A REPORT

ON
REDUCTION OF THE FAILURE RATE IN
VARIABLE FREQUENCY DRIVES

BY
SUBHRATAVA MANDAL – 2017A3PS0415G

Prepared in partial fulfilment of the

Practice School-I, Course No,
BITS F221
AT
GRASIM INDUSTRIES, NAGDA
A Practice School- I station of
BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE, PILANI
June, 2019

BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE

 PILANI (GOA)
Practice School Division

Station: Grasim Industries, Nagda

Duration: From: May 21, 2019 To: July 13, 2019
Title of the Project: Reduction of failure rates in VFDs

ID No. Name of the Student-

SUBHRATAVA MANDAL – 2017A3PS0415G

Name of expert: Mrs. Maya Yadav

Designation:
Name of the PS Faculty: Prof Kamlesh Tiwari

ACKNOWLEDGEMENT:
I would like to extend my heartfelt gratitude to the mentor, Mrs Maya Yadav of Grasim
Industries, under whose support and capable guidance this
report was made possible.
I would also like to thank Mr Rakshit Daga whose knowledge and suggestions
were instrumental in providing a structure to the entire project.
I would like to express my heartfelt gratitude to Dr Kamlesh Tiwari for his guidance
regarding the structure of the project.
I would like to thank each and every person who has been involved in the successful
compilation and presentation of this report.

ABSTRACT
Grasim Industries is India’s leading manufacture of Viscose Staple Fibre(VSF). With
a revenue of over 56,000 crores they need to maintain a certain amount of quality.
Variable Frequency Drives or VFDs A Variable Frequency Drive (VFD) is a type of
motor controller that drives an electric motor by varying the frequency and voltage
supplied to the electric motor. Most processes at the plant are continuous and any
break in the middle will cause the entire batch to go to waste. VFDs are used in the
plant to provide accuracy in changing the speed of the motors as well as reduce
mechanical losses. Thus, any failure or fault in the VFD will cause the machine to halt
all operations and thus create a standstill in the process. There are over 1000 VFDs
used all over the plant for various machines. Therefore, minimizing the rate of
failures in VFDs is of upmost importance to the plant.

Signature of Students: Signature of PS Faculty

Date: Date:
 Table of Contents
Acknowledgement
Abstract
1. Introduction
1.1. What is a VFD?
1.2. How does a VFD work?
1.3. Advantages of using a VFD
2. Main Text/ Data observations and tables
2.1. Reasons for failure
2.1.1. Build up
2.1.2. Excess heat
2.1.3. Moisture/ Condensation
2.1.4. Loose components and Component damage
2.1.5. Fan failure
2.2. Machine wise classification of VFDs in the plant
2.3. Analysis of problems
3. Results and Conclusion
4. Appendix (Data Tables)
5. References
Introduction:
Grasim Industries, Nagda is one of the leading manufactures of Viscose Staple Fibre(VSF).
Pulp and, CS2 and Caustic are the required inputs for manufacturing the fibre. The entire plant
is divided into different sections based on their processes. These include: Viscose section,
Spinning, Auxiliary and CS2 manufacturing. Each of these sections has their own set of
machines. VFDs are used to accurately control the speed of the different motors used
everywhere. There are over 1000 VFDs used here. Most of the above-mentioned processes are
continuous in nature. Any delay or break in the middle will cause a lot of wastage as the product
will have to be scrapped. Therefore, if and when a VFD fails the machine it controls also stops
working and this causes a lot of issues. To avoid unnecessary wastage and maintain product
quality, the maintenance of VFDs to reduce failure rate is of upmost importance.

We have collected data of all the VFD failures in the past two years and the possible reasons
for the same. We analysed the different patterns and found different causes and their possible
solutions. We further looked at the locations of all the VFDs in the plant and the precautions
that can be taken to avoid certain failures.

