Power Generation

Power Generation Engineering and Mechanical Failure Services

With the ‘green transition’ well underway, the world’s power generation sector is facing multiple challenges; amongst these, the need to maintain machinery such as steam turbines as well as possible, maximising uptime. 

Aside from avoiding machinery failures, the application of mechanical engineering best practices can have other benefits. Consider the reduction of friction and wear - this can reduce energy losses, boosting overall efficiency. The reduction of material degradation (via wear and friction) can also prolong the lifespan of important components, reducing the lifetime material footprint of your plant. 

So, whether you’re looking to proactively apply engineering best practices to your plant, or need to establish the root causes of a machinery failure, Neale Consulting Engineers can help. 

Power generation engineering and failure investigations in action

To give you an idea of the broad application of engineering and mechanical failure within the power generation sector, we have outlined some examples of our studies and investigations within this industry below: 

Steam and gas turbine failure investigations

Given the role they play, bearings are particularly subject to wear and friction related damage and failure. With power plant steam turbines being subject to long periods of operation, it’s no surprise then to find that bearing failures within these turbines are not uncommon. 

Here at Neale Consulting Engineers we have conducted several investigations of steam turbine bearing failures. Root causes identified include; assembly and commissioning defects, poor oil filtration, electrical grounding brushes malfunctioning, electrical current damage, inadequate oil film generation during rundown, and incorrect settings on jacking oil systems. 

Cooling tower fan gearbox studies

Cooling towers play an integral role in cooling the large volumes of water that are involved in the power generation process. However, the fans used within these cooling towers (or, more specifically, the fans’ gearboxes), can be subject to friction and wear related failures. 

Neale Consulting Engineers was commissioned to study why these failures occur. The conclusion of that study? There are a variety of failure modes associated with fan gearbox failures: 

• Water ingress into the gearbox oil. 
• System vibration frequencies resonating with blade passing frequency. 
• Gearbox manufacturing defects. 
• Incorrect oil levels in gearboxes. 
• Inadequate cooling of gearboxes. 

Hydropower turbine thrust bearing failures

During start-up and warm-up, the thrust bearings of large hydropower turbines can be subject to damage - most notably ‘wipes’ where the surface of the bearing is subject to rubbing, melting and general wear. This damage is primarily attributable to thermally-induced distortion of the bearing pads. 

Neale Consulting Engineers has successfully investigated these issues and provided recommendations to prevent their future occurrence. 

Engineering and mechanical failure consultancy services for the power generation industry

Should you wish to apply engineering best practices to your power generation operations, ensure you have the very best expertise to hand - Neale Consulting Engineers. 

Established half-a-century ago, Neale Consulting Engineers is one of the leading names in engineering and mechanical failure and has worked with businesses large and small to both proactively and reactively apply engineering understanding and best practice to assets of all kinds. 

Plus, as part of the Brookes Bell group, when you choose Neale Consulting Engineers you’re getting more than just engineers. Our broader talent pool includes metallurgists, NDT experts, materials scientists and more.