Improper Grounding Problems During Welding
Improper grounding during welding caused water contamination and electrical current issues, leading to a bearing failure in a boiler fan.
I come to share with friends the importance of correct grounding in the welding process.
Incident Report and Failure Analysis:
On 02/28/2025, together with the commissioning team, we started the operation of the primary fan, left side of boiler 1, which was released for normal process operation. However, on 03/10/2025, the boiler operation team requested a new test on the fan. During this test, vibration levels increased significantly, from 2.15 gE to 28.91 gE peak-to-peak.
After the variation in vibration levels, a detailed analysis was carried out, which found a defect in the inner and outer raceways of the engine's LA bearing. The cracks observed in the raceways and rotating elements indicate that the failure was caused by water contamination and the passage of electric current, probably as a result of an irregular ground during the welding process.
Here are the photos of the defects and spectra from before, during and after equipment maintenance.
Additional Images
