FAILURE ANALYSIS

C-43 Transformers 33 KV side cable failure

Date of failure : 18.06.05 at 9:18 AM Type of failure : New

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Incident Detail
DEPT SEC ARCHI VE NO. DATE OF EVEN T STAR T TIME E N D TI M E

Incidence Detail
EVENT DURATI ON DELAY BOOKE D EQPT. LOCA TION EQUIP. DESCRIPTI ON

EQUIP . CODE

F.I.R

FAILURE DESCRIPTION .

FAILUR E CODE

DEPARTMENT INVESTIGATIO N AND ACTION TAKEN

PH#3

OPN

PH3/0 5/019

18/06/ 05

09.18 AM

13 .3 5 P M

4 Hrs 17 mins

TG Buildin g

Turbo Generator #5

53

At 9.18 am Volta ge dip was obser ved, TG5 trippe d off & at ECR soun d of trippi ng 3 nos 13.6 KV ABC B break er was heard .

At 9.18 am Voltage dip was observed, TG5 tripped off & at ECR sound of tripping 3 nos 13.6 KV ABCB breaker was heard. Simultaneously Boiler 5 & Boiler 6 tripped off, Boiler 7 F.D Fan A tripped off. Current of C40 & C43 Trf were zero.

36

Current of C40 & C43 Trf were zero. Trf C 55 was on load & Bus coupler II at 33 KV was ON . At 13.6 KV bus Tx C 40 , Bus tie-1 and TG5 breakers were off but C 43 and Reactor-1 breakers were ON. C 43 & C 40 Breakers at 33 KV side were also OFF. C 43 ABCB Breakers were drawn out. After IEM clearance TG 5 synchronised at 01.35 pm & Boiler 5 & 6 connected thereby.

A.K.Gupta Back

Problem Statement : C-43 Transformer cable failed during operation of this transformer causing tripping of TG # 5 , C-40 & C-43 transformer.Approx. 7MW power was being evacuated through both transformers it at the time of tripping.

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Burnt portion C-43 transition joint

C-43 Transformer whose cable failed

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33 KV & 13.6 KV Power System SLD (PH#3)

CP Feeder - I ESS Feeder - I ESS Feeder - II (NOT IN SERVICE) NA CP Feeder - II MPDS Feeder Live PT TOP

1250 A

1250 A

1250 A

1250 A

1250 A

Live PT

BC-I

BC-II

C-40 20 MVA 13.6 KV / 33 KV

Bus PT-I

C-43 20 MVA 13.6 KV / 33 KV

Bus PT-II

Bus PT - III C-55 20 MVA 13.6 KV / 33 KV

ABCB 2500 A (1000 MVA) 2500 Adopter 2500 A VCB Bus Tie-I 2500 A Reactor# 01 30 MVA (1260 Amps) TG-5 13.2 KV

2500 Bus Tie-II

2500 Bus Tie-III

2500 Bus Tie-IV

2500 Bus Tie-V Adopter Adopter 2500 A VCB

Reactor# 02 30 MVA 1260) Amps) Empty Cubicle 13.2 KV Empty Cubicle

Reactor# 03 30 MVA (1260Amps) 13.2 KV Spare

Reactor# 04 30 MVA (1260 Amps) 13.2 KV TG-4

NGR (5 )

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Function
This cable is connected between 33KV side of the C-43 transformer and 33KV evacuation bus having SF6 breakers of VOLTAS make. In normal condition each 20MVA evacuates 6 -7 MW of power.

The cable has following Specifications: Voltage grade 33KV Cable size 3c x 300 sq.mm 19/33 KV PILCA & XLPE Make Fort Gloster PILCA 1990, XLPE 1997 Date of installation of PILCA cable 1991 Date of installation of transition joint which failed 1998

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Observations
Probable causes Low IR value of cable + Tx (C-43) Low IR value of cable only (C-43) Low IR value of Tx (C-43) Operation of relays Cable open circuit(C-43) Transition joint may have failed Normal condition Should be >33 Mohm Should be >33 Mohm Should be > 33MOhm E/F or Buchholz or O/C should operate Cable to be closed ckt & Multimeter should show continuity Transition joint distance-5% fr Tx. observation Ph to Gr > 100Mohm Ph to Ph >100Mohm Ph to Gr > 100Mohm Ph to Gr > 100Mohm E/F & Buchholz relays operated Continuity not available open ckt fault in B-phase. Testing shows failure at 3.5% dist. Remarks/Action taken OK OK

