Problem Statement

A high-capacity turbine at a power generation plant was facing periodic and unexpected downtimes, severely affecting both operational efficiency and revenue generation. Symptoms such as excessive vibrations, abnormal noise, and overheating were observed, but the root cause remained elusive. Despite multiple costly manual inspections and interventions, the plant’s existing monitoring systems failed to detect the underlying issue. Ultimately, the problem was traced to loose bearing pads, which posed a high risk of catastrophic turbine failure and unscheduled downtimes.

To address the situation, the plant engaged Impedance Data VIB for a comprehensive solution. We recommended the installation of our VIB 360 Turbine Condition Monitoring System, designed specifically to detect early-stage faults through continuous monitoring of critical operational parameters. This system provides real-time, precise diagnostics of the turbine’s mechanical health, offering insights not achievable with traditional monitoring methods. Within a short period of operation, the VIB 360 system flagged irregularities in the bearing’s performance, identifying looseness in the bearing pads. Real-time data from the system indicated misalignment between the bearing and its housing, signalling wear and slackness. A detailed vibration analysis further confirmed that the root cause of the vibrations and performance issues was the loose bearing pads, a fault that had previously gone undetected by standard inspection methods.

Final Impact

The early detection of loose bearing pads by the VIB 360 system allowed the maintenance team to take corrective action before any catastrophic failure occurred. The key outcomes were:

1. Cost Savings: The timely identification of the bearing defect prevented major turbine failure, resulting in significant savings in capital expenditure.
2. Increased Efficiency and Reliability: Early intervention restored the turbine’s performance, leading to improved efficiency and enhanced operational reliability.
3. Reduced Downtime: The plant experienced more than a 50% reduction in unexpected downtimes, significantly increasing machine availability over the following year.
4. Extended Bearing Lifespan: The early diagnosis and prompt maintenance extended the bearing’s lifespan, further reducing operational costs and improving overall turbine health.

Conclusion

The VIB 360 Torsional-Based Vibration Monitoring System delivered precise and actionable insights, enabling proactive maintenance that averted potential failures. By reducing downtime, improving efficiency, and extending the lifespan of critical components, the system provided a tangible return on investment, reaffirming its value as a vital tool in turbine condition monitoring and operational optimization.