OWNER : VEDANTA ALUMINIUM LIMITED, JHARSUGUDA

CONTRACTOR : VOLTECH OPERATION AND MAINTANANCE SERVICES

PROJECT : VEDANTA SMELTER-2

DOCUMENT TITLE

ROOT CAUSE ANALYSIS HP COMPRESSOR MOTOR START UP FAILURE

DOCUMENT CLASS : APPROVAL

DISCIPLINE : ELECTRICAL

0 30-Jul-19 FOR SUBMISSION MR RV CKC

DATE WRITTEN CHECKED APPROVED
REV REVISION MEMO
DD-MMM-YY BY BY BY

TOTAL NO. OF SHEETS : 27 (INCLUDING THIS COVER SHEET)

CONFIDENTIAL - Not to disclose without authorisation

 ROOT CAUSE ANALYSIS

TABLE OF CONTENTS

1 EXECUTIVE SUMMARY ..................................................................................................................... 3

2 INTRODUCTION ................................................................................................................................ 3

3 STUDY SUMMARY ............................................................................................................................ 3

4 EQUIPMENT DETAILS........................................................................................................................ 3
4.1 HP COMPRESSOR MOTOR ...................................................................................................................... 3
4.2 LP COMPRESSOR MOTOR ....................................................................................................................... 4
4.3 SWITCH BOARD AND FEEDER DETAILS ................................................................................................... 5

5 MOTOR PROTECTION ....................................................................................................................... 5

5.1 DESCRIPTION .......................................................................................................................................... 6
5.2 PROPOSED SETTING AND AVAILABLE SETTING ...................................................................................... 8

6 INCOMER PROTECTION .................................................................................................................. 11

6.1 DESCRIPTION ........................................................................................................................................ 11

7 HP-2 MOTOR WITH OPERATIONAL INTERLOCKS. ........................................................................... 14

7.1 INTRODUCTION .................................................................................................................................... 14

8 OBSERVATION ................................................................................................................................ 15

9 ANNEXURE-1 .................................................................................................................................. 19

10 ANNEXURE-2 .................................................................................................................................. 24

Page 2 of 27
 ROOT CAUSE ANALYSIS
1 EXECUTIVE SUMMARY

For Vedanta smelter plant-2, the root Cause analysis report has been analyzed based on the condition why
the HT compressor motor trips via SCADA operation.

During the analysis, it has been recorded that when closing of circuit breaker the over current measured in
the two phases L1 & L2. Hence there is no trip comment issued by the relay. During starting the overcurrent
protection will goes to block condition because of motor starting supervision.

As per the site status, the recorded breaker was tripped. It was happened based on SCADA trip. There is a
feedback taken from circuit breaker for CB status. In event log we did not find any trip event of breaker.

2 INTRODUCTION

This report covers the reasons why the HT compressor motor trips via SCADA operation while
starting. Also this report was prepared on the basis of study of electrical system aspects and not in
the basis of control and instrumentation.

3 STUDY SUMMARY

In Vedanta smelter plant-2, two compressor areas avail to full fill the plant compressed air
requirement. Compressor area-1 is rated as 11kV 1250A, 40KA/1s and it is Energized from the pot
line-1 and compressor area-2 is rated as 11kV 1250A, 40KA/1s and it is Energized the pot line-2.
There is a tie between the compressor area-1 & 2 in 11kV side to maintain the reliable power
supply.

4 EQUIPMENT DETAILS

4.1 HP COMPRESSOR MOTOR

TERMS DESCRIPTION

Rating 1750 KW

Voltage 11 KV

Starting method DOL

Starting Performance LRC/FLC<550% LRT/FLT 65%

Operating performance % Load 100 75 50 Break down Torque

Amp. 105 79.3 54 200 % FLT

EFF.% 95.3 95.0 94.5 Temp. Rise Limit.

