incident report

WHITE NILE SUGAR COMPANY

CO-GENERATION DEPARTMENT

TRIP INCIDENT REPORT

Report Date: 17.12.13 Incident Date:21.11.13 Time: 21.40 to 1:00

Operation Impact ---------→ Blackout:Yes Crushing stoppage:YES

Phase Section Sub-Section

SGU-Pahse-2 boiler#2 Steam temprature control

Area responsible for the Defect

Mechanical Electrical Control

Name of the Staff Involved Designation Department

vinoth kumar DCS operators operation

What Happened? Black out due to Steam Temprature low.

When did the incident occur?

time:21:40 date:21.11.13

Where did the incident occur?

Boiler#2

How did the incident occur? boiler#2 temprature control valve malfunction while boiler in line.

Why did the incident occur? main steam Temprature control valve malfunction.

Determine corrective action and its completion date. attemprator conrol valve mal function corrected 21/11/2013

Action to be taken to avoid similar incident in futureBoiler MSSV to be closed and load reduction.

Nos of Similar Incident: 1

Report prepared by: Yousif Mohammed Abdelmalik Signature: Yousif Date: 16/12/2013



Total Loss Time in Hrs: 3:20

Other Outage: Irrigation

Equipment Code No

Boiler#2-attemperator


Operation

Operation.

Shift Supt Name

Yousif Mohammed Abdelmalik

What Happened? Black out due to Steam Temprature low.


time:21:40 date:21.11.13


Boiler#2

How did the incident occur? boiler#2 temprature control valve malfunction while boiler in line.

Why did the incident occur? main steam Temprature control valve malfunction.

Determine corrective action and its completion date. attemprator conrol valve mal function corrected 21/11/2013

Action to be taken to avoid similar incident in futureBoiler MSSV to be closed and load reduction.

Ref No: WCG-SG-ITR-C13-14/01




Report Date: 17/12/13 Incident Date:22.11.13 time:7:44a.m to 10.30 a.m

Operation Impact ---------→ Blackout:Yes Crushing stoppage:YES


SGU-Phase-2 Fuel feeding




Ali Altoum Shift Super. Eng Mill House

Wali Eldin Mech.Technicain Operation

Herald Varghese DCS operator Operation

What Happened?

main steam temperature low in both boilers


22/11/13 7:44 a.m


Boiler#2&4

How did the incident occur?

wet bagaase from mill house.

Why did the incident occur?

high moisture bagasse.

Determine corrective action and its completion date.

Action to be taken to avoid similar incident in future

Arrangement with Mill Shift Supt to inform us for any gap or trash or any mill bypassed,feed boilers through back feeding .


Boiler#2&4

Bagasse transfer to baggase yard PH-01 at any starting of mill,during gap from mill and when low Feeding because of trash. Arrangement with Mill Shift Supt to inform us for any gap or trash or any mill bypassed.

Report prepared by: Eihab Mohammed Ali Signature: Eihab Date: 16/12/2013



Total Loss Time in Hrs: 2.46

Other Outage: Irrigation

Equipment Code No

Bagasse


Operation

Operation

Shift Supt Name

Ali Altoum

Eihab Mohammed Ali

Eihab Mohammed Ali

What Happened?

main steam temperature low in both boilers


22/11/13 7:44 a.m


Boiler#2&4


wet bagaase from mill house.


high moisture bagasse.



Arrangement with Mill Shift Supt to inform us for any gap or trash or any mill bypassed,feed boilers through back feeding .


Bagasse transfer to baggase yard PH-01 at any starting of mill,during gap from mill and when low Feeding because of trash. Arrangement

Report prepared by: Eihab Mohammed Ali Signature: Eihab Date: 16/12/2013




Report Date: 17/12/13 Incident Date:24/11/13 Time: 7.48 a.m to 10:57a.m

Operation Impact ---------→ Blackout:YES Crushing stoppage: Yes 4:05


SGU-Phase-02 BHS BC-6A




Khalid Field operator Operation

Abdel Rahim Shift Supv Operation

Herald Varghese DCS operator Operation

What Happened?

Chute Jam due to Angle Piece which led to BHS stoppage and Boiler 2&4 pressure drop and blackout.