OK Ok Not ok

Transition joint failure confirmed

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Observations (after exposing the failed joint):1. By exposing the cable route it was found that transition joint between 3c x 300 sq.mm PILCA, aluminium cable & 3c x 300 sq.mm XLPE aluminium cable has failed. 2. At PILCA side of transition joint one core found sheared and about 5 of core material found completely burnt and missing. 5. From end of combined tubing set, up to a distance of about 5, core material of one core found missing due to burning away of aluminum conductor 8. Outer shell, tinned copper wire mesh and earthing braid of that portion found burnt. 10. In the other two cores, outer layer of paper of core found partially burnt at a distance of 50 mm away from stress control tube. 13. Perforated paper metallic screen of all cores found burnt at that portion.

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Burnt & missing core of joint PILCA side

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Root Cause Identified

Insulation failure occurred in cable joint due to oil barrier tube not shrunk properly during installation and voids were left at that portion - Human error

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Remedial Action taken

Rejointing of failed cables transition joint got done by Reychem expert in presence of TISCO expert agency (i.e. Service & Transmission) as per guidelines given by Reychem.

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Preventive Actions taken The Inspection pit for inspecting health of cable joints through ULTRA PROBE has being made. This will give prior information for cable joint failure. It will be checked at two months intervals.

Horizontal Deployment 1. It has been decided that all such HT cable joints of 33kv and above shall be put into inspection pit for periodic monitoring.

3. Healths of these cable shall be monitored at regular intervals through ULTRA PROBE.

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THANKING YOU

FAILURE ANALYSIS 4

Failure of Dynodrive A in Boiler6

Date of failure : 01.06.05 ( 3.30PM to 5.15PM) Type of failure : New

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Incidence Detail

DEPT

SE C

ARCHIVE NO.

DATE OF EVENT

START TIME

END TIME

EVENT DURAT ION

EQPT. LOCATIO N

EQUIP. DESCRIPTION

F.I.R

FAILURE DESCRIPTION.

DEPARTMENT INVESTIGATION AND ACTION TAKEN

PH#3

IEM

PH3/05/0 17

01/06/2 005

15.30 hrs

17.15 hrs

1 hr 45 min

Boiler 6 Stoker A

Boiler 6 Stoker A Dynodrive unit

Boiler 6 Stoker A motor tripped off

Operation Foreman reported that Boiler 6 Stoker A has tripped

On investigation it was found that dynodrive bearing has got ceased

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Problem Statement

Boiler # 6 stoker A tripped as reported by the operator.

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Function (contd)
Control Circuit Diagram of Dynodrive for speed control:

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Observations
Probable causes Motor burnt Normal condition Good insulation of motor Observation Properly insulated Remarks/Action taken OK OK OK

Motor bearing jam Motor shaft should Motor rotated by hand & rotate freely found free Stoker Gear jam Dyno drive unit jam Bearing Bearing clearance Should rotate freely by hand Should rotate freely Should be free from dust Rotated freely by hand

Not rotating freely- bearing Not OK. found defective Found dusty Not OK Not OK
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Analysis
From the observations Dynodrive unit was found jammed, bearing dusty and After cleaning the bearing clearance was found on higher side.

Root cause
Bearing got jammed due to dust ingression, which led to the failure.

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Remedial Actions Taken Replaced the defective Dyno drive unit with another and the system was started. Preventive Actions Air blowing of dynodrive unit once in a shift with the help of instrument air (existing practice is once in a day). Sealing of tacho cable entry hole, exciter cable entry hole to prevent ingress of dust into bearing of dyno drive.

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Horizontal Deployment

1. It has been decided by the TOP management that all such HT cable joints 33kv and above shall be put into inspection pit for periodic monitoring.

3. Healths of these cable shall be monitored at regular intervals through ULTRA PROBE.

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PRESENT MAINTENANCE SYSTEM For A Category (critical) equipment condition based monitoring is being carried out. For B Category equipment maintenance practice Inspection & Repairing is being carried out.

