PT.
INTERNATIONAL NICKEL INDONESIA
Plant Engineering Group
Plant Maintenance Department (Dp.02)
BREAKDOWN REPORT
Subject Gear of F#1 Diverter Switch Failure
Date 10 July 2007
Reported by Rustam Saleh
Distribution M. Rifai, Handrijono, An Sudarno, Sutomo, Iqbal Al Farobi, Safri, Andrie
Kurniawan, Saleh
1. EQUIPMENT
List all equipment that experience breakdown problem. Specify the working area, equipment number, part
number, serial number, line number, etc. Descript the day/date/time of occurrence.
Equipment : Gear of Tap Counter of F#1 Diverter Switch assembled in the
Diverter Switch Compartment
Date of Report : 10 July 2007
2. ACTIVITIES
Ensure the chronologies of breakdown problem completely and write down the sequence when the
problem occurred. State the day, date, time and explain briefly.
No Date Time Description Who
1 10 July 8:30 It was reported by PM that the tap indicating plate stuck in Sutomo (PM)
07 between tap 25 and 26. PM suspected that the diverter
switch shaft snapped.
On the tap panel indicated tap 1 as well as on MMI
screen.
2. 10 July 9:00 Inspected the diverter switch, asked PM to turn to tap 2 Rustam
07 and it was successfully done. Tap panel indicated 2 and (PPE)
MMI screen as well. The off-load tap changer also moved Jahir (PM)
to tap 2 positions.
3. 10:15 Dismantling the diverter switch and checked the problem PM and PPE
inside. It was founded 2 teeth of Cam Wheel came out
and stuck in between cam wheel and Cogwheel. These
cam wheel teeth jeopardized the cogwheel.
The impact of this incident, Cogwheel stuck and damage
and also cam wheel teeth were not in position to drive the
counter.
3. FINDINGS AND ACTION TO BE TAKEN
List all the findings related to the problem/break down. Write down every anomalies/deviation that have
been occurred. Also include all information from mtce personnel and operation crew. If finding related to
some drawings or photos/pict then specify/indicate the photos or drg number.
1. Findings
• When opening the diverter switch, it was founded 2 cam wheel teeth of cam wheel
dropped down and stuck in between cogwheel and cam wheel.
• Cogwheel stuck and damage.
• No other parts broken so that this case may not influence the Transformer
performance or this is related to the ops report few days ago that power fluctuation of
F#1 was quite a bit strange compare to the other Furnace.
• Few months ago, F#1 Diverter Switch Shaft snapped off and We are up to now still
confused to determine the root cause of that incident. I am thinking about this whom
may have relationship.
2. Action to be taken
• Replaced the cam wheel and cogwheel with genuine spare parts we have.
• Adjusting and testing the tap movement after repair.
• Did ratio test where the result as follows:
RATIO TEST F#1 DETC 1 (Y connection)
TAP A-B A-N B-C B-N C-A C-N
1 326 118 331 255 342 219
2 357 123 387 299 375 237
3 399 144 398 322 408 264
4 423 153 420 340 438 284
5 477 168 470 364 477 315 Ratio tap 1 = 87
6 486 183 537 399 526 334 Ratio by calculation = 96
7 530 190 526 410 536 350
8 572 206 566 432 567 371
9 605 213 602 457 610 407
10 630 233 637 480 627 417
RATIO TEST F#2 DETC 2 (Delta connection)
TAP A-B A-N B-C B-N C-A C-N
1 591 225 585 447 586 390
2 632 244 647 487 649 414
3 708 271 723 527 713 430
4 742 290 746 553 739 489
5 806 325 803 624 805 529 Ratio tap 5 = 41.91
6 831 341 841 645 846 554 Ratio by calculation = 33000/806 = 40
7 930 372 925 692 896 592
8 977 379 990 709 984 639
9 1036 405 1050 743 1011 657
10 1108 441 1107 779 1109 701
Note:
Voltage input 33000 Volt
Current flow was kept 0 Amps
Result is OK
4. PRE-LIMINARY ANALYSIS
Collecting the data and analyze why the problem come. Write down every possibility and may refer to
standard/manual book/mtce procedure/operation procedure. Other resources comments (if any) should
include such as specialist, engineering, vendor or OEM, etc. All correspondents shall be included.
1. We have not been sure why the two cam wheel teeth came out but because of these
there was nothing to drive the cogwheel to rotate the indicating plate near the
compartment cover.
2. We suspected there is relationship between this incident and last incident few
months ago where the shaft snapped.
3. We suspected that cam wheel teeth dropped down because of poor material. This
conclusion is made because I involved when the tap changer installed during
transformer refurbishment and nothing wrong with this at the time. It is better to
confirm to vendor the possible root cause.
4. This incident may influence the tap changer performance to increase and decrease
the secondary voltage. This is the reason why the power fluctuation of F#1 was bad
lately.
5. After repair, ratio test indicates that ops can operate the transformer safely
5. RECOMMENDATION
Specify what required action must be performed to avoid any repetitive problem. Mtce or operation
procedure shall be studied to provide a better action to be done. Redesign/modification of equipment may
be required or other precious suggestion.
No. Action Required Who When
1 Purchase new spares to prevent similar case occur April Paulus Soon
2. Confirm to MR and discuss the possible root cause and find the Rustam Soon
best solution to avoid repetitive problem
3. Check performance of the diverter switch for 2 weeks after Sutomo From now
recovery just to ensure what we have done work well
6. ATTACHMENT
Fig. 1 condition after lifting up diverter switch
Damaging wheel
Fig. 2 Wrecked out wheel
These teeth came out from their original position
Fig. 3 Broken Wheel and Good Wheel
