Example of restoration of electric equipment from damage caused by flooding - Asahi Kasei EIC Solutions corporation Muneto Watanabe 1 From Plant Engineer.

Example of restoration of electric equipment from damage caused by flooding

- Asahi Kasei EIC Solutions corporationMuneto Watanabe

1From “Plant Engineer” Oct. 2011

-Translated into English by : Shigeru Tsujita , TPM (SCG and Siam Cast Iron Work Co.Ltd.,) consultant.

- แบ่�งปั�นโดย สมชาย น�ราพาธพงศ์�พรกรรมการม�ลน�ธ�ส�งเสร�ม ที�คิ�มเอ็�มในปัระเทีศ์ไทีย30 ต.คิ.54

1. At the beginning

At one of our plants, there was a big damage caused by flooding at September 1997. At that time, big typhoon came and high tide came at same time.Here, I will introduce some examples of restoration of electric equipment from the damage.

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2. Scale of the damage caused by floodingMaximum height of flooding : 1.6m

Damaged equipment Receive/Distribution equipment of power 15Motors 600Instrument 500Others: DCS, PC, Document (Drawings), etc.

Water level

Water level Water level

High voltage cableInside box

Condenser for improve power factor

Breaker for high voltage

motorLoad center

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3. Organization for restoration

We started restoration at the evening when the flooding went away.“Committee for measure for restoration” was organized and tentative organizations for production, electric, mechanical, construction were started.The organization was for unite chain of command and information.It is very important to unite command and information at the first time.

Before flooding, there were only two electric engineers. So we gathered 30 engineers from all of our plants.

We made groups for procurement, maintenance/test, motor, mobile force and wiring.Add to it, we asked to join subcontractors and suppliers.It became 100 workers for the restoration.

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4. Target setting of the restoration

Start to supply power within two weeksWorking hours for Maintenance : 16 hours/day

Meeting with production departmentInvestigation of parts/chemicals/ tool/supplyInvestigation of workers

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5. Procedure of the restoration

1) Investigation of damages (Wiring system, receive/supply system, motor, instrument )

2) Decision of priority (Secure safety power→ high voltage → Low voltage → equipment)

3) Make list of damaged equipment (Decide finishing date)

4) Grouping of countermeasure (Select Repair / change / lease)

5) Preparation of equipment (Arrange root, Check storage)

6) Investigation of cleaning method (Method of eliminate salt/ cleaning)

7) Performance test (electric non-conductance/resistance test, sequence test)

8) Plan for power supply

9) Countermeasure for safety (Insulation, temporary generator etc.

10) Starting operation6

6. Points for restoration6.1 Secure basic documentsFor restoration, following drawings were needed.Drawing of electric system / wiring system / specification of motor / sequence etc.

However, all drawings on paper and on computer became extinct.

Happily there were drawings at subcontractors, because we had implemented to make drawings on computer.

From this teaching, we noticed the importance of backup for decentralize risks.

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6.2 Shorten delivery time

Parts name Standard time Delivery of This time

1) Parts for high voltage power supply 20 day 4 day

2) Dry power transformer 30 day 6 day

3) Parts for control center 20 day 7 day

4) Parts change, test 7 day 2 day

5) Parts cleaning 5 day 2 day

6) Overhaul of motors 10 day/600 unit

example of shorten delivery time

We explained to subcontractors and suppliers that it was emergency disaster and asked to finish as soon as possible. They cooperated us. It must be because of good relationships.

When we ordered parts, we always asked to get one more part. Because we thought that there must be followings;Break when transportationInitial breakdownMiss-delivery of specification etc.

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6.3 Make standards for repair

Even if they were emergency maintenance, operation standards were needed.Such as

Instruction for electric checking Test procedure Procedure for motor overhaul Procedure for take out and set motor Instruction for check wiring etc.

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6.4 Maintenance methods(1) General switch board

We decided to change all high voltage breaker, control equipment, relay, dry transformer etc.

We decided to clean insulator, terminal board, and wiring.Usually the cleaning is done by wipe and dry. However, it brings bad insulation by scratch.

↓Clean as follows;General parts : Washing : SS-100 liquid (Water with 50 % alcohol) Protector : Lextend (Name is not sure, It is Japanese name)Print circuit board : Washing : Lexpure (same as above) Protector : Lextend (Name is not sure, It is Japanese name)

Lextend and Lexpure are made by NCH corporation in Japan.http://www.chemsearch.jp/jp/aboutus/Pages/aboutchemsearch.aspx

I add some explanation at following two pages.

