PROJECT : PROBLEM :

TALCHER STPP FAILURE OF ID FAN 5-B SHAFT AND BEARING ASSEMBLY

ID Fan 5-B was trial run on 25/04/04 with both inlet and outlet gates in open condition. Fan bearing temperature was observed to be raising and hence, the fan was stopped. The bearing was opened for inspection. It was observed that the liners of drive end and non-drive end bearings were damaged and the babbit has come out. The shaft journal was having pitting and which was observed to be the cause for damage of bearing liners. The following items were also damaged:1. 2. 3. 4. Shaft assembly Liner dodge pillow block assembly (expansion NDE ) Liner dodge pillow block assembly (non-expansion - DE) Thrust plate kit

On verification of records, it was observed that the shaft was inspected and cleared for erection by BHEL/Ranipet on 02/12/03, when it was taken up by Site about rusting and pitting of shaft. Further, the shaft supplied for Unit-6 was also found pitted at the journal portion. Site has inspected the bearings and polished the shaft further with oil stone and run with Servo system 68 oil with new liners on 03/05/04. The bearing temperature was found raising and it was stopped. On inspection of bearing, the babbit was observed to be slightly peeled off. Ranipet expert was deputed to site and journal was further polished. More viscous servo system 100 oil, which was recommended by bearing supplier, M/s Dodge/USA was used and the fan was run. Fan performance was observed to be in order. However, NTPC was

insisting to replace the shaft, since they do not want shaft with repaired journal in newly supplied Fan. It was decided to replace the shaft by a new one for final acceptance of the equipment by NTPC. The shaft supplied in mandatory spare to NTPC is also pitted and rusted. Further, the bearing liners were damaged due to pitting on the shaft journal. Similar pitting in ID Fan shaft journal portion is reported from NTPC/Ramagundam site also. Conclusion: The damage to shaft journal is attributable to lack of protection against corrosion probably due to poor preservation, packing and transport or storage. This could avoid high cost to BHEL/customer by way of replacement/delay in erection & commissioning, which is a deemed profit.