Onsite Head Cover Maintenance & Repair

Saguling Hydropower Plant (PLTA Saguling), operated by PT Indonesia Power, is one of Indonesia’s key renewable energy facilities, contributing significantly to the Java-Bali grid. In 2024, MI+ Unit 2 experienced structural degradation on its turbine head cover, a critical component ensuring sealing performance, hydraulic balance, and safe turbine operation.

Due to the unit’s strategic importance, the repair had to be executed directly at the plant site, avoiding long transportation delays and minimizing downtime. PT Indonesia Power entrusted Taka Turbo’s onsite team to carry out the project.

The Challenge

Severe Material Degradation
Cracks and wear developed after prolonged exposure to high hydraulic pressure.

Operational Risks
A damaged head cover could cause leakage, loss of efficiency, and potential turbine instability.

Onsite Execution Complexity
Precision welding, machining, and alignment had to be performed at the plant under strict safety and quality standards.

Tight Timeframe
The work needed to be completed within a limited outage schedule to secure grid stability.

Our Solution

Taka Turbo mobilized an onsite repair task force, equipped with specialized tools and expertise to deliver a full restoration directly at Saguling Hydropower Plant:

1. Comprehensive Inspection & NDT
Conducted at the site to assess crack severity and material condition.

2. Onsite Welding & Machining
Precision repair executed on the turbine head cover without the need for factory transfer.

3. Surface Reconditioning & Alignment
Ensured sealing accuracy and durability against high-pressure water flow.

4. Quality Assurance at Site
Dimensional control and pressure checks confirmed reliability before turbine recommissioning.

The Result

Structural Integrity Restored
The head cover was rehabilitated to OEM standards.

Rapid Execution
Completed fully within the scheduled outage window.

Operational Reliability Secured
Eliminated leakage risk and safeguarded unit stability.

Extended Component Life
Added years of dependable operation without costly replacement.

Business Impact

The successful onsite repair of MI+ Unit 2 at PLTA Saguling enabled PT Indonesia Power to restore generating capacity quickly, without the delays of component removal and shipping. This approach not only ensured grid stability but also provided significant cost savings compared to full replacement or workshop-based repairs.

For Taka Turbo, this project demonstrated our onsite repair capabilities, showing how we bring workshop-level precision directly to the field, helping clients maintain critical power assets with speed, efficiency, and reliability.