Case Study55 MW new rotor and overhaul

• During start up in the

process of opening

extraction there was a

increase in vibration and

the turbine was shut down.

• On opening and inspection

rotor bend found

• After due diligence

customer decided to come

to us due to quick turn

around of new rotor

Status report

As inspected by TTL at customer site

• Customer was unable to define exactly the

reason for the damage.

• Customer had explored many repair options by

then including number of OEM’s

• Requested them to send the rotor to our works

for inspection and engineering

• Invited customer to visit our works and review

our capabilities which they did and based on the

same entrusted us with the work

Further inputs

Blade drawing for manufacture by reverse engineering

As received

Blade lock pin hole drill

Blading Rotor machining

Shroud machining High speed balancing

Process

• Confidence by interaction with our

Engineering team at Bangalore on

procedures.

• Complete engineering process flow

discussed and given confidence

• Completed the reverse engineering

without any liability to the customer

Challenges Confidence building • To complete the reverse engineering

• Ship in 6 months from order to enable

customer save Insurance costs of shut

down.

• Find special materials at short notice to

match original rotor specs

• Blades with pre twist and to establish the

process for the same.

Post completion process• Shipped out 10 days before the

deadline making us eligible fora large bonus as per agreement

• The quality parametersadhered to during manufactureof rotor built confidence andcustomer asked us to take upthe overhauling andcommissioning of turbine aswell

Customer speak Current Status

• Operating for the past 2years satisfactorily.

“We are pleased to confirm theturbine is operating is much betterthan we had expected and we areachieving 8% improvement over thedesign parameters”

WE CARE

Overhaul at site

Final checks and operationalised

Customer speak Current Status

• Operational for the pastyear.

The ….. Team thanks the Triveniteam of Lindon and Matharu forworking efficiently andunderstanding the system to ensurethat the turbine was commissionedright and we appreciate theconfidence with which they workedfor standards including thevibrations of the HP rotor and gave anumber of suggestions for improvingthe operations. We are happy withour decision to go with Triveni asour partner for the project andrecommend them for future projectstoo

WE CARE

Efficiency improvement projects completed

Triveni turnkey expertise services for retrofitting of turbo-visory systems likeGoverning machinery management & power management systems

Retrofitting of Turbo visory Systems

Integration of existing water operated control system with electronic governor and retrofitting of vibration monitoring system

Electronic Governor Retro fitment of a 37 MW Turbine

Retrofitted with hydro mechanical actuator

Customer Perception

ExpectationsOverall Triveni Competitor 1 Competitor 2

% Mean % Mean % Mean % Mean

Service support 30.5 5.74 28.0 5.77 28.9 5.66 26.9 5.14

Product Performance

16.7 5.79 16.4 5.77 25.6 6.03 23.1 5.67

Commercial Terms 11.7 5.70 13.2 5.73 8.3 5.40 3.8 5.00

Maintenance 11.4 5.78 11.0 5.84 13.2 5.63 15.4 5.75

Quality of turbine 9.2 5.96 10.1 6.02 4.1 5.60 15.4 5.50

Product features 8.5 5.89 9.2 5.96 9.1 5.36 7.7 6.00

Delivery/ Supply 5.5 5.62 5.9 5.51 3.3 6.50 3.8 7.00

Others 2.0 6.16 2.1 6.20 1.7 6.00 . .

Customer PerceptionMean scores on 7 point scale

% Relative impact onOverall

After sales support

Competition Customers

Competitor 1 Competitor 2Competitor

3

16.6 5.83 5.23 6.00

15.9 5.75 5.40 -

12.8 5.17 5.30 5.40

11.2 5.75 5.40 -

7.8 6.25 5.40 -

5.4 6.50 5.80 -

5.1 5.83 5.43 6.00

4.8 5.50 5.10 5.00

4.3 5.50 5.07 5.40

3.1 6.00 5.37 6.00

2.4 5.50 5.40 -

2.2 5.50 5.60 -

2.2 5.50 5.33 5.80

1.9 5.17 5.40 6.00

1.8 7.00 5.80 -

1.5 6.00 5.80 -

0.9 5.50 5.60 5.60

0.0 5.50 5.40 -

- 5.67 5.36 5.40

< 5.67 > 5.82Based on quartile analysis

Mean scores on 7 point scale

Customer Perception

” I will admit that there were times when I doubted whether we could pull this off, but we did succeed, and I amespecially pleased because this validated our decision to award the contract to Triveni in the face of some doubt”

The first TG set was supplied over 7 years ago and the last one in 2010. The 30 MW turbine was commissioned in 2010 and willcomplete 2 years of operations. The 30 MW TG which we have understood is among the first one supplied by Triveni isperforming well above our expectation with consumption of 3.87 kg/KWWe are pleased to inform you that we are happy about having taken the decision of going with Triveni Turbines. All turbines areperforming as per the performance curves provided”

”The overhauling job of STG and the auxiliaries was carried out under the guidance and supervision of Mr CK Taneja . Weappreciate Mr Taneja and whole TTL team for their relentless efforts in completing the overhauling job in time to our satisfaction”

We have in operation 4 TG sets supplied by you : 5 MW back pressure , 15 MW back pressure, 16 MWextraction condensing , 30 MW extraction condensing and very satisfied with the performance

“During this job M/s TTL have supplied & rectified turbine rotor, casing, diaphragm and its accessories. They have modified theoil piping & hydraulic governing system and after completion of all modification job, TG set commissioned successfullyPresently, TG set is running satisfactorily on load. We appreciate entire team of TTL for their best efforts in completing therefurbishment, overhauling & commissioning job in time to our satisfaction”

Thanks so much for organising Ashok to visit us. We were impressed with his knowledge and were able to get the turbineserviced adequately

“Hello Mr Matharu, how are you doing?Our "baby" is going well here, and I'm sending this email to you because the STG project won a prize, the "Award for

Excellence". As you worked with us during the commissioning, you received a certificate (Siva & Dipak as well)”

Customer Speak