There's information no maintenance person wants to receive. Especially when the day is almost over and a long weekend looms. Downtime is a daily risk in any production facility. Unplanned machine downtime generates unexpected costs, stresses teams, and disrupts the entire company's workflow. In such situations, a rapid response from service is often crucial.
In this article, we will present, using the example of a real-life story from our client, a situation in which a quick service intervention helped restore production at the last minute before a day off.
Friday
The customer delivered a burnt-out engine to us, severely damaged mechanically. Within three days, we rewired the engine stator, balanced the rotor, replaced the bearings, seals, and faulty components. Finally, we cleaned and repainted it. All indications were that the problem had been resolved and the machine would be back in operation quickly.
Tuesday
The complications occurred at the worst possible moment – two days before the long holiday weekend. The pressure was immense. Production remained at a standstill, tensions were palpable among the maintenance team, and each day that passed without a solution meant significant financial losses.
During installation at the customer's site , it turned out that the engine wasn't the only problem. Diagnosis revealed that an additional cause of the engine failure was a clogged transmission system responsible for grinding and discharging straw and other materials. Years of intensive use without proper maintenance had caused this system to become clogged. The machine required immediate intervention from our team.
First, all of its mechanical components were thoroughly cleaned, allowing for an assessment of their actual technical condition. All worn-out components were then replaced with new ones.
The switchgear was also serviced, beginning with a thorough cleaning and maintenance of the mechanical components and replacing all seals. The switchgear oil was replaced with new oil specifically designed for this model, ensuring optimal operating conditions for the entire system. Finally, after the service, the switchgear was connected to the turbine. The entire process was carried out by our team.
Wednesday
Thanks to rapid action, the turbine was back at the customer's site the day before the holiday. It had been installed, inspected, and commissioned. This meant the company avoided further costs resulting from a prolonged downtime and regained production stability.
Emergency support allows companies to avoid unnecessary downtime and maintain business continuity, even when a failure occurs at the most inopportune moment. Our team has proven that they are undaunted by time pressures and unexpected complications.
