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
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
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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.
The tiny Angaback hydroelectric power plant, belonging to the Scandinavian giant Statkraft and the Polish large hydropower plant PGE Dychów. Very similar work involving the machining of a groove for sealing of vanes. However, the main difference is the diameter of the flow path of the water turbine. For this reason, we used different machines to achieve the same goal in both cases. Angaback Dychów Output [MW] 7 90 Commisioning 1952 1936 Damming [m] 7 18 Type Flow Pumped storage Number and type of turbines 2 x Kaplan 3 x Kaplan Machining diameter [mm] 4000 5000 Machine tool FF8200 CM6200 Type of machining Turning Circumferential milling
This time, the only underground hydroelectric power plant in Poland, operated by PGE. The scope of work typical for our company: machining flanges from large diameters.
In March 2017, ANDRITZ HYDRO begins supplying electromechanical equipment for a new hydro plant in the heart of Graz, the capital of the Austrian province of Styria. The start-up of the power plant is planned for the first half of 2019. Before the construction is completed, it is necessary to install the power plant equipment: turbines, generators, flaps, various types of drives and control systems. And here is the place for our services. Of course, as in a hydroelectric power plant, the main task is to process large-size flanges. It is a very avant-garde design, which can be seen in the following visualizations: More about the plant: The current state […]
Well-made measurements – quickly, accurately, repetitively – are a necessary condition of successful project. Two things are necessary for this: appropriate measuring equipment; trained and experienced staff. The measuring equipment must meet a number of requirements related to the nature of the work: most often there are remote measurement, resistance to humidity, dustiness and temperature changes. These requirements are met by Laser Tracker ™, which we use in our work. The measurements can be systematized as follows: For the needs of mobile machining: Before machining: initial dimensions and dimensional analysis – determination of allowances, determination of axes and theoretical points, marking out; During machining: dimensional inspection, necessary adjustments, forecasting of work progress; After processing: final dimensions, reporting; Metrological assistance: The service consists in performing measurements for disassembly and assembly works, including mobile machining; Assistance may cover the whole period of activities on the site; The result is ad hoc reports […]
Autumn in hydropower is often the necessity of post-seasonal repairs. As usual, a major part of our volume is work for hydropower. In recent weeks, it was the PGE Dychów Power Plant (88 MW) and PGE Solina (199 MW) as well as the Bulgarian Koprinka Hydroelectric Power Plant (29.4 MW), located near the town of Stara Zagora. Scopes of work were similar and often performed once more: machining on large diameters. How it done in hydropower