Juan Dela Cruz - Electrical Engineer - Career Episode 1

CAREER EPISODE 1 – ELECTRICAL MAINTENANCE SUPERVISOR

INTRODUCTION

CE1.1 From June 2003 to August 2004, I was employed as an Electrical Maintenance
Supervisor for EE Company and assigned at the power plant of CIP Power located in
Carmelray Industrial Park II, Punta, Calamba, Laguna, Philippines. Its office is at Queen’s
Court I Bldg., Makati City, Philippines.

BACKGROUND

CE1.2 EE Company is a consultancy and engineering firm of Poyry Group. It was under
contract for the operation and maintenance of the 21MW captive power plant and 13.8kV
distribution system of Carmelray Industrial Park II. The power plant operated as an island and
was not connected to the national power grid. It supplied power to 45 factories or locators
within the industrial park. The generators were composed of 2x3.5MW and 2x7MW and run
by bunker fuel. Power was transmitted through 13.8kV underground cables and distributed at
the plant substation, main substation and locator substations.

CE1.3 The plant substation collected all electricity produced by the generators, supplied
power to all plant auxiliaries, and transmitted electricity towards the main substation via two
underground power cables. The main substation was of two bus-bars and a tie configuration,
similar to the plant. Both bus-bars received power supply from the plant and in turn supplied
two underground ring loops towards the locators, the Punta loop and the Tulo loop – terms
concocted from the name of the areas where the underground cables transverse. Each ring loop
from both bus A and B ensured continuous connectivity. Each locator substation was
composed of three-bay metal-enclosed switchgear acting as two isolator switches for the ring
loop, and one transformer feeder. Included as part of CIP Power are the power transformers
and metering panels, while the low voltage switchgears were under the supervision of the
locators.

CE1.4 The scope of EE included the day-to-day operations of the power plant, metering
and billing of all locators and factories in the industrial park, ensuring less than 1% power
interruption throughout the year including scheduled shutdown, and the maintenance of the
power plant, main substation and locator medium voltage equipment. Since the power plant
did not supply nor receive power to or from the national grid, the power plant was operated at
the maximum efficiency of the engines, ensured continuous power supply to locators,
monitored the consumption of the connected loads for trending and projection, and conducted
preventive shutdown maintenance with minimum power disruption. These activities were
under the close watch of CIP Power.

CE1.5 As an Electrical Maintenance Supervisor, I was in charge with the daily activities
and maintenance program of my department. Under my supervision were 3 shift electrical
engineers, 3 plant electricians and 3 power distribution electricians. The shift electrical
engineers were in charge of the high voltage switchgear, plant essential equipment and
generators; the plant electricians were in charge of electrical balance of plant; and the power
distribution electricians were in charge with the distribution system, locator substation and
meter readings. Working time was 48 hours per week and extended during plant activities.

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Juan Dela Cruz - Electrical Engineer - Career Episode 1

CE1.6 Below is the organizational structure of EE at CIP:

EE Company /CIP II
Plant Manager

Preventive Maintenance Electrical Maintenance Mechanical

Supervisor Supervisor Supervisor
Juan Dela Cruz

Shift Electrical Power Distribution

Plant Electricians
Engineers Electricians

CE1.7 Reporting to the Plant Manager, my main task as an Electrical Maintenance

Supervisor was to effectively manage and control the activities of the electrical group -
including daily monitoring activities, maintenance and shutdown activities, installation of
electrical equipment, troubleshooting and repair, upkeep of the plant and distribution system;
and at the same time ensure that electrical personnel were abreast with the operational safety
of electrical equipment. Included in the responsibilities were:

