Case Study: Consecutive Failure of Lube Oil Cooler Fans Coupling

2021 ◽  
Author(s):  
Arumugampillai Manikandan ◽  
Zeeshan Anwar
Keyword(s):  
Centrifugal Compressor ◽  
Electric Motor ◽  
Normal Operation ◽  
Internal Diameter ◽  
Motor Shaft ◽  
Shear Plate ◽  
Oil Cooler ◽  
Air Cooler ◽  
Gear Box ◽  
Locking Screw

Abstract Do we analyze on why can even the most reliable turbomachinery are getting failure and stopped? In some cases, it's all about bad installation or design literally. This paper explores the challenges one site had with repeated failure of lube oil fin fan coolers coupling which caused the unit availability of more than 3 months. It outlines the troubleshooting attempts made to remedy this issue, its root cause, and the resulting solution. This issue occurred at a site with a train configuration of motor driven centrifugal compressors. The plant lube oil system has been configured with 3 trains. Each train has been configured with Main electric motor + Vorecon Gearbox + Low Pressure centrifugal compressor + High Pressure centrifugal compressor. Lube oil system of the train has been configured as 2 lube oil coolers and 2 working oil coolers. Lube oil coolers are having fins with air cooler type. Air is supplied by fin fans and each train has 2 lube oil cooler fans and 2 working oil cooler fans. In total site has 3 trains x 4 fin fans so it has 12 fin fan cooler fans. All cooler fans are driven by electric motor which is coupled with gearbox and gear box is connected with cooler fan. During normal operation of working oil cooler fan A- stopped rotation suddenly from normal operation. During investigation, motor shaft was found running freely. No movement was seen on cooler fan. Coupling between motor to gearbox was inspected. Coupling is shear plate coupling. Its spacer flexible element were found broken into several pieces. Further investigation revealed that motor coupling hub was moving free axially back and forth due to clearance between motor shaft to coupling hub internal diameter. Motor side Coupling hub bolt hole was found with loss of material and ovality in shape. Hub locking Allen screw was found in damaged condition. Missing materials were noted and broken shear plate materials were found around coupling guard area. While site team was conducting the investigation on the unit A, similar incident occurred in next unit and other 3 units with 2 days difference between them. During detailed investigation it has been noted that all motor to gear box coupling are shear plates and shear plates were broken. Coupling hub was found loose and coupling hub locking screw was found broken or partial damage.

Optimal Design Method of Fins in Automotive Oil Cooler Based on the Thermal-Hydraulic Performances

2012 ◽  
Vol 490-495 ◽  
pp. 2381-2385
Author(s):  
Bao Lan Xiao ◽  
Wei Ming Wu ◽  
Xiao Li Yu ◽  
Guo Dong Lu
Keyword(s):  
Heat Transfer ◽  
Neural Networks ◽  
Optimal Design ◽  
Heat Exchangers ◽  
Flow Resistance ◽  
Design Method ◽  
Normal Operation ◽  
Oil Cooler ◽  
Optimal Design Method ◽  
Simulation Results

The excellent thermal-hydraulic performances of oil cooler are the strong guaranty for automotives’ normal operation. In this study, the thermal-hydraulic performances of compact oil cooler units with different fin size parameters are numerical simulated. According to simulation results, combined with neural networks method, the optimal fin size parameters are determined. Based on this, the effects of different fin arrange layouts on performances are also studied, and optimal layouts for different requirements for flow resistance and heat transfer performances are put forward. This optimal design method can play a guidance role for the designer and manufacturer of heat exchangers.

Experimental Investigations of Effects of Centrifugal Compressor Impeller Design on Noise Characteristics

2014 ◽  
Author(s):  
Kyoung-Ku Ha ◽  
Chang-ha Lee ◽  
Yong-sun Park ◽  
Shin-hyoung Kang ◽  
Chi-young Park ◽  
...  
Keyword(s):  
Fuel Cell ◽  
Centrifugal Compressor ◽  
Noise Level ◽  
Processing System ◽  
Design Procedure ◽  
Low Noise ◽  
Design Flow ◽  
Normal Operation ◽  
Efficient Operation ◽  
Noise Characteristics