What is a VFD?
A Variable Frequency Drive (VFD) is a type of motor controller that drives an electrical
motor by varying the frequency and voltage provided to the electrical motor. Other names for
VFDs are variable speed drive, adjustable speed drive, adjustable frequency drive, AC drive,
Microdrive, and inverter. The Frequency (or hertz) of the current is directly proportional to
the motor’s speed (RPMs). In other words, the faster the frequency, the faster the RPMs. If an
application does not need the electrical motor to run at full speed, the VFD is used to ramp
down the frequency and voltage to fulfil the requirements of the electrical motor’s load. As
the application’s motor speed needs change, the VFD will merely increase or decrease the
motor speed to fulfil the speed demand.
VFDs are used in applications ranging from small appliances to large compressors. About
25% of the world's electrical energy is consumed by electric motors in industrial applications,
which can be more efficient when using VFDs in centrifugal load service however, the global
market penetration for all applications of VFDs is relatively small.

Over the last four decades, power electronics technology has reduced VFD price and size and
has improved performance through advances in semiconductor switching devices, drive
topologies, simulation and control techniques, and control hardware and software system.
VFDs are made in a number of different low- and medium-voltage AC-AC and DC-AC
topologies.
How does a Variable Frequency Drive work?
The first stage of a Variable Frequency AC Drive, or VFD, is that the convertor. The
convertor is comprised of six diodes, that are the same as check valves employed in plumbing
systems. They permit current to flow in one direction; the direction shown by the arrow
within the diode image. As an example, whenever A-phase voltage (voltage is analogous to
pressure in plumbing systems) is a lot of positive than B or C section voltages, then that diode
can open and permit current to flow. once B-phase becomes a lot of positive than A-phase,
then the B-phase diode can open and also the A-phase diode can shut. a similar is true for the
three diodes on the negative facet of the bus. Thus, we have a tendency to get six current
“pulses” as every diode opens and closes. this is often known as a “six-pulse VFD”, that is
that the commonplace configuration for current Variable Frequency Drives.
Let us assume that the drive is operating on a 480V power system. The 480V rating is “rms”
or root-mean-squared. The peaks on a 480V system are 679V. As you can see, the VFD dc
bus has a dc voltage with an AC ripple. The voltage runs between approximately 580V and
680V.

We can get eliminate the AC ripple on the DC bus by adding a capacitor.. A capacitor
operates in a similar fashion to a reservoir or accumulator in a plumbing system. This
capacitor absorbs the ac ripple and delivers a smooth dc voltage. The AC ripple on the DC
bus is often less then 3 Volts. Thus, the voltage on the DC bus becomes “approximately”
650VDC. The actual voltage will depend upon the voltage level of the AC line feeding the
drive, the extent of voltage unbalance on the power system, the motor load, the impedence of
the power system, and any reactors or harmonic filters on the drive.

The diode bridge converter that converts AC-to-DC, is typically simply mentioned as a
converter. The device that converts the dc back to ac is also a converter, however to tell apart
it from the diode converter, it's sometimes mentioned as AN “inverter”. it's become common
in the business to refer to any DC-to-AC converter as an inverter.
Note that in a real VFD, the switches shown would actually be transistors.

When we close one of the top switches in the inverter, that phase of the motor is connected to
the positive dc bus and the voltage on that phase becomes positive. When we close one of the
bottom switches in the converter, that phase is connected to the negative dc bus and becomes
negative. Thus, we can make any phase on the motor become positive or negative at will and
can thus generate any frequency that we want. So, we can make any phase be positive,
negative, or zero.

The blue sine-wave is shown for comparison purposes only. The drive does not generate this
sine wave.

Notice that the output from the VFD could be a “rectangular” waveform. VFD’s do not
produce a sinusoidal output. This rectangular wave would not be a good selection for a
general purpose distribution system, however, is absolutely adequate for a motor.

If we wish to scale back the motor frequency to 30Hz, then we need to merely switch the
inverter output transistors more slowly. But, if we cut back the frequency to 30Hz, then we
must conjointly cut back the voltage to 240V so as to keep up the V/Hz ratio. However are
we going to reduce the voltage if the sole voltage we have is 650VDC?

