Retrofit & Modification

Steam & Hydro Turbines

 TEXRON…A ISO 9001:2015 COMPANY
Texron is professionally managed by a team of young aspiring engineers in power
business committed to provide a wide range of products & services to customers
in Thermal & Hydro power plants sector.
The company is focussed on quality, committed delivery and cost effective
solutions, which are the drivers for good reach and acceptance in a short time.
Texron philosophy stands for the customer focused approach in providing the
complete service & solutions in order to achieve higher levels of efficiency.
We enjoy our work and we enjoy our customer accomplishments , but ultimately it
is relationships that we build along the way that brings the greatest satisfaction
and ensures continued success.
Vision, Mission & Quality Policy
Vision
To become a global leader and desirable partner for providing sustainable services and
solutions to customers in Power segments.

Mission
Extending our capabilities in manufacture, supply & services for the Power Plant needs in
Domestic and Overseas market. We target to be One of the leading Global players in
providing specialised Power solutions.

Quality Policy
We, Texron strongly believe in customer satisfaction at every stage through highest quality,
service and affordable pricing to customer, which is achieved by active participation from
every individual in the company. We consistently update the technological development
and take full responsibility for customer needs. We also believe in continual improvement
and quality is our way of growth.
We are the experts Steam Turbine repairs,

in.... steam path study and efficiency restoration.

Reverse engineering & Spares manufacturing.
Short & Long term Service agreements.
Electrical & Automation solutions.
Retrofit & Modernization of Steam Turbines, Hydro Turbines &
Generators.
Manufacturing of Governing Hydraulic systems for Steam &
Hydro Turbines.
Re-location of Power Plants.
Engineering & Consultancy service for Power Plant.
Verticals.....

• Turbine repairs, steam path study and • Electrical & Automation solutions
efficiency restoration.
• Retrofit & Modernization of Steam
• Reverse engineering. Turbines, Hydro Turbines & Generators
• Spares manufacturing. • Total Electrical EPC – Concept to
• Engineering & consultancy services Commissioning.
Why TEXRON…?

• Exposure in many Brand of

Turbines
Competency • Experience of R&M up to 120
MW
• Unique in Retrofits

• Voith
Products • Woodward
• ABB
Experience • MOOG
• CCC

• Developed special Hydraulic

products in retrofit area
Innovations • In house design & testing
• Tailor made solutions
 Advantages of R&M with Texron ...

Criteria Credentials
Being service provider, rich experience in all make and all
Experience type of turbines & R&M is our core area of Business and
executed many challenging projects

knowledge Good experience & knowledge in optimising the right

products of any make & also Experience in various Turbine
governing systems

Compatibil We are in similar in temperament with any OEM in the field

ity in some cases better than OEM

Support Capable to support on products of Woodward, Voith,

function MOOG, CCC and customized solutions, as per specific
requirements
Supports for turbine spares & all type of services
ROI for Retrofits…

Criteria Advantages Key Result

Technology Elimination of Mechanical governor and 1. Improvement in performance.
adopting Electronic governor. 2. Reduces down time.
Mechanical speed sensing converted to 3. More accurate and smooth function.
Electronics. 4. No wear and tear.
5. Easy spares and maintenance.
Monitoring Display and recording of parameters. 1. Continuous condition monitoring.
Historical Trends. 2. Preventive maintenance.
3. Performance assurance.
Automation Pre-determined program controller. 1. Easy operation with less manual interface.
API compatible protections. 2. Assured safety to the Human & Machine.

With above performance, Typical ROI is 18 to 24 Months…

 1

Electronic Governor Retrofit on Siemens /

BHEL Turbines
 SPEED SENSOR

Hydraulic skid:
•New Hydraulic skid with Solenoid
valves in place of old skid.
•IH converter is mounted in the skid.
•Operation of ESV and servo motor
Speed Sensor: covers by the skid.
•Magnetic Pick up for Speed Sensing.
VALVES
•Speed sensing gear teeth wheel is
typically fitted in the front end of
Turbine rotor.
•Speed sensors are fitted on the turbine
front to focus the gear teeth. and Control Panel:
Hydraulic skid. •Control panel accommodates Digital
Governor.
DUPLEX FILTER
•Trip logics and protection wiring is
done in control panel.
•Interface wiring between Control panel
and Hydraulic skid. 11
Hydraulic Scheme for Retrofit on Siemens/BHEL
Turbine

TYPE - 1 TYPE - 2
 Modification of Hydraulic Skid for 50 MW BHEL Turbine

BEFORE

AFTER
 2

Retrofit with Servo Actuator Replacement

Replacement of Servo Actuator with Woodward Varistroke / Voith Servo motor

12 MW SKODA TURBINE Hydraulic Power Pack

Supply and installation

Reasons for Replacement:

Before
 Original Servo cylinder was sticking and
After with
leading to instability.
Varistroke
 No spares support from OEM.
 Oil leakage in the cylinder.

