1. Example of restoration of electric equipment from damage caused by flooding - Asahi Kasei EIC Solutions corporation Muneto Watanabe 1 From Plant Engineer Oct. 2011 -Translated into English by : Shigeru Tsujita, TPM (SCG and Siam Cast Iron Work Co.Ltd.,) consultant. - 30..54

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. 2

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 High voltage cable Inside box Condenser for improve power factor Breaker for high voltage motorLoad center 3

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. 4

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 5

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 6

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. 7

8. 6.2 Shorten delivery time Parts nameStandard timeDelivery of This time 1) Parts for high voltage power supply 20 day4 day 2) Dry power transformer 30 day6 day 3) Parts for control center 20 day7 day 4) Parts change, test 7 day2 day 5) Parts cleaning 5 day2 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 transportation Initial breakdown Miss-delivery of specification etc. 8

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 wiring etc. 9

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. 10

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

12. Lexpure - Cleaner for electric parts- For cleaning print circuit board Out inside water by this cleaner Dont 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 : Dont disturb current at contact point 35 kV withstand voltage To be better contact point by light oiliness 12

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 13

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. 14

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 15

16. 8. Check safety We paid attention following items to secure safety; As many workers participated for the restoration, we grasped enter and go-out workers place where workers work workers who work overtime As power supplied partially depend on the restoration, we clarified indications for active wiring no-active wiring earth when operation on supplying power We supplied emergency power for safety devices fire alarm Pump for fire communication equipment 16

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. 17 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. 18

19. 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 date Bottle neck Spare parts Lease Fix control box Drawing Tools for fixing Test Restoration method Select fixer Emergency generator Temporary setting Operation manuals Power supply method Safety operation 19

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 20