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Troubleshooting Heat Trace Alarms - Procedure

This is EHT Groups internal technical procedure on how to field troubleshoot various heat trace alarms.

1

1.1  Purpose

This procedure describes the steps required to safely and effectively identify and troubleshoot failures in an electrical heat trace circuit.

The Purpose is to provide EHT Group EHT Technicians general guidance to ensure that EHT circuits and the associated insulation systems are functioning as designed and provide adequate protection to the equipment on which they are installed.

1.2  Precautions

Only qualified electricians to perform their respective tasks

Review application reference documents for the task

A safe work permit is required for this task and must be signed by the area Operator

Complete a Field Level Hazard Assessment (FLHA) with all personnel involved with the job before starting the work

Ensure EHT circuit is in good condition and operating as designed before commencing work.

Arc-flash rated coveralls must be worn.

Follow all arc flash safe work procedures and PPE requirements as required by this task.

1.3  Roles & Responsibilities

For best results 2 EHT technicians are required with access to ATCOM+ while troubleshooting.

2.    Procedure

2.1  Prioritize Walk Downs

Ensure highest priority walk down is completed first. This situation arises if multiple walk downs are received at once.

2.2  Visual Inspection

Review EHT Isometric and panel schedule to determine location of EHT Circuit

Complete visual inspection of entire EHT circuit – Verify the following match the EHT isometric:

  • Piping size and orientation
  • Piping adder location, quantity and size
  • EHT component location, part number and quantity (Includes RTDs, power box, junction/splice boxes and end kits)
  • Component install is installed as per Suncor Standard Detail (when available and not covered by insulation)
  • Insulation is all installed
  • Insulation type and size is correct
  • Insulation blankets are correct size and tightly installed

Record all findings on EHT Alarm Response Check Sheet Document

  • Identify on EHT Isometric if any section is not accessible and what is required to access

2.3  Identify Troubleshooting/Repair Steps

 

If Alarm Is …

Then …

Low Temperature

Go to 2.4

RTD Failure

Go to 2.5

Ground Fault

Go to 2.6

Switch Failure

Go to 2.7

Low Load

Go to 2.8

 

2.4  Low Temperature Alarm Procedure

Responsibility

Step

Action

EHT Maintenance Electrician

1

At the Control Panel (PJ) complete the following tests:

·        Identify EHT circuit and RTDs

·        Verify all panel wiring for RTD(s) are correct

·        Measure Resistance of all RTDs connected to EHT circuit

EHT Maintenance Electrician

2

Reverify all panel wiring for HTC and RTD(s) is correct

EHT Maintenance Electrician

3

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

4

Relocate to EHT circuit RTD using coordinates on EHT isometric

EHT Maintenance Electrician

5

At the EHT Circuit RTD complete the following tests:

·        Verify all control connections are correct and terminated

·        Measure Resistance of RTD

·        Verify all control connections are correct and terminated

EHT Maintenance Electrician

6

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

7

If …

then …

EHT Circuit has additional RTDs

Go to step 8

EHT Circuit has ONLY one RTD installed

Go to step 12

EHT Maintenance Electrician

8

Relocate to next sequential RTD (ex. RTD2) using EHT Isometric coordinates

EHT Maintenance Electrician

9

At the EHT Circuit RTD complete the following tests:

·        Verify all control connections are correct and terminated

·        Measure Resistance of RTD

·        Verify all control connections are correct and terminated

EHT Maintenance Electrician

10

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

11

If …

then …

EHT Circuit has additional RTDs

Go to step 8

Testing complete at all RTDs that are accessible

If applicable, record which RTDs are inaccessible and what is required to access

Go to step 12

EHT Maintenance Electrician

12

Ensure EHT Alarm Response Check Sheet Document is complete

EHT Maintenance Electrician

13

Go to Step 12

 

2.5  Ground Fault Alarm

Responsibility

Step

Action

EHT Maintenance Electrician

1

At the Control Panel (PJ) complete the following tests:

·        Verify all panel wiring for HTC and RTD(s) are correct

·        Identify EHT circuit and RTDs

·        Measure EHT circuit resistance and use EHT isometric to verify value matches design resistance

·        Measure Insulation Resistance of EHT Circuit – Click here for testing method and minimum requirements

