Failure Analysis Report

1) Location: Ramanmandi Dispatch Station

2) Equipment: RBPL Booster Pump P-10-11C
3) Problem: On 07.04.2019 High Vibration and abnormal noise observed
inside the pump. Pumps was immediately stopped and vendor (Prumatech)
lineup.
4) Last Maintenance Details:
Last Overhauling done on 08.09.2016 after commissioning of pump since
Oct, 2012.
5) Overhauling Schedule: As per OISD-119 Complete overhauling shall be
carried out after every 24000 hours or 4 years whichever is early. RBPL
Vertical Booster Pump No. of Hours run since last overhaul is 16128 hrs
which is well within 24000 hrs and 4 year.
6) Observation on Dismantling Pump 24.04.2019:
a) Cracks/Damaged found in one of the column Pipe.

Figure 1:Damage column pipe

b) Wear out found in both Driver and Driven Shaft, 5 nos. of Bushes,
Impeller, Wear Ring, Impeller Ring Impeller etc.

Figure 2:Impeller collar wear out

Figure 3: Shaft Wear out

7) Analysis:
a) Wear out found in Shaft, 5 nos. of Bushes, Impeller, Wear Ring, Impeller
Ring Impeller due to metal to metal contact between stationary and
rotary parts after loss of PTFE foil. Due to wear out excessive clearance
and unbalancing of impeller resulting into high vibration.
b) Cracks found in one of the column pipe due to eccentric dynamic radial
load on one of the column pipe Bush. Bearing housing not able to
withstand fatigue stress of the shaft result in initiation and propagation
of crakes on column piping near the Bearing Bush.
8) Root Cause of Cracks on Column: RBPL Vertical Booster pump consists of
three nos. of column pipe (Stationary Parts) with three nos. of Bearing cage.
Each column pipe support pump shaft with the help of Interference fit
Bearing Bush and provides passage to flow product from impeller to
discharge header. Bearing Bush is mounted on Bearing cage with the help
of Grub screw. Each Bush Bearing sustain radial dynamic load of shaft and
transmit load to Bearing cage which further transmit load to column pipe .
Due to wear out of top Bush Bearing(40 mm) Grub screw was detached
from top of the Bearing cage resulting in tilting of 40 mm Bearing Bush
which lies nearby muff coupling. Tilting of 40 mm Bearing Bush leading to
transfer of lateral eccentric load on lower 80 mm Bearing Bush which
further supported by Bearing cage on second column pipe. Bearing cage
not able to withstand lateral eccentric fatigue stress of shaft result in
initiation and propagation of crakes on column Pipe.
 Figure 4: Tilting of top Bearing Bush

Figure 5: Load transmitted by lower 80 mm Bush

9) Correction, Corrective Action:
All spares i.e. Shaft , Impeller, five nos. of Bearing Bush, Impeller Ring and
Case wear ring available at location except column pipe.
Column pipe to be made available by following three method:
Plan-1: Procurement of new column pipe from OEM (Ruhrpumpen India
Pvt. Ltd. ) having unit price is Rs. 26,50,007,Delivery period: 26 weeks.
Plan-2: Fabrication of new column pipe in HMEL workshop by procurement
of Stainless Steel Pipe of 10 inch NB , Sch.40 and 10 inch 150# SS Flange.
Plan-3: Procurement of new column pipe through local party such as
Oasis/Allwyn Industry.

10) Preventive Action:

i) Use of OEM spares.

ii) Column pipe to be kept in spares.
iii) Reduce frequency for periodic overhauling /Inspection of pumps.