Equipment

Sn. Sub-Equipments
System
R
 MAIN AIR COMPRESSOR

11KV MAIN AIR

COMPRESSOR
1
OUTGOING HT
BREAKER
MAI
 AIN AIR COMPRESSOR

MAIN AIR
COMPRESSOR FCMA
2
SOFT STARTER
PANEL
MAIN AI
SOR
 MAIN AIR COMPRESSOR
MAIN AIR
3 COMPRESSOR
MOTOR
 COMPRESS
MAIN AIR
DISTRIBUTED
OR
4
CONTROL SYSTEM
Component/
Primary & Secondary Function
Sub-Process

Busbars typically housed inside

switchgear / panel boards for local high
current power distribution. They are
used to connect high voltage equipment
at electrical switchyards, and low
voltage equipments. They are generally
HT PANEL uninsulated, and have sufficient
BUSBARS stiffness to be supported in air by
insulated pillars. These features allow
the ability to tap in at various points
without creating a new joint. There
should be proper insulation between
busbar and switchgear panel through
busbar insualtor.
 the ability to tap in at various points
without creating a new joint. There
should be proper insulation between
busbar and switchgear panel through
busbar insualtor.

Earth Switch is designed to ground

electrical circuit on both side of AC Vacuum
HT PANEL Circuit Breaker when the AC Vacuum
EARTH SWITCH Circuit Breaker is open. This ensures the
safety of the maintenance personnel during
maintenance and routine checking.

HT Panel Space Heaters are designed to

HT PANEL SPACE
maintain temperature and minimize
HEATER
moisture inside electrical panel.
 HT Panel Horizontal and Vertical Insulators
HT PANEL
are for their high electrical & mechanical
BUSBAR
strength used in electrical panels to support
HORIZONTAL
the copper busbar. They do not allow
AND VERTICAL
current to flow freely from conductor
INSULATOR
(busbar) to body of the panel.
 To feed uninterrupted power to Main Air
HT BREAKER
Compressor Motor

To detect the fault and initiates the

HT NUMERICAL
operation of circuit breaker to isolate the
PROTECTIVE
defective element from the rest of the
RELAY
system.

Allows the electric power transmission at

high voltage. Cable to be fixed with Breaker
Terminals properly insulated, clamped and
sealed connector to provide greater
HT CABLES
protecton from short circuiting of cables.
Cable joints and terminals must be designed
to control the high-voltage stress to prevent
breakdown of the insulation.
 Terminals properly insulated, clamped and
sealed connector to provide greater
HT CABLES
protecton from short circuiting of cables.
Cable joints and terminals must be designed
to control the high-voltage stress to prevent
breakdown of the insulation.

CT used to reduce the current to lower

values and to provide isolation between
high current and the relays and the other
CURRENT
instruments that are connected to their
TRANSFORMER
secondaries. CT is used to measure current
and also used for protective purposes as
input to relays in a power system

PT used to reduce the voltage to lower

values and to provide isolation between
high voltage power network and the relays
POTENTIAL and the other instruments that are connected
TRANSFORMER to their secondaries. PT is used to measure
voltage in high voltage circuits. Also, it is
used for protective purposes as input to
relays in a power system

Busbars typically housed inside

switchgear / panel boards for local high
 Busbars typically housed inside
switchgear / panel boards for local high
current power distribution. They are
used to connect high voltage equipment
at electrical switchyards, and low
voltage equipments. They are generally
HT PANEL uninsulated, and have sufficient
BUSBARS stiffness to be supported in air by
insulated pillars. These features allow
the ability to tap in at various points
without creating a new joint. There
should be proper insulation between
busbar and switchgear panel through
busbar insualtor.

HT Panel Horizontal and Vertical Insulators

HT PANEL
are for their high electrical & mechanical
BUSBAR
strength used in electrical panels to support
HORIZONTAL
the copper busbar. They do not allow
AND VERTICAL
current to flow freely from conductor
INSULATOR
(busbar) to body of the panel.
 BUSBAR
strength used in electrical panels to support
HORIZONTAL
the copper busbar. They do not allow
AND VERTICAL
current to flow freely from conductor
INSULATOR
(busbar) to body of the panel.

HT VACUUM
To ensure MAC Motor is ready to start
ISOLATION
when Isolation contactor come into effect.
CONTACTOR

HT FCMA To soft start the motor by limiting the

SOFTSTARTER starting current.
 HT FCMA To soft start the motor by limiting the
SOFTSTARTER starting current.

HT VACUUM
To feed uninterrupted power to MAC Motor
BYPASS
after bypassing HT Softstarter
CONTACTOR

To detect the fault and initiates the

HT NUMERICAL
operation of circuit breaker to isolate the
PROTECTIVE
defective element from the rest of the
RELAY
system.

