FAILURE ANALYSIS OF FUSE SWITCH UNIT

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd

FUSE SWITCH UNIT

Fuse Switch units are fitted with sturdy side operating han which drives the quick make-break mechanism incorpora operating springs. Liberal sized silver plated terminals, su for aluminium cable/bus-bar termination, are provided w terminal cover shields to prevent any accidental contact w live metal parts. Positive ON-OFF indication is provided o switch door.

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd

Healthy Fuse Switch Unit AND HRC Fuses

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd Bottom Part Of Fuse Switch Unit (FSU)

Drive shaft Male contact

Terminal bolt

Link

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd

The burnt SFU

The back side of the cubicle, not affected in fire

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd

ANALYSIS
THERMALLY DEGRADED
PLACE TO FIX LYRA UNIT

BURNT

LYRA

BURNT UPPER ASSEMBLY OF FSU

(INSULATED BLOCK)

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd

ANALYSIS
Defective Lyra
Spoiled lyra

Ring deformed

Jaws distorted

Female contact portion

Ring deformed

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd New New

Used

New

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd New New

Used

Used

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd From Jan 05 to April 05, six fuse switch unit has failed
OBSERVATIONS 1) Lyra becomes loose. 2) Ring of Lyra deforms. 3) Upper assly (insulated block) gets spoil

Lyra Ring

: which grips the fuse (Short grip HRC fuse) : A part of Lyra assembly

Upper assly : It is an insulated block which comprises the Lyra assly as well as female contact pt. of FSU

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd Reasons for the failure of Fuse Switch Unit

1) Thin layer of dust on Bakelite and Lyra grip. 2) Using different Make Fuses which results into loose grip of lyra. 3) Bakelite material problem.

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd ACTIONS TAKEN 1)All the fuses are standardised with same make as FSU and Current Rating. 2)Electrical Technology Group has been asked to check the Bakelite specification. 3)Inspection procedures has been made to inspect the FSU. 4)People are trained to do inspection according to PWI.

FAILURE ANALYSIS OF FUSE SWITCH UNIT..Contd Mr.Watanabes Comments: 1. Mapping of all the fuses of different make working at different locations in the plant along with existing conditions must prepared. 3. All the past failure data of fuses, section wise and make wise must be reviewed to identify the failure prone fuses / sections. 5. Subsequently Pareto Analysis can be done to identify the trouble prone fuses. 7. Based above analysis, cause and effect diagram can be made to identify the root-cause

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Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

OBSERVATION :
FAILURE DATE OF FAILURE NATURE OF FAILURE SHAFT OF B.F.BLOWER 05.07.2004 SHEARED INTO TWO PIECES FROM FIRST ENLARGED STEP OF COUPLING SIDE SYMPTOMS FREQUENCY OF FAILURE TYPE OF FAILURE SECTION NO LIFT B. F. GAS PRESSURE FIRST TIME BREAK DOWN BATTERY NO. 8 & 9, MECHANICAL

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

DETAILS OF B. F. BLOWERS :
CHARACTERISTICS CAPACITY INLET TEMPERATURE INLET DENSITY INLET STATIC PRESSURE OUTLET STATIC PRESSURE ABSORBED POWER AT 45 DEGREE C. MOTOR RATING DESIGN TEMPERATURE UNITS N M3/HR DEGREE C KG/M3 mm WG mm WG kW kW DEGREE C. VALUES DESIGN LOAD 75000 45 1.036 5 450 139 200 70

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

DETAILS OF B. F. BLOWERS :
REQUIREMENTS MASS OF BLOWERS WITHOUT MOTOR MASS OF BLOWER ROTOR ROTATIONAL SPEED CRITICAL SHAFT SPEED TEMPERATURE OF FLUID MD2 OF ROTOR (GD2) UNITS KG KG RPM RPM DEGREE C. KG.M2 VALUES 4255 332 1480 2916 45 164

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

DETAILS OF B.F.BLOWERS SPEED: OPERATING SPEED CRITICAL SPEED OF SHAFT RESONANCE PEAKS FLOW: SAFE MINIMUM FLOW OF BLOWER = 10 M3/SEC. = 36000 M3/HR. (TO AVOID DUCT VIBRATION AND TO GET PERFORMANCE STABILITY) FLOWTHROUGH BLOWER WITH INLET GUIDE VANE CLOSED CONDITION 2.5 M3/SEC. REQUIRED VOLUME OF B.F. GAS: FOR ONE BATTERY FOR TWO BATTERY = 55000 N M3 /HR. = 110000 N M3 /HR. = 1480 RPM = 2916 RPM = +/- 40 % OF OPERATING SPEED = 888 RPM AND 2072 RPM