12 MW DRESSER TURBINE P&I Scheme

Method of Execution:
 Installation of new actuator in place of old
servo cylinder.
 Supply of Hydraulic Power pack (16 Bar) for
Servo actuator.
 Interconnection between Power pack and
Servo actuator.
 Mechanical connection to Turbine valve rack.
Retrofit on HTC / HCTC & SIEMENS
Turbines with Voith Servo Motor

About HTC & HCTC Steam Turbines

• HTC & HCTC Turbines are from China, substantially About Siemens Turbine
occupied Global Power Sector.
• Siemens is one of the most familiar OEM in Global the
• Population: Nearly 20% Turbines are operated all over the
Turbine segment.
power sector in the range of 5 MW to 500 MW.
• Spares and services are obtained from OEM and other
• Most of the customers are running short of maintenance
service providers as well.
spares and technically competent service providers.
• Age of the turbines are from 15 to 40 years.
• Age of the turbines are from 15 to 30 years.
Present setup of Servo motor

• The HP / LP servo motor are customized by OEM.

• The principle of servo motor is pilot operated by secondary oil pressure, with
mechanical feedback.
• The pilot valve is made up of aluminum body that may develop crack.
• Mechanical feedback lead to inaccuracy and tend to get disturbed.
• Servo motor chattering is the most common problem in HTC / HCTC turbines due
to oil starvation and lead to valve hunting during operation.
Proposed modification on Servo motor

• The existing cylinder will be retained.

• The Pilot piston assembly will be removed.
EXISTING CYLINDER
• Mechanical feedbacks will be removed.
• Existing IH converter & Secondary oil line will be blocked.
MANIFOLD
• Voith Way valve with manifold will be introduced.
• Electronic position feedback sensor (LVDT) will be
introduced and connected to Way valve.
• Governor signal is directly connected to Way valve.

VOITH WAY VALVE

LVDT
Advantages on the modification
• We adopt optimum modification, replacing only the necessary components to provide
cost effective solution.
• Removal of pilot piston avoids one stage conversion, Governor signal directly acts to
Way valve, resulting fast response.
• Removal of mechanical feedback eliminates inaccuracy, electronic position feedback
improves the accuracy, result in smooth valve operation.
• Servo motor chattering is eliminated by removal of secondary oil and pilot valve
concept.
• Easy maintenance, service and spares availability.
• No existing components are disturbed, hence there is option to restore the old system
for any reason.
 3

Retrofit of Direct acting Pneumatic Actuator

 Retrofit with Voith DTc Governor & Pneumatic Actuator

Supply and installation 4.7 MW WORTHINGTON TURBINE. CUSTOMER: ICS INDORAMA LTD - SENEGAL

Scope of Supply:
 Governor panel with Voith DTc Electronic
Governor.
 Valtek make Pneumatic actuator with complete
new spindle assembly in place of PG PL
mechanical Governor.
 Vibration monitoring system for gear box.

Method of Execution:
 Installation of Valtek pneumatic actuator in place
of old fulcrum drive.
 Installation of Governor panel.
 Interconnection between governor and Valtek
actuator.
BEFORE AFTER  Interconnection between vibration monitoring
system and field sensors.
Retrofit with Voith DTc Governor, Direct acting Pneumatic Actuator & speed sensing wheel

Valtek make Pneumatic actuator

Teeth Wheel with Speed Sensors

Turbine Control Panel
 4

Retrofit of 120 MW SKODA make Turbine with ABB

TORRENT POWER LTD - Sabarmati Power Station
 About Torrent Power Ltd

•Major Utility Power Producer in

India .

•Distribute 450 MW Electricity

to Ahmedabad city.

•Generating about 3000 MW

power through various power
plants across the Country.
 Retrofit Of 120 MW SKODA Turbine
SCOPE OF SUPPLY :

Supply of Voith make I/H Converters.

Supply of Woodward make Over speed Protection system and speed sensors.

Manufacturing and Supply of Redundant I/H Converter block.

