Suzlon Energy Ltd.

STVCastings UsageDecisionforLTV
ATAnsari

Casting Forging Fabrication Fasteners Machining

BusinessCase

Suzlon Energy Ltd.

30Windturbinesareassembledforstandardtemperatureversion(STV) Assess canweusetheseturbinesinlowtemperatureversion(LTV)? Assess, ForUTS,0.2%Proofstrength,%elongation,thoughspecificationsare differentforLTV&STVbutfromactualtestreportsassessmentcanbe d done f forqualification lf toLTV ForSTVimpactischeckedat20C&forLTVimpactischeckedat40C UTS,0.2% UTS 0 2%Proofstrength&%elongationarecheckedinsamemannerfor STV&LTV Canwearriveatroughestimatedimpactvalueat40Cfortechnical decisionmaking?

Define
ProjectName Objective Benefits

Suzlon Energy Ltd.

AssessmentofSTVcastingsforLTVsuitability Arriveatroughestimatedimpactvalueat40Cfortechnical decisionmakingofSTVcastingsforacceptanceunderLTV

TurbineConversion willprovidedirectlygivehugebenefitofcash inflowforturbineswhicharecurrentlyongroundasinventory ProjectTeam Mr.Seenivasa Ragavan (HeadQA SEFORGE)

AbdullahAnsari(ASQCSSBB)

Schedule

Measure 24Jan2013

Analyze 27Jan2013

Improve

Control

Measure:TestProgram g
PlannedActions

Suzlon Energy Ltd.

IdentifycastingmanufacturedforSTVgradewithnormalprocess control ConductnormaltestingforSTV ConductadditionalimpacttestforLTV Recordthedataforanalysis.

Measure:TestData

Suzlon Energy Ltd.

Analyze: y Relationship p

Suzlon Energy Ltd.

Analyze: y Relationship p

Suzlon Energy Ltd.

Signal: Impactvaluedecreasesastesttemperaturedecreases At20:MaxImpact14.43atelongationof23.6%&MinImpact10.5atelongationof17% At40:MaxImpact8 8.5 5atelongationof21 21.7% 7%&MinImpact5 5.1 1atelongationof20 20.6% 6%

Improve p :FactorAnalysis y

Suzlon Energy Ltd.

Drawaregressionequationconsidering3significantfactors Impactat40C=18.2 (0.0508*UTS)+(0.112*impact@20C)+(0.0232*YS)

Control:ValidatetheEquation q

Suzlon Energy Ltd.

Outof14actualimpactvaluesat40,3doesnotmatchverycloselywithresultof regressioncalculation&11actualvaluesmatchwithin1Joule
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Way yForward:Recommendations

Suzlon Energy Ltd.

Whileconductingthisstudysomeotherparametersareconsidered meetingstandardnorms,sametobeverifiedbeforeusingthisequationto estimateimpactofLTV,whichare Nodulecount/Nodularity Nodule d l Size&Shape h UTS,YS,Elongation

Usethisequationwithcarethatitmaygiveresultwhichmaybehigheror lowerthanactualvalue(iftested)by1Joule.E.g.ifcalculatedis7Jitcan beactually6Jalsowhentested Thisequationisnotanalternatetoactualimpacttestingat40C,hence tousedonlyforcastingswhicharereleasedinassembly&whereimpact testforLTVisnotpossible. Decisionmustbetakenbyqualifiedpersonnelonlyandmustbe documented.

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ActualDatawithcalculatedestimateofimpactat40degree

Suzlon Energy Ltd.

Version STV 11 LTV

Min 10.26 5.73

Max 15.53 7.03

Avg 14.10 6.36

ComparisonofCalculatedimpactvalues with ithA Actual t l

ComparisionofCalulatedImpactvaluesat 40degreev/sActual@20degree
18.00 8 00 16.00 14.00 12.00 10.00 8 00 8.00 6.00 4.00 2.00 0.00 1 3 5 7 9

Suzlon Energy Ltd.

11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 Impact@20degree CalculatedImpact@40degree

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Suzlon Energy Ltd.

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Suzlon Energy Ltd.

ThankYou

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