Triveni Turbine Ltd

After Market Solutions

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 1

Index
Sl. Subject Page

1. Triveni Turbines life cycle solutions 3

2 Repair, rebuild, retrofit capability 4
3 Value proposition 5
4. Key resources 6-7
5. IT and customer interface 8

6. Key performance indicators 9

7. India offices 10
8. Case studies 11-24
9. Customer Perception 25-28

10 Contact 29

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 2

 Turbine Lifecycle Solutions
• Overhauls
• Residual Life, Health survey and • 24/7 availability of personnel
condition Assessment • 4 decades of experience in
• Up gradation and Indigenization
handling turbines.
• Reverse Engineering and
• Various options for service
• Re-engineering
support to customers
• Full speed balancing
• Continuous training programs
• Retrofitting of turbovisory systems
for service engineers to
• Modernization of Power & Control
upgrade skills
systems
• Relocation of turbine Islands
• Complete plant staffing
• Based on knowledge of turbines, • Fuel Management
efficiency improvement packages • Planned and unplanned
evolved alongwith customers. maintenance activities
• Strong R&D back up • Training
• Continuous improvements assist
value engineering
• Operation reliability
• Erection & commissioning of
• Reverse engineering capability with Triveni turbine island and
facilities like CMM, Material Erection & other equipment in scope
inspection, Fleet of Multi Axis Commissioning • E & C either on turnkey or
Machining center and Quality supervision basis
systems State of the Art Manufacturing • Skilled and experienced team
facility & Quality systems handling the projects

RESOURCE TO RESOURCE LEVEL OUTSOURCING : ON DEMAND RESOURCE DEPLOYMENT

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Refurbishing & Repairs
• The team handles turbines other than Triveni brand
• Steam Turbine Solutions offered are WE
CARE
i. Overhauls
ii. Residual Life Assessment
iii. Health survey and condition assessment
iv. Up gradation and Indigenization
v. Efficiency improvement solutions
vi. Reverse Engineering and Re-engineering
parts for supply
vii. Full speed balancing
viii. Retrofitting of turbo-visory system

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Value Proposition

As an OEM we
Latest machines
bring to the table - RIL,
To best fit damaged including With quick turn
parts Use of - Aditya Birla,
around and fit,
• Latest Maihar Cement
5 axis Lichtie ,
technology for India
Carl Zeiss CMM MHI Gantry and - IOCL
repairs
Engineering S/W Schenck High manufacturing - Banpong Sugar,
speed balancing
• Standardization base provides a - Medine Sugar,
Reverse engineer tunnel
of design Many other
cost benefit to
assuring future parts to ensure turbines across
ease of best fit to turbine Ensures quick customer industry spectrum
replacement turn around of
parts parts

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Key Resources – Equipment

Thermal stability facility Gantry milling machine CMM for reverse Portable boroscope for
for bend removal for casing machining engineering of parts in-situ inspection from
from MHI from Carl Zeiss GE

5 axis blade CNC turning centres CNC VTL Machining for On site vibration
manufacturing machine from Mazak repairs of large casings monitoring analyser &
from Lichtie & diaphragms field balancer

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 6

Key Resources – Equipment

High Speed Balancing Tunnel

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 7

IT Enabled Operations and Reporting
CUSTOMER INTERFACE
• MS Projects
• Lotus Notes
• Prima Vera
• DMS (Document Management System for CCC Department
• SAP

SOFTWARE DESIGN, FOR DESIGN & PROCESS PLANNING

• Ansys
• Auto CAD
• Pro E
• Hyper Mesh
• Uni graphics
• Dyrobes
• CFD
• Vericut
• Top solid

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CC - Key Performance Indicators
S.N Parameters Achieved
Resolution Time for solving 85% of Customer
1 < 48 Hours
Complaints

Resolution Time for solving 12% of Customer

2 < 5 Days
Complaints

Resolution Time for solving 3% of Customer

3 < 4 Weeks
Complaints
4 % of Spares Availability 100%

• Maintaining 99 % uptime of the current installed capacity of 1400 active

Steam turbines
• Proven competency in servicing other make turbines
• Overhauls > 700 Turbines every year ( Includes power and drive Turbines )

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Triveni India presence and support for International markets

• Total service strength – 180

• The location of each office is
Chandigarh identified based on ability
Noida / to reach customer
Delhi
• Benchmark to ensure we
reach customer with in 24
Ahmedabad Allahabad hours of a call
Kolkata
Nagpur • Service centers are
Mumbai equipped adequately to
Pune
Latur
support customer
Hyderabad
Kolhapur • International locations are
Vijaywada supported from India by
Bangalore Triveni Head Office engineers with valid travel
Triveni Turbines Works documents to travel at short
Service Centres notice

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 10

 Case Studies

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 11

Mechanical – 30 Mw turbine rotor repair

Customer Report:

• Turbine overhauled and during re-commissioning the TG

experienced high vibrations and was immediately shut down.

