PROJECT PROBLEM

: NALCO CPP UNIT-7 (120 MW) : AIR PREHEATER GUIDE BEARING FAILURE

PROBLEM FACED: Nalco CPP Unit-7 Boiler was stopped on 31.08.03 for Annual overhauling activity. To carry out PG Test after the overhauling, as a routine check up for PG Test , Air Pre-heater Seal setting was inspected. During this course of above work, the following were observed:? Guide bearing housing inside was looking dry and ash was found in the form of cake in both the APHs. ? The bearings were fully damaged with lot of pittings and abrasions marks on rollers and races. ? The failure of Guide Bearing was observed in both APH A&B. ? All 3 Nos. of locking cap holding bolts (M24x90) Gr.A 10.9 were found to be in sheared condition in APH A and found to be loose in APH B. Locking of cap plate bolts was not proper. ? Bearing adopter sleeve found dislocated in APH A by 90mm from its position and was in position in APH B. ? Trunion shaft tapered potion got worn out in both the APHs.

? The seal tube thinned out vertically creating a big hole for a width of 30-40 mm and more at the middle in APH A. Similar failure noticed in APH B as well.

? The protection sleeve provided in the trunion shaft (Trunion Sleeve) got thinned out and formed two grooves in both the APH. ? The adopter sleeve worn out from inside. ? Both the thermostats for oil temperature measurement have gone defective due to ash entry. FAILURE ANALYSIS: There was heavy deposit of ash over and below the guide bearing. The fine ash fallen from the Eco hopper cover the entire trunion shaft air seal housing arrangement touching upto the bottom of Guide bearing housing. The seal air was unable to escape to atmosphere and might have forced the fine ash between protective sleeve & trunion shaft and entered the bearing. The ash entered the bearing had contaminated the lub oil and jammed the bearing. This had resulted in free rotation of adaptor sleeve over tapered trunion and damaged the trunion as well. This has caused the loss of verticality of the trunion shaft and other associated problems. This has been depicted in the attached Sketch.

REMEDIAL PROBLEM:

MEASURES

TO

AVOID

RECURRENCE

OF

THE

? Ash falling from Eco hopper around the APH guide bearing should be totally avoided. Before every light up, proper functioning of Eco hopper sealing/flushing system is to be ensured. The area has to be kept cleaned always.

? During erection, all erection checks should be thoroughly done jointly and protocols are to be made by incorporating a log sheet for tightening of l ocking cap with locking cap holding bolts and locking the bolts. (Eventhough, the above event is to be checked as per Field Quality Plan, there is no log sheet for the above purpose). This has been incorporated in the Field Quality Plan of Erection/Commissioning of APH in Log sheet L-08 with a special note to avoid recurrence of such problem.

The lub oil level in bearings are to be regularly monitored and oil samples may be collected and analysed in case of increase in mechanical impurities, the bearing oil is to be replaced with fresh lub oil after thoroughly flushing out the contaminants.

CONCLUSION: The other reported lose of verticality of trunion and other associated problems can be avoided by maintaining very clean surroundings free from ash and other foreign materials around the guide bearing and properly ensuring all erection checks along with locking of lock plate will avoid recurrence of such problem. Periodic physical inspection of guide bearing lub oil and bearing and proper closing of inspection cover will further aid to improve the availability and reliability to the equipment.