Empowering Precision: Erudite’s Customized Training for Aboitiz’s Therma South and Therma Visayas
Title: Empowering Precision: Erudite’s Customized Training for Aboitiz’s Therma South and Therma Visayas
From November 20 to 22, 2024, Erudite Reliability Services OPC conducted a specialized three-day training program on Precision Maintenance, Vibration Analysis, and Balancing Theory for AboitizPower’s subsidiaries, Therma South, Inc. (TSI) and Therma Visayas, Inc. (TVI). This initiative underscores Erudite’s commitment to delivering client-focused training solutions, exemplified by their coordination of three local expert trainers to lead the sessions.
1. Precision Maintenance: Ensuring Accuracy and Reliability – Facilitated by Mr. Jason Mendoza
Overview of Precision Maintenance
Precision maintenance is a methodical approach to maintaining equipment, ensuring that every maintenance task is carried out with a high level of accuracy and attention to detail. Unlike traditional maintenance practices, precision maintenance aims to extend the lifecycle of equipment, reduce downtime, and improve overall efficiency. The goal is to eliminate small issues before they escalate into larger, more costly problems.
During this training session, participants from TSI and TVI were introduced to core precision maintenance principles, focusing on precision alignment, torque accuracy, and bearing installation. These concepts are critical for ensuring machinery operates at peak performance while avoiding unnecessary strain or misalignment.
Key Topics Covered in Precision Maintenance
- Shaft Alignment Techniques: Correct alignment of shafts minimizes vibration, reduces energy consumption, and extends machine life. Hands-on exercises were conducted where participants practiced aligning shafts using laser alignment tools.
- Proper Installation of Bearings: Bearings are essential for the smooth rotation of machinery. Participants learned the correct methods for installing and handling bearings, along with troubleshooting common bearing-related issues.
- Torque Management: Misapplied torque can cause bolt failures and equipment breakdowns. Participants learned how to measure and apply proper torque values to bolts, ensuring secure and lasting connections.
Impact of Precision Maintenance on Plant Operations
By mastering precision maintenance, participants from TSI and TVI were able to reduce human error, minimize rework, and increase the Mean Time Between Failures (MTBF) of critical equipment. This training contributed to the long-term operational efficiency of both power plants, reducing maintenance costs and unplanned downtime.
2. Vibration Analysis: Detecting and Preventing Equipment Failures – Facilitated by Mr. Alex Garejo
Overview of Vibration Analysis
Vibration analysis is a predictive maintenance technique used to detect early signs of equipment failure. By analyzing vibration patterns, technicians can diagnose mechanical issues before they become critical, ensuring early intervention and prevention. This method is essential for reducing unplanned downtime and optimizing asset reliability.
Key Topics Covered in Vibration Analysis
- Vibration Data Collection: Participants learned how to use vibration analysis tools, such as accelerometers and vibration data collectors, to measure equipment vibrations.
- Interpreting Vibration Spectra: Through real-world case studies, attendees were trained to identify common vibration patterns, such as unbalance, misalignment, looseness, and bearing defects.
- Condition Monitoring: The concept of continuous monitoring was emphasized, enabling participants to track vibration trends over time and set alarm thresholds to detect deviations from normal conditions.
Hands-on Learning Approach
Participants practiced collecting vibration data from real equipment, analyzing vibration spectra, and identifying early warning signs of failure. The interactive approach provided them with the skills to confidently diagnose mechanical issues, improving their ability to predict and prevent equipment failures.
Benefits of Vibration Analysis for TSI and TVI
With TSI and TVI operating large-scale power generation facilities, even a minor unplanned shutdown can have significant financial and operational consequences. By mastering vibration analysis, participants gained the ability to spot early signs of wear and tear in rotating machinery, such as motors, pumps, and turbines. The knowledge acquired during this training ensures that unplanned outages are avoided and maintenance interventions are scheduled at optimal times.
3. Balancing Theory: Reducing Vibration and Extending Equipment Life – Facilitated by Mr. Joveth Abutas
Overview of Balancing Theory
Unbalanced rotating equipment generates excessive vibration, leading to premature wear and tear of machine components. Balancing theory focuses on identifying and correcting these imbalances, ensuring smooth and stable equipment operation. Proper balancing reduces vibration, minimizes noise, and prolongs the lifespan of rotating assets.
Key Topics Covered in Balancing Theory
- Single-Plane and Multi-Plane Balancing: Participants were trained on how to balance rotors in single and multiple planes. This knowledge is essential for turbines, fans, and other large rotating equipment.
- Using Balancing Equipment: Attendees learned how to use balancing machines and vibration analyzers to calculate correction weights and determine where to place them on a rotor.
- Field Balancing: Field balancing techniques were taught to enable participants to balance machinery directly on-site, minimizing the need to remove equipment from production.
Hands-on Learning Approach
Erudite’s trainers guided participants through real-world balancing exercises, allowing them to apply their learning directly to equipment similar to what they encounter on-site. By physically handling correction weights and using balancing equipment, attendees developed the skills needed to reduce vibration on rotating machines.
Benefits of Balancing Theory for TSI and TVI
Unbalanced equipment causes unnecessary wear on bearings, shafts, and seals. Through this training, participants learned how to identify and correct unbalanced conditions, leading to better energy efficiency, smoother machine operation, and longer equipment life. This knowledge ensures that critical power generation assets operate at peak performance, reducing downtime and maximizing plant availability.
Collaboration with AboitizPower’s Key Subsidiaries
Therma South, Inc. (TSI)
TSI is a 300 MW coal-fired power plant that plays a critical role in stabilizing energy supply in Mindanao. The plant uses Circulating Fluidized Bed (CFB) technology, which requires precise maintenance practices to maintain its high operating efficiency. The training program supported TSI’s goal of enhancing the technical competency of its workforce, enabling them to conduct predictive and preventive maintenance more effectively.
Therma Visayas, Inc. (TVI)
TVI is a 340 MW facility that operates a unique coal dome storage facility, a first in the Philippines. The nature of the facility requires meticulous maintenance to ensure the continued operation of its conveyor systems, turbines, and pumps. By participating in the Precision Maintenance, Vibration Analysis, and Balancing Theory training, TVI’s maintenance teams enhanced their knowledge of how to diagnose and fix issues before they escalate.
Engaging Local Expertise
Erudite’s commitment to local development was demonstrated through its strategic decision to engage three local trainers to lead the program. This approach not only facilitated knowledge transfer but also showcased Erudite’s focus on fostering local talent.
By relying on local trainers, Erudite tapped into specialists who understand the unique operating conditions of TSI and TVI. Local trainers bring contextual experience, making it easier for participants to relate theoretical concepts to actual plant operations. This localization strategy enhanced participant engagement, fostered deeper learning, and strengthened the knowledge base of local maintenance teams.
Conclusion
Erudite’s three-day Precision Maintenance, Vibration Analysis, and Balancing Theory & Practical training for AboitizPower’s Therma South, Inc. (TSI) and Therma Visayas, Inc. (TVI) exemplifies a holistic, client-focused approach to professional development. By leveraging the expertise of three local trainers, engaging participants with real-world learning, and addressing the unique operational needs of AboitizPower’s subsidiaries, Erudite continues to demonstrate its leadership in reliability training.
The positive feedback from TSI and TVI staff reaffirms the value of customized, hands-on training programs. The success of this training highlights the potential for future collaborations, where precision, predictive maintenance, and technical excellence remain key priorities for the Philippine energy sector.
For more information on customized training, email us at [email protected].