For C Category equipment maintenance is being done as and when required.

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SCHEDULE / TIME BASED MAINTENANCE

Sl. No. 1 Equipment Oil Centrifuge Purpose Cleaning Elastic Pad Checking Valve check 2 Reciprocating Compressor Ring change Foundation Bolt / V. Belt Inspection Coupling Bush and foundation bolt Check Coupling Greasing Schedule Once in 3 Months Once in 6 Months Bi-Monthly Once in 4 Months Once in 4 Months Once in 6 Months Once in 3 Months

3 4 5

C.W.Pump B.F.Pump Fans

Oil tank & oil cooler cleaning Yearly Bearing greasing Bearing inspection Once in 3 Months Yearly
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CONDITION BASED MAINTENANCE

Now our focus is to shift from Time based maintenance to condition based maintenance (CBM) to reduce maintenance cost, increase equipment reliability and increase mean time to repair.

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CONDITION MONITORING PRESENT STATUS

Equipment Parameter Shaft vibration Bearing housing vibration First stage pressure Bearing metal temperature Axial shift (Turbine) Turbo Generator Axial shift (MOP) Oil Ferrography Oil particle count Oil view analysis Exhaust pressure Oil temperature C.E.Pumps Vibration Frequency On-line Monthly On-line On-line On-line On-line Monthly Once in three months Monthly On-line On-line Monthly Maint. Engg.
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Agency

Maint. Engg.

Maint. Engg. Maint. Engg. Maint. Engg.

CONDITION MONITORING

We have procured a handy Vibration Pen and Vibration Measurement on regular interval is being carried out by our Shift Personnel for following equipment.

Circulating Water Pumps Boiler Feed Pumps Instrument Air Compressors Induced Draft Fan for Boiler

6 Nos. 5 Nos. 3 Nos. 8 Nos.

Based on the report necessary corrective action is being done in house like dynamic balancing, bearing changing etc.
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LUBRICANTS IN USE

Sl. No. 1. 2. 3. 4. 5. 6.

Lubricant SP-68 SS-320 SS-220 SS-150 Ultra-10W Grease

Equipment Turbine, Boiler Feed Pump Stoker Gearbox secondary, Ash Plant Gearbox Reciprocating Compressor, Stoker Primary Gearbox C.T.Fan Gearbox Screw Service Air Compressor Boiler & Fan and Ash Plant bearing

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LUBRICATION MANAGEMENT

Standardization of Lubricant

Arresting leakages & sources of contamination Storage & disposal of Lubricant

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STANDARDIZATION OF LUBRICANT
EARLIER SP 68 SS150 SS 220 SS 320 Ultra 10 W Grease (Lithium complex) PRESENT SP 68 SS150 SS 220 SS 320 Ultra 10 W Grease (Lithium complex)
WE ARE EXPLORING THE POSSIBILITY OF STANDARDISATION

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TYPE OF LUBRICANT & APPLICATION

LUBRICANT- CIRCULATING TYPE

TYPE OF LUBRICANT & APPLICATION LUBRICATION OIL FOR TURBINE BEARING LUBRICATION OIL FOR COMPRESSORS BEARING / BUSH LUBRICATION OIL FOR BEARINGS OF ALL BOILER FEED PUMPS

POINTS OF MONITORING CHECKING OF OIL PROPERTIES PERDIODICALLY CONSUMPTION TREND

ACTION TAKEN PREVENT SOURCES OF CONTAMINATION

PREVENT SOURCES OF LEAKAGES

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TYPE OF LUBRICANT & APPLICATION

LUBRICANT- TOTAL LOSS TYPE

TYPE OF LUBRICANT & APPLICATION GREASE FOR STOKERS BEARING GREASING GREASE FOR ALL PUMPS & MOTORS BEARING GREASING GREASING FOR ROPES AT WAGON TRIPPLER

POINTS OF MONITORING FREQUENCY OF APPLYING GREASE

ACTION TAKEN DEFINED THE FREQUENCY AND RIGHT QUANTITY OF GREASE

CONDITION OF THE GREASED SURFACE

PREVENT SOURCES OF CONTAMINATION

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STORAGE & DISPOSAL OF LUBRICANT

PROCUREMENT AND STORAGE
We draw the material from central stores. Lubricants drums are kept in designated places.

