NAR1 Narogong Root Cause Analysis – June 2012

1. Kiln stop due to EP Stack Emmission High (Stop date 16.06.2012 01:00, Duration 21.0 hrs)
 Symptom
- Since 8 June, EP performance of compartment 1 was fluctuated but The PID still
able to take recovery. Abnormal GCT operation recorded twice 5 minutes after feed
on and for 1 hour after kiln feed on, the flow regulator and pump running unsmooth
- At 12 June 13:00 Raw Mill stop due to main drive trouble until 14 June 10:00.
During raw mill long stop, GCT had operated in normal condition.
- At 14 June 14:00 while raw mill running, Comp. 1’s mA drop with unknown reason,
and the emission was over the limit. Then at 15 June 22:00 Comp. 2 and 3 ’s mA
also drop and then at 16.06.2012 01:00 kiln was stopped
 Root Cause
- Under investigation (Possibility from abnormal GCT operation cause thermal
expansion and lumpy material at in let EP)
 Action
- Check inside EP after cooling process, then found lump
material at Comp. 3 Done
- Check wire gap and collecting plate, the result was no abnormal finding Done
- Doing test run, the result were high voltage at Comp. 1 and Comp 2
current still low 300 mA and 860 mA (normally is higher than 1000mA)
and at Comp 3 was normal: higher than 1000 mA Done 1
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 Narogong Root Cause Analysis – June 2012
NAR1

Action
- Check rapping system Done
- Check GCT lances Done

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 Narogong Root Cause Analysis – June 2012
NAR1

1. Kiln stop due to EP Stack Emmission High (Stop date 17.06.2012 05:00, Duration 27.67 hrs)
 Symptom
- After the first kiln stop at 16 June 22:00 Kiln Feed on, EP performance still not
optimum but the emission still normal
- 16 June 11:59 GCT trouble water flow reduce ,temp out let GCT was high up to 200
oC the PID react to open until 89 %, the water flow still didn’t increase, while the
water supply back to normal the flow of water jump to 60 m3/h, the PID oscillating for
0.5 hours and GCT indicate wet bottom. EP mA drop then start recovery , check PID
parameter was reset to default due to power control failure
- 17 June 02:20 mA drop at all EP compartments, emission is over limit then kiln is
stopped 05.00
 Root Cause
- Under investigation (Possibility from abnormal GCT operation cause thermal
expansion and lumpy material at in let EP)

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 Narogong Root Cause Analysis – June 2012
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Action
- Recheck inside EP the finding are: PIC : Sagi Done
• Isolation support discharge wire comp 1 not fixed, the collecting plate gap in
discharge wire to sort in one side, alignment and repaired all isolation OK
• Cleaning lump material at isolation hanger discharge wire at Comp. 1,2,3 OK
• Check transformer, isolation heater discharge wire and all rapping system OK
• Check and test GCT spray system , Tuning GCT PID and modify start pump
sequence OK
- Test high voltage EP: Comp. 1…..comp 2:…..comp3:…

- Optimization Process : Operating raw mill with low feeding,

reduce process gas flow, control temperature inlet EP at optimum range,

optimize rapping PIC : Wahyu Continue
- Measurement process :1. dust load EP: normal, False air normal,

operating temperature range : normal, dust chemical content : normal,

Gas Flow to EP normal comparing to the design. PIC : Wahyu Done

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NAR2 Narogong Root Cause Analysis – June 2012

1. Kiln stop due to EP Stack Emmission High

(Stop date 18.06.2012 18:07, Duration 33.83 hrs)
 Symptom
- before kiln stop to repair COG SLC, the emission is normal. Electricity at Field 1-2-
3 are 53/930, 66/1680, 56/1550 kV/Amps
- During no load condition at 13 June, Electricity are 50/930, 70/1680, 64/1530
- After start up Electricity are still normal 54/920, 72/1695, 61/1545
- 13.06.2012 20:41 Kiln feed on, GCT start running at 13.06.2012 21:07 while outlet
temp EP was 170 oC, Start up GCT was abnormal due to the lack of compressor
performance, actuator water and air abnormal , and improper local control setting
cause wet bottom CT for 30 minutes ( gas out let GCT 68oC), This evident may
cause thermal shock to internal EP and also lead high humidity in internal EP and
build dust lump in discharge wire or collecting plate
- 14.06.2012 06:07 raw mill running, 14.06.2012 12.00 All field Electricity are drop to
36kv/920mA, 42KV/1630mA, 42Kv/1730mA with the consequence lower EP
efficiency and dust emission is slightly increase from 66 to 75 mg/Nm3 at raw mill
on.
- Start that time the performance of Ep reduce from day to day, and worse while raw
mill off and Kiln feed has to reduce to minimum feed otherwise EP will trip over
spark.

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NAR2 Narogong Root Cause Analysis – June 2012
 Root Cause
- Under investigation (Possibility from abnormal GCT operation cause thermal expansion and
lumpy material at in let EP)

 Action
- At 18 June kiln is stopped to did local inspection due to during direct operation
(RM stop) the dust emission is 120 mg/Nm3 with 400 tph Kiln Feed.
- The findings are discharge wires were covered by wet material :
cleaning as much as possible Done
- Big hole Leakage in inlet EP casing lead false air
patching hole Done
- Some Discharge wire miss alignment align discharge wire was Done
- Testing no load and control function of EP high voltage (no result) Done
- Test High voltage during kiln stop still not optimum,
- Tuning EP control parameter PIC: Herry Continue
- Check all EP grounding and repair PIC:Herry On going
- Trial material non AFR (Result : no impact) Done

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 NAR2 Narogong Root Cause Analysis – June 2012
Action
- Re tuning GCT parameter , replace water and air proportional valve, testing
GCT spray Done.
- Service compressor and air dryer (1 control module compressor still waiting
delivery) PIC : Enjang K
- Measurement process : dust load EP: normal, False air normal,
operating temperature range : normal, dust chemical content : normal
Gas Flow to EP normal comparing to the design. Done
- Optimization process : Operating raw mill with low feeding,

reduce process gas flow, control temperature inlet EP at optimum range,

optimize rapping PIC : Wahyu Continue
- Perform GCT and EP Item in patrol check list PIC : Herry P On going
- Introduce SOP testing EP after repairmen to make sure activity already
perform PIC : Pomo A On going
Note: Both Ep tendency starting to recovered ( KV increase, but still not normal) This
effected by minimize the load and some action above, this usually happen due to
untouchable lumpy material or abnormal mechanical gab recover back to normal by it self
during operation with lower load. Focus on GCT Operation during start stop raw mill is a
must , it has high impact to EP performance. 7
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