This is called Pulse Width Modulation or PWM. Imagine that we could control the pressure
in a water line by turning the valve on and off at a high rate of speed. While this would not be
practical for plumbing systems, it works very well for VFD’s. Notice that during the first half
cycle, the voltage is ON half the time and OFF half the time. Thus, the average voltage is half
of 480V or 240V. By pulsing the output, we can achieve any average voltage on the output of
the VFD.
See the Picture below to understand what the different parts of a drive look like.
Advantages of using a VFD
1. Reduce Energy Consumption and Energy Costs

If you have an application that does not need to be run at full speed,
then you can cut down energy costs by controlling the motor with a
variable frequency drive, which is one of the benefits of variable
frequency drives. VFDs allow you to match the speed of the motor-
driven equipment to the load requirement. There is no other method of
AC electric motor control that allows you to accomplish this.

Electric motor systems are responsible for more than 65% of the power
consumption in industry today. Optimizing motor control systems by
installing or upgrading to VFDs can reduce energy consumption in
your facility by as much as 70%.

2. Power Factor Improvement

3. Smooth Starting
As compared to using a starter where a sudden increase in the speed
gives a jerk to the motor. This can be smoothened by changing the
acceleration and deceleration times of the VFD.
4. Reduces power intake when not required
5. Easy reversal of motor
Motors are usually reversed by either changing the terminals or
reversing the input. But a VFD has an inbuilt function that does not
require any of this.
6. Controlled starting, stopping and acceleration
7. Short Circuit Protection
8. Overload Protection
9. Earth Leakage Protection
10. Phase loss Protection
11. High Starting Torque
12. Smooth acceleration and deceleration time
13. Increase Production Through Tighter Process Control

By operating your motors at the most efficient speed for your

application, fewer mistakes will occur, and thus, production levels will
increase, which earns your company higher revenues. On conveyors
and belts, you eliminate jerks on start-up allowing high throughput.

14. 14 - Extend Equipment Life and Reduce Maintenance

Your equipment will last longer and will have less downtime due to
maintenance when it’s controlled by VFDs ensuring optimal motor
application speed. Because of the VFDs optimal control of the motor’s
frequency and voltage, the VFD will offer better protection for your
motor from issues such as electro thermal overloads, phase protection,
under voltage, overvoltage, etc.. When you start a load with a VFD you
will not subject the motor or driven load to the “instant shock” of
across the line starting, but can start smoothly, thereby eliminating
belt, gear and bearing wear. It also is an excellent way to reduce and/or
eliminate water hammer since we can have smooth acceleration and
deceleration cycles.
Methodology:

Grasim Industries, Nagda has over 1000 VFDs used all over the plant. After analysing the
data we have found several possible reasons for failure and the precations that can be taken to
avoid the same. These are as follows:
Buildup –
Mainly this means “gunk” made up of dust combined with typical plant air which
usually contains oil, moisture, and metallic particles. This buildup is probably the
number one cause of VFD failure. And it’s not the actual dirt itself. It’s that the
dirt/VFD drive repairs dust buildup attracts moisture and prevents good airflow. This
results in excess heat, and the metallic particles can create stray current paths on your
circuit boards. A triple play by the bad guys! The result? At a minimum, you will get
diminished performance from your drive and at worst, catastrophic failure – bang!
Prevention tips:
Clean regularly – everything. And have a solid maintenance schedule so cleaning
doesn’t get overlooked. You can regularly spray air through the heat sink and fan, and
compressed air in the VFD. Avoid spraying contaminated plant air by using a dedicated
air supply that is non-static generating (you don’t want to add electro static discharge
problems.) Use the correct VFD for your plant environment. Some have side vents for
cooling airflow but these can be more prone to dust contamination. Others drives are in
a sealed, dust-free housing.

Excess Heat –
usually caused by buildup, as discussed above. But excess heat can also be caused
when the current exceeds the drives rated level and/or by loose connections. You can
check the connections visually but it may require a temperature probe or handheld
digital pyrometer. The connections should never be hotter than the connecting wires.
Also check the temps of the drive and at the motor. Overheating can result in blown
capacitors and other components. It can also cause shorts which may not be enough to
blow a fuse or trip an overload but just enough to shut down the controller and have
you wondering why production came to a stand-still.
Here’s how to prevent this problem:
Use a temperature probe to check on the connections, the drive and the motor to make
sure they meet the OEM’s requirements.
Maintain a clean, well ventilated environment
Regularly check the fans for any sign of bearing failure or foreign objects. This is
usually a noisy problem and easy to track down.
 Look for bulging or leaking capacitors. Having either of these means you should shut
down the drive immediately and get it repaired! The risk is an expensive cascade of
component damage.

