FAC-2012-002 (Genset)
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Transcript of FAC-2012-002 (Genset)
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7/31/2019 FAC-2012-002 (Genset)
1/14
INTERPHIL LABORATORIES, INC.
Your Market Partner in Manufacturing
Engineering & Maintenance
Equipment Troubleshooting Report(Generator Set Equipment Breakdown)
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7/31/2019 FAC-2012-002 (Genset)
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INTERPHIL LABORATORIES, INC.
Your Market Partner in Manufacturing
E&M-FAC-12-002
Problem Statement:
During load testing of Genset equipments last 12 May,
Facilities group encountered erratic fluctuation of output voltage
on Generator sets, it was then coordinated to Monark to secure
further check up of both units. Load testing undergone on 19
May to verify fault encountered.
In the course of check up, recorded parameters display
overshooting voltage output & ampere loading to both units
eventually prompting genset #02 to trip & influence Genset #01
cut its supply to demand load (power loss)
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INTERPHIL LABORATORIES, INC.
Your Market Partner in Manufacturing
Problem Statement:
Note:
Prior loading both genset
subject for 30 minute test
run @ no load phase
Phases changed after it
sequenced to automatic
(exciter) paralleling. Both
unit display surging
parameters
Load at LVSG panel wasonly 2400 Amps
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INTERPHIL LABORATORIES, INC.
Your Market Partner in Manufacturing
E&M-FAC-12-002
Actions Performed:
Monark initiate check up on the unit, they check AVR and
rotating diode on both units but found normal, they recommend
to do check up on Master control center to trace the fault.
Monark send 3rd
party assessor last 23 & 24 May to check thesynchronizing panel, they do synchronization @ no load / load
sequence and found out the grid has circulating harmonic
currentsthat triggers to bust components on genset #02 ,
these are the following;
Automatic Voltage Regulator
Surge supressor
kWhr displays
Droop Current Transformers
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INTERPHIL LABORATORIES, INC.
Your Market Partner in Manufacturing
E&M-FAC-12-002
Actions Performed:
Genset #01 check upwith Monark last 19 May Check up of Rotating Diode
Automatic Voltage Regulator
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INTERPHIL LABORATORIES, INC.
Your Market Partner in Manufacturing
E&M-FAC-12-002
Damaged Surge Suppressorand melted heat sink
Check up of Genset last 24 May 2012
Genset #02 Rotor ExciterAssembly
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7/31/2019 FAC-2012-002 (Genset)
7/14INTERPHIL LABORATORIES, INC. Your Market Partner in Manufacturing
E&M-FAC-12-002
Defective kWhr Display
Voltage Frequency Ampere
Run hour
kWhrDisplay
GENSET #01 MCCGENSET #02 MCC
Master Control Center
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E&M-FAC-12-002
Root Cause Analysis:
By categorizing equipment failure modes based on
encountered fault to genset units, potential areas are;
1. Frequency instability due to maladjustments or component malfunction
2. Output voltage distortion : AVR sensitivity
3. Frequency and voltage instability due to control loop compatibilityconditions
Concentrating from this potential mode, problem can be
identified substantially
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9/14INTERPHIL LABORATORIES, INC. Your Market Partner in Manufacturing
E&M-FAC-12-002
Root Cause Analysis:
1. Frequency Instability due to maladjustments or componentmalfunction:
Based on visual observation frequency for both genset was stable during
on-load operation, though the engine is hunting. Frequency is steady at
60Hz
Frequency range should not more than 0.5% during paralleling
No adjustment activity was made on the control center during tests
therefore leaving no part of component on the inside panels can contribute
to malfunction.
Frequency Instability would not be a cause
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10/14INTERPHIL LABORATORIES, INC. Your Market Partner in Manufacturing
E&M-FAC-12-002
Root Cause Analysis:
2. Output voltage distortion : AVR sensitivity (heating effects)
AVR is used to monitor and output voltage and control the field strength of
the machine to maintain a constant voltage on output of generator set
under varying steady state load conditions
The group encountered overshooting of voltage during on load state voltage dips
from 500V to 515V
Loss of Voltage signal was encountered on Genset #01 last 19 May, but upon
check up AVR is found normal. It was also confirmed by 3rd party assessor that
AVR for #01 is OK.
In the case of Genset #02, AVR might already damaged due to circulating
current found on its grid. Unstable resultant voltage
AVR on both units was not yet replaced during the course of acquisition ofthis equipments. Genset #02 has history of breakdown due to reverse
loading. No reports concluded AVR on #02 was replaced during its
breakdown.
Breakdown of AVR on Genset could be a factor of the cause
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E&M-FAC-12-002
Root Cause Analysis:
3. Frequency and voltage instability due to control loopcompatibility conditions
Deviation on the panel metering on the control center is reported on last
inspection and trouble shooting. Display on ammeter of genset #02 picked
up above its operating limit (2000 A).
Upon check up rectifying diode and suppressor already damaged, Droop
CT might also affected due to circulating currents. Circulating current is
damageable to components if paralleling generators was serviced not
matched to their intended parameters.
Damage on the components was attributed to circulatingcurrents, it may presume that the generator was shedded notparallel on its limits
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E&M-FAC-12-002
Root Cause Analysis:
Cause of trouble can now be streamlined to 2 major causes;
1. Malfunctioned AVR resulting to distortion on its insidesystem.
2. Paralleling of both units was not attained while on loadmode due to deviations on the metering system resultingto uncontrolled circulating currents damaging rectifierdiode and its suppressor.
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E&M-FAC-12-002
Recommendations;
Replace listed defective comnponents of Genset #02
- AVR, diode and suppressor
Replace defective panel display to avoid misguided readings.
Continue Planned PMS of units and ensure bi-weekly testruns to conform integrity of operation of generator setsystem
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Thank You
Prepared By: Mark C. Centeno