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Predictive Maintenance (PdM) Integration for Electrical

Distribution Safety and Reliability

Dale P. Smith, CMRPVP Sales & Marketing

RAM USA

Agenda

• The Animal Darwin Awards• Danger: Humans Like Swiss Cheese• Predictive Maintenance Tool Box

Facility Walk Down Examples• Facility Walk Down Examples• Mountains of Data• KISS Your Assets

Thank Thank You

youThank You

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The Animal Darwin Awards

Just a Few Numbers Electrical Hazards / Failures

FM Global - Leading Cause of Fires/Explosions and costing nearly $1Billion

Zurich - 25-30% of all large loss fires

Canadian MOL - 50% of the 1,200 deaths / arc flash injuries “performing basic maintenance and repair on or around energized equipment”79% of Deaths were not electricians!

1. Keep Equipment From Hurting People

Two Key Electrical Safety Rules

Quiz: 70% of failures caused by what 2 things?

2. Keep People from Hurting Themselves

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Keep People From Hurting Themselves

Maintenance Safety

Keep Equipment From Hurting People

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Closer to Home

100+ Years Developing Layers of Protection

• Codes / Standards (NEC, OSHA, NFPA, etc.• Listed Engineered Equipment / Safety Devices• Risk & Loss Data / Lessons Learned • Training / Certifications / Expertise• PPE / PdM Tools• Procedures / Best Practices• Audits / Documentation

Barrier Analysis

1

Normal

Barriers / Layers of ProtectionDeviations

Undesired Event

Normal Operations

Active Failures & Latent Conditions & “We Like Cheese”

2

3

2

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Who Moved the Cheese?

Electrical Hazards

Layers of Protection

Failures, Injuries &

Losses

ondi

tion

Audible Audible NoiseNoise

Early Early Signal 3Signal 3

Hot to Hot to TouchTouch

Point where Point where Failure starts Failure starts

to occurto occur

Early Early Signal 1Signal 1 Early Early

Signal 2Signal 2

(P)

NewNew

Forecasting Failure with Condition Monitoring & PdM Tools

TimeTime

Equi

pmen

t Co

BrokenBroken

(F)

Cost to Repair

CM Detects Problems EarlyCM Detects Problems EarlyEquipment Fails HereEquipment Fails Here

S-P-F Curve

100%S = Startup

P = Potential Failure

Equipment Condition

10%

0%

Time

F = Functional Failure

Complete Failure

S-P Interval P-F Interval

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Run-To-Failure

100%S = Startup

P = Potential Failure

S = Startup

ReactiveMaintenance

Equipment Condition

10%

0%

Time

F = Functional Failure

Complete Failure

MTTRPeople Equip

Darwin Life Lessons

Ripple Effects

Injuries & Deaths Fires Explosions

Lawsuits, Fines & Litigation

Business Interruption Property Damage

Insurance Claims Spoilage Lost OrdersInsurance Claims Spoilage Lost Orders

Supplier Bottlenecks Energy Losses Production

Interruption

Poor Quality Poor Morale Shareholder Dissatisfaction

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Rule of ThumbBB

eerinoculars

Management Spectrum

L

C

awn

hairIn the parking lot!

1. Keep Equipment From Hurting People

2. Keep People from Hurting Themselves

Two Key Electrical Safety Rules

“You Allowed It to Happen

or

You Caused It to Happen”

Safe Power Distribution Simplified Insulated Conductors

Clean, Dry, Tight and Cool

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Hazard Indicators & Failure Indicators• Excessive Dust, Dirt & Debris• Humidity / Water / Corrosive Atmospheres• Water / Vibration • Vibration / High-Resistance Connections & Contacts• Lack of Maintenance • Too High or Too Low Ambient Temperatures

Failures Indicators

Electrical Arcing Overloads, damage, metal fatigue uninterrupted faults overheating

Tracking Path of damaged insulation & Dirt

Corona / Partial Discharge Electrical stress / sharp points sound / Ozone

Overheating Heat, damage

Uninterrupted Fault Current Heat, melting, fire arcing

Voltage Irregularities Heat, surges, unbalanced loads

Sensory Inspections

Infrared

Oil Analysis

Ultrasound

Motor Circuit

Many more. . .

