comprehensive service solutions · rebuilt the whole turbine through reverse engineering and...

ComprehensiveService SolutionsCase Studies

Triveni Turbine Limited2

Clean EnergyTurbine SolutionsThe power generation industry is evolving continuously. The demand for higher efficiencies at lower cost is constantly being stretched. At Triveni Turbines, we understand the economics and needs of the power producers to have equipment with better operating efficiencies, long term reliability, maximum availability and extended operating life to maximise return on investment.

We offer steam turbine solutions for Industrial Captive and Renewable Power. We manufacture world class steam turbines up to 100 MW that enable our customers to achieve unhindered performance and power self-sufficiency at an optimal cost while minimising environmental impact. Triveni Turbines partners with customers to provide a comprehensive range of service solutions for the complete life cycle of steam turbines. We are also one of the world’s largest manufacturers of steam turbines ranging up to 30 MW for providing renewable power solutions specifically for Biomass, Independent Power Producers, Sugar & Process Co-generation, Waste-to-energy and District Heating

Triveni Turbine Limited 3Triveni Turbine Limited 01

We also operate in a higher capacity range of above 30 MW to 100 MW Steam turbines through our subsidiary, GE Triveni Limited (GETL), a joint venture company with General Electric. GETL is engaged in the design, supply and service of steam turbines for the global market. Manufactured in the state-of-the-art plant at Triveni Turbines, Bengaluru, the product is marketed globally under the brand of “GE Triveni”. Our partnership with GE is a testimony of the globally benchmarked processes followed at Triveni Turbines.

Presence inover 50 Countries

Higher sustained efficiency

Lower Lifecycle

cost

Reliable & Robust

steam turbines

Over 2500 turbines installed globally

Range upto 100 MW

Installations in over 50 countries

Over 11 GW of

installations


InTROduCTIOnThe customer is an IPP from Southern Africa, generating over 500 MW of power. It was operating a Turbine Generator (TG) Set which was commissioned in 1956. This TG had not gone through any major repairs since its commissioning. When the rotor was sent to Triveni Turbines for overhauling, the refurbishing team observed pitting and corrosion due to ageing on the blades.

CHaLLEnGEStudying the rotor and redesigning the same in line with the new technologies without compromising on the performance of the same was the main challenge for Triveni Turbines.

Along with this challenge was to reverse engineer, manufacture new blades, assemble the rotor, high speed balance it and ship it – all within a span of 5 months.

SOLuTIOnTriveni Turbines took up the challenge and put the complete cycle on a fast track mode. The project was taken up in different stages which included reverse engineering on the Carl Zeiss, manufacture of blades and sampling for root in 3-4 days for each row.

Independent Power Plant : HP Rotor Rebuild


Triveni Turbine Limited 5

The rotor was completed well within 5 months and shipped to customer. The turbine has since been operating smoothly on full power.

CuSTOMER SPEak“I believe that this machine in particular is quite different from the generation of steam turbines in the way its steam path components are constructed, be it a robust and complex blade assembly design, the materials selected for the construction amongst other factors, which is why I appreciate Triveni Turbines team’s diligence in understanding this complex machine and come out with a repair solution.

The selection of materials for the manufacturing of new blades, shrouds, balancing weights, etc are at par with the best in the industry and I am sure this will add value when we take this turbine on line in the coming few months.

As I have mentioned earlier about the complexity of this project, I believe Triveni Turbines has also derived excellent learning from it which will help you and come out with quick repair solutions when our other HP and LP rotors come up for refurbishment in the near future”.



InTROduCTIOnThe customer is a reputed group in the palm oil segment from Malaysia.

The turbine in operation was completely damaged and the rotor shaft was sheared off.

CHaLLEnGEThe challenge was to rebuild the complete turbine without existing drawings and replace the broken parts ensuring that it operates at the designed efficiencies.

Rebuild : damaged Turbine Reconstructed



SOLuTIOnTriveni Turbines shipped the whole turbine to its factory in Bangalore where the Triveni Turbines team rebuilt the whole turbine through reverse engineering and simulation. The simulation was done using advanced software to ensure that the turbine will operate as per the requirement.

The casing was rebuilt and then a new rotor shaft was designed and manufactured to suit the casing. The entire steam path calculation was redone to ensure that the design was suitable.

There was a need to manufacture new blades and it was found that the old design (root blades) was no longer used. A decision was hence taken after consulting the customer to replace the same with a new blade design.

The entire project was completed within 4 months. The turbine is on full power for over 3 years with no issues since and we have yet another satisfied customer.


InTROduCTIOnThe customer is a large player in the steel and process PCG space in India.

They imported an old plant manufactured in the year 1940 from Germany and wanted to put back the same in operating condition.

CHaLLEnGEThe challenge was to recreate the blade profiles and the blade packets. 10 blades made one packet and every 3rd blade had a profile angle change which had to be incorporated. Further, the original packet was brazed with gold and silver which could not be recreated.

