PLTCM STAND # 4 WORK SIDE HYROP CYLINDER FORCE MOTOR FAILURE

PROBLEM DESCRIPTION:
Description:
Abnormal sound and vibration was observed from TCM stand # 4 cylinder during Weld Point passing.

Problem Start Date:

Observed initially on 10.05.05

History:
Similar vibration was observed earlier 2 times, 1. 2. First time due to problem in motor drive Second time due to problem in work side HYROP cylinder position feedback.

(From problem type, we found that this was different problem ).

Trouble Type:
NEWF

Time diagram

10.05.05 Vib & Sound noticed

20.05.05 Vib / sound aggravated. Initial actions taken

24.05.05 Further checks on shutdown day

02.06.05 Action taken & prob solved

Data collection, phenomenon observation and analysis

Further observation & analysis

PHENOMENON OBSERVATION:

Observations during 10.05.05 to 20.05.05

3.

Abnormal sounds during some weld point passing at stand #4.

5.

We also observed that this was predominant in Gap Open Flying Gauge change cases.

7.

Vibration was easily felt even in TCM pulpit.

9.

No vibration was felt at normal rolling at any speed.

Observations Made On 20.05.05

chart). Abnormal cylinder position feedback was observed from std# 4 WS (PLC Work side FMV current appeared abnormal (fluctuations) compared to drive side FMV current. Initially we suspected the SIU unit (see fig below) of HYROP panel, which had failed earlier as well. Mill Housing

Line Controller

S I U

HYROP PLC

P. AMP

- + - +
Sony Processor F M V

HYROP Cylinder

Magnascale

HYDRAULIC CIRCUIT

RESULT:

After Changing SIU Card, Problem still persisted.

Position Feedback Recording Observation

MILL SPEED

WELD POINT

STD 4 LOAD

AVERAGE GAP STD 4

Operator side cylinder hunting

OPERATOR SIDE POSITION F/B

No hunting on drive side cylinder.

DRIVE SIDE POSITION F/B

STD 4 GAP REFERENCE

Only Operator side, Position feedback is abnormal at Stand#4 at the time of vibration

Root Cause Analysis

Possible reasons of abnormal WS cylinder movement as under:

3.

Position feedback Sensor (magnascale) Malfunction.

5.

Position feedback processing Unit.

7.

Problem in Hyrop hydraulic system / circuit.

9.

Problem in Force Motor Valve.

Testing the Possible Root Causes - 1

Position feedback Sensor (magnascale):

Problem

With HYROP Controller ON Observations: Conclusion:

With HYROP Controller OFF

Magnascale position feedback is only showing abnormal signal during Mill gap Open Command under Hyrop Controller ON Condition. Position detector (Magnascale) is OK

Testing the Possible Root Causes - 2

Position feedback processing Unit.

Test:

The channels for Work side and Drive side position signal processing unit has been inter-changed.

Result:

There is no change in abnormal phenomenon.

Conclusion:

The position signal processing unit is OK.

Testing the Possible Root Causes - 3 Hyrop hydraulic system / circuit.

Accumulator at FMV manifold Silent chamber

FMV POCV

Cont.

Following checks have been done for the Hydraulic circuit: Accumulator pressure at FMV manifold. Pressure was found Zero in place of 110KG/cm2. Silent chamber flow control valve Silent chamber flow control valve opening was checked and was found OK (Should be 0.75 to 1.5 rotation open). POCV malfunctioning Circuit was analyzed to identify possibility of any POCV malfunctioning. Based on circuit diagram, pressure checking was done at various points by operating HYROP in UP and DOWN directions. No abnormality was found.

Above checks have been done in Consultation with Hitachi.

Testing the Possible Root Causes - 4

Force Motor Valve current Controller (Power Amplifier).
Observations: 1. 2. 3. For any Gap open command (HYROP controller ON condition), it was observed that the FMV current reference is hunting. The FMV current reference is hunting during cylinder standstill condition also (HYROP controller ON condition). No FMV current hunting is observed in HYROP controller OFF condition.

Test :

In order to reduce current reference hunting, the HYROP controller gain is reduced.

Result:

No improvement Observed.

Conclusion: FMV current reference Controller is OK.

Testing the Possible Root Causes - 5

Force Motor Valve (FMV)
1. During Gap Open Command, Drive side cylinder takes positive current whereas the work side cylinder takes negative current. Ideally, both cylinder should take POSITIVE current.
WS FMV current meter (Abnormal as compared to other stand) Gap Close Hold Gap Open

Abnormal

DS FMV current meter Gap Close Hold

-

Gap Open

1. 2.

The above observation, indicated free falling tendency of Work side cylinder, to which the Hyrop controller tries to control by passing negative current. The above phenomenon is confirmed by alarm Leak Compensation Limit in Hyrop control panel.

Conclusion
The FMV current fluctuation phenomenon during gap opening case was indicating towards problem in FMV, which was also validated by Hitachi. The above point was validated with the help of dial gauge, which again confirmed the jerky motion in WS cylinder, while gap opening. This also strengthened doubt on FMV.

So, it was decided to change FMV. Most probable root cause.

On 02.06.05, FMV was changed. After this FMV current became normal and cylinder movement became smooth in both direction. Subsequently, no abnormal vibration and sound was observed inside the mill thereafter.

Confirmation of Root Cause

Failure of work side Force Motor Valve (FMV).

Factors responsible for Failure

1. Premature Failure of FMV: Normal life of FMV is about 10 years, as per Hitachi and NSC. The defective FMV is being sent to Hitachi for analysis of failure. 2. Maintenance practice : We had just started changing FMVs last year. With available resource we can change 2 FMV / year. This way we could have changed all 10 FMVs in about 9 years of operating life.

Mr.T.Watanabes Comments

1. Good Case showing phenomenon observations 3. Give your conclusion after your observation