1. FAILURE ANALYSIS AND ALTERATION OF RECYCLE GAS BLOWER

2. Presented by AFZAL SHIHAB Roll NO: 04 ARUN KUMAR.N Roll No: 70 JINEESH.K.M Roll No: 73 VIVEK SUBRAMANIYAM Roll No: 72 MITHUN SOMAN Roll No: 71 Guided By: Mr.ANEESH LME – MACE Mr.VIPIN PM & Mr. RIJU STEPHEN PLANT ENGINEERS KMML

3. INTRODUCTION The Recycle Gas (RG) blower is used in Pigment Processing Plant(PPP) of Kerala Minerals And Metals Limited (KMML).The section deals with conversion of Beneficiated Illuminate to Rutile Titanium Dioxide. The blower used in PPP section is manufactured by TLT Egg India Ltd, Ahmadabad. Significant machine in KMML

4. PLANT PROFILE KMML is India’s only rutile grey titanium dioxide faculty through chlorine route. The trade name of KMML product is KEMOX. Products have many applications in plants like Plastics, medicines and cosmetic industries. KMML was established by a private enterprise in 1932 as F.X. Perriera and Sons P Ltd During 1956.this concern was taken over by state government as an ltd company with effects from 1972 with its present name.

5. PIGMENT PRODUCTION PLANT PPP consists of following units 1. Raw material handling unit (U-100) 2. Chlorination Unit (U-200) 3. Oxidation Unit (U-300) 4. Pigment production unit (U-400) 5. Chemical storage (U-500)

6. In U-100, raw materials like BI,PC are stored in their respective storages. In chlorination unit (U-200),the illuminate is chlorinated with chlorine gas to form Titanium tetra Chlorine(TiCl4) Oxidation plant (U-300) oxidation takes place TiCl4 is converted to TiO2, here chlorine gas is liberated. The liberated chlorine gas is serrated in the pigment separator, the gas is recovered,cooled,dried and compressed to enable it flow up in to chlorine.

7. The Cl 2 gas is carried to chlorinator by the RG blower. The finished Titanium Dioxide pigment is produced in U-400 1. Sand milling 2. Treatment 3. Filteration 4. Micronisation & cooling 5. Product bagging In U-500 the finished products are stored.

8. Process Description at KMML

9. BLOWERS Gas turbo machinery- gas is compressed and moved by the dynamic action of rotating vanes. Exhauster- remove gas from a process and discharge it to atmosphere Booster- raise the pressure of a system that is already in atmospheric pressure

10. CLASSIFICATION OF BLOWERS Axial Centrifugal Special designs Recycle Gas Blower

11. GENERAL PARTS Impeller Housing Drive mounting mechanism Electric motor

12. IMPELLER Rotating component of the fan. Imparts mechanical energy of the rotating shaft in to stationary air pressure and flow. Axial fans impeller is fan blade In Centrifugal fans it is cylinder shape

13. HOUSING It is also known as casing. Purpose is to gate the gas to the impeller. Volute casings are suited for single stage blowers, small size and cost.

14. DRIVE & MOUNTING ARRANGEMENTS Includes components that support and transmit power from motor to impeller. Frames Bearings Shaft Pulleys Belts

15. ELECTRIC MOTOR Directly driven – impeller has its own shaft, this shaft is directly coupled with the motor.- optimum speed cannot be achieved. Belt driven- any speed may be achieved by choosing the correct pulley ratio & fan selection is simple.

16. BEARINGS Types of Bearings Roller bearings Ball bearings Spherical Roller bearings Needle Roller bearings Tapered Roller bearings Cylindrical Roller bearings Single Row Deep Groove Bearing Filling Notch Bearing Double Row Bearing

17. BALL BEARINGS Uses ball to maintain separation between bearings Purpose is to reduce rotational friction and support radial and axial 2 races one fixed one rotating Least expensive, Lower load capacity

18. SPHERICAL ROLLER BEARING Thicker in middle and thinner at the ends. Support misaligned loads Expensive & higher friction Outer ring inner ring & a locking feature

19. NEEDLE ROLLER BEARING Small cylindrical rollers are used. Large area of contact Inner race, needle cage of needle rollers & the outer race. Used in engine components such as rocker arm, pumps, compressors and transmission.