(Res)
PF. % 92.0 91.5 90.1

Page 3 of 27
 ROOT CAUSE ANALYSIS
TERMS DESCRIPTION

R.P.M. 2975 2979 2983 Stator 75 °C

Motor WK^2 805Lb-ft^2

Locked Rotor withstand time 80% (RV) 100% (RV) 110%(RV)

Hot condition 30.0s 19.8s 15.8s

Cold Condition 34.5s 22.7s 18.1s

Torque Break away Pull-up Pull-out

2689ft-lb 2689ft-lb 8273ft-lb

Starting Time 80% (RV) 100% (RV) 110%(RV)

Coupled 12.0s 9.0s 6.0s

Uncoupled 7.5s 4.0s 3.2s

Allowable start Cold 3, Hot 2

Thermal withstand time 22.7s

4.2 LP COMPRESSOR MOTOR

TERMS DESCRIPTION

Rating 1150 KW

Voltage 11 KV

Starting method DOL

Starting Current 5.0

Operating performance % Load 100 75 50

Amp. 72 55 39

EFF.% 95.2 95.1 94.1

PF. % 88 87 82

Motor Inertia Rotor/ Load 23 kgm2 / 27 kgm2

Maximum Stalling Time Cold condition Warm Condition

100% (RV) 24s 60s

80% (RV) 20s 36s

Starting Time 100% (RV) 80% (RV)

9s 16s

Number of Consec. starts Cold condition Warm Condition

Page 4 of 27
 ROOT CAUSE ANALYSIS
TERMS DESCRIPTION

3 2

Torque Rated Starting Maximum

3680 Nm 0.4 FLT 2.2 FLT

4.3 SWITCH BOARD AND FEEDER DETAILS

BOARD NAME DESCRIPTION

Compressor area-1 11kV 1250A, 40KA/1s

Compressor area-1 11kV 1250A, 40KA/1s

5 MOTOR PROTECTION

There are a wide range of A.C. motors and motor characteristics in existence, because of the
numerous duties for which they are used. All motors need protection, but fortunately, the more
fundamental problems affecting the choice of protection are independent of the type of motor and
the type of load to which it is connected.

Motor characteristics must be carefully considered when applying protection; while this may be
regarded as stating the obvious, it is emphasized because it applies more to motors than to other
items of power system plant. For example, the starting and stalling currents/times must be known
when applying overload protection, and furthermore the thermal withstand of the machine under
balanced and unbalanced loading must be clearly defined.

The conditions for which motor protection is required can be divided into two broad categories:
imposed external conditions and internal faults.

The following functions are used to protect induction motor.

Thermal Over load Protection

Motor starting protection

Over current protection

Cold load pickup Protection

Earth fault protection

Unbalance (Negative seq.) protection

Page 5 of 27
 ROOT CAUSE ANALYSIS
5.1 DESCRIPTION

5.1.1 THERMAL OVER LOAD PROTECTION

The thermal overload protection is designed to prevent thermal overloads from damaging the
protected equipment. The protection function models a thermal profile of the object being
protected (overload protection with memory capability). Both the history of an overload and the
heat loss to the environment are taken into account.

APPLICATIONS

In particular, the thermal overload protection allows the thermal status of motors, to be
monitored.

If an additional thermal input is available, the thermal profile may take the actual ambient
or coolant temperature into consideration.

5.1.2 MOTOR STARTING PROTECTION

There are two protections for the motor protection, 1. Motor starting protection 2. Motor restart
inhabits.

In particular, rotor-critical high-voltage motors can quickly be heated above their thermal limits
when multiple starting attempts occur in a short period of time. If the durations of these starting
attempts are lengthened e.g. by excessive voltage dips during motor starting, by excessive load
torques, or by blocked rotor conditions, a tripping signal will be initiated by the device.

Motor starting is detected when a settable current threshold I MOTOR START is exceeded.
Calculation of the tripping time is then initiated. The protection function consists of one definite
time and one inverse time tripping element.

The inverse time overcurrent element is designed to operate only when the rotor is not blocked.
With decreased starting current resulting from voltage dips when starting the motor, prolonged
starting times are evaluated correctly and tripping with appropriate time delay. The tripping time is
calculated based on the following equation.

5.1.3 OVER CURRENT PROTECTION

General time overcurrent protection is the main protective function of the relay. Each phase
current and the ground current is provided with three elements. All elements are independent of
each other and can be combined in any way. If it is desired in isolated or resonant-grounded
systems that three-phase devices should work together with two-phase protection equipment, the
time-overcurrent protection can be configured such that it allows two-phase operation besides

Page 6 of 27
 ROOT CAUSE ANALYSIS
three-phase mode High-current element 50-2 and overcurrent element 50-1 always operate with
definite tripping time, the third element 51, operates always with inverse tripping time.