·        Measure EHT circuit voltage and verify it matches EHT Isometric

·        Measure EHT circuit current and verify it matches EHT Isometric

EHT Maintenance Electrician

2

Reverify all panel wiring for HTC and RTD(s) is correct

EHT Maintenance Electrician

3

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

4

Relocate to EHT circuit power box using coordinates on EHT isometric

EHT Maintenance Electrician

5

At the EHT Circuit Power Box complete the following tests:

·        Verify all power connections are correct and terminated

·        Measure EHT cable(s) resistance and use EHT isometric to verify value matches cables(s) design resistance

·        Measure Insulation Resistance of EHT cables(s) – Click here for testing method and minimum requirements

·        Measure EHT cables(s) voltage and verify it matches EHT Isometric

·        Measure EHT cables(s) circuit current and verify it matches EHT Isometric

·        Verify all power connections are correct and terminated

EHT Maintenance Electrician

6

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

7

If …

then …

EHT Circuit has additional power, splice and/or junction box(es)/kit(s) installed

Go to step 8

EHT Circuit has ONLY one power box installed

Go to step 12

EHT Maintenance Electrician

8

Relocate to next sequential power, splice or junction box (ex. SB2)

EHT Maintenance Electrician

9

At the EHT power, splice or junction box complete the following tests:

·        Verify all power connections are correct and terminated

·        Measure EHT cable(s) resistance and use EHT isometric to verify value matches cables(s) design resistance

·        Measure Insulation Resistance of EHT cables(s) – Click here for testing method and minimum requirements

·        Measure EHT cables(s) voltage and verify it matches EHT Isometric

·        Measure EHT cables(s) circuit current and verify it matches EHT Isometric

·        Verify all power connections are correct and terminated

EHT Maintenance Electrician

10

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

11

 

If …

then …

EHT Circuit has additional power, splice and/or junction box/kit installed

Go to step 8

Testing complete at all power, splice and/or junction boxes/kits that are accessible

If applicable, record which boxes are inaccessible and what is required to access

Go to step 12

EHT Maintenance Electrician

12

Ensure EHT Alarm Response Check Sheet Document is complete

EHT Maintenance Electrician

13

Go to Step 12

2.6  Switch/Relay Fail

Responsibility

Step

Action

EHT Maintenance Electrician

1

At the Control Panel (PJ) complete the following tests:

·        Verify all panel wiring for HTC is correct

·        Measure EHT circuit voltage and verify it matches EHT Isometric

·        Test operation of SSR

o   Communicate with EHT Software Technician to test HTC (Turn ON and OFF)

·        Test operation of HTC Module

o   Communicate with EHT Software Technician to test HTC (Turn ON and OFF)

·        Measure EHT circuit current and verify it matches EHT Isometric

EHT Maintenance Electrician

2

Reverify all panel wiring for HTC and RTD(s) is correct

EHT Maintenance Electrician

3

Verify programming of EHT circuit is set back to design parameters

EHT Maintenance Electrician

4

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

5

Relocate to EHT circuit power box using coordinates on EHT isometric

EHT Maintenance Electrician

6

At the EHT Circuit Power Box complete the following tests:

·        Verify all power connections are correct and terminated

·        Measure EHT cables(s) circuit current and verify it matches EHT Isometric

·        Verify all power connections are correct and terminated

EHT Maintenance Electrician

7

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

8

If …

then …

EHT Circuit has additional power, splice and/or junction box(es)/kit(s) installed

Go to step 9

EHT Circuit has ONLY one power box installed

Go to step 13

EHT Maintenance Electrician

9

Relocate to next sequential power, splice or junction box (ex. SB2)

EHT Maintenance Electrician

10

At the EHT power, splice or junction box complete the following tests:

·        Verify all power connections are correct and terminated

·        Measure EHT cables(s) circuit current and verify it matches EHT Isometric

·        Verify all power connections are correct and terminated

EHT Maintenance Electrician

11

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

12

 

If …

then …

EHT Circuit has additional power, splice and/or junction box/kit installed

Go to step 9

Testing complete at all power, splice and/or junction boxes/kits that are accessible

If applicable, record which boxes are inaccessible and what is required to access