20. TAPERED ROLLER BEARINGS Use conical rollers that runs on conical axis Can take radial & axial loads Wheel bearings of most cars, trucks, buses etc

21. CYLINDRICAL ROLLER BEARING Have short rollers guided in a cage Rigid against radial motion Lowest coefficient of friction Used in high speed service

22. SINGLE ROW DEEP GROOVE BEARINGS Race dimensions close to ball dimensions. Less tolerant of misalignment of inner and outer races High load carrying capacity & suitable for high running speed

23. FILLING NOTCH BEARING Have notches in the inner & outer races. Permits more balls to be inserted High load bearing capacity Misalignment is considerably less

24. DOUBLE ROW BEARING Radial or angular contact between balls & races Narrower than two single row bearings Load capacity is less 60-80% wider & 50% more radial capacity than single row deep groove bearings

25. VIBRATION ANALYSIS It is the back & forth movement from rest. Useful technique to control machinery condition Measuring and noting vibration characteristics mechanical defects are identified Help to take appropriate action before the failure occurs

26. STEPS IN VIBRATION ANALYSIS Characteristic measurement Vibration detection and analysis Data interpretation

27. CHARACTERISTICS MEASURMENT Frequency measurement Displacement measurement Velocity measurement Acceleration measurement Amplitude measurement

28. VIBRATION DETECTION & ANALYSIS Plotting Amplitude Vs Time or Amplitude Vs Frequency. Mechanical problems can be identified and displayed. DATA INTERPRRETATION Compare the reading of significance with vibration of various type of troubles. The key to comparison is frequency.

29. BENEFITS OF VIBRATION ANALYSIS Prolongs machinery life. Minimize unscheduled down time. Eliminates unnecessary overhauls. Eliminates stand by equipment. Provides more efficient operation. Increases machinery safety. Improve quality of performance.

30. RECYCLE GAS BLOWER AT KMML Single inlet centrifugal fan. The impeller is arranged on the shaft Bearing nearer to impeller is located bearing(B1), other one is no located bearing(B2). Motor of 250KW drives the impeller fan at a speed of 2980 rpm. MOTOR B2B2 B1B1 IMP ELL ER

31. SPECIFICATIONS OF RG BLOWER Make: TLT Engg Type:33531/308 Material handled:Cl 2 gas Capacity:39m 3 /sec Pressure rise:39777Pa Speed:2980 rpm Gas temperature:1500c Power required at shaft:193.2 Kw Coupling: Flexible Coupling FX212A(671361240) Bearing: Oil lubricated bearings: SKF 6318 & SKF NU222ECP Mass moment Inertia:J = 0.25*GD 2

32. MOTOR Power:250 Kw Speed:2980 rpm Bearing Housing: 671360040 Materials of construction Impeller: SS 316(1φ100) Shaft: CK 45(φ125* 1090 long)

33. FAN Unit is a single inlet centrifugal fan. Bearings are outside the casing. Impeller is arranged on one shaft end. Stator parts of the impeller can be replaced with out any difficulties. The rotor consist of shaft impeller, coupling and Labyrinth seal. Impeller draws the gas through a control butterfly valve.

34. SHAFT Made of stainless steel (SS 31610). Supported by two bearings. Impeller attached to shaft by means of washer, bolt and securing plate. The threaded centre holes for mounting the bearing, the coupling and the impeller.

35. BEARING ASSEMBLY Plummer block bearing consist of located& non- located bearing. located is cylindrical roller bearing of NU design(Nu- 2220). Non Located bearing is Deep Groove ball bearing (SKF 6318). Lubrication is provided by flinger.

36. PHASE - I VIBRATION ANALYSIS OF RG BLOWER Monitoring parameters displacement & velocity were read by IRD-306 vibration meter. Three selective positions horizontal, vertical & axial. F=(V/D)2ΠN V=velocity mm/s D=displacement in microns

37. OBSERVATIONS DateAxisVelocityDisplacementRemarks Motor FAN ND D D NDMotor Fan 23/1/12horizontal3.1 3 7 6 vertical4 3.4 7 10 46V/D*19120 axial5.9 4 3 8 39 2/2/12horizontal2.6 3 3.4 vertical axial 2.3 2.7 2.8 1.6 1.9 2 Balanced

38. VIBRATION CALCULATIONS (V/D)*19120=(10/46)*19120 = 4156.52 = 1.39*rpm (V/D)*19120=(8/39)*19120 = 4025.26 = 1.35 *rpm If F= 1*rpm- Unbalance 2*rpm-Misalignment 3*rpm- Bad Bearing Vibration Analysis has been done.

