25 MW Power Turbine :

Under the Condition Monitoring Program, at a Captive Power Plant at a Chemical  factory in Andhra Pradesh State, the clogging of 4th Stage of 25 MW Power Turbine was detected. Because of this clogging the high vibrations were generated which further damaged the Reduction gearbox of the Power Turbine and further developed unbalance because of the heavy vibrations on the Alternator. On stripping off the Turbine during regular shut down, it was observed that the 4th stage was totally clogged because of the scaling. The required action was suggested to the O & M department to ensure that the scaling is reduced to a minimum level, during the next Production phase. A major breakdown and damage to the valuable and critical machine such as Power Turbine set was avoided. The net saving to the Customer on account of saving of the Power Turbine was to the tune of Rs. 150 Million ( US $ 3.5 Million ) plus the production loss of several Millions of US $s.

Alternator 2.5 MW :

A Paper Factory, in Maharashtra State was benefited in reducing the downtime as we had forecasted the tripping of the Alternator of their Captive Power Plant as early as 39 days under Condition Monitoring Program implemented by us at the paper Factory. Because of this advance warning, the concerned Factory had preponed the maintenance schedule and also had called the concern out side agency to attend to the Alternator well in time. As a result of this the fault was rectified within the period of scheduled maintenance and the unforeseen, sudden stoppage was avoided. A major breakdown and damage to the valuable and critical machine such as Alternator set was avoided. The net saving to the Customer on account of saving of the Alternator was to the tune of Rs. 50 Million ( US $ 1.2 Million ) plus the production loss of ONE MONTH worth Millions of US $s.

Shredder :

A Leather Factory, in Madhya Pradesh State, having a Shredder with rated RPM of 1200 was unable to run the Shredder even for the 800 rpm because of high vibrations. Since they had implemented the Condition Monitoring Program, the history was available with us in the form of dynamic signal of the mechanical vibrations. The actual fault was traced to the weakness in the structure as some of the natural frequencies were suspected to be resonated because of the operating speed of the Shredder. We had suggested to apply the stiffeners at certain locations. As a result of this the Shredder vibrations have come down and the Shredder could be run at around 1145 rpm.

2 MW Alternator :

At another Captive Power Plant in Gujarath State, where the Condition Monitoring program is implemented regularly, by us, during the first vibration measurement, the non drive end bearing of the 2 MW Alternator, was found defective. Since the spare bearing was not available at hand, we had advised the concern factory to run the Alternator with certain load, till the new bearings are made available within 1 months time. On receipt of the new bearings, the non drive end bearing housing was opened and it was observed that the bearing was really damaged because of severe high points, deep scratches and erosion of material on the bearing inner surface. The damaged bearing was replaced and thus a sure break down at the start of the Production schedule, was successfully avoided. The net saving to the Customer on account of saving of the Alternator was to the tune of Rs. 50 Million ( US $ 1.2 Million ) plus the production loss of ONE MONTH worth Millions of US $s.

Alternator 3 MW :

The developing electrical unbalance and reduction in the air gap, in 3 MW Alternator was observed and promptly reported to the Engineering Department of Chemical factory in Gujarath State, immediately after the start of the Production Schedule in December 96. It was also monitored more closely during the subsequent visits under Condition Monitoring Program implemented by us and the assurance was also given to the Engineering Department that this Alternator can be run, without any failure till end March 97. However the seriousness of the fault was explained to the Works Manager. When this Alternator was opened, during the shceduled maintenance shutdown in 1st week of April 97, it was observed that the Air gap had reduced alarmingly, was almost at the Trip condition. This is one more case where we had detected the developing fault at an early stage, monitored and helped the Engineering Department in avoiding the damage to the valuable machinery and the sure breakdown. The net saving to the Customer on account of saving of the Alternator was to the tune of Rs. 80 Million ( US $ 1.9 Million ) plus the production loss of ONE MONTH worth Millions of US $s.

Power Turbine Set 3 MW :

During our regular visits to implement the Condition Monitoring Program at a Fertilizer Factory in Uttar Pradesh State, the fault such as loose bolts in the Slow Speed Coupling was detected and was reported to the Engineering Department, who intern, during the planned shutdown, checked that coupling and taken the corrective action. As a result the vibrations were reduced and probable damage (to the tune of millions of US $) to the Alternator and the Reduction Gear Box was avoided.