Manufacturing and Supply of 2 Out of 3 Logic Hydraulic trip block.

Manufacturing and Supply of Acceleration valve for Over speed prevention.

Manufacturing and Supply of Teeth wheel and sensor mounting brackets.

Supply of Pressure Transmitters. & Switches.

Supply of complete pipes and hardware.

Installation, testing and commissioning.

 Project Highlights

•The Redundant I/H converter block and 2 Out of 3 Logic Hydraulic trip block are India’s first
development products by Non-OEM.

•The complete design, development, manufacturing and supply has been achieved within 12
weeks time.

•All the equipments are tested for functionality at our works.

•Installation and commissioning has been achieved in 3 weeks time.

•Complete system has been proven for successful functionality.

•Turbine full load operation achieved and all parameters satisfactory.

Hydraulic Scheme for Governing System
 Modification

BEFORE

AFTER
Turbine Before – After Modification

BEFORE AFTER
 5

TEXRON GEO-THERMAL R&M WITH ABB

EDC PHILIPPINES 3 X 20 MW FUJI TURBINE
 Green Core Geothermal, Inc.
Palinpinon Geothermal Power Plant

• Located in Puhagan and Malauany, Valencia,

NEGROS Oriental.
• A beautiful location, on top of hills at 935
Meters (MSL).
• Installed capacity is 192.5 MW.
• Successfully completed 25 years of operation.
 Geothermal Turbine Governor Retrofit

• Fuji make Geothermal Turbine 3 x 20 MW supplied on

1993 in Philippines.
• Presently running with hydro mechanical governor with
governor oil pressure of 9 bar.
• The turbines operation found sluggish during grid
fluctuations and sudden frequency variations.
• The R&M solution is providing high pressure oil system
for governor control in conjunction with present low
pressure protection system.
 KEY PARTS FOR RETROFIT

The Retrofit involved following key modifications:

 Present low pressure actuators for Main steam stop valves (MSV) and control valves (CV) are removed.

 Associated pipelines for old MSV and CV actuators are removed.

 Hydro mechanical governor cabinet is removed.

 New High Pressure oil unit (135 bar) is introduced.

 Linear actuators for MSV and Rotary actuators for CV are introduced to operate in 135 bar.

 Protection system is 2 out of 3 voting based Voith make trip block.

 Complete new high pressure piping for MSV and CV.

 Turbine control system is ABB – Symphony Plus.

 Modification Photos – BEFORE - AFTER

Main Steam Valve Rotary Actuator Gov Hyd. Cabinet

BEFORE

AFTER
 HIGH PRESSURE GOVERNING OIL SYSTM

• Separate HP oil tank & OPU.

• Operating pressure 135 bar.
• Main & standby pumps.
• Kidney loop pump for pre-heating.
• Air cooled heat exchanger.
• Piston Bladder accumulator.
 REPLACEMENT OF AVR SYSTEM
EXISTING ANALOG AVR REPLACED WITH ABB UNITROL 6000 SYSTEM

BEFORE AFTER

Analog AVR System Digital AVR System

 REPLACEMENT OF AVR SYSTEM
SCHEMATIC SLD OF ABB UNITROL 6000 SYSTEM

Key Features:
• Fully Digital Control.
• Dual channel hot redundant.
• Fastest control in critical grid conditions.
• Historical Trends for fault Analysis.
• Operator Interface with HMI / SCP
• Modbus TCP/IP Protocol
 6

CPC REPLACEMENT IN SIEMENS TURBINES

 Retrofit of Voith IH Converter in place of Woodward CPC
Supply and installation VOITH IH Converter & Adopter Plate

Woodward CPC Scope of Supply:

 Supply of VOITH IH Converter along with plug connecter and cable.
 Supply of CPC to IH Converter Adopter plate.
BEFORE
 Fixtures and Hardware for installation.

Reason & Method of Execution:

 Siemens Turbine servomotor ports and dimension are provided suitable for
Woodward CPC by OEM.
 Many CPC installation are running in and out of India.
VOITH IH CONVERTER  Woodward CPC if faced many kinds are operation issues and frequent
AFTER failure.
 Customers prefer Voith IH converter in place of CPC.
 Our solution involves supply of Voith IH converter along with conversion
plate, that suits to existing dimension on the servomotor.
 Easy replacement with minimum down time.
ADOPTER PLATE
 7

Governor Retrofit on Hydro Turbines

 Texron Services For Hydro Turbines

Our Supports for Hydro Turbines

 Manufacturing and supply of Governing Hydraulic system (Valve table assembly).