Moisture/Condensation –
a common problem in many plants. Excess moisture can cause corrosion damaging the
circuit boards in your electronics. A VFD that operates 24/7 usually creates enough
heat from the heatsink to prevent internal condensation. If you run yours less often,
you will need to take steps to prevent condensation.
What can you do about this?
Dehumidifiers can help but make sure they are not dripping near electronic equipment.
There are many dehumidifier choices so get help making the best choice for your
environment.
If you operate a food processing facility you need to call in the experts on this subject.
Choose a VFD with a sealed housing if possible.
Regularly fire up any stored backup VFDs to make sure they are operating at peak
performance and store them in a clean, dry, protected area. Having a VFD down and no
decent backup will cost you in multiple ways.

Drive controller repairs Loose Connections/Component Damage –

if you are having erratic performance from your VFD, loose connections and bad/aging
components are likely causes. Vibration and heat cycles are typical causes of loose
connections which can then lead to dangerous arcing. Arcing at the output can damage
other components and cause over-current faults. What can you do?
As a part of your PM cycle regularly inspect the components looking for bulging or
leaking capacitors, date codes on the capacitors (caps need to be replaced after about 5-
10 years), damaged fans, problematic heat sinks, corrosion and/or damaged traces on
circuit boards.
Take voltage measurements preferably with the VFD in operation. The OEM will have
measurement guidelines for this. Voltage problems can indicate bad capacitors, a bad
diode bridge, and/or transistor leakage. You can check for voltage drop across the
connection if you are powered up or resistance through a connection if you are powered
down. Isolate the connection to get a reliable reading.
Do not just automatically “re-torque” screws as a way of checking the tightness which
can result in more harm than good. Check your manual as this often requires an infra-
red check with a digital pyrometer.
Do not exceed the operating limit. This means getting the proper training and/or
familiarizing yourself with the OEM’s recommendations.
 Do not connect the input power to the output motor terminals. This actually happens
and it can destroy the power module and possibly cause catastrophic damage. Not all
VFDs are set up the same way so check carefully.
Re-educate yourself if you buy a VFD from a different manufacturer than what you are
used to. Don’t assume the operation or maintenance is the same. The OEM’s
maintenance guidelines do vary.
Fan Failure:
There are 3 types of fan failures. One is the extrenal fan failure, the the inside Drive
card fan failure and thirdly the control card fan failure. The most common failure out
of there three is the first one i.e. the extrenal panel fan failure. This occures because of
the dust and fibre deposits on the fan. This majorly occurs in M/C 1,2,3 area because
the VFDs are placed near the fibre. The filtres need to be cleaned every 10-15 days
because of this.
Machine wise classification of VFDs
VFDs in an isolated room: PP
shaft, Cutter, AFT,Dryer

M/C-1

VFD in the open: Dosing

All VFDs in the room: PP

M/C-2 Shaft,Godet, Hexa, Cutter, AFT,
Dryer, Dosing

Room: PP Shaft, Cutter

M/C-3

Open: Dosing, Dryer

All in a room: PP Shaft, Godet,

M/C-4
Cutter, Hexa, AFT, Dryer

Room: PP Shaft, Godet, Quadra,

Cutter, Dryer
PC-1

M/C-5

Open: Dosing, Bath Circulation,

Nip Roller

Room: PP Shaft, Cutter, Dryer

M/C-6

Open: Dosing

Room: PP Shaft, Godet, Quadra,

Dryer

M/C-7

Open:Dosing, Nip Roller

Partially in an Aluminum
partition: PP Shaft, Godet, Penta,
M/C-10 Hexa, Cutter, Dosing, Dryer,
AFT
 Room: PP Shaft, Cutter

