A 54 MW Hydro Generator was experiencing abnormally high shaft vibrations

Key Results Achieved

85%

Vibration Reduction

Reduced vibration levels from critical to acceptable range

12%

Efficiency Improvement

Enhanced turbine efficiency and power output

₹2.5 Cr

Cost Savings

Avoided shutdown costs and production losses

Project Overview

A 54 MW Hydro Generator was experiencing abnormally high shaft vibrations at both the Upper Guide Bearing (UGB) and Lower Guide Bearing (LGB).

The Challenge

A 54 MW Hydro Generator was experiencing abnormally high shaft vibrations at both the Upper Guide Bearing (UGB) and Lower Guide Bearing (LGB). The machine’s vibration amplitude and phase angle were fluctuating significantly, indicating instability in the rotor system and a potential risk of bearing damage or forced outage.

High vibration levels causing operational concerns

Risk of unplanned shutdown affecting power supply

Complex rotor dynamics requiring specialized expertise

Time-critical resolution needed

Our Solution

Vibrovision team performed precision adjustments were carried out on bearing gaps and alignment, followed by in-situ dynamic balancing of the rotor. These corrective measures stabilized the rotor system, resulting in a substantial reduction in vibration levels at both UGB and LGB and achieving consistent phase readings. The machine was successfully restored to smooth operation, ensuring reliable and safe performance.

Comprehensive vibration analysis using advanced monitoring

Phase analysis and modal testing

In-situ dynamic balancing

Root cause identification and corrective action

Implementation Process

1

Deployed portable vibration monitoring system

2

Conducted detailed phase and amplitude analysis

3

Performed in-situ dynamic balancing procedures

4

Implemented precision alignment corrections

5

Validated results through continuous monitoring

Project Outcome

The intervention was highly successful, reducing vibration levels by 85% and improving overall turbine efficiency by 12%. The plant avoided a costly shutdown and continues to operate reliably.

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