PreditTransf detected asymmetries in both the primary (HV) and secondary (LV) sides, isolating the issue to the secondary side windings. This early detection provided actionable insights to the operator.
Enging's PreditGen system was installed after the client suspected of an issue in a generator. The system quickly confirmed an abnormal condition in the stator, with persistently high severity indicator, affecting phase C in particular with larger values.
This diagnosis was afterwards validated by the client, who confirmed the presence of inter-turn short circuits in the stator winding and implemented a temporary bypass solution.
In a 24/7 critical compressor, Enging detected an abnormally high spectral component at 896 Hz, causing a high-frequency ripple in the motor phase currents.
By validating the motor's internal design with the client, it was confirmed that this frequency was linked to internal stator winding vibration — a fault that often goes unnoticed until severe damage occurs.
With early detection powered by Electric Signature Analysis (ESA), the issue was identified before it escalated, ensuring reliability and continuous operation.
IMPORTANCE OF THE MILL IN FERTILIZER PLANTS
In fertilizer production, mills are a central component of the process chain. Their primary function is to reduce raw materials – such as phosphate rock, urea, ammonium sulfate, or compound blends – into fine, uniform particles that meet strict chemical and physical specifications. Particle size distribution directly affects reaction efficiency, granulation quality, nutrient availability, and the homogeneity of the final fertilizer product. Whether in grinding, pulverizing, or blending operations, the mill's performance influences product quality, energy consumption, and overall plant efficiency. Any irregularities in mill operation, such as uneven grinding or particle agglomeration, can lead to substandard product, process inefficiencies, and increased operational costs.
IMPORTANCE OF THE GEAR SYSTEM IN MILL PERFORMANCE
The gear system, including the girth gear, pinion, and supporting bearings, is critical for transferring motor torque to the mill shell in a controlled and precise manner. In fertilizer mills, which often operate under high torque and abrasive conditions, proper alignment, lubrication, and condition of the gear system are essential to maintain smooth rotation, reduce vibration, and prevent mechanical stress. The gear system's integrity directly affects the mill's operational stability, energy efficiency, and equipment lifespan. Inaccurate torque transmission or gear wear can propagate dynamic loads through the drive train, affecting bearings, couplings, and the mill foundation.
CONSEQUENCES OF MILL GEAR FAILURE IN FERTILIZER PLANTS
Failure of the mill gear system in fertilizer plants can have significant operational, financial, and safety consequences. Common failure modes include gear tooth wear, pitting, fatigue, or fracture, typically caused by misalignment, insufficient lubrication, overloading, or abrasive material handling. Such failures lead to abnormal vibration, noise, and potentially complete mill stoppage. Unplanned downtime directly impacts production schedules, leading to costly losses and potential delays in supplying critical fertilizer products. Moreover, failure propagation can damage bearings, motor couplings, and structural components, increasing repair complexity and safety risks. Continuous monitoring, early fault detection, and predictive maintenance are essential to ensure gear integrity, extend mill service life, and guarantee safe, efficient, and uninterrupted fertilizer 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.
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.
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.
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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