23/11/2013 7:10 hr


Ph-02 Bagasse Handling System


during boiler 2&4 runnig with back feeding angle piece in conveyor which led to final chute jam and BC-6A trip.


foreign material in BHS


Chute Jam Cleaning started and finished 8:00 Am


Bagasse yard PH-02 cleaned from foreign material as well as the walk way for all conveyor PH-02.


Report prepared by: Eihab Mohammed Ali Eljack Signature: Eihab Date: 16/12/2013




Other Outage: irrigation load

Equipment Code No

BC-6 conveyer


Operation

Operation

Shift Supt Name

Eihab Mohammed Ali

Eihab Mohammed Ali

Eihab Mohammed Ali

What Happened?

Chute Jam due to Angle Piece which led to BHS stoppage and Boiler 2&4 pressure drop and blackout.


23/11/2013 7:10 hr


Ph-02 Bagasse Handling System


during boiler 2&4 runnig with back feeding angle piece in conveyor which led to final chute jam and BC-6A trip.


foreign material in BHS


Chute Jam Cleaning started and finished 8:00 Am


Bagasse yard PH-02 cleaned from foreign material as well as the walk way for all conveyor PH-02.


Report prepared by: Eihab Mohammed Ali Eljack Signature: Eihab Date: 16/12/2013




Report Date: 17/12/13 Incident Date:11/12/13 Time: 17:58

Operation Impact ---------→ Blackout:Yes Crushing stoppage: Yes


SGU-Pahse-I Boiler#1 Travelling Grate



Electrical Control


What Happened? Travelling grate NO.1 motor stopped due to communication problem


17:58 hr 11/12/2013


Boiler#1


Why did the incident occur? problem still not rectified.

Determine corrective action and its completion date. travelling grate motors to be checked for communication problem.

Action to be taken to avoid similar incident in futuremany equipment have the same problem (communicaion problem) to be checked.


During boiler#1 running with 3 burners travelling garte motor stopped due to communicatio problem and led to burners trip due to interlock.




Other Outage: Irrigation load

Equipment Code No

Travelling Grate Motor


Operation

Shift Supt Name

Yousif Mohammed Abdelmalik

Abubaker Imam Ahmed

Ahmed Abdelrahman

What Happened? Travelling grate NO.1 motor stopped due to communication problem


17:58 hr 11/12/2013


Boiler#1


Why did the incident occur? problem still not rectified.

Determine corrective action and its completion date. travelling grate motors to be checked for communication problem.

Action to be taken to avoid similar incident in futuremany equipment have the same problem (communicaion problem) to be checked.


During boiler#1 running with 3 burners travelling garte motor stopped due to communicatio problem and led to burners trip




Report Date: 20\12\2014 Incident Date:20\12\2014 Time: 02:27pm

Operation Impact ---------→ Blackout:Yes Crushing stoppage:Yes


1 BOILER BOILER-03




HERALD K. VARGHESE Dcs operator BOILER

K.C. BHORADE BOILER FIELD OPERATOR BOILER

Mohamed.Elsagadi BOILER FIELD OPERATOR BOILER

What Happened?

Boiler-3 pressure, and furnace temp. coming down, due to wet baggase from mills.


20\12\2014 02:27pm


Boiler-03



DUE to wet baggase furnace got dumped and furnace temp. comes down


We have to stop Belt Conveyors as not allow from mills go to the boilers.


Nos of Similar Incident:

After NO-CANE mills started at 1.20pm. Wet baggasse and more gap and less cane feeding starting from 1.50 pm. experienced we close the silo gates and max. bagasse diverted to yards mean time seeing SC4 current we are taking yard baggase. silo got empty we opened silo gates this wet bagasse entered to silo. Due to moisture baggase in silo furnace temp. comes down to 650 to 580 deg.c we closed PRDS (2.5ATA, 11ATA). At 53KG/Sq cm we try to start oil burner but BURNER READY indication not came ( after seeing furnace condition we started oilbpump, and purging given)

Report prepared by: A.GOVINDARAJAN Signature: Date: 20/12/2014

we have to stop bc-3, and we have to take back feeding, , and situation not improved we have to put minimum one burner in service



Total Loss Time in Hrs:

Other Outage:hrs 2:40 hr:min

Equipment Code No


Operation

ü

Shift Supt Name

A.GOVINDARAJAN

What Happened?