 Manufacturing and supply of Speed sensing wheel, Over speed trip hydraulic device and

mounting accessories.

 Revamping and Automation of MIV and Silt Gates.

 Supply of hydraulic valves and instruments.

 Overhauling services for existing hydraulic systems.

 Maintenance of valve table assembly and hydraulic accessories.

 Retrofit of Governing Hydraulic System

We provide design, engineering, manufacture, assembly and Governing

Hydraulic system that generally consists of:

 MS modular manifold block for mounting all valves.

 Duplex oil filter.
 Proportional valve for Guide vane control.
 Proportional valve for Runner control (for Kaplan Turbine).
 Directional & logic valves for manual operation.
 Directional & logic valves for emergency trip.
 Valve Table Assembly (VTA)with manifold and valves duly mounted.
 Pressure gauges / transmitters as per requirement.
 Electrical junction box with duly wired for external connection.
 Typical Modification in Governor Retrofit

As optimum modification, the regular practice (unless specified by customer) is as below.

 Existing OPU tank, pumps and motors are retained intact.

 Existing pressure vessel / accumulator is retained intact.
 Existing Guide vane cylinders are retained intact.
 Existing Runner blade cylinder actuator is retained intact.
 Existing Hydro Mechanical Cabinet (HMC) is removed from its position.
 Inlet & outlet pipes are cut at nearest point to HMC.
 New Valve Table Assembly (VTA) is installed at the position of HMC.
 Inlet & outlet pipes are connected to VTA with suitable orientation.
 Speed sensing teeth wheel and mechanical over speed hydraulic device are installed in the
turbine rotor.
 Piping from over speed hydraulic trip device to VTA is connected.
 Governing System Diagram for Kaplan Turbine
A Typical Governing System Line Diagram with HMC:
 Typical Replacement of HMC / MDV with VTA
A Typical Internal components diagram of HMC/MDV & VTA

HMC – BEFORE RETROFIT VTA – AFTER RETROFIT

 Typical Replacement of HMC (MDV) with VTA

PICTORIAL REPRESENTATION OF HMC & VTA

VTA – AFTER RETROFIT

HMC / MDV – BEFORE
RETROFIT
 Additional Parts in Retrofit

Other additional Parts in Retrofit:

Teeth Wheel for Speed sensing.

Mounting holders for speed
sensors.
Over speed trip device.
 OUR PRODUCTS GALLEY IN R&M

2 Out of 3 Trip Block Teeth Wheel for Hydro Turbine

with Mechanical Over speed Trip
Valve position Sensor Hydraulic Power Pack
for Servo Motor

Throttle valve with Turbine Control Panels with TG & Grid Load Sharing
Pneumatic Actuator Governor & Turbo-visory system Governing Hydraulic Skid Hydraulic Power Pack Panel
for Servo Motor
 7

Retrofit of Relays & Electrical Panel

Solutions
RETROFIT OF PROTECTION RELAYS
R&M solution for Electromagnetic Relays with Numerical Relays

Reasons for Replacing Electromagnetic Relays:

 Obsolete in Technology.
 Wear and Tear due to mechanical operation.
 No records and trending.
 Difficult for Spares and services.
 Accommodates huge space & Increase in panel size.

Advantages in Numerical Relays:

 Latest in Technology and Compact size.
 No mechanical device and no wear and tear.
 Lesser burden of CT and PT.
 Measurements, Alarm, Trip and Trend facilities.
 PC Connectivity & Online monitoring.
 ELECTRICAL SOLUTIONS

