Analysis of CWTP - 02 Motor TB Burn

Dt.22/04/2021

Problem:
CWTP-02 Motor TB found overheated and burnt.

History:
CWTP-02 motor TB replaced on dt.27/03/2021 during Preventive Maintenance.

Ratings-
1. Motor- 45KW, FLC-76A
2. MCCB (LnT)- In-200A, Inst.- 12*In, Icu-65kA, Ics- 75%Icu
3. Overload- (66-110)A Setting-66A
4. Contactor- MNX-185 Coil-110V,50Hz
5. SPV- Minilec VSP-02

Trip Logs:
1. Motor tripped on overload on dt.21/04/2021 B-shift.
2. Reset done. Current unbalanced 66A, 60A, 85A found.

Running Logs:
Date CWTP-01 CWTP-02 CWTP-03
01-04-2021 N/A Running Running
02-04-2021 Running Running Running
03-04-2021 N/A Running Running
04-04-2021 N/A Running Running
05-04-2021 N/A Running Running
06-04-2021 N/A N/A N/A
07-04-2021 N/A N/A N/A
08-04-2021 N/A Running Running
09-04-2021 N/A Running Running
10-04-2021 N/A Running Running
11-04-2021 N/A N/A N/A
12-04-2021 N/A N/A N/A
13-04-2021 N/A N/A N/A
14-04-2021 N/A N/A N/A
15-04-2021 N/A Running Running
16-04-2021 N/A Running Running
17-04-2021 N/A Running Running
18-04-2021 N/A Running Running
19-04-2021 N/A Running Running
20-04-2021 N/A Running Running

ON/OFF Schedule:
1. In A shift motor-02 runs continuously and motor-03 gets ON/OFF as per process requirement.
2. In B shift motor-03 runs continuously and motor-02 gets ON/OFF.
3. The schedule continuously changes in alternate shift.
Observations:
1. Motor TB in burnt condition.
2. Motor Internal leads found overheated and burnt.
3. Motor run continuously 24*7 hr. before burnt out.
4. Motor gets ON/OFF frequently.
5. No change over of Motor due to CWTP-01 not available.
6. Motor PM Schedule for every 3 months.

Analysis:
1. Motor overheats as it runs for long hours continuously without proper changeover.
2. High frequency of ON/OFF can cause reduction of Motor lifespan.
3. Even if Motor is designed for S1 duty, Overheating will be produced at the weak/Loose points of the
electrical circuit.
4. Weak/Loose points on the electrical circuit (MCCB/Contactor/Overload/Motor TB/Lugs etc.) arise due to
inappropriate Motor PM Schedule.

Recommendations:
1. Its highly recommended to increase Motor PM frequency as one motor is in breakdown.
2. Proper changeover schedule to be made for Motor running.
3. Frequent ON/OFF issue can be resolved by proper soft starter/drive modification.
4. Motor and Feeder condition monitoring to be done regularly.
5. CWTP-03 Motor to be made ready as early as possible.

Concerns:
Operation cannot give motors for PM as two motors always run for plant requirement.

BURNT MOTOR TB