PT Samator Taiyo Nippon Sanso Indonesia

TROUBLE REPORT

Chiller Trip During Normal Operation (Abnormal)

Trouble Date 21 March 2023
Location Nitrogen & Hydrogen Area In JSGI
Facility Nitrogen Gas Supply
Equipment Chiller Unit No.1
Prepared By Dian Ferdinan T
Reviewed By Kenji Sasaki
Reporting Date 1 August 2023

A. TROUBLE HISTORY AND CHECKING RESULT

 21 March 2023, 07:42 – 11:39 PM
 07:42 PM : PLN Status blackout from power supplier, and info have some problem
in their site(1st)
 09:31 PM : DCS off, due to UPS not enough power
 09:33 AM : PLN info want to run power again
 09:40 AM : Power ON
 10:20 AM : Startup preparation
 12:00 AM : The signal input that received by DCS didn’t catch
 12:00 AM : Operator notice the valure of the O2 PPM to DCS
 12:00 AM: Site PIC (Ferdinan) contact vendor for consult
 12:00 AM : Site PIC (Ferdinan) request the colleguas in office anybody can help
for check the analyzer O2 portable or not and request the driver for sent to AMG
 12:00 AM : ChAnalyzer find in broken condition, can’t ON.
 12:00 AM : AMG PIC (Ferdinan) request their colleguas to check the fix analyzer
old type still in office rak or not, because AMG PIC understanding have this
analyzer on rack inventory in office. But fix type analyzer is still not found.
 13:52 PM : The colleguas (other site PIC) suggest sent the other analyzer portable
from other site (Helium in office)
 13:52 PM : The colleguas (other site PIC) find the fix Analyzer and continue sent
to Asahimas site
 13:30 AM :
 14:00 AM : Thir colleguase sent the
 14:40 AM : Asahimas coming for meeting regarding switch supply with dew point
metter

 14:47 AM : Notice the old Analyzer
Operator notice Chiller in DCS Status is STOP and contact STNI PIC.
It is found That Chiller Unit No.1 is STOP, Chiller Sub Unit (Chiller No.2) still
running.
STNI decide to keep running Nitrogen Generator Unit and check the Chiller
condition.

2 1
  It is found that Chiller Main Unit (Chiller No.1) ELCB is trip condition. This ELCB
rated ampere is 60 Ampere.

 11:39 PM: STNI Technical manager and PIC arrive at JSGI. Check megger on
compressor. It is found that compressor no.1 of chiller unit no.1 megger test not
good (+- 0 M Ohm). STNI try to Switch the ELCB from TRIP to ON , and Chiller
Unit No.1 restart to run. STNI then decide monitoring condition and contact chiller
vendor for schedule checking.

 22 March 2023
 08:14 PM : Chiller on DCS Status is STOP, ELCB trip again (2nd)
 08:39 PM : Operator notice Chiller in DCS Status is STOP and contact STNI PIC.
STNI manager and PIC then request operator to try Switch the ELCB from TRIP to
ON and restart the Chiller.
 09:06 PM : Chiller No.1 Stop, ELCB trip again (3rd)
 09:25 PM : ELCB switch to ON, and restart chiller unit No.1. STNI then decide to
put blower to blow mist from chiller area. At this point chiller can running.

.
 23 March 2023
 06:43 AM : Chiller on DCS Status is STOP, ELCB trip again (4th )
 07:31 AM : ELCB switch to ON, and restart chiller unit No.1.
 09:10 AM : Chiller on DCS Status is STOP, ELCB trip again (5th )
 09:18 AM : ELCB switch to ON, and restart chiller unit No.1.
 10:09 AM : Chiller on DCS Status is STOP, ELCB trip again (6th )
 10:09 AM : STNI manager, technical, and PIC arrive on site. Check chiller no.1
connection cable on compressor. It is found that the connector is rusty.

 STNI then try cleaning the connector and dry the wet area, after that install air
dryer hose tubing inside compressor connector and nearby electronic board. This
is for countermeasure for mist.
 STNI also check the current of compressor no.1, 2, and 3 of chiller unit no.1 to
check if there are overcurrent. Result show the current is still normal.
  10:56 AM : Turn ON ELCB and restart chiller

 26 March 2023
 06:01 PM : Chiller on DCS Status is STOP, ELCB trip again (7 th ). Try turn ON
ELCB and restart chiller many times but it could not successfully running.
 08:06 PM : To protect MS and Nitrogen Generator Unit, STNI decide to shutdown
Nitrogen Generator Unit. Change supply to Backup Tank. STNI then contact
Chiller service vendor for emergency checking and repair.