39. PHASE – II BALANCING OF BLOWER ROTOR What is Un Balance in Rotating Parts? Unbalance is caused by the displacement of the mass centerline from the rotor's axis by an eccentricity in the distribution of the rotor mass. In simpler terms, due to centrifugal force, the "heavy" point of a rotor exceeds the centrifugal force exerted by the light side of the rotor and pulls the entire rotor in the direction of the heavy point. Balancing is the correction of this phenomena by the removal or addition of mass to the component to compensate for centerline error.

40. ROTOR BALANCING AT KMML KMML currently using Dynamic Balancing Machine made by Fuel Instruments & Engineers Pvt Ltd.

41. BALANCING CALCULATIONS Rotor Weight (W)=300Kg Radius (R)=500mm Recorded Unbalance=437g at 211 0 Existing Residual Unbalance= R*w/W =(500*437)/300 =728.33gmm/Kg Permissible Residual Unbalance=20gmm/Kg (from graph)

42. ISO SPECIFICATION CHART FOR RESIDUAL UN BALANCE

43. Since Existing Residual unbalance is greater than the permissible residual unbalance, balancing weight is to be added at required angle Weight added at 500mm radius at 211 0 =437g New recorded un balance=10g Residual Unbalance=(R*w)/W=(500*10)/300 =16.6gmm/Kg Since new Residual unbalance is within the permissible limit the RG Gas Blower is ready to use

44. PHASE – III MODIFICATION OF BEARINGS Reason for modification of bearings From the previous maintenance history card and verification of vibration data we noticed that one of the major problems faced in U-300 plant is with the maintenence of the blower.The usually occuring problems were with the bearing life.

45. MAJOR PROBLEMS FACED IN BEARINGS The current life of the bearings is less than the expected range hours. Single housing common oil lubrication system,maintenance becomes much more difficult. Deep groove bearings and cylindrical roller bearings are used they can’t accommodate slight misalignments.

46. BEARING DESIGN & ANALYSIS 0.230.560.465 Wt of the Impeller Udl 1.149KN/m Bearing Assembly Support (Datas Collected From the Records) A BCD

47. BEARING ANALYSIS Reactions Calculation Axial load F a =5000N (given data) The radial load can be calculated by means of the data- Weight of the impeller, W1=1.57KN Weight of the shaft =1.373KN Length of the shaft= 1.195m Weight of motor= 1.15KN

48. Length of AB=0.230m Length of BC= 0.560m R B +R C =2.943KN Taking moment about B M B =1.149* 0.23 2 /2 + 0.56RC-1.149*0.965 2 /2 - 1.573*0.9615 0.0303+0.56R C -0.5349-1.515=0 0.56R C =2.01 R C = 3.60KN R B =-663N

49. EXISTING BEARING LIFE CALCULATION ANALYSIS OF BEARING LIFE OF NON LOCATED BEARING SKF 6318 F A = 5000 N F R = 663 N N = 2980 rpm Data's Collected from SKF Bearing Catalogue Page no: 312 Dynamic Load Carrying Capacity of the Existing bearing C 0 = 108000 N Static Load carrying Capacity of the Existing bearing C = 151000 e= 0.0465 F A /F R = 7.541> e Radial Load Factor, X = 0.56 Axial/Thrust Load Factor, Y = 1.8 Rotation Factor, S = 1.5

50. The values of X,Y,S Collected from Data Book of PSG College Of Technology –Bearing Design EQUIVALENT LOAD, P = (X F R + Y F A ) S = ( 0.56× 663+ 1.8×5000) = 14056.93 N Life in Million revolutions L n =(C/P) 10/3 = (151000/14056.9) 10/3 = 2732.89 mR Life in Hours = L*10 6 /60*N ( From PSG College Of Technology Design Data book- Bearing Design) =(2732.89*10 6 )/(60*2980) =15284.61Hrs Life in years = 1.7 Yrs

51. ANALYSIS OF BEARING LIFE OF NON LOCATED BEARING SKF NU222 ECP(CYLINDERICAL ROLLER BEARING) F A = 5000 N F R = 3606 N N = 2980 rpm Datas Collected from SKF Bearing Cataloge Page no: 312 Static Load carrying Capacity of the Existing bearing C = 185000N F A /F R = 1.387> e Radial Load Factor,X = 0.92 Axial/Thrust Load Factor,Y = 1.4 Rotation Factor,S = 0.9-1.1