• Provide technical assistance to client during inspection and commissioning of new

electrical installations.
• Undertake preventive maintenance servicing of the engine and generator controls, and
related auxiliary equipment.
• Supervise the maintenance of switchgears, transformers and other power distribution
equipment at the power plant, main substation and all locator substations.
• Conduct periodic inventory of the electrical spares and other materials related to
electrical works maintaining a reasonable level of stocks.
• Initiate recommendations to the Preventive Maintenance Supervisor activities to be
undertaken by the electrical group during engine shutdown.
• Regularly inspect power transmission equipment to ensure top condition and
recommend items for replacement or repair.
• Supervise shift electrical engineers in monitoring all auxiliary motors, perimeter
lighting, indoor and outdoor lighting, batteries, chargers and UPS, and others.
• Supervise power distribution electricians in monitoring of 45 locator parameter and
meter readings for load projection and billing purposes.
• Enact a swift and decisive plan of action during complete power failure or any
electrical problems of the locators and ensure 99% uninterrupted service per year.
• Update the electrical group on new electrical installations and modifications, train on
safety lock-out/tag-out procedures and familiarize with operation and maintenance.

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Juan Dela Cruz - Electrical Engineer - Career Episode 1

PERSONAL ENGINEERING ACTIVITY

CE1.8 Preventive Maintenance Servicing (PMS) of the engine and generator controls was
one of the main activities I supervised within the electrical group. During shutdown
maintenance, the task is to regularly verify the health of the diodes of the excitation system,
condition of the automatic voltage regulator (AVR), wiring integrity of the reference voltage,
voltage feedback and current signals from CTs, and also instrumentation sensors such as
thermocouples, fuel flow meters, accelerometers and magnetic pick-up. We also perform
troubleshooting when abnormalities were noticed in the generator SCADA like erratic
temperatures, speed, metering or vibration. Instrumentation sensors and electrical readings will
then be verified following a work permit and careful evaluation to potential engine shutdown
using schematic drawings, protection settings, and sensor trip levels.

CE1.9 At one instance, a generator was operating wildly and the electrical department was
dispatched to perform the investigation and testing. The first approach was checking the
integrity of potential and current transformers that send generator condition to the AVR. It
included verification of ratio, insulation and connected burden that these devices can carry. By
applying rated current to the CT, and rated voltage to the PT, it was confirmed that the CTs
and PTs were still in good condition. Next was investigating the AVR by adjusting the
frequency, voltage and stability settings at no-load condition and verification of constant
speed. Exciter field voltage and current on-load values were compared with the calculated
resistance of the given standard at a certain temperature. Found the result within range and
ruled out any loose connection of the wiring or overheating of windings. And lastly, the
generator was tested on both isochronous or droop speed control, to see if the problem was
caused by defective setting selector as the other generators have similar setting. The problem
has no indication pointing to the direction. The mechanical department was requested to check
the governor and discovered that fuel feed change was due to leak on its seals causing the over
speed without consideration of load or paralleling condition.

CE1.10 Part of my responsibility was maintaining a reasonable projected level of inventory

for all electrical spares, including protection relays, generator SCADA, PLC modules,
electrical devices, indication lamps and holders, fixtures and bulbs for perimeter outdoor and
indoor lighting, battery cells and acids, electrical contact cleaners and other consumables. I
submitted to the Plant Manager the summary projection for spares and maintained orders
based on frequency of use, local counterpart availability, shipping time for foreign sourced,
costs of individual and bulk orders, and importance to the electrical system. I evaluated
various consumables from different suppliers and made sure the best quality and most
economical were selected. I relied on the contract agreement for essential spares requiring CIP
Power decision and consumable spares that were part of EE maintenance agreement. I
prepared very convincing propositions with catalogues and data sheets as essential spares were
expensive and a monetary consideration for the owner.

CE1.11 It was in our contract to maintain less than 1 percent of power interruption
including scheduled maintenance. The power plant experienced total power failure and I
noticed unnecessary lapses that could have decreased the downtime. I evaluated the delay of
restoring power was due to operators’ confusion and came up with the solution to implement a

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detailed power restoration procedure. It was composed of numbered sequences, quick

instructions in each stage, miniature photos and optional actions if the conditions said
otherwise. In cooperation with the operations, we initiated regular mock test for all shift
operators on duty to eliminate complacency. The program proved to be a success as the
downtime was reduced and traces of confusion were eliminated in a blackout.

