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PILLAR HEAD PRESENTATION

ON 28th Dec 2005

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FAILURE ANALYSIS - 1

Problem
Frequent tripping of C18 Breaker at BH1
Date & Time: 01.06.05, 06.00PM & 02.06.05, 09.00AM

Failure Category: CMNT

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FAILURE ANALYSIS - 1

Introduction C18 Feeder is one of the two main trunk feeders of 13.2 KV coming from PH-3 to BH-1 and supplies power to the West Plant area such as Blast Furnaces , Blower and Pump Houses , Spares Manufacturing etc. If this feeders trip, there will be load shedding to critical plants. The closing power to the breaker is 250 v DC & trip power is 48v DC.The closing & and trip power is tapped from the same supply. The Breaker is of FERGUSION & PALIN make OCB and installed in the year 1951.
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FAILURE ANALYSIS - 1

Single Line Diagram of BH-1

C23 FROM PH #3 C18 FROM PH #3 10MVA , 13.2/3.3 KV 2 0 0 0/ 1
A FCE BCP BOILER PH#2 HOUSE TIE #1 3.3 KV BUS PPH#2 TIE RRW

10MVA , 13.2/3.3 KV

B/C-1
BUS PT A FCE SP#4 WPSS RRE

B/C

300/5

1000KVA T/F#1

GCP

MOTOR BLR1 BLR2 ERS CONV COND COND ENSER ENSER

1000KVA BCP#3 BCP#2 T/F#2

BLR3 COND ENSER

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FAILURE ANALYSIS - 1

Incident report
Date & Date & time Section time of of area failure restoration Equipment Part BH# 1 01/06/05 , 01/06/05 , C18 Breaker 06:00PM 06:30PM Transformer BH# 1 02/06/05 , 09:00AM 02/06/05 , 3:30PM C18 Breaker Transformer

Description of Observed Attended Corrective problem by by measure taken Trip w ithout any fault AKP AKP/BBS Checked the protection relays & Put on the breaker. Trip w ithout any fault AKB AKB Put on the stand by source breaker& took the shut dow n of the feeder. .

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FAILURE ANALYSIS - 1

Observation & Check points

Sl. No.Parameter
1 2 3 4 5 6 Control Power Tripping Power Protection Relays Trip mechanism Trip Coil resistance Trip coil to ground resistance

Desired Value Actual Value

250 V DC 48 V DC Should not oper. Healthy 50 Ohms in Mega ohms 250 V DC 48 V DC Not operated Healthy 52 Ohms 200 Ohms

Remarks
OK OK OK OK OK Not OK

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FAILURE ANALYSIS - 1

Control Circuit
Trip coil ABB Closing coil ABB Closing coil C23 Closing coil C18 Trip coil C23 Trip coil C18 Battery 250 V DC 48v DC

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FAILURE ANALYSIS - 1

Cause Cable going to the trip coil getting grounded. Immediate action taken
Removed the trip coil ground & Batery -ve ground by changing the cable.

Root Cause
1 2 3 4 5 Inadequate compliance with basic requirement Non-compliance with usage requirements Neglected deterioration Inherent design weaknesses Lack of skill

Preventive action
Installation of separate battery and charger Also provided earth leakage indicator. PLANNED MAINTENANCE

Mr.T.Watanabes Comments

No Comments

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FAILURE ANALYSIS - 2

Frequent tripping of GHH Axial Blower at BH # 2 Date: 26th NOV04 & 29TH NOV04 Failure Category: REPETITIVE (CMNE)
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FAILURE ANALYSIS - 2

Problem Tripping of Axial Blower without any annunciation.

