G1-607 A High Speed Shaft Inducer Stud Failure Investigation Report

Date: 22nd May 14

Investigated by: MZS

Reviewed by: KSK/RS

History

On 2nd May 14, G1-607 B was changed over to G1-607 A at 1020 hrs as part of monthly
changeover regime. However, on 3rd May 14 at 0400 hrs, the pump got tripped on under
current. It was started again the next morning, but was found only drawing 32 amperes and
producing no flow and pressure. The gearbox was resultantly lifted and the impeller and
inducer were found dislodged from the high speed shaft. Earlier, on 18th April 14, the same
pump was reported to have some flow induced abnormal sound and was shut down
preventively. It was attempted the next day and was found normal but was tripped on under
current on 20th April 14 after which it was kept as a standby till 2nd May 14.

Observations

Both the impeller and inducer were found heavily rubbed against the diffuser and pump casing.
The tail of the inducer was also found completely worn off. Detailed examination revealed that
the stud holding the impeller and inducer with the high speed shaft was excessively corroded
along with the splined part of the shaft. The o-ring on the back of the impeller was found
pressed and cut while the o-ring on the inducer could not be found anywhere during pump
dismantling although it was installed at the time of assembly.

Inducer rubbed against the casing (left), tail completely worn off (right)
 Rubbing on impeller (left), corrosion and damage to high speed shaft spline and stud (right)

Root Cause Analysis

Since the failure was the first of its kind, advice from the pump OEM, Sundyne, was also sought.
All the relevant details regarding the failure were shared including the trends of pump flow and
current recorded from 18th 20th April 14 and on 3rd May 14. As per OEM, the process trends
were normal and there was no abnormality in the process conditions that could have led to this
failure. Metallurgy of the o-rings was also checked and was found the same as that supplied by
the OEM (PTFE). The root cause was therefore identified to be the improper installation of the
o-ring that is installed on the back of the impeller. The improper installation led to process
ingress into the carbon steel high speed shaft and the inducer stud, causing corrosion and
ultimately, the failure of the stud.

Sundyne has also mentioned that after several startups, the PTFE o-rings fail to follow the
expansion and contraction of the high speed shaft and dont self-tighten anymore, providing
room for process ingress and leading to corrosion of carbon steel components.

Recommendations

The following are the recommendations:

1. Seek proper procedure from Sundyne for the installation of impeller and inducer o-rings
and make it part of the maintenance check sheet. (Action: MZS, Target Date: 02nd June
14)

2. Ask Sundyne to share the maximum number of allowable startups per annum and
modify the changeover frequency accordingly. (Action: MZS/RS / Target Date: 02nd June
14)