augumentation of electrical feeders for power control center of sewage treatment plant- brown field...

7/29/2019 AUGUMENTATION OF ELECTRICAL FEEDERS FOR POWER CONTROL CENTER OF SEWAGE TREATMENT PLANT- BROWN FIELD PROJECT

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EPC SENATE CONFERENCE AT BANGKOK

23 & 24 SEPT 2013

ORGANIZED BY: TRUEVENTUS,MALAYSIA

CASE STUDY -PRESENTED BY

.FUTURA ELECTRONICS PRIVATE LTD

29,GOWRI AVENUE

ANAGAPUTHUR

CHENNAI600070


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EPC PROJECTS


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ENHANCE

AUGUMENT

RENOVATEMODERNIZE

BROWN

FIELDPROJECTS


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Assess Aged EquipmentUnderstand additions

Study technical feasibility

Drawings / documentsUndocumented changes

Obsolete Spare parts


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PCC Brown Field EPC @ Salalah-Oman

Futura Electronics Private Limited,Chennai,600070,India

Project Lead- S.Santhiraj

April - 2011


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Brownfield

Project Salalah

STP

Through Prime

EPCI contractor-MPE-Turkey


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OVERALL ACTION PLAN

Site Visit for Data Collection

Proposal with Requirements

Front End Engineering Design

Detailed Design &Owners Consultant Approval

Estimation, Negotiation & Order receipt

Manufacture

Factory Acceptance Testing

Installation

Commissioning

Dispatch


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SITE VISITPanel Cross Section Dimensions

Bus bar Size & disposition

Foundation

Discussion with maintenance for

collecting undocumented wiring changes

Drawings collectionCondition Assessment

Spare parts inventory check

Feed back from operation groupUnattended problems

Additional requirements

Photos of bus bars and PCC


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SITE VISIT EXISTING POWER CONTROL CENTER


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SITE VISIT PCC BUS BAR EXTENSION ONLY TO THE LEFT SIDE


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Site DataBill Of

Quantities

Scope

Definition

Risks

QHSE

Engineering

Man HoursSite Work

Estimation

Feasi i ity

HAZOP


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HAZOP -STUDYONE INCOMER AVAILABLE

ONE MORE INCOMER

NEEDED

WHAT IF BOTH INCOMERS

PRESSED INTO SERVICE?


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POKA YOKE MISTAKE PROOFING


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POKA YOKE -coined by

Japanese industrial processengineer Shigeo Shingo


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ENABLE:ONE INCOMER FOR SERVICE

DISABLE:

PUTTING TWO INCOMERS INTO SERVICE BY ERROR

NEED YOKE


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TWO LOCKS ONE KEY

KEY REMAINS STAY PUT WHEN LOCK IS

OEPRATED

SO, OPERATOR CAN OPERATE ONLY

ONE LOCK AT A TIME


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RISKSPHASE RISKS / CONSTRAINTS REMARKS

TECHNICAL PARALLELING OF TWOSOURCES LEADING TO

FLASHING

2 LOCK+1 KEY INTERLOCK

INSTALALTION CYCLE TIME DAMAGE WHILE REMOVAL BACK UP SPARES

COMMISSIONINGTIME

FAILURE OF COMPONENTSWHILE TESTING

72 HOURS SHUT DOWN

BACK UPSPARES/CONSUMABLES

Proper Plan of scope of work

Briefing before S/D

Course Correction

Crises handling


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QHSE COMPLIANCE

Quality Assurance Plan

FAT procedureMethod Statement for pre commissioning &

commissioning

Tool box meeting and briefing

ns a a on epor

Power up after installation with only controls power ONfor functional checking

Commissioning

Training of Owners personnel

Training of Owners O&M contractorsSafety Plan for Installation and Commissioning

Waste disposal plan as per prevailing norms of House

Keeping policy of owner


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TECHNICAL PROPOSAL & SUBMIT TO

CLIENT

SITE VISIT

OK ?

Front End Engineering Design


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ESTIMATIONNEGOTIATION

ORDER RECEIPT


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DETAILED DESIGN


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Scope of Work

Bus Bar Extension to the left of existing PCC

Extension Panel Size 1800(H) x 2340(H)x1800(D) Single front

Extension panel to house1 x ACB 2000A + 1 X ACB1250A + 2X MCCB800A

Bus bar interfacing between above panel & old panel

Termination of cables to extra feeders

Interlocking of Two Incomers with 2 Lock +1 Key , so that only

any one incomer active always

Electrical connections to be done within 72 hours of shutdown


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Single Line Diagram

KWH

METER

Power from the existing Generator

2000A, ACB, 3P, EDO, WITH O/L, S/C AND E/F RELEASE

415V, 50HZ, 3Ph, 4 Wire Bus with EXTENSION COUPLING TO EXISTINGCOPPER BUS 3000A,COPPER 85KA

800A, 3P,MCCB

800A, 3P,MCCB

1200A, ACB, 3P, MDO, WITH O/L AND S/CRELEASE

MCC-B MCC-4B MCC-3C


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S.NO DESCRIPTION SPECS MAKE QTY REMARKS

