ROOT CAUSE FAILURE ANALYSIS

MODULE 2 - ONLINE

ACTIVITY TEN (10) - FAILED ELECTRIC MOTOR BEARING

NAME JOEL MINAFI

DATE 26-Feb-23
1. DATA COLLECTION OF FAILED ELECTRIC MOTOR BEARING

1a. Grease Flow Chart through the grease chamber and bearing housing

GREASE ENTRY GREASE NIPPLE GREASE CHAMBER BEARING HOUSING GREASE CHAMBER GREASE RETAINER

OVERGREASE PURGE ROLLER BEARING OVERGREASE PURGE

2. Pictures taken for the failed parts

3. CM trending graph of Bearing Temperature 4. Bearing Design schematics

5. Estimated cost of Motor Assembly

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2. FISHBONE DIAGRAM OF FAILED ELECTRIC MOTOR BEARING

Equipment Environmental

Inadequate Tools
Malfunction

Location of Drive
No grease
Faulty Grease Purge metering tool

Inaccessible
Grease metering
Grease purge tool faulty
spring faulty

Failed electric
Lack of Work Instruction
Lack of knowledge Lack of understanding

No Maintenace
Schedule Don't know how Don't understand CM
to do the greasing Temperature change &
pinpoint emerging

No Work Instruction
to check Grease
Purge function Don't know the
Being Lazy
during Maintenance right amount of

Key Believed failed path

Procedures People

2. Fishbone diagram of the contributing factors/causes including latency issues like attitudes, beliefs, company culture norms, etc.
Evidence present:
1. Grease purge port is blocked Report Compiled By:
2. Grease found inside the motor winding. Signature:
3. High temperature reading was noted starting from 6 July on CM trending graph. Date:
4. Failed Bearing cage and displaced bearing seal Distribution: Manager/Superintendent/Workshop Supervisors/File
3. CREATIVE DISASSEMBLY INSPECTION & TEST RECORD OF FAILED ELECTRIC MOTOR BEARING
Equipment ID: PWS01 Equipment Description: Process Water Pump Parent Component: Main Drive Motor of Compressor 5
Work Order: W1687433 Date: 16-Feb-2023 Child Component: MD5-EB ( Motor Drive End Bearing)

1. Problem Identified:

The bearing was over-greased and ran hot until the cage failed from overstress

2. Evidence of Problem:

Grease was found throughout the motor windings

3. How I investigate the Cause of the Problem:

After it failed, the motor was removed and disassemble and observe grease was found inside the motor windings.

4. What I Believe to Be the Causes and the Supporting Evidence:

Cause 1: Faulty Grease relief Port
Evidence: Blocked grease relief port
What I did to Fix the Cause: Replace new grease relief port and add in maintenance work pack to do function tests

Cause 2: High Temperature readings

Evidence: CM Temperature Trending Graph as well as displaced bearing seal & oxidization
What I did to Fix the Cause: Add in condition monitoring template the 3T of functional temperature range of bearing and check limit.

Cause 3: Over-greasing
Evidence: Grease found throughout the motor windings as well as failed beariing cage
What I did to Fix the Cause: Put inplace a grease chart to include how much quantity is required to grease the bearing housing.

Test performed to prove problem was corrected and result from the Test:

1. Testing Grease relief Port: Grease was pumped through the nipple and access grease was observed coming out of the relief port.
2. Test run was done and temperature readings were monitored to be within the normal range.

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4. ROOT CAUSE FAILURE DECISION TREE OF FAILED ELECTRIC MOTOR BEARING

Cause 1: Faulty Root Cause: Grease Solution: Replace grease relief port & plan in
Grease relief Port relief spring faulty to check function during inspection

Failed Electric Cause 2: Oxidization Root Cause: Over- Solution: Set temp operating range and alert
Motor Bearing heating limit.

