Tackling Electrical System Efficiency, Safety and Reliability for pharmaceutical plants

Transcription

1 Tackling Electrical System Efficiency, Safety and Reliability for pharmaceutical plants.

2 MSD Rathdrum Site History 1961 Loftus Bryan Chemicals Ltd 1964 P1 Production Plant 1975 P2, QC / R&D & Pilot Plant 1, Engineering / Warehouse 1977 FDA Approval q 1980 Schering-Plough acquired LBC q 1983 P3 Production Plant q 1986 R&D II / Pilot Plant Ext (P7) q 1995 P5 Production Plant q 2000 P5 Extension q 2005 P2/3/4 Annex q 2009 Construction of H2 Facility (P6) q 2009 Merck/Schering Plough Merger

3 Facility Aerial View

4 Incidents at Rathdrum P7 Fire Failure of Switchgear Protection Coordination not configured correctly Power disruption to complete Facility Significant property damage & Business disruption Equalisation Tank Explosion Electrical Fault Inadequate Electrical Protection Significant property damage & Business disruption Both out of hours no injury to personnel

5 Fundamental Objectives of the Electrical Maintenance Function In most large-scale manufacturing sites the Electrical Distribution System (EDS) might be considered as the Back Bone that sustains all operations on site. The key objectives of EDS maintenance fall under three headings 1. Safety of the EDS Ensuring that the EDS presents no safety hazards to personnel using or interacting with the system 2. Reliability / Continuity of Supply Ensuring that all possible precautions are taken to prevent power outages that could inflict serious losses due to interruption of critical production processes. 3. Efficiency & Protection of the EDS Asset In most large-scale manufacturing sites, the EDS represents a significant investment that must be protected against inadvertent abuses or incidents: e.g. Ø Ø Ø Overloads/Short-circuits Local site hazards e.g. corrosion, explosive atmospheres Extraneous circumstances e.g. storm or lightning damage

6 Safety of the Electrical Distribution System

7 Safety of the EDS 1. Statutory Instruments governing Safety at Work It is important to understand how the legal framework governing electrical safety at work is structured 1. Health & Safety Authority HSA The Safety Health and Welfare at Work Act Commission for Energy Regulation CER 3. Local Fire Authority Ø Electrical Safety legislation in Ireland is determined by two published documents - S.I. 299 General Application Regulations - National Wiring Rules published by the Electro Technical Council of Ireland (ETCI)

8 Safety of the EDS 2. The Safety Statement The cornerstone of the Health and Safety Act is the Safety Statement The Act requires every employer to: a) identify the hazards and assess the risks at his place of work b) prepare a written statement which specifies the manner in which safety of employees will be secured In the event of an accident at work the starting point in all follow-up investigations is the same: Can I see your Safety Statement In addition, special protection related to Electrical Systems is now the focus of critical attention from HSA and needs to be addressed appropriately. Ø Periodic Electrical inspection & testing 2014 Ø Electrical PPE Ø Control of Electrical Hazards

9 Recent statistics Thirty-two workers were killed in fatal electrical accidents over the ten-year period , according to the annual report of the Electro-Technical Council of Ireland s Safety Committee. The equipment involved in the fatal accidents was: Ø overhead lines in 18 cases, Ø fixed apparatus in 6 cases, Ø 3 in both cable/wiring and portable apparatus, Ø 3 accidents involved circuit breakers and Ø 2 flexes. Ø 1power transformer and Ø 1 socket.

10 Arc Flash Hazard Is an explosive release of energy caused by an electrical short circuit

11 Consequences of an Arc Flash Hazard Ø Arc flash injuries range from minor burns to 3 rd degree burns and potential death due to the energy released. Ø Equipment Damage: Costly to repair Ø Plant Shutdown: Reduced productivity It is estimated that as many as 80% of electrical injuries are a result of Arc Flash rather than electric shock (NFPA 70E).

12 Arc Flash Study Arc Flash Hazard Analysis conducted using a Software Model Ø Compliance with industry standards: S.I.299, NFPA70E, IEEE1584, IEC Ø Identified the magnitude of the electrical hazard Protection circuitry changes were required to reduce energy levels. Ø Helped to develop a safety program to mitigate the risks associated with electrical equipment. Labelling of Switchgear Ø Recommendations for Electrical PPE. Change of Maintenance Overalls Appropriate Electrical Tools

13 Software Model Load Flow, Capacity, Protection Coordination, Actual usage, etc

14 Software Model Advantages: - Centralised source of electrical data & drawings - Analysis tool for various modes of operation - Expansion planning - Equipment sizing and capacity identification Analysis Types: - Load/Power Flow Analysis - Fault Level Analysis - Protection Coordination - Arc Flash Analysis - Reliability Analysis - Harmonic Analysis, etc.

