POWER DIVISION THERMAX LTD.

SITE (Sudarshan Chemicals Industries) Rev Sheet

No
Document Title Operation Performance 1 1
Monitoring System (OPMS) THERMAX
TRIPPING ANALYSIS REPORT

Report No:- SCIL/19-20/01 Date:- 13/07/2019

Tripping Incident in Brief: - FD fan VFD tripped on earth fault alarm

Trip -1

FD fan tripped at 5.00 pm on dated 04/07/2019 on earth fault alarm recorded in FD VFD panel.
Alarm reset and try to start FD fan but FD fan VFD tripped again on Earth fault.

After that Turbine tripped at 5.13pm on TG inlet steam pressure low low. Try to synchronized
the generator with grid to avoid the complete blackout of the plant but unable to connect as
frequency was not matched at that time. It was decided to keep Boiler in hot box-up condition &
thorough inspection to be carried out of FD Fan Motor and VFD. All parameters found normal.

Meager Value of Motor

Phase To Phase Phase to Earth

R - Y = 1090 MΩ R - E = 697 MΩ
B - R = 1200 MΩ B - E = 697 MΩ
Y - B = 1130 MΩ Y - E = 697 MΩ

Boiler taken in service at 7.48 pm. TG sync with grid at 9.21 pm.
Date and Time of the Tripping: 04/07/2019 5:00 pm
Date and Time of the Synchronization 04/07/2019 7:48 pm
Outage Duration (In Hours Mins) 2 hrs. 48 min

Trip -2

FD fan again tripped at 12.44 am on dated 05/07/2019 on earth fault alarm on FD VFD panel.
Hence decide to shut down the plant & keep boiler in hot box up condition. Turbine tripped on
low steam pressure.
Again motor and cable checked and values are as follows.

Cable 1 Cable 2 Cable 3

R - E = 1120 MΩ R - E = 1200 MΩ R - E = 980 MΩ
Y - E = 1000 MΩ Y - E = 1004 MΩ Y - E = 1130 MΩ
B - E = 960 MΩ B - E = 960 MΩ B - E = 0 MΩ

Prepared By: Thermax Power Division Page 1 of 4

POWER DIVISION THERMAX LTD.
SITE (Sudarshan Chemicals Industries) Rev Sheet
No
Document Title Operation Performance 1 2
Monitoring System (OPMS) THERMAX
TRIPPING ANALYSIS REPORT

Meager Value of Motor

R - Y = 960 MΩ
B - R = 1026 MΩ
Y - B = 1100 MΩ

Resistance Value of Motor

R = 0.1 MΩ
B = 0.1 MΩ
Y = 0.1 MΩ

Out of three runs one cable of 150 Sqmm B phase meager shows zero ohms with respect to
ground. So decided to replace the faulty cable. But due to unavailability of 150 sqmm cable so it
was replaced with 2 run of 120 sqmm.

After replacement of cable on 05/07/2019 at 7.00 pm during boiler light up FD fan again tripped
two times on over current/earth fault alarm. As suspected VFD was giving the false alarm so first
VFD checked.

Output cables of VFD disconnected and start in on scalar-fly mode. Found VFD working normal
so conclude there is no issue. Hence to avoid any other tripping with same cause we decided to
replace the motor & all the old cables with new as suspected there is the issue.

Date and Time of the Tripping: 05/07/2019 12:44 am

Date and Time of the Synchronization 07/07/2019 3:00 am
Total Outage Duration (In Hours Mins) 51 hrs. 44 min

Stopage-3

On 07/07/2019 at 12.00 PM FD Fan stopped as burning smell observed from FD fan junction
box. Junction box checked and found Y-Phase termination cable is heating so tightness done and
after that boiler light up at 4.05 pm on 07/07/2019 TG syncronized with grid at 6.06 pm. JB kept
in observation.

Date and Time of the Tripping: 07/07/2019 12:00 pm

Date and Time of the Synchronization 07/07/2019 6:06 pm
Total Outage Duration (In Hours Mins) 6 hrs. 06 min

Prepared By: Thermax Power Division Page 2 of 4

POWER DIVISION THERMAX LTD.
SITE (Sudarshan Chemicals Industries) Rev Sheet
No
Document Title Operation Performance 1 3
Monitoring System (OPMS) THERMAX
TRIPPING ANALYSIS REPORT

Has this tripping Occurred earlier:- Yes

On dated 30/6/2019 FD fan tripped on Earth fault alarm but Boiler taken in service before TG
tripping & plant normalized.

Chronology of Events(Alarms):-

Sr No Time Event Action/Remark

04/07/2019 FD fan tripped due to earth
1 ON VFD
5:00 pm fault alarm
05/07/2019 FD fan tripped due to earth
2 ON VFD
12:44 am fault alarm

Tick on relevant category:-

Operations Electrical C&I Mechanical

Mention relevant Sub-category : NA

Why-Why Analysis:-

Why-Why Explain the cause

Why Plant tripped
Why FD fan tripped
Why Earth fault sense on VFD
Why Cable is short.
Why Water ingress in JB
TG tripped on Turbine steam pressure low low as FD fan tripped on earth
fault alarm recorded in FD VFD.
FD fan tripped due to earth fault alarm on VFD panel.
Following causes for the Earth Fault
1. Meager - One 150 Sqmm cable B phase found short with ground,.
2. Terminal short or ground due to water /moisture ingress in JB.
3. Suspected damaged in Motor Bearing and Motor internal output
terminal short with motor body.
Only B - Phase found short and the cause may be
1. Over heating
2. Puncher
JB was fabricated at site and due to heavy rain moisture/water can ingress
from isolator screw.

Prepared By: Thermax Power Division Page 3 of 4

POWER DIVISION THERMAX LTD.
SITE (Sudarshan Chemicals Industries) Rev Sheet
No
Document Title Operation Performance 1 4
Monitoring System (OPMS) THERMAX
TRIPPING ANALYSIS REPORT

Why Motor bearing damaged
Why Burning smell was coming from
JB
Due to ageing and Motor was running since last 3 year and no stand by
available.
As 3 runs of 150 Sqmm mm cable changed with 4 runs of 120 sqmm cable
( from VFD to JB ) and also 6 run of 50 sqmm flexible copper cable
replaced with 9 run of 50 sqmm copper cable ( From JB to Motor ). Due to
increase of the cable JB overfilled and difficult to tight the connection.

it may be the cause of loos connection and burning.

Root cause –
Following are the cause of Earth fault

1. B phase cable short with ground.

2. Motor insulated beating/ Motor internal output terminal short with motor body. Motor send to IEC
Pune (Siemens Authorized Service provider.) and primarily inspection it’s found insulation of motor
bearing damaged and also output terminal was short with body. Final report is pending with IEC.

Final conclusion of Trip:

Cable Replaced
Motor Replaced

Analysis Done By:

Electrical
Position SM Dy. SM P&E Cell
Department HOD
Ameet
Name Mayur Saraswat K. V. V. Ramana _
Nampalliwar

Prepared By: Thermax Power Division Page 4 of 4