kdc west fatal electrocution presentation...the synchronous motor compressor starter panel consist...
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AMRE Safety Seminar 17 April 2012
P.C. Wheeler
KDC West Fatal electrocution presentation
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Location 10 Shaft Compressor House
10 Shaft
Compressor
10 Shaft Main
Substation
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Compressor
house
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Background
� During December of 2011 a five yearly scheduled maintenance was performed on a VK 50
Compressor, part of this routine included for the electric motor to be removed and send to an
motor repair company for testing and cleaning.
� On completion of the scheduled activities the motor was returned, installed and connected in
the configuration as originally disconnected.
� On the 2nd January 2012 during start-up of the machine excessive vibration was detected on
the motor, the motor was removed and send back to the repair company.
� On the 3rd January 2012 it was decided to install the spare motor as no estimated time could
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� On the 3rd January 2012 it was decided to install the spare motor as no estimated time could
have been given on when the motor would be returned to site.
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Panel Configuration
The synchronous motor compressor starter panel consist of a four panel board comprising of
the following:
• Auxiliary Feeder
• Main Motor Breaker
• Step 1 Breaker
• Step 2 Breaker
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This starter panel is fed from the main substation at the shaft ± 300m away from the
compressor house
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Synchronous Motor Sarter Panel Configuration
Aux Breaker
Step 1
Breaker
Step 2 BreakerMain Breaker
Incoming Cable
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Connection Box
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Synchronous Motor Sarter Panel Power Diagram
Power
terminations from
Main Substation
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Events and Actions Leading to the Casualty
� The spare motor was installed and when the connections had to be done it was seen that the
termination configuration was not marked in the same configuration as the one that has been
removed.
� At this stage the Main Motor Circuit Breaker including the Step 1 and Step 2 breakers was
racked out, removed and locked out from the enclosure.
� To ensure correct phasing, it was required to identify of the motor and power leads as the
starting reactor, the electric motor, main breaker and the step 2 breaker are all connected in
series.
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series.
� The Electrical foreman and two electricians discussed the process of identifying the conductor
connections for the correct termination configuration of the motor, this process required the
back cover plates of the terminations to be opened to execute the testing.
� Both electricians then tested the terminations at the back of the panels with a high voltage
tester and confirmed “dead”.
� The foreman and the electrician were at the back of the Compressor starter panel and the other
electrician at the motor end of the cables.
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Events and Actions Leading to the Casualty
� They then continued with the testing as required .The first phase was tested and no continuity
could be established, they proceeded to the centre phase and continuity was established, the
conductor leads and termination was numbered. They returned to the first phase, when the
electrocution occurred.
� First aid in the form of CPR was administrated until the paramedics arrived, the electrician was
taken to hospital and declared dead.
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Power Circuit Phase configuration diagram
Main
breaker
Step 2
breaker
Step 1
breaker
Starting
Reactor
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Motor
terminations
Star
Point
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Motor termination configuration
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Motor
termination
leads
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Findings after the accident
� The VT connections were not visible from the position the electrician was in during the
testing operations, due to a small cover plate at the top portion not being removed.
� No warning signs were displayed to warn maintenance staff of live connections from
busbar compartment in the cable compartment.
�
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� The VT on the cable compartment was connected with leads through holes in the plate
that separated the cable compartment from the busbar compartment.
� VT connection changes were made to the main Breaker panel as this panel was originally
manufactured to be used as an Eskom Main Incomer.
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Back view of Main Breaker
VT
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View at back of Main Panel
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Motor power
cable
terminations
Top section
cover plate
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View with top cover removed
Live VT
connections
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Motor power
cable
terminations
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View of VT connections to busbar chamber
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Conductor leads
to Busbar
chamber
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Diagram showing Busbar connected VT
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Power flow
direction
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Diagram showing Cable connected VT
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Power flow
direction
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� Inspect the complete compartment for any other “live” sources or terminations.
� Treat all connections as “live” until proven “dead”.
� Check all auxiliary equipment, which forms part of your installation and make sure that it is
included in the risk assessment.
� Document and record all changes and modifications to equipment.
Lessons Learned
� Document and record all changes and modifications to equipment.
� Be meticulous when equipment are used for applications not intended for.
� Display informative signs and notices at all machinery and equipment.
� Regular revisions and improvements on standards and procedures.
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Questions?Questions?
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