Form No.

-
MAINTENANCE STANDARD REPORT Issue Date 24 June’2019
Revisi 00
Section: Long Term Maintenance
Title:
ROOT CAUSE ANALYSIS

I. SECTION DETAIL

Activity Date : 06 June 2019

Report Date : 24 June 2019
Prepared By : Surianshah
Checked By : Adi Purwanto

II. ASSET DATA

Asset_id 1HDE10AT001
Asset_desc EMITING RAPPING DRIVE SYSTEM
Location ELECTROSTATIC PRECIPITATORS UNIT #1
Service Req. -
WO_Id -
Work Type  Inspection  CM  PM  Others ……………
 WO : Work Order
 CM : Corrective Maintenance
 PM : Preventive Maintenance

III. EQUIPMENT DATA

Brand : ALSTOM India Limited

Type : 1*FPA-4*37.5M-1*148-115-A2
Flue Gas Flow : 223.6 m³/s
Flue Gas Temp. : 145 °C
Inlet Dust Concent. : 30.96 g/Nm³ dry 6% O2
Outlet Dust Emission : 40 g/Nm³ dry 6% O2
 Form No. -
MAINTENANCE STANDARD REPORT Issue Date 24 June’2019
Revisi 00
Section: Long Term Maintenance
Title:
ROOT CAUSE ANALYSIS

IV. BACKGROUND

First Observation of Tripping / Stoppage:

On 06.06.2019 ESP#1 of all field manhole in roof opened for checking to inside. Found in field#4 of

pin wheel small damage, bolt broken in bottom bearing stopper and shaft touching on ceramic cone.

Field#2 found also pin wheel small of damage and bolt broken in bottom bearing stopper.

Reasons of Tripping / Stoppage:

The mechanical failure of emiting rapping drive system causes the shaft pin wheel touching on
ceramic cone, pin wheel small damage and also The shaft insulators coupling damage, eroded into
thickness less. As indicate in the picture.
 Form No. -
MAINTENANCE STANDARD REPORT Issue Date 24 June’2019
Revisi 00
Section: Long Term Maintenance
Title:
ROOT CAUSE ANALYSIS

V. ACTION

Action Taken to Prevent the Failure:

1) Emiting rapping drive system dismantled and cleaned the eroded portion at shaft insulators

coupling

2) Build up shaft insulators coupling with cast iron welding C1-A1 filler wire

3) Replace new one of pin wheel small

4) Tab bottom bearing stopper bolt hole and install new bolts with large size than existing Hex

bolt M14 grade 12.9

5) Because the thickness of shaft insulators coupling is very poor so very difficult to weld. Finally

lock bolt is permanently welded to shaft insulators coupling

Root Cause Analysis for Failure:

a) May be because bottom bearing stopper bolt damage during the pin wheel rotates so shaft

which connected to shaft insulator coupling is shifted sideways and touching with ceramic cone

b) Shaft bearing are not aligned to make pin wheel small wear out

c) Due to continuous running of shaft bearing rotated not straight make shaft insulator coupling

eroded
 Form No. -
MAINTENANCE STANDARD REPORT Issue Date 24 June’2019
Revisi 00
Section: Long Term Maintenance
Title:
ROOT CAUSE ANALYSIS

Action to be taken to Prevent in Failure:

FIELD 2# FIELD 4#

1. Build up with cast iron welding done on shaft insulator coupling

2. Installation of new pin wheel, bottom bearings, stopper bolts and strength with tag weld also
realignment
3. New shaft insulator coupling has to be installed in field#4 and need to check shaft alignment
worry about bending
4. The results of megger get pretty good value and ensure there is no short on wire electrode