M/C-3

Open: Dosing, Dryer, Bath

Circulation

Room: PP Shaft, Cutter

PC-2

P/C-2

Open: Dryer, Dosing

All drives are on the machine

M/C-11 with a partially open Aluminium
partitiion

AREA CR HASH MOD TT

AUX1 5 9 14 28
AUX 2 7 9 27 43
AUX
VIS 1 85 48 53 186
CR- Control Room
VIS 2 57 37 25 119
VIS
HASH- VFDs are kept in
SPG 1 85 101 23 209
harsh conditions
SPG 2 10 49 37 96
MC 10 28 15 18 61 MOD- VFDs are stored in
MC 11 0 47 19 66 moderate conditions.
SPG
Genosorb 10 0 10 20 TT- Total VFDs
PC 3 0 0 50 50
PC3
TT 878
 No.
Make installed

ABB 850

AMTECH 16

DANFOSS 12

ALLENBRADELY 0

Total 878
Data Tables included in the appendix.
Analysis of the problems encountered and the solutions:
Problem: Probable causes:
Over Temperature 1.Fan failure
Obstructions in the air flow.
2. Dirt or dust coating on the
heat sink.
3. Excessive ambient
temperature.
4.Excessive motor load.
No Display Panel communication is lost
and either:
1. Drive is in local control
mode (the control panel
displays HAND or OFF)
2. Drive is in remote control
mode (AUTO) and is
parameterized to accept
start/stop, direction or
reference from the control
panel.
AI not working Analog Input less then Fault
Limit
Earth Fault 1.Possible ground fault
detected in the motor or
motor cables.
2.The drive monitors for
ground faults while the drive is
running and while the drive is
not running.
3.Detection is more sensitive
when the drive is not running
and can produce false
positives.
Over Current Output Current is excessive.
Solution:
Maintain the room
temperature using an air
conditioner.
Regular cleaning and
maintenance of the fan.
Communication lines and
connections.
1. Parameter 3002 PANEL
COMM ERR.
2. Parameters in Group 10:
START/STOP/DIR and Group
11: REFERENCE SELECT (if drive
operation is REM).
1.Check source and connection
for analog input.
2.Parameter settings for AI1
OR AI2 FAULT LIMIT and 3001
OR 3022 AI<MIN FUNCTION.
Check for/correct faults in the
input wiring.
1.Verify that motor cable does
not exceed maximum specified
length.
2.A delta grounded input
power supply and motor
cables with high capacitance
may result in erroneous error
reports during non-running
tests. To disable response to
fault monitoring when the
drive is not running, use
parameter 3023 WIRING
FAULT. To disable response to
all ground fault monitoring,
use parameter 3017 EARTH
FAULT.
Check for and correct:
• Excessive motor load.
• Insufficient acceleration time
 • Faulty motor, motor cables
or connections

Motor Overtemperature Motor is too hot, based on • Check for overloaded motor.
either the drive’s estimate or • Adjust the parameters used
on temperature feedback. for the estimate.
• Check the temperature
sensors and Group 35
parameters.
Voltage Unbalance Intermediate circuit DC voltage Check for and correct:
is excessive or not sufficient. • Static or transient over-
voltages in the input power
supply.
• Insufficient deceleration
time.
• Undersized brake chopper (if
present).
• Verify that overvoltage
controller is ON.
• Missing phase in the input
power supply.
• Blown fuse.
• Undervoltage on mains.
Line Converter Fault Fault in the motor circuit. One Mostly occurs due to internal
of the motor phases is lost. faults in IGBTs in the inverter
stage of the VFD. Check for
and correct:
• Motor fault.
• Motor cable fault.
• Thermal relay fault (if used).
• Internal fault
Auxiliary Fan Fault • Defective temperature One way to quick check the
switch, coolant sensor fan circuit is to start the engine
or other sensors and turn on the A/C to max. If
• Engine thermostat is the fan runs, the fan motor,
stuck OPEN (engine relay, fuse and wiring are all
never gets hot enough okay. To check the
to turn on the fan) temperature at which the fan
• Faulty fan relay comes on, turn the A/C off and
• A wiring problem keep the engine running until
(blown fuse, lose or it reaches normal operating
corroded connector, temperature.
shorts, opens, etc.)
• Bad fan motor
• Defective fan control
module

Drive not responding • Drive stops responding Internal circuit fault

Results and Conclusions:

The VFDs should be stored in an isolated room away from the machines. The room should
have an air conditioner to maintain the temperature within the 18-23 deg celsius range which
is the optimum temperature for VFDs to function.

