FAULT ANALYSIS REPORT

1. FAULT OCCURANCE DATE : 17/3/11 TIME : 15-15 HRS

2. AREA/UNIT: Refinery Area.

3. EQUIPMENT TAG NO :

4. DESCRIPTION OF FAILURE: Siren motors failed to operate in Refinery area

during Mock Drill on 17-03-2011.

Condition prior to failure:

I)The refinery area sirens were not available as job was going on vide cold work
permit no. 00270 dated 17/03/2011.

II) The Township area sirens were available.

Conditions after failure:

I) At the time of Mock Drill at 15:15 hours, all the sirens in the Refinery areas
failed to operate.

II) The Township area sirens operated normally.

5. NOTIFICATION REF.(If Reqd ):

10037023,10037076,10039271,10039339,10039972

(Signature of Officer-in-
charge)
Name: DC Baruah
Designation: M (EM)
6. ANALYSIS OF FAILURE :

The earlier Fire Siren system was based on timer circuits, the variation of time
was found during the daily test run and during Mock Drills in all the Siren
operating modes i.e., All Clear/Test, Major Fire and Disaster. Based on the report
on “audibility of Sirens in NRL and NRMT area dated 11-09-2006”, the
requirement of New Electronic Siren Panel was proposed. The New Electronic
Siren Panel was commissioned on 09-02-2011. The commissioning report is
enclosed in Annexure-1.

During the commissioning of New Electronic Siren Panel it was observed that in
the siren distribution system, numbers of sirens of different locations are connected
in parallel loop (Layout of old siren distribution system attached in Annexure-2).
The disadvantage of this system are:

A. Fault propagates from one faulty siren to the other connected sirens in
parallel loop.
B. Checking of individual siren not possible without taking shutdown of the
complete loop.
C. Fault troubleshooting was time consuming.
D. No protection available in the load side.
E. Siren distribution system was not done in a sequential manner.
F. Colour coding of the cables in the MDF (located in EPABX) was not
done.
G. The positive of the 48 VDC was connected directly to the individual
siren’s outgoing, due to which manual tracing of the positive voltage
cables required to be done.

Based on above a new siren distribution scheme (Ref. Annexure-3) was

prepared having the following advantages:

A. Individual siren distribution is there preventing the fault propagation from

one siren to the other sirens.
B. No parallel loop connections are present.
C. Checking of individual siren possible without taking shutdown.
D. Fault troubleshooting will be fast.
E. Fuse provided in the outgoing of the individual sirens.
F. Colour coding followed for better distinction.
G. Positive voltage is connected separately to individual sirens.

Sequence of Events:

I) As per notification no. 10037023 dated 7/11/2010,10037076 dated

9/11/2010,10039271 dated 12/2/2011,10039339 dated 13/2/2011,10039972
dated 17/3/2011 from F&S Dept., the following sirens were found not
working:
a) OIL
b) NRMT MCC Room
c) NRMT Control Room
d) LPG Loading Gantry
e) CPP
 f) SS#4
g) ETP
h) SS#2

II) Cold permit no. 00270 was issued from F&S Deptt. dated 17/3/2011 at
10:00 HRS up to 16:45 HRS.
III) The checking of the siren motors was carried out w.r.t. permit no 00270
(F&S). & the same informed to all concerned via mail dated 17.3.2011 at
9.13 HRS (as attached in annexure 4).
IV) The non functioning sirens were thoroughly checked one by one in the
following locations as provided in TABLE 1:

Sl NRMT NRMT SS#4 CPP FIRE

LOCATIONS
No CONTROL MCC AND
ROOM ROOM SAFETY
Disconnection of Done Done Done Done Done
1
Power Cable
2 Voltage Injected Done Done Done Done Done
Voltage measured 52 VDC 52 VDC 52 VDC 52 VDC 52 VDC
3
at MDF side
Voltage measured 45 VDC 45 VDC 45 VDC 45 VDC 45 VDC
4
at field side
Simulation of 48 Done Done Done Done Done
5 VDC control
contatctor
Result of Contactor Contactor Contactor Contactor Contactor
simulation of 48 pick up pick up pick up pick up pick up
6
VDC control found OK found OK found OK found OK found OK
contatctor
Simulation of 230 Done Done Done Done Done
7 VAC power
contatctor
Result of Contactor Contactor Contactor Contactor Contactor
simulation of 230 pick up pick up pick up pick up pick up
8
VAC control found OK found OK found OK found OK found OK
contatctor
Reconnection of Done Done Done Done Done
9
power cable
Control circuir Done Done Done Done Done
10 normalization in
field side

TABLE 1

V) From the above exercise, 5 numbers of siren’s (NRMT MCC ROOM,

NRMT CONTROL ROOM, F&S, CPP & SS#4), outgoing 48 V DC control
telephone cable pairs were identified and marked in the EPABX MDF.
VI) At 15:15 HRS information came from Township Telephone Exchange that
the Township Sirens were blowing.
VII) Subsequently information from F&S Deptt. came regarding non operation
of the whole siren system in Refinery area and the scheduled Mock Drill
program also.
VIII) Immediately the main control fuse was put on line and the fuse blown off.
IX) The six numbers of unchecked and unhealthy sirens came on line with the
healthy ones as there was no isolation in the system.
X) As the fault already existed in the load side, the control fuse blown off.
XI) The fuse was immediately replaced with a new one.
 XII) The unhealthy sirens were taken out from the healthy ones.
XIII) The checked five sirens were taken on line again within 10 minutes.
XIV) But the siren command was not given during that time from F&S Deptt.
XV) The 6 numbers of unchecked siren’s outgoing cables were checked as given
in Table 2