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Lexpure (sell by 12 bottles)Non-chlorinate electric parts cleaner

Lextend (sell by 12 bottles)Protector for humidity, corrosion and

lubricant for electric parts

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Lexpure - Cleaner for electric parts-For cleaning print circuit boardOut inside water by this cleanerDon’t damage materialEarly dry / 100% volatilization/easy treatment35 kV withstand voltage

Lextend - Insulation protector -For insulation protect for high/low voltage equipmentTo prevent lower insulation by humidity / dirtyOut inside water by this protectorVery thin oil film type : Don’t disturb current at contact point35 kV withstand voltageTo be better contact point by light oiliness

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(2) Motors

We asked to restore 600 motors to subcontractors and motor suppliers. To secure the finishing date, our engineers continued to stay there.

Method of restorationDisassemble ⇒ Washing by warm water ⇒ Steam washing ⇒ Drying ⇒ Paint varnish ⇒

Rust prevention ⇒ Change bearings ⇒ Assemble ⇒ Painting ⇒ Test

(It was effective for motors in salted water to dip it to warm water tank)

Wash motor Steam washing Paint varnish

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(2) Cable for high voltage (3kV)

As there was possibility that water invade to the cable from end part, we tested it by special insulation resistance meter (DC 6,000V) as simple test.Then we tested it by DC current leaking test as precious test.

As the result, we found 3 bad cables and changed them.

6.5 Confirmation of soundness of equipment

After the restorations, we tested (insulation register, withstand voltage, protector relay test, sequence test) and checked voltage, current and rotating direction.Then we set them to the plant.

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7. Re-connection operation

Before supplying power, it was decided to apply followings;

① Procedure for power supply, Check sheet for acceptance inspection② Organization for power supply, Information system for power supply③ How to confirm power supply

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8. Check safetyWe paid attention following items to secure safety;

① As many workers participated for the restoration, we graspedenter and go-out workersplace where workers workworkers who work overtime

② As power supplied partially depend on the restoration, we clarified indications foractive wiringno-active wiringearth when operationon supplying power

③ We supplied emergency power for safety devicesfire alarmPump for firecommunication equipment

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9. Examples of miss-operation

① When we received breaker and relay for high voltage, we found these were for low voltage. But we found it at receiving inspection happily. We could get them because we always ordered one more parts. (see page 8 )

② As many workers worked at noon around panel board, we started to supply power at night. However, it was very difficult to prepare tentative lights and preparation for power supply check because of wide area.

③ As we passed over blowing fuse of condenser trip system for air compressor control circuit, it stopped suddenly just after starting it.

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I thought that it is important to check not only main circuit, but also surrounding equipment.

10. Conclusion

We learned many lessons through the restoration from damage of flooding. (see page 19)Add to it, I write important items;①Considering emergency, it is important to keep back up data. It needs to be newest and keep it outside of plant. Good relation with subcontractors and suppliers are also important.②It is important to be thorough the chain of command and to hold information in common, even at emergency organization. To do them, it is important to clarify emergency system.③It needs high total technology of engineers, as it needs speedy reaction and speedy judgment for safety at restoration from disaster.

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10. Conclusion Flow for countermeasure of disaster

Initial operation

Happen disaster

Committee for measure for restoration

Target setting of restoration

Group for procurement

Group for maintenance/test

Group for motor Group for mobile force

Group for wiring

• Prevention of secondary disaster (electric shock)• Gather core member• Grasp situation of disaster

• Decide restoration center• Gather engineers• Make organization and decide role

• Decide schedule for restoration

Control due dateBottle neckSpare partsLease

Fix control boxDrawingTools for fixingTest

Restoration methodSelect fixer

Emergency generatorTemporary setting

Operation manualsPower supply methodSafety operation

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11. At the end

We could do best for the restoration from flooding. It is because there were a lot of skilled engineers and technicians. However, there are tendency that many skilled workers retire from our company and subcontractors.

So we are implementing following items;applying these old engineers and techniciansEducation for young engineers and techniciansEngineering exchange with suppliers

Finally I think it is importantTo make manual for “Business continuity plan”

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