BEARING FAILURE OF BITUMEN PUMP

13P14

EQPT NO
MODEL/MAKE
MECH. SEAL MAKE
MECH. SEAL TYPE
BEARING TYPE
SERVICE
TEMPERATURE

: 13P14
: M/S RUSSIAN
: M/S EPIL
: 1502-52 SPL
: 6216, 7414
: BITUMEN
: 220deg C

BEARING FAILURE OF BITUMEN PUMP

13P14
PAST HISTORY AND CHAIN OF EVENT :
13P14 PUMP OF BITUMEN PUMP HOUSE WAS EARLIER
GLAND PACKED TO ARREST LEAKAGE. AFTER
SUCCUSSEFUL
CONVERSION
AND
GOOD
PERFORMANCE OF MECH. SEAL IN 13P11 & 13P12
BITUMEN PUMPS , IT WAS DECIDED TO CHANGE THE
GLAND PACKING WITH SIMILLER MECH. SEAL IN THIS
PUMP ALSO.
13P14 PUMP WAS SENT TO WORKSHOP FOR
MODIFICATION AND SEAL INSTALLATION ON 29/2/99.
PUMP WAS OPENED IN WORKSHOP AND STEAM
JACKETING IN PUMP CASING DONE. DUE TO NON
RECEIPT OF MECH SEAL, PUMP WAS KEPT OPENED
FOR ALMOST 6 MONTHS.

BEARING FAILURE OF BITUMEN PUMP

13P14
ASSEMBLY OF PUMP WAS DONE ON 22/7/2000, AFTER
RECEIPT OF SEAL.
PUMP WAS STARTED ON 10/09/2000 AND PUMP THRUST
BEARING FAILED JUST AFTER 4 HOURS OF ITS RUN.

PUMP AGAIN SENT TO WORKSHOP AND ITS BEARINGS

WERE REPLACED & SEAL FITTED AFTER CLEANING.
PUMP AGAIN SENT TO SITE AND STARTED ON 25/09/2K
AND AFTER 3-4HRS OF ITS OPERATION, ITS THRUST
BEARINGS AGAIN FAILED.
PUMP AGAIN SENT TO WORKSHOP FOR BEARING
REPLACEMENT.

BEARING FAILURE OF BITUMEN PUMP

13P14
OBSERVATION MADE AT WORKSHOP AFTER
OPENING:
BOTH THE THRUST BEARINGS BRASS CAGES WERE
FOUND BROKEN AND ITS BALLS GOT DEFORMED.
ALL OTHER COMPONENTS OF PUMP AND SEAL WERE
FOUND INTACKED.
THERE WAS 10MM GAP FOUND ON OD OF RADIAL
BEARING AND ID OF BRG. HOUSING, RADIAL BEARING
WAS NOT RESTING AT ALL ON HOUSING.

ANALYSIS:
SLEEVING ON HOUSING WAS DONE ON RADIAL BEARING
PORTION , WHICH WAS CAME OUT WHILE REMOVAL OF
BEARING FROM HOUSING. AS PUMP WAS KEPT OPENED
AT WORKSHOP FOR ALMOST 6MONTHS ,

BEARING FAILURE OF BITUMEN PUMP

13P14
ANALYSIS:
SLEEVE WAS MISSED AND BOTH THE OCCASION
BEARING WAS FITTED WITHOUT SLEEVE. SINCE RADIAL
BEARING WAS NOT RESTING ON HOUSING TOTAL
RADIAL LOAD TRANSMITTED TO THRUST BEARINGS. AS
THRUST BEARINGS ARE DESIGNED FOR AXIAL LOAD
AND NOT FOR RADIAL LOAD , ITS WAS FAILED
IMMEDIATELY.
REPAIR /REPLACEMENT CARRIED OUT:
BEARING HOUSING WAS REPLACED WITH SPARE
BEARING HOUSING AND BOTH THE BEARINGS WERE
REPLACED. NOW PUMP IS RUNNING NORMAL

DAMAGE TO RETAINER

BEARING FAILURE OF BITUMEN PUMP

13P14

REPEATED BEARING FAILURE OF BARARI

PUMP 603P3
EQPT NO
MAKE
SERVICE
TEMPERATURE
BEARING

Past Failure Event:

1996

16/10/96
04/12/97

:603P3
:M/S KIRLOSKAR BROTHER
:TREATED EFFULENT
WATER (BOOSTER)
:AMBIENT
:3311,6311

-New pump provided in BARARI minor Pump

house for boosting up the fire water pressure.
Pump is taking suction from discharge of
603P2 pump.
-Thrust Bearing failed & oil seal damaged.
-Both the bearing (radial & thrust )
damaged,wear ring loose.

