Turnkey on-site 3–21 days typical

Turnkey Overhauling & Maintenance

Turnkey Shutdown Planning to Zero-Defect Restart

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OEM Makes Overhauled

26+

Years Field Experience

0.001mm

Clearance Resolution

24×7

Emergency Response

Why Our Engineers

A poorly executed overhaul is worse than no overhaul: it introduces new clearance errors, contamination, and re-assembly faults. Our engineers were trained by the OEMs. They know what tolerances actually mean at operating temperature and speed, not just what they say in the manual.

Overview

Turbine overhauling is not a maintenance activity: it is a precision engineering intervention. Keshav Enterprises deploys ex-OEM engineers from Triveni, Siemens, BHEL, Belliss, Maxwatt, Man Turbo, KKK, and ABB to execute turnkey overhauls with the same discipline and documentation standards as the original manufacturer. Every overhaul begins 4–6 weeks before shutdown with scope finalisation, spares pre-inspection, and manpower mobilisation planning. Every component is measured before disassembly, during strip-down, and after reassembly. A written condition report, clearance register, and photographic record is produced for every overhaul, creating a baseline for the next outage.

Our Process

Pre-Shutdown Planning & Scope Finalization

Review of previous overhaul records, operational data, vibration history, and performance trends 4–6 weeks before shutdown. Definition of scope, critical spares list, consumables list, and manpower mobilisation plan. Pre-shutdown inspection of stocked spare parts with shortfall report issued to client.

Site Mobilization & Tooling Setup

Full overhaul tool kit deployed: hydraulic jacks, precision chain blocks, rotor handling slings, dedicated measurement instruments, lapping tools, and the complete overhaul documentation package. Tool condition checks and instrument calibration verification before work begins.

Disassembly & Initial Inspection

Controlled disassembly with all pre-disassembly measurements recorded: bearing clearances, shaft runout, gland clearances, coupling alignment, and rotor end float. Every component photographed. Condition noted against OEM specification before cleaning.

Component Inspection & Condition Reporting

Visual, dimensional, and NDT inspection of rotor, blades, bearings, glands, casing, all valves, and coupling. Crack detection using dye penetrant or magnetic particle methods on critical components. Written condition report with specific recommendation for each component: replace, repair, or reuse with justification.

Component Repair & Spare Part Installation

Babbitt re-metalling and precision machining of journal bearings, labyrinth seal replacement, blade inspection and selective replacement, journal polishing (Ra 0.4 μm), casing joint face lapping, gland packing replacement, and valve seat lapping to blue-match standard.

Reassembly & Clearance Setting

Precise reassembly with all clearances set and recorded against OEM specification: journal bearing clearances (diametral and axial), labyrinth seal radial and axial clearances, gland clearances, coupling alignment, and rotor end float. All readings entered in the clearance register and compared against previous overhaul baseline.

Recommissioning & Handover

Post-overhaul lube oil system recommissioning flush to ISO 4406. Safety system proof test: over-speed trip, low oil pressure trip, emergency stop valve. Monitored start-up with vibration and bearing temperature trending. Written clearance for full load with complete overhaul documentation package handed to client.