Root Cause Analysis (RCA) related to the eleven numbers of Cooling Tower Fan frequently failing drives.
Article Type: | Root Cause Analysis (RCA) |
Category: | Mechanical |
Equipment Type: | Miscellaneous Rotating Machine Problems |
Author: | S. Raghava Chari |
Note: This root cause analysis (RCA) is from real-time scenarios that happened in industries during the tenure of two or three decades ago. These articles will help you to improve your troubleshooting skills and knowledge.
The author after detailed study considered the two below given alternatives to solve his 3 predecessors gave up 10‑yearlong problem:
Shift the motor inside the CT shell and couple the motor to the Gearbox (GB) to eliminate the 3-m long tubular shaft (LTS) – the problems’ Root cause. The management already besieged with pain in the neck electrical problems instantly rejected it.
Replace LTS with universal joint shaft (UJS, below figure) – the problem vexed management approved instantly trial at two fans.
The author decided replacing the poor life LTSs with universal joint shafts (UJS) because, being a well-engineered, strictly quality controlled for material quality, dimensional tolerances, assembly fit ups and special-painted to withstand the dusty and wet environs the automobiles face.
The faced constraints (C) and remedies (R) follow:
C1-The torque capable longest available UJS was not long enough to couple the motor to the JB!
R1- The author got the motor pushed towards the fan; cutting a hole in the wooden door. 1/3 motor length penetrating into the fan chamber enabled coupling to the GB input shaft
C2-1500 RPM rotation centrifugal force threw the grease out of the UJS; the lubricant starved UJS would fail within weeks; in addition, the falling grease would contaminate the water and pose housekeeping problems.
R-2; Covered the UJS with UJS vendor sold low cost ‘boot,’ benzene washed the old grease, recharged new grease during the two-yearly TAs and covered the joint with new boot. Hence, the UJS lasts forever
Below given are the benefits from UJS:
Author: S. Raghava Chari
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