Connecting Terminals-Case Study

By Prateek Singh, CMNM

Indian Oil , M&I, RHQ, Delhi
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Small but Significant

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 INTERRUPTION SYNOPSIS
Gujarat Refinery : HGU-I unit tripped owing to actuation of
reformer trip command from control room Push button.

Panipat Refinery : DHDT unit tripped due to activation of Process

Trip Signal.
 Case Study - 1

Gujarat Refinery

HGU-I unit tripped due to

actuation of reformer trip
command from control room
 Event in Brief
• HGU-1 Unit was running normally when it got tripped on 21.12.2018 at 22:34
hrs.

• Activation of reformer trip was recorded in SOE as "REFORMER TRIP PB FROM

C/R" by hard wired switch "CHS1607" at 22:34:02 hrs of 21.12.2018.

• At the same time, i.e. at 22:34:02 hrs, activation of another six inputs HS1108,
HS2202, CHS1111, CHS1112, CHS1208, STEAMLO was also observed.

• All these seven inputs were from the same card and were powered through
the same power source.

• Activation of CHS1607 resulted in tripping of Reformer with Feed and Fuel

cut off to the reformer. PSA also tripped.
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 Why –Why Analysis
 HS-1607 (Reformer trip PB from CR) loop involves following components:
 PLC Input Module
 PLC processor
 TBs/Wiring
 Push button
 Relay
 Fuse

• Activation of push button as well as malfunction of any of the

components may lead to activation of the interlock.

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 Why –Why Analysis
Failure in Push Button or Relay
Ruled out - Stamping of all six buttons has been recorded in SOE at the same time.

Failure of PLC input module & processor

Ruled out - System Diagnostics found OK.

Fuse
Not Blown

Digital Inputs' were chattering through fuse of negative supply terminal (Schematic attached).

Minor gap found in the fuse holder at one end of terminal strip, which was making/breaking contact with the fuse.
Deformation due to heating Ruled out as the current flow in this TB is in the range of mAs and there is no physical evidence of heated TB.

It can be concluded that trip has been initiated on spurious activation of HS1607 due to the problem in fuse holder terminal of negative power
supply of PUSH BUTTON. Since this negative supply is looped in all 16 channels of Dl card, energized input toggled their state after fault.
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Root Cause Analysis – Gujarat Refinery

Terminal
Block
PLC input • Minor gap
Deformed Fuse
module & • Spurious
Activation Holder
processor
• System
Diagnostics
Push Button ok
• Simultaneous
recording of
all 06 buttons

* TBs were installed in ~1998

 Case Study -2

Panipat Refinery

DHDT unit tripped due to activation

of Process Trip Signal.
 Event in Brief

 02 PLC systems in DHDT.

 Process trip contact (72K001_TRIP) is configured in PLC-1 and is taken

from PLC-1 (DO) to PLC-2 (DI) to trip RGC.

 Both DO and DI are connected in separate cabinets.

 Interpanel wiring – To take the DO from PLC-1 cabinet to PLC-2 cabinet

through relay and fuse terminal block.

 RGC tripped due to activation of Process trip contact (72K001_TRIP),

leading to DHDT unit trip.
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 Why –Why Analysis
Why DHDT Trip?
DHDT Trip due to RGC trip

Why RGC trip?

RGC tripped on activation of Process trip Signal (72K001_TRIP)

Why Process Trip Signal activated?

Fuse Cables Terminal Block
• Not Blown • No looseness • Malfunctioned
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Root Cause Analysis – Panipat Refinery

Defective
Terminal
Cables Block
No looseness

Fuse
in order
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 RECOMMENDATIONS

• Thermal Scanning of TBs

 Every six months
 Before & after shutdown

• Critical control loops should be checked for physical deformity in

every shutdown.

• Installation of Push-in type of TBs to be explored.

• Old TBs (melamine) to be replaced in a phased manner.

• Military-grade fuses with standard sizes to be used during maintenance.

• Use of torque screw driver.

 Requirements from Industry/ Manufacturers

• TB manufacturers should specify the make of fuses to be installed with their

TBs.

• Considering plant life of 30 yrs, MTBF of TB > 50 yrs.

• Special TBs should be designed for SIL 3 loops.

• TBs should be designed with a tolerance band to accommodate different

manufacturers’ fuses.

• Is the IEC 60947-7 followed?

• Manufacturer to provide guidelines for checking healthiness of old

installed TB’s.
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