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

VIEW OF BF BLOWER OF BATTERY NO. 8 & 9

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

LAP SEAL BEARING

LAP SEAL

SCHEMATIC DIAGRAM OF BLAST FURNACE GAS BLOWER

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

BROKEN PART OF THE SHAFT

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

BROKEN PART OF THE SHAFT

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

ANALYSIS :
TOPIC MATERIAL OF THE SHAFT BEARING STATUS LAP SEAL STATUS COMMENTS STAINLESS STEEL OK FOUND PARTIALLY DAMAGED AT THE DRIVE END BOTTOM PART . OK FIRST TIME CRITICAL

PROCESS PARAMETER BEFORE FAILURE FREQUENCY OF FAILURE EQUIPMENT

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

ORIGINAL DRAWING BEFORE FAILURE

1990 108

80

65

100

Sharp corner at the failure area

Drg No. 50571

80

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

COUNTER MEASURE MODIFIED DRAWING

Polish Surface

R 15 14.5 0.5

ENLARGE VIEW

Drg No. 50571/A

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd

ACTION PLAN
To change shafts of other B.F Blowers as per the modified design. To carryout Dye penitent test on the change of cross section of the shaft to find out any cracks being developed Frequency - Once in two months. To give training to Mechanical staff regarding fitting procedure of bearing and impeller on the shaft. No impact load to be given on the polish surface of the shaft during fitting.

Failure Analysis of Blast Furnace Gas Blower Shaft Of Battery # 8&9Contd Mr.Watanabes Comments: 1. The analysis was done systematically and approach is in right direction 3. The recommendations must be implemented in other areas where similar shaft are in use.

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FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7)

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd
OBSERVATION :
FAILURE DATE OF FAILURE NATURE OF FAILURE SYMPTOMS BEARINGS OF SUPPORT ROLL 16.05.2005 BEARINGS BROKEN INTO SEVERAL PIECES TILTED SUPPORT ROLL & BULGED END COVER FIRST TIME BREAK DOWN BATTERY NO. 5, 6 & 7, MECHANICAL

FREQUENCY OF FAILURE TYPE OF FAILURE SECTION

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd
DETAILS OF PUSHER RAM BEAM :
PARAMETERS MASS OF PUSHER RAM BEAM MASS SUPPORT ROLL NO. SUPPORT ROLL LINEAR SPEED OF PUSHER RAM MOTOR RATING MOTOR RPM UNITS TONNES KG PAIR METER/MIN KW RPM 5 24 105 1000 VALUES 12.0 500

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

PHOTOGRAPH OF STAMPING CHARGING & PUSHING MACHINE

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

PHOTOGRAPH OF SCP MACHINE WITH EXTENDED PUSHER RAM BEAM

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

PHOTOGRAPH OF SUPPORT ROLLS

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

DRAWING OF PUSHER RAM BEAM WITH SUPPORT ROLLS

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd
U - guide Pinion Rack

Pusher ram beam

Grease Pipe Pendulum Support rolls Support rolls Sliding shoe Pusher head Centralized grease lubrication pump.

SCHEMATIC DIAGRAM OF PUSHER RAM BEAM WITH SUPPORT ROLLS

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

DRAWING OF SUPPORT ROLLS ASSEMBLY SHOWING BEARING POSITION

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd
BEARING DATA & OBSERVATION AFTER DISMENTALING THE SUPPORT ROLL :
TOPIC Bearing DATA / OBSERVATION Spherical roller bearing (Cylindrical bore) Size 140 X 250 X 68 mm. No. 22228 CC, C-3 clearance. Broken into several pieces Extreme Pressure - 2 (suitable upto 800c) Scored Scored Buldged Bearings were Found dry First Time Critical

Bearing condition Grease being used Condition of support roll pin Condition of support roll bore Condition of end cover Lubrication condition Frequency of failure Equipment

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

BROKEN PIECES OF THE BEARING OUTER RACE

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

SCORED END COVER

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

BULGING IN END COVER

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd
ANALYSIS OF LUBRICATION FAILURE
POSSIBLE REASONS REMARKS

Centralize grease pump was not working Checked and found OK. for quite some time. Grease lost its property due to heat. Lubricating pipe got choked . Grease Distribution valve of support rolls not working. Checked and found OK. Found malfunctioning Grease Property found OK

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd
ACTION PLAN
To check Grease Distribution valve - open grease pipe at the bearing connecting point and run centralize grease pump during shut down of SCP machine. To check quantity Grease going to bearing. Running time -10 minutes in every 5 hrs. To open the end cover of support rolls and check grease in the bearing. Frequency - Once in three months during shut down of the SCP machine To give training to Lubrication staff on Grease Distribution valves (operation

FAILURE ANALYSIS OF SUPPORT ROLL BEARINGS OF PUSHER RAM BEAM IN SCP II (Battery 5,6&7).Contd

Mr.Watanabes Comments:

This is a back-up presentation and not shown to Mr. Watanabe

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