Common Failures in Gas and Steam Turbines

Gas and steam turbines are at the heart of many industrial operations, powering energy generation, petrochemical plants, fertilizer industries, and more. Because they operate under extreme pressure, heat, and mechanical stress, these critical rotating machines are prone to specific types of failures. If not addressed properly, even small issues can escalate into costly downtime and reduced equipment lifespan.

Below are some of the most common turbine failures and strategies to prevent them.

1. Blade Cracking and Erosion

The Problem:
Turbine blades are exposed to high temperatures, corrosive environments, and continuous vibration. Over time, this can lead to cracking, erosion, or pitting of the blade surface.

Prevention:

• Regular inspection using advanced non-destructive testing (NDT).
• Applying protective coatings such as High Velocity Oxygen Fuel (HVOF).
• Timely re-blading or welding repair to restore performance.

2. Bearing Wear and Failure

The Problem:
Bearings support the rotating shaft of turbines and compressors. Poor lubrication, contamination, or misalignment can cause overheating and premature wear.

Prevention:

• Routine lubrication monitoring and oil analysis.
• Precision rebabbitting of bearings.
• Dynamic balancing to minimize vibration.

3. Rotor Misalignment and Vibration Issues

The Problem:
Misaligned rotors can cause excessive vibration, leading to component fatigue and operational instability.

Prevention:

• Accurate alignment during installation and maintenance.
• Onsite balancing to restore smooth operation.
• Using vibration analysis tools for early detection.

4. Fouling and Deposits

The Problem:
Dust, oil, and other particulates can accumulate on turbine blades, reducing aerodynamic efficiency and increasing heat stress.

Prevention:

• Regular cleaning and inspection routines.
• Implementing effective filtration systems.
• Preventive maintenance schedules to reduce fouling impact.

5. Overheating and Thermal Fatigue

The Problem:
Extreme operational temperatures can weaken metal components, causing cracks and thermal fatigue.

Prevention:

• Monitoring temperature profiles during operation.
• Using advanced welding and heat-treatment techniques (PWHT).
• Preventive shutdowns for controlled cooling and inspection.

Why Preventive Maintenance Matters

Proactive maintenance is always more cost-effective than emergency repairs. By investing in regular inspections, precise repair methods, and advanced workshop capabilities, industries can:

• Extend turbine lifespan.
• Reduce unexpected downtime.
• Improve operational safety and efficiency.

Partnering for Reliability

Taka Turbo provides world-class inspection, workshop repair, field service, and reverse engineering solutions for gas turbines, steam turbines, compressors, pumps, and gearboxes across industries. With more than 25 years of experience and a team of 100+ certified experts, Taka Turbo ensures every project is executed with precision, safety, and reliability.