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FAILURE ANALYSIS - 2

AXIAL BLOWER AIR BLOWING LAYOUT & CONNECTION OF BACK-UP SYSTEMS

FLOW MEASUREMENT ORIFICE

SNORT VALVE

HOT BLAST

C O L D

STOVES

BF

DISCHARGE VALVE

B L A S T

SILENCER ROOM NRV

BOV AXIAL BLOWER BLOWER # 5 IV-2, MOTORIZED CONTROL VALVE, BACK-UP FROM G FURNACE, OPERATING CONDITION COLD BLAST HEADER PR. < 7 PSIg. (EITHER F OR G)

IV-1, PNEUMATIC CONTROL VALVE, BACK-UP FROM D FURNACE, OPERATING CONDITION COLD BLAST HEADER PR. < 7 PSIg.

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FAILURE ANALYSIS - 2

Incident report
Date & Section tim e of area failure BH#2 26/11/04 , 12:30AM Date & tim e of restoration Equipm ent Part 26/11/04 , Axial Blow er Turbine 01:30AM Description of Observed Attended Corrective problem by by m easure taken Axial Blow er tripped RK /RSS RK/RSS Checked the w ithout any indication. system & found steam temp.w ent high. So Restarted the machine . Axial Blow er tripped AK /DCP AK /DCP Restarted the w ithout any indication. machine for analysis

BH#2

29/11/04 , 07:30PM

30/11/04 , 08:30PM

Axial Blow er Turbine

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FAILURE ANALYSIS - 2

The System
The Axial Blower at BH#2 is a steam driven turbo blower and supplies cold blast air to F Blast Furnace at a flow 1,50,000 Nm3/hr at a pressure of 2.6 bar gauge for meeting iron. This turbo blower was commissioned in the year 1982 and is of GHH Germany make and the Turbine is supplied by m/s BHEL. The Turbine governing system was originally fitted with Askania regulator and due to failure of Askania regulator system has been retrofitted with in house developed Electronic Governor..The Electronic Governor speed used to fluctuate occasionally about 200rpm.Due to this problem we have hired the services of M/S Turbo Machinery Hyderabad,for rectification of the problem .They came here and did the modifications in the oil lines and the system has worked satisfactorily for about 2 weeks. The turbine speed governing mechanism is electro-hydraulic and totally depends on the oil pressure. The minimum oil pressure required for smooth operation of the turbine is 6.5 bar. This oil pressure is developed by means of 3 pumps.one running & 2 standby.
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FAILURE ANALYSIS - 2

The System
Normally, when the machine is in normal operation the shaft driven oil pump supplies the oil pressure. During start up of the machine steam driven pump develops the pressure and it is put off once the shaft driven MOP takes over. Separate steam driven AOP is a stand by pump. The turbine can be tripped electrically as well as mechanically. The electrical trip interlocks are lube oil pressure low low, Turbine and Compressor Axial shaft low and Mechanical trips are trip oil pressure low . over speed and by operating manual trip gear. The Turbine speed control is done by sensing the speed of the turbine shaft by means of three speed pickups and is compared against a set point in a controller and the output of the controller is given to a EHC. Control oil pressure is derived from MOP through a pressure regulator is given as input to EHC for developing secondary oil pressure for controlling steam inlet valve position for controlling the speed.
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FAILURE ANALYSIS - 2

START- UP OIL (6 kg/cm) & TRIP OIL (5.5 kg/cm) FROM CONTROL DESK SOP FROM SR- III GOVERNOR (CONTROL DESK)

STEAM CONTROL VALVE

ESV STEAM TO TURBINE PR.- 15 kg/cm, T- 315C

VARIABLE ORIFICE IN SOP LINE

EHC

BLOWER SUCTION FILTER

TO COMMON DRAIN DRAIN TO OIL TANK PILOT PISTON & SERVO MOTOR

TRIP GEAR & TRIP GEAR TESTER

TRIP OIL TO CONTROL DESK P.OIL

BLOWER DISCHARGE

GOP REG. OIL PR.6 kg/cm

ORIFICE IN MOP LINE

G.O.P

MOP REG.

