Narogong Root Cause Analysis – May 2012

NAR 2
1. Kiln Stop due to Cooling Water Low Level ( Utility )
(Stop date 19.05.2012 01:48:00 , Duration 5.30 hrs)
 Symptom
- Hot well pump consist of 3 pumps, such as M34-WPC (716 WPC), M34-WPD (716 WPD) and M34-
WPE (716 WPE). When operation based on SOP, 2 pumps (M34-WPC and M34-WPD) were auto
running and 1 pump (M34-WPE) was standby for local running. Hot well pumps supply water to Cold
Well.
- Cold well pump consist of 3 pumps, such as M34-WP1(716 WP3), M34-WP2 (716 WP4) and M34-WP3
(716 WP5). When operation based on SOP, 2 pumps were auto running and one 1 pump standby. Cold
well pump supply water to Plant and CT. Some water were consumed by CT and water from plant will
circulate to Hot well.
- Cold well not only supply from Hot well pumps but also from Reservoir pumps and WP27. Reservoir
pump consist of 2 pumps, such as M04-WP5 (716-WP1) and M04-WP6 (716 WP2). When operation
base on SOP, M04-WP5 (716-WP1) was running and M04-WP6 (716 WP2) was standby. If there is
problem with reservoir pump, there is prime pump to trigger M04-WP5 (716-WP1) running well. WP 27
is used just for emergency when all reservoir is not enough to supply to cold well.
- Firstly, 444- CT1 stopped at 00.30 due to low-low indication from CCR. Then Patroller checked Cold
well level which indicated at 6.5 steps. The normal steps of Cold Well is below 4 steps. At the time,
M34-WP1 and M34-WP2 were running but M34-WP2 couldn't inhale the water. While repairing M34-
WP2, the patroller checked level of Hot Well and Hot well pump to check water supply to Cold Well.
- Patrollers checked Hot Well level where indicated at 8 steps. Then all Hot well pumps decide to local
running to supply water to Cold well. Hot well pumps were local running until the level indicated 12
steps. The effect of local running hot well pumps made M04-WP5 and M04-WP6 were not auto running
(remote).

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NAR 2
- Then WP 27 gate valve decided opened at 25% to supply water into Cold well, because there was no
flow water sound, the gate valve opened until 50% to supply water. After cold well have been supplied
by WP 27, M34-WP2 was running normal then CT could run normal.
- After CT running normal, patroller cheeked Cold Well level where the level didn’t increase but
indicated from 6.5 to 7 steps. Then Patroller went to Reservoir pumps to check pumps. At the time,
M04-WP5 was auto running but the condition was in cavitation and hot chasing. The standby pump,
M04-WP6 was in local stop. Then M04-WP6 decided to start local running but ampere was low to
trigger M04-WP5 . Actually, The cavitaion of M04-WP5 can be triggered by prime pump. Because
gate valve of M04-WP6 was opened so water flew to leakage foot valve of M04 WP6 then M4-WP5
fail to be triggered by prime pump. No water supplied from reservoir pump made WP27 opened until
100%. Because of decreasing Cold well level that caused by unbalance between water supply and
water consumed, made Kiln stopped
 Root Cause
- M04 – WP5 didn’t supply water properly due to prime pump failed to trigger M04 – WP5 running.
Failed supply from prime pump caused by valve to M04-WP6 opened (foot valve leaking).
 Action
- Install pressure switch at M04-WP5 and M04-WP6 PIC : Enjang K (Juni 2012)
- Install KW indication to CCR for M04-WP5 and M04-WP6 PIC : Enjang K (Juni 2012)
- Install facility platform for foot valve of M04 - WP5 and M04 - WP6 preventive maintenance PIC :
Hervian Next Overhaul NAR 2
- Replace new foot valve M04-WP6 pic : Hervian (Juni 2012)
- Changing new gate valve type of WP 27 PIC : Hervian (Juni 2012)
- Install prime pump each reservoir pump PIC : Hervian (Juni 2012)
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 Narogong Root Cause Analysis – May 2012

NAR 2

WP 27
COLD WELL
HOT WELL

M34-WPC Prime pump M04-WP5

(716 WPC)
M04-WP6
M34-WPD
(716 WPD) Reservoir Pumps
M34-WPE
6 Step
8 Step (716 WPE)
Install KWH meter
Install pressure
switch

M34-WP1

M34-WP2

M34-WP3
Cold Well Pump
circulation
Plant + CT
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