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Professional Machining: Worldwide

Mechanical metal machining is a key process for many companies. It allows for the creation of precise and complex machine components and various types of devices. One of the most important techniques in mechanical machining is CNC milling, which enables precise shaping and finishing of objects. At our company, WWtech, we provide comprehensive services at the highest level – we undertake even the most complex and demanding projects. Renowned companies from all over the World, such as GE Vernowa, Andritz, Pesa, Doosan, PGE, Orlen, Newag, Lotos, and others, use our services – join them!

Mobile Component Manufacturing, Repairs, Service

We offer comprehensive services with portable metal machining equipment. To achieve the best results and ensure full customer satisfaction, we use modern mobile machining technology “in-situ,” which allows for on-site monitoring, diagnosing, and repairing machines, significantly impacting the efficiency and reliability of various systems and devices. This technology is extremely useful for complex and often unpredictable systems, such as industrial equipment, machinery, infrastructure, and many others. The portable machining services we offer provide numerous benefits, including:

  • time and cost savings: traditional methods requiring the disassembly and transport of equipment to a repair workshop can be time-consuming and costly. With “in-situ” technology, machine repairs and maintenance can be carried out on-site – faster and cheaper!
  • minimal production disruption: in industries where every production halt means financial losses, the ability to repair machines and perform maintenance on-site is invaluable. Equipment can be upgraded without the need to stop the entire production line
  • increased equipment lifespan: with regular monitoring and on-site repairs, equipment can operate much longer, translating into long-term savings;
  • increased reliability: by monitoring systems in real-time, “in-situ” technology allows for the detection of potential failures and issues before they occur, enhancing system reliability and safety

Metal Machining and More – What We Offer and Perform “In-Situ” at the Client’s Location

Using mobile machining technology, we perform boring and turning, milling, grinding, honing, drilling and reaming, threading, thread cutting, bolt removal, pipe cutting and bevelling, welding, construction services, and special metal machining. We combine precision, efficiency, and sustainable production. We invite you to collaborate with us.

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Xayaburi HPP, Laos

Xayaburi HPP, Laos

Xayaburi HPP (Sayaburi) power plant on the Mekong River, with a capacity of 1,285 MW, operated by CKPower Ltd. The plant, which was commissioned in October 2019, is equipped with 7 units of 175MW each, supplied by ANDRITZ. Our task was to design, manufacture, deliver, and implement two special machine tools for final machining of the new Kaplan turbine components on-site in Laos. A specially designed, mobile, universal circular milling machine with a working range of up to fi2000mm, A mobile boring machine (actually, two boring machines, thanks to an additional mounting system) based on the iconic BB5000, was prepared by our company upon the customer’s special request. The entire machining process was supervised by our specialist, who traveled to the site and ensured the successful completion of the project. The project was carried out in close cooperation with VERG, which also supplied the hydraulic power unit (HPU). ➝ Meet VERG Sp. z o.o. ← Machine Tools → ← Surroundings →

Kayrakkum units 4 and 3, Tajikistan

Kayrakkum units 4 and 3, Tajikistan

“At GE’s invitation, the supplier of new turbo sets, we are performing machining on additional units. We have just finished work on unit number 5, the second of six, being machined by us. Four more units are ahead of us.” This sentence appears in the previous post about this power plant from 2022. ➝ Click to see the previous post about the Kayrakkum power plant and the photo gallery In 2023 and 2024, we performed machining on the next two units: U4 and U3. The scope, similar to units U6 and U5: machining of the upper and lower rings, face and cylindrical surfaces, drilling and tapping of holes in the lower ring, machining of the spherical part of the rotor chamber. Two more units are ahead of us. All these machining operations are carried out using our KWW525 machine tool. ➝ More about the KWW525 machine tool Dismantling old equipment after 60 years of operation Snapshots from our work Power Plant Surroundings

Bjufors HPP, Sweden

Bjufors HPP, Sweden

Bjufors HPP, a power plant owned by Statkraft, is located on the Umealven River in northern Sweden. It consists of two units with a total power of 42 MW. Similar to Bergvik, in 2023, we carried out mobile machining services at Bjufors for Unit 1, and this year, the same scope of work is being performed for Unit 2. The scope includes: machining of the rotor chamber (spherical surface).

