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Table of Contents

Case Study

Indian Air Force Validates Tech That Accurately Pinpoints Defects on Any Engine

Table of Contents

Background

Industry
Defence
Solution
Engine Condition
Monitoring System
(ECMS)
Make & Model
Engines &
Generators
Asset
Aircraft

Objective

The Indian Air Force operates several legacy engines and generators, some of which are over 40 years old. Ensuring the reliability of these assets is a challenge due to limited availability of spares and their aging condition. To address this, the Air Force tested Neptunus’ Made-in-India Condition Monitoring Technology, Vib360, at their Base Repair Depot (7BRD) from October 18 to October 24, 2021.
  • Validate the accuracy of Vib360 across multiple engine types.
  • Accurately identify induced and natural faults at the component level.
  • Demonstrate system compatibility for legacy Air Force assets.

Challenge / Problem Context

  • Difficulty in pinpointing faults in old engines and generators.
  • Need for real-time and non-intrusive fault detection.
  • High maintenance costs due to unnecessary overhauls.
  • Requirement for a system that works across different engine models.

What Did We Do?

  • Conducted controlled trials on used and overhauled Greaves Cotton TBDv8 and PES-100 Russian engines, running at 70 KW load each.Induced faults like fuel cut-off and partial decompression to test detection accuracy.
  • Monitored and recorded torsional vibration data to capture variations in torque and uneven firing. Used our central command system for remote monitoring of induced conditions.
  • Identified leaky compression and overload impact on other cylinders caused by fuel cut-off. Demonstrated that the data could reliably extend overhaul intervals scientifically.
  • Proved Vib360’s adaptability by running successful trials across both Indian and Russian engine models. Verified accuracy regardless of make, model, or age of the engine.

Results That We Achieved

  • Accurate Fault Identification:
    - The system precisely detected 8 separate fuel cut-off trials and pinpointed the affected cylinders.
    - Successfully identified leaky compression during partial decompression tests.
  • Real-Time and Reliable Monitoring:
    - Torsional angle indicators highlighted uneven torque and increased vibrations due to induced faults.
    - Enabled engineers to monitor all parameters remotely under one central command.
  • Extended Overhaul Intervals & Reduced Costs:
    - Provided reliable fault data that allowed the Air Force to avoid unnecessary overhauls.
    - Demonstrated clear potential for significant cost savings in long-term operations.
  • Proven Engine-Agnostic Technology:
    - Validated Vib360 as a universal solution for different engine types, including legacy assets.
    - As a direct outcome of these trials, the Air Force placed an order for a customized portable unit for field applications.

Conclusion

Neptunus’ Vib360 successfully proved its accuracy, reliability, and adaptability during Air Force trials, making it a trusted solution for extending engine life, cutting costs, and ensuring mission readiness.

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