A 54 MW Hydro Generator was experiencing abnormally high shaft vibrations
The machine was successfully restored to smooth operation, ensuring reliable and safe performance.
Read Case StudyFeatured Case Study
A 10 MW vertical motor exhibited high vibration levels
Spectrum analysis revealed a combination of soft foot and rotor imbalance as the root causes.
Industry
Heavy machinery
Location
Rajasthan, India
Duration
6 weeks
Completed
July 2024
Motor OverhaulVibration AnalysisHeavy Machine PlantPreventive Maintenance
Key Results Achieved
95%
Reliability Improvement
Achieved 95% uptime after overhaul completion
60%
Maintenance Cost Reduction
Reduced annual maintenance expenses
8%
Energy Efficiency
Improved motor efficiency and power consumption
Project Overview
A 10 MW vertical motor exhibited high vibration levels, measuring 14 mm/s (Horizontal, NDE side) and 8 mm/s (Horizontal, DE side).
The Challenge
A 10 MW vertical motor exhibited high vibration levels, measuring 14 mm/s (Horizontal, NDE side) and 8 mm/s (Horizontal, DE side). Spectrum analysis revealed a combination of soft foot and rotor imbalance as the root causes.
Aging motor fleet with frequent breakdowns
Production losses due to motor failures
High maintenance and operational costs
Need for reliability improvement
Our Solution
Vibrovision team analyzed and corrected Soft foot was corrected, followed by in-situ dynamic balancing, which reduced vibration levels to 1.2 mm/s (NDE) and 0.7 mm/s (DE). The motor was restored to stable operation, ensuring enhanced reliability and reduced risk of failure.
Complete motor teardown and inspection
Rotor and stator refurbishment
Bearing replacement and alignment
Updated protection systems
Implementation Process
1
Detailed motor condition assessment
2
Complete disassembly and component inspection
3
Rotor balancing and stator rewinding
4
Precision bearing installation
5
Updated protection and monitoring systems
Project Outcome
The overhauled motors now operate at 95% reliability with significantly reduced maintenance costs. The plant has achieved consistent production schedules and improved energy efficiency.
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A 160 MW Hydro Generator was experiencing abnormally high vibrations under load conditions
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.
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