SOLuTIOnTriveni Turbines took up the challenge and created a new methodology to weld the blade packets together and all necessary tests and validations were done to rule out the future possibilities of problems during operations.

Rebuild : Value Engineering of damaged Blade Profiles


The turbine was put into operation soon after the repairs. It has been operational for the past 2 years meeting all efficiency requirements of the customer.

CuSTOMER SPEak“Triveni Turbines is a good engineering company in India capable to standing up with global players and we are glad that we took the decision of doing this project with Triveni Turbines.”


InTROduCTIOnThe customer is an IPP generating over 500 MW of power.

The customer is an IPP from Southern Africa, generating over 500 MW of power. It was operating a Turbine Generator Set which was commissioned in 1956. Post overhauling, a new rotor was replaced in the Turbine. The blades of one row of this rotor broke within 2 weeks of operation. This also led to vibration and damage to the adjacent rows.

CHaLLEnGEThe challenge was to study the reasons of such

failure and redesign the blades to ensure that this does not recur. Triveni Turbines was given

a deadline of 3 months to complete the project.

SOLuTIOnThe blade design was studied in detail to identify

the reasons for the breakage and subsequently necessary design changes were made to ensure that

the same does not recur.

The rotor has now been put into operation and is operating trouble free.

Independent Power Plant : LP Rotor Rebuild



InTROduCTIOnThe customer is a part of a large Sugar group in Southern Africa.

The problem started with a close down in power generation due to break down of their 30 MW turbine at their unit. This turbine had been commissioned just 11 months back.

The first information recorded was that the 30 MW was on full power and due to high vibration the turbine had tripped. The customer approached the OEM who reviewed the rotor and classified it as ‘beyond economical repair’. The customer decided to explore other options and service providers before taking the final decision when the Triveni Turbines team met him. The team reassured him that as an OEM, they could support him in putting back his turbine to working condition.

CHaLLEnGEThe visual inspection carried out at the customers place gave us adequate confidence that we could repair the rotor. The confidence was stemming out of the 2500 turbines we have commissioned across the world and knowing the fact that our turbines operate in more difficult conditions that we had ever witnessed.

To give the customer confidence in our statements we confirmed we would do the RLA and NDT and establish the integrity and life of the rotor.

The rotor was then shipped to India for further analysis.

SOLuTIOnAll necessary tests were carried out as per the established procedures and we documented that the rotor was fit for use and the life of the rotor was also informed to the customer.

Repair and Rebuild : Rotor Classified ‘Beyond Economic Repair’


The rotor was then inspected, reverse engineered, necessary corrective actions taken, re-bladed, high speed balanced in the Schenck tunnel and then dispatched to the customer.


CuSTOMER SPEakThis left just over 3 months to transport our rotor to the Triveni Turbines workshop in Bangalore, affect the repairs, transport the rotor back and commission the turbine successfully. The fact that the team was able to succeed in this very difficult task is testimony to the customer focus and professionalism, not to mention very high levels of competency, that exist in Triveni Turbines.

I will admit that there were times when I doubted whether we could pull this effort off, but we did succeed and I am especially pleased because this validated our decision to award the contract to Triveni Turbines, in the face of some doubts. Triveni Turbines now has a good name and we have not held back extolling the company’s virtues to whoever will listen, what Triveni Turbines did in assisting us in a very difficult situation’.

InTROduCTIOnThe customer is from Southern Africa and is in a niche space in petroleum products operating with large fleet of turbines at multiple locations.

One of the TG commissioned in 1974 was ageing and on open inspection they found that 3 rows of blades totalling 1000 were severely pitted which added a major risk to operations.

They decided to get the job done at Triveni Turbines after a detailed discussion and reassurance from our team. Triveni Turbines gave them confidence on its capabilities.

CHaLLEnGEThe challenge was to complete the project in 11 weeks and the customer was willing to airfreight the rotor both ways.

Triveni Turbines decided to take up the challenge.

SOLuTIOnTriveni Turbines norms were to treat a break down job on the highest priority. This was in a green channel for the manufacture and assembly.

The rotor testing, machining and correction was completed in 11 weeks and shipped to the customer. The turbine is on full power for over 2 years with no issues since.

Replacement : damaged Rotor Blades



CuSTOMER SPEakThe team at Triveni Turbines is professional with good back up in engineering and manufacturing with a number of state-of-the-art equipment which supports manufacturing.

‘Though we faced some difficulties during the project, I sincerely appreciate your team’s patience and confidence in coming out with quick solutions to tide over the situations. Your proactive approach towards problems has also been instrumental in mitigating major risks especially on the engineering, procurement and expediting fronts.

You also have a dedicated team of sub-contractors who can ensure quick turnaround of parts under pressure when needed which we witnessed during the shroud machining. Though the infrastructure and communication leaves a lot to be desired, they are able to achieve the desired results.