The subject of this study is a centrifugal compressor for fuel-cell vehicles which produces compressed air and sends it to the cathode channels of a fuel-cell stack. It uses up a lot of electricity and it is the only component in the processing system that has a rotating part moving a high angular velocity. So, it is important to improve the centrifugal compressor in efficiency and noise respects. As demand for quiet and comfort of vehicles increases recently, it becomes more and more important for the compressor to achieve low noise level. But it is difficult to design a suitable compressor with a conventional design method, which was formulated to provide highly efficient operation at the design point without considering the noise. Actually, the noise of a compressor is hard to be considered in the early steps of the design procedure because of a lack of information. So, this study aims to describe noise characteristics of centrifugal compressors experimentally and to pull noise considerations into a design procedure of the centrifugal compressor. According to previous studies, a tonal component leads to overall noise of a compressor in normal operation and there is a close connection between the instability intensity and the circumferential flow fluctuations of an impeller. Therefore an experimental study was designed to check the aero-acoustic characteristics of the impeller. An existing compressor was modified to install pressure transducers at the inlet and outlet of the impeller. And two microphones were installed to measure noise signals of the compressor in a sealed room. Tests were carried out to investigate the phenomena governing the overall noise and the dominant noise source of the centrifugal compressor. Then pressure fluctuations, noise signals and spectra of them were examined closely. After that, several impellers varying exit blade angles and design flow coefficients were tested also. They were all designed to satisfy the same pressure performance at a design mass-flow rate. Then investigations into the noise characteristics were carried out to find out effects of the impeller design variables on them. The results show that a large value of a blade angle is good for efficiency and noise level of the compressor. It is expected to be an optimal value to improve noise characteristics in terms of the design flow coefficient. The experimental facility, conditions and the results were described in this paper minutely.

Fatigue Cracking of a 3-MW Electric Motor Shaft

2015 ◽  
Vol 15 (2) ◽  
pp. 211-218 ◽  
Author(s):  
S. W. Stafford ◽  
L. Trueba
Keyword(s):  
Electric Motor ◽  
Fatigue Cracking ◽  
Motor Shaft

Signature Analysis for Mechanical Systems via Dynamic Data System (DDS) Monitoring Technique

1980 ◽  
Vol 102 (2) ◽  
pp. 217-221 ◽  
Author(s):  
S. M. Wu ◽  
T. H. Tobin ◽  
M. C. Chow
Keyword(s):  
Quality Control ◽  
Electric Motor ◽  
Control Variable ◽  
Data System ◽  
Statistical Quality Control ◽  
Normal Operation ◽  
Signature Analysis ◽  
Dynamic Data ◽  
Monitoring Technique ◽  
On Line

A new modeling technique called Dynamic Data System (DDS) is introduced for signature analysis. A one-horsepower electric motor experiment is used to demonstrate the methodology. The ‘normal’ operation is simulated by idling runs and eccentric loads representing the ‘defective’ operations. A DDS Monitoring Technique, by employing statistical quality control theory, is developed to monitor the operations of imposed electric motor defects. It takes thirteen seconds for data processing and calculation of a control variable value from an On-line programmed microprocessor to provide the control justification. The DDS Monitoring Technique proves to be effective and sensitive in identifying the operational status of a mechanical system.

scholarly journals Developing the model of normal operation of starter motor traction relays

2019 ◽  
Vol 124 ◽  
pp. 05039
Author(s):  
Andrey Puzakov
Keyword(s):  
Mathematical Model ◽  
Electric Motor ◽  
Traffic Accident ◽  
Internal Combustion Engines ◽  
Normal Operation ◽  
Combustion Engines ◽  
Magnetomotive Force ◽  
Diagnostic Parameters ◽  
Starter Motor ◽  
Voltage Loss

Malfunction of motor starter traction relays cause the impossibility of the reliable start of internal combustion engines which, if the worst comes to the worst, can create the risk of traffic accident occurrence. Electric resistances of traction relay coils are structural and diagnostic parameters at the same time. Emergence and development of failures causes the change of magnetomotive force generated by the traction relay coils. Critical values of electric resistances correspond to failures of traction relay coils, i.e., inability to perform the built-in functions. The developed mathematical model of traction relay normal operation includes the amount of effort generated and voltage loss on contacts as controlled values for the drive mechanism and the starter electric motor, respectively. The results obtained contribute to the development of the method of motor-and-tractor starter diagnostics without removing it from the engine.

Device for measuring the angle of rotation of an electric motor shaft

1973 ◽  
Vol 16 (1) ◽  
pp. 52-53
Author(s):  
A. L. Shte�ner ◽  
I. S. Pinchuk ◽  
B. K. Kavavashkin ◽  
A. Ya. �rgard
Keyword(s):  
Electric Motor ◽  
Motor Shaft ◽  
Angle Of Rotation

Application of the Gmc-1000 and Gmc-2000 Mine Cooling Units for Central Air-Conditioning in Underground Mines / Zastosowanie górniczego urządzenia chłodniczego gmc-1000 i gmc-2000 w centralnej klimatyzacji kopalń podziemnych

