Massive Fabrication for Hydropower Turbines
Hydroelectric power plants rely on incredibly massive metal components that must withstand extreme water pressure, continuous vibration, and cavitation over decades of operation. Manufacturing these parts requires a rare combination of heavy plate rolling, massive 5-axis CNC machining, and flawless certified welding.
With 180 acres of factory space and lifting capacities up to 250 tons, Openex is one of the few contract manufacturers in the world equipped to handle the sheer scale of hydropower equipment. We fabricate and machine critical components for Kaplan, Pelton, and Francis turbines, supplying global OEMs and energy infrastructure projects.
Hydropower Components We Manufacture
Spiral Cases & Penstocks
Heavy plate rolling and full-penetration submerged arc welding (SAW) for massive steel water conduits and turbine housings.
Stay Rings & Discharge Rings
Fabricated from heavy carbon steel or stainless steel, followed by precision vertical turning on our massive 8-meter VTLs.
Wicket Gates (Guide Vanes)
High-precision 5-axis CNC milling of stainless steel forgings to create the perfect hydrodynamic profiles required for water flow control.
Turbine Runners & Shafts
Machining and dynamic balancing of massive turbine runners and main shafts to eliminate vibration during high-speed rotation.
Hydropower Manufacturing Specifications
We build components to exact OEM blueprints and strict international energy codes. Below are our general facility capacities for hydroelectric projects:
| Max Component Weight | Up to 250 Tons (Single piece assembly) |
|---|---|
| Max Turning Diameter | Ø 8,000 mm (For stay rings & covers) |
| Materials Processed | Carbon Steel (Q345/S355), Stainless Steel (304/316/410), Martensitic Stainless, Bronze Alloys, and Heavy Forgings. |
| Heavy Plate Rolling | Cold and hot rolling of extra-thick plates for spiral cases and penstock sections. |
| Testing & NDT | 100% Ultrasonic Testing (UT), Magnetic Particle Inspection (MPI), Radiography (RT), and Hydrostatic Pressure Testing. |
Strict Quality & Metallurgy Control
Massive weldments like spiral cases contain extreme residual stresses. Our large-scale on-site heat treatment furnaces ensure complete stress relief before final machining, preventing warping in the field.
We utilize specialized weld-overlay and cladding techniques on wear-prone areas (like turbine runners and draft tubes) to provide maximum resistance against pitting and cavitation erosion.