Design & Manufacturing Electrical panels

LA, SC, PT Panel LT Distribution Panel Non Compartment MCC

LT Distribution Panel Turbine & Generator Turbine Load Sharing

Control Panel Panel
Project pinnacles
• Adopting world class state of art proven product, approved globally by all OEM.
• Trouble free operation increases reliability and quality.
• User friendly, proven for environment and easy maintenance.
• Elimination of existing problems, convert to better production.
• Minimum down time for assembly and re-starting.
 Reference R&M Projects in our Carrier hood
Sl.No Name of Customer Turbine Detail R&M Detail
1 Sarda Energy & Minerals Ltd, Raipur 30 MW, Siemens make Electronic Governor & Vibration system
2 Sarda Energy & Minerals Ltd, Raipur 2 x 30 MW, Borsig make Electronic Governor for water governing system
3 Godawari Power & Ispat Ltd, Raipur 2 x 10 MW, Parsons make Electronic Governor & Over speed protection
4 Godawari Power & Ispat Ltd, Raipur 10 MW, Hitachi make Electronic Governor & Over speed protection
5 Century Pulp & Paper Ltd, Lalguan 6.8 MW, BHEL make Electronic Governor & Hydraulic system
6 Century Rayon Ltd, Shahad 3.0 MW, BHEL make Electronic Governor & Hydraulic system
7 Vishal Papers Ltd, Patiala 5.4 MW, AEG-Kanis make Electronic Governor & Hydraulic system
8 Bhavani Sugars Ltd, Karnataka 1.5 MW, Skoda make Electronic Governor & Hydraulic system
9 Relience Ltd, Vadodara 12.5 MW, BHEL make Electronic Governor & Hydraulic system
10 Parle Biscuits Pvt Ltd, Lucknow 3.0 MW, Belliss make Electronic Governor
11 India Glycols Ltd (Shakumbari sugars, UP) 4.2 MW, PBH make Electronic Governor
12 India Glycols Ltd (Shakumbari sugars, UP) 3.25 MW, WH Allen make Electronic Governor & Hydraulic system
13 Atul Limited, Atul 2 x 5 MW, Triveni make Electronic Governor
14 S.V.Sugar mills Ltd, Kanchipuram 27.3 MW, Siemens make Electronic Governor & Hydraulic system
15 K.C.P.Sugar & Industries Ltd, Vuyyuru 12.5 MW, Siemens make Electronic Governor & Hydraulic system
16 Biltube Industries Ltd 6 MW English Electric make Electronic Governor & Hydraulic system
17 Gujarat Industries Power Company Ltd, Vadodara 50 MW BHEL make Electronic Governor & Hydraulic system
18 Chembal Fertilizers Ltd, Kota 6 MW BHEL make Electronic Governor & Hydraulic system
19 IFFCO # 1 – Bareli 12 MW BHEL make Electronic Governor & Hydraulic system
20 IFFCO # 2 – Bareli 25 MW BHEL make Electronic Governor & Hydraulic system
21 Zuari Fertilizers Ltd, GOA 12 MW Dresser make Hydraulic Power pack & Servo cylinder
22 Birla Copper Ltd – Dahej 12 MW Skoda make Hydraulic Power pack & Servo cylinder
23 Tata Steels Ltd, Jamshedpur 6 MW BHEL make Redundant CPC hydraulic system
24 Torrent Power Ltd, Ahmedabad 120 MW Skoda make Electronic Governor & Hydraulic system
25 Indo Gulf Ltd, Lucknow 15 MW BHEL make Electronic Governor & Hydraulic system
26 Nepa Ltd 8 MW BHEL make Electronic Governor & Hydraulic system
27 Depriya Papers Ltd, Meerut 3 MW Maxwatt Turbine Electronic Governor
28 Vishal Fabrics Pvt Ltd, Ahmedabad 3 MW Triveni make Electronic Governor
29 Sukari Industries Ltd, Kenya 3 MW Triveni make Electronic Governor
30 National Fertilizers Ltd – Vijaypur TAIO LTD Japan Electronic Governor & Hydraulic system
31 ICS Indorama Ltd – Senegal 4.7 MW Worthington make Electronic Governor
32 EDC – Philippines (Geothermal Application ) 3 x 20 MW FUJI make Supervision of Hydraulic system
33 KSEB – Panniyar 18 MW BHEL Hydro Turbine Governing Hydraulic system Re-vamping
34 NHPC – Salal 6 x 110 MW BHEL Hydro Turbine Re-vamping Penstock & Silt gate Hydraulics
35 IOCL – Barauni (CCC) 3 MW BHEL make Compressor drive Turbine
Countries we serve…

Turkey

Bahrain Bangladesh

TEXRON
Senegal Bangalore

Philippines

Ghana Srilanka
Malaysia
Uganda
Singapore
Kenya
Indonesia
Tanzania

Zambia

Uruguay
texronpower.com

For more information, please contact:

R. STANLEY JAYAKUMAR, +91 8904017774

B.G. JAGADISH, +91 8904017775
OFFICE: +91 6364829650

Regd Office: No. 1/16 – 3RD FLOOR, NG ARCADE, HESARAGHATTA MAIN ROAD, BANGALORE – 560073.