APPLICATIONS
The non-directional time overcurrent protection is suited for networks that are radial and supplied
from a single source or open looped networks or for backup protection of differential protective
schemes of all types of motors

5.1.4 COLD LOAD PICKUP PROTECTION

It may be necessary to dynamically increase the pickup values if, during starting, certain elements
of the system show an increased power consumption after a long period of zero voltage. Thus, a
general raise of pickup thresholds can be avoided taking such starting conditions into
Consideration. With the cold load pickup function, pickup and delay settings of directional and non-
directional time overcurrent protection can be changed over dynamically. As a further option the
pickup thresholds may be modified by an automatic reclosure function in accordance with its ready
or not ready state.

5.1.5 EARTH FAULT PROTECTION

Depending on the variant, the fourth current input of the multi-functional protection relays
7SJ62/63/64 is equipped either with a sensitive input transformer or a standard transformer for
1/5 A.

In the first case, the active protective function is designed for ground fault detection in isolated or
compensated systems due to its high sensitivity. It is not very suited for ground fault detection with
large ground currents since the linear range is transcended at about 1.5 A at the sensitive ground
fault detection relay terminals.

If the relay is equipped with standard transformers for 1/5 A, also large currents can be detected
correctly.

APPLICATIONS

Sensitive ground fault detection may be used in isolated or compensated systems to detect ground
faults, to determine phases affected by ground faults, and to specify the direction of ground faults.

In solidly or low-resistance grounded systems, sensitive ground fault detection is used to detect
high impedance ground faults.

This function can also be used as supplementary ground fault protection.

Page 7 of 27
 ROOT CAUSE ANALYSIS
5.1.6 UNBALANCE (NEGATIVE SEQ.) PROTECTION

Negative sequence protection detects unbalanced loads on the system.

The application of negative sequence protection to motors has a special significance. Unbalanced
loads create counter-rotating fields in three-phase induction motors, which act on the rotor at
double frequency. Eddy currents are induced on the rotor surface, which causes local overheating
in rotor end zones and the slot wedges. This especially goes for motors which are tripped via
vacuum contactors with fuses connected in series. With single phasing due to operation of a fuse,
the motor only generates small and pulsing torques such that it soon is thermally strained
assuming that the torque required by the machine remains unchanged. In addition, the unbalanced
supply voltage introduces the risk of thermal overload. Due to the small negative sequence
reactance even small voltage asymmetries lead to large negative sequence currents.

In addition, this protection function may be used to detect interruptions, faults, and polarity
problems with current transformers.

It is also useful in detecting 1 pole and 2 pole faults with fault current lower than the maximum
load current.

5.2 PROPOSED SETTING AND AVAILABLE SETTING

ABB Voltech Present units

Functions Address Parameters
setting setting setting
Thermal 4201 FCT 49 ON ON ON
4202 49 K-factor 0.805 0.74 0.74
4203 TIME CONSTANT 11.00 30.0 30.0 min.
4204 49 θ Alarm 90.00 90 90 %
4205 I ALARM 0.77 0.74 0.74 A
4207A Kt FACTOR 1.00 1.00 1.00
4208A T EMERGENCY ON 100 100 sec
Startup 4101 FCT 48/66 3.72 (Ith
ON ON
Supervision 1.05)
4102 startup current 3.85 3.85 3.85 A
4103 startup time 3.85 11.0 11.0 Sec
4104 locked rotor time ON ∞ ∞ Sec
4105 Startup time warm sec
13.00
motor
4106 temp. limit cold %
33.00
motor
4301 FCT 66 ON ON ON

