Documente Academic
Documente Profesional
Documente Cultură
Andreas Holtman
Carlos Da Silva
Oct, 9th, 05
General Comments
This report will content the RCA (Root cause analysis) for the
Failure on the Rolls bearings of the Vertical Raw Mill at the Kollenbach plant
(Germany).
This is being created for two main reasons, the first one is the
analysis of such important failure, and the second one as training for Plant
personnel.
This RCA will be analyzed from two points of view, one will be
finding the root cause of the mechanical problem and the next one will be to
find why this failure was not predicted.
Vertical Raw Mill
None Predicted
Vertical Raw Mill
Bearing Failure (Rolls)
See comments
External Object into Raw Mill Deffective Assembly Seals Failure Vibration Monitoring
See comments See comments See comments See comments
The repairs were made in 80 hours, all liners were changed from
the rolls in operation to the spare set of rolls and then installed. Kiln was
stopped for lack of Raw material on Saturday September 24th at 4:20 am.
The total downtime for the kiln was 24.5 hours.
These rolls that failed were installed on the last Major Repair in
February 2005, they were brand new rolls fabricated and assembled by
Gebr. Pfeiffer.
Rolls Bearings Raw Mill Failure
After the Mill was brought back in operation the 2 damaged rolls
were sent to Gebr. Pfeiffer for inspection after all pictures, oil samples, etc.
were taken, the order was given to them not to open the rolls until CEMEX
personnel arrived to the shop.
Now, the team has enough information to start with the RCA.
External object into Raw Mill
All three rolls were inspected at the time of the failure and not
apparent damage was seen on any of the surface of the rolls. Table and Mill
internals were inspected as well and not evidence of external object damage
was found, as seen on the picture, click to enlarge.
Roll Picture
Equipment Overload
Not apparent overload had occurred in the Mill in the last 6 months,
it can be seen in the Amps of the table and the pressure of the hydraulic
system in the following trends from the control room:
Mechanical Failure
It is pretty obvious that a catastrophic failure happened on the
bearings, as showed on the following pictures, Click on Picture to enlarge:
Yoke Side Bearing, Roll 1 Yoke Side Bearing, Roll 1 Yoke Side Bearing, roll 1
Outside Bearing, roll 1 Spinning signs on outer race #1 Spinning signs on outer race #3
Both Inside bearings (Yoke side) were most damaged and both of
them show signs of spinning on the outer race, in the outside bearings (Self
aligned rolls) this effect is not shown.
ROLL
Roll drawing
YOKE
ROLL
Yoke Side Bearing, Roll 1
Yoke Side Bearing, Roll 1
SIGNS OF SPINNING
Lubrication Wheel
CONTACT WITH
DISTANCE BUSHING
Defective Assembly
None apparent indication of a defective assembly has been seen
yet. Gebr. Pfeiffer is going to take measures of all parts involved and a
report will be sent to plant personnel next week.
Installation Problems
None apparent indication of a defective installation was noticed,
plus the installation on the field is pretty straight forward.
Defective Bearings
As soon the third roll arrives to Gebr. Pfeiffer and get disassembled,
an SKF technician will visit the shop to analyze the bearings.
It is interesting to see the oil analysis results from the laboratory for
all three rolls, the roll that was found with not apparently damage (Not Iron
particles on the Magnetic bolt) is # 2 Roll which shows the lowest amount of
silica content.
AIR FLOW
AIR FLOW
Vibration Monitoring
There are continues Vibration Monitoring on all three rolls, this was
not an original feature of the Mill but it was installed by plant request.
But After all evidence was collected an analyzed we can say that
some of the root causes of the problems seems to be as following, please
remember we are analyzing two problems (Mechanical failure of bearings
and the fact that the failure was not predicted):
•Dust Seals design: There was evidence of silica inside the rolls, plus
the damage on the bearings is more severe on the Yoke side (Seal
side) than the outside (Self aligning bearings)
•Oil analysis frequency (Predictive)
•None continues monitoring of temperature in place (Predictive)
Root Causes & Recommendations
Recommendations
For the Mechanical Failure recommendations are as following: