EQUIPMENT PROBLEM REPORT

1. CREATED ON ( fill by Planner )

Refference ID : EPR0002 (Fill in 5 digits)

Plant : Utility
Maintenance Notification : XXXXXXXXXXX
Created by : Planner I (Fill in as patern)
Date Creation : 23 / 10 / 2012 (Fill in as patern)

2. SUBJECT
Furnace BA-106 trip due to loss of total air
3. EQUIPMENT INFORMATION

3.1 Equipment Data :

a. Equipment ID : GI-101
b. Description : GAS TURBINE GENERATOR
c. Classification : TURBINE
d. Function location : CA30-01-01
e. Equipment type :
f. Manufacture : GE ALSTHOM

3.2 Maintenance History

MTBF (If any) : XXXX (Fill in)
MTTR (if any) : XXXX (Fill in)
Maintenance Order :
1. MO No. : XXXXXXX (1) (Fill in)
2. MO No. : XXXXXXX (2) (Fill in)
3. MO No. : XXXXXXX (3) (Fill in)
Etc…..

Proposed to : Olefin Instrument Section

SAVE (Klick) SEND (Klick)
 EQUIPMENT PROBLEM REPORT
4. BASIC INFORMATION : by MTN SV or ENG

4.1 Detail Description of Failure Event and Consequence :

If possible, fill Parameter data during failure occurred ( Temperature, Pressure, Flow, Vibration, etc )

On Friday 28 September 2012 At 17:30 the GTG load down from 3.5 MW to 2.5 MW and switch the
fuel from methane gas to DO ( in order for PLN Synchronize with STG ).

At 20:22 GTG trip when switching back the fuel from DO to Methane Gas with indication alarm
appeared on speedtronic monitor “Alarm150 : Electrical Trouble – Normal Shutdown”

4.2 Basic Correction Action :

1. On 28/9/12 Restart the GTG by operation with HOT start but still malfunction due to Atomizing
Air and CA-2 oil contaminate with water replace the oil for lubrication and tighten the water lake from
flanges, restart 3 times but still big leakage when Diesel Engine accelerate.

2. On 29/9/12 Checked the exchanger for HX-1 for Cooler Atomizing Air was leaked 1 tube and
plug, after completed restart the GTG but still not success by Failure for Ignite, we assumed that
checked valve related with Atomizing Air was malfunction, Checked for suction CA-1 and discharge
CA-2 both Check valve was good then re install, Check the drain valve of CA-2 found plugging,
repaired and cleaning was ok. Re-start the GTG but still problem failure to Ignite.
3. On 30/9/12 Checked the Fuel Oil system by checked all Fuel oil check valve there are 10 pcs.
Check setting pressure to 100 PSI (replaced 1 Check valve). In the night we rechecked again and
cleaning spark plug, checked and cleaning flame detectors ( B,C,D), than function test all detector
the result was good, change the start up parameter FKSSU-AR from 26.9 à 30.0 and FSKSU-FI
from 21% à24% à 27%, start the GTG with success FSNL at 23:23 and synchronize with STG with
load 3.2 MWChecked the Spark plug and Flame Detector C and D the result 1 spark was fail
(replaced by new spare). Function test of the flame sensor was good. Checked and overhaul the
VA17-1 (false start drain valve) due to stuck close and VA17-5 (Auto drain when fail to start or ignite)
trial to start GTG but only 1 flame (#A) can be detect and trial several time after return to crank then
auto again is same result.

4. On 1&2/10/12 GTG still running with DO and check the supply gas, hydraulic pressure and
several times change the fuel from DO to Gas with load 3,4 MW 1 time and 5, 22 MW 2 times, but
not success.

5. On 3/10/12 Continue trouble shooting why the GTG can’t be switching from DO to Methane Gas.
Stop GTG then stroke test Gas Valve and Valve Ratio for Gas Control system. Stroke test on GCV
and SRV looks not ok, there is an indication that RST not balance. Replaced HSAA card for slot 2E
R Controller. After that there is no unbalance and LCV/GCV can move up and down with balance
indication. Remove and cleaning filter Servo valve than installed again. Stroke test by adjusting
LVDT seems good result, 23:00 restarted by DO 3 times was fail with indication alarm Loss of Flame

6. On 4/10/12 Opened and checked all of 10 pcs Fuel Nozzle and found very dirty, replaced all Fuel
Nozzle by spare. Replaced Spark plug one for Nozzle #1, Remove and recheck all flame detector
still clean condition. Replaced Flame detector for B and D and installed all flame detector, Restart
GTG with fuel oil but GTG trip with lube oil pressure low, during this priode diesel engine can’t stop
due to coupling hub slip and repaired by mechanical. Operation flushing the line lube oil line after
change over filter. Re-start GTG was success. Change over fuel from DO to gas but still problem,
than GTG running back with fuel DO.

