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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.

Malta Hydroelectric Power Plant

Malta Hydroelectric Power Plant

Our last major project took place in an unusual place – in Tyrol. The site of the project was the Malta pumped-peak power plant installed in the Kölnbrein, on Lake Speicher Kölnbrein. Not only are the landscapes unheard of, the plant design is also remarkable. Kölnbrein Dam with Malta Hydroelectric Power Station and Observation Deck and Lake Speicher Kölnbrein; the dam is 200 m high (the highest in the country), a crown with a length of 626 m and a width of 7.6 m, at a base of 41 m and a volume >2,000,000 m3; dam tank: 200.000.000m3. Malta Oberstufe and its Galgenbichl power plant are a pumped-peak power plant […]

Automated external defibrillator

Automated external defibrillator

Once again, all WWtech employees take part in first aid courses organized by WENA Konsulting. The course program, in addition to standards (BLS – Basic Life Support), covers the following topics: • Wound management, • Cardiopulmonary resuscitation (CPR), • Using the Automated External Defibrillator (AED). Automated external defibrillator (AED) – a highly specialized, reliable, computerized device that, by voice and visual commands, guides both people with and without medical training through a safe defibrillation procedure in cardiac arrest. Cardiopulmonary resuscitation in combination with defibrillation within 3-5 minutes of loss of consciousness can allow effective resuscitation in 49-75% of cases, and every minute of defibrillation delay reduces the likelihood of survival […]

Regeneration of pump casings

Regeneration of pump casings

Two casings for regeneration, which consisted in turning the internal diameter (about 300mm), and then mounting the stainless steel lining (bushings). An interesting fact is that the sleeves-linings were made of a typical pipe with a slightly larger diameter, by cutting an appropriate part of the pipe circumference along a radial line. This allowed the cladding to fit tightly inside the casings. Tooling was also made for assembly, which allowed to close the circumference of the cladding and push it inside the casing. The effect meets the customer’s expectations.

Modernisation of turboset in Turkey

Modernisation of turboset in Turkey

At the power plant located on the Turkish Riviera, GE has modernized the turbosets, consisting in the complete replacement of high- and medium-pressure modules. The remaining elements of the turbine had to be adapted to the new modules. Our scope of work was relatively wide, including supervision of the work carried out by a local subcontractor. Milling the foundation for sliding plates Grooves of bearings 1 and 2 Installation of the insertion Supervision of the machining of the bottom parts of the bearing pedestals. Bearing grooves No. 3,4,5, and 6 Machining the casing for blade carriers