CE 1.12 In addition to this commitment, I prepared an annual shutdown program that

ensured preventive maintenance for the distribution network was completed as per agreed
period, scheduled usually during holidays like Christmas and Holy Week. I made sure that the
team was not distracted by the festivities by providing leadership and proper allocation of
manpower, tools, equipment and assigned tasks. Some locators were not allowed to sustain a
whole day of power interruption therefore we provided back-up generators for the event and
any delay in power restoration will be back-charged against EE . More so, as some locators
were of electronic manufacturing or computer data processing using sensitive equipment, we
were bound to connect power quality analyzer to locator low voltage side and provide printout
graphs for traces of frequency fluctuation, voltage instability and harmonics. Sample data at
given periods were evaluated and evidences of parameter fluctuation constitute to plant
corrective action.

CE1.13 As part of the operation of the power plant and distribution system, it was my
responsibility to review, approve, inspect and commission any additional switchgear, power
cable, transformer and metering panel for new locators. I reviewed protection settings and
compared with that of the upstream main substation and power plant switchgear, to ensure no
untoward incident will cause power dip or total shutdown should there be improper load
connected to the system. Transformer overload and short circuit trip and alarm levels, and
inverse definite minimum time curves were compared with set points of upstream feeder,
generator settings, and incoming medium voltage fuse rating. During my brief stint, I was
given the opportunity to render my proficiency in Schneider Electric and Alstom metal-
enclosed switchgears during commissioning of the locator substations for Matsushita–
Panasonic, Aliron Philippines, SHS and LGC Logistics, Ito-focus and Container Packaging
Corporation. While some existing locator buildings had substation ready built and only
required minor pre-commissioning tests and re-evaluation of relay settings, others with new
buildings needed to be inspected for compliance with international standards and Philippine
Electrical Code, from the design proposal up to the final commissioning.

CE1.14 As supervisor for electrical concerns, I had to learn the overall operation of the
plant, from the diesel engines, bunker fuel system and storage, fuel-oil separators, mechanical
maintenance activities, black start generator, generator SCADA and operations plant start-up.
This helped the electrical department in providing credible explanation whenever untoward
incident occur affecting the electrical system or when a plan of action of other departments
may deem detrimental to the plant. One example was during engine efficiency tests conducted
by the operations, I warned not to test the engines at the designed full capacity as engine
performance will not be equal due to age, there’s not enough load to allow more engines to run
as back-up, and there was never any contingency plans. Unfortunately, one test caused fire in
the engine turbocharger and another test causing a total shutdown. I prepared a detailed
explanation regarding temperature rise, engine cooling system and effect of ambient
temperature on enclosed space; and another about sudden bulk load transfer from one

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generator to another and its effect on the mechanical operation of the engines. With this
foresight, I gained the confidence of the plant manager and CIP Power and was constantly
sought advice regarding various plant related concerns.

CE1.15 I conducted a system investigation after the power plant chimneys were struck with
lightning causing the failure of all PLCs and automated engine management system. I verified
the integrity of the system grounding resistance, AC/DC control circuits from UPS/battery
chargers, lightning arresters, equipment and panel grounding, and separation of clean and dirty
ground. After ruling out possible deficiencies, I recommended to install surge suppressors in
all circuits pertaining to PLCs and engine control system. I reviewed various product brands
and was able to come up with the most economical, enough capacity, easy installation, less
wiring modification and minimum intervention to the circuits. I supervised the installation of
surge suppressors in an efficient manner by carefully studying the affected circuits, ensuring
minimal disruption to the plant operation, drafting a schematic wiring guide and conceiving a
detailed installation procedure as guidance to the electrical engineer and plant electrician on
duty. Moreover, the affected PLC modules were replaced and restored the automated control
of the engines.

