Beyond Commissioning: Optimizing Electrical Systems files/Chapters/San Francisc… · electrical...

© 2012 Eaton Corporation. All rights reserved.

Beyond Commissioning: Optimizing Electrical Systems“Testing, Start-up, Maintenance, NFPA, Life Extension”

Presented By

Jill Jackson, Tom Santrach, Scott Manske & David RudolphEaton Corporation

2© 2012 Eaton Corporation. All rights reserved.

Introductions

• Jill Jackson – Healthcare Industry Specialist• Tom Santrach – Director of West Zone Operations• Scott Manske – District Manager• David Rudolph – Service Sales Specialist Healthcare

Systems

Thank You to CPMC for hosting this evening!


Agenda

• Overview• Equipment Testing & Maintenance• NFPA 70E• Equipment Life Extension Methods (ELEM) • Q&A


Power & Energy in Healthcare Facility The objectives of today’s healthcare providers are therefore twofold; provide the bestand safest level of patient care, while ensuring reliable infrastructure performance atthe best possible cost.

• Critical Infrastructure• Regulation / Codes / Standards• Data Management & Information• Investment• Safety Systems

As a planned and precautionary measure, healthcare facilities should design orretrofit integrated power solutions to achieve superior patient care by protecting theirpower distribution, building management, IT, and security.

In addition to improved safety, robust critical power supplies can also haveadvantageous financial repercussions, as well as long-term gains in productivity.


Power & Energy in Healthcare Facility

• Critical Infrastructure: Maintaining power to critical loads when loss of power occurs. Facilities rely on

their IT and medical equipment for patient care, and equipment relies on the constant availability of

electrical power.

• Regulation / Codes / Standards: Hospitals must meet strict regulatory requirements related to keeping

the power infrastructure compliant – NFPA, OSHPD, Fed/State/Local

• Data Management & Information: The modern day hospital/care center handles huge amounts of

patient data every day, IE test results, patient records, prognosis/prescriptions, registrations, billing and

collaboration with insurance companies -- hospital data relies heavily on the facility’s IT and data center

solutions.

• Investment: Energy Management, Maintenance, Training, Repairs, Unplanned Downtime, Backup

systems.

• Safety Systems: Fire, Air, Water, Lighting, Evaluations, Security, Disaster Events all lean on reliable

and well managed power distribution systems.


Testing and Maintenance…Definitions

1. New-Installation Equipment Testing (Acceptance Testing)2. Start-up/Commissioning

• Systematic Planned Approach to Energize• Bring Loads in an Organized Manner• Optimization• System is placed into Operation.

3. Service-Aged Equipment Testing (Maintenance Testing)• Preventative – Time/Scheduled Based• Conditional – Predictive (Developing Technologies)


New Equipment Acceptance Testing

Focal Point – Design, Documentation, Studies, Manufacturing, Installation, Energize• Meet Design Specification & Requirements• Installed Properly per OEM, Local Regulatory Codes, Engineers Design• Functional & Ready for Intended Use – Ready to Energize• Performance Criteria • Safe to Operate• Warranty• Documentation• Safety• At Site, not a Factory Test• Baseline Data for Future Analysis/Trends


Commissioning & Start-up of Equipment

Systematic Approach to Energization• Plan developed to bring power distribution equipment to operation• Systematic approach, with additional checks/tests staged• Ensure voltages, rotations, connections, flow and protection are correct• Conduct performance tests• Ensure applications are working• Brings loads under a planned approach• Safe and secure approach• System applications started and tested• Plant wide final commissioning and tuning


Service-Aged Equipment Testing (Maintenance Testing)

Routine, Annual and Long Term 3/5 Year Maintenance• Determination if the Electrical Equipment is Suitable for Continued

Service• Equipment that falls out of Specification or Standards• Safe/Unsafe - Danger to Equipment and Personnel – Public Safety• Conduct Requirement Maintenance

o Cleaning, Mechanical, Electrical, Tolerances • Repair or Replacement – Now or Near Term• Life Cycle Investment

o Reliability of the Equipment – MTTF, MTTRo Availability of Power – 100%o Maintainability


