A 160 MW Hydro Generator was experiencing abnormally high vibrations under load conditions

Key Results Achieved

0.02mm

Alignment Accuracy

Achieved precision alignment within tolerance

75%

Vibration Reduction

Significant reduction in operational vibration

3x

Equipment Life Extension

Extended bearing life and reduced failures

Project Overview

A major oil refinery was facing chronic misalignment issues with their critical API pumps, leading to premature failures and high maintenance costs. Our precision alignment services provided the solution.

The Challenge

A 160 MW Hydro Generator was experiencing abnormally high vibrations under load conditions. Vibration levels reached 679 microns at the Upper Guide Bearing (UGB) and 450 microns at the Lower Guide Bearing (LGB). Interestingly, the machine ran smoothly in mechanical split condition, but as soon as load was applied, the vibration levels increased significantly.

Chronic misalignment causing premature failures

High vibration levels in critical pumps

Frequent bearing replacements required

Production efficiency concerns

Our Solution

Detailed vibration analysis by Vibrovision revealed irregular pole gaps as the root cause of the problem. The gaps were corrected, and in-situ dynamic balancing was subsequently performed. After rectification, the vibration levels were successfully reduced to 45 microns at the UGB and 38 microns at the LGB, restoring smooth and stable machine operation.

Advanced laser alignment technology

Precision coupling alignment

Vibration analysis validation

Preventive monitoring setup

Implementation Process

1

Comprehensive pump condition assessment

2

Advanced laser alignment procedures

3

Precision coupling adjustments

4

Vibration analysis validation

5

Ongoing monitoring recommendations

Project Outcome

The precision alignment achieved accuracy within 0.02mm tolerance, reducing vibration by 75% and extending equipment life by 3 times. The refinery now enjoys reliable pump operation.

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