VISUAL CONTROL OF STORAGE

At lubricant storage place, for each type of lubricant name / grade is marked

DISPOSAL OF USED LUBRICANT

Disposal of used lubricant is being done as per environmental norms.
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Consumption in Litres / Month

1000

1500

2000

2500

500

0
Base Level

1942

Avg.`04

1522

Avg.`05

1104

Q1-FY06

1087

AVERAGE MONTHLY LUB. CONSUMPTION

PERIOD
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Jul`05

940

Aug`05

900

Target FY06

830

GOOD

STEPS TAKEN FOR REDUCING LUB. CONSUMPTION

Off-line Oil Filtration system provided for Turbo Generators Regular Centrifuging of Turbo equipment oil. Dehydrator put on service in TG-4 & 5.

Most of the leakages in both TGs were attended during the combined shutdown. Proper training on handling and application of Lubricants. Mechanised handling system provided.

Proper storage and maintenance of oil storage area to prevent any mix up and wastage. Condition based monitoring and oil changing based on condition.

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RESULT

1. Interruption rate 2. MTBF 3. Lubrication cost 4. Maintenance cost

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INTERRUPTION OF TURBO GENERATORS

12 10 No. of Interruption 8 6 4 2 0 Base Level FY 05 PERIOD FY 06

0 0

10

Target
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No. Of Interuption (T.G)

Good

TG#4 INTERRUPTION
12 10 No. of Interruption 8 6 4 2 0 Base Level FY 05 FY 06 0 Target
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10

No. Of Interuption (T.G)

TG#5 INTERRUPTION
12 10 No. of Interruption 8 6 4 2 0 Base Level FY 05 FY 06 0 Target
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10

No. Of Interuption (T.G)

INTERRUPTION BOILER

16 14 No. of Interruption 12 10 8 6 4 2 0

15
Good

11

3
0 0

Base Level

FY 05 PERIOD

FY 06

Target
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No. Of Interuption (Blr.)

BOILER INTERRUPTION
16 14 12 No. of Interruption 10 8 6 4 2 0 Base Level FY 05 FY 06 3 0 Target
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15

11

No. Of Interuption (Blr.)

MEAN TIME BETWEEN FAILURE OF TG#4 & 5

Sl. No. 1. 2. Equipment TG#4 TG#5 M.T.B.F. FY`04 3.0 Month 2.0 Month M.T.B.F. FY`05 3.0 Month 4.0 Month M.T.B.F. FY`06 4.0 Month 2.0 Month

4.5 4 3.5 3 2.5 2 1.5 1 0.5 0

4 3 3 2

M.T.B.F. (In Month)

TG#4 FY`04 FY`05

TG#5 FY`06

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MEAN TIME BETWEEN FAILURE OF BOILERS

Sl. No. 1. 2. 3. 4. Equipment Boiler 5 Boiler 6 Boiler 14 7 Boiler 8 M.T.B.F. FY`05 12.0 Month 6.0 Month 6.0 Month M.T.B.F. FY`06 12.0 Month No Failure 6.0 Month

M.T.B.F. (In Month)

12 10 8 6 4 2 0

12 12 2.0 Month

12

12.0 Month

12

No Failure

Boiler#5

Boiler#6 FY`05

Boiler#7 FY`06

Boiler#8

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LUBRICATION COST
8 7 6 7.31

Rs. Lakh

5 4 3 2 1 0 Total FY`05
Target is 10% less than FY`05

3.30

PERIOD
Total FY`05

Total FY`06(Till Aug'05)

Total FY`06(Till Aug'05) Target FY`06

Target FY`06
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Good

6.58

CONSUMPTION & COST LUBRICANT WISE

Lakh
8 7 6 5 4 3 2 1 0 Total FY `05
Total FY`05

7.31 6.58

Rs.