MOP

TURBINE

AXIAL BLOWER

OIL INJECTOR V.E.FAN MOP OIL REGULATING PR.- 7 kg/cm OIL TANK
DUPLE XFILTE R

MOP SUCTION

LUB.OIL PR. REG. LUB. OIL HEADER FOR BRG. OIL PR.- 3.5 kg/cm

TO OIL CENTRIFUGE

EOP T.AOP M.AOP

OIL COOLERS

BGP OIL PR. - 35 kg/cm BOOSTER PUMPS

BOV OIL PR.REG. PR.- 11.5 kg/cm

TO BLOW-OFF VALVES

DRAIN OIL

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FAILURE ANALYSIS - 2

OBSERVATION
All the operating parameters were normal before the trip Suddenly the machine tripped. Emergency systems such as start up of Auxiliary oil pump and start up of emergency air worked properly. The system has not recorded any trip signal provided in the trip logic of Axial Blower.

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FAILURE ANALYSIS - 2

Speed controller

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FAILURE ANALYSIS - 2 CAUSES OF TRIP

ELECTRICAL

MECHANICAL

LUBE OIL PRESSURE LOW LOW

TURBINE AXIAL SHIFT HIGH HIGH

BLOWER AXIAL SHIFT HIGH HIGH

TURBINE OVER SPEED

MANUAL TRIP LEVER

TRIP OIL PRESSURE LOW

DAS NOT RECORDED

DAS NOT RECORDED

DAS NOT RECORDED

DAS NOT RECORDED

DAS NOT RECORDED

DAS RECORDED

DAS:- Data Acquisition System

FAILURE ANALYSIS - 2

As the Trip oil pressure can become low due to the following reasons which were checked and rectified.
Electrical MSV malfunction PLC malfunction Cable defective Checked and found ok. Checked and found ok. Checked and found ok. Checked and found ok Checked and found ok. Checked and found ok. Not responding

Over speed mech. Manual trip lever Mechanical Pressure regulator Oil pressure variation with respect to speed

FAILURE ANALYSIS - 2 Observation on trip oil pressure vs turbine speed

TURBINE SPEED vs OIL PRESSURE

OIL PRESSURE

TURBINE SPEED 0 4000 4 4100 4.5 4200 4.75 4300 5 4400 5.5 4500 5.8 4600

4800 TURBINE SPEED 4600 4400 4200 4000 3800 3600 0 4 4.5 4.75 5 5.5 5.8 OIL PRESSURE TURBINE SPEED

Minimum oil pressure required to hold ESV valve is 4.0 bar Cause of trip : sudden increase in load use to reduce the turbine speed hence reduction in trip oil pressure due to more consumption of oil in EHC Circuit.

Action taken

S o a i lnh e t e r m m i c dy l s e an h i l n e n r O i e a b n k fo t e a o p s r lni s a o r occi. r s e e t d fti i i u e u i ne pl r t

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FAILURE ANALYSIS - 2

Modified line

Speed controller

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FAILURE ANALYSIS - 2

Cause Wrong tapping of oil line in the turbine oil governing circuit. Inherent design weakness Analysis Correct But Implementation Not Correct
Poor Design Change

1 2 3 4 5

Inadequate compliance with basic requirement Non-compliance with usage requirements Neglected deterioration Inherent design weaknesses Lack of skill

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FAILURE ANALYSIS - 3

Problem
Sudden Flow Reduction to the F Blast Furnace
Date & Time 13/04/05,6:15AM ; 14/04/05,11:05 ; 16/04/05,08:45
Failure Category: CMNM

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FAILURE ANALYSIS - 3

Incident report
Date & Section time of area failure BH# 3 13/04/05 , 06:15AM BH# 3 14/04/05 , 11:05PM BH# 3 16/04/05 , 08:45AM Date & time of restoration 13/04/05 , 06:25AM 14/04/05 , 11:15PM 16/04/05 , 08:55AM

Equipment Part Turbo Blow ers Blow er Turbo Blow ers Blow er Turbo Blow ers Blow er

Description of problem Flow reduction to the Blast Furnace Flow reduction to the Blast Furnace Flow reduction to the Blast Furnace

Observed Attended Corrective by by measure taken SP SP/TkS/SPD Increased the flow set point. AKD AKD/ASS/SP Increased the flow set point. SP SP/SKD/SPD Increased the flow set point.