CE1.16 Although the job was supervisory in nature, I was a team player in all activities of
the electrical section. I engaged in activities such as design and installation of metering
devices for new locators, replacement of indoor and perimeter lighting, replacing bearings of
motors, troubleshooting motor operated valves, replacing PLC and generator control modules,
maintaining exhaust gas recorder and included myself in the workforce during shutdown
maintenance. I demonstrated to the electrical group the team leadership and helping hand to
guarantee work will be finished on time and my peers also gained knowledge from the
experience. Safety was my utmost concern, as one technician was electrocuted with 13.8kV
during shutdown maintenance prior to my employment. I conducted lock-out/tag-out, safety
demonstration and equipment familiarization using my expertise with IEC designed high
voltage equipment. I also demonstrated my knowledge in metal enclosed switchgear when I
repaired the spring loaded mechanism of fused isolator caused by improper operation during
maintenance shutdown. I was able to impart knowledge to the electrical group regarding the
precautions when the high voltage compartment door is open, pinpointed the mechanical
interlocks and how to safely defeat them during maintenance without causing damage to
mechanisms.

CE1.17 The power plant had to comply with government restrictions on emissions. It was
part of my responsibilities to ascertain that the exhaust gas analyzer was working perfectly
24/7. I coordinated with the analyzer vendor a quarterly system calibration and performed the
regular necessary checks of system data acquisition; apart from the daily inspection of system
room temperature to avoid failure on overheated CPU. I relayed any high concentrations of
carbon monoxide and nitrogen oxides, and elevated exhaust temperatures to the plant
manager. He’ll then instruct the operations to adjust accordingly, from the quality of fuel to
frequency of maintenance schedules of the four engines. Exhaust gas parameters were used in
decision making for the maintenance of the engines, cooling system and fuel oil separators as
well as the number of running generators for maximum efficiency. This responsibility was
very critical, any non-compliance with the Philippine Clean Air Act will either result in
environmental penalties; and severe violations will even result to closure of the power plant.

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Juan Dela Cruz - Electrical Engineer - Career Episode 1

CE1.18 During my last month in office, there was a pilfering incident that required an
impartial investigation. Bunker fuel haulers (truck drivers) were in connivance with some
personnel to smuggle bunker fuel by bypassing metering devices during delivery. The owner,
CIP Power, had specifically nominated me to lead the investigation – determine operational
loopholes, ascertain those who had administrative liability, look at the extent and duration of
financial loses, and to prepare the necessary recommendations. It was an honor to be bestowed
such confidence, but it was also uncomfortable given the fact that I will be investigating my
colleagues. After several deliberations by CIP Power and EE , it was decided that I initiate the
investigation with the aid of hand-picked trustworthy personnel. I was able to determine the
methods of bypassing metering devices, calculated the time to unload fuels of different
volumes, provide cut-off time of haulers’ entry into the premises, disallow night time delivery
and recommend to the security personnel a more stringent inspection for vehicle entry and
exit. CIP Power and EE were satisfied with my report and recommendations.

SUMMARY

CE1.19 My work as an Electrical Maintenance Supervisor has greatly improved my

leadership skills, I was able to impart teamwork, ethics and right attitude, and gained the trust
of the people I worked for and respect of the men I worked with.

• Technical skills – evaluation of plant operations’ accumulated data was useful in

decision making regarding trending, maintenance schedules and operation of the
individual generating equipment. I also applied theoretical principles in the analysis of
plant abnormalities, commissioning of new equipment and maintenance.

• Leadership, teamwork and commitment - I was able to handle the crew properly and
created a harmonious relationship among them, particularly when pressure mounts during
strenuous shutdown activities; coordinate with other section supervisors our major
maintenance activities, assign responsibilities to my subordinates but never failed to
support them, and assisted our client regarding technical matters about the plant, ongoing
constructions and future connections to the power grid.

• Character and ethical standards - albeit the unverified threat, I was able to conduct an
impartial investigation during the pilfering incident. It did not come to a point were
personnel were fired, but those involved tendered their voluntary resignations and some
were given reprimands.

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