Example of restoration of electric equipment from damage caused by flooding

1. 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. • แบ่งปันโดย สมชาย นิราพาธพงศ์พร • กรรมการมูลนิธิส่งเสริม ทีคิมเอ็มในประเทศไทย • 30 ต.ค.54 From “Plant Engineer” Oct. 2011

2. 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.

3. 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 motor Water level Water level High voltage cable Inside box Breaker for high voltage Condenser for improve power factor

4. 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.

5. 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

6. 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

7. 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.

8. 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 • 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.

9. 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 wiringetc.

10. 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.

11. Lextend (sell by 12 bottles) Protector for humidity, corrosion and lubricant for electric parts Lexpure (sell by 12 bottles) Non-chlorinate electric parts cleaner

12. 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

13. (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

14. (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.

15. 7. Re-connection operation Before supplying power, it was decided to apply followings; • Procedure for power supply, Check sheet for acceptance inspection • Organization for power supply, Information system for power supply • How to confirm power supply

16. 8. Check safety We paid attention following items to secure safety; • As many workers participated for the restoration, we graspedenter and go-out workersplace where workers workworkers who work overtime • As power supplied partially depend on the restoration, we clarified indications foractive wiringno-active wiringearth when operationon supplying power • We supplied emergency power for safety devicesfire alarmPump for firecommunication equipment

17. 9. Examples of miss-operation • 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 ) • 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. • 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.

18. 10. Conclusion We learned many lessons through the restoration from damage of flooding. (see page 19) Add to it, I write important items; 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. 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. It needs high total technology of engineers, as it needs speedy reaction and speedy judgment for safety at restoration from disaster.

19. 10. Conclusion Flow for countermeasure of disaster Happen disaster • Prevention of secondary disaster (electric shock) • Gather core member • Grasp situation of disaster Initial operation • Decide restoration center • Gather engineers • Make organization and decide role Committee for measure for restoration Target setting of restoration • Decide schedule for restoration Group for mobile force Group for motor Group for wiring Group for procurement Group for maintenance/test Operation manuals Power supply method Safety operation Control due date Bottle neck Spare parts Lease Emergency generator Temporary setting Fix control box Drawing Tools for fixing Test Restoration method Select fixer

20. 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”