• Rotor Gland areas subjected to heavy rubbing & rotor seized

due to bend of 1.8 mm

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 12

Bend removal & repair of HP 30 MW rotor

Rotor after removal of

Dis-assembly of Rotor post thermal Thermal cycle Time Vs
blades, under thermal
blades after inspection Stability Temperature
stability

post Thermal Stability

Rotor run out values on lathe for correction In process on lathe Bend removal complete
post thermal stability of residual run out

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 13

Process completed with Reverse Engineering

Rotor post re-blading Drawing from reverse engineering

STG running on load for the past 2 years

14
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Mechanical Case Studies

Turbine efficiency improvement by redesign of steam path

Customer Report:

• Purchased a 7.5 MW 2nd hand machine from Europe

• To improve efficiency and performance

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Redesign of steam path

Original with 10 stage Modified design with 11th

Old turbine as received
rotor stage introduction

Casing modified for one

New diaphragms Turbine as ready for despatch
additional diaphragm

To change the steam path for improved efficiency. Improvement of 8% achieved

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 16

Mechanical Case Studies

10 MW TURBINE REBUILD

Customer Report:

• Year of manufacture -1940

• Turbine imported by customer to be rebuilt and commissioned.

• Damaged rows of Rotor and casing to be re-bladed

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 17

10 MW Turbine Re Build

Blades re-designed. Laser Groove preparation for

Damaged rows of blades
welding done blading

Blade packet fitment in Special spacers to ensure

Ready for despatch
groove fitment

Damaged blades in casing Rows identified for blading Rebladed row

STG put on load and operating as per requirement for the past 1 year

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 18

Mechanical Case Studies
5 MW TURBINE REPAIR
a) Re-blading of Curtis stage and 6 Rateau stages (stage 2, 3,7,8,9&10)
b) Replacement of fully bladed 6 discs (Rateau stage 3,4,5,6,11&12)
c) Replacement of 5 diaphragms (stage 4,5,6,11&13)
d) Replacement of fully bladed inter holder assembly
e) Modified design of Curtis stage blading from welded type shrouding to riveted
type
f) Correction of bore ovality in old bladed discs of stage 13 & 14
g) Correction of coupling flange face out and enlarging coupling holes and
supply of new bolts suitably
h) Correction of thrust collar face out and supply of new thrust pads suitably
i) Supply of new bearings and labyrinth seals
j) Full speed balancing and over speed test of rotor
k) Re-erection and Commissioning

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 19

5 MW Turbine Repair

Repaired and
Damaged rotor Re-bladed rotor Damaged diaphragm
repositioned

Original welded shroud Modified to rivetted Damaged diaphragm Repaired diaphragm

STG put on load and operating as per requirement for past 1 year

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 20

Mechanical Case Studies
35.2 MW TURBINE OVERHAULING

Overhauling of CPP :

• STG not taking load more than 22 MW

• TEIL offered to overhaul & rectify the problem with in 10 days.

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 21

35.2 MW Turbine Overhauling

Single casing turbine Removal of insulation Rotor protocols recording

Excessive scaling noted Rotor lifted for cleaning Lifting in progress

Overhauling of controls Box up

STG put on load on 9th day as against 10 days as per commitment and loaded up to 29 MW.

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Retrofitting of Turbo visory Systems

Triveni turnkey expertise services for retrofitting of turbovisory systems like Governing
machinery management & power management systems

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 23

Electronic Governor Retro fitment of a 37 MW Turbine
Integration of existing water operated control system with electronic governor and
retrofitting of vibration monitoring system

Retrofitted with hydro

mechanical actuator

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 24

Customer Perception

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 25

Customer Perception
Mean scores on 7 point scale

Overall Triveni Competitor 1 Competitor 2

Expectations
% 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 . .

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Customer Perception
Mean scores on 7 point scale
Competition Customers
% Relative impact on Overall
After sales support Competitor 1 Competitor 2 Competitor 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

Based on quartile analysis < 5.67 > 5.82

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 27

 Customer Speak
“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)”
“Thanks so much for organising Ashok to visit us. We were impressed with his knowledge and
were able to get the turbine serviced adequately. “

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

”The overhauling job of STG and the auxiliaries was carried out under the guidance and supervision of Mr CK Taneja .
We appreciate 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 MW extraction
condensing , 30 MW extraction condensing

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
will complete 2 years of operations. The 30 MW TG which we have understood is among the first one supplied by Triveni is
performing well above our expectation with consumption of 3.87 kg/KW
We are pleased to inform you that we are happy about having taken the decision of going with Triveni Turbines. All turbines
are performing as per the performance curves provided”

C Proprietary & Confidential 2013, Triveni Turbine Ltd June 2013 28

Sudhir Srivastava Sujay G
sudhirsrivastava@triveniturbines.com sujayg@triveniturbines.com

Triveni Turbine Ltd.,

12-A,Peenya Industrial Area, Bangalore, KA India

Contact : +91 80 22164000

Email : rfb@triveniturbines.com
Visit us at : www.triveniturbines.com

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