Transcript PowerPoint プレゼンテーション

Example of restoration of electric equipment from
damage caused by flooding
- Asahi Kasei EIC Solutions corporation
Muneto Watanabe
-Translated into English by :
Shigeru Tsujita , TPM (SCG and
Siam Cast Iron Work Co.Ltd.,)
consultant.
From “Plant Engineer” Oct. 2011
- แบ่งปั นโดย สมชาย นิราพาธพงศ์พร
กรรมการมูลนิธิสง่ เสริ ม ทีคิมเอ็มในประเทศไทย
30 ต.ค.54
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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 flooding
Maximum height of flooding : 1.6m
Damaged equipment
Receive/Distribution equipment of power 15
Motors
600
Instrument
500
Others: DCS, PC, Document (Drawings), etc.
Water level
Load center
Water level
High voltage cable
Inside box
motor
Water level
Condenser for improve
power factor
Breaker for high
voltage
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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 weeks
Working hours for Maintenance : 16 hours/day
Meeting with production department
Investigation of parts/chemicals/ tool/supply
Investigation 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 operation
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6. Points for restoration
6.1 Secure basic documents
For 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
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.
example of 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
When we ordered parts, we always asked to get one more part. Because we thought that there
must be followings;
 Break when transportation
 Initial breakdown
 Miss-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 board
Out inside water by this cleaner
Don’t damage material
Early dry / 100% volatilization/easy treatment
35 kV withstand voltage
Lextend - Insulation protector  For insulation protect for high/low voltage
equipment
 To prevent lower insulation by humidity /
dirty
 Out inside water by this protector
 Very thin oil film type : Don’t disturb current
at contact point
 35 kV withstand voltage
 To 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 restoration
Disassemble ⇒ 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 inspection
② Organization for power supply, Information system for power supply
③ How to confirm power supply
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8. Check safety
We paid attention following items to secure safety;
① As many workers participated for the restoration, we grasped
enter and go-out workers
place where workers work
workers who work overtime
② As power supplied partially depend on the restoration, we clarified indications for
active wiring
no-active wiring
earth when operation
on supplying power
③ We supplied emergency power for safety devices
fire alarm
Pump for fire
communication 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.
I thought that it is important to check not only main circuit, but also surrounding equipment.
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10. Conclusion
We learned many lessons through the restoration from damage of flooding. (see page 19)
Add to it, I write important items;
① Considering 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.
② It 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.
③ It 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
Happen disaster
Initial operation
Group for
procurement
Control due date
Bottle neck
Spare parts
Lease
•
•
•
Prevention of secondary disaster (electric shock)
Gather core member
Grasp situation of disaster
Committee for measure for restoration
•
•
•
Decide restoration center
Gather engineers
Make organization and decide role
Target setting of restoration
•
Decide schedule for restoration
Group for
maintenance/test
Fix control box
Drawing
Tools for fixing
Test
Group for motor
Restoration method
Select fixer
Group for mobile
force
Emergency generator
Temporary setting
Group for wiring
Operation manuals
Power supply method
Safety 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 technicians
 Education for young engineers and technicians
 Engineering exchange with suppliers
Finally I think it is important
To make manual for “Business continuity plan”
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