Why do Maintenance of PD/PQ Equipment

1. Complexity of Technology2. Criticalness of Applications3. Investment4. Safety5. Documentation


Complexity of Technology

• Microprocessor – Protection, Control & Monitoring• Complex Transfer Schemes – MTM, UPS & Batteries, Generators• Multiple Levels of Redundancy• Communication Networks• Fault Tolerant Demand• Integration w/ Alternative Energy – Wind, Solar, FC, Geo, Battery• Integration w/ Foreign Systems• - Energy & Demand Management, BMS, Manufacturing Systems, CMMS, SCADA• Energy Efficiency, Demand Management & Load Shedding• Regulatory Agencies & Utility Companies


Criticalness of Applications

• Hospitals/Medical Centers• Data Centers (Power, UPS and Cooling)• Financial• Internet/Retail• High-WIP Manufacturing (Semi, Pharmaceutical, Food)• Transportation• Public Infrastructure• Energy• Entertainment


Investment

• SAT & PM can approximately Cost 4-8% of the Overall Project• Design, Equipment, Installation, Commissioning, Fees

• Much Higher Percentage in Data Centers (15% excluding the Computers)

• Distribution Gear• Power Monitoring• Power Quality - UPS/Generator Systems

• Energization is Critical Path in the Project Schedule• Minimum 20 Year Life Cycle• 2/3 of all Electrical System Failures…..

……are do the “Lack of Maintenance”


Safety & Protection

- Protection of Utility Feed/Grid- Prevent Loss of Equipment- Arc Flash/Aux Equipment- Personnel Safety- Downtime Cost

- Average Downtime Impact- $ 4,800 Labor/hr- $12,800 Revenue/hr- $30,000 - $40,000/hr Liability- x100 for repair cost


Documentation

- Baseline Comparison – Trending Issues- Develop Accurate Records – Troubleshooting, Recalibration,

Replacement, Repair- Testing Labels – Who, Want, When- Capture Corrections and Updated – Redlines- Settings As Found/As Left/As Entered- Update O&Ms- One Lines, Schematics, Wiring Diagrams, BOM, SCCS, VFD & SS Parameters- Coverage of Training


Why Do Testing – On What Equipment…

• Power Distribution Equipment• Cables• Bus• Bus Duct• Circuit Breakers• Controllers & PLC & HMI• CTs/PTs• Generator• Grounding Equipment• Low voltage assembled equipment• Low voltage discrete equipment• Medium voltage assembled equipment• Motors and generators• Network Protectors• Power Supplies/CPTs• Relays, Trip Units• Surge Assistors/Snubbers• Switches• Transformers• VFDs and Starters

Power Monitoring Equipment– Power & Energy Meters– Gateways & Networks– Monitoring Software– Enterprise Software– Historical/Reporting– Demand Management– Load Shed

Power Quality Equipment– Power Factor Correction– Power Conditioning– UPS – ATS & Paralleling Systems– Stand-by & Emergency Power Software– Batteries/Fly Wheel– Generators


Approach…Maintenance Testing Frequency

• Battery Visual Inspection Monthly• Battery Specific Gravity Annual• Battery Capacity Test 3 year• MV Cables 3 - 5 Years• Breakers Exercise/Inspection Annual• Breakers Full PM 3 - 5 years• Breakers Exercise 6 - 12 Months• Relays/Meter Observation Weekly or Network• Relay/Trip Unit Full Test 2 - 4 years• Oil Sampling 1 year• Generators/ATS Monthly Tests/Transfer• Generator Load Test 2 years• LV and MV Switches PM 3 years• LV and MV Switches Exercise 6 - 12 Months• Grounding 3 - 6 years

• Most OEMs, Standards Agencies will have recommendations…


• Surface TRACKING is Common - Bushings, PTs, Bus, Isolators• High Electric Field at End-points• Contamination & Moisture – One Builds on the Other• Evaporation into “Tiny Islands” due to heat, starting at end-

points • Small Arcs between these “Tiny Islands”• Permanent Carbon Tracking• Short Circuit

4160 Volt breaker bushing with surface tracking -detected with only 5/8” remaining before fault

(PD occurs in the non-tracked area)

Voltage Isolation Build-up


Predictive Maintenance

IR Scans & Ultrasonic (Partial Discharge)NFPA 70B indicates that routine IR scanning should be conducted annually for all critical process equipment.