3.30

Total

FY `06(Till

Aug'05)
Target FY`06

Target

FY `06

Total FY`06(Till Aug'05)

Object 12

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MAINT. COST EXPENDITURE 2005 2006

50 45 40 35 30 25 20 15 10 5 0
Apr`05 May`05 Jun`05 Jul`05 Aug`05 Sep`05 Oct`05 Nov`05 Dec`05 Jan`06 Feb`06 Mar`06 Avg. YTD

GOOD

Rs. in Lakhs

23.78 15.63

25.28

Monthly Target-23.75 L (FY`05-06) 26.65

21.56

PERIOD

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MAINT. COST EXPENDITURE 2004 2005

50 45 40 35 30 25 20 15 10 5 0
Mar`04 Apr`04 May`04 Jun`04 Jul`04 Aug`04 Sep`04 Oct`04 Nov`04 Dec`04 Jan`05 Feb`05 Mar`05 Avg. YTD

45.3
No shutdown / washout during this period. So cost was low.

1. Washout of Blr.-8. 2. Year pending bill (service) clear for about 18.0 Lakh

GOOD

Rs. in Lakhs

Monthly Target-23.75 L (FY`04-05) 29.09 29.2 26.8 26.7

35.31

19.93

21.16 17.43 14.03 11.83 13.29

23.15

22.33

PERIOD

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FUTURE ACTION PLAN

Activities Failure Analysis Red Tag Management Spare / Inventory Management Condition based Maintenance system Continue Continue Analysis to be started Already provided for TGs and partially extended to other equipment. Skill gap matrix prepared and training programme prepared. Analysis to be started Status Target Zero Per month by Dec`06 To minimise Red Tag by supporting to JH Dec`05 To be introduced for Auxiliary equipment such as I.D.Fans, C.W.Pumps, C.E.Pumps, and Compressors, Continuous Process.

Enhancing skill for maintenance staff MTTR

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SPARE MANAGEMENT

1. IDENTIFICATION OF CRITICAL SPARES 2. PROCUREMENT 3. STORING 4. INVENTORY

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LIST OF CRITICAL SPARES

50 45 40 35 30 25
26.8 19.93 26.7 21.16 17.43 14.03 11.83 13.29 29.09 29.2 23.15 22.33 45.3

35.31

Rs. in Lakhs

20 15 10 5 0

Mar`04 Apr`04 May`04 Jun`04 Jul`04 Aug`04 Sep`04 Oct`04 Nov`04 Dec`04 Jan`05 Feb`05 Mar`05 Avg. YTD
Object 16

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PROCUREMENT AND STORING

PROCUREMENT THROUGH PM MODULE (SAP) *Indenting (SAP) Order placement (SAP) Material received at Central Store Material drawn to Sectional Store PROCUREMENT THROUGH OFFLINE *Indenting (SAP) Order placement(SAP) Material received at Central Store Material reservation raising (SAP) Material drawn to Sectional Store

*Indenting based on verbal feedback and planned shutdown **Inventory can be seen in SAP for individual item
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INVENTORY STATUS
100 90 80 70 70 90.28

85.48 77.6 74.11 78.15 70

Rs. Lakh

60 50 40 30 20 10 0 Avg. FY`05
Avg. FY`05

Target FY`05
Target FY`05

Apr`05

May`05

Jun`05

Jul`05

Aug`05

PERIOD
Apr`05 May`05 Jun`05 Jul`05 Aug`05

Avg. Target FY`06

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Avg. Target FY`06

MTTR
Activity Present Planned (days) (days) 21 18 Action to be taken Review of activities & resources, exploring new ideas / methods -do10 10 7 7 -doReview of activities & resources

