We have developed a unique onsite repair procedure using VARIM (Vacuum Assisted Resin Infusion Moulding) for lamination. This innovative technique has resulted in a remarkable 96% cost reduction in blade repairs. Additionally, the restoration time has been significantly reduced from 95 days to just 15 days. One of the key advantages of this method is that it eliminates the dependency on Original Equipment Manufacturers (OEMs), providing us with greater flexibility and efficiency in managing repairs.
We became the first Independent Power Producer (IPP) in India to adopt craneless generator replacement technology through installing a derrick structure in the nacelle and use a traction winch system for the replacement process. This advancement has led to a 75% reduction in costs and an impressive 80% reduction in execution cycle time. Moreover, it eliminates transportation challenges associated with traditional crane-based methods, enhancing the overall efficiency of generator replacement.
We utilise drones equipped with pressurised water and solvents to monitor and clean turbine blades. This approach has numerous benefits, including reduced manpower requirements, lower costs, and decreased cleaning time. Moreover, it enhances Health, Safety, Security, and Environment (HSSE) practices by minimising risks associated with manual blade cleaning. Additionally, the use of drones ensures a higher quality of cleaning, resulting in increased power generation efficiency.
We have also become the first IPP in India to develop a generator upgrade process outside of OEMs. This approach proves to be cost-effective and time-efficient, reducing downtime during upgrades. By eliminating dependency on OEMs, we gain a competitive edge in mergers and acquisitions by offering more flexibility and control over our equipment.
We have also pioneered the introduction of craneless technology for de-erecting WTG (Wind Turbine Generator) blades longer than 60 metres in India. This breakthrough innovation has resulted in a remarkable 75% cost reduction and a 50% reduction in execution cycle time. The elimination of transportation-related challenges further enhances the efficiency and effectiveness of blade de-erection. We have successfully completed the restoration of two turbines using this technology, with a third turbine in progress.