Reducing Exposures Increases Reliability

100%

PF

S = StartupS

Equipment Condition

10%

0%

Time

PF

FF

Complete Failure

MTTR

People Equip

Proactive PdM Task Interval Increased PdM Task Interval

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Switchger Bus Uninsulated

Bus Duct

Cable Joints

Cable Terminations

PM / PdM Electrical Component Failures

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Circuit Breakers

Transformers

Disconnect Switches

Switchgear Bus Insulated

W/O PdM With PdM

Source: Institute of Electrical and Electronic Engineers

PdM Tool Box & Electrical Equipment Matrix

PdM Tool BoxPrimary Equipment Targets

HV / MV Service

Cables / Bus bars XFMR CB /

FusesMCC / Motors

Senses X X X X XSenses X X X X X

Infrared Thermography X X X X X

Ultrasound X X* X X X*

Oil Analysis X X

Motor Circuit / Current Testing X

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Hot and Cold Surfaces

All Types of Physical Degradation and Code Gaps

Arcing / Crackling / Humming

Chemicals, Melting and Burnt Odors

Taste Ozone Odors

and Code Gaps

Compliance Issues (NEC/OSHA) and other problems

Overloaded Lug Dirt & Debris Improper Fuse

Sensory Inspections & Culture of Safety

Clearance Violation Clearance Violation

I don’t Need No Stinkin’ Fuses

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Infrared Thermography

All Electrical Systems and Components• Power Distribution• Substations• Breakers• Fuses• Transformers• Motor / Generator Control Centers• Starters and Thermal Overloads• Disconnects• Bus Connections • Relays • Electrical Vaults• Voltage Regulators

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Excessive Heat Impact

Temperature Effect on Insulation Resistance

e (o C

)

Every 18 oF (10 oC) rise

Resistance (Megohms)

Tem

pera

ture beyond rated

temperature, reduces insulation resistance

and useful life by 50%.

Failing Systems

Hot Disconnects Poor Bushing Connection 13.8 kV Air Switch

Tracking on Insulators

Ultrasound

• Corona discharge & Arcing on HV/MV electrical components• Turbulence / “White Noise” above 20 kHz• Airborne and Contact Probes

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Infrared for Everything?

No Thermal Signature Damaged Bushing from Tracking/Arcing

Time Signal A-Phase Bushing – Cleaning & Tightening

Before

After

Incoming Line Feed

This is the top “T” section of the wooden pole that tipped 90 degrees and caused phase to phase shorting

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Oil-Filled Transformers

Sudden Pressure Disk

Nameplate

Cooling Fins where insulating fluid is circulated and cooled by air.

Hot spot temperature gauge

Oil Level Gauge

Oil Temperature Gauge

Radiator Fins

High Voltage Bushings

Transformer Nameplate

Low Voltage Bushings

Oil-Filled Transformer Hazard Indicators

• Mineral Oils are fire hazard due to flammability of oil• Incipient faults, internal arcing and overheating• Gases such as acetylene or ethylene are produced, increasing the probability

of tank rupture and could lead to ignition of transformer fluid

Transformer Hazards and Failures

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Transformers

Kraft Paper Internals

Conductors of a transformer are typically wrapped in Kraft paper.

HV Winding

Press board spacers’ support and separate

each turn in the winding.

Press board cylinders support and separate HV

& LV windings

LV Winding

Press board cylinders support and separate the windings from the core.

