Medium-Voltage Drive Repair – Solutions for Board Burnout and PLC Module Damage

1. Incident

Burnt medium-voltage drive board caused by electrical surges exceeding the threshold, resulting in damage to the control module.

2. Consequences

The pump drive became non-operational, and the PLC module lost control capabilities, leading to insufficient water supply for the plant and causing a critical water shortage.

3. Scope of Work

• • Repair the burnt cells in the medium-voltage drive.
  • Replace the damaged PLC module caused by electrical surges.
  • Install signal isolation between the drive and the PLC.
  • Deploy overvoltage protection devices.

4. Solutions and Implementation

To address the incident efficiently and effectively, the following measures were implemented:

Repair of Burnt Cells in the Medium-Voltage Drive

• • Conducted a detailed analysis of the burnt components to determine the extent of the damage.
  • Identified and procured necessary replacement parts.
  • Performed repair operations and conducted durability and safety tests to ensure reliability.

Replacement and Reconfiguration of the PLC Module

• • Identified the damaged PLC module and selected a compatible replacement.
  • Backed up and reconfigured the control program to ensure system compatibility.
  • Conducted operational tests to verify that the PLC regained full control functionality.

Implementation of Signal Isolation Between the Drive and PLC

• • Reviewed existing wiring configurations and implemented electrical noise reduction measures.
  • Installed isolation transformers and optical isolators to enhance control signal stability.
  • Conducted reliability tests across the entire system.

Installation of Overvoltage Protection Devices

• • Deployed surge protectors to minimize the impact of voltage spikes.
  • Implemented a voltage monitoring system to detect and alert operators to abnormal conditions.
  • Integrated a data logging system for continuous monitoring and analysis.

5. Results and Impact

The implemented measures successfully achieved the following outcomes:

• • Rapid Equipment Recovery: Repairs and replacements were completed swiftly, restoring full operational capacity of the pump station.
  • Enhanced System Reliability: Signal isolation and overvoltage protection significantly reduced the risk of similar failures in the future.
  • Stable Water Supply: With the pump drive back in operation, the plant received an adequate water supply, preventing production downtime.
  • Long-Term Maintenance Strategy: The preventive maintenance schedule was revised to strengthen future risk management.

6. Conclusion

This case study highlights how a burnt medium-voltage drive could have severely impacted plant operations. By implementing immediate repair solutions and preventive measures such as signal isolation and overvoltage protection, system stability was successfully restored, ensuring continuous and reliable plant operations.

At IDEA Technology, we provide expert solutions for industrial electrical and control system challenges. If you need assistance with system troubleshooting or preventive solutions, feel free to contact us.