Air conditioning :
The Air conditioning will prevent overheating of the VFDs. It will also prevent
derating. If the drive temperature exceeds 50 deg celsius then the rating of the VFD
drops by 1 everytime. The optimum temperature mentioned above should always be
maintained. Keeping the room too chilled is also can issur as it causes the moisture
and gases in the air to condense.

Air Purifiers:
Air Purifiers like ‘SAAF Air Purification systems’ should also be used in the rooms.
This helps keep the dust levels low as well as neutralises the gases in the air.
The rooms must have a two level door system or a double door system. This will help
keep the gas level low as well not let the cool air leave the room. The dust level will
also not rise.

Preventive Coating:
We can ask the manufacturing company to provide VFDs with preventive coating.
This is an anti corrosive coating that will increase the life of the internal circuitry. All
the recently bought VFDs have a teo layer preventive coating. Plastic 70, crc coating

Enclosure Type:
Enclocure is the box the VFD is stored in.Using the latest enclosure type is the best
option.
Like some of the earlier models like IP20 has a grilled type of packing that only
helped keep the drive cool but did not prevent any of the gas effects. This was
because the grill let external air flow into the VFD.
IP55, which is one of the more recent models has a complete enclosure and and 3-4
inbuilt fans that keep the drive cool. It does not let any external air interact with the
VFD.
IP60 is a water proof drive enclosure that would let a VFD function completely under
water.
For VFDs already stored in rooms further precautions can be taken by the use of:
Anti corrosive pockets:
These absorb the moisture in the air and reduce the effects of moisture and gases on
the VFD.

Nitrogen filling:
The VFD enclosures can be filled with Nitrogen gas. The will reduce the effects of
gases. Unfortunately this is a little hard to maintain because everytime the enclosure is
opened for general maintainance or inspection the Nitrogen gas ecsapes.

Further if the VFDs are out in the open the following guidelines should be followed:
Routine checkups
Preventive maintainence should be taken every 60 days.
Regular cleaning of the fan using an air jet.

