Once again, we are cutting something of large dimensions. Usually, these are pipes, but this time it’s a welded shaft, where part of the narrow-gap weld had to be removed. The shaft has a diameter of over 1400 mm, and the cut was made to a depth of 140 mm. Cutting and bevelling of pipes Other examples of large diameter cutting and bevelling
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 […]
“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 […]
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.
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
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 […]
This time the faces of flanges – pipes of the gas collector. A task very similar to the one recently carried out: Flanges’ faces machining | WWTECH – On site machining
The purpose of standard flange machining is to obtain the correct flange geometry: flatness of 0,05 mm, perpendicularity to the axis – not more than 0,02 mm, and, importantly, adequate surface roughness (< 3.2 μm) More: Machining of flanges | WWTECH – On site machining
In order to obtain the desired state of dynamics of the device, it is first of all necessary to take care of the quality of the foundation, i.e. the adherence of the device base (flaps) to the foundation plate. It is important to maintain the flatness of the foundations plates, but the second, often forgotten, and an extremely important parameter is the deviation of the position of the foundation plate plane in relation to the basic plane, i.e. the sea level plane (water level). In this case, the total deviation of the flatness and level shall not exceed 0,05 mm/m.
Bujagali Power Plant is a hydroelectric power plant on the Victoria Nile, a place considered the beginning of the great Nile River – near the beautiful Bujagali Falls in Uganda. Construction began in 2007 and was completed in 2012. The power plant has a capacity of 250 megawatts. The Bujagali Power Plant was uganda’s largest source of energy when it was commissioned. GE supplied all electromechanical equipment – including five Kaplan turbine-generator units with a capacity of 50 MW each, control and protection systems and other power plant equipment. GE’s Kaplan turbines feature adjustable rotor blades and adjustable steering blades that enable them to efficiently deliver power over a wide range of flows, where river flows vary greatly depending on the season. More about power plant equipment: Bujagali – Flawless project execution | GE Renewable Energy About the Bujagali hydropower project – AKDN This time, at the invitation of GE, we performed […]
