Dertemining Root Causes of Problems at the Control Panel Using a Fishbone Diagram

Abstract

The Electrical Control Panel system is a critical infrastructure that serves as the center for power distribution and control in the engineering and fabrication facilities of PT Wasco Engineering Indonesia. Extreme industrial environments frequently trigger the degradation of electrical performance, characterized by a high frequency of disruptions such as short circuits, overloads, and insulation failures. This study aims to systematically identify the root causes of these failures (Root Cause Analysis) using the Fishbone Diagram method. The data collection methods included comprehensive field observations, visual inspections, and structured electrical testing on the P80 module (de-energized state) and the P83 module (energized state). Specific testing parameters included Condensation Tests, Corrosion Case Studies, and Sealing Protection Performance Tests. Historical maintenance data revealed 20 major failure incidents, heavily dominated by insulation failures (40%) and loose terminals (30%). The baseline P80 module test showed normal ambient conditions without visible condensation. However, the P83 module test indicated that the internal temperature during operation surged to 52.3°C, with relative humidity reaching 86%, directly triggering conductive condensation and elevating the component failure risk to a critical level. The verification of the root causes concluded that Environmental factors and Machine-induced vibrations were the primary contributors to the system's degradation. The implementation of targeted corrective actions, including sealing replacements and moisture control, successfully restored the insulation resistance of the critical cables to a highly safe operational level (ranging from 145 MΩ to 287 MΩ)