PCEA:

Electrical Preventive Maintenance SPEND A LITTLE SAVE A LOT

Kent Fukuhara A-1 A-Lectrician,Inc.

Industry Trends:
A-1 Founded in 1957 A-1 Philosophy The Customer Defines Our Business Electrical Contracting Industry has seen a growth in Construction & Electrical Service/Maintenance (10 years) Why has there been an increase in PMS? (preventive maintenance service)

Business Managers are beginning to realize the benefits of a Structured Preventive Maintenance Program. Preventive Maintenance Can help in:
1. Preventing costly Business Interruptions & Reduce risk factor 2. Increase the Life and Efficiency of Your Electrical Distribution System 3. Reduce overall Operating Costs 4. Ensure the Safety of your Facility and Work Force 5. Insurance Requirements & Industry standards

Why Should I Spend Money on PMS ?

12,470 volts explosion on a Main Switch

Consequences of no PM: 1. Electrical Fires & Outages 2. Hazardous Environments to employees & workers. 3. OSHA Violations w/ Fines.
480 volt switchboard disaster

Junction box rusted out from water leak from above for years

Why Should I Spend Money on PMS ? More Examples

Characteristics of Preventive Maintenance:

PMS is to. Be Proactive not Reactive:
Budget Costs vs. Emergency Situations

PMS Checklist:
9 Budgeted Maintenance 9 Planned Shutdown
vs. Forced Shutdown

Be Knowledgeable about your Electrical System:

Know your Components Know what should be serviced?

9 Yearly Service Plan 9 Emergency Protocols

Electrical After hours Contract?

9 Trending Problem Areas

Tracking Improvement on yearly basis

Knowing where to Start?

Begin with Critical Areas and branch out as budget allows.

Preventing Costly Business Interruptions?

Implement Structured PMS Program:
1. 2. 3. 4. 5. 6. 7. Infrared Inspections Ultrasonic Inspections Voltage/Current Testing Torque/Clean/Lubricate Power Quality Analysis Code Compliance Issues Know Your System!

Step:1 Infrared:
Loose Connections Overloaded Circuits Hot Spots Worn Contacts
Problem

127.1C 120 100 80 60 Reference 40 20 7.8C

Infrared interpretation is key:

1. Hot Spots are not always problem areas. 2. Many Problem areas are due to loose connections, which can be fixed on the spot while system is open. 3. Licensed Electricians can tell you if & why area is hot.

2. Ultrasonic:
1. Arching 2. Tracking 3. Corona

Ultrasonic complements Infrared!

1. Ultrasonic can pick up areas that Infrared cannot see. 2. Ultrasonic gives us additional insight. 3. We have the capability to hear over 20K + hertz. 4. Ultrasonic is key in testing circuit breakers/xfmrs.

3. Voltage & Current Testing

Assures the correct voltage and current is applied to all equipment and lighting. Know your limits for code and future expansion. Establish a baseline for trending.

Step 4:
Tighten (Torque) Connections Clean Inspect Lubricate

5. Power Quality
Voltage Sags/Surges Harmonics Grounding / Bonding

277/480 Volt Switchboard

277 voltage system with a 155 volt voltage sag

Care on your EDS is Critical Because the Way We Use Power Today is Different From our Past Usage..
9More Computers 9More Electronic Devices 9Constant Load Changes to Electrical Distribution System >>> Harmonics

Step 6: Know Your Code?

Facility Engineers need to know what can and cannot be done by Code in their facilities? Code is designed for safety & guidance:
Existing Areas Code Compliance Non-union electricians doing renovations per code in your facilities? Build Relationships w/licensed electricians & contractors

Know Your Code?

Facility Engineers is this OK ?..Non-Union
Whats this doing here ? & where is the grounding ?, where is the bonding ? Old wiring cut but not removed is it live ?

How are you going to reach this ?

Wheres all the support for all these conduits ?

Know Your Code?

Facility Engineers is this Better ?Union

7. Know Your System !

PMS Can-Increase the Life & Efficiency of your Electrical Distribution System:

VALUE

EDS

$AVING$

TIME

PMS can help in Reducing overall Operating Costs:

Scheduled 3 Year Preventive Maintenance on this Circuit Breaker = $ 100-200. Unscheduled Blowout of 225A circuit breaker feeding power & lighting cost:
Breaker = $500 - $1500 Overtime labor c/o = $ 500 Lead Time = 1-2 weeks? 1-2 week downtime? Loss Revenues? Temporary Relocation/Power? Workforce attitudes? Loss Productivity? Lost Information? Unhappy Customers? Hospitals.Critical Situation ?

Typical buildings may have 50-100 critical points that are essential for operations!

June 2005 - Actual Transformer Failure at Facility

Temporary Transformer being installed outside of Main Electric Room
Man how much is this going to cost us ?? We sure are going to make money off this job !

Unscheduled Transformer Failure Total Cost..

1500 KVA Transformer = $ 20,000.00 Overtime Labor = $ 26,492.75 ( 26 Hours Straight of working to complete the job w/ 7 men !!!! ) Total Material Cost = $ 16,467.90 HV Splicing 12470v = $ 3,954.90 Hawaiian Crane & Rig = $ 5,240.59 4.167% GE Taxes = $ 3,006.02

Ive been working 18 hours so far, when can I go home and sleep!!!!

Man we stink after working through the night When will we finish this job !!!

Actual Total Cost

= $ 75,162.16

Annual PM Costing = $ 700.00 You Decide Which is Better

Its a good thing I can leave after this transformer is in placeThey smell

Typical buildings have 1-2 Main Transformers 500 2500 KVA for Switchgears that are very critical points for operation!

"Without an EPM (Electrical Preventive Maintenance) Program, management assumes a much greater risk of a serious electrical failure and its consequences. A well-administered program will reduce accidents, save lives, minimize costly breakdowns and unplanned shutdowns of equipment. Impending troubles can be identified and solutions applied - before they become major problems requiring more expensive, timeconsuming solutions.
ANSI/NFPA Std. 70B;

Electrical Equipment Maintenance;

Increase Safety !

A Study by The Factory Mutual Insurance Group shows that an average of 56% of all electrical fire losses were due to lack of preventive maintenance.
National Fire Protection Association, Std. 70-B, p. 9. Over 72% of Electrical losses could have been avoided with predictive and proactive care From a Hartford Steam Boiler Inspection and Insurance Co. study.

Show & Tell:

Electrocuted Rat: Improper Lug Installed:

Unsealed Opening

Mismatched Fuses

Be Observant:
No Insulation 480v Wire Cardboard Insulation

Missing Switchboard Covers

Feeder Cables in Salt Water

Be Observant:
480v Panel rust falling down Capacitor Wire Burnt Off

Switchboard Bus Bolts Loose !!!

Feeder Cables Bypass Breaker

Visual Highlight:
148 degreesw/aluminum wire Insulation cracking 110 degrees- wire changed to copper Spliced energized w/ no down time to Hotel 38 degree drop in temp- Main wires operating more efficiently.

Halekulani

Hawaii Prince Hotel

Castle Medical Center

Manele Bay Hotel

How Preventive Maintenance Can Help You:

9Reduce Your Risk of Business Interruptions 9Increase the Life and Efficiency of Your Electrical Distribution System 9Increase and Assure The Safety of Your Facility 9Minimize Electrical Utility Costs 9Increase Your Peace of Mind