Allows the electric power transmission at

high voltage. Cable to be fixed with Breaker
Terminals properly insulated, clamped and
sealed connector to provide greater
HT CABLES
protecton from short circuiting of cables.
Cable joints and terminals must be designed
to control the high-voltage stress to prevent
 Terminals properly insulated, clamped and
sealed connector to provide greater
HT CABLES
protecton from short circuiting of cables.
Cable joints and terminals must be designed
to control the high-voltage stress to prevent
breakdown of the insulation.

CT used to reduce the current to lower

values and to provide isolation between
high current and the relays and the other
CURRENT
instruments that are connected to their
TRANSFORMER
secondaries. CT is used to measure current
and also used for protective purposes as
input to relays in a power system
PT used to reduce the voltage to lower
values and to provide isolation between
high voltage power network and the relays
POTENTIAL and the other instruments that are connected
TRANSFORMER to their secondaries. PT is used to measure
voltage in high voltage circuits. Also, it is
used for protective purposes as input to
relays in a power system

To form magnetic field when energized

HT MOTOR with current to produce torque. Check
WINDINGS for winding resistance and megger value
of Motor.
 HT MOTOR
To provide support and guide the Rotor.
BEARINGS

For rotation of mechanical drive due to

HT MOTOR the interaction between the windings
ROTOR and magnetic fields which produces a
torque around the rotor's axis.

Allows the electric power transmission

at high voltage. Cable to be fixed with
Motor Terminals properly insulated,
clamped and sealed connector to
HT MOTOR provide greater protecton from short
POWER CABLE circuiting of cables.
Cable joints and terminals must be
designed to control the high-voltage
stress to prevent breakdown of the
insulation.
 insulation.

They are used for control logic for

DI / DO / AI / AO
starting, stopping and interlocking of
DCS CARD
Motor.
 FAILUR
FMEA Number
FMEA Date 08.10.2018
FMEA Revision Revision 1
Revision Date

Potential S
Functional Potential
Failure E
Failure Failure Mode
Effects V

6
Incomer of
Incomer HT
BUS will not feed Main Air
Breaker is 6
power to Main Air Compressor
continuously
Compressor Motor Motor will not
tripping
get charged
6
 6

HT Breaker will HT Breaker will

HT Breaker will not not come to not get charged
be closed to feed service position and can not be 5
power to the system if earth switch taken into
fails. service.

Moisture gets 1
Space Heater is not Space Heater accumulated
working terminal open inside the HT
Panel
1
 6

Incomer HT 6
Direct conduction of
Breaker is BUS will not
busbar and panel
continuously get charged
body
tripping 6

6
 4

No power supply to 4
the Main Air Incoming
BUS will not
Compressor Motor breaker not 4
get charged
OUTGOING HT getting closed
BREAKER 4

4
4

4
No tripping or
HT Numerical relay BUS will not
False tripping of
damaged. get charged
HT Breaker
4
4
7

7
Panel cannot be
taken into
Will not be able to
service. 7
feed power to Main
Flashover at
Air Compressor
panel Burning of
Motor OUTGOING
cables, CT, PT,
HT BREAKER
panel
insulators.
 service.
feed power to Main
Flashover at
Air Compressor
panel Burning of
Motor OUTGOING
cables, CT, PT,
HT BREAKER
panel
insulators. 7

Will not be able to 5

Panel incomer
feed power to Main Current
breaker /
Air Compressor transformer
outgoing
Motor OUTGOING failure
breaker trip
HT BREAKER

Will not be able to

Panel incomer
feed power to Main Potential
breaker /
Air Compressor transformer 5
outgoing
Motor OUTGOING failure
breaker trip
HT BREAKER

6
 6

6
BUS will not feed HT Breaker is
Motor will not 6
power to Main Air continuously
run
Compressor Motor tripping
6

6
Incomer HT
Direct conduction of
Breaker is Motor will not
busbar and panel 6
continuously run
body
tripping
Direct conduction of
Breaker is Motor will not
busbar and panel
continuously run
body
tripping
6

MAC outgoing 5
MAC Motor is not Motor will not
Breaker not
ready to start run
getting closed
5

5
5

Motor will not

get required Motor will not 8
No power supply to
balanced run or motor
the motor
voltage or single winding burn.
phasing.
 get required Motor will not
No power supply to
balanced run or motor
the motor
voltage or single winding burn.
phasing.
8

8
8
8

Breaker will 5
No power supply to Motor will not
continuously
the motor run
trip
5

5
5

4
No tripping or
HT Numerical relay BUS will not
False tripping of
damaged. get charged
HT Breaker 4
4
8
8
Panel cannot be
taken into
service. 8
BUS will not feed
Flashover at
power to Main Air
panel Burning of
Compressor Motor
cables, CT, PT,
panel
 service.
BUS will not feed
Flashover at
power to Main Air
panel Burning of
Compressor Motor
cables, CT, PT,
panel 8
insulators.

