RCM-II
INFORMATION SHEET
FUNCTIONAL FAILURES
FUNCTIONS
1
To supply the compressed
atmospheric air at 4.2
kgf/cm2 (G), 4200 Nm3/h of
dry air with the flow
tolerance of 4% & at 41.73
O
C.
No air is supplied.
Compressed air is supplied below
4.2 kgf/cm2(G).
FAILURE CAUSES
FAILURE EFFECTS
Units fails to start
Air demand is not fulfilled. Check for
circuit breaker, set points & relay.
Tripped drive motor
Impeller damaged.
Damaged coupling due to
disc fastener kit or hub
failure
Air demand is not fulfilled. Push reset
button, check operator interface unit,
check oil level or inspect starter for
damage.
Impeller key sheared.
Due to damaged coupling, power from
the motor is not transmitted to driven
unit.
Malfunctioning of IGV due
to inlet valve actuator
When flow rate tends to increase, IGV
throttles to maintain the pressure. But
when IGV fails to throttle, flow rate
increases & pressure decreases.
Malfunctioning of IGV due
to defective transducer
Leakage in piping from the
1st stage to outlet
Pressure decreases when air leaks out
from piping e.g. piping between 1st stage
& intercooler.
Compressed air is supplied above
4.2 kgf/cm2(G).
Worn carbon seal rings or
O-ring (shaft)
Air leakage occurs along the shaft due to
wornseal ring.
Rotor imbalance
Due to dirt accumulation or worn rotor
blades, imbalance occurs which effects its
rotating speed (rpm).
Drive Bull gear imbalance
Due to dirt accumulation, worn out gear
or damaged teeth, Imbalance of drive
gear will occur & cause less power
transfer to driven gears & hence less rpm
of driven gears.
Driven gear imbalance
Low rpm of corresponding impeller.
Coupling misalignment
Excessive vibrations which will cause
power dissipation.
Worn bull gear bearing
Power dissipation at bearing housing
resulting in low rpm of both impellers.
10
Worn pinion bearings
Power dissipation at bearing housing
resulting in low rpm of respective
impeller.
11
Worn or damaged carbon
seal in regulator.
Excessive air leaks from regulator which
results in decrease in discharge pressure.
Dirt accumulation in
impeller, diffuser or
It hinders the air flow rate thus pressure
increases & a condition called Surge may
backplates
also occur. Surge can also occur due to
high inlet temperature.
Obstruction in air filter
It causes reduction in air flow rate &
ultimately increases the air pressure.
Erratic operation of
unloading control valve
due to leaks & obstruction
in UCV piping
Due to erratic operation upstream and
downstream pressure decreases which
ultimate effects flow rate
Defective unloading valve
actuator
Lock up pressure may change resulting in
undesired opening or closing of UCV.
Defective I/P transducer
Wrong signal may be generated which
may result in wrong output
Flow rate is above 4368 Nm3/h.
Defective discharge
pressure transmitter
If discharge pressure transmitter does
not give right signal, it may cause either
increase or decrease in discharge
pressure which will consequently effect
the flow rate.
Flow rate is below 4032 Nm3/h.
Looseness of Impellers
due to looseness of
mounting nut
Less power is transmitted to impellers
Temperature of Discharged Air is
above 41.73OC.
Flow rate of LP & HP
intercooler is below
37gal/min due to .
It will cause less heat transfer
consequently the temperature of air will
increase.
Corrosion or
Less Heat Transfer.
Fouling/Scaling of tube
side of LP or HP
intercooler
G
Temperature of Discharged Air is
below 41.73OC.
After-cooler RTD
malfunctioning.
Inappropriate signal may show wrong
values of temperature.
Malfunctioning of cooling
water Solenoid valve
(CWS).
IF CWS provides coolant above 35
gal/min, temperature of discharged air is
decreased and vice versa.
To provide the coolant
(water) at 37 gal/min for Low
& High pressure intercooler
Coolant is provided above or
below 35 gal/min.
Leakage in LP & HP
intercooler drains.
Coolant will leak from the drains which
will result reduction in flow rate
consequently effecting the heat transfer.
To allow the heat transfer
between coolant &
compressed air in LP
intercooler such that coolant
outlet temperature is 148OF.
Coolant outlet temperature for
LPIC is above 148OF.
Final Interstage
Temperature RTD
malfunctions.
Wrong signal displayed.
Coolant outlet temperature for
LPIC is below 148OF
Blockage in Shell side of LP It causes reduction in flow rate which
Intercooler.
results in decrease in heat transfer& also
due to corrosion/fouling.
Coolant outlet temperature for
HPIC is above 135OF.
Aftercooler air
temperature RTD
malfunctions.
Inappropriate signal is transmitted which
displays wrong output on control panel.
Coolant outlet temperature for
HPIC is below 135OF.
Blockage in Shell side of
HP Intercooler.