Triveni Turbines was ahead of the project till the shroud material was delayed from USA and compounded by material getting rejected.

Outstanding Point: Normally imported materials are accepted and used but Triveni Turbines did not blindly accept the same. They ensured all quality measures were in place to cross check the quality of the material received from USA. The material were promptly tested and rejected. This is in line with our organizations requirement of quality & correct parts.

Despite all the pressure Triveni Turbines proactively took decisions for using the more expensive blade material of different profile for machining showing the proactive approach and the engineering capability to take such informed decisions.

Steam Path design :achieving Higher Efficiency

InTROduCTIOnThe customer is a large player in the steel PCG space in India.

They imported an old plant manufactured in the year 1972 from Germany and wanted the same to be put back in operations with an improved efficiency of 4.8 kg/kw hr to 4.4 kg/kw hr.

CHaLLEnGEThe challenge was to establish the new steam path in the absence of any manufacturing data and to be able to give the customer a solution for the turbine to operate at better efficiencies than the original.

SOLuTIOnTriveni Turbines took up the challenge and decided to map the existing steam path and interpose on it the new Triveni Turbines design to review if it will work.

The new design was a feasible option and would require a full steam path change including introduction of a new row of blades and a new diaphragm.


Based on this a 10 stage rotor was designed to a 11 stage rotor.

We needed to manufacture new blades and found that the old design of root was no longer used and a decision was taken after consulting the customer to replace the same with our new design.

The rotor was rebuilt and assembled in the turbine. The turbine is on full power for over 2 years with no issues since.

On start up achieved a efficiency improvement of 8%. The turbine with these changes is operational for the past 2 years and meeting the efficiency requirement of the customer.

CuSTOMER SPEak“Triveni Turbines has displayed strong engineering skills to translate our requirement to operational reality.

We recommend them to all customers.”



InTROduCTIOnThe customer is a leading player in India in sugar and has a large fleet of turbines.

They had a stoppage in power generation due to break down of their 30 MW turbine at their unit and on information we immediately rushed our service team to their site for inspection and support.

The first information recorded was that the 30 MW was on full power and due to grid fluctuation, high vibration occurred and the turbine tripped. The turbine was over 30 years old and the customer had no past data on the turbine. The customer put his faith in us to put the turbine back on power.

CHaLLEnGEOn receipt of the turbine and inspection of run out we found that the turbine had been subjected to a complex bend of 1.8 mm across the length of the shaft and the challenge was to use the same shaft since the customer had serious financial constraints.

Bend Removal : Rotor Rebuilt


On Receipt Post Thermal Process


SOLuTIOnOn review of the possible solutions the best way forward to remove the complex bend was to de-blade the rotor and subject it to a thermal cycle to remove all the stresses and enable us to bring the rotor within the desired levels of tolerances of straightness. The thermal cycle is shown below and we achieved the desired results.

We were required to manufacture new blades and found that the old design of root was no longer used and a decision was taken after consulting the customer to replace the same with our new design.

The rotor was rebuilt and assembled in the turbine. The turbine is on full power for over 2 years with no issues since.

CuSTOMER SPEak“Triveni Turbines has displayed a lot of engineering skills in being able to bring our turbine into operation.

We had complete confidence in Triveni Turbines and hence on the forced stoppage we put our faith in Triveni Turbines to complete the job for us and they have reposed the faith.”


duBaI OffICETriveni Turbines DMCCUnit No – 30-01-2379Jewellery & Gemplex 3Plot no – DMCC – PH2 – J&GPlexSJewellery & GemplexDubai, United Arab Emirates

www.triveniturbines.com

© Copyright 2015 Triveni Turbine Ltd.

All rights reserved. No part of this brochure may be reproduced, copied, translated, adapted and so on or stored in a retrieval system, tapes, discs, microfilms and so on or transmitted in any form or by any means of electronic, mechanical, photocopies, recording or otherwise, without the written permission of Triveni Turbine Limited.

[Case Study Brochure May 2015]

MaRkETInG OffICETRIVEnI IndIaTriveni Turbine Limited12-A, Peenya Industrial Area,Peenya, Bengaluru-560 058, INDIA.Phone: +91 80 22164000Fax: +91 80 22164100Email: [email protected]

MaRkETInG OffICETRIVEnI ukTriveni Turbines Europe Pvt. Ltd.10th Church Street, Market Deeping,Peterborough, PE68DA,United Kingdom.Phone : +44 (0)1778346998, +44 (0)7477479996Email : [email protected]

ManufaCTuRInG & SERVICE faCILITyTriveni Turbine Limited12-A, Peenya Industrial Area,Peenya, Bengaluru-560 058, INDIA.Phone: +91 80 22164000Fax: +91 80 22164100Email: [email protected]

LOndOn OffICETriveni Turbines Europe Pvt Ltd,18 South Street,Mayfair,London, W1K 1DGUnited Kingdom.Email: [email protected]

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