Page 8 of 27
 ROOT CAUSE ANALYSIS

ABB Voltech Present units

Functions Address Parameters
setting setting setting
4302 Istartup/ MOT.Nm 5.50 5.50 5.50 A
4303 T START MAX - 9 9 Sec
4304 Tequal - 1 1 min
4305 I MOTOR NOMINAL 0.70 0.70 0.70 A
4306 MAX.WARM
2.00 2 2
STARTS
4307 #COLD - WARM
1.00 1 1
STARTS
4308 KT at STOP - 5 5
4309 KT at RUNNING - 2 2
4310 T MIN.INHIBIT 6 6 min
4311 Rotor overload
ON
protn
Load Jam 4406 Blocking after Sec
12.00
motor start
4402 Tripping Threshold 1.40 A
4403 Trip Delay 2.00 Sec
4404 Alarm Threshold 1.05 A
4405 Alarm Delay 1.00 Sec
O/C 1201 FCT 50/51 ON ON ON
1202 50-2 PICKUP 6.81 6.16 6.16 A
1203 50-2 DELAY 0.05 0.05 0.05 sec
1204 50-1 pickup ∞ ∞
1205 50-1 DELAY ∞ ∞
1207 51 PICKUP 0.81 4.00 4.00 A
1208 51 Time Dial 3.00 ∞ ∞ sec
1210 Dropout Disk
INSTANT INSTANT
Characteristic Emulation
1211 IEC Curve Normal Normal Normal
Inverse Inverse Inverse
Cold Load 1701 COLDLOAD PICKUP - ON ON
1702 Start condition No No A
-
current current
1703 CB open time - 0.00 0.00 sec
1704 Active Time - 14.00 14.00 sec
1705 Stop Time - 12.00 12.00 sec
1801 50c-2 PICKUP - 6.16 6.16 A
1802 50c-2 DELAY - 0.05 0.05 sec
1803 50c-1 PICKUP - 4.24 4.24 A

Page 9 of 27
 ROOT CAUSE ANALYSIS

ABB Voltech Present units

Functions Address Parameters
setting setting setting
1804 50c-1 DELAY - 0.20 0.20 sec
1805 51C PICKUP 4.00 4.00
1806 51C DELAY ∞ ∞
1901 50N-C 2 PICKUP ∞ ∞
1902 50N-C 2 DELAY ∞ ∞
1903 50N-C1 PICKUP ∞ ∞
1904 50N-C1 DELAY ∞ ∞
1905 51N C PICKUP 4.00 4.00
1906 51N C DELAY ∞ ∞
E/F 1302 50N-2 PICKUP ∞ ∞
1303 50N-2 DELAY ∞ ∞
1304 50-N1 pickup 0.70 0.21 0.21 A
1305 50-N1 DELAY 0.01 0.10 0.10 sec
1307 51N PICKUP 0.07 4.00 4.00
1308 51N Time Dial 0.20 ∞ ∞
1310 Dropout Disk Disk Disk
Characteristic Emulation Emulation Emulation
1311 IEC Curve Normal Normal Normal
Inverse Inverse Inverse
Unbalance 4001 FCT 46 ON ON ON
4002 46-1 PICKUP 0.105 0.10 0.10 A
4003 46-1 DELAY 5.00 20.00 20.00 sec
4004 46-2 PICKUP 0.42 0.40 0.40 A
4005 46-2 DELAY 2.00 1.00 1.00 sec
U/V 5101 FCT 27 - ON ON
5103 27-1 PICKUP - 88.00 88.00 A
5106 27-1 DELAY - 1.50 1.50 sec
5111 27-2 PICKUP - 77.00 77.00 A
5112 27-2 DELAY - 0.50 0.50 sec
Power 201 CT STAR POINT TOWARDS TOWARDS
-
System LINE LINE
data 202 Vnom PRIMARY - 11.00 11.00 kV
203 Vnom SECONDARY - 110.00 110.00 V
204 CT PRIMARY - 150.00 150.00 A
205 CT SECONDARY - 1.00 1.00 A
206A VPH/VDELTA - 1.73 1.73
209 PHASE SEQUENCE - ABC ABC

Page 10 of 27
 ROOT CAUSE ANALYSIS

ABB Voltech Present units

Functions Address Parameters
setting setting setting
210A Tmin TRIP S
- 0.15 0.15
COMMAND
211A Tmax CLOSE S
- 1.00 1.00
COMMAND
212 BREAKER CLOSED A
- 0.04 0.04
IMIN
213 VT CONNECT. 3ph Van, Van,
Vbn,Vcn Vbn,Vcn

214 RATED FREQUENCY - 50.00 50.00

6 INCOMER PROTECTION

Protection against excess current was naturally the earliest protection system to evolve. From this
basic principle, the graded overcurrent system, a discriminative fault protection, has been
developed. This should not be confused with ‘overload’ protection, which normally makes use of
relays that operate in a time related in some degree to the thermal capability of the plant to be
protected. Overcurrent protection, on the other hand, is directed entirely to the clearance of faults,
although with the settings usually adopted some measure of overload protection may be obtained.

