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Electrical Preventive Maintenance “SPEND A LITTLE – SAVE A LOT”
Kent Fukuhara A-1 A-Lectrician,Inc.
• • • • 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…. Emergency Situations PMS Checklist: 9 Budgeted Maintenance 9 Planned Shutdown vs. • Be Proactive not Reactive: – Budget Costs 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.
7. 6. 5.Preventing Costly Business Interruptions? • Implement Structured PMS Program: 1. 2. 4. Infrared Inspections Ultrasonic Inspections Voltage/Current Testing Torque/Clean/Lubricate Power Quality Analysis Code Compliance Issues Know Your System! . 3.
8°C .1°C 120 100 80 60 Reference 40 20 7.Step:1 Infrared: – – – – Loose Connections Overloaded Circuits Hot Spots Worn Contacts Problem 127.
Infrared interpretation is key: 1. Many Problem areas are due to loose connections. . Licensed Electricians can tell you if & why area is hot. which can be fixed on the spot while system is open. Hot Spots are not always problem areas. 3. 2.
Tracking 3. Corona . Ultrasonic: 1.2. Arching 2.
3. 2. Ultrasonic gives us additional insight.Ultrasonic complements Infrared! 1. Ultrasonic can pick up areas that Infrared cannot see. Ultrasonic is key in testing circuit breakers/xfmrs. We have the capability to hear over 20K + hertz. 4. .
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 .
Power Quality • Voltage Sags/Surges • Harmonics • Grounding / Bonding .5.
277/480 Volt Switchboard 277 voltage system with a 155 volt voltage sag .
. 9More Computers 9More Electronic Devices 9Constant Load Changes to Electrical Distribution System >>> Harmonics .Care on your EDS is Critical Because the Way We Use Power Today is Different From our Past Usage……….
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 ?. where is the bonding ? Old wiring cut but not removed – is it live ? How are you going to reach this ? Where’s all the support for all these conduits ? ..Non-Union What’s this doing here ? & where is the grounding ?.
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 .
$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…. • Unscheduled Blowout of 225A circuit breaker feeding power & lighting cost: – – – – – – – – – – – Breaker = $500 .PMS can help in Reducing overall Operating Costs: • Scheduled 3 Year Preventive Maintenance on this Circuit Breaker = $ 100-200.Critical Situation ? Typical buildings may have 50-100 critical points that are essential for operations! .
00 – Overtime Labor = $ 26.162.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…….90 – Hawaiian Crane & Rig = $ 5.240.90 – HV Splicing 12470v = $ 3.954.467.006. 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.June 2005 ..59 – 4.492. – 1500 KVA Transformer = $ 20.16 – Annual PM Costing = $ 700.02 I’ve been working 18 hours so far.167% GE Taxes = $ 3.00 – You Decide…… Which is Better It’s a good thing I can leave after this transformer is in place…They smell Typical buildings have 1-2 Main Transformers 500 – 2500 KVA for Switchgears that are very critical points for operation! .000.75 – ( 26 Hours Straight of working to complete the job w/ 7 men !!!! ) – Total Material Cost = $ 16.
Impending troubles can be identified and solutions applied .” ANSI/NFPA Std. minimize costly breakdowns and unplanned shutdowns of equipment.before they become major problems requiring more expensive. Electrical Equipment Maintenance. 70B. management assumes a much greater risk of a serious electrical failure and its consequences. A well-administered program will reduce accidents. save lives."Without an EPM (Electrical Preventive Maintenance) Program. timeconsuming solutions. Increase Safety ! .
. 9. 70-B.” National Fire Protection Association. Std. study. “ Over 72% of Electrical losses could have been avoided with predictive and proactive care” From a Hartford Steam Boiler Inspection and Insurance Co. p.“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.
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 .
Main wires operating more efficiently.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. .
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 .