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Preventive Maintenance Strategies for Electrical Distribution System
Presented by:Charles Alvis
Schneider Electric
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· The cost of ignoring maintenance and testing
· Recommended steps to an effective electrical preventive maintenance program:
- Assess the current state of the electrical system - Maintenance and testing protocol - Planning for outages
· Considerations for outsourcing - Is in-house staff qualified, as defined by NFPA 70E?
- Do they have the capability to make corrective recommendations for issues that may arise?
·Fixed Cost Service Agreements
·Multi-year service plans help make maintenance easy for facilities
·Predictive Maintenance Technology and Trends
Preventive Maintenance Strategies
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The Cost of Ignoring Maintenance
“A well-administered Electrical Preventive Maintenance program:
· Reduces accidents
· Saves lives
· Minimizes costly breakdowns and unplanned outages
Impending troubles can be identified, and solutions applied, before they become major problems requiring more expensive, time-consuming solutions.”
NFPA 70B-2013 Ed., Section 4.2.1
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The Cost of Ignoring Maintenance
Section 4.2.7 goes on to state:
“An Electrical Preventive Maintenance (EPM) program satisfies an important part of management’s responsibility for keeping costs down and production up.”
Having a preventive maintenance program in place can reduce the risk of unplanned downtime by as much as 66%. Source: IEEE
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Recommended Steps: Assess the Current State of the Electrical
System• An up-to-date one-line
diagram of the electrical system provides clear and precise information concerning the exact interconnections of all electrical equipment.
• Due to modifications made to the electrical infrastructure, many facilities do not have a current drawing.
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Recommended Steps:Assess the Current State of the Electrical System
• A licensed professional electrical engineer should be contracted and commissioned to create and maintain current electrical one-line diagrams and equipment name plate data.
• Prior to initiating a preventive maintenance program, have a short circuit analyses, a time-current coordination study, and an arc flash analysis of all of the power distribution systems to ensure equipment is properly rated, set and labeled.
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Recommended Steps:Maintenance and Testing Protocol
• A comprehensive preventive maintenance and testing program should incorporate detailed policies, procedures, and maintenance activities for the entire electrical power distribution system, regardless of the manufacturer.
• NETA-MTS, NFPA 70B and OEM operations and maintenance manuals can provide recommended guidelines for developing the work scopes as frequency for performing maintenance and testing. - If OEM manuals are not readily available, contact the manufacturer or check online.
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Recommended Steps:Maintenance and Testing Protocol
The recommended maintenance and testing interval may need to be altered if any of these factors exist:
• Potential to safety of equipment failure
• Operating environment and equipment condition
• Operating load and ratings
• High repair cost equipment
• Cost of down-time to production
• Performance history of equipment
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Recommended Steps:Maintenance and Testing Protocol
Any specific maintenance of separate pieces
of electrical equipment does not guarantee a
completely coordinated and reliable power
distribution system as intended and
necessary.
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Recommended Steps:Maintenance and Testing Protocol
The facility’s management needs to clearly communicate to the service provider:
· Which equipment is included in the maintenance program
· The specific order the electrical equipment should be removed from service for maintenance
· The detailed scope of work for each piece of equipment or component
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Recommended Steps:Maintenance and Testing Protocol
Recommended items or equipment to Incorporate into a Preventive Maintenance Program:
• Monitoring equipment• Metering equipment• Protective relays• Service-entrance switchgear• Circuit breakers• Switchboards• Panelboards• Motor control centers
• Transformers• Automatic transfer switches• UPS Systems• Busway• Optional Stand-by Generatorsand…• Bonding & Grounding Systems (often overlooked)
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Recommended Steps: Planning for Outages
· With FEW exceptions, electrical equipment should NOT be cleaned, inspected, maintained, serviced, or tested while it is energized.
· When planning for an outage, ‘critical’equipment should be identified andscheduled, as noted earlier.
· Arrangements for temporary electricalpower should be made, if needed.
· Above all, it is management’s responsibility for onsite safety, whether for in-house or third-party electrical workers.