3.7.On 5/10/12 Calibration Servo Valve 65GC and data printout sent to Mr Richard for observation
and suggest for next action.

3.8.On 6/10/12 Replaced the LVDT 96GC1 and 96GC2, Replaced Servo Valve 65GC and stroke
test / calibration the valve gas control VGC, restart the GTG and switch fuel from DO to methane
gas the result still same, when the signal fuel stroke reference FSR2 increase to 16% the actual
opening valve gas control VGC still 0%.

3.9.On 7/10/12 Changed the parameter for mechanical offset bias (FSKOUTB) from 0.1 VDC to 0.5
VDC and simulate the control system, the result is GCV valve can be open when FSR2 signal < 5%.
At that time we intend to started the GTG and change the fuel to Gas but not yet done because the
root cause of the offset of GCV valve not yet found.At 13:00 Mr Richard arrived at CAP and
explanation the chronology of the problem to him after that observation at site. Check all data on
speedtronic and compare with original data still same.Check and make simulate signal for valve gas
control (FSROUT) and compare with the feedback of LVDT not matching.FSROUT indicated 16%
but LVDT position indicated 0%.Check all resistance of servo valve R,S,T indicated 1.05kohm. Ok
Remove the termination and check polarity of servo valve was OkFunction test the servo valve by
using battery AA 1.5 VDC and compare the stroke opening with gas ratio valve and found valve gas
control abnormal moving.Suspect the seal of the piston hydraulic cylinder leak. Replaced the
hydraulic cylinder with new spare and recalibration the valve gas control VGC Ok Start up GTG and
switching the fuel from DO to Methane gas was success.

4.3 Result of Basic Correction Action :

4.4 Attachment

Drawing/picture/document
 EQUIPMENT PROBLEM REPORT
5. ROOT CAUSE ANALYSIS : by MTN SV or ENG
5.1 Problem Solving Objective

5.2 Root Causes Analysis 5 Why :

1. Why :GTG trip during change DO to Gas……………………………..
Answer : Because no fuel Gas supply to combustion to fire the turbine……
2. Why :No fuel Gas supply to combustion to fire the turbine……………..
Answer :Because CGV valve not enough opening when Fuel Stroke Reference
(FSR) sent signal to open valve 16%.……….
…………………………...….
3. Why :CGV valve not enough opening when Fuel Stroke Reference (FSR)
sent signal to open valve 16 %....
……………………………………………..
Answer :Because no sufficient pressure of hydraulic cylinder to open the CGV
valve as signal fuel stroke reference (FSR)……………………..
4. Why :No sufficient pressure of hydraulic cylinder to open the CGV valve as
signal fuel stroke reference (FSR)……………………………….
Answer :Because seal of hydraulic cylinder piston leakage and effected to
release the pressure……………………………………………..
5. Why :Seal of hydraulic cylinder piston leakage and effected to release the
pressure……………………………………………………….
Answer :Because seal of hydroulic cylinder worn-out or
deterioration………………………………..………………………..
Conclussion :
1. On 28 Sept 2012 GTG trip during change DO to Gas because CGV valve not
open when Fuel Stroke Reference (FSR) sent signal to open so no fuel to
combustion to fire the turbine (refer to conclusion 4.4)

2.On 28 Sept 2012 GTG stop on Acceleration mode because Atomizing Air and
CA-2 oil contaminate with water
3. On 30 Sept,3,4Oct 2012 GTG can’t started because fuel nozzle dirty and
effect to fuel spray and firing detected very low (detected by flame #A only) than
GTG trip by lose of flame.
4. On 28 Oct 2012,1,2,5 Oct 2012 GTG can’t switch from DO to Methane Gas
because not sufficient pressure of hydraulic cylinder to open the CGV valve as
signal fuel stroke reference (FSR) due to seal of piston leakage.