2013 ◽  
Vol 58 (1) ◽  
pp. 199-216
Author(s):  
Jerzy Wojciechowski
Keyword(s):  
Air Conditioning ◽  
Underground Mines ◽  
Evaporative Water ◽  
Cooling Unit ◽  
Oil Cooler ◽  
Air Cooler ◽  
Central Air Conditioning ◽  
Water Cooler ◽  
Air Conditioning Systems

The paper describes the design and results of operating measurements of the GMC-1000 and GMC- 2000 Mine Cooling Units. The first part describes the design of the cooling unit and its key components: the chiller, evaporator, condenser, oil cooler, evaporative water cooler and gallery air cooler. The possibilities of use in central air conditioning systems of underground mines are described. The second part discusses the results of the workstation and operating measurements and determines the coefficients for evaluating the performance of the mine cooling unit.

scholarly journals Analysis and Experimental Verification of a Variable Speed Turbo Air Centrifugal Compressor System for Energy Saving

Energies ◽  
2021 ◽  
Vol 14 (4) ◽  
pp. 1208
Author(s):  
Sung-An Kim ◽  
Kyung-Pyo Hong
Keyword(s):  
Energy Saving ◽  
Centrifugal Compressor ◽  
Electric Motor ◽  
Mechanical Energy ◽  
Recovery Period ◽  
Economic Feasibility ◽  
Constant Speed ◽  
Inlet Guide Vane ◽  
Energy Losses ◽  
Variable Speed

Conventional constant speed turbo air centrifugal compressor systems (TACCSs) consist of an electric motor driven at the constant speed and an inlet guide vane (IGV) for pressure control. TACCSs with an inverter for a variable speed drive (VSD) of the electric motor are more efficient than the conventional constant speed TACCS because they have a wide operating range and can minimize the power consumption. Therefore, this paper proposes a quadratic V/f control and VSD to reduce electrical and mechanical energy losses. To verify the energy saving effect of the TACCS with the proposed controls, this paper analyzes the performances of an electric motor drive system (EMDS) using the proposed quadratic V/f control considering load conditions of the turbo air centrifugal compressor (TACC) to reduce electrical energy losses. Furthermore, the performances of the conventional constant speed drive (CSD) using the IGV control and the proposed VSD were compared and analyzed in the test bench that represented an actual factory environment. As a result, the proposed quadratic V/f control and VSD experimentally verified energy savings of 4.44% and 23.37% compared to conventional controls. In addition, the economic feasibility of the proposed VSD was verified in the TACCS by analyzing the recovery period of the initial investment due to the addition of the inverter.

Design of a Centrifugal Compressor With Low Specific Speed for Automotive Fuel Cell

2008 ◽  
Author(s):  
Xinqian Zheng ◽  
Yangjun Zhang ◽  
Hong He ◽  
Zhiling Qiu
Keyword(s):  
Fuel Cell ◽  
Centrifugal Compressor ◽  
Electric Motor ◽  
High Speed ◽  
High Efficiency ◽  
Pressure Ratio ◽  
System A ◽  
Automotive Fuel ◽  
Low Specific Speed ◽  
Specific Speed

Centrifugal compressors driven by electric motor are the promising type for fuel cell pressurization system. A low specific speed centrifugal compressor powered by an ordinary high-speed (about 25,000rpm) electric motor has been designed at Tsinghua University for automotive fuel cell engines. The experimental results indicate that the designed low specific speed centrifugal compressor has comparatively high efficiency and wide operating range. In the condition of designed speed (24,000rpm), the highest efficiency and pressure ratio of the centrifugal compressor is up to 70% and 1.6, respectively. The designed low specific speed centrifugal compressor can meet the requirement of air systems of automotive fuel cell engines preliminarily. Moreover, the low specific speed centrifugal compressor avoids difficulties of usage of ultra-high-speed electric motors (about 60,000rpm) in high specific speed compressor. Based on the preliminary results of this centrifugal compressor, a new low specific speed centrifugal compressor with higher performances is being developed.

scholarly journals Power antenna radar with variable speed

2015 ◽  
pp. 81-87
Author(s):  
V. F. Strelkov ◽  
M. V. Andryushin ◽  
V. V. Vanyev
Keyword(s):  
Mathematical Model ◽  
Control System ◽  
Electric Drive ◽  
Electric Motor ◽  
Permanent Magnets ◽  
Performance Characteristics ◽  
Variable Speed ◽  
Motor Shaft ◽  
Radar Antenna ◽  
And Control

A mathematical model of the "mains - regulated electric drive" radar antenna us with a synchronous motor with permanent magnets. Peculiarities of work at a controlled electric variable speed electric motor shaft. A method and control system with motorized adjustable mechanical and electronic scanning of the antenna, improving performance characteristics of radar stations.

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