Power Turbine Set 2.5 MW :

During our regular visits to implement the Condition Monitoring Program at a Captive Power Plant at a Chemical Factory in Maharshtra State, the fault in the High Speed Coupling was detected and was reported to the Engineering Department, who intern, during the shut down, checked that coupling and taken the corrective action. As a result the vibrations were reduced and probable damage to the Alternator and the Reduction Gear Box was avoided.

2.5 MW Power Turbine :

Under the Condition Monitoring Program, at a Captive Power Plant at a Fertilizer Plant in Utter Pradesh State, the clogging of 3rd Stage of 25 MW Power Turbine was detected. Because of this clogging the high vibrations were generated which further damaged the Reduction gearbox of the Power Turbine and further developed unbalance because of the heavy vibrations on the Alternator. In this case even the couplings, both high and slow speed, were failed. We had detected these faults well in advance and based on our findings when the Power Turbine was opened during the scheduled shut down, the clogging of 3rd stage was really observed. Based on our report, the balancing of Alternator was also carried out. The net saving to the Customer on account of saving of the Power Turbine was to the tune of Rs. 200 Million ( US $ 4.8 Million ) plus the production loss of several Millions of US $s.

ID Fan :

The loose foundation bolt and the pedestal bolts were detected during our regular visits, for period vibration measurements under Condition Monitoring Program, at a Power Station in Maharashtra State. This fault was reported to the O & M Department. After inspection, it was observed that the bolt was broken inside the foundation. The bolt was replaced and the vibrations were brought down. Thus unforeseen break down, damage to the ID fan & the production loss was avoided with the net savings running in thousands of US $s.

Reactor :

At a Chemical Factory, in Maharshtra State, we are entrusted with the implementation of the Condition Monitoring covering critical machines. The Reactor was one of the machine monitored on a regular basis. The Reactor included Drive Motor, a Reduction Gear Box & Reactor. During the periodic Vibration measurement, the developing fault with the bearings of the Motor was detected & corrective action was also suggested so as to avoide stoppage before the scheduled maintenance shutdown. During the shutdown the bearing was found damaged. Since the advance warning of the bearing replacement was issued by us, the same was made available & was replaced during the shcedule maintenance shut down & thus unforeseen shutdown was avoided. The net saving by avoiding the shut down was around Rs. 400,000.00 ( S $ 16,000.00 or US $ 9,500.00 ) on account of loss of production plus the cost of the Motor & Gear Box around Rs. 500,000.00 ( US $ 12,000.00 ).

Ball Mill :

While implementing the Condition Monitoring program at a Chemical Factory, in Maharshtra State, a Ball Mill was covered under the program. The Ball Mill included a Drive Motor, a Reduction Gear Box with 3 internals, an Auxiliary shaft & the Ball Mill. The periodic vibration measurement & analysis detected a growing fault with the Roller bearing of the Auxiliary shaft. The rate of increase of vibration for the bearing fault was very high & as such the shut down was planned in 2 weeks time. After the openong of the bearing housing it was observed that the Roller bearing had damaged & had developed a crack. The bearing was replaced during the shut down & unforeseen breakdown was avoided by avoiding a production loss of a entire batch valued at Rs. 2, 00,000 ( S $ 8,000.00 or US $ 5,000.00 ) plus the cost of the Gear Box of Rs. 1 Million ( US $ 24,000.00 ).

Hydraulic Motors :

During the regular vibration measurements under Condition Monitoring Prigram, at a Chemical Factory in Maharashtra State, the vibrations because of the misalignment fault were found to be increasing. Simultaneous bearing vibration analysis was also carried out and it was observed that the bearing looseness had occurred. This fault was reported to the Engineering Department, who in turn, inspected the said bearing, by stopping the Plant on priority and it was observed that the bearing lock nut had almost come out. After tightening these nuts, misalignment & bearing vibrations were reduced substantially. A major breakdown was thus avoided. The net saving by avoiding the shut down was around Rs. 200,000.00 ( S $ 8,000.00 or US $ 4,700.00 ) on account of loss of production plus the cost of the Motor & Gear Box around Rs. 500,000.00 ( US $ 12,000.00 ).

We are sure the above mentioned examples will throw sufficient light on the advantages / benefits of implementing Condition Monitoring Program, thereby reducing downtime of the Plant and increase in productivity and of course the profit.

Please feel free to contact us for your enquiries to implement the Predective & Preventive Maintenance through Condition Monitoring Program at your Plant.