Cause 3: Over- Root Cause: No Solution: Put up grease quantity chart in the
grease chart routine maintenance schedule

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5. 6 WHY TABLE OF FAILED ELECTRIC MOTOR BEARING

6Whys Questionnaire

2x Technicians - Daniel Sioni & Tarashiape Wiriasong

Team Members DATE 18-Feb-23
Reliability Engineer - Joel Minafi

Failed Electric Motor Bearing

Problem Statement
Estimated Cost
>PGK80, 000.00 (NEW MOTOR, AC, 355KW, 4P, PROCESS WATER PUMP)
(Damage)
Recommended
Put grease chart quantity next to motor, add grease relief port function test in maintenance plan & set alarm limit in CM temperature readings
Solutions
Latent Issues Lack of proper; maintenance system, training & analytical skills.

3W2H Answers
Why Questions Evidence Solution
(with what,when,where,how,how much)

Grease found in the motor windings Stop grease to enter motor windings
Why did the motor failed Because grease covered the motor windings
Photo provided in section 1. Clean and rewind the motor

Why did the grease enter motor Bearing seal & cage displaced Use geniune & specified bearing as per
Because the bearing cage and seal failed
windings Photos provided in section 1 designed.

Because of high of overheating & high Oxidization & Temperature CM graph Set alarm limits for abnormal temperature
Why did the bearing cage & seal fail
temperature attached in CM graph.

Put up greasing chart next to the motor for

Why are overheating & high Because no pressure or over-greasing were Excessive grease found in motor
Lube Technician to see how much is needed
temperature reading observe relief windings
by this particular bearing.

Install new grease relief port

Why were pressure/excess grease not
Because grease relief port is faulty Grease blocked relief port Create PM task to change out grease relief
relief
port every 4000hr pm inspection

Because the coil spring in the grease relief port Spring can't recoil Create PM task to change out grease relief
Why is the grease relief port faulty
is stiffen & unable to operate Grease covered the port. port every 4000hr pm inspections.

5. Using 6Whys Questionnaires to test the failure path of the Electric Motor Bearing Failure to determine the Root Cause

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6. RECOMMENDATIONS TO PREVENT FAILURE REOCCURRENCE OF FAILED ELECTRIC MOTOR BEARING

Recommendation to prevent the failure reoccurrence

1. Amend Preventative Maintenance Tasks to include grease relief valve change out every 1000hr of operation.
2. Set temperature alarm/alert limit in Temperature Condition Monitoring tasks so when trending Temp change can be identified and immediate action will be
taken to resolve and developing problems.
3. Do up a grease quantity chart and put next to the motor so Lube Technician will know the exact amount is required during greasing tasks.

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Signature:
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7. LUBRICATION CHART

ANTI FRICTION/BALL
HOURS TO MAX SHAFT IDLE TIME GREASE METHOD ALTERNATE GREASE
BEARING MOTOR PREFERRED GREASE* ALTERNATE GREASE* GREASE QUANTITY
LUBE FRAME PREFERRED** METHOD***
MANUFACRTURER
404/5-5010 (8grams)
WEG 1100 90 DAYS MOBIL POLYREX EM N/A L5010 (15grams) AT REST OPERATIONAL
L5809 (19grams)
1.5 cubic inches
TOSHIBA 1000 90 DAYS MOBIL POLYREX EM N/A AT REST OPERATIONAL
(25grams)
1.5 cubic inches
TECO 1000 90 DAYS MOBIL POLYREX EM CHEVRON SRI-2 OPERATIONAL AT REST
(25grams)
PER DATA KLUBBERPLEX 1.5 cubic inches
ABB 90 DAYS MOBILITH SHC 100 OPERATIONAL AT REST
PLATE BEM41-132 (25grams)
1.5 cubic inches
RAM 1000 90 DAYS MOBIL POLYREX EM CHEVRON SRI-2 AT REST OPERATIONAL
(25grams)
1.5 cubic inches
1000 90 DAYS SHELL ALVANIA RL3 MOBILITH SHC 100 AT REST OPERATIONAL
RELIANCE (25grams)
SEE MANUFACTURERS SEE MANUFACTURERS
SIEMENS 1000 90 DAYS NAMEPLATE FOR N/A NAMEPLATE FOR AT REST N/A
APPLICABLE GREASE APPLICABLE GREASE
IMPORTANT REMINDER:

* NEVER MIX GREASE TYPE OR BRAND. IF CHANGING FROM OR TO THE ALTERNATE OR PREFERRED, THE BEARING CAVITIES, HOUSINGS, AND LINES MUST BE CLEANED OF THE OLD GREASE.
**FOLLOW ALL STANDARD LOCK OUT TAG OUT PROCEDURES PRIOR TO GREASING THE MOTOR.
**AFTER GRESING MOTOR AT REST - RUN MOTOR FOR MINIMUM OF 45 MINUTES BEFORE REPLACING GREASE PURGE PLUG, IF EQUIPPED.
***MOTOR MUST BE EQUIPPED WITH GREASE EXTENSIONS ON DE BEARING FOR PERFORMANCE OF THIS TASK.
VERIFY WITH MOTOR NAMEPLATE ANY DISCREPANCY BEFORE LUBRICATING - CONTACT TECHNICAL SUPPORT/RELIABILITY FOR CLARIFICATION.
REMOVE/REPLACE GREASE RELIEF PLUG IF FAULTY- PRIOR TO GREASING. NOT EVERY GREASE INTERVAL WILL RESULT IN USED GREASE DISCHARGE.

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8. MOTOR BEARING GREASING WORK PROCEDURE/PLAN

NAME EMPLOYEE NUMBER DATE

WORK ORDER
JOB LOCATION JOB DESCRIPTION
#
IF YOU HAVE TICKED ANY OF THE BOXES BELOW YOU MUST NOT START WORK UNTIL YOU HAVE A JOB SAFETY & ENVIRONMENTAL ANALYSIS (JSEA)/
STANDARD WORK INSTRUCTION (SWI) OR PERMIT TO WORK FOR THE WORK ACTIVITIES TO BE CARRIED OUT.
DOES ANY OF YOUR WORK INVOLVE ANY OF THE FOLLOWING HIGH RISK ACTIVITIES?
ISOLATION & TAGGING OUT WORKING AT HEIGHTS
CONFINE SPACE ENTRY HOT WORK ACTIVITIES
USE OF HAZARDOUS SUBSTANCE/CHEMICAL WORKING NEAR ROTATING MACHINERY
USE OF CRANES & LIFTING DEVICES ACCESS TO RESTRICTED AREAS

ALL TICKED NO RED BOX ANSWERS BELOW SHALL BE REPORTED TO THE SUPERVISOR
TRAINED AND COMPETENT
HAVE I BEEN TRAINED IN THIS TASK? YES NO
AM I TRAINED AND CERTIFIED TO OPERATE/CARRY OUT THIS TASK AND MY TRAINING PERMIT IS CURRENT YES NO
AM I CONFIDENT TO DO THIS TASK SAFELY YES NO
SAFE WORK PROCEDURES
IS THERE A JOB SAFETY & ENVIRONMENTAL ANALYSIS OR STANDARD WORK PROCEDURES FOR THIS TASK? YES NO
DO I UNDERSTAND THE JSEA, SOP/SWP AND PERMIT? YES NO
IS THERE A JSEA, SWP/SOP OR PERMIT AVAILABLE AT THE WORK PLACE (NOT IN THE OFFICE)? YES NO
TOOLS & EQUIPMENT
DO I HAVE THE CORRECT TOOL(S) FOR THE JOB? YES NO
IS THE TOOL IN GOOD CONDITION? YES NO
HAVE I BEEN TRAINED TO USE THIS TOOL? YES NO
CONTROLLED WORK ENVIRONMENT
HAVE I INSPECTED THE WORK AREA AND IS IT FREE FROM HAZARDS? YES NO
HAVE I LOOKED ABOVE, BELOW AND AROUND FOR THE HAZARDS? YES NO
HAVE HAZARDS BEEN IDENTIFIED AND CONTROLS UNDERSTOOD? YES NO

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