REPEATED BEARING FAILURE OF BARARI

PUMP 603P3
15/01/98
19/06/98

-Shaft key way damaged, welding & M/C done.

-Sleeve damaged, gland leak, sleeve made in
workshop.
10/06/99 -Thrust bearing seized & shaft damaged.
25/10/99 -Both the radial & thrust bearing damaged.
08/02/2000 -Bearing & oil seal damaged.both the bearing &
oil seal changed.
06/03/2000 -Bearing & oil seal damaged
Observation1. Bearing housing cover bush, provided for
fixing of
oil Seal,found detached from cover and got rotated.
2. Oil seal found damaged.
3. Radial bearing races found rubbed against rollers
4. Thrust bearing clearances increased.
5. Bearings got rotated and found loose on housing.

REPEATED BEARING FAILURE OF BARARI

PUMP 603P3
09/05/2000 -Overhauling done, bearing Replaced.
24/05/2000 -Bearing damaged.Bearing housing support
plate replaced with thicker plate and
perpendicularity maintained.

19/07/2000 -Bearing failed.Heavy love-joy coupling

replaced with lighter shim pack type coupling.
26/08/2000 -Bearing failed.Pump manufacturer M/s
Kirloskar Brother called and assembly done in
their presence.
18/09/2000 -Bearing failed.Elect.cabling checked, as motor
was tripping at high load.

FLAKING

REPEATED BEARING FAILURE OF BARARI

PUMP 603P3
23/09/2000

-Bearing damaged.foundation bolts

welding done.

10/10/2000

-Bearing failed. Foundation RCC

filling done, to strengthen the
base plate.

28/11/2000

-Bearing & oil seal damaged.Asked

operation to run the pump with
full opening of discharge valve.

08/01/2001

-Overhauling Done, bearing

changed.

REPEATED BEARING FAILURE OF BARARI

PUMP 603P3
29/01/2001 -Pump bearing again failed.Impeller diameter
checked with the data folder of the pump and
found that impeller OD is 14mm higher than
the rated diameter of the impeller
Impeller OD trimmed to required rated
diameter and pump was assembled with
trimmed impeller and new bearing.Now pump is
running since 05/02/2001.

Cause of failure:

Due to higher impeller diameter of the pump it was

developing high axial thrust, which was causing repeated
thrust bearing failure of the pump.

REPEATED BEARING FAILURE OF

BARARI PUMP 603P3

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

EQPT. DETAIL :

Tag. No..
Eqpt. type
Make
Model
Service
Working temp.
Bearing - Thrust
- Radial
Capacity Rated
Minimum

:
:
:
:
:
:
:
:
:
:

12P5S Column bottom pump

Centrifugal pump
M/S Sulzer pump (I) ltd.
ZE-100-4500
Short residue
380-400 Deg. C.
7312 BG 2 nos
NU312
200 m3/hr
90 m3/hr

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

PAST HISTORY AND CHAIN OF EVENTS:
Old Russian Pump 12P5S was replaced in year2000 revamp shutdown.

Pump 12P5S was attended due to bearing failure on 25/08/2000 and

following spares were replaced.
a- Bearing 7312 (2nos) & NU 312 (1 no)
b- Complete Mech. Seal .
Pump 12P5S was commissioned at 17.00hrs on 28/8/01.
At 19.00 hrs. pump bearing failed after a run of 2hrs. As per
production log book Pump bearing housing was found abnormally hot
& steam was coming out from CW out let line. Immediately pump
was stopped & 12P5A was put on service.
Pump 12P5S was opened and sent to work shop for maintenance. the
pump thrust and radial bearings were found badly damaged and
seized on shaft. The following spares were replaced.

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

a.
b.
c.
d.

Bearing 7312 (2nos) & NU 312 (1 no)

Complete Mech. Seal .
Pump Shaft.
Bearing housing cover repaired

On 5/9/2001 at 9hrs pump was started and its bearings again failed
at 1645hrs. event before failure of the pump bearing is as follows
as per production log book.
Pump 12P5S started at 9hrs in presence of MLE. Informed to
SELE. Vibration checked by MLE and found normal at 9.15hrs.
12P5A stopped.
12P5S tripped at 10.10hrs. motor bearing temperature is also high.
12P5A started again.
12P5S again started at 11.15hrs informed to MLE and SELE. 12P5A
also running.
12P5 stopped at 14.30hrs and the load checked from sub station
for 12P5A & 5S and found 250 & 260 A respectively. As per SELE
12P5S load not to be kept beyond 250Amp. So 12P5 restarted at
15.00hrs. all the 3pumps kept running.