The following functions are used to protect the incomer

Overcurrent protection

Earth Fault Protection

Under voltage protection

6.1 DESCRIPTION

6.1.1 OVERCURRENT PROTECTION

General time overcurrent protection is the main protective function of the relay. Each phase
current and the ground current is provided with three elements. All elements are independent of
each other and can be combined in any way. If it is desired in isolated or resonant-grounded
systems that three-phase devices should work together with two-phase protection equipment, the
time-overcurrent protection can be configured such that it allows two-phase operation besides
three-phase mode (see Section 2.1.3.2). High-current element 50-2 and overcurrent element 50-1
always operate with definite tripping time, the third element 51, operates always with inverse
tripping time.

Page 11 of 27
 ROOT CAUSE ANALYSIS
APPLICATIONS

The non-directional time overcurrent protection is suited for networks that are radial and supplied
from a single source or open looped networks or for backup protection of differential protective
schemes of all types of lines, transformers, generators, motors, and bus-bars.

6.1.2 EARTH FAULT PROTECTION

Depending on the variant, the fourth current input of the multi-functional protection relays
7SJ62/63/64 is equipped either with a sensitive input transformer or a standard transformer for
1/5 A.

In the first case, the active protective function is designed for ground fault detection in isolated or
compensated systems due to its high sensitivity. It is not very suited for ground fault detection with
large ground currents since the linear range is transcended at about 1.5 A at the sensitive ground
fault detection relay terminals.

If the relay is equipped with standard transformers for 1/5 A, also large currents can be detected
correctly.

APPLICATIONS

Sensitive ground fault detection may be used in isolated or compensated systems to detect ground
faults, to determine phases affected by ground faults, and to specify the direction of ground faults.

In solidly or low-resistance grounded systems, sensitive ground fault detection is used to detect
high impedance ground faults.

This function can also be used as supplementary ground fault protection.

6.1.3 UNDER VOLTAGE PROTECTION

The under-voltage protection function detects voltage collapses on transmission lines and electrical
machines and prevents the persistence of inadmissible operating states and a possible loss of
stability.

Page 12 of 27
 ROOT CAUSE ANALYSIS
6.1.4 PROPOSED SETTING AND AVAILABLE SETTING

COMP AREA#2 COMP AREA#2

Description
BUSCOUPLER INCOMER
Rated current
594.35 1000
(A)
Relay Make & Model SIEMENS-7SJ61 SIEMENS-7SJ63
CT
1000/1 1000/1
Ratio
51-
1211 Normal Inverse Normal Inverse
IEC Curve
1207 51 Pickup I> (A) 1 1
51
M/s. Siemens 1208 0.11 0.3
Time Dial
settings
Operating
(Recommended 0.25 0.45
time (s) for 51
settings)
50-1 Pickup
1204 1.35 2.5
I>> (A)
50-1 Delay
1205 0.25 0.45
t>>(Sec)
51-
1211 Normal Inverse Normal Inverse
IEC Curve
1207 51 Pickup I> (A) 0.59 1
51
M/s. Voltech 1208 0.14 0.2
Time Dial
Suggested Operating
settings 0.3 0.55
time (s) for 51
50-1 Pickup
1204 1.85 3.7
I>> (A)
50-1 Delay
1205 0.3 0.55
t>>(Sec)

Page 13 of 27
 ROOT CAUSE ANALYSIS
7 HP-2 MOTOR WITH OPERATIONAL INTERLOCKS.

7.1 Introduction

The motor can be started by two different operations they are,

Local control

Remote Control

1. Local Control

In this operation, the motor was started by manual operation (i.e closing the breaker manually).
The following conditions are checked by the relay.

