Beruflich Dokumente
Kultur Dokumente
: 04
Rev. Date: 24.02.2019
Owner Site: KOCHI Function: Mechanical
1 Team Selection
Function Name Role (Leader, Facilitator, m
Engineering Devesh Shah Leader
Mechanical Iqbal member
Mechanical Dinesh Member
Mechanical Srinivas Member
Mechanical P Balaji Member
2 Failure Description
What happened with what with background information (where & when problem occurred, who and what were involved and seriousness of problem)
Problem Statement:
High Vibration in Purge Gas Fan & Abnormal Sound in NDE Side Bearing of Purge Gas fan leads to Tread Line Stoppage for 3
On 6/10/2019 in purge gas fan abnormal sound coming in NDE Side Plummer block & it seems like bearing running dry. (
4
8.9 A DE Side & 6.5 H, 3.5 V, 8.1 A NDE Side)
On 8/10/2019 Vibration got increase and even temperature reached above 90 degree centigrade. So decided to take a S/D
5
10/10/2019 and attend the same.
On 10/10/2019 S/D Taken Impeller & Bearing Replaced of Purge Gas fan Now working ok with Control Vibration. Vibration
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after S/D is (3.9 H, 2.1 V, 3.7 A of DE Side & 3.5 H, 1.8 V, 3.4A NDE side) with Max. Temperature of NDE side 79 degree cen
Immediate Containment Actions (Temporary actions to contain the failure and “fix” until permanent co
action is in place)
3 S/D of Tread Line Taken & Purge Gas Fan Impeller & Both Side Bearing Replaced & even NDE Si
Plummer block also replaced
Key observations / information / Facts (List down data / information from site visit, process parameters, discussions / inte
concerned people, operation and maintenance history, technology documents, engineering standards, etc without jumping to conclusion.
2 Extra Gland packing provided to arrest leakage which act as a barrier to guide smoke upto the seal o
8D- ROOT CAUSE ANALYSIS REPORT Rev. No.: 04
Rev. Date: 24.02.2019
3 CB in side NDE Plummer Block
NDE Side Bearing Running Dry though greasing is done in everyshift, as got burnt due to presence o
4 Set greasing frequency fortnightly, consider greasing fill-up quantity 60 gm]
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6
7
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Getting to the Root cause:
A) Fish-Bone Analysis (Attach annexure if required)
B) Why-Why Table (Carry out Why-Why on outermost causes on Fishbone; insert more why-why tables if required)
Problem Purge Gas Fan NDE side Bearing Failure Answers
Why-1 Why Purge Gas FAN NDE Side Bearing Fail? Bearing Become Dry & running at full speed
Why-2 Why Bearing Become Dry? Contamination of Carbon Black in plummer block with Greas
Why-3 Why Carbon Black got contminated with Grease? Carbon Black Leakage from Seal of Fan
Why-5
5 Identify Corrective Actions (Solutions that address and correct the root cause and escape point i.e. pre
root cause from recurring. Should be directly linked to Root Cause(s) mentioned above)
Checkpoint addition in Preventive/Preventive/
CLTI
Single Point Lesson Equipment Modi
Predictive Maintenance
System Modification Visual Control/ Mistake Proofing SOP SMP Drawing Others
Validation :
6 # Verify effectiveness of Corrective Action (as applicable). In some instances, the positive results demonstrated by the CA will be obvious
no validation will be necessary.
# Establish a system to monitor long term results
Closure of Report
Sign Team Leader Sign Functional Head (as applicable) Sign Unit Head
Rev. Date: 24.02.2019
Function: Mechanical
aring of Purge Gas fan leads to Tread Line Stoppage for 32 hrs.
Side Plummer block & it seems like bearing running dry. (6.0 H, 4.1V,
orary actions to contain the failure and “fix” until permanent corrective
Answers
Bearing Become Dry & running at full speed
Contamination of Carbon Black in plummer block with Grease
Carbon Black Leakage from Seal of Fan
aft
d
Rev. Date: 24.02.2019
address and correct the root cause and escape point i.e. prevent identified
use(s) mentioned above)
Equipment Modification
Others
Remarks
In Next Opportuinity
Rev. Date: 24.02.2019
stances, the positive results demonstrated by the CA will be obvious in which case
Remarks
Remarks
g Opportunities
Remarks
of Report
Improper Bearing Fixing Seal for Purge Gas Fan Leak Sealing Machine Struture Reliability
Improper Bearing Clearance Setting Bearing Selection as per application Availability of Heat Shield
Balancing of Impeller
Dusty Enviroment
Improper Allingment
Clearance Setting of
0 Bearing
Available Lubrication
Balancing of Impeller plan is ineffective
Allignment Procedure
Inadequate SOP Followed
METHOD
MATERIAL
0 0
0 0
0 0
Allingment Checked by
Blade in placed of Dial 0
Guage or Laser
allignment
MEASUREMENT
MACHINE
Machine Struture
0 Reliability
0 0
Lubrication Grease as 0
per Application
0 0
Carbon Spillage/
leakage from the fan or 0
in surrounding area
Dusty Enviroment 0
ENVIRONMENT
0
Availability of Heat
Shield
0
Purge Gas Fan NDE Side
Bearing Failure with High
Vibration & Abnormal
Sound