2.5MW Industrial Power Plant Turbocharger Refit & Overhaul
Continuous heavy-duty turbine overhaul and compressor cartridge overhaul for heavy manufacturing plant
Project Overview & Operational Context
A 2.5 MW captive power plant supplying electricity to continuous textile and steel production suffered severe thermal degradation and compressor surging, reducing generator capacity by 28%. Nordroy was contracted for complete overhaul, thermal crack repair, and performance tuning.
Engineering Performance Metrics
Power Recovery
Restored generation to full 2.5 MW nameplate rating
Thermal Efficiency
Significant reduction in specific fuel consumption
Downtime Adherence
Completed 8 hours ahead of critical 96h limit
Availability Guarantee
Zero unplanned outages since commissioning
A continuous manufacturing process with hundreds of loom lines could only sustain a maximum 96-hour plant shutdown. Casing distortion and blade micro-fractures required on-site metallurgy and immediate precision remediation.
Utilizing our portable dynamic balancing equipment and high-purity argon micro-TIG welding rigs, we repaired the gas inlet casing on-site, replaced the turbine rotor assembly, and dynamically balanced the rotor to aerospace tolerances. Total heat rate improved by 6.4%.
Scope of Technical Work & Overhaul Steps
- On-site cartridge dismantling with specialized hydraulic pullers
- Fluorescent penetrant inspection (NDT) to identify invisible micro-fissures
- Micro-TIG argon welding of casing erosion using nickel-alloy filler wires
- Dual-plane dynamic balancing of compressor wheel and turbine shaft assembly
- Laser alignment between generator shaft, gearbox, and turbine rotor
- Full electrical load testing and vibration signature spectrum analysis
Photographic Documentation
Click photo to enlarge
Project Specifications
2024- Client
- Apex Industrial Energy & Steel Consortium
- Location / Port
- Gazipur Industrial Belt, Bangladesh
- Industry Sector
- Heavy Industry / Captive Energy
- Equipment Rating
- 2.5 MW Dual-Fuel Turbocharged Generating Unit
- Execution Window
- 4 Days Scheduled Maintenance Outage
- Classification
- ISO 9001:2015 Class A Certified
- Project Status
- Operational & Fully Commissioned
Need Urgent Flying Squad or Dynamic Balancing?
Our mobile engineering squads mobilize within 2-4 hours for maritime anchorage and industrial plants across Bangladesh and Southeast Asia.
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