8
Panel incomer 5
BUS will not feed Current
breaker /
power to Main Air transformer 5
outgoing
Compressor Motor failure
breaker trip 5

Panel incomer
BUS will not feed Potential
breaker /
power to Main Air transformer 5
outgoing
Compressor Motor failure
breaker trip

6
Motor will not drive Motor windings Motor will not
the compressor burnt run
6

6
 6

6
Motor Bearings
Motor will not drive Motor will not
seized or 6
the compressor run
damaged

5
Motor will not drive Rotor Motor will not 5
the compressor unbalance run
5

Motor will not 8

get required Motor will not
No power supply to
balanced run or motor
the motor
voltage or single winding burn.
phasing.

8
 8
5
5
Motor Control
Motor will not drive Motor will not
Circuit Logic 5
the compressor run
problem
5
FAILURE MODE AND EFFECTS ANALYSIS for <> MAIN AIR

Core Team

O D R
Current
Potential Causes C E P
Controls
C T N

Failures of Bolted Joints

on Bus-bars
1 6 36

Failures due to moisture

content in the Breaker 1 6 36
BUS cabinet

Failure due to
Inadequate Bolt Size
1 6 36

Bolted Joint Failures

due to High 1 6 36
Temperature

Inspection in
Fractures of Bus-bars 1 Annual 6 36
maintenance
Bus-bar Failures in
Transformers due to 1 6 36
Sharp Bends
Bus-bar Failures due to
Vibration
1 6 36

Bus-bar Failures due to

Thermal Stresses and 1 6 36
Fatigue

Failure of Support
Insulators
1 6 36

Short-Circuits between
Bus-bars
1 6 36

Inspection in
Earth Switch
1 Annual 6 30
mechanism failure
maintenance

Loose contact of the

1 Inspection in 6 6
terminal connections
Annual
maintenance
Space heater cable
1 6 6
open or short
Failures of Bolted Joints
on Bus-bars and 1 6 36
Insulators

Failures due to moisture

content in the Breaker 1 6 36
BUS cabinet

Failure due to
Inadequate Bolt Size
1 6 36
Inspection in
Annual
Bolted Joint Failures maintenance
due to High 1 6 36
Temperature

Fractures of Insulators 1 6 36

Insulator Failures due to

Vibration
1 6 36

Insulator Failures due to

Thermal Stresses and 1 6 36
Fatigue

Short-Circuits between
Bus-bars
1 6 36
Breaker mechanism
1 6 24
failure

Breaker pole insulator

1 6 24
failure
Inspection in
Breaker pole failure
1 Annual 6 24
or jamming
maintenance
Breaker closing coil
1 6 24
failure
Closing circuit
1 6 24
problem
No control supply 1 6 24

Loose contact of the

1 6 24
terminal connections Inspection in
Annual
Short-Circuits at maintenance
1 6 24
terminal
Ageing 1 6 24
Insulator failure 1 6 42

Moisture ingress 1 6 42

Entry of foreign Inspection in

object through Annual
1 6 42
unattended panel maintenance
openings during TAN-
DELTA test of
HT Cable
 Annual
maintenance
during TAN-
DELTA test of
Localised heating at HT Cable
busbar/ cable joints
1 6 42
due to losse
connection
Overloading 1 6 42

Due to overloading 1 6 30
Inspection in
Annual
maintenance

Loose connection at
1 6 30
termination
CT saturation 1 6 30

Inspection in
Loose connection at
1 Annual 6 30
termination
maintenance

Failures of Bolted Joints

on Bus-bars
1 6 36
Failures due to moisture
content in the Breaker 1 6 36
BUS cabinet

Failure due to
Inadequate Bolt Size
1 6 36
Bolted Joint Failures
due to High 1 6 36
Temperature
Inspection in
Fractures of Bus-bars 1 6 36
Annual
Bus-bar Failures in maintenance
Transformers due to 1 6 36
Sharp Bends
Bus-bar Failures due to
Vibration
1 6 36
Bus-bar Failures due to
Thermal Stresses and 1 6 36
Fatigue
Failure of Support
Insulators
1 6 36
Short-Circuits between
Bus-bars
1 6 36
Failures of Bolted Joints
on Bus-bars and 1 6 36
Insulators

Failures due to moisture

content in the Breaker 1 6 36
BUS cabinet

Failure due to
Inadequate Bolt Size
1 6 36
Bolted Joint Failures Inspection in
due to High 1 Annual 6 36
Temperature maintenance
 Inspection in
Annual
maintenance
Fractures of Insulators 1 6 36
Insulator Failures due to
Vibration
1 6 36
Insulator Failures due to
Thermal Stresses and 1 6 36
Fatigue
Short-Circuits between
Bus-bars
1 6 36
Failure of movable
1 6 30
contacts
Failure of Fixed
1 6 30
Contacts
Loose connection at Inspection in
1 6 30
termination Annual
maintenance
Contactor Coil Failure 1 6 30

