Experiences and learnings in executing a flawless turnaround at a petrochemical facility

Petrochemical facilities depend on electrical power availability to ensure a safe and profitable business. Periodic testing of electrical equipment leads to a safe and reliable operation. Electrical apparatus, including switchgear, motor control centers (MCC) and uninterruptible power supplies (UPS) must be de-energized periodically and taken out of service for maintenance testing, repairs or installation of additional sections to accommodate growth. The process is lengthy, with planning starting years in advance to prepare for extensive inspection and testing activities. This paper discusses the experience, findings and lessons learned at one petrochemical facility during a 70 day operational turnaround. Significant investments were made in purchasing temporary power equipment and hiring numerous electrical speciality contractors to perform maintenance testing of electrical equipment in nine substations, including 9 secondary selective automatic transfer switchgear line-ups, 67 LV MCC's and 13 UPS's. The journey covers temporary power plans, testing plans, operational issues, reporting, backfeed connections, component upgrades due to manufacturer product safety advisories, equipment repairs, inspection findings, relay firmware upgrades, training of personnel, isolation, switching, grounding plans, guarantee of isolation documentation, electrical personal protective equipment (PPE), testing equipment, and communications plans to advise of power outages.