Root Cause Failure Analysis
Trydanol Energy Solutions experience systematically identifies underlying issues
Main equipment failure can have a significant impact on facility safety, reliability and operability, bring additional external scrutiny on operations and ultimately impacts the bottom line of revenue. Failure investigation can be an additional drain on resource and disruptive to ongoing operations but is important in understanding the underlying issues, mitigating residual risk and codifying learning in the organisation.
Technical issues as well human factors can be significant contributors to the loss event. Awareness and understanding of design requirements, technology readiness, installation aspects and operational needs are also key to ultimately identify the underlying cause.
Having the right experience and breadth of knowledge and ability to draw analogy to previous similar events to hand at an early stage of an investigation is key to resolving often complex issues in a timely manner. Trydanol has both led and supported many incident investigation covering both electrical discipline specific problems to more complex and multi-faceted issues involving both internal and external parties. These investigations have highlighted many issues but ultimately have delivered improved safety, deep learning and enduring outcomes for organisations.
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Alternator
Context
- Rotor pole bolt sheared on run-up
- Stator core destroyed
Cause
- Manufacture process deficient
- Serial #1 60Hz designRemedial Action
- Stator replaced
- Fleet wide inspection
- Future orders suspended -
UPS
Context
- Disruptive failure of inverter
- Facility wide blackout
Cause
- Construction debris initiator
- UPS shutdown logic inadequate
- Facility alarm handling deficient
Remedial Action
- Cleaning and critical card replacement
- Firmware updates -
Cable Gland
Context
- Overtightening of locknut
- Cold flow of jacket
- Deluge seal ineffective
Cause
- Installer competency
- Lack of manufacturers instruction
Remedial Action
- Site wide additional inspection
- Update of manufacturers literature
- Additional training for constructor
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HV Termination
Context
- Construction defect
- Basic insulation level clearances not maintained
Cause
- Constructor resource limited
- Terminations by non-skilled personnel
Remedial Action
- Site wide replacement of terminations -
Protection
Context
- Motor shunt capacitor sparking fault
- Upstream protection trip
- Site wide production disruption
Cause
- Motor protection inadequate
- Protection philosophy lacked definition
Remedial Action
- Faulty capacitors replaced
- Settings reviewed and modified -
Busbar Fire
Context
- Busbar field joint overheated
- In-service failure after many months
- Facility shutdown
Cause
- Excessive torque to fishplate bolts
- Bolt yield point breached
- Thermal cycling on load
Remedial Action
- Busbar partial replacement
- Site wide inspection