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Failure analysis study on failed fin fan shaft assembly from Air Cooled Heat Exchangers unit
(A case study from Egyptian LNG plant)
Omar Eid Khorshed Mechanical Engineering Program, University Teknologi PETRONAS
Abstract This case study is focused in understanding the cause of the repetitive failures happening to machined shafts in the Air Cooled Heat Exchangers units in Egyptian LNG plant. The study was focused on the latest occurred case which was on 30th of September 2012. It involves various aspects to understand the reasons of failure, including fracture face analysis, loads, stress and torque analysis, failure analysis using Distortion Energy Theory for ductile material failure and extensive maintenance history investigation. The study showed that the repetitive failures are due to faulty machining and maintenance activities carried on the failed shafts and returning them back into operation. Taking all the discovered reasons from the extensive analysis, a list of recommendations were put to prevent such problems from occurring again. Index Terms Shaft, Fatigue, Distortion Energy Theory, Relief groove, Stress concentration
1 INTRODUCTION
shaft is a rotating member, usually of circular crosssectional area used to transmit power. Its supported by bearings and support gears, sprockets, fly wheels and rotors. It is subjected to torsion, traverse or axial loads, acting in single or in combination. Generally shafts are not of uniform diameter but are stepped to provide shoulders for locating gears, pulleys and bearings. The stress on the shaft at a particular point varies with rotation of shaft there by introducing fatigue. Shaft and bearing failures have been a repetitive and a well expected problem with rotating equipment machinery in most of the Oil and Gas plants & facilities equipment. On 30th of September 2012, a vertical cooler fan shaft (2E 3201B) had been broken at the upper part just above the bearing assembly. This failure was preceded with an exact similar shaft failure but at the lower bearing of the fan assembly. Accompanying these reported shaft failures, a long history of bearing failures for the fans. Egyptian LNG has been facing repetitive failures and reported problems from cooling fans used in the plants refrigeration cycles. This repetitive failures cost the plants massive amount of money in maintenance and renewal, as well as downtime for process production losing the plant a good amount of revenue and bigger profit margins.
This shaft has been machined 2 years ago after an upper bearing failure. Upon the bearing failure, the shaft had been sent to workshop to get fixed. To fix, the area of the failed bearing went through welding and lathe operations to return the shaft to its original shape and dimensions. A new bearing assembly was then assembled to the new machined area. Machined and fixed shaft was then returned into operation. As shown in figure 1, the failure of the shaft happened right above the upper bearing assembly of the shaft
A free body diagram resembling the shaft and its features is shown in figure 2.
brittle failure happened, from the shape of the IZ we can understand the following: The IZ is oval shaped with a part extending towards the circumference of the shaft. The centered IZ shows that the fracture is caused by torsional fatigue. However, the extended part of the IZ shows that bending stress was also included. From the size of the IZ, we can understand that the stress causing the failure was relatively low. Crack Origins: Crack origins have started from the circumference of the shaft, and then the crack propagated towards the middle. The IZ part that extended towards the edge of the circumference shows that no cracks originated from this area. Friction marks: There are rough friction marks along the direction of rotation of the shaft, showcasing that the shaft kept on rotating even after the failure by some time. Causing the two fractured faces to keep contact and hence the friction marks occurred.
FAILURE ANALYSIS
FR2
FB
Friction marks
Crack Origins
FR1
Figure 5. Static radial forces on shaft
FB: Bending force resulting from belt tension. FR1: Reaction force from lower bearing assembly. FR2: Reaction force from upper bearing assembly. From belts, sprockets and motor assembly:
Instantaneous Zone
Analyzing the fracture face we can find the following: Instantaneous Zone: IZ is the roughest part of the fracture face, and it is the last part of the face that the crack reached and where
+ 2 32()2 16
, = 4 (1)
Pitch Length (lp) = 154.33 in, = . , Sub in (1) = 75.34 = 1.9136 Belt tensions:
R is the radius of the shaft (mm) n is the rotational speed of the shaft (rpm) G for drive shafts = G16 = 16 mm/s R = 39mm n = 226.5 rpm P = = ( 2 ) = 81.718 100 Sub in (4) = =
10 (
) 1000
1016 (
226.5 ) 1000
= 706.4 m
Torque transmission: We can calculate the amount of torque transmitted to the shaft from tracing the amount of torque generated by the turning force from the motor. Turning force = 3620.941 Shaft sprocket pitch diameter = 39.300 in = 0.99 m 1 m = = .