5.3 Corrective Action

Recommendation
1. Additional alarm when any deviation between FSROUT and FSG_V to
identify if any abnormal on fuel stroke reference and feedback LVDT rapidly
 2. Periodic leak check of piston hydraulic cylinder by check physically or
additional pressure gauge at output of servo valve due to the failure mode of this
device is hidden.

3. Prepare spare part for critical equipment as safety stock such as Servo valve,
LVDT, hydraulic cylinder and special tools required such as special L key for
remove the filter in the servo valve.

4. Make Standard Operation Procedure (SOP) for maintenance and Trouble

Shooting.
5. Improve knowledge how to maintain GTG by additional training as
requirement.

5.4 Preventive Action :

Action PIC DEPT Plan
1
2
3
4
5

5.5 Attachment
SAVE (Klick)
 EQUIPMENT PROBLEM REPORT
7. GROUP REVIEW : by SI and or SM

Document Review : (reviewer name defined by planner Approve Result Comment

1 EDA ( Browse) PLN ( Browse )

REVIEW 4-Sep-12 ( Browse ) YES NO SEND

2 RICKY ( Browse) PLN ( Browse )

REVIEW 5-Sep-12 ( Browse ) YES NO Also fill t SEND

3 Name & Nik ( Browse) Section ( Browse )

REVIEW Day & Date ( Browse ) YES NO SEND

4 Name & Nik ( Browse) Section ( Browse )

REVIEW Day & Date ( Browse ) YES NO SEND

5 Name & Nik ( Browse) Section ( Browse )

REVIEW Day & Date ( Browse ) YES NO SEND

6 Name & Nik ( Browse) Section ( Browse )

REVIEW Day & Date ( Browse ) YES NO SEND

8. APPROVAL : by DEPARTMENT

Name & Nik ( Browse) Dept ( Browse )

REVIEW Day & Date ( Browse ) YES NO SEND

9. APPROVAL : by OPERATION

Name & Nik ( Browse) Dept ( Browse )

REVIEW Day & Date ( Browse ) YES NO SEND

Note :
- Planner has defined the review group persons. All person in charge for Preventive Actions should be includ
- For Group review has parallel mode, if no review 2 weeks, considered to be agreed/ Approved
- If reviewer will add some comment, Click "NO" than the document will go "Review
Comment form" and then Click SEND when finish.
- If no comment Click "YES" then SEND
 tive Actions should be included in group review.
greed/ Approved
 EQUIPMENT PROBLEM REPORT
6. FOLLOW UP OF PREVENTIVE ACTION : by MTN SV or ENG

6.1 Follow Up of Preventive Action

PIC DEPT Plan Actual Ref Doc
Adjust process condition Mr. A ETD ###
Modify new bearing Mr. B MTN ###
Add redundant motor Mr. C EGD TA2014

6.2 Result of Preventive Action

Preventive action incompleted
Preventive action completed
Preventive action effective
Preventive action not effective as recurrent failure occurs
and Re- EPR No, …………………

6.3 Attachment

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 EQUIPMENT PROBLEM REPORT
9. ADDITIONAL OR REVIEW COMMAND : by MTN SI or SM

COMMAND 1 Name & Nik Section

COMMAND 2 Name & Nik Section

COMMAND 3 Name & Nik Section

COMMAND 4 Name & Nik Section

COMMAND 5 Name & Nik Section

COMMAND 6 Name & Nik Section

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 EQUIPMENT PROBLEM REPORT
11. DISTRIBUTION : by SI PLANNER

List of Distributed Person :

1 Name & Nik ( Browse) Section ( Browse )

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2 Name & Nik ( Browse) Section ( Browse )

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3 Name & Nik ( Browse) Section ( Browse )

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4 Name & Nik ( Browse) Section ( Browse )

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5 Name & Nik ( Browse) Section ( Browse )

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6 Name & Nik ( Browse) Section ( Browse )

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7 Name & Nik ( Browse) Section ( Browse )

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8 Name & Nik ( Browse) Section ( Browse )

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9 Name & Nik ( Browse) Section ( Browse )

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10 Name & Nik ( Browse) Section ( Browse )

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11 Name & Nik ( Browse) Section ( Browse )

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12 Name & Nik ( Browse) Section ( Browse )

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