Rupture of Vacuum
1 6 30
Bottles
No control supply 1 6 30

Winding Insulation
1 6 48
failure of Softstarter

Operating at high
1 6 48
ambient temperature

Overcurrent of motor Inspection in

1 6 48
during starting Annual
maintenance
 Inspection in
Annual
maintenance
High Starting Current
due to capacitor 1 6 48
damage
Short circuiting of
1 6 48
motor cable
No control supply 1 6 48
Short circuiting of
1 6 48
motor terminals
Failure of movable
1 6 30
contacts
Failure of Fixed
1 6 30
Contacts
Loose connection at Inspection in
1 6 30
termination Annual
maintenance
Contactor Coil Failure 1 6 30

Rupture of Vacuum
1 6 30
Bottles
No control supply 1 6 30

Loose contact of the

1 6 24
terminal connections Inspection in
Annual
Short-Circuits at maintenance
1 6 24
terminal
Ageing 1 6 24
Insulator failure 1 6 48
Moisture ingress 1 6 48
Entry of foreign
object through Inspection in
1 Annual 6 48
unattended panel
openings maintenance
during TAN-
DELTA test of
HT Cable
 Annual
maintenance
during TAN-
Localised heating at DELTA test of
busbar/ cable joints HT Cable
1 6 48
due to losse
connection
Overloading 1 6 48
Due to overloading 1 6 30
Inspection in
Loose connection at
1 Annual 6 30
termination
maintenance
CT saturation 1 6 30

Inspection in
Loose connection at
1 Annual 6 30
termination
maintenance

Motor Terminal Short

circuit
1 6 36
Winding Insulation
failure
1 6 36

Winding resistance
1 6 36
unbalance Inspection in
Annual
Overloading of the maintenance
Compressor
1 6 36

Motor power cable short

circuit
1 6 36

Failure of Terminal
Support Insulators
1 6 36
Contamination of Oil 1 6 36

Misalignment 1 6 36
Inspection in
Improper oil pressure Annual
inside bearing housing
1 6 36
maintenance

Improper circulation of
oil inside bearing 1 6 36
housing

Improper handling. 1 6 30
Inspection in
Alignment issue 1 Annual 6 30
maintenance
Fitment issue 1 6 30

Insulator failure 1 6 48

Moisture ingress 1 6 48

Entry of foreign
object through
1 6 48
unattended panel Inspection in
openings Annual
maintenance
Localised heating at
busbar/ cable joints
1 6 48
due to losse
connection
Overloading 1 6 48
I/O Card failure 1 6 30
No control supply 1 6 30
Inspection in
Hanging of control cards 1 Annual 6 30
maintenance
Loose connections at
cards and TBs.
1 6 30
r <> MAIN AIR COMPRESSOR

ANAND GHADIGAONKAR, AMIT GAWALI, RAJEND

Actions Recommended Execution

NKAR, AMIT GAWALI, RAJENDRA ULGEKAR, VIPUL SINGH

Finalise
Resp. Target Date Status
d
L SINGH

Revised
Rating
S O D R
Actions Taken E C E P Remarks
V C T N
 Severity Scale
Marks Production Cost Safety
1 No production loss Cost of Maint. Minor No safety concern
2 SD <30 min Cost of Maint. Minor No safety concern
3 Shut Down 30 min to 1 hr Cost of Maint. Low No safety concern
4 Shut Down 1 hr to 2 hrs Cost of Maint. Low No safety concern
5 Shut Down 2hrs to 4 hrs Cost of Maint. Medium No safety concern
6 Shut Down 4hrs to 6 hrs Cost of Maint. Medium May cause FAI
7 Shut Down 6hrs to 10 hrs Cost of Maint. Medium May cause LTI
8 Shut Down 10 hrs to 16 hrs Cost of Maint is Very High May cause MTI
9 Shut Down 16hrs to 20 hrs Cost of Maint is Very High May cause MTI
10 Shut Down 20 hrs and Above Cost of Maint is Very High May cause fatality

Occurrence Scale
Marks Frequency
1 2 years and above
2 Once in 2 years
3 Yearly
4 Half Yearly
5 Quarterly
6 Monthly
7 Fortnightly
8 Weekly
9 Daily
10 Every Shif

Detection Scale
Marks Detection Time
1 Detected Immidietly Afer failure(PLC)
2 Detect in shif check list
3 Detect in daily check list
4 detect in weekly check list
5 detect in monthly check list
6 Detect in annual checklist
7 Detect in planned shutdown
8 Hard to detect
9 External support is required for detection
10 Detection time is very high