Boiler Overhauling

Transformer overhauling Condenser cleaning Wet washing

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PH3/MEC/05.00

BOILER OVERHAULING
Page 1 of 3

ANNEXURE 4 EFFECTIVE DATE: 15.12.2001

1 1

8 2a 2f

(PH 3) 10 11 12 13 14 15 16 17 18 19 20 21 2b 2g 2i 2h 3b 3c 4c 4d 2c 2d

2e 3a 4a 4f

4b 4e 5 6a 7 6b 6d 8c 8g 8h 8i 8j 9c

6c

8a

8b

8d

8e

8f

9a

9b 9e 9f 10a 10d

9d

10b 11a 11b 12

10c

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PH3/MEC/05.00

BOILER OVERHAULING ACTIVITIES

Page 1 of 3

ANNEXURE 4 EFFECTIVE DATE: 15.12.2001

Object 20

Object 19

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Object 21

PQCDSM
Criteria OEE BOILER AVAILABILITY T.G AVAILABILITY PERFORMANCE RATE P NO. OF INTERUPTION INTERUPTION HRS GENERATION TOTAL NO. OF FAILURE PRODUCTIVITY Q REACTIVE GENERATION POWER COST C COAL RATE D COMPLIANCE ON ABP MOU COMP. Kg/Ton of steam NO. OF UNPLANNED OUTAGE OF TG./YR MAJOR S NO. OF ACCIDENT MINOR NO. OF ACCEPTED SUGGESTION/EMP/YR. 4.0 0 210 12 0 204.8 6.0 0.0 206 0 0 Performance Indicator UNIT % % % % NO. HRS MW NOS./MONTH KW/EMP. MVAR Rs/MWh Base Level 70.7 90.5 92.79 83.87 21 347 67.841 18 281.494 36.4 1337 Actual till date 99.01 98.95 100.0 97.1 3.0 166.0 54.3 2 287.7 39.3 1293 Target FY '06 89.3 93 96 100 0 0 44 0 225.6 40

SUGGESTION

0.65

0.60

1.2

LUBRICATION CONSUMPTION
18000 16000 14000 12316.5 12000 16422

Litre / Kg

10000 8000 6000 4000 2000 0 Total FY`05

Total FY`05 Target is 10% less than FY`05

6910

Total FY`06(Till Aug'05)

Total FY`06(Till Aug'05) Target FY`06

Target FY`06
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 Support to Jishu Hozen Continue Critical ranking of Equipment Completed Preparation / Modification of Maint. Schedule Completed Lubrication Management Continue Condition Based Monitoring -

Started

BACKGROUND & OBJECTIVE

BACKGROUND OBJECTIVES

High failures rate

Minimize failure to ZERO

Conventional maintenance style. Lack of skill in Jishu Hozen Members for Fuguai identification & rectification.

Condition based maintenance Corrective maintenance Imparting on the job training to Jishu Hozen Members for cleaning, lubrication, inspection & tightening.

BOILER AVAILABILITY
Percentage
120 100 80 60
93.7 100 90.5 89.9 92.5
90.5 93.7 Blr-5 & 8 w/o

8.6

6.5

7.0

98.5

100

98.95

100

40 20 0

Benchmark (06/03 to 05/04)

Avg. FY`05 (Jun`04Mar`05)

Qtr.1

Jul`05

Avg. Till Date

Target FY`06

BOILER WASHOUT

Period

93

GOOD

OEE
Percentage
120 100
92.0 Blr-5 & 8 w/o - 104 days Boiler Washout - 27 days planned shutdown of TG

60 40 20 0

70.4

97.89

87.98

90.45

92

Benchmark (06/03 to 05/04)

70.4

Avg. FY`05 (Jun`04Mar`05)

Qtr.1

Jul`05

Avg. Till Date

Target FY`06

Period
OUTAGE DUE TO WASHOUT TG SHUTDOWN

89

GOOD

80

8.6

96.1

97.89

99.01

7.04

8.6

100

RESULT

As a result of the above steps oil consumption in the Turbo Generators was come down to about 20 to 25%. Mainly due to reduction in online filter jamming and cleaning. Each time when we clean this filter about 25 litres of oil is getting drained out. It is totally a loss.

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Aux. Power Consumption

7.90 Aux. Power (%) 8 6.43 6.35 6 4 2 0
BENCHMARK FY`03 FY`04 FY`05 Q!FY06 Jul -05 FY`06 Ti l l date Tar get

10

7.88 6.83

7.36

GOOD

Period

Power Cost
Rs. 1700 / MWh
1600 1500 1400 1300 1200 1100 1000 03-04 04-05 Till Date Target 1337 1293 1435

Good

Benchmark

Period

 gap

TPM Present Completion of JH Step # 4Focus

Completion of first cycle of training as per skill

matrix. Reduction in Oil consumption. Sustain the higher operational performance. To Focus on MTTR