Equipment No.

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

PROBLEM DESCRIPTION -Lube oil leak at blower DE bearing on 19/2/2014

BACKGROUND The Equipment Equipment Tag No Equipment Criticality Service Equipment Type Running Philosophy Fan Manufacturer Driver Rated Speed Rated Flow Last Maintenance Last PM Maintenance Cost ULPO Sequence of Event : K-21201B :1 : Blower FDF for F-21201 : Centrifugal Fan : 1 running 1 standby (N+1) : Zurn : Steam Turbine (160kW) : 1500 RPM : 140883 kg/h th : 10 Feb 2014 th : 27 January 2014 (Coupling ) : RM 37,261 : No

5/2/2014 - 9/2/2014 K-21201B running in good condition mechanically

10/2/2014 Oil reported leak thru DE bearing oil stopper & high vibration reported at DE bearing. Online rectification by CRG via tightening the plunger screw. Vibration reduce & oil leak stopped

19/2/2014 Bearing stopper vibrate and lube oil leak trough rubber seal. DE bearing temperature high ~600C

20/2/2014CRG perform DE bearing inspection & replaced the damaged sleeve bearing.

21/2/2014 K-21201B t/run by CBM . Condition good.

DATA /FINDINGS: 1. Maintenance / PM history

2. Verification at site a. CBM refer to DiagRep K-21201B_1902

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

3. Pi Trending a. Trending & observation (5/2/2014 -19/2/2014)

b. Correlation of Pi observation with Fan performance curve

A-B is the region the fan was operated during the period of 7/2/2014 to 10/2/2014 . C is the average point where the Fan was normally operated . It was observed that the during the period of 7/2/2014 to 10/2/2014 the fan was forced to operated in stall region of the performance curve.

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

4. Vibration analysis

As overall, the fan axial displacement (pk-pk) , DE bearing temperature and Gs amplitude increased based on the data collected on the 7/2/2014 . The axial & Gs amplitude value was observed decrease after online tightening of the plunger screw (on 10/2/2014). However, the temperature shown increasing pattern. Impacting pattern of the DEs sleeve bearing was visible & these pattern still observed even after the online plunger screw tightening. The increased of the temperature taken at the DEs bearing & the visible high impa cting sign on the time waveform indicating possible damage on the DEs sleeve bearing.

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

5. CRG Inspection (Refer to CRGs QCP dated xxx) a. Inspected component

Item : DE Pedestal Bearing Manufacturer : Dodge Lubrication : Oil bath with oil slinger Bearing Type : Sleeve bearing

b. Damaged component

The scuffing mark at the sleeve bearing indicated metal to metal rubbing which in this case the rubbing of

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

the shaft & the sleeve bearings babbit.Its probably due to the losses of thin oil film that was separating the shaft & the sleeve bearings babbits. The insufficient of the oil level probably due to the leaking of the lubricating oil from the rubber grommet to the atmosphere.This was supported by the fact that the bearing 0 temperature at the DE increased & reached >60 C just before the blower was stopped for rectification. It was also observed that the scuffing area was badly at the side toward the gearbox compared to the side toward NDE bearing. This indicating that possibly the fan shaft was misalign/unbalancely rotating as per illustrated below at some stage of duty ;

FAILURE ANALYSIS

1.Failure analysis based on the reported problem

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

2.Further failure analysis on dislodged oil seal (grommet)

POSSIBLE CAUSES Based on the collected & available evidence it can be concluded that the possible failure was due to the following ; 1. Increased in system resistance due to throttling at 21FC082.pv & 21FC087.pv (refer to pi trending on 7/2/2014 to 10/2/2014 ) forcing the centrifugal fan to run in the stall region eventually making the centrifugal fan running with unpredictable flow characteristic i.e unstable.These instability possibly causing the increase in axial & DE s bearing vibration (Evidence based on vibration data taken on 7/2/2014) which eventually causing the bearing stopper to vibrate & dislodge the oil seal(grommet). Hence, oil leaked. 2. The scuffing of the DEs bearing babbits was aftermath effect. Losing pr otective oil film thickness due to the loss of oil lubrication (due to oil leakage) amplified by the vibration transmitted from the unbalance fan . Failure component Oil Seal (grommet) Failure Mode Oil leak Failure Cause 1. Bearing stopper vibrate & dislodge the oil seal(grommet)due to amplified vibration transmitted from the fan side (Fan running at stall region) 1. Losing protective oil film thickness due to the loss of oil lubrication (due to oil leakage) amplified by the vibration transmitted from the fan

DEs sleeve bearing

Bearing High temperature

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

Failure Cause Category

Operational X

Maintenance

Manufacturing Defect

Unintended service condition

End of design life

RECOMMENDATIONS: No. 1 Recommended Action for improvement To operate the fan to the right side of the curve avoiding the stall region i.e >80000Nm3/h. Action by Operator Remarks Alternatively, if operation wish to run the fan at < 70000Nm3/h they shall require to reduce the dampener opening to ~ 40%.

To ensure the shaft not sitting on one side CRG during installation *Please mention in the remarks whether or not notification has been raised to appropriate parties who carry out the recommended actions.

PREPARED BY NAME : Muhammad Fadzlee Samsubaha DATE : 11/3/2014

APPROVED BY (TP) NAME : DATE :

Equipment No.:

K-21201B
Service:: Blower FDF for F-21201 Equipment type:

Rotating Equipment Failure Analysis Report

Maint. Order/ Notification No.: Problems detected via:

Centrifugal Fan

96480741

Routine findings. Request/Notification.

Area.:

ATTACHMENT ATT:1 Diagnostic report : DiagRep K-21201B_1902 ATT:2 CRGs QCP report : XXX