20.17.5 Inspection Frequency and Procedures. Routine infrared inspections of energized electrical systems should be performed annually prior to shutdown.

20.17.5.1 All critical electrical equipment or hazard related equipment…

20.17.5.2 Infrared surveys should be performed during periods of maximum possible loading but not less than 40 percent of rated load.

Top Percentage of IR Issues – Connections

Do Not Over Tighten!


Approach…Preventative Maintenance

• IR Scans• Best Solution to Safety - IR Scan Ports


NFPA 70E – Moving from 2015 to 2018


NFPA 70E – 2015 Changes110.1 Electrical Safety Program

(B) Maintenance.The electrical safety program shall include elements that consider condition of maintenance of electrical equipment and systems.


NFPA 70E – 2015 Changes130.2(A) Energized Work - Permitted

(4) Normal Operation Permitted if equipment is:

• properly installed• properly maintained• doors are closed and secured• covers are in place and secured• no evidence of impending failure


Properly Maintained?


No Evidence of Impending Failure?


Implications of 2015 NFPA 70E

130.5 Arc Flash Risk AssessmentAn arc flash risk assessment shall be performed and shall:

(3) Take into consideration the design of the overcurrent protective device and its opening time, including its condition of maintenance.

If the equipment condition is unknown or the setting are not properly implemented, the electrical worker may be exposed to a higher incident energy level than anticipated


How to Determine the Condition of Maintenance

• Test Forms• Service Labels• Documentation


205.3 General Maintenance Requirements.

• The equipment owner or the owner’s designated representative shall be responsible for maintenance of the electrical equipment and documentation.• Common practice is to apply test or calibration decals to

equipment to indicate the test or calibration date and overall condition of equipment that has been tested and maintained.

• Decals provide employees immediate indication of1. Last maintenance date2. If the tested device or system was found acceptable

Information can assist the employee with electrical equipment maintenance status.


205.4 Overcurrent Protective Devices

Overcurrent protective devices shall be maintained in accordance with the manufacturers’ instructions or industry consensus standards. Maintenance, tests, and inspections shall be documented.


Implications of 2015 NFPA 70E

• NFPA 70B states a maximum of 3 years between maintenance intervals for most equipment.

• NFPA 70B is a guideline to be used if the manufacturer does NOT have specific recommendations.


22.6 kA SymmetricalAvailable Fault Current

@ 480 V, 3 Phase

Arc Flash Risk Analysis for this PanelIncident Energy: 5.8 cal/cm2 @ 18”AFB: 47 inches

Panel

800 A OCPD6-cycle opening for arcing current

Electrical Safety Work Practices Equipment Condition


22.6 kA SymmetricalAvailable Fault Current

@ 480 V, 3 Phase

What happens if…Lack of maintenance causes the OCPD to clear in 30 cycles rather than 6 cycles?

Panel

800 A OCPD30-cycle opening for arcing current 29 cal/cm2125”

Arc Flash Risk Analysis for this PanelIncident Energy: 5.8 cal/cm2 @ 18”AFB: 47 inches



1Arc flash risk assessment

PPE Level for OCPD 1 Then, PPE Level for

OCPD 2“Protecting” overcurrent protective

deviceX If does not

operate

2

Next higher upstream

OCPD used for analysis




• What am I required to do?• Explicit

• NFPA 70E 110.1 - …electrical safety program shall include elements that consider condition of maintenance…

• NFPA 70E 130.2(A)(4) – …normal operation of electric equipment shall be permitted where all of the following conditions are satisfied:

(2) The equipment is properly maintained.• NFPA 70E Chapter 2 (highlights below)

• Maintenance is defined as the act of preserving or restoring the condition of electrical for the safety of employees who may be exposed to electrical hazards

• Must maintain an up to date single-line diagram• The equipment owner shall be responsible for the maintenance

of the electrical equipment• Overcurrent protective devices shall be maintained in

accordance with the manufacturers’ instructions or industry consensus standards.



