TECHNICAL REPORT No 4197.

ROOT CAUSE ANALYSIS REPORT ON LOCKED

ROTOR CONDITION IN EP/09/11105A AND
HIGH MOTOR CAVITY TEMPERATURE IN
EP/09/11105B AT HNPCL,VIZAG .

AUTHOR(S) : A. Gupta

DATE : 11/07/2015

APPROVED BY : R. Knowles

REVISION : A
1.1 Proprietary information
This Report has been prepared by Hayward Tyler Ltd. (‘Hayward Tyler’) for internal
use and approved release to external parties. The Report contains confidential
information relating to Hayward Tyler’s products, designs and technical know-how,
and shall not be disclosed to any external party except within the terms of a non-
disclosure agreement. In any case, disclosures shall be restricted to a need-to-know
basis.

1.2 Disclaimer
This Report is based on data and information from various sources, which Hayward
Tyler has carefully evaluated, qualitatively and/or quantitatively, using experience
and judgement. The conclusions and recommendations made in this Report may be
based on assumptions and/or information furnished by other parties, and therefore
are not guaranteed by Hayward Tyler.

Hayward Tyler shall not under any circumstances whatsoever accept any liability
arising from any external party's use of the report, in any manner or form.

1.3 Revision History

Revision Date Reason

0 11/07/2015 First Issue

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 2 of 12
Rev A July 15 Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
1.4 Table of contents

1.1 Proprietary information………………………………………………………………….......2

1.2 Disclaimer……………………………………………………………………………….........2
1.3 Revision History………………………………………………………………………….......2
1.4 Table of contents……………………………………………………………………….........3
2.0 Introduction……………………………………………………………………………….......4
2.1 Field Service engineer report…………………………………………………….......4
3.0 Analysis of BCP unit EP/09/11105A………………………………………………………..6
3.1 Initial investigations concluded……………………………………………………….6
3.2 Operational data available…………………………………………………………….8
4.0 Conclusion………………………………………………………………………………........8
5.0 Analysis of BCP unit EP/09/11105B………………………………………………….........10
5.1 Initial investigations concluded……………………………………………………….11
5.2 Operational data available……………………………………………………............12
6.0 Conclusion………………………………………………………………………………12

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 3 of 12
Rev A July 15 Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
2.0 Introduction
The purpose of this report is to determine the root cause of locked rotor condition in BCP
unit-EP/09/11105A and Increasing motor cavity temperature in BCP unit-EP/09/11105B at
HNPCL,Vizag site, following a site visit by Hayward Tyler Field Service Engineer and the
reports from BHEL.
2.1 Field Service Engineers Report.

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 4 of 12
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3.0 ANALYSIS OF BCP UNIT NO- EP/09/11105A

3.1 Initial Findings:-

3.1.1) The Rotor was found to be sized.

Figure 1

3.1.2) Tilt pads at thrust cover were fused with Journal sleeve

Figure 2

3.1.3) Significant Damage to the tilt pads

Figure 3

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3.1.4) Foreign Material accumulated on the Motor case

Figure 4

Figure 5

3.1.5) Foreign material inside motor

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 Figure 6

3.1.6) The debris was weighed and found out to be in excess of 3 kgs.

3.1.7) An IR (Insulation resistance) test was completed and was recorded as acceptable.

3.1.8) The major damage was on the bearings.

3.1.9) The commissioning was not carried out by Hayward Tyler and Motor cooler was not
Hayward Tyler supplied

3.2 Operational Data available:

Pump Commissioning:
Start Date & time : 16.04.15 at 1700hrs
Stop Date & time : 16.04.15 at 1804hrs
Total Run time : 1.04 hrs
Motor current : 76.5amps
Cavity water temperature : 36.5 - 40.6 ⁰C
LP cooling water Flow : 13 m3/hr or 13 lpm (contradictory data available)

EDTA cleaning:
Start Date & time : 23.04.15 at 1904hrs
Stop Date & time : 23.04.15 at 1915hrs
Total Run time : 11mins
Motor current : reached to the max of 99amps
Purge water : 14kg/cm2

The BCP was started again on 24.04.15 or 26.04.15(contradictory data available) but it
tripped at locked rotor condition.
Total Run time of BCP :1.15mins.

