progress seminar#1

8/4/2019 Progress Seminar#1

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A PROJECT ON

Root cause analysis of Bridle Roll shaftfailure at continuous process industry

By:V.S. Khangar

M.Tech (CAD/CAM) III Sem

Guide:Dr.S.B.Jaju

Department of Mechanical EngineeringG.H. Raisoni College of Engineering, Nagpur

Session: 2011-2012


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Objective

The Bridle roll#8 shaft fails after

every six months (approximately) of use.

Failure of bridle roll at a cost ofi)Rs 80000 appro. (line stoppage)

ii) min 5-6 hrs of delay.

iii) cost of equipment & spares

This reoccurring failure has been

costly to the company; therefore a redesigned

shaft that will no longer fail is needed.


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Bridle Roll

Bridles function as

i)tension amplifiers or

ii)line-speed pacers in metal strip process lines.


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Probable solution or conclusion

Redesignsi) Extend Shaft Through Rollii) Increasing no of round plates

iii) Dimensions of shaft


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Literature review

1.FAILURE ANALYSIS OF SHEARED SHAFT OF ABRINE RECYCLE PUMP1Saleh A. Al-Fozan, Anees U. Malik and Mohammad Al-HajriTechnical Report No. TSR 3804/05005 in August 2005.Research and Development CenterSaline Water Conversion Corporation (SWCC)

1) The combined action of environment, geometryand stresses caused the crack initiation.

2) The propagation stage resulted by corrosionfatigue.

3. The cracks on the key area could be due to thelooseness of key installation in key groove.


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DPT RESULTS1. Cracks were found at many locations in key position

at both sides.

2. One crack was found in groove in sleeve area.

RECOMMENDATIONS1. closing of discharge valve of down pump to avoid

back flow from running pump.2. DPT during routine maintenance.3. The pump motors must be internally inspected.


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Stress raiser in shaft are due toCornersKeywaysPress or shrink fit

Welding defectsNicks & notchesSplinesQuench cracksLocalised corrosionmisallignment

3 A l i f th f t


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3.Analysis of the causes of recentroll shaft failure in natal sugar mills

Failure:- 93 roll shaft breakages which haveoccurred at eight selected sugar mills in Natal since1979Theoretical analyses of shaft stresses and fatiguestressThe feasibility of using adhesive to fix the shell to

the shaft is discussedrecommendations to users and manufacturers onroll shaft and shell specification, design, assemblyand operation are given.


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Conclusion

There are many external causes of shaft failurewhich can be eliminated by changes in mill designand operation improvement in the tail bar coupling, and

limitation Of the hydraulic loading.adequate planning of the roll repair and reshellprogram for the annual off crop.roll shaft should give a minimum life of 10

million tons of cane.


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PLAN OF WORK

Inspection of bridle roll material composition

Comparing with IS:2062 FE 410 steelmentioned in drawing

DPT Test for roll shaft

Checking for other causes

mathematical modeling


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Bridle Roll#8


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Technical Details

Roll Diameter = 1050mmBarrel Length = 1500mmBearing center = 1750mm

Dai of roll at failure = 110 mmMaximum wrap angle= 225 degreeMaximum roll RPM = 65Maximum roll load = 3500 KgRoll material = IS:2062 FE 410 steel.


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This case history involved ashaft that is 110 mm

diameter as shown inPhotograph 1.

However, all of the shafts

had been reportedly failedafter a short time in servicei.e. within every 6-7 monthsof operation

The investigation identifiedthe material as IS:2062 FE

410 steel.

Photograph 1.


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References..

1. Analysis of the causes of recent roll shaft failure

in natal sugar millsProceeding of The south African technologists association-june1988

2. Root Cause Failure Analysis-UnderstandingMechanical Failures. Reliability Magazine, Reliability CenterInc. Available from: www.reliability.com/article28.htm Sachs, N.1999.

3.Process RollsRoot Cause Failure Analysis, 1999, Pages 164-170Keith MobleyScience Direct

4. FAILURE ANALYSIS OF SHEARED SHAFT OF A BRINERECYCLE PUMP1

Saleh A. Al-Fozan, Anees U. Malik and Mohammad Al-HajriTechnical Report No. TSR 3804/05005 in August 2005.
http://www.reliability.com/article28.htmhttp://www.reliability.com/article28.htm


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Thank you

progress seminar#1

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