LTT FortiFire Substation Protection Overview


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LTT FortiFire Substation Protection Overview

  1. 1. Who is Luse Thermal Technologies? Luse Companies started 1923. 4 th generation is actively running the company Our Primary Utility Services Include: Substation , Fossil, & Nuclear Firestopping Transformer Protection Power Plant Heat Rate Recovery Repairs Nuclear Mech. Insulation Nuclear & Fossil Abatement
  2. 2. WHY IS LTT QUALIFIED TO WORK IN YOUR FACILITY? The Live Electric and Substation Environment LTT has installed fire protection in over 230 energized substations during the past three years, without accidents, injuries, or lost time incidents. Customers include ComEd, PG&E, PECO, DTE, Beta Steel, & Ameren to name a few. SAFETY IS LTT’s FIRST PRIORITY
  3. 3. FIRE: The uninvited guest to the dance of electrons Proactive decisions help ensure the electrons keep flowing: ▪ Install fire protection enhancements. ▪ Learn from root cause lessons of others: When new cable is pulled, restore the fire protection system, (i.e., rebuild penetration seal). Plan for the restoration of fire protection items and schedule time for their repair, not just time to pull the new cable. Implement a periodic fire protection inspection program. PLANNING FOR FIRE EVENTS
  4. 4. <ul><li>Utilities are undertaking a proactive campaign to help ensure the electrons keep flowing. Some first steps to take are: </li></ul><ul><li>▪ Learn from root cause lessons and review industry practices </li></ul><ul><li>▪ Implement a multi-year fire protection program </li></ul><ul><ul><ul><li>Passive Fire Protection </li></ul></ul></ul><ul><ul><ul><li>Fire Plans and Fire Department Training </li></ul></ul></ul><ul><ul><ul><li>Detection </li></ul></ul></ul><ul><ul><ul><li>Suppression </li></ul></ul></ul>FIRE: The uninvited guest to the dance of electrons Planning For Fire Events
  5. 5. FIRE: The uninvited guest to the dance of electrons Planning For Fire Events Planning For Fire Events
  6. 6. Cable SpaceHatch 12kV Circuit Breakers Cable Duct Cable Duct Station Battery (DC Control Power) To street 12kV Power Cables in Cable Space Cable Space Grade 12kV Bus Control Wire To street Substations with Cable Space Areas
  7. 7. Environments can be challenging Dealing With Challenges
  8. 8. Finding Solutions
  9. 9. THE FIRE DOOR HAD A HOLE IN IT Creative Problem Solving Some field conditions go beyond unique. This door opening was sealed with Hilti Fire Blocks restrained by steel plate (painted yellow) and door frame. The door closes against this seal assembly, providing an enhanced level of fire resistance for this untested configuration.