 27 March 2023
 12:23 PM : Berca Carrier, Chiller service vendor come and check chiller. It is
found that megger test for Compressor No.2 of chiller Unit No.2 not good. It also
found when try restart chiller and trip, compressor No.2 current recorded is 50 A,
while normal current is 14-15 A, ELCB specification is 60 A. Its suspected
compressor No.2 overcurrent/broken. STNI and Berca carrier then decide to
bypass the compressor no.2. So, chiller unit no.1 only run compressor 1 and 3.

 02:53 PM : Bypass work finish and restart Chiller. Chiller can run normally
 04:00 PM : Start Nitrogen Generator Unit air compressor. Due to many time chiller
issue, MS Regen conducted for 2 column before continue start-up

 28 March 2023
 08:45 AM : Supply from Nitrogen Generator Unit

 10 April 2023
  01:41 PM : Chiller on DCS Status is STOP, ELCB trip again. Try turn ON ELCB
and restart chiller many time but can not.
 06:36 PM : STNI manager found that compressor No.1 of chiller unit no.1 megger
test is bad, suspected compressor no.1 also broken. STNI then decide to bypass
compressor no.1. This time chiller unit no.1 only run compressor no.3. Bypass
work finish and chiller can run.

 16 April 2023
 STOP Nitrogen Generator Unit for Yearly Air Compressor Maintenance and Chiller
Repair

 19 April 2023
 Change Chiller No.1 compressor. All 3 compressor change with new compressor.
 Commissioning chiller, already working properly.
 Put additional seal to chiller cover panel to prevent mist and moisture.

B. ROOT CAUSE ANALYSIS

 Trouble
Chiller Unit No.1 Stop Running

 Root Cause (5 Why)

 1st Why: “ Why Chiller No.1 Stop Running?”
Because ELCB Trip
 2nd Why: “ Why ELCB Trip ?”
Because possible earth leakage or overcurrent happen?
 3rd Why: “ Why earth leakage or overcurrent happen?”
Because possible compressor internal short circuit or broken
 4th Why: “ Why compressor internal short circuit or broken ?”
Because possible internal compressor wet and corroded
 5th Why: “ Why internal compressor wet and corroded ?”
Because environment around compressor have high humidity, especially when
vaporizer nearby is used
 Chiller
Vaporizer
 Compressor

Mist
 Humidity Monitoring
 After Chiller replacement work, STNI conduct moisture monitoring inside the chiller
for 1 week, the result is:
 During CGL Mode (Vaporizer NOT Use)
Humidity Night Time =+- 80-88%
Humidity Day Time = +- 50-60 %

 During CAL Mode (Vaporizer Use)

Humidity Night Time = +- 90%
Humidity Day Time = +- 60 %

Humidity environment outdoor around vaporizer is very high.

C. COUNTER MEASURE & IMPROVEMENT PLAN
1. Change Broken Compressor with New Compressor
19 April 2023. Broken compressor already finish change with new compressor. Additional
compressor will be purchased for spare in future

2. Install Dry Air Hose on Chiller Compressor

23 March 2023. Hose to flow dry air already installed on chiller. Hose installed to
compressor connection cable and electronic board. The effectiveness of this method will
be monitored.

3. Put Additional Insulation on Chiller Cover Panel

19 April 2023. Put additional insulation that hope will prevent mist to enter and affected
chiller.

4. Shorter Periodical Maintenance and Cleaning for Chiller

STNI will consider for faster periodical chiller maintenance for chiller, from once per year,
to once per 6 month or once per 4 month.

5. Put Blower to Prevent Mist Entering Chiller

When nitrogen consumption is on CAL mode, STNI will put additional/arrange additional
blower to reduce mist on chiller area

6. Install Additional Heater (Consider for Future)

STNI will discuss internally and discuss to HQ what the best countermeasure for the high
humidity situation. One of idea is to install additional heater inside chiller.