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STVCastings

ATAnsari

ForgingFabricationFasteners

1

Machining

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BusinessCase

30Windturbinesareassembledforstandardtemperatureversion(STV)

,

ForUTS,0.2%Proofstrength,%elongation,thoughspecificationsaredifferentforLTV&STVbutfromactualtestreportsassessmentcanbe

doneforqualificationtoLTV

ForSTVimpactischeckedat20C&forLTVimpactischeckedat40C

, .

STV&LTV

Canwearriveatroughestimatedimpactvalueat40Cfortechnical

decisionmaking?

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Define

ProjectName AssessmentofSTVcastingsforLTVsuitability

Objective

Arrive

at

rough

estimated

impact

value

at

40C

for

technical

decisionmakingofSTVcastingsforacceptanceunderLTV

TurbineConversion willprovidedirectlygivehugebenefitofcash

inflowfor

turbines

which

are

currently

on

ground

as

inventory

ProjectTeamAbdullahAnsari(ASQCSSBB)

Mr.Seenivasa Ragavan (HeadQA

SEFORGE)

Schedule Measure Analyze Improve Control

24Jan2013 27Jan2013

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Measure:Test

Pro ram

PlannedActions

control

ConductnormaltestingforSTV

ConductadditionalimpacttestforLTV

Recordthe

data

for

analysis.

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Measure:Test

Data

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Anal ze:Relationshi

6

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Anal ze:Relationshi

Signal:

Impactvaluedecreasesastesttemperaturedecreases

At20:MaxImpact14.43atelongationof23.6%&MinImpact10.5atelongationof17%

7

. . . .

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Im rove:Factor

Anal sis

Drawaregressionequationconsidering3significantfactors

Impactat40C=18.2 (0.0508*UTS)+(0.112*impact@20C)+(0.0232*YS)

8

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Control:Validate

the

E uation

9

Outof14actualimpactvaluesat40,3doesnotmatchverycloselywithresultof

regressioncalculation

&

11

actual

values

match

within

1Joule

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Wa

Forward:Recommendations

Whileconductingthisstudysomeotherparametersareconsidered

meetingstandardnorms,sametobeverifiedbeforeusingthisequationto

estimateimpactofLTV,whichare

Nodulecount/Nodularity

NoduleSize&Shape

UTS,YS,Elongation

lowerthanactualvalue(iftested)by1Joule.E.g.ifcalculatedis7Jitcan

beactually6Jalsowhentested

Thisequation

is

not

an

alternate

to

actual

impact

testing

at

40C,

hence

tousedonlyforcastingswhicharereleasedinassembly&whereimpact

testforLTVisnotpossible.

Decisionmustbetakenbyqualifiedpersonnelonlyandmustbe

documented.10

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Suzlon Energy L td.ActualDatawithcalculatedestimateofimpactat40degree

11

Version Min Max Avg

STV 10.26 15.53 14.10

LTV 5.73 7.03 6.36

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Suzlon Energy L td.ComparisonofCalculatedimpactvalues

w

c uaComparisionofCalulatedImpactvaluesat

40degreev/sActual@20degree

14.00

16.00

18.00

10.00

12.00

4.00

6.00

.

0.00

2.00

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51

12

Impact@20degree CalculatedImpact@40degree

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Suzlon Energy Ltd.Suzlon Energy Ltd.

13

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Thank

You

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