Sl No ADMIN
LOCATIONS ETP SS#5 SS#2 OIL LPG LG
BUILDING
1 Disconnection of Done Done Done Done Done Done
Power Cable
2 Voltage Injected Done Done Done Done Done Done
3 Voltage measured at 52 VDC 52 VDC 52 VDC 52 VDC 52 VDC 52 VDC
MDF side
4 Voltage measured at 45 VDC 45 VDC 45 VDC 45 VDC 45 VDC 45 VDC
field side
5 Simulation of 48 Done Done Done Done Done Done
VDC control
contatctor
6 Result of simulation Contactor Contactor Contactor Contactor Contactor Contactor
of 48 VDC control pick up pick up pick up pick up pick up pick up
contatctor found OK found OK found OK found OK found OK found OK
7 Simulation of 230 Done Done Done Done Done Done
VAC power
contatctor
8 Result of simulation Contactor Contactor Contactor Contactor Contactor Contactor
of 230 VAC control pick up pick up pick up pick up pick up pick up
contatctor found OK found OK found OK found OK found OK found OK
9 Reconnection of Done Done Done Done Done Done
power cable
10 Control circuir Done Done Done Done Done Done
normalization in field
side

TABLE 2

XVI) The cold permit no 00270 was extended up to 21:00 HRS on17/03/2011 at
16:50 HRS.
XVII) Process of migration to the new siren distribution system initiated as per
table 3.
 Sl ADMIN
LOCATIONS
No ADMIN Building NRMT
CPP SS#4 LPG LG
Building Electronic MCC Room
siren
1 Identification of Done Done Done Done Done Done
outgoing pair cable
2 Krone Point 02B0901 02B0901 02A0406 02A0507 01D0203 01D0409
3 Colour of the outgoing Green/Red Orange/Red Blue/Red Orange/Red Black/Green Green/Red
cables
4 Tagging of the outgoing Done Done Done Done Done Done
cables
5 Voltage measurement -52VDC -52VDC -52VDC -52VDC -52VDC -52VDC
before disconnection
6 Voltage measurement 0V 0V 0V 0V 0V 0V
after disconnection of
the outgoing cables
7 Voltage measurement at 0V 0V 0V 0V 0V 0V
Krone point
8 Clamping of the Contactor Contactor Contactor Contactor Contactor Contactor
outgoing cables with the pick up pick up pick up pick up pick up pick up
cables of the new found OK found OK found OK found OK found OK found OK
system
9 Field side isolation done Done Done Done Done Done Done
10 Simulation of 48 VDC Done Done Done Done Done Done
control contatctor from
EPABX end
11 Result of simulation of Contactor Contactor Contactor Contactor Contactor Contactor
48 VDC control pick up pick up pick up pick up pick up pick up
contatctor found OK found OK found OK found OK found OK found OK
12 Reconnection Done Done Done Done Done Done
 Sl NRMT
LOCATIONS FIRE &
No Control OIL SS#5 SS#2 ETP
SAFETY
Room
1 Identification of Done Done Done Done Done Done
outgoing pair cable
2 Krone Point 01C1008 02B0201 01A1010 01A0506 02A0910 01B0310
3 Colour of the outgoing Green/Yellow Blue/White Grey/ Blue/ Grey/Red Grey/Red
cables Yellow Red
4 Tagging of the outgoing Done Done Done Done Done Done
cables
5 Voltage measurement -52VDC -52VDC -52VDC -52VDC -52VDC -52VDC
before disconnection
6 Voltage measurement 0V 0V 0V 0V 0V 0V
after disconnection of
the outgoing cables
7 Voltage measurement at 0V 0V 0V 0V 0V 0V
Krone point
8 Clamping of the Contactor Contactor Contactor Contactor Contactor Contactor
outgoing cables with the pick up found pick up pick up pick up pick up pick up
cables of the new OK found OK found OK found OK found OK found OK
system
9 Field side isolation done Done Done Done Done Done Done
10 Simulation of 48 VDC Done Done Done Done Done Done
control contatctor from
EPABX end
11 Result of simulation of Contactor Contactor Contactor Contactor Contactor Contactor
48 VDC control pick up found pick up pick up pick up pick up pick up
contatctor OK found OK found OK found OK found OK found OK
12 Reconnection Done Done Done Done Done Done

TABLE 3

XVIII) Admin Building Electronic siren was manually checked from Fire &
Safety.
XIX) The whole system was functionality was checked on 18-03-2011 morning
during daily checking of sirens from Fire & Safety Deptt.

7. ATTRIBUTABLE TO: a) Preventive Maintenance:

b) Predictive Maintenance :
c) Corrective Maintenance :
d) Quality of Materials :
e) Others (specify):
1. No specific guidelines are there for Fire
Siren job clearance.
2. As built drawings not available.
 8. MODIFICATION REQUIRED(If any) : Yes
(If required enclose separate sheet)

Signature of Area –in-Charge

Name:
Designation:

9. RECOMMENDATION/APPROVAL:

Sl No Recommendation Person Target Status

responsible Date
Specific guideline Guidelines as given in
required for Fire the Mock Drill review
Siren System job meeting dated
1 clearance. 17/03/2011 by CM
(F&S) (Ref Annexure-
5)will be followed
henceforth.

Signature of HOD
Name:
Designation: