ROOT CAUSE ANALYSIS REPORT

IPP/QR-RCA/DEPT/Number
Shift
B
Stop Time: 21:33:14 (23.06.2016)
25.06.2016
Start Time:17:50:12 (25.06.2016)
Total Hrs.
Name of Fault / Breakdown (Please state the parts damaged , Location if any )
Instantaneous Differential over current protection and instantaneous over current protection
Dept
Section
Frequency:

Electrical
BTG
First time

Equipment
Equipment Code
Date

ID FAN MOTOR-1B

Condition Prior to failure ( Please state the past performance , history )

Unit 1 was running on 440 MW Load, ID fan-1B was running and taking load current of 207.0 Amperes.
Observations
ID fan motor-1B tripped on Instantaneous Differential over current protection and instantaneous over current
protections, and unit-1 load reduced to 260.0 MW from 440.0 MW
Causes of failure/ Root Cause:
Why Why Analysis ?
1. Why ID fan Motor-1B tripped?
A. ID fan motor-1B's Motor Differential protection relay and Motor Management Relay detected fault and tripped
the motor on instantaneous Differential over current and Instantaneous over current protections respectively.
2. Why MDR and MMR acted?
A. Motor Stator winding Internal Fault occurred
3. Why fault detected by relay?
Probable causes for the above mentioned faults would be:
1. Interturn short circuit
2.Insulation failure between phases R-Y-B
3. Open circuit of any phase winding
4. On what reason fault occurred?
A. After opening motor bearing inspection cover of NDE side it is found that one coil broken and became open
circuit.
5. Why coil open circuits occur?
A. coil open circuit occurred because of joint failure at brazing point of coil due to ageing, insulation deterioration,
and overheating at joint. All these three cumulatively responsible for winding open circuit.
Action Taken
1. After taking PTW (Permit no: 4001981046) measured the insulation resistance and winding resistance of Motor
from panel end.
IR: R-E=668 Mohms & winding resistance: RY=0.51 ohms YB=0.54 ohms BR=0.52 ohms
2. Measured the winding resistance from motor end by disconnecting star point of motor winding with motor
checker.
WR values: RY=0.5 ohms, YB and BR (Unbalance and varying resistance found)
3.Motor tripped on Differential protection but Meggar values shows motor is healthy so decided to open the
motors bearing inspection cover for winding inspection.
4. After opening inspection cover it is found that one winding coil became open circuited.
5. After confirming Motor Winding coil open circuited, it is decided to change the ID fan motor with ID fan 2A
motor.
6. Dismantled the motor from its base and shifted to Phase-2 Maintenance Bay

7. After inspecting ID-2A Motors healthiness it is shifted to ID-1B position on 24.06.2016

8.After assembling motor, Insulation resistance and winding resistance checked.
IR value = 2.91 Gohms and WR : RY=0.5 ohms YB=0.5 ohms BR=0.5 ohms
9. After satisfactory IR and WR test results, Power cable connected and clearance given for De-coupled (no-load)
trail of motor.
10. No-Load trail taken on 25.06.2016 at 17:55 hrs, Vibration and no-load current are
NDE
DE

Horizontal Vertical
1.1
0.9
0.4
1.2
No-Load current is 123 Amps

Axial
0.8
0.8
balance

15. Clearance given to Operation and BMD for coupling.

Recommendations to avoid recurrence
1. Opportunity Based Inspection of healthiness of winding insulation to be recommended to avoid insulation
failure.
2. Over hang portion of winding to be thoroughly inspected by Expert and strengthen the overhang coils.
3. Online partial discharge test is recommended to determine any leakage of current due to weak insulation.
Comments by Approver / Reviewer (if any)

Prepared by
Suleman Baig(PMPL)
Siba Hota (Vedanta)

Approved by
(HOD,PMPL )
Naseem Akhtar Khan

Reviewed by
(Deputy Plant Manager, PMPL)
Anil shahi

Approved by
(HOD, VEDANTA)

Reviewed by
(Maintenance Head, VEDANTA

Manas Panda

Pradip Mahapatra

MDR

Winding coil open circuit

MMR

Winding coil open circuit

a