CP MANUFACTURING ELECTRICAL SYSTEM AUDIT PROJECT … · 2020. 5. 18. · Title: Electrical System...

Company/Dept.: CP GROUP / Advanced MRF

Title: Electrical System Audit Project #3870 Document Number: Audit‐200116

Author: Juan Chavez

Date: 2020/01/21

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CP MANUFACTURING

ELECTRICAL SYSTEM AUDIT

PROJECT #3870

Audit Date: January 16/17, 2020

All hard copies of this document are considered “uncontrolled”.



Author: Juan Chavez

Date: 2020/01/21

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TABLE OF CONTENTS

EXECUTIVE SUMMARY ............................................................................................................................... 3

PURPOSE ......................................................................................................................................................... 4

SCOPE ............................................................................................................................................................. 4

DEFINITIONS & RESPONSIBILITIES .......................................................................................................... 5

GENERAL OBSERVATIONS ......................................................................................................................... 6

OBSERVATIONS .................................................................................................................................................................. 6 GENERAL HOUSEKEEPING ................................................................................................................................................. 6

ELECTRICAL AUDIT .................................................................................................................................... 7

RECOMMENDED SYSTEM UPGRADES OR ENHANCEMENTS .............................................................. 47

RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE .............................................................. 48

SEMI-ANNUALLY: ...................................................................................................................................................... 48



Author: Juan Chavez

Date: 2020/01/21

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EXECUTIVE SUMMARY

This report will outline CP Group’s electrical system audit for the Material Recovery

Facility located at 6700 DELILAH RD, EGG HARBOR TWNSP, ATLANTIC COUNTY, NJ

08234.



Author: Juan Chavez

Date: 2020/01/21

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PURPOSE

The purpose of this audit is to provide a detailed report as to the condition of the

equipment installed at the recycling plant. This report provides a technical view of the condition

of the electrical system and gives suggestions to remedy problem areas observed. A preventative

maintenance schedule ensures all involved have an understanding of the recommended

inspections and tasks to facilitate trouble-free operation of the MRF.

SCOPE

The Audit will encompass the electrical control panels (MCC’s), motor wiring and

conduit, emergency stop devices, and all other devices connected to the control system. Within

this report are preventative maintenance recommendations, recommended spare parts, and

recommended system enhancements and upgrades. The preventative maintenance

recommendations are guidelines, which if followed can minimize downtime and emergency

repairs. The recommended spare parts list is a list tailored to your system that would allow

quicker resolution of common problems and provide preventative maintenance supplies for

easier scheduling of maintenance. The recommended system enhancements and upgrades will

point out possible improvements and upgrades to refine your operations to achieve less

downtime, better throughput, and higher yields of recyclables.



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Date: 2020/01/21

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DEFINITIONS & RESPONSIBILITIES

MRF Material Recovery Facility

E-Stop Emergency Stop

MCC Motor Control Center



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GENERAL OBSERVATIONS

Observations

The MCC 1, 2 & 3 Panels requires minimal Corrective Maintenance in order to improve the panel’s efficiency. The main areas of concern on the MCC Panels are the following:

1. Some items in the panel present erosion on the frame of the component, apparently looks like it’s due to extreme heat from the same component (page 30 & 36).

2. The Emergency Stop Circuit requires an upgrade to improve the life span of the VFD 3. The Terminal Box and disconnect Switches on some motors has been damaged, this requires

immediate attention. Foreign material can trigger a Single Phase fault on the motor since the Terminal Box is not sealed.

4. Some Wire Assemblies are not labeled or placed inside the terminal ducting. Having disorganized wire connections can cause extensive delays on corrective maintenance.

General Housekeeping

A Preventative Maintenance Program should be created in order to prevent unwanted downtime due to electrical failure. The electrical assessment done on the Variable Frequency Drive circuit revealed few loose wires. Having a loose phase on the Drives Load Side can create a fault known as “Single Phasing”. A Single Phase Fault generates high current consumption at the motor’s winding which damages the corresponding VFD.