15 Efficiency & Protection of the EDS Asset

16 Protection Coordination Ø Protection relays disconnect the fault in a time that; q Safely limits fault energy q Prevents electrocution q Is within equipment capability q Minimises the impact on the network Ø Discrimination is adequate Ø Protection relays remain stable Ø Relay performs at minimum fault levels

17 Protection Coordination

18 Protection of the EDS Asset 1. Circuit Capacities Ensuring that all major circuits in the system have a current carrying capacity commensurate with the existing plant loadings. 2. Protection Coordination This is the simple principle of ensuring that circuit breaker trip settings are set in a hierarchical manner that ensures that faults are cleared as close as possible to the point of occurrence A fault at [A] should be cleared by the breaker at [A] not by the breaker at [B] thereby bringing out many branches of the network unaffected by the original fault. 3. How can these settings be wrong? The EDS system is an evolving asset. It is constantly being modified to accommodate new plant and processes. It can happen that significant extra loads are added to particular circuits without fully appreciating their impact on the overall protection setting of the system

19 Load Flow Analysis Ø Power Flow (kw, kva, kvar) Ø Sizing of Switchgear and Cables Ø Assess Branch and Network Losses Ø Examine the impact of changes before implementation Ø Stranded capacity identification

20 Reliability / Continuity of the Electrical Supply

21 Electrical System Reliability Model for continuous reliability used at Rathdrum

22 Consequences of Poor Reliability Ø Equipment Downtime/Failure - 64bln Ø Waste in Product - 45bln Ø Production Downtime - 36bln Ø Labour - 5bln * EU 2007 Leonardo Energy

23 Incidents at Rathdrum P7 Fire Failure of Switchgear Power disruption to complete Facility Equalisation Tank Explosion Electrical Fault Significant property damage & Business disruption Significant property damage & Business disruption Cost 800k+ Cost 600k+ Both out of hours no injury to personnel

24 Key elements of Electrical Reliability Ø In depth knowledge of the existing Electrical Infrastructure Ø Power Quality Analysis Ø Detailed System Modeling Ø Probabilistic Risk Assessment using IEEE 493 Reliability Standard

25 Power Quality Problems encountered with Poor Power Quality Ø Failure of mission critical electronic systems Ø Computer / Electronic Equipment Damage Ø Data Loss (Server locking up 200k+) Ø Circuit Breaker tripping (?) Ø Relays - Nuisance Tripping Ø Capacitor Bank Failure Ø Transformers & Cables overheating ( 100k+) Ø Motor / Process Equipment Malfunction

26 EDS Monitoring Capital justification for Energy Monitoring

27 Batch Manufacturing No Baseline Alerts Able to quantify Improvements

28 Added Benefits EDMS Analyse harmonics, voltage sag, PFC, transients, system unbalance Assist in preventive and predictive maintenance Identify source and frequency of events Determine the need for power conditioning equipment

29 TRANSIENT VOLTAGES Hidden Transients are (typically a few milliseconds duration) power disturbances: Ø Surge - Ø Noise - Effect - Effect - Large magnitude voltage/current problems Hardware Damage Small magnitude fast rise voltage problem Software / Hardware errors, system lock-up

30 Voltage Sag / Swell Voltage sag / swell events generate high currents (inrush of motors and other devices).

31 Reliability Evaluation Methods Failure Mode Evaluation Analysis (FMEA) State Enumeration Method IEEE493 Software model is the basis

32 Reliability Overview

33 Reliability Solution Cost vs. Plant Availability Cost of unplanned downtime Software Model Power Quality capability Using Data for the Elec Dist performance Availability

34 MSD Rathdrum Hosts Visit A conference of EU member state regulators visited the Rathdrum site to view the two Hydrogenation installations, due to the exemplary standard of work. A design comparison between the original 1988 installation and the more recent 2010 project.

35 Summary Key Take Away 1. Safety of the EDS Arc Flash Assessment Electrical PPE 2. Reliability / Continuity of Supply Electrical Maintenance Reliability Programme 3. Efficiency & Protection of the EDS Asset The EDS represents a significant investment that must be protected against inadvertent abuses or incidents. 4. Site Wide Overview Holistic approach required to assess the impact of add on or extensions

36 Questions Thank You