Some of the VFDs in the plant are stored according to these recommendations but the VFDs
can be reduced to a huge extent if 100% of the VFDs are stored properly.
Appendix:
FY 18-19
S. No S. No S. No S. No Problem Make Rating/HP
1 11-01-2018 M/C-10 Mat Opener Over Temperature ABB 25
2 20-01-2018 Water T Water TreatmentNo Display ABB 75
3 21-01-2018 M/C-8 Spike Lattice AI not working ABB 15
4 26-01-2018 M/C-7 Nip Roller Top Output Loss ABB 7.5
5 26-01-2018 M/C-11 Cutter-2 Over Current ABB 15
6 06-02-2018 Aux-1 Jumbo Bagging Motor Temperature ABB 2
7 07-02-2018 M/C-8 Feed Roller No Display ABB 7.5
8 12-02-2018 M/C-7 Suction fan Over Current ABB 40
9 14-02-2018 Rip-1 Vis Transfer PP-1No Display Amtech 40
10 15-02-2018 Genosorb Blower Pump 101No Display ABB 75
11 24-02-2018 Aux-1 MSFE 15/Circ PP-1 Aux Fan Fault ABB 150
12 26-02-2018 CS2 Calciner PP-3 Earth Fault ABB 25
13 06-03-2018 Vis-1 Sund Press D-14 Voltage Unbalance ABB 40
14 07-03-2018 Spg-2 Zinc Transfer PP-1Drive not responding ABB 40
15 08-03-2018 M/C-4 Clamp roller Voltage Unbalance ABB 7.5
16 13-03-2018 M/C-2 Drum Drive No Display ABB 7.5
17 12-04-2018 M/C-2 Trio Roller-1 Over Temperature ABB 7.5
18 27-04-2018 Aux-1 M 15 Circ PP-2 No Display ABB 150
19 21-05-2018 Vis-2 MD Jacket waterCurrent
PP X1 Measure ABB 7.5
20 26-05-2018 M/C-10 Feed Roller Voltage Unbalance ABB 7.5
21 04-06-2018 M/C-7 Booster Fan Drive Flash ABB 25
22 11-06-2018 Vis-1 Spg PP 6B Over Current ABB 40
23 04-07-2018 Vis-1 CT Fan-7 No Display ABB 40
24 10-07-2018 Vis-1 Jacket water PP-4No Display ABB 40
25 11-07-2018 Vis-1 Spg PP 7A Over Current ABB 40
26 16-07-2018 M/C-11 Penta Roller I/O Fault ABB 75
27 20-07-2018 M/C-3 Drum Drive No Display ABB 7.5
28 28-07-2018 M/C-2 Drum Drive Over Current ABB 7.5
29 30-07-2018 M/C-11 Bleach Dozing Over Current ABB 7.5
30 18-08-2018 M/C-10 Godet Earth Fault ABB 75
31 24-08-2018 M/C-7 Transport Fan-2 No Display ABB 40
32 03-09-2018 Vis-2 Filter PP Earth Fault ABB 40
33 12-09-2018 Vis-1 Simplex Jct PP-4 Over Current ABB 40
34 13-09-2018 Aux-1 SBCP S-1 No Display ABB 75
35 16-09-2018 Ref-1 CT PP-3 No Display ABB 75
36 20-09-2018 Aux-1 RV-2 No Display ABB 7.5
37 01-10-2018 M/C-7 Nip Roller bottomCurrent Measure ABB 7.5
38 09-10-2018 M/C-5 Spike Lattice Over Current ABB 7.5
39 25-10-2018 Vis-2 GCF F Pump F7 Earth Fault Amtech 40
40 03-11-2018 M/C-11 Cutter-2 Drive not responding ABB 25
41 20-11-2018 Vis-1 Reject PP-1 No Display ABB 40
42 05-12-2018 M/C-8 Desulph Dozing Over Current ABB 7.5
43 20-12-2018 Vis-1 E press Analog I/P ABB 40
44 30-12-2018 Vis-2 11C Pump Drive not responding ABB 40
45 16-01-2019 M/C-9 Cutter-1 Over Current ABB 25
46 23-11-2019 Vis-1 GCF F Pump C1 Over Current ABB 40
47 24-01-2019 Vis-2 Feed PP K3 No Display ABB 40
48 25-01-2019 M/C-11 Penta Roller Line Converter Fault ABB 75
49 01-02-2019 CS2 Boiler F P 3-2 No Display ABB 40
FY 17-18
S. No Date Machine No Area Problem Make Rating/HP
18-01-
1 2017 Vis-1 Simplex Jct PP-4 Over Temperature ABB 40
22-01-
2 2017 MC-7 Mat Opener No Display ABB 25
25-01-
3 2017 MC-8 Spike Lattice Over current ABB 15
27-01-
4 2017 MC-6 Nip Roller Top Output Loss ABB 7.5
30-01-
5 2017 MC-6 Cutter-2 AI not working ABB 7.5
02-02- Drive not
6 2017 Aux-1 Drum Drive responding ABB 150
10-02-
7 2017 MC-8 Feed Roller No Display ABB 7.5