Go to step 13

EHT Maintenance Electrician

13

Ensure EHT Alarm Response Check Sheet Document is complete

EHT Maintenance Electrician

14

Go to Step 12

 

2.7  Low Current Alarm

Responsibility

Step

Action

EHT Maintenance Electrician

1

At the Control Panel (PJ) complete the following tests:

·        Verify all panel wiring for HTC and RTD(s) are correct

·        Identify EHT circuit and RTDs

·        Measure EHT circuit resistance and use EHT isometric to verify value matches design resistance

·        Measure Insulation Resistance of EHT Circuit – Click here for testing method and minimum requirements

·        Measure EHT circuit voltage and verify it matches EHT Isometric

·        Measure EHT circuit current and verify it matches EHT Isometric

·        Test operation of SSR

o   Communicate with EHT Software Technician to test HTC (Turn ON and OFF)

·        Test operation of HTC Module

o   Communicate with EHT Software Technician to test HTC (Turn ON and OFF)

EHT Maintenance Electrician

2

Reverify all panel wiring for HTC and RTD(s) is correct

EHT Maintenance Electrician

3

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

4

Relocate to EHT circuit power box using coordinates on EHT isometric

EHT Maintenance Electrician

5

At the EHT Circuit Power Box complete the following tests:

·        Verify all power connections are correct and terminated

·        Measure EHT cable(s) resistance and use EHT isometric to verify value matches cables(s) design resistance

·        Measure Insulation Resistance of EHT cables(s) – Click here for testing method and minimum requirements

·        Measure EHT cables(s) voltage and verify it matches EHT Isometric

·        Measure EHT cables(s) circuit current and verify it matches EHT Isometric

·        Verify all power connections are correct and terminated

EHT Maintenance Electrician

6

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

7

If …

then …

EHT Circuit has additional power, splice and/or junction box(es)/kit(s) installed

Go to step 8

EHT Circuit has ONLY one power box installed

Go to step 12

EHT Maintenance Electrician

8

Relocate to next sequential power, splice or junction box (ex. SB2)

EHT Maintenance Electrician

9

At the EHT power, splice or junction box complete the following tests:

·        Verify all power connections are correct and terminated

·        Measure EHT cable(s) resistance and use EHT isometric to verify value matches cables(s) design resistance

·        Measure Insulation Resistance of EHT cables(s) – Click here for testing method and minimum requirements

·        Measure EHT cables(s) voltage and verify it matches EHT Isometric

·        Measure EHT cables(s) circuit current and verify it matches EHT Isometric

·        Verify all power connections are correct and terminated

EHT Maintenance Electrician

10

Record all findings and measurements on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

11

 

If …

then …

EHT Circuit has additional power, splice and/or junction box/kit installed

Go to step 8

Testing complete at all power, splice and/or junction boxes/kits that are accessible

If applicable, record which boxes are inaccessible and what is required to access

Go to step 12

EHT Maintenance Electrician

12

Ensure EHT Alarm Response Check Sheet Document is complete

EHT Maintenance Electrician

13

Go to Step 12

 

2.8  Repair & Progress

Responsibility

Step

Action

EHT Maintenance Electrician

1

If Circuit …

then …

Deficiency can be repaired or mitigated (ie. no additional support is required and can be fixed within allotted notification time)

Go to Step 2

Deficiency requires additional time, material, support, etc.

Go to Step 9

EHT Maintenance Electrician

2

Complete required repair to resolve alarm/deficiency

EHT Maintenance Electrician

3

Verify operation of circuit with EHT Software Technician

EHT Maintenance Electrician

4

Record work completed on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

5

Go to Step 13

EHT Maintenance Electrician

7

If Circuit Alarm

then …

Can be mitigated (ex. Install temp wrap, isolate failed trace, etc.)

Go to Step 8

Cannot be mitigated

Go to Step 10

EHT Maintenance Electrician

8

Complete required work to temporarily resolve/mitigate alarm/deficiency

EHT Maintenance Electrician

9

Record work completed on EHT Alarm Response Check Sheet Document

EHT Maintenance Electrician

10

Identify and record what is required to resolve alarm & notify supervisor:

·        Time required

·        Permit requirements

·        Material required

·        Access

·        Trade Support

·        Work involved