Toktogul HPP, Kyrgyzstan

Toktogul HPP, Kyrgyzstan

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

Reverse engineering of Kaplan turbine blades

Reverse engineering of Kaplan turbine blades

Due to the erosion and corrosion wear of the old blades, the customer decided to replace them. For this purpose, we made a number of 3D laser measurements and scans to redesign the casting as well as the finished machining. The individual stages are presented in the diagram: In the same way, the steering vanes were recreated. More about reverse engineering: MEASUREMENT TECHNIQUE AND REVERSE ENGINEERING | WWTECH – On site machining

Flanges’ faces machining

Flanges’ faces machining

We processed over 200 flanges on cooling system pipelines with diameters Dn270 – Dn610 near Frankfurt am Man, at the construction site of the new Google server station. The aim was to obtain the correct roughness and flatness parameters of the sealing surface.

Reaming the central bore in the generator rotor

Reaming the central bore in the generator rotor

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 […]

Kuurna – North Karelia, Finland

Kuurna – North Karelia, Finland

A small power plant with two Kaplan turbines with a total capacity of 18MW. The current modernization will allow for an additional 1 MW/ unit. In our scope a.o. the machining of the runner chamber. More: Our Hydro Services | WWTECH – On site machining For machining all flat, cylindrical, toroidal and spherical surfaces, we used the KWW525 machine tool. Read more: The Machines | WWTECH – On site machining Note: This photo is composed of two photographs. This is the only way to show the whole machine tool.