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

At 16.45hrs, 12P5S bearing housing found smoking,its lube oil
burnt out, oil cup was out and fumes were coming. Pump
stopped immediately in presence of SPNM(U). M/M & E/M
kept informed.
Observation
-Before opening of pump.
a) Lube oil was found burnt and having bearing wear particle.
b) Coupling DBSE is found 190mm against 180mm.
c) Coupling shims were found distorted and broken.
d) Coupling spaces was found damaged.
-After opening at work shop.
a)both the thrust and radial bearings are found damaged and
seized with shaft ( identical to earlier failure).
b)Shaft found 0.20mm bent at radial bearing seating.

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

c)Bearing cover labyrinth found rubbed with bearing inner race

got damaged.
d)Mech. seal collar found rubbed with purge bush.
e)Deep rubbing marks on Wear ring observed and clearance
1.5mm and 1.0mm found in front & back respectively.
f)Throat bush clearance 1.0mm found.
g) Ovality of 0.05mm found in outer thrust bearing seating.
Repair replacement done.
1.All the thrust and radial bearing replaced with new one.
2.Bearing housing cover labyrinth repaired.
3.Bearing housing ovality removed and bearing center checked.
4.Pump shaft replaced with new one.
5.All the wear rings except case wear ring replaced and its
clearance maintained. Throat bush also replaced and
clearance maintained.

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

6.Mech. Seal faces are lapped and reused as new bellow is

not available,
7.New coupling is issued and hub boring is done, which is to be
replaced along with its spacers.
Suspected cause of failure:
Thrust bearing failure may be due to following reason.
1.Lack of lubrication in housing.
2.Excessive hydraulic thrust on bearings.
3.Improper mounting of bearings.
4.Improper loading of thrust bearing during operation.

Lack of lubrication in housing.

The possibility of lack of lubrication is ruled out as after
failure of bearing there was oil found in housing and it has run
for approx.7 hrs.

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

Excessive hydraulic thrust on bearings.
The pump is single stage and fitted with both side wear rings
and balancing holes and its clearances are also not abnormally
high, which can not create that much thrust load on bearing.
However during starvation of pump thrust balancing of rotor
will be disturbed.
Improper mounting of bearings.
As the pump has run for approx. 7hrs on load and no abnormal
sound or vibration was observed. This possibility may be ruled
out.
Improper loading of thrust bearing during operation
Due to high Distance between shaft ends 190mm (DBSE)
maintained, compared to recommended DBSE of 180mm,
coupling will cause pulling of pump rotor in motor side, which
will result in improper loading of outer thrust bearing.

REPEATED BEARING FAILURE OF VDU PUMP 12P5S

Improper loading of thrust bearing will cause sliding of rolling
elements. As sliding friction of bearing elements, will cause
high heat generation and continue rise in bearing temperature
and subsequent failure of thrust bearings. The failure of
thrust bearing will allow the pump rotor assembly moving in
pump side and it will cause rubbing of cover, purge bush and
case wear ring.

CCRU RGC TURBINE 15KT1

THRUST BEARING FAILURE
The Recycle Gas Compressor (15-K-1) of CRU is
driven by a back pressure type steam turbine.
EQPT. DETAIL :-

TAG NO.
MAKE
MODEL
SPEED
TYPE OF BLADE
STEM INLET PR.
STEAM OUT LET PR.

:
:
:
:
:
:
:

15KT1
EBARA JAPAN
SBHEG4-4
7446 RPM
4 STAGES CURTIS WHEEL
60 KG/CM2
4 KG/CM2

CCRU RGC TURBINE 15KT1

THRUST BEARING FAILURE
PAST HISTORY AND CHAIN OF EVENT

ON 28-2-01, 15K1 COMPRESSOR TRIPPED ON HIGH AXIAL

DISPLACEMENT.
ON 28-2-01, 19.10HRS COMP. ROLLED AFTER CHECKING.
TRIPPED AT 6000 RPM ON HIGH THRUST BEARING TEMP &
AXIAL DISPLACEMENT.
AFTER ANALYSIS THE PROBLEM, DECIDED TO OPEN THE
THRUST BEARING FOR CHECKING.

OBSERVATION

THRUST PAD (ACT.SIDE) FOUND COMPLETELY WIPED OFF.

NO OTHER ABNORMALITY OBSERVED.

