Coordination of electrical protections is a crucial aspect in the design and operation of industrial plants. Inadequate coordination can lead to dangerous and costly situations. This article explores the 5 most common causes of poor coordination, presents 5 real-life cases, and discusses the 5 most serious consequences.
Lack of Detailed Information:
The absence of comprehensive information about the electrical system hinders the accurate study of protection coordination.
Undocumented Changes:
Modifications in the installation without updating the plans can affect the protection coordination.
Incorrect Device Selection:
Choosing the wrong protection devices can lead to poor coordination.
Relay Programming Failures:
Incorrect configurations of protection relays can cause inadequate coordination.
Lack of Testing and Adjustments:
Failing to conduct regular testing and adjustments on protection devices can lead to their malfunction.
These factors can lead to risk situations and unplanned shutdowns in plant operations. Therefore, it is crucial to ensure proper coordination of protections in industrial systems.
5 real-life cases demonstrating poor protection coordination
Design:
Petrochemical Plant. In a refinery, the protection system was designed without considering actual short-circuit currents. This resulted in the failure of a main transformer during a fault event, causing a widespread blackout.
Repair:
Textile Factory. After repairing a main breaker, it was not properly calibrated. During an overload event, the breaker did not trip, causing extensive damage to downstream machinery.
Construction:
Data Center. During construction, lower-capacity breakers were mistakenly installed in a critical circuit. This led to frequent trips and data loss when the load reached normal operating levels.
Plant Expansion:
Automotive Factory. During an expansion, the short-circuit study was not updated. The new protections installed were not adequate for the actual fault currents, resulting in the destruction of a distribution panel during a short circuit.
Food Processing Plant:
When modernizing control systems, electromagnetic compatibility with existing protections was not considered. This caused untimely trips and production losses.
These cases illustrate the importance of proper protection coordination to avoid serious consequences in terms of safety, operational continuity, and economic impact.
5 Serious Consequences of Having Inadequate Protection Coordination at the Industrial Level
Fires:
Lack of protection coordination increases the risk of fires in industrial facilities. An undetected short circuit or overload can trigger a fire, causing property damage, loss of products, and most importantly, endangering the lives of workers.
Production Disruption:
When an electrical system failure occurs due to inadequate protection coordination, production can come to a complete halt. This interruption can have a significant impact on productivity, delivery schedules, and the company’s reputation.
Risk to Worker Safety:
The lack of adequate protection coordination can jeopardize worker safety. Uncontrolled electrical failures can lead to dangerous situations such as fires, explosions, or electric shocks, resulting in serious injuries or even loss of life.
Legal and Reputational Costs:
In serious cases, inadequate protection coordination can result in legal claims from injured workers or damages to third parties. Additionally, it can damage the company’s reputation and affect its relationships with customers, suppliers, and regulatory authorities.
Proper coordination of electrical protections is essential for the safety, reliability, and efficiency of industrial plants. Errors in this area can have devastating consequences, both in terms of safety and economically. It is essential to conduct regular studies, update systems as needed, and ensure that all personnel involved are properly trained in the importance of correct protection coordination.
Continuous monitoring, updating studies, and investing in modern protection systems are key to maintaining a safe and efficient industrial electrical system.
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