52. The values of X,Y,S Collected from Data Book of PSG College Of Technology –Bearing Design EQUIVALENT LOAD, P = (X F R + Y F A ) S = ( 0.92× 3606+ 1.4×5000)×0.9 = 9510.6 N Life in Million revolutions L n = (C/P) 10/3 = (185000/9510.6) 3.333 = 19774.94 mR Life in Hours = L*10 6 /60*N ( From PSG College Of Technology Design Data book- Bearing Design) =(19774.94*10 6 /60*2980 ) = 110598.02Hrs Life in years = 12.5 Yrs

53. BEARING DESIGN MODIFICATION From the studies we had conducted and the datas available with us we decided to repalce the existing bearings(Deep groove Ball Bearing&Cylinderical Roller Bearing) with Spherical Roller Bearings Analysis and the Calculation for the same as follows

54. ANALYSIS OF BEARING LIFE OF NON LOCATED SPHERICAL ROLLER BEARING 22218E Shaft diameter,d= 90mm Axial load,F a =5000N Radial load,F r =663N N=2980 rpm Spherical roller bearing 22218E page 718 of SKF Catalogue Dynamic bearing capacity,C=325KN F a /F r = 3.949>0.23(e=0.23) Rotation factor X=0.67 Axial / Thrust load factor Y=4.4 Equivalent load, P=(XF r +YF a )S =(0.67*663+4.4*5000)*1.1 = 24688.631N

55. Life in millions of revolutions (Data book page 325 of Mahadevan) L=(C/P) 10/3 =(325*10 3 /24688.631) 10/3 5386.266 Mr Life in hours= L*10 6 /60*N =5386.266*10 6 /60*2980 =30124.53hours Life in years =L h /360*24=30124.53/24*365 = 4 years

56. ANALYSIS OF BEARING LIFE OF LOCATED SPHERICAL ROLLER BEARING 22222E Shaft diameter,d = 100 mm Axial load,F a =5000 N Radial load,F r = 3606 N N= 2980 rpm Spherical roller bearing 22222E Dynamic bearing capacity,C= 560KN page 718 SKF Catalogue. F a /F r = 5000/3606= 1.38 >0.26(e=0.26) Rotation factor X=0.67 Axial / Thrust load factor Y=3.9 Equivalent load,P=(XF r +YF a ) =(0.67*3606 +3.9*5000)1.1 = 24107.622 N

57. Life in millions of revolutions (Data book page 325 of Mahadevan) L =(C/P) 10/3 = (560*10 3 /24107.622) 10/3 = 35726.48mr Life in hours L h = L*10 6 /60 N = (35726.48*10 6 /60*2980) = 199812.67Hrs Life in years =L h /24*365=22 years

58. COMPARISON OF BEARING LIFE  LIFE OF EXISTING BEARING  Deep Groove Ball Bearing = 15284.61hrs = 1.7Years  Cylindrical Roller Bearing = 110598.02hrs = 12.5 Years  EXPECTED LIFE AFTER MODIFICATION  Spherical Roller Bearing = 30124.53hrs = 4 Years  Spherical Roller Bearing = 1422751.6hrs = 22 Years

59. OBSERVATIONS From the analysis made on the bearing life of the spherical roller bearing as well as the deep groove ball bearing and the cylindrical roller bearing it is very clearly observed that the life of the spherical roller bearing is comparitively higher than the ones in use now.together with higher bearing life the spherical roller bearing also has the property of accomodation shaft mis allignments,self alligning property, etc.Hence the use of spherical roller bearing will help to reduce the frequent breakdowns and other maintenance problems. Vibration analysis and the rotor balancing will also help to improve the efficincy of the RG blower system.

60. CONCLUSION RG blower is one of the main important machine of PPP Works 24 hours through out the year. Break down of the blower cannot be accommodated. Vibration analysis and the rotor balancing will leads to the improved life of the system. Break down of the blower can be reduced due to the increase in life of the bearing. Maintenance operations can be done faster, hence maintenance cost can be reduced. Thus the Alteration of the Regenerative Gas Blower has been done.

61. REFERENCES Stephanoff A.J, Turbo Blowers SKF Catalogue Book. R S Khurmi & J K Gupta,a text book for machine design. Design Data handbook,K.Mahadevan K Balaveera Reddy. Heinz.P.Bloch,red.K.Gitner,Machinery failure & Troubleshooting.