Advanced Diagnostics in Action: Vib360 Identifies Critical Faults in 32MW Gas Turbine
Machine & Event Overview
- Two identical GE 5002 32MW Gas Turbines, IDC 15 and IDC 16, were operating under similar conditions. Operational concerns were raised for IDC 15, while IDC 16 continued to perform normally.
Vib360 Detection & Diagnostic Insight
Using Vib360 advanced torsional analysis of the 60-tooth speed sensor signal, the team identified:
- Cycle-to-cycle irregularities in IDC 15
- Non-uniform torsional behavior indicating dynamic instability
- Transmission of these irregularities into bearing disturbances
Importantly, Vib360 did not just highlight that IDC 15 was different; it explained how and why it was failing.
Root Cause Identification
The VIB360 diagnostic insights pointed toward:
Geometric misalignment of the first-stage guide vane
This defect created a cascading effect across the system:
- Airflow distortion → Non-uniform gas entry and turbulence
- Dynamic loading → Increased forces acting on the turbine shaft
- Vibration amplification → Instability transmitted to bearings
- Thermal rise → Elevated bearing temperatures and lubricant degradation
From Symptom to Cause with Vib360:
- The problem was
- traced to a specific mechanical-geometric source
- The relationship between flow, vibration, and bearing health was clearly established. Confirmed by the visual cracks.
Limitations of Conventional Monitoring
Both IDC 15 and IDC 16 were also monitored using an online conventional monitoring system
- No significant anomalies were detected by the system
- Both turbines appeared to be operating within acceptable limits
However, in reality:
- IDC 15 exhibited abnormal bearing temperature behavior, indicating underlying distress
- The issue remained undetected by conventional monitoring tools
This highlights a critical gap between traditional vibration monitoring and advanced torsional diagnostics
Outcome & Impact
IDC 15 was confirmed to be operating under damaging internal conditions
- The fault was diagnosed at its true origin, not just observed at symptom level
- Vib360 demonstrated its capability to convert complex signals into actionable engineering insight
Advanced torsional diagnostics enable operators to move beyond fault detection to informed decision-making, ensuring corrective actions are taken before damage propagates.