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Transformer Failure
Transformer Failure
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10/30/06
E:/wkg_fdr/ppt/slide_prsnt1.ppt
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
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
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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.
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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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10/30/06
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10/30/06
E:/wkg_fdr/ppt/slide_prsnt1.ppt
1250 A
1250 A
1250 A
1250 A
1250 A
Live PT
BC-I
BC-II
Bus PT-I
Bus PT-II
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
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
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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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
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10/30/06
E:/wkg_fdr/ppt/slide_prsnt1.ppt
Incidence Detail
DEPT
SE C
ARCHIVE NO.
DATE OF EVENT
START TIME
END TIME
EQPT. LOCATIO N
EQUIP. DESCRIPTION
F.I.R
FAILURE DESCRIPTION.
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
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Problem Statement
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10/30/06
E:/wkg_fdr/ppt/slide_prsnt1.ppt
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.
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3 4 5
Oil tank & oil cooler cleaning Yearly Bearing greasing Bearing inspection Once in 3 Months Yearly
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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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Agency
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
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.
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
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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 LUBRICATION OIL FOR TURBINE BEARING LUBRICATION OIL FOR COMPRESSORS BEARING / BUSH LUBRICATION OIL FOR BEARINGS OF ALL BOILER FEED PUMPS
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TYPE OF LUBRICANT & APPLICATION GREASE FOR STOKERS BEARING GREASING GREASE FOR ALL PUMPS & MOTORS BEARING GREASING GREASING FOR ROPES AT WAGON TRIPPLER
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1000
1500
2000
2500
500
0
Base Level
1942
Avg.`04
1522
Avg.`05
1104
Q1-FY06
1087
PERIOD
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Jul`05
940
Aug`05
900
Target FY06
830
GOOD
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
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10
Target
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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
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
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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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
4 3 3 2
TG#5 FY`06
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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
Target FY`06
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Good
6.58
7.31 6.58
Rs.
3.30
Total
FY `06(Till
Aug'05)
Target FY`06
Target
FY `06
Object 12
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GOOD
Rs. in Lakhs
23.78 15.63
25.28
PERIOD
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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
35.31
19.93
23.15
22.33
PERIOD
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SPARE MANAGEMENT
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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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*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
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
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
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PH3/MEC/05.00
BOILER OVERHAULING
Page 1 of 3
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
10c
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PH3/MEC/05.00
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
6910
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
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
Qtr.1
Jul`05
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
70.4
Qtr.1
Jul`05
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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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
matrix. Reduction in Oil consumption. Sustain the higher operational performance. To Focus on MTTR