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Technical questions with answers on gas turbines

By NTS. What is a gas turbine? A gas turbine is an engine that converts the energy from a flow of gas into mechanical energy. How does a gas turbine work? Gas turbines work on the Brayton cycle, which involves compressing air, mixing it with fuel, and igniting the mixture to create a high-temperature, high-pressure gas. This gas expands through a turbine, which generates mechanical energy that can be used to power a variety of machines and equipment. What are the different types of gas turbines? There are three main types of gas turbines: aeroderivative , industrial, and heavy-duty. Aeroderivative gas turbines are used in aviation and small-scale power generation. Industrial gas turbines are used in power generation and other industrial applications. Heavy-duty gas turbines are typically used in large power plants. What are the main components of a gas turbine? The main components of a gas turbine include the compressor, combustion chamb
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Top 8 Reasons for Mechanical Seal Failure and How to Prevent Them

Mechanical seals are critical components of pumps, responsible for maintaining a fluid-tight seal between the rotating shaft and the stationary pump housing. However, these seals can fail due to various factors, leading to leakage, reduced pump efficiency, and costly downtime. In this article, we will discuss the top reasons for mechanical seal failure in pumps and how to prevent them. 1-Improper Seal Selection Choosing the wrong mechanical seal can cause it to fail. Consider the following factors that can contribute to seal failure: • Chemical compatibility: All seal components, such as the seal faces and O-rings, must be compatible not only with the process fluid being pumped, but also with non-process fluids used for cleaning, steam, acid, and caustic flushes, etc. • Physical degradation: Using soft seal faces on abrasive liquids will not last. Shear-sensitive liquids, like chocolate, can break down and leave behind solids (such as cocoa powder) and force out liquids (like oil). • S
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Operation and Maintenance of Screw Compressors

Intermittent motion compressors, or non-continuous flow compressors, include screw compressors which are categorized as medium flow and medium pressure compressors when compared to other compressor types based on pressure/flow charts. The screw compressor gets its name from the two screws it contains, one of which is mounted with the prime mover (motor, turbine) and the other is driven. The screws are mounted together by gears and rotate in opposite directions to each other, squeezing the compressed air with oil in the compression zone to raise its pressure according to the direction of rotation of the driver (counter-clockwise). During operation, the compressed air is mixed with oil (flooded type) inside the compressor. The compressed oil and air are then separated in an oil separation unit, with the air being removed to the discharge line and the oil being returned to the oil filter for filtration before being returned to the suction of the compressor. This compressor type is kno
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PREVENTING CREEP IN SUBMERSIBLE PUMP BEARINGS

Submersible pumps are commonly used in various industries such as construction, mining, wastewater treatment, agriculture, and general manufacturing. Typically, these pumps consist of a vertical electric drive motor that is directly connected to the impeller, and they are designed to operate for long periods with minimal maintenance. BEARING ARRANGEMENT The bottom bearing, also known as the locating bearing, usually consists of a double-row angular contact ball bearing or a pair of angular contact bearings, which are responsible for supporting the axial and radial loads generated by the pumped fluid. Since the bearing is subjected to heavy loads, it is important to select the appropriate bearing to achieve the desired service life. On the other hand, the top free bearing is generally a deep groove ball bearing that takes a light radial load. Typically, C3 clearance is used to compensate for the reduction in clearance caused by the heat generated by the electric motor. CREEP PHENOME
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Why Pump Shafts Often Break at the Keyway Area

By NTS Pump shaft failure can lead to significant downtime and repair costs in industrial plants. One of the most common locations for pump shaft failure is at the keyway area. In this article, we will explore the reasons why pump shafts often break at the keyway and what can be done to prevent such failures. The keyway is a high-stress point (weakest point)  on the shaft, where a key is inserted to transmit torque between the shaft and the pump impeller or coupling. During operation, the keyway experiences cyclic loading that creates a bending moment in the shaft, which is concentrated in the keyway area. Over time, this cyclic loading can cause fatigue failure in the shaft material, leading to a fracture at the keyway. In addition to cyclic loading, other factors can contribute to shaft failure at the keyway. Improper keyway design or installation can lead to stress concentrations or inadequate clearance between the key and keyway . Misalignment or overloading can also cause excess
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Pump Shaft Breakage: Case Studies and Solutions

By NTS Pump shaft breakage is a common issue that can cause costly downtime and repairs in various industries. In this article, we will explore several case studies of pump shaft breakage and the solutions implemented to prevent future failures. Case Study 1: Chemical Processing Plant A chemical processing plant experienced repeated pump shaft breakages in their cooling water pumps. Investigation revealed that the pumps were not properly aligned with the motor and had excessive vibration due to the misalignment. This caused the pump shaft to fatigue and break over time. The problem was resolved by realigning the pumps and installing vibration monitoring equipment to detect any future misalignment or excessive vibration. Case Study 2: Wastewater Treatment Plant A wastewater treatment plant had issues with pump shaft breakage in their sludge pumps. The pumps were designed with a straight shaft and lacked a flexible coupling, causing excessive stress and vibration on the pump sha
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