A proactive resolution is to create a Preventive and Corrective Maintenance procedure that address the following items:

1. Tighten all terminal screws found inside the MCC Panels, Emergency Stop Devices and Motor Terminal Box.

2. Have on hand Spare Parts to resolve electrical failure that renders down time. 3. Clean the MCC Panels by using compressed dry air inside the panel to remove dust and debris. 4. Train a lead maintenance person to deliver corrective maintenance when working with electrical

issues. Training can be done on a yearly basis depending on the crew’s experience.



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ELECTRICAL AUDIT

Picture 1

Picture 1 shows trash/dirt buildup on the motor and disconnect switch. Maintaining equipment clean and free of foreign objects is important to extend the life of all gear.

Motor Number M-1 Location Conveyor 1 Description LOWER HORIZONTAL CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Remove trash buildup Motor Terminal Box Remove trash buildup E-Stops Conduit Connections



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Picture 2 shows damaged Disconnect Switch box for HPU. The Disconnect Switch box is broken. This will not prevent foreign material from entering and causing a malfunction with the Disconnect switch operation.

Motor Number M-3 Location Infeed Description HYDRAULIC POWER UNIT Component Okay Repair N/A Comment Motor Disconnect Switch Broken Motor Terminal Box E-Stops Conduit Connections

Picture 2



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Picture 3

Picture 3 shows trash/dirt buildup on the motor and disconnect switch. Maintaining equipment clean and free of foreign objects is important to extend the life of all gear.

Motor Number M-9 Location Under Pre-sort platform Description SCALPING SCREEN UNDERS TRANSFER CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Remove trash buildup Motor Terminal Box E-Stops Conduit Connections



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`

Picture 4

Picture 4 shows damaged Disconnect Switch box for HPU. The Disconnect Switch box is broken. This may cause a malfunction with the Disconnect switch operation if temporary fix stops working.

Motor Number M-19E Location Cp Screen 19 Description HYDRAULIC POWER UNIT Component Okay Repair N/A Comment Motor Disconnect Switch Loose Motor Terminal Box E-Stops Conduit Connections



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Picture 5

Picture 5 shows loose Disconnect Switch for Motor M-14A. This could cause the conduit to break or loosen from the connector, exposing the wires and causing an electric hazard.

Motor Number M-14A Location NewScreen 14 Description NEWSCREEN, INCLINE DECK MOTOR 1 Component Okay Repair N/A Comment Motor Disconnect Switch Loose Motor Terminal Box E-Stops Conduit Connections



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Picture 6

Picture 6 shows loose Disconnect Switch for Motor M-30. This could cause the conduit to break or loosen from the connector, exposing the wires and causing an electric hazard.

Motor Number M-30 Location Conveyor 30 Description CONTAINER SORT CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Loose Motor Terminal Box E-Stops Conduit Connections



Author: Juan Chavez

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Picture 7

Picture 7 shows Disconnect Switch for C-20. The Disconnect Switch is inoperable because of dirt accumulation. Requires cleaning.

Motor Number M-20 Location Conveyor 20 Description FERROUS TRANSFER CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Non-operational, cleaning required Motor Terminal Box E-Stops Conduit Connections



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Picture 8

Picture 8 shows exposed wires on the conduit feed for Motor M-36A. The connector and conduit are loose and need to be refitted.

Motor Number M-36A Location Eddy Current 36 Description EDDY CURRENT ROTOR Component Okay Repair N/A Comment Motor Disconnect Switch Motor Terminal Box E-Stops Conduit Connections Loose connectors and conduit



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Picture 9

Picture 9 shows damaged conduit feed for Motor M-58. The conduit is loose from the connector on the Motor Terminal Box.

Motor Number M-58 Location Glass baling Description IMPACTOR GLASS CRUSHER - MODEL APS-0406/K BY

"HAZEMAG" Component Okay Repair N/A Comment Motor Disconnect Switch Motor Terminal Box E-Stops Conduit Connections Loose conduit



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Picture 10

Picture 10 shows loose conduit from JB1. The conduit is loose and held in place with zip ties. This may cause accidental snagging by other equipment.