• What am I required to do?• Explicit

• NFPA 70 700.3(C) – Systems shall be tested periodically…to ensure systems are maintained in proper operating condition

• NFPA 70 708.6(C) - The AHJ shall require a documented preventive maintenance program for critical operating systems

• NFPA 99 6.4.4 Administration (Type 1 EES)6.4.4.1.1 Maintenance and Testing of Alternate Power Source and Transfer Switches

6.4.4.1.1.3 • Required to do maintenance per NFPA 110

6.4.4.1.2 Maintenance and Testing of Circuitry.6.4.4.1.2.1* Circuit Breakers.

• Requires service and feeder circuit breakers to be inspected yearly and exercised

A.6.4.4.1.2.1* • Main and feeder circuit breakers to be overload tested

periodically



• What am I required to do?• Implicit

• NFPA 70 90.1(B) - This Code contains provisions that are considered necessary for safety. Compliance therewith and proper maintenance results in an installation that is essentially free from hazard…

• OSHA Subpart R & S – …n



• What can I do to guarantee the condition of the equipment I’m responsible for?• Insulation integrity – catastrophic failure

• Cables• Transformers• Switchgear/Switchboards/MCCs

• Protective devices & controls – risk management• Circuit breakers• Relays• Fuses• Transfer Switches



• What can I do to guarantee the condition of the equipment I’m responsible for?• New systems

• Perform Site Acceptance Testing (SAT) – baseline data • Perform periodic maintenance done in accordance with

manufacturer instructions and industry standards (NFPA 70B)• Existing systems

• Perform periodic maintenance done in accordance with manufacturer instructions and industry standards (NFPA 70B)

• Recondition to improve performance• Modernize equipment where any of the following exists:

• Equipment has reached the end of serviceable life• Ex: Serviceable replacement parts are difficult to find or expensive

• Service or operation of equipment increases personnel risk• Newer generation solutions offer better performance and/or

decreased risk



• NFPA 70 National Electrical Code • Installation Requirements • Some maintenance requirements• Adopted as law• National consensus standard

• NFPA 70E Standard for Electrical Safety in the Work Place• Safe Work Practices• Includes maintenance requirements (not prescriptive)• National consensus standard

• NFPA 70B Recommended Practice for Electrical Equipment Maintenance• Best practices• Preventative Maintenance• Guide (easy to understand language)• Not intended to duplicate or supersede manufacturers’ instruction


Equipment Life Extension & Modernization

• Switchgear modernization and upgrade solutions offers cost-effective renovation to existing equipment, with minimal power interruptions and without total replacement.

• Solutions extend the useful life of aging electrical power systems by providing safe and reliable reconditioning of existing equipment, as well as new replacement circuit breakers and other components that improve reliability and safety in existing power systems.

• Extension programs on average cost 40% less than capitol replacement.

• Modernization projects are usually 1/4 the time of replacement projects.


Power System Modernization Breaker Solutions

Technology Upgrades• Protective relaying & metering• Switchgear & Bus• Retrofits (New Trip Systems)-• AR & MVVR• Grounding Schemes• Power Factor Correction• Remote switching• Transfer schemes• Communications/Automation

Expanding or Improving the regulatory compliance, life, capacity, and/or

functionality of existing infrastructure


After

• Direct replacement of Siemens-Allis LA1600B Air Circuit Breaker• Customer required power on at all times (no outage for bus work) • Replaced for reliability reasons and high repair expenses • ANSI tested design

Before

Power System ModernizationLow Voltage Replacement Breaker


ELEM Examples

Arc Flash ReductionArc Flash LimitersArc Quenching

Relay & Project UpgradesSnubber

Bus Duct Systems

Safety Systems

Rating UpgradesUL CertsSeismic Retrofits

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