(144,067) (18,008) (2), = = (3) ()() ()() Where: DHP = Horsepower x Service Factor (hp) PD = Sprocket Pitch Diameter (in) = 6.141 in RPM = Sprocket Speed (rev/min) = 145 rpm Service Factor for 50 hp motor = 1.15 HP = 49.6, DHP = 49.6 x 1.15 = 57.5 Sub in (2) , (3) = . = . = ( + ) = Turning force(Causing torque) = = 4138.18 517.239 = . In Shaft assembly:
FR2
Unbalance Forces
FB
Unbalance Forces
FR1
Using sum of moments around a point is zero equation = = . Using sum of forces along a static shaft is zero equation = = 2333.45 2049 = . Shaft unbalance: Permissible residual unbalance: =
10 (
) 1000
(4)
Where, G is the balanced grade (mm/s) P is the weight of the shaft. (Kg) p is the unbalanced amount (grams) is eccentricity (m)
16 3
= .
Figure 10. FEA typical example
From the figure, we can understand that the stresses concentrate and multiply around the circumference of the shaft shoulder. (Stress concentration area).
CONCLUSION
Shaft failure was mainly due to torsional fatigue, the torsional fatigue for ductile materials cause a cut off fracture face feature. This torsional stress is mainly from the torque originating from the driving motor. This is further proved by the fracture face analysis. Failure analysis showed that design conditions is correct, therefore, an off design reason caused the failure. Since failure occurred at the exact same area thats been machined before, this proves that the machining and improper assembly/maintenance was the main cause of the shaft failure.
Machined area undergone welding and lathe operations, causing the area to be affected with heat treatment and inhomogeneity that differs from that of the original shaft properties, causing design conditions to differ at this area. (Higher stress concentrations, different material strength properties, etc.) The traces of the bending loads on the fracture face is mainly due to the radial forces generated by the shafts unbalance.
Therefore, a strict decision to stop repairing failed shafts and returning them back to duty has to be made, in order to increase the lifespans of the cooling tower fans.
RECOMMENDATIONS
REFERENCES
[1] The University of Oklahoma, Refrigeration basics and LNG course notes, 2009 [2] Deepan Marudachalam M.G, K.Kanthavel, R.Krishnaraj, Optimization of shaft design under fatigue loading using Goodman method International Journal of Scientific & Engineering Research Volume 2, Issue 8, August-2011 [3] Hudson Products Corp, Air Cooled Heat Exchangers technical specifications manual, 2009 [4] Neville W Sachs, Practical plant failure analysis: A guide to understand material deterioration and improving equipment reliability, Taylor & Francis group, [5] Gates Corp, Gates Poly Chain GT2 Belt System Specifications manual. [6] Hayward Gordon Ltd., Shaft Design, Section TG8, July 2000. [7] Flygt ITT Industries, Shaft and Bearing calculation, February 2003. [8] Kruger, Permissible Residual Balance, Technical Bulletin, 2001 [9] Deepan Marudachalam M.G, K.Kanthavel, R.Krishnaraj, Optimization of shaft design under fatigue using Goodman method, International Journal of Scientific & Engineering Research Volume 2, Issue 8, August 2011 [10] Bary Dupen, Notes for Strengths of Materials, ET 200, 2011 [11] Pilkey, Water D. Peterson's Stress Concentration Factors. Second Edition. New York:John Wiley & Sons, Inc., 1997. [12] Emerson Process Management, Cooling Tower Monitoring: Wireless Vibration Monitoring for Motor and Gearbox Combinations, 2012 [13] Gates Corp., Solving wind milling problems on beltdriven ACHE fan systems: How to improve worker safety and reduce maintenance.