Motor Number JB1 Location Baling Area Description Feed from JB1 Component Okay Repair N/A Comment Motor Disconnect Switch Motor Terminal Box E-Stops Conduit Connections Loose



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Picture 11

Picture 11 shows exposed wires on the conduit feed for compactor #42 disconnect switch. The conduit is loose from the connector exposing wires.

Motor Number Compactor #42

Location Trash compactor

Description Trash compactor #42 Disconnect Switch Component Okay Repair N/A Comment Motor Disconnect Switch Motor Terminal Box E-Stops Conduit Connections Loose conduit



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Picture 12

Picture 12 shows Disconnect Switch for C-39. The Disconnect Switch is covered with dirt. Requires cleaning

Motor Number M-39 Location Conveyor 39 Description TRASH TRANSFER CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Cleaning required Motor Terminal Box E-Stops Conduit Connections



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Picture 13

Picture 13 shows damaged Disconnect Switch & conduit feed for Motor M-21A. The flexible conduit is broken off from the motors feed, Disconnect Switch is damaged and must be replaced immediately. The Damaged conduit and broken Disconnect Switch present an electrical hazard.

Motor Number M-21A Location Conveyor 21A Description OMP TRANSFER CONVEYOR REVERSIBLE Component Okay Repair N/A Comment Motor Disconnect Switch Damaged box Motor Terminal Box E-Stops Conduit Connections Damaged conduit



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Picture 14

Picture 14 shows damaged Disconnect Switch box for C-18. The Disconnect Switch box is broken. This will not prevent foreign material from entering and causing a malfunction with the Disconnect switch operation.

Motor Number M-18 Location Conveyor 18 Description CP SCREEN FEED CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Damaged box Motor Terminal Box E-Stops Conduit Connections



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Picture 15

Picture 15 shows damaged Disconnect Switch box for C-18. The Disconnect Switch box is broken. This will not prevent foreign material from entering and causing a malfunction with the Disconnect switch operation.

Motor Number M-18 Location Conveyor 18 Description CP SCREEN FEED CONVEYOR Component Okay Repair N/A Comment Motor Disconnect Switch Damaged box Motor Terminal Box E-Stops Conduit Connections



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Date: 2020/01/21

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Item # E-Stop Zones Location MCC1 Description: SINGLE STREAM LINE

ZONE Location Okay Repair Comment

Zone 1 MCC-1 PANEL DOOR ES-1

Zone 2 INCLINE CONVEYOR C-2 ES-2 ES-3 Replace button ES-3

See Picture 16

Zone 3 PRE SORT CONVEYOR C-4 PC-1 PC-2 Replace carabiner

See Picture 17

Zone 4 SCALPING SCREEN #5 ES-4 ES-5

Zone 5 OCC SCREEN #6 ES-6 ES-7

Zone 6 GLASS POST SORT CONVEYOR C-10 PC-3A PC-3B

Requires cleaning See Picture 18. Notes

Zone 7 GLASS BREAKER (12) ES-8 ES-9

Zone 8 NEW SCREEN (14) ES-10 ES-11

Zone 9 ONP SORT CONVEYOR C-16 PC-4 PC-5

Replace Pull Cords See Picture 19. Notes

Zone 10 CP SCREEN (19) ES-12 ES-13

Zone 11 OMP SORT CONVEYOR C-20A PC-6 PC-7

Replace Pull Cords See Picture 19. Notes

Zone 12 ADS (25) ES-14

Zone 13 CONTAINER SORT CONVEYOR C-30 PC-8 Replace Pull Cord

See Picture 20

Zone 14 MSS ALADDIN ES-15

Zone 15 PET QC SORT CONVEYOR C-37 PC-9 Replace Pull Cord

See Picture 21

Zone 16 GLASS TROMMEL SCREEN (59) ES-16 ES-17

Zone 17 COMPACTORS AREA ES-18



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Date: 2020/01/21

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Notes:

Zone 6 Pull Cords requires cleaning, does not comply with NFPA 79 10.7.3, RED button should have a YELLOW background color.