  10. 10. Preview of LTT’s FortiFire ® System Firestopping Live Cable Penetrations Power Cable Joint Protection Control Cable Protection Hatch Cover Protection FortiFire ® FortiFire ® FortiFire ® FortiFire ®
  11. 11. Dawn of LTT FortiFire ® System Luse Thermal Technologies ELECTRICAL SUB-STATIONS LTT Installs Fire Protection in live 12,000 volt environment NO OUTAGE REQUIRED
  12. 12. WHY SPEND MONEY ON FIRE PROTECTION ? Cost / Benefit Ratio LTT’s FortiFire ® passive fire protection upgrade package will help reduce the level of equipment damage, outage time to a service area, and negative PR which can follow an event. The cost of one substation fire exceeded $7,000,000 . A similar fire event in a sub-station where LTT’s turnkey package had been installed, helped reduce repair costs to less than $300,000. It makes sense to consider spending a little now to save a lot later. Proactive Approach Reactive Approach $ Sub-station repair costs after a fire Fire Protection upgrade costs
  13. 13. SAFETY IS BUILT INTO LTT WORK PROCESS The Live Substation Environment <ul><li>Job Brief / Safety meeting 2 times a day </li></ul><ul><li>Perform &quot; l essons learned&quot; job critique at end of shift </li></ul><ul><li>Underground Electrician can be part of LTT work crew if required </li></ul><ul><li>Field survey spots unique design conditions prior to arrival of work crew </li></ul><ul><li>Hazards identified before the work starts </li></ul><ul><li>Use of designs and procedures, validated by years of hands-on experience </li></ul><ul><li>LTT installer and staff certifications include: OSHA 30 </li></ul><ul><li>OSHA 1910.269 </li></ul><ul><li>OSHA 1910.331-335 </li></ul><ul><li>NFPA 70E </li></ul><ul><li>Confined Space Entry </li></ul><ul><li>CPR / First Aid </li></ul>
  14. 14. Stop - Think - Act - Review WORK SAFE AND SMART Respect Equipment Zones
  16. 16. THE DEGRADED FIRESTOP PROBLEM Recognizing Fire Barrier Deficiencies <ul><li>Unqualified or missing penetration seals (firestops) degrade the fire rating of the floor separating the switchgear room from the basement. </li></ul><ul><li>Examples of degraded fire barriers can allow passage of fire and smoke through the floor openings, creating problems for the operation of switchgear and/or the total loss of sub-station. </li></ul><ul><li>Smoke can travel up to 420 feet per minute, making containment essential. </li></ul><ul><li>Problems: </li></ul><ul><li>Sealant degradation </li></ul>No seal installed Unqualified design Combustible material
  17. 17. THE UP-SIDE-DOWN APPROACH Solutions for the Substation Basement <ul><li>The vast majority of Firestop Systems are designed to be installed from above the floor. </li></ul><ul><li>In substation basements, “above the floor” typically means inside a switch gear or bus cabinet. </li></ul><ul><li>LTT has worked with Hilti for three years developing seal designs as part of the FortiFire ® system that can be efficiently installed from underneath the floor. </li></ul><ul><li>LTT communicates directly with Hilti Fire Protection Engineers. </li></ul>One of the first steps is the removal of unqualified sealant designs. Digging into the unknown requires use of safety equipment, such as 12 kV rated lineman gloves. LTT has developed safety protocols to remove materials under all energized conditions
  18. 18. LTT FortiFire ® DESIGN LIBRARY LTT Penetration Seal Solutions <ul><li>LTT has performed penetration seal upgrade work in over 230 substations. </li></ul><ul><li>This experience created a library of seal designs engineered to be installed from underneath the floor. </li></ul><ul><li>The LTT library includes seal designs for different floor types, including: </li></ul><ul><ul><li>Hollow core floors </li></ul></ul><ul><ul><li>3 inch concrete slab </li></ul></ul><ul><ul><li>6 to 9 inch concrete slab </li></ul></ul><ul><ul><li>Concrete on metal pan deck </li></ul></ul><ul><ul><li>Metal floor </li></ul></ul>
  19. 19. LTT ENHANCED FortiFire ® DRAWINGS New Penetration Seal Design Drawing Format <ul><li>Photographs are used to describe field conditions, helping personnel to choose correct firestop design for the specific field situation. </li></ul><ul><li>New installation directions are based upon installing sealant from underneath the floor. </li></ul><ul><li>Design limitations have been expanded by sealant manufacturer to encompass expected field conditions. </li></ul>
