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How an Aluminium tape caused a complete plant stoppage?

Case Study of an Aluminium tape caused a complete plant stoppage

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How an Aluminium tape caused a complete plant stoppage?

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  1. ISO 9001:2015 ISO 45001:2015 (OH & S) Certified Company Case Study How an Aluminium tape caused a complete plant stoppage? www.systemprotection.in +91-265-2225137

  2. Background : Incident Details: Breakdownarealwaysoneofthebiggest obstaclesinsmoothrunningofPlantsand leadingtofinancialimpactalso. Ifplant runssmoothlywithoutanybreakdown, profitabilityincreases, andyouknowthat muchbetterthanus. Peoplefollow100sof maintenancepracticestokeeptheirplant running24x7withoutinterruptionand breakdown. Butstillsometimesfew breakdownshappeninsuchawaythat, theymakeuslearnmanynewthingsand whattoandwhatnottododuring maintenancepractices. Thisisonesuch casestudy, wherethemaintenance activitiesfollowedbymanyplantsbecome thereasonforBreakdown. OnafinedayofDhuleti, whenmanyof plantpeoplewerecelebratingHoliwithall theprecautionsandeatingvarioussweets andsnacks. ACallcamefromplantShift engineertohisManagerfromplant. Call was “Sir, Jaldiaaiye, PreheaterFan (2750 kW) bandhogayahai, uskiMVdrivenahi chalrahiauruskiwajahseplantbhiband hogaya (Sir, pleasecomesoon, Preheater fan (2750kW) isstoppedduetosomeissue inMVdriveandduetothatplantisalso stopped)”. WheneverMaintenanceengineerhearsuch thingshisheartbeatalwaysgoesup. He askedhisshiftengineertocheck, whilehe isonhiswaytoplantfromtownship. He gatheredhisteamandwenttoplantto checkthebreakdownandstartplant immediately. How? Wewillseeincomingparagraphsand PleasedonotlaughwhenIsaythisincident happenedon2020Dhuleti. Yes, youheard itright, on Dhuleti and 2020. SometimesI feelbreakdownandholidayare synonymous. Majorityofplantbreakdown keepsonhappeningonSundayorHoliday. Seems, ithasbecomeatrend. Afterreachingthesubstationhefoundout conditionofpanelasbelow. www.systemprotection.in +91-265-2225137

  3. Picture of Panel where flashover took place (1.1) Littleflashover, asyoucanseeinabovepicturenearfuse, whichcausedthePreheater MVVFDdrivetotrip, ultimatelycausingcompletestoppage. Meanwhilereplacementof burnoutfuses, busbar, etcwasstarted. Manageralsoinquiredhowthisflashover occurred. Theengineershownthemtheburnoutculprit (showninanimagebelow) Picture of the Culprit that caused flashover & Hence plant stoppage (1.2) www.systemprotection.in +91-265-2225137

  4. Precautions to be taken: HowdidthisAluminiumtape, whichwas thereatbottomofpanelforclosingpanel holes, wentneartothefuse? So, wheneveryouarepastingAluminium tapeinanypaneljustsee, whatifthistape glueweakensanditcomeout, itshouldnot comeincontactwithanypowerorcontrol circuit, whichcanultimatelycreateaflash- overandanunnecessarybreakdown. Root Cause: ThepanelwasofMVVFDDrivefor3000kW 6.6kVMotor, andithas4nosfanof3.7kW forcooling. Andtheywereusedforcooling ofdriveandwereblowingairfrominsideof paneltooutside. Duetothisanegative pressurewascreated. NowtheAluminium tape, whicharenormallyusedtoclose unusedholesinpanel, waspastedinthis driveduringatthetimeofcommissioning. Andifthetapegluequalityisnotgoodorif thetapeisnotpastedafterremovingdust fromsurface, Aluminiumtapecancome outfromthesurfaceaftersomemonthsor year. Youcanstillimaginehowa100Rs Aluminiumtapecauseddamageoflacsto thisplant. So, wecanlearnfromhere. Alwaysdo “HazardIdentification & Risk assessment” (HIRA) whiledoinganyworkor anymodificationinPanelsorSystem. Nowduetonegativepressure, the Aluminiumtapewhichlosesitglueornot properlypasted, comeupandencountered powerfuse (inimage1.1) andultimately causedbreakdown. However, the breakdownwasnotmajor, andplant startedwaswithin5-6hoursofaccident. www.systemprotection.in +91-265-2225137

  5. CONTACT INFORMATION 301/2/306, SilverlineComplex,OppositeBBC Tower,Sayajigunj,Vadodara - 390005, Gujarat, India. bdm@systemprotection.in www.systemprotection.in +91-265-2225137

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