Motor Starting Supervision by relay

Starting current

Duration of starting

No of start

CB Status to relay

VCB ON

VCB OFF

Trip Circuit Supervision

Page 14 of 27
 ROOT CAUSE ANALYSIS
2. Remote Control

In this operation, the motor was started by SCADA operation (i.e closing the breaker manually). The
following conditions are checked by the relay and the SCADA.

Motor Starting Supervision by relay

Starting current

Duration of starting

No of start

CB Status to relay

VCB ON

VCB OFF

Trip Circuit Supervision

Status required for SCADA from utility

Electrical protection status (from relay output contact)

Circuit breaker status(C.B Auxiliary NO & NC contact)

Compressor status (Thermal and Mechanical status)

8 OBSERVATION

Event-1

As per the trip log of relay, the details are extracted and mentioned below as per time. Also
annexure-1 has detailed record.

Date: 16.04.19 Time: 10.59.10

Number Indication Value remarks

00301 Power system fault ON
01761 Time over current picked up ON
01762 Time over current phase L1 picked up ON
01763 Time over current phase L2 picked up ON
00301 Power system fault OFF
As per the event log of relay, the details are extracted and mentioned below as per time. Also
annexure-2 has detailed record

Page 15 of 27
 ROOT CAUSE ANALYSIS
Date: 16.04.19 Time: 10.59.10

Number Indication Value remarks

VCB OFF OFF
01515 Overload current alarm ON
00301 Power system fault ON
VCB ON ON
06823 Motor start up time supervision ON
00301 Power system fault OFF

Conclusion for event-1

As per the above records, during closing of circuit breaker the over current measured in the two
phases L1 & L2. Hence there is no trip command issued by the relay. During starting the
overcurrent protection will go to block condition because of motor starting supervision.

As per the site status they recorded breaker of tripped. It is happened based on SCADA trip. There
is a feedback taken from circuit breaker for CB status. In event log we could not found any trip
event of breaker hence we conclude the two phases (L1 & L2) of circuit breaker was closed and L3
phase remains in open condition. Hence the status (closed) of circuit breaker was not extended to
SCADA input. It shows starter feedback trip in SCADA.

Recommendation

Condition monitoring is required for VCB.

Ensure the feedback from breaker to PLC.

Event-2

As per the trip log of relay, the details are extracted and mentioned below as per time, also
annexure-1 has detailed record.

Date: 16.04.19 Time: 11.13.16

Number Indication Value remarks

00301 Power system fault ON
01761 Time over current picked up ON
01762 Time over current phase L1 picked up ON
01763 Time over current phase L2 picked up ON
00301 Power system fault OFF

Page 16 of 27
 ROOT CAUSE ANALYSIS
As per the event log of relay, the details are extracted and mentioned below as per time, also
annexure-2 has detailed record.

Date: 16.04.19 Time: 11.13.16

Number Indication Value remarks

VCB OFF OFF
01515 Overload current alarm ON
00301 Power system fault ON
VCB ON ON
06823 Motor start up time supervision ON
00301 Power system fault OFF

Conclusion for event-2

Event-1 conclusion is applicable for event-2.

Recommendation

Event-1 recommendation is applicable for event-2.

Event-3

As per the trip log of relay, the details are extracted and mentioned below as per time. Also
annexure-1 has detailed record.

Date: 16.04.19 Time: 11.43.53

Number Indication Value remarks

00301 Power system fault ON
01761 Time over current picked up ON
Time over current phase L1
01762 ON
picked up
Time over current phase L2
01763 ON
picked up
00301 Power system fault OFF

As per the event log of relay, the details are extracted and mentioned below as per time. Also
annexure-2 has detailed record

Page 17 of 27
 ROOT CAUSE ANALYSIS

Date: 16.04.19 Time: 11.43.53

Number Indication Value remarks

VCB OFF OFF
01515 Overload current alarm ON
00301 Power system fault ON
VCB ON ON
06823 Motor start up time supervision ON
00301 Power system fault OFF

Conclusion for event-3

Event-1 conclusion is applicable for event-3.

Recommendation

Event-1 recommendation is applicable for event-3.

Page 18 of 27
ROOT CAUSE ANALYSIS

ANNEXURE-1

Page 19 of 27


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Page 23 of 27
ROOT CAUSE ANALYSIS

ANNEXURE-2

Page 24 of 27


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