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Considerations for Outsourcing
• Facility management needs to insure that electrical workers are experienced in the specific equipment or system that is to be maintained.
• Very few companies have in-house staff who have the experience to service all of the electrical equipment within the facility’s electrical power system.
• Proposed third-party electricalproviders should be thoroughlyqualified by management.
- An in-depth interview is suggested and applicable references obtained.
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Considerations for Outsourcing
Personnel performing the maintenance activities need to be qualified as defined by OSHA and NFPA 70E.
Fundamental requirements include:
• Complete understanding of equipment, the required work scope and electrical hazards present.
• Proper use of protective equipment, tools, shielding and test equipment as well as precautionary techniques.
• Discipline and decision making skills to determine risk and ability to maintain a safe work environment.
Photo Courtesy of Oberon
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Code and Regulatory Compliance Requirements
Regularly scheduled electrical preventive
maintenance helps companies meet the
requirements of OSHA, NFPA 70E and other
authorities having jurisdiction.
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Code and Regulatory Compliance Requirements
Conditions that may warrant preventive maintenance be performed more frequently than the OEM’s recommendations include:
● Environmental conditions, including humidity, corrosive atmosphere, dirt or dust
● Equipment runs constantly or with heavy loads
· Requirements of localauthorities having jurisdiction
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Maintaining quality records of maintenance (and repair) activities support regulatory compliance as well as provide trending data.
●Helps identify potential problems to avoid equipment breakdown.
●Enables management to track costs of maintenance activities over time.
Code and Regulatory Compliance Requirements
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In addition to maintenance records, having the following documentation available* will prove helpful in the event of an electrical incident.
● Tools, materials and equipment needed
● Average time to perform tasks
● Reference manuals
● Past test reports
● Past incident reports
● Record of repair work
Code and Regulatory Compliance Requirements
For each piece of equipment being tested.
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Fixed-costs service agreements are a growing trend to manage increasingly complex electrical power distribution systems or systems with multiple brands of equipment.
● In addition to meeting regulatory requirements, these plans offer the flexibility to customize a scope of work and term.
● A fixed-cost service plan avoids fluctuations to the maintenance budget
● Billing can usually be structured to provide a fixed > payment schedule.
Fixed Cost Service Plans
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Fixed Cost Service Plans
Typically Three Levels Of Outsourced Field Support
Maintenance Service
Emergency on Site Response
Replacement Parts
(All Inclusive)
A New Approach for Maintenance
EasyComprehensive supportPredictable operating costs
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Predictive maintenance techniques safely provide condition status to help anticipate and plan maintenance activities.
Predictive maintenance solutions detect early warning signs and help prevent downtime.
Predictive Maintenance Solutions
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Infrared Viewing Windows
Enhances safety by allowing infrared inspections without the need to remove equipment covers.
Infrared Viewing Window
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Allows monitoring of critical connection points.
Exceptionally valuable for areas not seen by infrared cameras.
Temperature Monitoring
SensorSensor
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Detects impending insulation breakdown in MV equipment, which can lead to costly equipment damage and downtime.
Coupling Capacitors
RF CTs
Bushing Sensor
Partial Discharge Monitoring
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Active Asset Condition Based Monitoring
Emerging – Comprehensive Asset Monitoring
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References
• National Fire Protection Association (NFPA) 70B, Recommended Practice forElectrical Equipment Maintenance.
• National Fire Protection Association (NFPA) 70, National Electrical Code.
• National Electrical Manufacturer’s Association (NEMA) Standard AB4, Procedures for Verifying Field Inspections and Performance Verification of Molded-Case Circuit Breakers.
• National Electrical Testing Association (NETA), Maintenance Testing Specifications for Electrical Power Distribution Equipment and Systems.
• IEEE Standard 902-1998, IEEE Guide for Maintenance, Operation, and Safety of Industrial and Commercial Power Systems.
• IEEE Standard 142-2007, IEEE Recommended Practice for Grounding of Industrial and Commercial Power Systems.
• National Electrical Manufacturer’s Association (NEMA) Standard MG1.