  20. 20. UTILIZE NEW FIRESTOP DESIGNS The Substation Basement <ul><li>Installation of firestopping in substation floor (ceiling of basement) to maintain the fire rating of the floor slab. </li></ul><ul><li>Firestopping work performed from underneath the floor. </li></ul><ul><li>Custom Hilti Firestop Designs </li></ul><ul><li>Trained Installation Personnel </li></ul><ul><li>Working safely is our first step </li></ul>Example basement and fire barrier penetration seals
  22. 22. 1 st step INSTALL HILTI FIRE BLOCKS Three power cables penetrating hollow core floor, as shown below. Install Fire Blocks into opening, so 8&quot; depth of block goes through floor. Top of Fire Block should reach upper portion of opening (area above hollow core). PENETRATION SEALS Four Steps of Collar installation
  23. 23. 2 nd step INSTALL HILTI FS-ONE CAULK Three power cables penetrating hollow core floor, as shown below. Install FS-ONE Caulk into all gaps between: cables and cables cables and fire blocks cables and opening fire bocks and fire blocks fire blocks and opening PENETRATION SEALS Four Steps of Collar installation
  24. 24. 3 rd step INSTALL FIRESTOP COLLAR Three power cables penetrating hollow core floor, as shown below. Install Firestop Collar PENETRATION SEALS Four Steps of Collar installation
  25. 25. <ul><li>FASTENING COLLARS TO BARRIER </li></ul><ul><li>Collars are connected to concrete barriers with concrete screws and washers. </li></ul><ul><li>The fasteners should be evenly spaced around the collar. </li></ul>Approved sizes of fasteners and washers: 3/16 X 1-1/4 CONCRETE SCREW WITH 3/4&quot; WASHER 1/4 X 1-1/4 CONCRETE SCREW WITH 3/4&quot; WASHER LARGER SIZE WASHERS ARE ALSO ACCEPTABLE PENETRATION SEALS Firestop Collars
  26. 26. 4 th step CAULK INSIDE OF COLLAR Three power cables penetrating hollow core floor, as shown below. Install FS-ONE Caulk inside of Collar PENETRATION SEALS Four Steps of Collar installation
  28. 28. FIRE CAUSED BY CABLE JOINT FAILURE Cable Splices Problem: Cable connections (joints / splices) have overheated and exploded. Loss: Fire and molten metal from cable fault knocked out adjacent cables, shutting down other power and control circuits. Circle shows area of previous joint failure. White material shows partial coverage of new EP3990 Wrap to protect adjacent cables. CABLE JOINTS
  29. 29. POWER CABLE WRAP SOLUTION Cable Splices <ul><li>The Power Cable Wrap solution involves wrapping the joint (plus one foot on each side) and the adjacent cables above and below the joint. </li></ul><ul><li>Upon exposure to fire, EP3990 Wrap forms a char layer (similar to ceramic cell structure) which helps protect the underlying cable. </li></ul><ul><li>This wrap is not designed to contain an arc blast. </li></ul>CABLE JOINTS
  31. 31. BURNING POWER CABLES THREATEN CONTROL CABLES Protect the Control Cables Problem: Burning power cables have damaged control cables routed above power cables, degrading ability to operate station. Power Cables Power Cables Control Cables Control Cables
  32. 32. EACH SUBSTATION IS DIFFERENT Protect the Control Cables When burning power cables are envisioned, the hot gasses will rise and then be deflected by the FB3600-UT Silica Cloth. This installation prevents the cable tray from acting like a large frying pan, where the control cables are cooked. Talk about cooking! This hanging pile of spaghetti will take some thought to come up with an appropriate method of protection.
  33. 33. CONTROL CABLE PROTECTION Protect the Control Cables <ul><li>The FB3600-UT high temperature fabric provides thermal protection for control cables inside of cable tray. </li></ul><ul><li>Air gap between fabric and cable tray shields cables from direct flame exposure. </li></ul><ul><li>Cable drops / cable bundles are individually covered. </li></ul>CONTROL CABLE PROTECTION CABLE DROP
  34. 34. INSTALLATION EXAMPLE 3 of the 4 FortiFire ® elements As connections to unistrut hanger occur, the finished FortiFire ® barrier system takes shape.
