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AWP-03 Breakdown Analysis

1. The AWP-03 motor experienced a burnt terminal block (TB) and damaged softstarter SCR, likely due to loose connections causing overheating and sparking of the R and Y phases. 2. No earth fault protection was provided for the softstarter or outgoing feeder, resulting in the PMCC IC-B tripping on a ground fault. 3. Recommendations include using lock nuts or bimetallic washers to prevent loose connections from vibration, adding proper fusing for softstarter protection, and employing earth fault protection.

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vitthal01
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94 views

AWP-03 Breakdown Analysis

1. The AWP-03 motor experienced a burnt terminal block (TB) and damaged softstarter SCR, likely due to loose connections causing overheating and sparking of the R and Y phases. 2. No earth fault protection was provided for the softstarter or outgoing feeder, resulting in the PMCC IC-B tripping on a ground fault. 3. Recommendations include using lock nuts or bimetallic washers to prevent loose connections from vibration, adding proper fusing for softstarter protection, and employing earth fault protection.

Uploaded by

vitthal01
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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AWP-03 Breakdown Analysis.

Dt.12/05/2021

Problem-
1. AWP-03 Motor TB Burnt.
2. Softstarter SCR damaged.
3. PMCC IC-B tripped on Earth Fault.

History-
1. Last motor PM done on 06/03/2021.
2. During motor PM R- phase found overheated. TB stud tightness and HT/PVC tapping done.

Nameplate Details-
Motor- Allen-Bradley Overload-
132 KW, 225A FLC, 1490 RPM Setting-187.50A
Allen Bradley Soft starter- Soft starter Settings- Incomer Breaker Details- Outgoing Breaker details-
150-F251NBD Overload class-10 L&T C-Power ACB L&T C-Power ACB
3-phase Service Factor-1.15 4000A, 50Ka 630A, 50kA
Line voltage- 200-480 AC Start mode- Soft
Control voltage- 100-240V AC Stop mode- Coast Protection Settings- Protection Settings-
Maximum continuous current- Ramp time-10 sec Long term- 1*In @2.5sec Long term- 1*In @2.5sec
251A Starting Torque- 70% LRT Short circuit- 6*In @125ms Short circuit- 6*In @100ms
Trip rating is 117% of FLA. Ground fault- 0.3*In @100ms
Aux. Contact ratings-
Max. Volts 240V AC
Make-3600
Break-360
Line controller
400V, 132KW

Running Schedule-
Motor runs continuously for 24hrs. with an interval of 48hrs.

Observations-
1. R&Y phase of Motor internal leads found burnt and power cable found overheated.
2. R&Y phases loose connection found.
3. Softstarter SCR found shorted.
4. No ground fault protection in outgoing feeder for Motor soft starter.
5. Link is used instead of 315A HRC Fuse.
6. No external sensor (CBCT) found in Softstarter for Ground Fault protection.

Analysis-
1. Overheating of R&Y phases due to loose contacts.
2. Loose contacts may be due to cable tension and vibration.
3. Sparking produced due to loose contacts and high starting current.
4. After sparking it may behave as ph-ph and ph-G fault.
5. Due to high fault current SCR is damaged as no fuse is there and high short circuit current Settings of CBs.
6. PMCC I/C-B tripped on Earth Fault (1200A, 100ms) as no Earth Fault protection available on soft starter and outgoing Breaker.
7. Not in short circuit as Settings
I/C CB- 24KA, 125ms
O/G CB- 3.78KA, 100ms

Recommendations-
1. Spring washer/Lock nut/bimetallic washer should be used to avoid loose connection due to vibration.
2. Proper rating of Fuse/MCCB should be used for protection of Softstarter.
3. Earth Fault protection should be employed.
4. Frequency of PM should be increased.

Concerns-
1. No Earth Fault protection provided in Softstarter.
2. PMCC Incomer tripping will result in tripping of Belt conveyor and screen.
3. No starting current limit Settings available in Softstarter during soft starting.
MOTOR NAMEPLATE ALLEN-BRADLEY SOFTSTARTER NAMEPLATE

PMCC INCOMER ACB PMCC OUTGOING ACB

OVERLOAD RELAY
PMCC INCOMER ACB SR-18G RELAY CT RATIO 250/5A PMCC OUTGOING ACB SR-18 RELAY

BURNT MOTOR TB BURNT MOTOR LEADS BURNT MOTOR TB & LINK

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