Normal Load Surge Load

No Moving Parts but it Does Move

Dielectric Clearance

Mechanical vibration

Switching surges

Line surges

Limited short circuits

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Traps heat

Accelerates destruction

B id & fl h

21

Water Soluble Acids

Low Molecular Weight Acids

Fatty Acids

W t (F )

3Increasing Acid Levels Sludge

Acid Spiral

Bridge gap & flashover

.05 Acid .10 Acid

.20 Acid .30 Acid

Water (Free)

Moisture (Dissolved/Emulsion

Visible Sludges of Asphaltene

Peroxide Gas

Alcohols

Metallic Soaps

Aldehydes

Ketones

Lacquers

Color Pigments

Dissolved Gases and Probable Causes

Key Gases Most Likely Cause

Hydrogen (H2) Partial Discharge (Corona)

Methane (CH4) OverheatingMethane (CH4) Overheating

Acetylene (C2H2) Arching

Ethylene (C2H4 Localized Overheating

Ethane (C2H5) General Overheating

Carbon Monoxide (CO) Cellulose Overheating

Carbon Dioxide CO2 Oil and/or Cellulose Overheating

Oil Sampling CAN be Easy

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Sampling CAN be Hazardous

Internal Distribution

Distribution Bus Work

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Switch Gear / Circuit Breaker IssuesPoor Connections

Oil CB Allowed Fire to Spread Fire in Vacuum Breaker on to Cables

Dry Transformer Hazard Indicators

Dust accumulation on transformer windings causes Inadequate cooling and fire potential

How will you access this growing Mountain of Data?

• Director of Facilities & Maintenance

• Assume 22,000 Assets at 10 Plants

• 17,000 IR/Ultrasound/Oil/Sensory x 3 points = 51,000

• 5,000 Rotating x 6 locations x 10 points x 4 / year = 1,200,000

• 1,251,000 Points of Data Annually

• Standardization

• Best Practices / Lessons Learned

• Increased Safety and Reliability

• Reduced Plant/Corp Program Costs

• Large Data Population for Trending / Data Mining

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Issues with Integration of Reliability Program Data

• Building New Database

• Data Centralization

• Added Resources to Manage

• Multiple Data Types

CMMSP

Your Team3rd Party Services

Reliability Data

Ultimate Goal of Targeted Data Mining

MCCInventory

Get Accurate, Complete Info When, Where and How You Want it

Motors

PumpsCompressors

Chillers

Transformers

Problems

Cost / Benefit

Injuries

KISS Your Data - Start Small w/ Balanced Build Up

Excel / MS Access

3rd Party Platforms

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KISS to Close the Deal

Keep It Super Simple• Start Small• Equipment IDs / Criticality• Target Problem Areas• Collect DataCollect Data• Centralize your information • Trend Results (Good and Bad)• Financial Benefits to Corporation • Keep Everyone Engaged - Communicate,

Communicate, Communicate• Repeat

4 Years of FindingsTotal Years of Data in

Sample4 Years

(2004 –2008)

Equipment Inspected 637,976Thermal Anomalies 42,869 6.7% *Compliance Gaps 16,607 2.6% *

