Format No.

: MTPL/RCA/01
ROOT CAUSE ANALYSIS REPORT (RCA) Rev: 00
Date: 15/05/2020

Report Title: RCA for Failure of 300sq mm SCB outgoing DC cable

Ref.: EEIPL/2023-23/SCB-01 Report Date: 9-Sep-23

A] Solar Plant details

Client: Ecoren Energy India Pvt Ltd Division O&M
Plant Name: Ecoren Chakrayapeta Region South
Site Location : Chakrayapeta Installed Capacity: 25.37MWp
State : AP
Country: India
B] Breakdown Details
Inverters Switchyard Control Room Modules Others
Category
Equipment SCB
Equipment Serial No. SCB-8 _10000180201171070005220068 and SCB-17_10000180201171070005220081 Equipment Make TRINITY TOCH
Area/Section ICR-3 / INVERTER
Breakdown Start Date 07-09-2023 Breakdown Start Time 07:31
Breakdown End Date 10-09-2023 Breakdown End Time 08:01

Brief Description of BD On 07-09-2023 at 07:31AM Inverter -3 tripped on Insulation resistance Failure and Engineer observed fire with smoke and cable
puncture at Inverter-3 SCB 8 &17 field area. Team done IR test for all SCB outgoing Dc cables pertaining to inverter3, found all SCB
cables IR values were satisfactory except SCB 8 and 17.

Equipment Last Date of Commissioning NA Past Performance Issues if any : NO

Under Operation Under Break down

Breakdown Brief History : On 07-09-2023 at 07:31AM Inverter -3 tripped on Insulation resistance Failure and Engineer observed smoke and cable puncture at Inverter-3 SCB 8
C]
&17 field area. Team done IR test for all SCB outgoing DC cables pertaining to inverter-3, found all SCB cables IR values were satisfactory except SCB 8 and 17.

Date Of Failure / Observation 07-09-2023 07:31 Hrs Correction completed on: 08-09-2023 05:45AM

D] Failure details:

Component Name Inverter -3 SCB 8 & 17 300 Sq.mm SCB OUT going cables Make/Supplier Name Polycab
Component Type 1.8KV DC Cable Component Part No. NA

SCB to inverter 1XC

Serial Number Of Component NA Equipment Description
300SQMM cable

E] Breakdown Analysis :
Problem Description
Sr.
(Observations of Anomalies)
1. Inverter-3 SCB 8 &17 positive and negative
cable both punctured .
2. MCS pipeline damaged at SCB 17
3.OFC cable for SCADA from ICR 4 to ICR 3
damaged .
4. Fire catches to all strings cable pertaining to
SCB 8& 17 along with approx 24 moduels
carbonized and need to test modules for
helathyness as some were physically damaged
1 too.
Suspected Reasons of Failure
Corrective Action Carried Out Remark
(Why, Why Analysis )
Why 1:Pin hole/scratches happend during errection time may lead to damage of outer sheath of cable.
Why 2:Quality of Cable.
Why 3:Improper Cable backfilling and bedding
Why 4:Ingress of moisture into cable insulation layer
Why 5:Bunch of cables irrespective of cable size in same trench
Why 6:MCS pipeline is on the DC cable with approx. 1.5 feet gap
1. Excavated the cable trench, found
SCB 8 &17 positive and negative cable
punctured.
2.Checked the cable IR values of both
SCB positive and negative cables after
removing punctured portion
3.Found both cables IR values are
satisfactory.
4. Then cable Jointing done.
5.After jointing IR values are taken and
found ok and connected to inverter.
6. SCB 8 & 17 taken into full load
7.Aside, OFC cable splicing done and
ICR 4 communication restored.

Photograph evidences:

Major Root Cause Analysis Identified : Moisture ingression into cable insulation layer due to pin holes or improper DC trenching aswell cable undergrounded irrespective of polarity and size.

Highlights : Kaizen / Any Change or major modification suggested / Manufacturer comments if any: - Need to provide separate route and trench for cables with respective size, polarity as well as for MCS pipe line

F] Corrective action & preventive action taken to avoid re-occurrence

1. DC cables are undergrounded irrespective of polarity and size of cable , it must be corrected
2. On DC cable maximum MCS pipe line routed which will increases chances of moisture ingression in cable if any leakage happend in MCS pipe so it has to re route.
3.300 Sq.mm Cable is undergrounded just 1 to 1.5 Feet from gound levelnear to SCB due to which fire easily catches feild area during puncture and effect of puncture (blast) made module and other asset damage so need to review depth and trench quality.

Prepared by: Checked by: Authorised by:

Name: D Siva Prakash Reddy Name: Name: A. Surendra kumar
Sign: Sign: Sign:
Date: 9-Sep-23 30.06.23 9-Sep-23

1 OF 3
 ANNEXURE-1: WHY WHY ANALYSIS
SCB outgoing DC cable 300 Sqmm failure

Bunch of cables irrespective of

Pin holes during errection Quality issue Improper Bedding Moisture ingress
cable size in same trench

No proper spacing between

Ingress of moisture and water Manufacturing defect Poor workmanship during installation No proper heat disipation
cables and overlapped

No proper spacing between

Cracks / damage of outer sheath All cables are in bunch
cables and overlapped
Electrical stress
All cables are in bunch

Corrective action & preventive action taken to avoid re-occurrence

CA; PA: 1. cables are
CA;
1. For newly laid portion, cable to cable minimum undergrounded irrespective of
1) IR value must be taken, record to be
gap to be maintained for heat dissipation polarity and size of cable , it
maintained for all DC cables ( Inverter
must be corrected
to SCB )
2. Adequate area for loop cable
2) Low IR value cable need to be
to be provide
rectified.

PA:Cable routing to be checked for nay

anomalies and must be re route as per
requirement
 ANNEXURE-2: Action plan tracking sheet
Sr no CA / PA Description Responsibility Target time line Remarks
IR value must be taken, record to be maintained for all DC cables ( Inverter to SCB ) during
1 CA O&M 30-09-2023
immediate PM
2 CA Low IR value cable need to be rectified. Client
4 PA To provide effective & periodical training sessions for awareness covering the risk assessment during cable
Client
laying activity inOn
future
going
5 CA For newly laid portion, cable to cable minimum gap to be maintained for heat dissipation O&M On going
6
8
9
10
11
12
13
14