CCRU RGC TURBINE 15KT1

THRUST BEARING FAILURE

REPAIR REPL. DONE

ALL THE 6NOS ACTIVE SIDE THRUST PADS REPLACED.

COMPLETE LUBE OIL REPLACED AND FILTER CHANGED.
SOLO RUN OF TURBINE CHECKED.

TURBINE ROLLED ON 6-3-01 AND FOLLWING

PARAMETER WERE OBSERVED
AXIAL DISP.
TH. BEARING TEMP
CHEST PR.
1ST STAGE PR.

:
:
:
:

0.23/.19
85,91,85OC
25 KG/CM2
19 KG/CM2

FROM 1ST WEEK OF MAY THESE READINGS HAVE STARTED

INCREASING WITH OUT ANY CHANGE IN OPERATING
PARAMETER

CCRU RGC TURBINE 15KT1

THRUST BEARING FAILURE
ON 29-6-01 TURBINE TRIPPED, DUE TO HIGH
THRUST BRG. TEMP. AND AXIAL THRUST. DECIDED
TO OPEN THE TURBINE.

OBSERVATION MADE AFTER OPENING:

THRUST(ACT.SIDE) FOUND DAMAGED.

3RD & 4TH ROW BLADES OF TURBINE FOUND 80% CHOCKED
DUE TO SEVERE SILICA DEPOSITION.
DIAPHRAGM NOZZLES WERE FOUND ERODED.

REPAIR REPL. DONE

ROTOR AND DIAPHRAGM OF TURBINE WERE CLEANED BY

HYDRO-SAND BLASTING .
ERODED PORTION OF DIAPHRAGM NOZZLES WERE WELD
BUILD UP AND GRINDED OFF.
ACTIVE SIDE THRUST BEARING REPLACED WITH NEW
ONE.

CCRU RGC TURBINE 15KT1

THRUST BEARING FAILURE

AFTER REPAIR / REPLACEMENT TURBINE ROLLED

ON 12-7-01 AND TURBINE IS RUNNING WITH
FOLLOWING PARAMETER.
AXIAL DISP.
TH.BEARING TEMP.
CHEST PR.
1ST STAGE PR.

:
:
:
:

(-)0.02/(+).01
50,51,53 DEG. C
21KG/CM2
13 KG/CM2

THRUST BEARING FAILURE OF CCRU RGC

TURBINE 15KT1
REASON OF REPEATED FAILURE OF THRUST BEARING:

Brief on Existing system

The HP steam requirement of CRU RGC turbine (Ebara

make) is met partly from captive generation with the
balance (about 45%) thru import from TPS. The
turbine is designed for an inlet steam temperature of
420oC @60 Kg/cm2g. However, the actual steam
temperature remains in the range of 360-370oC.

Reasons of failures

The rise in thrust bearing temperature and high axial

displacement of turbine rotor were due to deposition on
the moving and static blades of the turbine.
The suspected reasons for metal erosion of turbine
diaphragm nozzles is the supply of steam at lower
temperature and impurities present in it

THRUST BEARING FAILURE OF CCRU RGC

TURBINE 15KT1

Prevention of silica deposits

The most significant factor in corrective action is the
maintenance of low silica concentration on BFW that in
turn will ensure less than 0.02 ppm silica in HP steam.
Industrial experience shows that deposition difficulties
due to silica will not generally develop if steam silica
content is held below 0.02 ppm.
We have also seen that the silica finds its way to steam
(at definite distribution ratio) and silica rejection by
steam is drastic at exhaust steam specific volume of 0.6
cu ft/lb and above
.
Based on the above discussion, the actions to avoid
recurrence of heavy silica deposition on CRU RGC steam
turbine blades can be summarised as follows :

THRUST BEARING FAILURE OF CCRU RGC

TURBINE 15KT1

a) Lab test on regular basis for DM water and BFW

separately to monitor silica concentration. This will also

help detection of possible contamination of condensate
thru tube leaks of STG condensers.
b) The exhaust at the turbine to be maintained at
4.0+kg/cm2g on sustained basis to retard silica rejection
by steam. All the MP to LP PRDS are being checked for
performance so that LP steam header pressure is always
maintained.
c) Action being initiated for providing improved insulation
to ensure steam availability to RGC at design level.
Steam generator at 15 F-1 of CRU are being looked into
for ascertaining reasons for low superheat temperature
of steam generated.

THRUST BEARING FAILURE OF CCRU RGC

TURBINE 15KT1

CHOKAGE OF BLADES

EROSION ON DIAPHRAGM