Kaushal Kishore


3 Root Cause Analysis of a Catastrophically Failed Output Pin Bush Coupling of a Raw Material Conveyor Belt

Authors: Kaushal Kishore, Suman Mukhopadhyay, Susovan Das, Manashi Adhikary, Sandip Bhattacharyya


In integrated steel plants, conveyor belts are widely used for transferring raw materials from one location to another. An output pin bush coupling attached with a conveyor transferring iron ore fines and fluxes failed after two years of service life. This led to an operational delay of approximately 15 hours. This study is focused on failure analysis of the coupling and recommending counter-measures to prevent any such failures in the future. Investigation consisted of careful visual observation, checking of operating parameters, stress calculation and analysis, macro and micro-fractography, material characterizations like chemical and metallurgical analysis and tensile and impact testings. The fracture occurred from an unusually sharp double step. There were multiple corrosion pits near the step that aggravated the situation. Inner contact surface of the coupling revealed differential abrasion that created a macroscopic difference in the height of the component. This pointed towards misalignment of the coupling beyond a threshold limit. In addition to these design and installation issues, material of the coupling did not meet the quality standards. These were made up of grey cast iron having graphite morphology intermediate between random distribution (Type A) and rosette pattern (Type B). This manifested as a marked reduction in impact toughness and tensile strength of the component. These findings corroborated well with the brittle mode of fracture that might have occurred during minor impact loading while loading of conveyor belt with raw materials from height. Simulated study was conducted to examine the effect of corrosion pits on tensile and impact toughness of grey cast iron. It was observed that pitting marginally reduced tensile strength and ductility. However, there was marked (up to 45%) reduction in impact toughness due to pitting. Thus, it became evident that failure of the coupling occurred due to combination of factors like inferior material, misalignment, poor step design and corrosion pitting. Recommendation for life enhancement of coupling included the use of tougher SG 500/7 grade, incorporation of proper fillet radius for the step, correction of alignment and application of corrosion resistant organic coating to prevent pitting.

Keywords: Cast Iron, brittle fracture, coupling, pitting, double step, simulated impact tests

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2 Unusual Weld Failures of Rotary Compressor during Hydraulic Tests: Analysis revealed Boron Induced Cracking in Fusion Zone

Authors: Kaushal Kishore, Vaibhav Jain, Hrishikesh Jugade, Saurabh Hadas, Manashi Adhikary, Goutam Mukhopadhyay, Sandip Bhattacharyya


Rotary air compressors in air conditioners are used to suck excessive volume of air from the atmosphere in a small space to provide drive to the components attached to them. Hydraulic test is one of the most important methods to decide the suitability of these components for usage. In the present application, projection welding is used to join the hot rolled steel sheets after forming for manufacturing of air compressors. These sheets belong to two different high strength low alloy (HSLA) steel grades. It was observed that one batch of compressors made of a particular grade was cracking from the weld, whereas those made of another grade were passing the hydraulic tests. Cracking was repeatedly observed from the weld location. A detailed comparative study of the compressors which failed and successfully passed pressure tests has been presented. Location of crack initiation was identified to be the interface of fusion zone/heat affected zone. Shear dimples were observed on the fracture surface confirming the ductile mode of failure. Hardness profile across the weld revealed a sharp rise in hardness in the fusion zone. This was attributed to the presence of untempered martensitic lath in the fusion zone. A sharp metallurgical notch existed at the heat affected zone/fusion zone interface due to transition in microstructure from acicular ferrite and bainite in HAZ to untempered martensite in the fusion zone. In contrast, welds which did not fail during the pressure tests showed a smooth hardness profile with no abnormal rise in hardness in the fusion zone. The bainitic microstructure was observed in the fusion zone of successful welds. This difference in microstructural constituents in the fusion zone was attributed to the presence of a small amount of boron (0.002 wt. %) in the sheets which were cracking. Trace amount of boron is known to substantially increase the hardenability of HSLA steel, and cooling rate during resolidification in the fusion zone is sufficient to form martensite. Post-weld heat treatment was recommended to transform untempered martensite to tempered martensite with lower hardness.

Keywords: cracking, Boron, Compressor, martensite, weld, hardenability, high strength low alloy steel

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1 Wind Resource Estimation and Economic Analysis for Rakiraki, Fiji

Authors: Kaushal Kishore


Immense amount of imported fuels are used in Fiji for electricity generation, transportation and for carrying out miscellaneous household work. To alleviate its dependency on fossil fuel, paramount importance has been given to instigate the utilization of renewable energy sources for power generation and to reduce the environmental dilapidation. Amongst the many renewable energy sources, wind has been considered as one of the best identified renewable sources that are comprehensively available in Fiji. In this study the wind resource assessment for three locations in Rakiraki, Fiji has been carried out. The wind resource estimation at Rokavukavu, Navolau and at Tuvavatu has been analyzed. The average wind speed at 55 m above ground level (a.g.l) at Rokavukavu, Navolau, and Tuvavatu sites are 5.91 m/s, 8.94 m/s and 8.13 m/s with the turbulence intensity of 14.9%, 17.1%, and 11.7% respectively. The moment fitting method has been used to estimate the Weibull parameter and the power density at each sites. A high resolution wind resource map for the three locations has been developed by using Wind Atlas Analysis and Application Program (WAsP). The results obtained from WAsP exhibited good wind potential at Navolau and Tuvavatu sites. A wind farm has been proposed at Navolau and Tuvavatu site that comprises six Vergnet 275 kW wind turbines at each site. The annual energy production (AEP) for each wind farm is estimated and an economic analysis is performed. The economic analysis for the proposed wind farms at Navolau and Tuvavatu sites showed a payback period of 5 and 6 years respectively.

Keywords: Turbulence Intensity, Wind Speed, annual energy production, Weibull parameter, Rakiraki Fiji, Wind Atlas Analysis and Application Program

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