technical challenges, the project was a huge logistical challenge. The machining Power Station and landscapes

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The unusual task of reaming the existing, twisted central hole in the shaft of the generator rotor was carried out in accordance with the customer’s requirements. The task was to ream the holes Ø81 to Ø90, with the maintenance of a new hole in the shaft axis. Also a challenge was the required roughness Ra = 0.8 µm. And above all, the depth: more than 2000 mm! The task was carried out using a modified BB6000 machine tool, equipped with an appropriate mounting system and a spindle bearing system in the hole according to our concept. Metrological supervision – the reliable Laser Tracker – ensured ongoing alignment corrections and continuous control of the spindle position in the bore.