ESBD_File_339527_EXHIBIT_B-_ProcessTechCtrPTUComm_and_ElectricalProject.pdf

EXHIBIT “B”- Process Technology Center: PTU Communications and Electrical Project

A. What's Wrong

I. The two panels housing the communications hardware was installed with higher (480 V) voltage/power supply hardware for the Delta-V and Cooling Tower panels in the PTU shown below. This installation causes premature component failure and creates a significant safety issue as instructors and students have a need to open the panels to troubleshoot Delta-V signals to the control room. 480 Volt power is dangerous and should only be encounters by a qualified electrician which is not a PTC-resource.

2. The controllers and 1/0 hardware are housed in a Non-NEMA (wrong) enclosure and open to direct sun light most of the day and not properly sun shielded. NEMA standards for industrial construction is the standard we should have. The 480 Volt motor drives and power for Controller system are not properly isolated and grounded causing signal interference and power surge handling uncertainty. Interference creates process control problems.

3. Controller and I/O are mounted in the vertical mode with no forced air to properly cool the system. It is a horizontal mounted base plate system causing higher and component damaging temperature inside the panel.

4. 1/0 shield system has been compromised with the control wiring exposed to the 480 Volt VFD (variable frequency drive) drive signals, no isolation. Shield and drain wire should be maintained to within 2 to 3 inches of the 1/0 termination point.

5. Panel Enclosure is not properly ventilated and sealed. Needs to be a NEMA enclosure for the area and cooled including proper sun screening. Most likely the present hardware failures due to high temperatures.

Communication Hardware

480V

B. Proposal to remedy improper installation:

I. Panels I and 2 housing the communications low voltage hardware (DeltaV/other) and 480 V power is to be separated into two NEMA-4xs cabinets each. Replace Panels with NEMA-4xs cabinet for outside service. The cabinet for housing 480 V service to have an external ON/OFF switch gear to increase assurance of a de-energized main cabinet for opening.

2. Panel I and Panel 2 Re-design, modification, and recommissioning of the new electrical/communications panels will require DeltaV and PLC (Cooling Tower Start-up/Operation) related skilled technicians by Puffer-Swieven and other subs to confirm the new panels work properly locally and from the control room.

3. An Electrical System Survey by a certified electrician skilled in the National Electric Code

(NEC) and OSHA (CFR) Code of federal regulations for Industrial electrical systems. Survey to include proper labeling of components within the system and recommendations for regular maintenance of the systems.

4. An Arc Flash survey of power distribution panels including labeling and recommendations to minimize the potential of an Arc Flash occurring.

C. Outcomes

I. The purpose of the PTU is to train students earning an AAS in Process Technology or AAS in Instrumentation Technology. The students learn how to operate and maintain industrial systems based on their education at PTC. With a properly designed and operating communications and electrical systems, instructors and students can safely interact with the hardware mentioned to carry out instruction.

2. Repairs will increase reliability of the PTU so that its ready to use throughout the semester, so students get the full experience as operators and instrument technicians

3. Safer Operation of the PTU