Executive Summary
Jindal Steel’s Oman facility faced persistent vibration issues on one of its seawater pumps, impairing full-capacity operation and increasing operational risk whenever the standby pump was offline. After years of inconclusive diagnostics, Jindal partnered with IRISS to perform an advanced motion amplification analysis. Within a single visit, the root cause—poor foundation contact and degraded rubber beading—was identified, allowing the plant to move forward with targeted corrective actions. This case highlights how IRISS’s non-contact vibration technology provided rapid, visual diagnostics that saved time, reduced guesswork, and restored operational confidence.
Challenge
Jindal Steel operates two critical seawater pumps at its Oman plant, each rated for 20 m³/hr. One of the pumps displayed abnormal vibration behavior when running at around 46% of its rated speed, disrupting operations whenever the standby unit was unavailable.
This intermittent issue persisted for several years despite repeated internal investigations. Suspected causes included structural resonance induced by a neighboring plant’s pump and potential back pressure within the piping system. The unresolved nature of the fault created considerable maintenance overhead and posed a reliability risk to core operations.
Solution
IRISS deployed a certified Category III vibration analyst to the site to collaborate directly with Jindal Shadeed’s experienced condition monitoring team. The IRISS engineer explained the diagnostic methodology and captured high-resolution motion data across various operational loads.
Using motion amplification technology, the following findings were quickly identified:
• Motor DE Rubber Beading Deterioration: Physical wear on the motor’s drive end beading, indicating reduced mechanical dampening.
• Foundation Contact Issue: Suboptimal surface contact between the pump stool and the concrete foundation, allowing for micro-movements that became pronounced during partial load operation.
In addition, visual data ruled out previously suspected issues:
• Cross-Pump Resonance: No vibrational energy transfer was detected from the adjacent plant’s pump.
• Piping Back Pressure: Bellows inspection showed no deformation or pressure-related anomalies.
The root cause of the vibration was conclusively identified in seconds, thanks to IRISS’s motion amplification diagnostics.
Outcome: Improved Safety and Electrical Reliability
Jindal confirmed that the pump entered a resonant excitation state at approximately 46% of its rated speed due to:
- Poor mechanical coupling between the base stool and the foundation.
- Deteriorated rubber beading reducing vibration absorption.
This rapid diagnosis, made possible by IRISS technology, eliminated years of uncertainty and paved the way for targeted repairs. It also strengthened collaboration between Jindal’s internal team and outside experts.
Key Takeaways
- Motion amplification identified the root cause within seconds—after years of inconclusive investigation.
- Visual diagnostics confirmed structural deficiencies and ruled out false leads.
- The IRISS engineer provided clear, actionable recommendations:
- Regrout or reinforce the foundation interface.
- Replace damaged rubber beading on the motor DE side.
- Conduct load-based validation post-repair.
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