Problem Statement

A prominent power generation site in France encountered operational inefficiencies in one of its key turbines. The turbine began to exhibit performance issues. During a routine quarterly review, the VIB 360 system, integrated with the VibBox, which was already installed on the system detected abnormal vibration patterns. The data revealed that torsional vibrations were impacting the turbine’s dynamic operation due to a geometric defect in the shaft and bearing contact points. These irregular vibrations, if not addressed promptly, could have led to significant damage, increased maintenance costs, and unplanned downtimes, jeopardizing the site’s power output.

Upon analyzing the quarterly data, the VIB 360 system’s diagnostic tools identified the exact location and nature of the defect. The system revealed irregular wear patterns on the shaft, causing a slight misalignment with the bearing. This misalignment was generating excessive torsional forces, which were responsible for the abnormal vibration patterns observed.

Final Impact

The early detection and detailed diagnostics provided by the VIB 360 system enabled the power generation team to act swiftly. They realigned the shaft and replaced the affected bearings during a scheduled maintenance window, successfully averting a major failure. As a result:

1. Operational Efficiency Improved: Following maintenance, the turbine resumed optimal performance with significantly reduced vibration levels
2. Cost Savings Achieved: By preventing unplanned downtime and avoiding more extensive repairs, the site saved substantial costs in both maintenance and potential lost revenue.
3. Prolonged Equipment Life: The VIB 360 system helped extend the turbine’s lifespan by ensuring the health of critical components and addressing issues before they could escalate.

Conclusion

The deployment of the VIB 360 Torsional Vibration Monitoring System was pivotal in detecting a geometric defect in the shaft-bearing interface, preventing costly turbine failure. With real-time monitoring, predictive analysis, and proactive maintenance, the power generation site in France maintained reliable operations and improved long-term efficiency. This case highlights the significant value of advanced vibration monitoring systems like VIB 360 in safeguarding critical infrastructure within the power generation industry