  36. 36. UNPROTECTED HATCH COVERS Protecting back-up Power, the 4 th element of the FortiFire ® system Problem: Heat radiating through closed steel hatch cover (during basement fire) melted the battery, resulting in failure of sub-station backup power. Loss: Damage to backup power system prevented operation of switchgear, leading to larger outage. Radiant heat through metal hatch melted and shorted out battery
  37. 37. SOLUTION: RADIANT ENERGY SHIELD Protecting back-up Power Open hatch in process of having radiant heat shield fastened to steel plate. Closed hatch with radiant heat shield.
  38. 38. ELECTRICAL CABINET DAMAGE FortiFire ® System in Action 12 kV cable fault explosion in electrical cabinet deformed metal covers. Fire detection system recorded two simultaneous events; one arc blast on 1 st floor (in electrical cabinet) and second in basement (joint failure). Fire modeling predicted this substation to be a high risk station, so fire protection enhancements had been installed before this event took place. No injuries occurred during event or restoration work. CABINET BULGE CASE STUDY
  39. 39. CABINET DAMAGE FortiFire ® System in Action Electrical cabinet where arc blast occurred. A and B phases had visible damage. Cabinet in process of being cleaned. A C B CASE STUDY
  40. 40. CABLE CONNECTION DAMAGE FortiFire ® System in Action Phase A fault occurred at junction between 15 KV cable and connection plate. Fire is an uninvited guest to electrical distribution facilities. Invitation! I don't need no stinking invitation! CASE STUDY
  41. 41. CABLE CONNECTION DAMAGE FortiFire ® System in Action Fault vaporized nuts and bolts (arrows) securing phase B cable connection plate to bus bar. CASE STUDY
  42. 42. CONTAINMENT FortiFire ® System in Action Phase A and B cables show charring of cable jacketing. Firestop materials were installed from underside of floor. Firestop was not dislodged, even though arc blast was strong enough to deform steel cabinet. ILLUMINATION FROM FLASHLIGHT FIRESTOP AT BOTTOM OF CABINET KEEP FIRE CONTAINED CASE STUDY
  43. 43. UNDERSIDE OF FIRESTOP FortiFire ® System in Action Photo of firestop in floor opening taken six months prior to cable fault. Condition of firestop eight hours after cable fault. Water from sprinkler actuation is visible on cable and wire mesh. Seal is in &quot; as new&quot; condition with no degradation after explosion and 45 minutes of water spray exposure. CASE STUDY
  44. 44. CABLE JOINT FAILURE FortiFire ® System in Action EP3990 Cable Wrap installed on joint and adjacent power cables. Dark areas identify where cable wrap absorbed energy from joint failure, helping to protect underlying power cables. Water drops from sprinkler actuation can be seen dripping from underside of cable wrap. Adjacent control cables were also covered with FB3600-UT (gold fabric) protecting underlying cables from direct arc blast. FB3600-UT CONTROL CABLE WRAP EP3990 POWER CABLE WRAP CASE STUDY
  45. 45. CONTROL CABLE PROTECTION FortiFire ® System in Action Control cable protection stayed in place during 45 minutes of sprinkler actuation. FB3600-UT Fabric allowed clean water to flow through fire resistant weave. Sprinkler heads were directly above cable tray. Basement had 1.5 foot depth of water when sprinklers were turned off. SPRINKLER HEAD CASE STUDY
  46. 46. FINDINGS FortiFire ® System in Action <ul><li>Firestopping contained the fire to the inside of the electric cabinet. </li></ul><ul><li>EP3990 Power Cable Wrap protected adjacent power cables from impact of joint failure arc blast. </li></ul><ul><li>FB3600-UT Control Cable Wrap protected several control cables from direct arc blast exposure. </li></ul>3 out of the 4 LTT FortiFire ® System components were activated and helped mitigate damage caused by example cable faults: 1 2 3 CASE STUDY
  48. 48. HERE TO HELP Martin Rozboril Cell: 708.819.5238 Email: John Provencher Cell: 708.363.3838 Email: Jim Ford Cell: 630.240.6381 Email: Your information requests receive our highest priority! ASSET PROTECTION ENHANCEMENTS