12-02-
8 2017 MC-7 Booster Fan Over Current ABB 25
14-02-
9 2017 Vis-1 Spg PP 6B No Display ABB 40
15-02-
10 2017 Genosorb Blower Pump 107 No Display ABB 75
20-02-
11 2017 Vis-1 CT Fan 1 I/O Fault ABB 40
02-03-
12 2017 MC-3 Penta Roller No Display ABB 7.5
03-03-
13 2017 MC-2 Drum Drive Over Current ABB 7.5
06-03-
14 2017 Aux-1 MSFE 15/Circ PP-1 Earth Fault ABB 150
10-03-
15 2017 Vis-1 Jacket water PP-4 Over Current ABB 40
13-03-
16 2017 MC-2 Drum Drive No Display ABB 7.5
12-04-
17 2017 MC-2 Trio Roller-1 Auxiliary Fan Fault ABB 7.5
07-05-
14 2017 Spg-2 Zinc Transfer PP-1 Voltage Unbalance ABB 40
21-05- MD Jacket water PP
19 2017 Vis-1 X1 Current Measure ABB 7.5
26-05-
20 2017 MC-10 Feed Roller Voltage Unbalance ABB 7.5
04-06-
21 2017 MC-7 Booster Fan Drive Flash ABB 25
15-06- Line Converter
22 2017 Vis-2 Filter PP Fault ABB 40
21-06-
23 2017 MC-4 Booster Fan Voltage Unbalance ABB 7.5
30-06-
24 2017 Vis-2 11A Pump Over current ABB 40
 01-07-
25 2017 MC-7 Nip Roller bottom Earth Fault ABB 7.5
16-07-
26 2017 MC-11 Penta Roller I/O Fault ABB 75
20-07-
27 2017 Vis-1 Sund Press D-14 Voltage Unbalance ABB 40
26-07-
28 2017 CS2 Calciner PP-1 Earth Fault ABB 25
30-07-
29 2017 MC-2 Bleach Dozing Over Current ABB 7.5
18-08-
30 2017 MC-10 Godet Earth Fault ABB 7.5
24-08-
31 2017 MC-7 Transport Fan-2 No Display ABB 40
11-09-
32 2017 Vis-2 Spg PP 7A Over Current ABB 40
12-09-
33 2017 Vis-1 Simplex Jct PP-4 Analog I/P ABB 40
13-09-
34 2017 Aux-2 SBCP S-1 No Display ABB 75
18-09-
35 2017 Ref-2 CT PP-2 Over Current ABB 75
20-09-
36 2017 Aux-2 RV-2 No Display ABB 7.5
26-09- Drive not
37 2017 Aux-1 Jumbo Bagging responding ABB 2
20-10-
38 2017 Vis-1 Reject PP-1 No Display ABB 40
04-11-
39 2017 Vis-2 Godet No Display ABB 40
23-11- Drive not
40 2017 MC-11 Cutter-2 responding ABB 25
20-12-
41 2018 Vis-2 E press Analog I/P ABB 40
05-12-
42 2018 MC-8 11C Pump Over Current ABB 7.5
09-01- Drive not
43 2018 MC-5 Spike Lattice responding ABB 7.5
16-01-
44 2018 Vis-2 GCF F Pump F7 Earth Fault Amtech 40
24-01-
45 2018 MC-9 Cutter-3 Over Current ABB 25
08-02-
46 2018 CS2 Boiler F P 3-1 No Display ABB 40
14-02-
47 2018 Rip-2 Vis Transfer PP-1 Over current Amtech 40
23-02-
48 2018 Vis-1 GCF F Pump C1 No Display ABB 40
03-03-
49 2018 MC-10 Auxiliary Fan Fault Earth Fault ABB 7.5
 15-03-
50 2018 Aux-1 SBCP S-2 Analog I/P ABB 2
21-03- Drive not
51 2018 Ref-1 CT PP-1 responding ABB 75
24-03-
52 2018 MC-7 Penta Roller Over current ABB 75
05-04-
53 2018 CS2 Calciner PP-2 Earth Fault ABB 25
10-04-
54 2018 Genosorb Blower Pump 101 Voltage Unbalance ABB 75
24-04-
55 2018 Rip-2 Vis Transfer PP-2 Voltage Unbalance Amtech 40
30-04- Drive not
56 2018 MC- 6 Bleach Dozing responding ABB 7.5
05-05-
57 2018 MC-7 Transport Fan-1 Analog I/P ABB 40
14-05-
58 2018 Aux-1 RV-1 Earth Fault ABB 75
26-05-
59 2018 Ref-1 CT PP-1 No Display ABB 40
08-06-
60 2018 MC- 6 Cutter-2 No Display ABB 60
26-06-
61 2018 Vis-1 Reject PP-2 Over current ABB 40
30-06-
62 2018 Aux-2 RV-1 I/O Fault ABB 7.5
07-07- Line Converter
63 2018 MC-10 11A-Pump Fault ABB 25
19-07-
64 2018 MC-2 Cutter- 2 Over current ABB 25
References:
https://www.vfds.com/blog/what-is-a-vfd
https://en.wikipedia.org/wiki/Variable-frequency_drive
https://www.elprocus.com/brief-explaination-about-working-of-vfds/