From Early Warning to Catastrophic Failure: A Missed Opportunity
- Customer: Industrial energy production facility, Toulouse
- Asset: 7 MW Siemens Turbine and gearbox assembly (GTA)
- Industry: Energy recovery / industrial turbine systems
Installation & Monitoring Initiation
Following a shaft replacement in October using a previously used component, the Siemens turbine was brought back into operation.
At this stage, the Vib360 condition monitoring system was installed to provide continuous vibration diagnostics and early fault detection.
Early Detection by Vib360
Almost immediately after commissioning, Vib360 analytics began identifying abnormal vibration patterns associated with the shaft.
The system indicated:
- Possible structural or fatigue-related issues
- Deviation from baseline vibration signatures
- Early-stage fault characteristics
These observations were promptly escalated to the customer for further attention
Customer Response
Despite the early warning and escalation:
- The issue was not considered critical enough for intervention
- No shutdown or detailed inspection was initiated
- The turbine continued operating under normal conditions
The detected anomaly remained unresolved.
Failure Event
In January, the turbine suffered a sudden shaft failure, resulting in a complete breakdown and unplanned outage.
The failure aligned with the same fault indicators previously identified by Vib360, confirming that the issue had been present and progressing over time.
Following the incident:
- The earlier Vib360 alerts were revisited and validated
- The failure was recognized as preventable with timely action
- Confidence in the monitoring system significantly increased
Post-Repair Validation
Following the shutdown and shaft replacement in March, the turbine was brought back into operation under monitored conditions using Vib360.
The system enabled a direct comparison of vibration signatures before and after the repair, clearly highlighting:
- Elimination of abnormal vibration patterns
- Restoration of stable operating conditions
- Alignment with expected baseline levels
This before-and-after validation provided the customer with clear evidence of both:
- The previously existing fault condition
- The effectiveness of the corrective action
Outcome & Impact
As a direct result:
- The customer proceeded to deploy Vib360 systems across multiple similar installations
- Preventive monitoring was prioritized to avoid recurrence
The case became a reference example of early detection value
Cost of Downtime
The unplanned shutdown of the 7 MW turbine resulted in a direct loss of power generation over an extended period.
- Turbine capacity: 7 MW
- Downtime duration: ~2 months (January to March)
- Assumed electricity value: €80–120 per MWh
Estimated Production Loss
- Daily generation loss:
7 MW × 24 h = 168 MWh/day - Revenue loss per day:
≈ €13,000 – €20,000/day
Total estimated downtime cost (60 days): €780,000 – €1.2 million+
Ignoring validated condition monitoring insights can allow minor defects to evolve into catastrophic failures, whereas timely intervention can prevent both damage and downtime.