Balforsen HPP, Sweden

Balforsen HPP, Sweden

Balforsens HPP, a power plant owned by E.ON, is located at the Ume reservoir dam in northern Sweden. It consists of two units with a total power of 88 MW. In 2024, we carried out mobile machining services at Bjufors, focusing on the machining of the runner chamber – spherical surface, for Unit 1.

Ojeforsen HPP, Sweden

Ojeforsen HPP, Sweden

Ojeforsen HPP, a 28.8 MW power plant owned by Fortum, is located on the Ljusan River in northern Sweden. In 2024, we carried out mobile machining services at Ojeforsen, focusing on the machining of the runner chamber – spherical surface.

Chaira Pump Storage HPP, Bulgaria

Chaira Pump Storage HPP, Bulgaria

Hydroelectric power plant of Chaira (Chaira PSHPP) was built in the Rila Mountains, about 100 kilometers southeast of the Bulgarian capital, Sofia. Chaira has a generating capacity of 864 megawatts (1,159,000 HP) and a pumping capacity of 788 megawatts (1,057,000 HP). The plant is equipped with four reversible Francis-type pump-turbines, each with a power of 216 megawatts (290,000 HP) in generating mode and 197 megawatts (264,000 HP) in pumping mode. Units 1 and 2 have been in operation since 1995, and during that time, Chaira was the largest pumped-storage power plant in southeastern Europe, with the highest single-stage pump-turbine drop in the world (690 meters in generating mode and 701 meters in pumping mode). Units 3 and 4 were commissioned in 1999. The pump-turbines and generators were supplied by Toshiba, with three of them produced in Bulgaria under Japanese supervision. The upper reservoir for Chaira is created by the Belmeken dam, which connects to the pumped-storage power plant via two 4.2-meter diameter penstocks and two 4.4-meter diameter pipelines, reducing to 4.2 meters. Water flowing from the Belmeken reservoir supplies the Sestrimo hydroelectric power plant (Wikipedia). This time, the scope differs from the other projects of the year: milling of the spillway edge guides. For this purpose, a special machine tool has been designed and built.

Hydro Power Plant Bergvik

Hydro Power Plant Bergvik

Bergvik HPP, a Fortum-owned power plant located between Lake Marmen and Lake Bergviken in central Sweden. Two units with a total capacity of 16.2 MW. In 2023, we provided mobile machining services on Unit 1, and this year, the same scope on Unit 2. The scope included: machining of the runner chamber (spherical surface) and the creation of a seal groove in the lower ring. Machined sphere in the runner chamber Milling of the seal groove

Works related to the modernization of the boiler – rotary air preheater

Works related to the modernization of the boiler – rotary air preheater

A Rotary Air Preheater is a rotary heat exchanger in which heat exchange takes place thanks to the heat capacity of slowly rotating elements – sheets placed on the rotor. These elements take over the heat from the flue gases from the boiler (they heat up) and transfer it to the air sucked in from the environment, next directed further to the boiler burners. Thanks to the use of OPP, the efficiency of the installation is significantly improved by recovering a large part of the heat from the flue gases. OPP is used in virtually all solid (coal) fuel boilers.   Our scope included machining work in four holes: rounding/turning of the hole to size Ø615H7, facing from approx. Ø120 mm to Ø 615 mm with allowance 50 mm (very large allowance!), production and assembly of centering sleeves, drilling and threading holes in the heater body and covers.

The Crusher

The Crusher

A large scope of works related to the main overhaul of the device. Facing approx. Ø1000mm Lock turning approx. Ø1000mm Facing approx. Ø500mm Turning the diameter approx. Ø500mm Turning the diameter approx. Ø600mm Facing approx. Ø600mm Turning the conical surfaces of the body and cover approx. Ø1900 mm

Regeneration of the surface of the long journal

Regeneration of the surface of the long journal

The heavily damaged surface of the journal is salvageable! If the scratches are too deep and it is possible to make mating elements (e.g. bearing shells) on a slightly smaller shaft diameter, then turning is enough to remove scratches and grooves and obtain the right surface quality. If it is important to maintain the original diameter, the turning operation must be preceded by premachining (optional) and layer welding. Only then can the original geometry be restored. We implemented such technology, for example, in the Bujagali power plant, Bujagali HPS, Uganda | WWTECH – On site machining In both cases, the last step of treatment can be honing using the same machine tool.

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