Rotating equipment in power and desalination industries often encounter specific issues leading to operational inefficiencies or failures. Several prevalent problems include:
1. Shaft Failures in Desalination Plants
In seawater desalination facilities, motor shafts in pumps and compressors frequently fail due to stress-related factors such as stress corrosion cracking, mechanical fatigue, and localized corrosion like crevice corrosion. A study highlighted cases where design shortcomings and environmental conditions led to shaft shearing in brine recycle pumps and cracking in high-pressure seawater pumps.
2. Vibration-Induced Failures in Gas Turbines
In combined cycle power plants, gas turbines are susceptible to destructive vibrations resulting from mechanical failures. Common causes include unbalancing, misalignment, rubbing (contact between rotating and stationary components), steam flow fluctuations, rotor critical speed issues, and electrical faults like shorted-turns. These vibrations can lead to catastrophic failures if not properly monitored and addressed.
3. Localized Corrosion in Desalination Components
Desalination plants often face localized corrosion problems, such as pitting and crevice corrosion, affecting materials like carbon steel and stainless steel. Factors contributing to these issues include chloride-induced corrosion, CO₂ attack, internal stresses, weld defects, and material mismatches. Affected components encompass flash chambers, pipelines, pumps, valves, heat exchangers, demisters, storage tanks, intake systems, and ancillary power-generating units.
Addressing these issues requires proper material selection, environmental control, thoughtful design, and the implementation of advanced monitoring technologies to enhance the reliability and efficiency of rotating equipment in these industries.
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