It causes reduction in flow rate which
results in decrease in heat transfer & also
due to corrosion/fouling.
To allow the heat transfer
between coolant &
compressed air in HP
intercooler such that coolant
outlet temperature is 135OF.
To supply the lube oil at
desired pressure for
lubrication between Bull
Gear & Pinions.
Lube oil is not supplied.
Low Lube Oil Pressure
Disengaged/broken
coupling between motor
& oil auxiliary pump.
Power is not transmitted from motor to
oil auxiliary pump. So pump does not
provide the lube oil to meshing gears.
Motor of auxiliary oil
pump fails to start.
If motor fails to start, auxiliary oil pump
will not start and oil supply will be zero.
Disengaged/ broken
coupling between driving
shaft & main oil pump.
Power is not transmitted from main shaft
to main oil pump so oil will not be
supplied.
Chocked oil filter
cartridge.
Dirt in oil filter will restrict the oil
pressure to remain low than required.
Defective/improperly
adjusted pump relief valve
If pump relief valve is excessively open or
damaged, oil will leak out from it so
restricting desired oil pressure to
develop.
Obstruction in oil pump
suction line.
Obstruction due to corrosion or dirt
particles will decrease the oil suction.
Leaks in oil pump suction
line.
It will restrict the oil pump to develop
required suction resulting in less oil
pressure.
Obstruction in spray
nozzle.
Uniform spray of lube oil on meshing
gears will not be possible so exaggerates
the wear of gears.
Low oil level protection
system not working.
Leakage in oil sampling valve or oil
reservoir drain will lower the oil level. If
LOLS is not working, low oil level will not
be detected consequently oil pump
suction will lost.
To provide the coolant
(water) at 19 gal/min.
To allow the heat transfer
between lube oil & coolant
such that coolant outlet
temperature is 110 0F.
High Lube oil pressure
Defective oil pressure
transmitter.
Defective transmitter will not give the
desired signal. It may cause auxiliary oil
pump not to start consequently lube oil
supply will cut off or wrong input may
cause control panel to display
inappropriate output.
Coolant is provided above or
below 19 gal/min.
Excessively open cooling
water flow control valve.
It will increase the flow rate of cooling
water as a result less heat will be
transferred to unit volume of cooling
water. Thus increasing the outlet
temperature of coolant.
Leakage in oil cooler.
It willnot only effect the flow rate of lube
oil but also let the coolant and oil to mix.
Fouling, scaling or
corrosion in oil cooler.
It causes resistance to heat transfer
between water & lube oil which results in
decreased values of coolant outlet
temperature.
Oil reservoir heater
thermostat
malfunctioning.
Thermostat will cause oil heater to
overheat the lube oil thusmore heat will
be transferred from oil to coolant in oil
cooler thus increasing the coolant outlet
temperature or vice versa.
Coolant outlet temperature is
above or below 110 0F.
To provide the rotational
power at 2970 rpm with the
Motor service factor of 1.15.
Motor is not operating at desired
rpm.
Mounting nut loosened
due to vibration
Impeller adrift (drifting without
control)
Power cable fails
Input current not supplied resulting in
pump Off.
Shaft sheared
Impeller uncontrollable resulting in
damage to pump casing.
Impeller bearing getting
hotter due to less
lubrication.
Bearing seized
Casing cracked
Oil leakage resulting in pressure loss
Damaged motor inboard
bearing.
Increased friction will result in power loss
thus reducing rpm.
Damaged motor outboard
bearing.
Increased friction will result in power loss
thus reducing rpm.
Voltage & current
harmonic (result of nonlinear loads)
Increased heating of the motor core,
CEMF (counter electromotive force) due
to 5th harmonic; shortening the service
life.
Over/under voltage
condition (when the
voltage exceeds/lags the
nominal voltage by 10%
for more than 1 minute)
Efficiency drops,
Power factor improves with lower
voltage and drops sharply with higher
voltage
Motor stator heats Up.
Voltage imbalance(result
of single-phase motors
installed on a three-phase
circuit)
Generates unwanted heat in
motors. This, in turn, results in wasted
energy, insulation breakdown, and
improper/inefficient motor operation
Over load
Excessive rise in temperature in the
motor windingsto a point that is
damaging to the insulation and
lubrication of the motor.
Short winding
Motor winding destroyed, Current surge,
Electro-dynamic stress on conductor.
Loose connection
Will cause failure of the system if left
uncorrected. Monitoring is required.
Mechanical vibration due
to Electricity
May be the root cause for the other
faults. In addition, is a potential noise
hazard. It is determined that monitoring
is recommended.
10
High load applied
High current is drawn resulting in heating
of windings.
Malfunctioning motor
stator temperature RTD.
RTD sends wrong signal to control panel
which displays wrong output.
Malfunctioning motor
ventilation fan.
Dirt accumulation, fan imbalance or wear
of fan blades will cause excessive
vibration and fan will not be able to
rotate at desired rpm.