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 8 of 12
Rev A July 15 Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
4 Conclusion :
4.1 Bearing Failure:-

i) Based on the report from the Field Service engineer that there wasn’t any
issue in dismantling the motor from pump case and no damage was found to
the shaft, it is unlikely that mis-alignment could be the cause of the failure.

ii) Based on the evidence gathered and the Field Service Engineer information,
the failure is due to foreign material present inside the motor, preventing
correct operation of the hydrodynamic bearings. The foreign materials caused
the bearings to breakdown and cease to work hydrodynamically – resulting in
the subsequent rotor seizure.

iii) The location and the quantity of the foreign material found in the BCP indicate
that the bearings failed due to the ingress of foreign material.

4.2 Over Current:-

i) Based on the Insulation resistance value found(1.GῺ),any reasons like Mis-

wiring / Insulation Fault/Single phase etc can be ruled out to be the cause of
over current.

ii) The supply voltage during BCP operation is assumed to be the rated voltage
and not below and hence assumed not to be the reason for over current.

iii) BCP was found with enough debris to cause the overloading of the motor
which can result in the motor drawing over current. In addition to this, the
bearing failure due to the foreign material resulted in the excessive over-
loading and eventually the stator reached to the Locked rotor condition in an
attempt to run the motor before it tripped.

4.3 Final Conclusion :-

With the above analysis, it can be concluded that the ingress of foreign material was the sole
contributor to the failure of BCP.

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 9 of 12
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5 ANALYSIS OF BCP UNIT NO- EP/09/11105B

5.1 Initial investigations concluded:-

5.1.1) Traces of Dirt on the filter assembly

Figure 7

5.1.2) Tilt Pads on pump end bearing found with score marks

Figure 8

5.1.3) Thrust bearing found in good condition

5.1.4) IR(Insulation resistance) was recorded and found as acceptable.

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 10 of 12
Rev A July 15 Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
5.1.5) There was no obvious damage and the BCP was found in good condition.

5.1.6) The bearing clearances and end float were found to be in the acceptable range.

5.1.7) The BCP was in storage for close to 3 years and it has been reported by BHEL that all
the procedures of storage were followed.

5.1.8) The commissioning was not carried out by Hayward Tyler and Motor cooler was not
Hayward Tyler supplied

5.2 Operational Data available:

Pump Commissioning:
Start Date & time : 16.04.15 at 1845hrs
Stop Date & time : 16.04.15 at 1848hrs
Total Run time : 3minutes
(The trip was due to DP transmitter fault which was
rectified and BCP was again started. The data after
which isn’t available.)
Motor current : 77.6amps
Cavity water temperature : 38.6 ⁰C
LP cooling water Flow : 14 m3/hr or lpm( contradictory data available)

EDTA cleaning:
Start Date & time : 23.04.15 at 1520hrs
Stop Date & time : Not available
Total Run time : Not available
Motor current : Not available
Cavity water temperature : reached to the max of 50.22 ⁰C or 54⁰C(contradictory
data available)
LP cooling water flow : 14 m3/hr or lpm( contradictory data available)
Purge water : 14kg/cm2

BCP temperature was normal during standby mode or rose to 54⁰C (contradictory data
available)

6 Conclusion

6.1 Heat generation during running condition is commonly due to the increased electrical
losses, however the Insulation resistance was checked and found to be ok which
indicates that in this instance, the windings were not the reason for increase in Heat in
motor cavity.

6.2 Heat can be generated due to the bearing friction. Since the bearings used in BCP are
hydrodynamic means that they shall not produce heat during running, but the
score marks have been found on the tilt pads which may be due to dry run during start
/stop or any foreign burr / material etc and hence the possibility of generation of heat
due to bearings can’t be ruled out completely

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 11 of 12
Rev A July 15 Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401
 6.3 Heat can be generated due to conduction from Pump case or flow of water into motor
cavity through Hot neck. Since the design of HT BCP is a tested and proven design,
installed on 1000s of units worldwide, Hayward Tyler is confident this is not a design
related issue.

6.4 As the motor cooler isn’t supplied by Hayward Tyler and hence whether Cooler was
working properly or not cannot be ascertained.

6.5 Reports that the temperature increased during stand-by condition indicates that the
heat transfer from pump to the motor was not being cooled efficiently as there isn’t any
other source of heat generation during that time.

6.5 Final Conclusion:-

Based on the data available and the analysis carried out, it is likely that the poor
performance of the motor cooler, likely due to ingress of minor foreign particle, is the
likely cause of the motor cavity temperature increase.

Report Hayward Tyler Ltd, 1 Kimpton Road, Luton, England. LU1 3LD Page 12 of 12
Rev A July 15 Telephone: + 44 (0) 1582 731144 Fax: + 44 (0) 1582 393401