1 ACB, EDO 3P, 2000A ABB 1

2 ACB, MDO 3P, 1200A ABB 1

3 MCCB 3P, 800A ABB 2

4 R,Y,B IND. LAMPS 230V AC TEKNIC 3

5 VOLTMETER 500V AC NIPPEN 1

6 AMMETER 0-3000A NIPPEN 1

7 ENERGY METER KWH NIPPEN 1

BILL OF MATERIALS

8 RED CLOSE LAMP 230V AC TEKNIC 1

9 GREEN OPEN LAMP 230V AC TEKNIC 1

10 AMBER TRIP IND.LAMP 230V AC TEKNIC 2

11 CTS 3000/5 NIPPEN 3

12 VOLTMETER SS 600V AC TEKNIC 1

13 AMMETER SS 4 POSL TEKNIC 1

14 PANEL ENCLOSURE 1

15 CONTROL FUSES-SET 6A 1

16 NEUTRAL LINK-SET 32A TEKNIC 1

17 NAME PLATES-SET 1

18 SELECTOR SWITCH 4


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Incomer Control Circuit Scheme with 2 Lock + 1

Key Interlock

PTB-2

E,

50HZSUPPLYBYUSER

-MCB1

E-110VAC

ED

37ST81

STB-1

R-BUS

-MCB2

ECOIL

D1U1 37

110V ACP 110V ACP1 230V R230V R1

2000 A

PTB-1

110VAC,

SINGLEP

HA

DP-6

SPRINGCH

AR

SPRINGCH

AR

38ST

82

STB-2

N-BUS

DP-6

UNDERVOL

TAG

YU

D2U2 38

110V ACN 110V ACN1 230V N 230V N1

ACB


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Front Elevation of the additionalPCC section


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Bus Bar Matching for Extension using

Fish Plates 940 860

Suggested cut outs in existing panel

for connection size: 200[H]*100[W]

R-Phase copper bus 90*6 sq.mm.

- *

170

225

. .

B-Phase copper bus 90*6 sq.mm.

N-Phase copper bus 90*6 sq.mm.

170

275


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MANUFACTURE

PREPARE QUALITY ASSURANCE PLAN & GET IT APPROVED

PREPARE DETAILED DESIGN DRAWINGS & GET THEM APPROVED

PREPARE FAT PROCEDURE & GET IT APPROVED

PROCURE COMPONENTS WITH TEST CERTIFICATES

PERFORM INCOMING CHECKS FOR QUALITY & LOG

MANUFACTURE PANEL WITH STAGE INSPECTION & LOG

MOUNT COMPONENTS AS PER APPROVED DRAWINGS

BUS BAR BENDING,MOUNTING & FIXING

CABLING WITH FERRULES

IN HOUSE ASSEMBLY TEST

HV TEST

MEGGER

POWER UP

FUNCTIONAL TEST

FAT BY CLIENT


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INSTALLATION

Civil work for cable trench as per

foundation planLaying of cables for extra feeders with

enough loop lengths for termination

connectionPositioning additional panel to location

Cut out in existing panel for bus bar

access

Identifying circuit points for controlcircuit supply of 110VAC new panel,

from the old panel


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EXISTING PCC FRONT ELEVATION


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Existing PCC switch board

Left side wall of the existing

PCC removed

Bus bar extension coupled

using fish plates for theadditional panel


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New PCC Extension Panel Front View

Bus Bar Extension

ABB make ACBs &

Cable Entry

MCCBs

2000A-ACB-Incomerwith EDO,O/L,S/C,E/F &

U/V protection

1200A-ACB-Outgoing

Feeder with MDO,O/L &

S/C release


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New PCC Extension Panel Bus Bars View at back side

us ar atc ng n

Elevation & Depthfor proper fish plate

seating


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EXTENDED BUS BAR


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OLD PCC PANELEXTENSION PANEL


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COMMISSIONING PROBLEMDG feeder(IC2) could

not be put into service,

when the other

incomer(IC1) was put

out of service


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SURPRISES COMMISSIONING PHASE

Tapping for Control Voltage DG

incomer-2000A, changed to new

panels incomer bus bar , this is toensure power availability before

switching on the DG Incomer.When DG

is OFF, DG incomer cannot be put onservice, as there is no control voltage


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The Team


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For Flawless Planning & Execution of

Brownfield Projects in E&I

Contact:

S.SANTHIRAJ, +91 98400 46463

FUTURA ELECTRONICS PRIVATE LIMITED29,Gowri Avenue

Anagaputhur

Chennai

600070

India

[email protected]

[email protected]

augumentation of electrical feeders for power control center of sewage treatment plant- brown field...

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