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Implementing Root Cause Failure Analysis (RCFA) improves reliability, problem-solving, and cost efficiency. This study examines abnormal vibrations in 14 hydro-turbines at a desalination plant producing 200 million liters of fresh water daily via reverse osmosis. Each rack consists of an electric motor, a high-pressure pump, and a hydro-turbine. Using the Fishbone diagram method, statistical analysis reveals increasing high-frequency vibrations. Failure records indicate hydro-turbine and pump issues are more critical than motor failures. Vibration signal processing identifies potential bearing and pump blade pass frequency failures. Grease analysis detects sodium and iron, suggesting water intrusion, supported by shaft-bearing clearance checks. Mitigation efforts, including adjusting the fluid flow angle, reduce water infiltration but don’t resolve vibrations. Envelope spectrum analysis later confirms bearing failure due to electrical discharge, prompting replacement. The study concludes with solutions to extend equipment lifespan, demonstrating RCFA’s effectiveness in diagnosing and addressing complex failures. These insights benefit researchers tackling similar industrial challenges.

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Root Cause Failure Analysis of Hydro-Turbines in a Desalination Complex

  • 会议论文

  • 发表日期：

    2026年

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  • Mehdi Behzad,
  • Somaye Mohammadi,
  • Hesam Addin Arghand,
  • Mojtaba Javaheri,
  • Masoud Beyrami,
  • Parisa Hejazi Dinan

摘要

Implementing Root Cause Failure Analysis (RCFA) improves reliability, problem-solving, and cost efficiency. This study examines abnormal vibrations in 14 hydro-turbines at a desalination plant producing 200 million liters of fresh water daily via reverse osmosis. Each rack consists of an electric motor, a high-pressure pump, and a hydro-turbine. Using the Fishbone diagram method, statistical analysis reveals increasing high-frequency vibrations. Failure records indicate hydro-turbine and pump issues are more critical than motor failures. Vibration signal processing identifies potential bearing and pump blade pass frequency failures. Grease analysis detects sodium and iron, suggesting water intrusion, supported by shaft-bearing clearance checks. Mitigation efforts, including adjusting the fluid flow angle, reduce water infiltration but don’t resolve vibrations. Envelope spectrum analysis later confirms bearing failure due to electrical discharge, prompting replacement. The study concludes with solutions to extend equipment lifespan, demonstrating RCFA’s effectiveness in diagnosing and addressing complex failures. These insights benefit researchers tackling similar industrial challenges.