Rotor Reconditioning of Steam Turbine Generator STG-2, GT-1602

PT Pupuk Kalimantan Timur (PKT), the largest fertilizer producer in Southeast Asia, relies on a series of critical utility units to support its continuous production process. Among them is the Steam Turbine Generator STG-2, GT-1602 at Utility Plant P6, a vital asset responsible for ensuring uninterrupted power and steam supply across the facility.

After years of long operational hours under extreme thermal and pressure conditions, the turbine rotor began showing performance degradation. Recognizing the strategic importance of this asset, PKT engaged Taka Turbo to execute a comprehensive rotor reconditioning project—aimed at restoring full operational capacity while minimizing production risks.

The Challenge

The project presented several key challenges:

Component Wear and Tear
Prolonged exposure to high temperature and pressure environments caused significant material degradation.

Rotor Imbalance Risk
Imbalances threatened not only efficiency but also the safe and stable operation of the turbine.

Tight Project Timeline
The repair had to be completed within a strict timeframe to prevent costly downtime and production disruption.

Our Solution

Taka Turbo deployed a systematic and multi-stage reconditioning program, combining advanced diagnostic techniques with precision engineering:

1. Non-Destructive Testing (NDT)
To identify micro-cracks, hidden flaws, and early-stage material fatigue.

2. High-Precision Rotor Balancing
Ensuring smooth rotation, reducing vibrations, and stabilizing long-term performance.

3. Targeted Repair & Reconditioning
Addressing worn-out sections through specialized machining, welding, and material restoration.

4. Multi-Level Quality Control
From initial inspection to final reinstallation, every stage followed strict quality protocols to guarantee reliability.

The Result

The reconditioning project delivered measurable improvements:

Performance Fully Restored
The turbine rotor returned to peak operational efficiency.

Significant Vibration Reduction
Stable operation was ensured, protecting both the equipment and surrounding systems.

Extended Component Lifespan
Optimized durability minimized the likelihood of future failures.

On-Time Completion
The project was executed precisely within the agreed timeframe, allowing uninterrupted production at PKT.

Business Impact

This project reinforced PT Pupuk Kalimantan Timur’s operational reliability and energy efficiency, while highlighting Taka Turbo’s capability as a trusted partner in industrial turbine reconditioning services.

This project not only secured operational reliability for PT Pupuk Kalimantan Timur but also contributed to greater energy efficiency and production stability. By entrusting Taka Turbo, PKT reinforced its commitment to sustainable, high-performance operations.

For Taka Turbo, the success of this project underscores our position as a trusted partner in industrial turbine reconditioning, delivering value through engineering excellence, reliability, and timely execution.