Zone 9/11/13/15 Pull Cords need replacement. Pull Cord actuators require a Red Push Button for emergency stop.

Zone 23 conduit and connector feeding E-Stop button is not using proper connector ans conduit for this application. For the panel to maintain proper NEMA Ratings all conduits should used proper connectors.

Item # E-Stop Zones Location MCC3 Description: BALING LINE E-STOP ZONE DESIGNATION

Component Location Okay Repair Comment

Zone 20 MCC-3 PANEL DOOR

Zone 21 BUNKER CONVEYOR C-53

Zone 22 TOUCH SCREEN TS-3

Zone 23 BUNKER DOOR HPU Replace feeder conduit & connector. See Picture 22



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Picture 16, Push Button ES-3

Picture 17, Pull Cord PC-1



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Picture 18, Pull Cord PC-3A & PC-3B



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Picture 19, Pull Cord PC-4, PC-5, PC-6 & PC-7



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Picture 22, Push Button ES-24



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MCC 1

MCC1 Wiring not organized and dust accumulated at VFD’s

Conserving the cleanliness inside the MCC panel is essential to decreasing downtime caused by electrical faults. The pictures show a good degree of cleanliness inside the panel, with some exceptions. The following items were observed in regards to the panel’s cleanliness: 1. Dust and debris entering the panel will degrade the air circulation of the VFD’s heat sink, the screw terminal connections and affect the Motor Contactors. 2. The wire assembly inside the MCC1 Panel is disorganized. Some of the wires do not have a label for electric drawing reference. Any corrective maintenance will be limited due to MCC Panels housekeeping. 3. The main function of a wire duct is to keep all wire conductors inside the raceway to prevent an electrical hazard. The MCC 1 panel shows that some of the wire conductors are exposed. Solution: Proper housekeeping is highly recommended in order to best manage the electrical wiring, and harmful contaminants.



Author: Juan Chavez

Date: 2020/01/21

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Motor group RV/RT present formation or wear on the outer case of the gear. This is most likely due to extreme heat for a long period of time.

Solution: If possible leave a gap between each motor Group RV/RT to allow some air circulation in between, helping them to cool down faster.



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Date: 2020/01/21

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MCC 2

MCC2 is farly clean and maintained in its original configuration. Dust acummulation is very well controlled, some spots require dust remooval but nothing major.



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Date: 2020/01/21

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Door lock.

Door 1 and 2 of the panel where not working properly. Door lock would not close completely and would stick out, this could pose harm to anyone opening the panel without knowing the danger it poses if not properly powered down.

Solution: doors need to change lock handle or fix existing to properly close door.



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Date: 2020/01/21

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MCC 3

Additional gear was added to MCC3 panel. Fuse box was added to a distribution buss bar feed, fuse box should be fed directly from the power distribution buss.



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Date: 2020/01/21

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MCC3 dust accumulated at VFD’s and panel,

Conserving the cleanliness inside the MCC panel is essential to decreasing downtime caused by electrical faults. The pictures show a good degree of cleanliness inside the panel, with some exceptions. The following items were observed in regards to the panel’s cleanliness: 1. Dust and debris entering the panel will degrade the air circulation of the VFD’s heat sink, the screw terminal connections and affect the Motor Contactors. Solution: Proper housekeeping is highly recommended in order to best manage the electrical wiring, and harmful contaminants.



Author: Juan Chavez

Date: 2020/01/21

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Heat signatures readings

The following section annunciates the evidence found when performing the heat readings. To explain, a loose wire or faulty connection will create a “Hot Spot” due to the fact that a resistance point is created. This focal point will create additional heat and it’s visible in the infrared rage. The risks of not amending a loose connection is to allow the cable insulation to degrade by the heat generated. Once the insulation of the cable has been compromised the potential of an electrical hazard can occur.

