Executing a Flawless Turnaround: Lessons Learned at a Petrochemical Facility

Abstract

Petrochemical facilities rely on electrical power availability to ensure a safe and profitable business. The periodic testing of electrical equipment is necessary for safe and reliable operation. Electrical apparatuses, including switchgear, motor control centers (MCCs), and uninterruptible power supplies (UPSs), must be de-energized periodically and taken out of service for maintenance testing, repairs, or installation of additional sections to accommodate growth. This process is lengthy, and planning begins years in advance to prepare for extensive inspection and testing activities. This article discusses the experiences, findings, and lessons learned at a 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 nine secondary selective automatic transfer switchgear lineups, 67 low- voltage (LV) MCCs, and 13 UPSs. The journey includes temporary power plans, testing plans, operational issues, reporting, backfeed connections, component upgrades because of manufacturer product safety advisories, equipment repairs, inspection findings, relay firmware upgrades, training of personnel, isolation, switching, grounding plans, guarantee of isolation (GOI) documentation, electrical personal protective equipment (PPE), testing equipment, and communications plans to advise regarding power outages.