Troubleshooting Service
Root Cause Found. Corrective Action Deployed. Turbine Back Online.
24×7
Emergency Deployment
10+
OEM Makes Diagnosed
FFT+Thermal
Dual Diagnostic Method
48hr
Post-Repair Trend Monitoring
Why Our Engineers
A misdiagnosed fault repaired without finding its root cause will fail again, often sooner than the first time. We do not guess. We measure, analyse the spectrum, strip only what the data tells us to strip, confirm the root cause physically, and fix it with the same team that found it.
Overview
Unplanned turbine trips and unexplained performance degradation cost industrial plants millions in lost production every year. Keshav Enterprises deploys ex-OEM troubleshooting engineers with full diagnostic instrumentation to identify, document, and rectify the precise root cause of any steam turbine fault, from high vibration and bearing failure to governor instability, oil contamination, and steam leakage. We cover all turbine makes from 5 kW to 60 MW across the full spectrum of India's process and power industries. Our methodology is systematic: online measurement first, physical inspection targeted by the data, root cause confirmed in writing, and corrective action executed by the same team that diagnosed the fault.
Our Process
Emergency Mobilisation & Site Data Collection
24×7 response deployment to site with full diagnostic kit. Collection of all available operational data: vibration history, DCS trip logs, oil analysis reports, bearing temperature trends, steam condition logs, and maintenance records. Interview of operations and maintenance personnel who witnessed the fault event.
Baseline Vibration & Performance Measurement
Online vibration measurement at all bearing housings: overall vibration level (mm/s RMS), real-time FFT spectrum analysis, 1X and 2X amplitude and phase angle, sub-synchronous and high-frequency components. Steam inlet/exhaust pressure, temperature, and flow benchmarked against design duty. Bearing temperatures mapped using thermal imaging camera.
Fault Signature Identification & Hypothesis
Analysis of vibration spectrum, phase data, bearing temperature map, and oil sample results to build the fault signature. Each potential root cause systematically mapped against measured evidence: imbalance (dominant 1X), misalignment (dominant 2X), bearing wear (sub-synchronous or bearing defect frequencies), rub (sub-harmonics, high 1X), looseness (multiple harmonics), or steam path fouling (thermal bow).
Targeted Strip-Down & Physical Inspection
Minimum-invasive disassembly targeting only the suspected fault zone, not a full strip unless data demands it. Physical measurement of bearing clearances, shaft runout, coupling alignment, gland seal clearances, and labyrinth seal fits compared against OEM specification. All findings photographed and dimensionally documented.
Root Cause Confirmation & Written RCA Report
Formal root cause analysis (RCA) report combining on-machine data, strip-down measurements, and OEM specification comparison. Root cause classified and confirmed in writing. Contributing factors identified. Corrective action plan with priority ranking, parts required, estimated downtime, and recommended preventive measures issued to client before work begins.
Corrective Action Execution
Direct execution of the corrective action by the same troubleshooting team: rotor re-balancing, bearing replacement and clearance setting, laser alignment correction, gland seal and labyrinth packing replacement, lube oil system flush to ISO 4406, governor overhaul and calibration, or control system calibration. All corrective work documented against OEM specification.
Post-Repair Commissioning & 48-Hour Trend Monitoring
Monitored restart with continuous vibration and bearing temperature data logging during speed run-up. Post-repair vibration levels compared against pre-fault baseline and OEM acceptance limits (ISO 10816-3). 48-hour continuous trend monitoring at full load before written clearance report issued and turbine returned to unattended operation.
Gallery
What's Included
- High vibration: imbalance, misalignment, bearing wear, rub diagnosis
- Governor hunting, speed instability & overspeed trip investigation
- Bearing oil contamination: carbon ring seal & lube system analysis
- Steam gland leakage: labyrinth seal, packing & gland steam pressure issues
- Blade fouling, erosion & steam path efficiency loss analysis
- Unexpected trip investigation: oil pressure, temperature & control system faults
- 24x7 emergency deployment across India with all diagnostic equipment
OEM Expertise
Related Case Studies
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