8D REPORT FORM

Customer Name: M/S.CAIRN ENERGY - TRIVENI

Complaint Qty : 1

Material Description: GENERATOR SPI100015000KVAIM10014P11000VI

Date:11.07.2014

8D PROCESS :

Leader : BARBARA LEHMKUHL COELHO

Select the Team D1

Team : (INDUSTRIAL ENGINEERING), BARBARA LEHMKUHL COELHO (QUALITY), MUDASSAR NAZAR (QUALITY),PALANIVEL (QUALITY),DINESH

HANS ERICH STOLTENBERG NETO (PRODUCTION), LUIZ FERNANDO CAMARINI DE OLIVEIRA (DESIGN),BALAJI (SERVICE),RITURAJ
KUMAR (SERVICE),ANURAG KUMAR (SERVICE)

What is the problem ? ; What is the situation ?

Describe The
Problem - D2*

Defect Picture

Commissioning activity of the generator started on 17th May14 and put on no

load on 21st May14. Generator loaded at 4 MW on 23rd May14. On 26th May
14, load increased from 4 MW to 6, 8,10 and 12 MW gradually and was running
on rated load for 13 hours. On 27th May14 at 1:11 pm generator tripped due to
differential relay in the stator followed by rotor earth fault relay actuation.
The generator was inspected at site, checked all accessory terminal boxes and
found insulation pieces and carbon dust inside the boxes.
Thereafter NDE side inspection window was opened and found that rotor
overhang portion and banding tape was completely damaged.
Insulation resistance checked for generator stator and rotor found 0 M.

Immediate actions :
Actions

Owner

Planned date

Implementation date

Balaji / Palanivel

25.06.2014

Completed

Balaji / Cairn energy

07.08.2014

In process

Organized Meeting and communicated to all concern

Containment actions.
What is being done to
contain this issue & how
is the customer being
protected?
- D3

Machine has to be moved to WEG for disassembly,failure analysis and further

repairs

Verification action: (Refer preliminary RCA analysis report)

Verification done on the alternators supplier from WEG india towards failure of rotor overhang bandage and found no overhang failure reported / registered till
date. This is the first complaint received on this matter.

Define the root causes ; Select likely causes

Tools : Brainstorming

Ishikawa

* BRAIN STORMING SESSION :

5 Whys

1. Site condition of machine - Machine running with over speed,Over current,Over load,High vibration
2. Poor quality of raw material
3. Wrong material specification of bandage
4. Wrong dimensioning of the bandage
5. Improper banding
6. Improper impregnation
7. Improper curing
8.Poor workmanship
9.Procedure not followed
10.Improper procedure
* CAUSE AND EFFECT DIAGRAM :
Define Root causes D4

MEN
Wrong material specification
Wrong dimensioning

MACHINE
Machine running with
over load

Poor quality of raw material

Machine running with

over current

Poor workmanship
Procedure not followed

MATERIAL

Machine running with

over speed

Machine running with

high vibration

ROTOR OVERHANG PORTION AND BANDING TAPE

Improper procedure

Improper banding

Improper impregnation
Improper curing

METHOD

MEASUREMENT

ENVIRONMENT

* VALIDATION OF EACH CAUSES :

Possible casuses

Related to problem
(Yes / No)

Poor workmanship

No

Procedure not followed/Improper procedure

No

Machine running with over load

No

Machine running with over current

No

Machine running with over speed

No

Machine running with high vibration

No

Remarks
Process follow-up was done by specialist in Rotor manufacturing from Brazil and no
deviations were found.

Based on site data , we understand the machine was running without any failure
indication

Bandage tape manufacturing date : 19.09.2011

Rotor bandage finish date : 04.06.2013
Duration of storage inhouse : 1.8 years
The expired date of the bandage tape according to manufacturer can go up to 2
years after the manufacturing date, respecting the storage rules. See table below

Poor quality of raw material

Yes
The control of the shelf life of bandage tape is done by the foreman. When he is
collecting the material from the storage area he needs to check the expired date of
the tape and cross check with the temperature of the area that the tape is being
stored (information available in the label of the tape). There is no register to ensure
us where this tape was storage (in the 20C area or in the 10 C freezer), so we
cannot confirm that the tape was used inside its shelf life.
Note :
* We have performed Tg test in CPRI and also Tensile strength test in a sample
from DE of the rotor and the results did not present any evidence of material defect.

Wrong thickness specification

No

Wrong material specification of bandage

No

Improper curing

No

Improper Impregnation

No

Improper banding

No

The complete design of the rotor was reviewed by our Design team in Brazil & in
India, and all specifications and dimensions were found according to WEG criteria

Inprocess data for this rotor was checked and found satisfactory

5 WHYS
Rupture of the Polyglass K220 bandage tape

Why?

Due to weakened properties of the tape

Why?

Because tape used in the bandage had expired or was

wrongly storage.

Why?

Because control of tape shelf life or storing conditions was

not done properly.

Why?

Because there is no written register/procedure to

control the shelf life of the tape. It was given only verbal
instructions.

Root cause

ROOT CAUSE: No written register and procedure to control the shelf life of the banding tapes. It was given only verbal instructions.

Why this problem have

not been detected
before ? - D5

Why this problem have not been occurred before ?

No Quality Complaints regarding this issue

Actions

Owner

Planned date

Implementation date

Asst Manager Winding

31st of July / 2014

In process

Industrial Engineer

31st of July / 2014

Store Kevlar banding tapes in freezer and maintain temperature below 10C to
extend the banding tape shelf-life up to 2 years, and avoid mistakes while
selecting the tapes from the storage area.

Industrial Engineer

Completed

Review periodical inspection/records for all raw materials with limited shelf life.

Quality control

31st of July / 2014

Register will be introduced to monitoring the lot and expired date of the bandages
tapes used.

Identify corrective
actions - D6*

First in First out system should be introduced for bandage tape to ensure that
always the oldest tape from the storage area will be used.

In process
Completed

In process
Include the verification of the register with lot and expired date of the tape used in
each rotor during Quality inspection.

Quality control

31st of July / 2014

Ensure that the rotor manufacturing process will be monitored and documented by
check-lists.

Quality control

31st of July / 2014

In process

In process

Quantify the effectiveness of the solution

Verify corrective actions
- D7*

To be analysed after implementation of actions.

Initiated By :

Checked By:

Approved By:

Closing of Report - D8
PALANIVEL K

BARBARA LEHMKUHL COELHO

BARBARA LEHMKUHL COELHO