Boiler-3 pressure, and furnace temp. coming down, due to wet baggase from mills.


20\12\2014 02:27pm


Boiler-03



DUE to wet baggase furnace got dumped and furnace temp. comes down


We have to stop Belt Conveyors as not allow from mills go to the boilers.


Ref No: WCG-SG-ITR-

After NO-CANE mills started at 1.20pm. Wet baggasse and more gap and less cane feeding starting from 1.50 pm. experienced we close the silo gates and max. bagasse diverted to yards mean time seeing SC4 current we are taking yard baggase. silo got

we opened silo gates this wet bagasse entered to silo. Due to moisture baggase in silo furnace temp. comes down to 650 to 580 deg.c we closed PRDS (2.5ATA, 11ATA). At 53KG/Sq cm we try to start oil burner but BURNER READY indication not

Report prepared by: A.GOVINDARAJAN Signature: Date: 20/12/2014

we have to stop bc-3, and we have to take back feeding, , and situation not improved we have to put minimum one burner in




Report Date: 15\01\2015 Incident Date:14\01\2015 Time: 05:06pm

Operation Impact ---------→ Blackout:No Crushing stoppage:Yes


1 BOILER Slat conveyor




Tanaji Patil Dcs operator BOILER

Rajendra Badode Dcs operator BOILER

Anglo , Salah,Omer Musa,Ibrahim Ramadan SC-4 Operator BOILER

What Happened?

Slat conveyor SC-4B break down.


On 14\01\2015 at 05:06pm


SC-4B




1-Mill stopped at 3:28 pm due to some problem mill side,3:56pm mill started again, improper low feeding up to 4:25pmsame time wet bagasse entered in silo,Boiler pressure drop to 56.1Kg/cm2 at 04:18pm,2- @04:25 pm crushing stopped as per our request ,BC-3 &BC-1 stopped accordingly due to wet bagasse. 3- @04:31pm Mill crushing started after pressure maintained ,boiler Pressure dropped again due to wet bagasse one burner lighted up @04:42pm and @04:50pm crushing stop from boiler side by stopping BC-3&BC-1,still there is no improvement in bagasse quality at,4-@5:01pm Mill start, Pressure 63kg/cm2. 5- @ 5:06pm Pull cord operated by SC-4 Operator observed abnormal sound at drive end side,Same time all SC-4 operator are near blr 01 silo gate to monitor bagasse quality and to close silo gates.



Report prepared by:Eihab Eljack Signature: Date: 14/01/2015

SC-4B occured break down due to a lumps of bagasse fallen in SC-4B discharge chute,not moved forwerd and chute jam occured.

Breakdown maintenance immediately started after SC-4 stopped,damaged slats has been removed,renewed by new with link attachment ,completed at 02:00 am on 15/01/2015.

To give more attention to discharge chute to avoid chocking of discharge chute during mill start up



Total Loss Time in Hrs:

Other Outage:hrs 9:20 hr:min

Equipment Code No

SC-4B


Operation

ü

Shift Supt Name

Eihab

Eihab

Eihab

What Happened?

Slat conveyor SC-4B break down.


On 14\01\2015 at 05:06pm


SC-4B




1-Mill stopped at 3:28 pm due to some problem mill side,3:56pm mill started again, improper low feeding up to 4:25pmsame time wet bagasse entered in silo,Boiler pressure drop to 56.1Kg/cm2 at 04:18pm,2- @04:25 pm crushing stopped as per our request ,BC-3 &BC-1 stopped accordingly due to wet bagasse. 3- @04:31pm Mill crushing started after pressure maintained ,boiler Pressure dropped again due to wet bagasse one burner lighted up @04:42pm and @04:50pm crushing stop from boiler side by stopping BC-3&BC-1,still there is

5- @ 5:06pm Pull cord operated by SC-4 Operator observed abnormal sound at drive end side,Same time all SC-4 operator are



Report prepared by:Eihab Eljack Signature: Date: 14/01/2015

SC-4B occured break down due to a lumps of bagasse fallen in SC-4B discharge chute,not moved forwerd and chute jam

Breakdown maintenance immediately started after SC-4 stopped,damaged slats has been removed,renewed by new with link

To give more attention to discharge chute to avoid chocking of discharge chute during mill start up

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