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Case Study

Early Detection of Faulty Contactors in Solar Inverters

By Case Study

IDENTIFIED FAILURES

INDUSTRY

  • Renewable Energy

ASSET

  • Inverter

PROBLEM

  • Contactors

AVOIDED

  • Unplanned Stoppage
  • Loss of production

THE ROLE OF PV plants IN ENERGY PRODUCTION

Photovoltaic (PV) plants are at the forefront of the global transition to renewable energy, offering clean, scalable, and increasingly cost-effective electricity generation. With the deployment of large-scale solar farms, solar energy plays a vital role in diversifying the energy matrix and reducing greenhouse gas emissions. To ensure consistent energy output, the reliability of critical components such as inverters, transformers, and power electronics is fundamental.

IMPORTANCE OF CONTACTORS

Contactors are key components in managing harmonic filtering and reactive power compensation in PV inverters. Their proper functioning directly impacts inverter performance, safety, and energy quality. Failures in these contactors, especially when undetected, can trigger abnormal behavior in the transformer, operational noise, or complete shutdowns, undermining system reliability.

CONSEQUENCES OF THE FAILURE OF THE CONTACTORS

Failure of contactors in solar plants can lead to unexpected system shutdowns, interrupting power generation and causing extended periods of downtime. This not only results in immediate energy production losses but may also compromise the stability of connected components such as transformers or inverters. In critical scenarios, repeated failures can accelerate equipment degradation and pose safety risks. Moreover, if replacement parts are not readily available, recovery can be delayed significantly, highlighting the importance of preventive diagnostics, inventory planning, and condition based monitoring to ensure operational continuity and minimize revenue impact.

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    Cable Junction Anomaly in Wind Turbines

    By Case Study

    IDENTIFIED FAILURES

    INDUSTRY

    • Renewable Energy

    ASSET

    • Wind Turbine

    PROBLEM

    • Cable Joint damage

    AVOIDED

    • Unplanned Stoppage
    • Loss of production

    THE ROLE OF WIND TURBINES IN ENERGY PRODUCTION

    Wind turbines are essential in the global transition to sustainable energy. By converting wind into electricity, they offer a clean, renewable alternative to fossil fuels with no direct carbon emissions. Advances in turbine technology have made wind power more efficient and affordable, helping decarbonize the energy sector. As countries aim to reduce fuel imports and diversify energy sources, wind energy strengthens energy security, supports economic stability, and promotes environmental sustainability.

    IMPORTANCE OF CABLES CONNECTING THE WIND TURBINE TO THE SUBSTATION

    Cables linking wind turbines to substations are crucial for transporting generated electricity to the grid. These components must endure environmental stress, mechanical loads, and voltage fluctuations. Their quality and condition affect energy efficiency, operational safety, and overall system reliability. Proper cable design, insulation and maintenance help to avoid faults and ensure long-term performance of wind energy systems.

    CONSEQUENCES OF CABLE FAILURES

    Cable failures can disrupt power transmission, causing energy losses and financial setbacks. These failures are especially costly due to the complexity of repairs and limited access. Persistent or unnoticed damage can lead to overheating, system faults and further component failures, reducing lifespan and safety. Extended downtimes may also affect grid reliability and investor trust, underscoring the importance of durable cables, continuous monitoring, and preventive maintenance.

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      Rubber Coupling and Sprocket Failures in Cement Mill Elevator

      By Case Study

      IDENTIFIED FAILURES

      INDUSTRY

      Cement

      ASSET

      Silos Feeding Elevator

      PROBLEM

      Damaged rubber coupling
      and worn sprockets

      AVOIDED

      Unplanned Stoppage

      Loss of production

      IMPORTANCE OF THE SILOS FEEDING ELEVATOR IN CEMENT PRODUCTION

      The Silos Feeding Elevator plays a crucial role in the cement production process, particularly in the stage where raw materials such as clinker, gypsum, and additives are transported to the mill. It ensures´the consistent and efficient delivery of materials to the cement mill, which directly influences the overall production efficiency, material handling, and energy consumption.

       

      IDEAL FUNCTIONING OF THE SILOS FEEDING ELEVATOR

      Under optimal conditions, the Silos Feeding Elevator operates with uniform speed and precise material feeding, ensuring a continuous and smooth supply of materials to the cement mill. This helps in maintaining a steady grinding process and contributes to the consistent quality of the cement.
      The elevator system should have minimal mechanical stress, with effective lubrication, proper alignment, and condition monitoring to avoid irregular wear on the components. Regular maintenance and condition monitoring are essential to ensure uninterrupted operation and prevent material flow disruptions, which can impact the  efficiency of the entire cement production line.

       

      MECHANICAL TRANSMISSION FAILURES: DAMAGED RUBBER COUPLING AND WORN SPROCKETS

      The detection of a damaged rubber coupling and worn sprockets highlighted mechanical transmission vulnerabilities. The rubber coupling, which connects rotating shafts while damping vibrations and compensating for misalignments, had deteriorated, potentially due to misalignment, overload, or material fatigue, resulting in impaired torque transmission and increased mechanical stress.
      Simultaneously, the sprockets, essential for driving chain-based power transmission, showed signs of tooth wear and deformation. This condition can cause chain slippage, irregular motion, and excessive vibration. The combined degradation of these components compromises the efficiency, reliability and longevity of the cement mill’s drive system, underlining the necessity of timely inspection and replacement to prevent unplanned failures and ensure stable mill operation.

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        Kiln Crank Effect

        By Case Study

        IDENTIFIED FAILURES

        INDUSTRY

        Cement

        ASSET

        Kiln

        PROBLEM

        Crank Effect

        AVOIDED

        Unplanned Stoppage

        Kiln permanent deformation

        The rotary kiln is essential in cement production, transforming raw materials into clinker through high-temperature processing. Ideally, it rotates smoothly to ensure uniform heat distribution, which is crucial for efficient chemical reactions and high-quality clinker production.
        A major issue affecting kiln operation is the kiln crank effect, caused by uneven thermal expansion. This leads to deformation, irregular rotation, and mechanical stress on critical components, increasing wear, power consumption, and potential structural damage. Proper maintenance and temperature control are key to preventing these issues.

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