Anomaly Category %Poor Connection 72%

Internal Flaw 18%Overload 6%

Misc: Items 4%100%

* % of equipment Inspected

Plastic Pipe Manufacturer2008

Sites: 34

Inventory: 5327Problems: 358

% Problems / Insp.: 7%

Energy Savings: $220,177Run to Failure Cost: $112,720

Less Repair Cost: $38,299 Proactive Repair vs. RTF

Cost: $74,421

Known Fines: $22,000 $316,598

Temp Rise for All 24,975 oF

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5

10

15

20

25

30

35

16%18%20%

ProblemsSites

Growing Corporation, Decreasing Problems

2005 2006 2007 20080

1000

2000

3000

4000

5000

6000

2005 2006 2007 20080

0%2%4%6%8%

10%12%14%16%

2005 2006 2007 2008

Assets

Poultry / Beef Producer

Thermal Anomalies

1,500

2,000

2,500

otal

s

Critical

50% Reduction of Thermal Anomalies over 3 Years

50% Reduction of Thermal Anomalies over 3 Years

1 25,450 Electrical Asset Population

2 Annualized savings calculated at $0.04 / kWh with 24/7 operations

0

500

1,000

,

2005 2006 2007 2008

Years

Annu

al T

o

SeriousImportantMinor

Global Automotive Risk Reduction & Reliability Program Overview

Reliability Metrics

Sites: 56

Inventory: 5,435

Problems: 1,692

USACanadaMexicoSouth AmericaEurope

Energy Savings: $630,670

Run to Failure Cost: $387,606

Less Repair Cost: $153,750

Proactive Repair vs. RTF Cost: $233,856

Known Fines: $237,000

$1,100,923

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Automotive Trends - Problems

84% - 3 Asset Types82% - 4 Causes72% - Low cost / No

Cost Fixes

What Gets Measured, Gets Done!

200% More Likely to Fix Issues with Email Alerting System

* Graph based upon the survey of more than 100 facilities with multi-year programs totaling over 1,000 sites.

Grain Processing Plant:Embedded Reliability ChampionVibration Analysis / Balancing

Ultrasound Compressed Air

Electrical Infrared

VibrationInfraredVisual Cogen

Wet Mill

6,550 Assets

6,325 IR Electrical Points

650 Vibration Rotating Assets

124 Oil Sample Points

VisualOilUltrasonic Motor Current

* Also includes Wet Mill EIR WIP as of 9.9.10

g

Dry Mill

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Cost Benefit Potentials (2009 – 2010)

Category Reliability Strategy Total Savings

Energy Savings Infrared Electrical Anomalies $502,409

Vibration Misalignment $  49,428

Ultrasound Compressed Air Leaks $189,617

Total Electrical Energy Savings $714 454Total Electrical Energy Savings $714,454 Repair Costs1 Run to Failure $178,029

Proactive Repair ‐ $73,085

Labor / Equipment Savings from  Proactive Repairs $104,944 

Fines Known Possible OSHA / NEC $8,000 

Total Potential Savings: $859,398 

1 Annualized savings calculated at $0.04 / kWh with 24/7 operations

2 Annualized savings based upon Client provided $0.48 / 1000 cf and UE loss calculator

3 Material / Labor Costs Derived From Electrical Repairs Only

Carbon Foot Print Reduction Potentials

Resolving Electrical / Mechanical Exposures would:

1. Create over $714,454 in Potential Energy Savings

2. Eliminate Over 17,861,350 kWh of electrical usage at site

3. Eliminate Over 10,769 Metric Tons of CO2

These are equal to: Electrical Consumption of 1,494 Single Family Homes

or

Removing 2,071 Passenger Cars from the Road

, 2

4. Current Carbon Credit Trading is $30 / Metric Ton

5. Value of Trading Credits $323,070

Sharing Data Empowers People

Energy

Safety

Maintenance

Engineering

Operations

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Integrated PdM for Electrical Distribution Benefits

• Safety – Reduced arc flash and shock exposures• Energy Engineer – Energy Reductions and Savings• Environmental – Carbon Footprint reductions• Risk – eliminate/mitigate casualty and property loss businessRisk eliminate/mitigate casualty and property loss, business

interruption, contamination exposures and increase bidding• Reliability / Maintenance – increased uptime and labor

savings

Additional Resources

Additional Resources

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ROOF

WALLS

Protecting Value Inside by Securing the Outside

Engineering DesignEngineering Design Vegetative

Surveys & info ManagementSurveys & info Management

FOUNDATION

MaintenanceMaintenance

Project ManagementProject Management

Healthcare Manufacturing Education Commercial Government

Solar

Additional Information

Dale P Smith, CMRPVP Sales & Marketing Roof Asset Management USA

877.RAM.4949 Toll Free440.263.7493 celldsmith@RoofRAM.com

www.RoofRAM.com

Thank Thank you

youThank you