Inst ToolsInst ToolsInst Tools
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Standards
    • Basics
    • Formula
    • Erection & Commissioning
    • Process Fundamentals
    • Root Cause Analysis
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
Search
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Reading: Pulverizer Electrical Problem Solved
Share
Notification Show More
Font ResizerAa
Inst ToolsInst Tools
Font ResizerAa
  • Courses
  • PLC
  • Control Systems
Search
  • Courses
  • Automation
    • PLC
    • Control System
    • Safety System
    • Communication
    • Fire & Gas System
  • Instrumentation
    • Design
    • Pressure
    • Temperature
    • Flow
    • Level
    • Vibration
    • Analyzer
    • Control Valve
    • Switch
    • Calibration
    • Standards
    • Basics
    • Formula
    • Erection & Commissioning
    • Process Fundamentals
    • Root Cause Analysis
  • Interview
    • Instrumentation
    • Electrical
    • Electronics
    • Practical
  • Q&A
    • Instrumentation
    • Control System
    • Electrical
    • Electronics
    • Analog Electronics
    • Digital Electronics
    • Power Electronics
    • Microprocessor
Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Inst Tools > Blog > Root Cause Analysis (RCA) > Pulverizer Electrical Problem Solved

Pulverizer Electrical Problem Solved

Electrical engineering root cause analysis (RCA) related to pulverizer poor availabilities and the problem solved.

Last updated: September 28, 2022 3:08 pm
S Raghava Chari
Root Cause Analysis (RCA)
No Comments
Share
3 Min Read
SHARE

Electrical engineering root cause analysis (RCA) related to pulverizer poor availabilities and the problem solved.

Contents
Pulverizer ProblemAuthors SolutionBenefits of the RCA Solution
Article Type:Root Cause Analysis (RCA)
Category:Electrical
Equipment Type:Bus ducts, Switchgear, Transformers,
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.

Pulverizer Problem

Why low on stream hrs? Because of the V-belts coupling the 1500 RPM motor and 750 RPM pulverizer last max a month!

Why? The reasons are: 

  1. Because of corrosion and dust frozen Inoperable belt tensioners, the crew crow bar the first belt into first drive and driven pulleys’ grooves and crow bar it to the last grooves, groove by groove. All belts go this way. Thus they are ½ dead right at installation
  2. Belts running in the hygroscopic dust deposited pulley grooves slip, squeal to the high heavens and die within a month or often sooner
  3. Consequent 750 sets of V-belts and 24 pulleys sets changes reduce pulverizer availabilities to 50%, require frequent pulverizers changeovers etc. and tire the operation and maintenance crew unbearably and reduced production by 10 to 15%

Authors Solution

A few days ponder showed a way out:  the author recalled his college day pole changing motor topic; though he did not understand Motors application Handbook” given winding change details, and electrical engineers were diffident, a smart re-winder rewound a test motor for 750 RKM.

Its tire coupling coupled to a pulverizer did so well that all enthusiastically modified all the pulverizers’ drives within a month.

Benefits of the RCA Solution

The below are the mentioned benefits of the author’s solution.

  1. Rs 5, 00, 000 yearly savings from no pulleys and no belt changes
  2. No Crew overtime payments 
  3. 5% less power consumption i.e. yearly recurring Rs 5, 62, 000 – 1980 costs –  savings 
  4. Far higher pulverizers and motors bearing lives
  5. Pulverizers and hence plant availability shot by 10%
  6. Freedom from boring, repetitive and low-tech tasks boosted technicians and operators morale
  7. The operation and maintenance crew freed of dull low tech repeat chores thanked the author and spent the saved time for knowledge improvement
  8. Thanks to items 1-5, the modification pays for itself in a day

Author: S. Raghava Chari

Do you face any similar issues? Share with us through the below comments section.

If you liked this article, then please subscribe to our YouTube Channel for Instrumentation, Electrical, PLC, and SCADA video tutorials.

You can also follow us on Facebook and Twitter to receive daily updates.

Read Next:

  • Poorly Built Switchgears
  • Lightning Arrester Burst
  • 110 KV Connection to Feeder
  • Transformer Problem Solved
  • Replace Failed Motors Quickly
Don't Miss Our Updates
Be the first to get exclusive content straight to your email.
We promise not to spam you. You can unsubscribe at any time.
Invalid email address
You've successfully subscribed !

Continue Reading

Pressure Switch Frozen Screwed Cover Extends the Plant Shutdown
Turbo-Compressor Problem – Root Cause Analysis
Multistage Flash Drums Erratic Level Readings
Learnings from the BP Refinery Explosion at Texas City
NH3 Plant Turbo-compressor Sudden Rise in Temperature
Frequent Feeder-A Lightning Arrester (LA) Bursts – Root Cause Analysis
Share This Article
Facebook Whatsapp Whatsapp LinkedIn Copy Link
Share
Leave a Comment

Leave a Reply Cancel reply

Your email address will not be published. Required fields are marked *

Stay Connected

128.3kFollowersLike
69.1kFollowersFollow
208kSubscribersSubscribe
38kFollowersFollow

Categories

Explore More

Cooling Tower fan FRP fan blades saves and saves
Primary Reformer RFG main Hot Spots threaten Indefinite Outage
Lessons Learned from Actuator Passing Incidents
Boiler Feed Water Heater Shell Flange Leaks
Safety Liquid Ammonia Disconnect threatens NH3 Vapor Spill
8000 RPM 8000 kW Turbine Problem
Phosphate Dozing System Problems
Under and Over-Capacity Control Valve Pose Poor Controllability

Keep Learning

Flash Vessel All Level Instruments Stopped Working

Ammonia Flash Vessel All Level Instruments Stopped Working

Fasteners and General Corrosion of Electrical Motors

Fasteners and General Corrosion of Electrical Motors

On Off Valve Root Cause Analysis

Root Cause Analysis for FRP Line Damaged due to On-Off Valve

Capacitor Bank

Poor Power Factor Boosted – Industrial Electrical Problems

Fired Boiler Induced Draft Fan (IDF) Failures

Fired Boiler Induced Draft Fan (IDF) Failures Upset all Plants Operations

Inability to Test Repaired HT Motors

Inability to Test Repaired HT Motors in Workshop Posed Problems

Centrifugal Compressor outage reduced

Centrifugal Compressor Outage Reduced – Root Cause Analysis

Thermocouple Extension Lead Minimizer Circuit

Thermocouple Wires and Extension Lead Issues

Learn More

Metric Prefixes and Unit Conversions

Metric Prefixes and Unit Conversions

PLC offline data of a project are compared

Compare Two Offline PLC Projects

Power Electronics Objective Questions

Type C Chopper Objective Questions

PLC Temperature Control using Pulse Width Modulation

PLC Temperature Control using Pulse Width Modulation (PWM)

Transducer

What is a Transducer ?

What is Barring Gear Logic? Why is it Required in the Steam Turbine?

online silica analyzer

Silica Analyzer Problems and Troubleshooting Tips

Non-Contacting-Radar-Level-Transmitter-Animation

Non Contacting Radar Level Transmitter Animation

Follow US
All rights reserved. Reproduction in whole or in part without written permission is prohibited.
Welcome Back!

Sign in to your account

Username or Email Address
Password

Lost your password?