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FAILURE ANALYSIS - 3

The System
There are two nos of Demag make Turbo Blowers at BH #3 and supplies about 170000 NM3/Hr. at a pressure of 2.6 Bar to F Blast furnace. These two blowers run in parallel with load sharing control. The discharged flow of the blowers is controlled by varying the speed of the turbines and inlet guide vanes of the blower. The speed is varied from 0 to 7900 rpm and the blade angle of the compressor is varied from +40 deg. To -14 deg. The two Blowers have separate anti surge control ,individual flow control and common flow control.

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FAILURE ANALYSIS FAILURE ANALYSIS - 1 3 System

BPH

SYSTEM
BLOWER HOUSE #3 SNORT VALVE DISCHARGE VALVE HOT BLAST

DEMAG BLOWER 1 STOVES F BLAST FURNACE

DEMAG BLOWER 2 COLD BLAST (170000 NM3/Hr. at a pressure of 2.6 Bar )

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FAILURE ANALYSIS - 3

OBSERVATION

Sl. No. Parameter

1 2 3 4 5 6 Discharge flow at Blower end

Desired Value Actual Value

1,70,000 NM3/Hr 2.6 Bar 1,55,000 NM3/Hr 2.5 Bar Fully closed Nil

Remarks
OK OK Not OK OK OK OK

1,70,000 NM3/Hr Discharge Pressure at Blowerend 2.6 Bar Flow at 'F' Blast Furnace end 1,70,000 NM3/Hr Pressure at 'F' Fce. End 2.6 Bar F' Fce. Snort Valve Position Fully closed Leakage in stoves/CB pipe line Nil

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FAILURE ANALYSIS FAILURE ANALYSIS - 1 3 System

SYSTEM LAYOUT WITH G BLAST FURNACE
BLOWER HOUSE #3 COLD BLAST (170000 NM3/Hr. at a pressure of 2.6 Bar )

BPH

SNORT VALVE

HOT BLAST

DEMAG BLOWER 1 STOVES F BLAST FURNACE

DEMAG BLOWER 2

G BLAST FURNACE

DISCHARGE VALVE

New G Furnace Blower

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FAILURE ANALYSIS - 3

System
SNORT VALVE HOT BLAST

F
STOVES

C O L D B L A S T

BF

DISCHARGE VALVE

SNORT VALVE

HOT BLAST

G
STOVES

Inter connection Valve

BF

Demag BLOWER

New Blower

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FAILURE ANALYSIS - 3

Observation Then compared the F Furnace Flow and pressure with G Furnace Flow and pressure on real time basis in the data acquisition system and noticed this problem was happening during G Furnace going on low pressure. Trends
300000 Flow (nm3/hr) 250000 200000 150000 100000 50000 0 1 2 3 Time 4 5 6 F-Fce Flow G-Fce Flow

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FAILURE ANALYSIS - 3

Pre s ure (ba r) s

Trends
4 3.5 3 2.5 2 1.5 1 0.5 0 1 2 3 Time 4 5 6 G-Fce Pr. F-Fce Pr.

From this observation we checked the inter connection valve. Found the valve indication was showing closed . When we rotated the valve manually , it got closed further 4 turns. From this it was understood that the main cause was Disturbed Close limit switch position.
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FAILURE ANALYSIS - 3

Action Taken The valve was manually closed fully and valve open / close limit switch has been readjusted. Root Cause
1 2 3 4 5 Inadequate compliance with basic requirement Non-compliance with usage requirements Neglected deterioration Inherent design weaknesses Lack of skill

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FAILURE ANALYSIS - 3

Problem is due to:

TBM Schedule Not Made

Preventive Action Actual valve open / close checking has been introduced in the Turbine Start up check list. Periodic calibration of the valve has been included.

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