Solution: Promote a preventive maintenance program in order to ensure that all screw terminals are torque upon a set schedule. The schedule should start at least every 6 months, if it is determine that the period of the schedule is not sufficient then re-schedule to every 3 months. In addition, it is strongly recommended to purchase an infrared camera as part of the troubleshooting tool for the maintenance team. The infrared camera is a great tool that helps quickly identify areas of concern.

MCC1 Main Disconnect Switch In.

MCC1 Main Disconnect Switch Out.



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MCC1 Distribution Block.

MCC1 Disconnect RV/RT MG-1 to MG-8.

MCC1 24V Power supply.



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MCC1 PLC.

MCC1 I/O Rack, F-DI.

MCC1 110V transformer.



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MCC1 Direct Starter MS-32 & MS-33 heat exhaust.

MCC1 Direct Starter MS-808 wire output.

MCC1 Direct Starter MS-65.



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MCC1 Direct Starter MG-1, MG-2 & MG-3 wire feed.

MCC1 Direct Starter MG-5, MG-6 & MG-7 wire feed.

MG‐1 MG‐2 MG‐3

MG‐5 MG‐6

MG‐7





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MCC2 I/O Rack F-DO.

MCC2 RV-AC.

MCC2 RV-25C.



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MCC2 RV wire duct feed.

MCC2 RV-1 to RV-10.

MCC2 RV-12A to RV-16.



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MCC2 RV-19A to RV-25A.

MCC2 VFD-4.

MCC2 VFD-14D.



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MCC2 VFD-59.

MCC2 RT-58.

MCC2 RT-56A to RT-59.



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MCC2 RT-14B output.

MCC2 Wire output.

MCC3 24V Power supply.



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Date: 2020/01/21

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MCC3 F-DI A6 & A8.

MCC3 110V Power Transformer.

MCC3 RV/RT MG1.



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MCC3 Direct starter MS-15.

MCC3 RT-53 to RT-69.

MCC3 VFD-69.



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RECOMMENDED SYSTEM UPGRADES OR ENHANCEMENTS

The following sections describe the suggested system upgrades in order to improve production and minimize downtime. We recommend that a Preventive maintenance schedule is implemented, as it will aid in avoiding major down time caused by electrical failures. In addition the following improvements are recommended at this facility:

1. The Emergency Stop Circuit can be upgraded to our current standards. This upgrade will reduce the time it requires to achieve a complete auto start after an Emergency

Stop event.

2. The Auto Start sequence can be corrected to the current material flow Having a dysfunctional auto start sequence will not stop the system accordingly in the event of a

fault. Improper auto start sequence can create extensive time consuming jams.

3. Remote Connection can be establish via VPN The remote connection looks like is currently offline. Having a VPN connection via the internet

allows more flexibility when delivering support since internet access is easily available.

4. Updated Electrical Drawings Having an updated prints of electrical drawings will reduce time on corrective maintenance events.

5. Warning Device Install a four signal warning device, this will visual enhance the MRF status. The four signal

announce a motor fault, warning and starting, estop is active and estop circuit is reset, system

running and system stop.



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Date: 2020/01/21

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RECOMMENDED PREVENTIVE MAINTENANCE SCHEDULE

WEEKLY:

Check all E-Stops

Check panel cooling fans, air conditioners, and filters

SEMI-ANNUALLY:

Check motor disconnect switches – Open enclosures and tighten wire terminals

Check all sensors, limit switches, photo eyes etc.

Visually inspect all conduits and cables

Check panel door latches, locks, and seals

Open all E-Stop enclosures and tighten wire terminals

Check and adjust pull cord E-Stops

MCC panels – tighten all high voltage wire terminals

Clean any accumulated dust on electrical components

Check for discoloration, melted insulation, and other evidence of overheating

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CP MANUFACTURING ELECTRICAL SYSTEM AUDIT PROJECT … · 2020. 5. 18. · Title: Electrical System...

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