FAILOUR ANALYSIS OF RE-CYCLIC

GAS BLOWER

AMALNATH V J
PRASIDH M S
ANEES A
MAJEED
AKSHAY MOHAN
FIROZ KHAN
 RG- BLOWER
The RG- Blower is used in the pigment processing
plant (PPP) of KMML

Where it is used to recycle the liberated

chlorine gas from the Oxidation Unit
of PPP to Chlorination unit

About 90% of chlorine gas is thus recycled

 WORKING OF RG BLOWER
• Main parts of RG Blower
1) MOTOR
A 250 KW motor with an RPM of 2980
is used.
The motor is coupled with impeller
directly with the help of shaft
2) IMPELLER
• Which is the rotating component of the
centrifugal fan having single inlet
• The impeller is arranged on the one shaft
end outside of the two bearings
• The impeller draws the gas through a
control butterfly valve by the suction
side expansion joint and through the
suction nozzle
3) SHAFT
• Stainless steel shaft supported by two
bearings
• The shaft accommodated the impeller and the coupling
half of fan side
4) BEARING
Two bearing are used
a) Located Bearing
The bearing mounted adjacent to the
impeller is located bearing
• A cylindrical roller bearing of designation NU
2220 is used as located bearing
b)Non Located bearing

• The bearing mounted on the shaft adjacent

to the motor is called non located bearing
• Deep Groove Ball Bearing of designation NTN
6318 is used as Non located bearing
 REPESENTATION

BE
BEARINGS

MOTOR

Rb Wi

a b c d

Rc
 RG BLOWER MAINTANANCE
HISTORY REPORT
DATE DESCRIPTION REMARKS
21.03.2009 Motor replaced due to high Due to vibration
vibration
18.05.2009 Motor replaced due to high Due to vibration
vibration
19.08.2009 Seal assembly replaced Due to leak
25.08.2009 Casing leak welded inside Due to vibration

13.09.2009 Casing and rotor assembly Due to vibration

replaced
17.09.2009 Suction leak Due to leak

27.09.2009 Suction leak and replaced Due to leak

10.11.2009 Impeller cleaned Due to vibration

 RG BLOWER VIBRATION
ANALYSIS REPORT
LOCATION POSITION V mm/s D microns X . RPM
H 30 180 1
1 ON MOTOR V 10 25 3
A 25 80 3
H 18 100 2
2 ON IMPLR V 17 90 3
A 17 100 3
D – displacement, V – velocity If we get f = 1 x RPM --- BALANCE
2 x RPM --- MISALIGNMENT
3 x RPM --- BAD BEARING

Frequency f = (V/D) x 6.28N

REASONS FOR MODIFICATION
• From Vibration analysis and maintenance history
report, it is clear that the main failure of RG blower
is due to heavy vibration caused by poor bearing life
• The bearing used to support the shaft are
• 1 Deep groove ball bearing
• 2 Cylindrical roller bearing
• The major problem faced by bearing are
• The expected life of bearing is more than
60,000 hours. But the bearing currently used
is less than the expected
• The bearing are placed in the housing with
common oil lubrication system, hence the
maintenance become more complicated
• The bearings currently used cannot
accommodate any slight misalignment and
also the thrust loads
 IMPLEMENTING NEW DESIGN

• From the above analysis and studies which

we conducted in U200 plant (chlorination
plant) of KMML implies that the main
drawback of the industry is the breakdown
of production cycle
• If an RG Blower get damaged, the recycling
of chlorine gas to the chlorination plant get
stopped result in stopping of complete cycle
So we decided to change increase the life and
load capability of bearings
By conducting deep study in bearing we find
that DOUBLE ROW SPHERICAL ROLLER
BEARING have all the features which we are
looking for
So we decided to replace the current bearings
by DRSRB
 FEATURES OF DRSRB
• Very high load caring capacity
• High degree of angular aligning capability
• Capability of caring thrust load
• Having very long life
• Frictional loss can be reduced
• It has special geometry that assures a high
combined radial and axial load
• The outer race of the bearing is a portion of sphere,
results that they are internally self-aligning
 NEW BEARINGS
• Non-located
• Replace the Deep groove ball bearing NTN
6318 by Double row spherical roller bearing
21318E
• Located
• Replace the cylindrical roller bearing NU
2220 by Double row spherical roller bearing
24120 CC\W
 LIFE OF CURRENT BEARING

NON LOCATED BEARING

Deep groove ball bearing NTN 6318
Life in hours= 48442.596

LOCATED BEARING
Cylindrical roller bearing NU 22220
Life in hours= 10297.260
 LIFE OF NEWLY DESIGNED
BEARING
• NON LOCATED
• Double row spherical roller bearing 21318E
• Life in hours = 103087.9
• LOCATED
• Double row spherical roller bearing 24120
CC/W
• Life in hours = 91973.7
 COMPARISON
Existing bearing in hours
deep groove ball bearing[NL] = 48442.596
cylindrical roller bearing [L] = 10297.260

Expected life of modified bearing in hours

Spherical roller bearing[NL] = 103087.9
Spherical roller bearing[L] = 91973.7
 CONCLUSION
The RG Blower is one of the main important
machines used in the pigment processing
plant working 24 hrs. the brake down of any
of the blower cannot be accommodated.
There for by incorporating the suggestion,
the operating life of the blower and the
bearing can be comparatively increased.
Also during the operation the brake down
due to failure of blower can be reduced