PARTIAL REPLACEMENT OF S/R 1 POWER CABLE

ONLY PARTIAL REPLACEMENT WAS IMPLEMENTED DURING POWER CABLE

To attain reliable insulation resistance for medium voltage 3.3kV power cable.
1. Monitoring activity for S/R 1 power cable
results shown LOW insulation resistance

BACKGROUND OF
THE PROBLEM

for " S " phase.

JEC 146 standard provides that recommended insulation for medium voltage

80

Me ga Ohm s

PROJECT TITLE
PROBLEM
PURPOSE / GOAL

3.3 kV should be 4 M or higher.

S/R 1 POWER CABLE INSULATION RESISTANCE

Prepared by: WRBorja / JAMorano Noted:

40
30

PROBLEM
INVESTIGATION
JAN ' 09

JUN ' 09

AUG ' 09

Cable
spliced
portion
Bell-mouth STN. 435

STN. 87

a. Tunnel to SNT E/R = 10,000 M, good

b. Tunnel to S/R 1 = 3.5M, not good

6. Solutions were formulated to correct the problem.

1. Option 1. - Tracing and repair of buried cable at bend portion of bell mouth.
2. Option 2. - Replace cable from Station 87 to bell mouth with used flat cable from S/R 1.
3. Option 3. - Replace portion of the cable (500M) from the bell mouth to tunnel splice.

Spliced portion inside

tunnel
2.1 Mar. 15, 2010 - Inspection of
buried splice at STN. 80
revealed water intrusion
at spliced portion.

SOLUTION
FORMULATION

Spliced portion at STN. 80

A104R/ B111R
Junction

STN. 80

Tunnel from SNT E/R

Bell-mouth STN. 445

3. Mar. 15, 2010 - Countermeasure implemented to improve insulation resistance of cable.

Results improved from 3.8 M to 24 M.

IMPLEMENTATION

IMPLEMENTED
COUNTER
MEASURE
Remove old taping

AVGalaura-DM

50

INVESTIGATION /
DIAGNOSIS

RRBordo-MGR

60

10

A 102/ B 111 junction.

Test results shown

ELECTRICAL DEPARTMENT
MAINTENANCE DIVISION

5. Sep. 20, 2011 - Verification activity from at spliced portion at STN 80 revealed spliced portion is good
insulation deterioration has already creep from STN 80 to yard center.

70

20

2. Tracing of low insulation portion conducted

Oct. 14, 2009 inside cable tunnel near

DEPARTMENT
DIVISION

Cleaning of cable

Installation of Junction box

Cutting of cable at STN. 87

Flat and round cable junction

Commisioning
Splicing of cable at junction box
Insulation test at bell mouth
7. October 22, 2011 - Solution option 2 yeild remarkable results up to 500 M.
Retaping of splice

Before:

After:

RESULT AND
CONCLUSION
4. A year after the implementation of first countermeasure low insulation resistance problem recu
8. TANGIBLE BENEFITS

ENCOUNTERED
PROBLEM

BENEFITS
Total savings: P 2,050,000.00 - 220,000.00 = P 1,830,000.00
SCHEDULE OF
ACTIVITIES

2009

2010

Monitoring of cable First Cntr. measure

SEP 2011
Problem Recur

OCT 2011

Present

2nd solution

Cable good condition

Project
: Hydrated Lime Plant PLC Replacement Project
Department : Electrical
Subject
: Gantt Chart of Activities

LEGEND:
- actual work
- plan work

ACTIVITY

March
Weeks
1

April
Weeks
4

May
Weeks
4

Weeks
4

June
Days

2###
###
###
###
###
###
###
###
###
###
###
###
###
###
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###1

1) Material Preparation
1.01) Evaluation of existing PLC condition
1.02) Data gathering of existing PLC system configuration
1.03) Preparation of DPRs
1.04) Approval ( PO items)
1.05) Delivery / arrival of materials at PSC warehouse
a) Installation materials
b) PLC modules and accessories
2) Engineering Works
2.01) Generation of construction drawings
2.02) Preparation of wiring schedule
2.03) Preparation of wire markers
2.04) Programming of ladder diagram in SIEMENS PLC
2.05) Checking / debugging of PLC program
2.06) Wiring PLC front connectors
2.07) Loop checking of PLC wirings
3) Cabling works
3.01) Layout of power cable from BLP UPS to HLP HL41 panel
3.02) Layout of control cable in HLP (HL 41-45)
4) Fabrication / Installation works
4.01) Installation of MCCB for PLC supply (from BLP UPS)
4.02) Insulation test of power and control cables
4.03) Termination works of control cable (FUJI PLC section)
4.04) Assemble new PLC modules/hardware at HL 41 Panel
4.05) Installation of terminal blocks and PVC ducts in HL 41
4.06) Installation of wired PLC front connectors in modules
4.07) Termination of PLC wirings to HL 41 terminal blocks
4.08) Loop checking of PLC external signals
5) Commissioning
5.01) No load test
5.02) Operation test
5.03) End / Turnover

July
Days

NO HLP OPERATION

COMPLETED
PERCENT
DATE
3

REMARKS

(%)

(mm.dd.yyyy
)

100
100
100
100

03.07.2011
03.07.2011
03.09.2011
04.25.2011

100

04.28.2011

100

06.11.2011

100

04.11.2011

100

04.11.2011

100

04.25.2011

100

04.20.2011

100

05.25.2011

100

06.18.2011

100

06.20.2011

100

04.16.2011

100

04.20.2011

100

04.14.2011

100

05.02.2011

100

05.16.2011

100

06.18.2011

100

05.17.2011

100

06.20.2011

100

06.25.2011

100

06.28.2011

100

06.30.2011

100

07.01.2011

100

07.01.2011 project completed

S
70
67
78

T
1.9
2.8
3.9

23.9
38.6
35

Mega Ohms

R
JAN ' 09
JUN ' 09
AUG ' 09

S/R 1 POWER CABLE INSULATIO

80
70
60
50
40
30
20
10
0
JAN ' 09

JUN ' 09

CABLE INSULATION RESISTANCE

R
S
T

JUN ' 09

AUG ' 09

Production Loss per month:

(if problem was not resolved)

Hydrated Lime Production / month

BLP Daily Production (A) = 68T
HLP Monthly Production = (A) X (30days) X (1.1)
HLP Monthly Production = (68T) X (30days) X (1.1)
HLP Monthly Production = 2,244 T
Class A (55% of HLP production)
Class B (40% of HLP production)
Class C (5% of HLP production)

1,234 T
898 T
112 T

2,244

Class A Opportunity Loss / mo (@7,300php/T)

o. (1,234T) X (7,300php/T)
Class B Opportunity Loss / mo (@6,800php/T)
o. (898T) X (6,800php/T)
TOTAL OPPORTUNITY LOSS:
PLC Replacement Savings:
2,866,766php
Connecting PLC to Existing UPS:
587,049php
Monthly Opportunity Loss:
(if problem was not resolved)

15,113,340php

socomec
mitsubishi

ss / mo (@7,300php/T)
9,009,660 php

ss / mo (@6,800php/T)
6,103,680 php
### php