PCEA: Electrical Preventive Maintenance - “SPEND A LITTLE – SAVE A LOT” Kent Fukuhara A-1 A-Lectrician,Inc.
Nov 06, 2015
PCEA:Electrical Preventive Maintenance -SPEND A LITTLE SAVE A LOT
Kent FukuharaA-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 factor2. Increase the Life and Efficiency of Your Electrical Distribution
System3. Reduce overall Operating Costs4. Ensure the Safety of your Facility and Work Force5. Insurance Requirements & Industry standards
Why Should I Spend Money on PMS ?
Consequences of no PM: 1. Electrical Fires & Outages 2. Hazardous Environments to employees & workers. 3. OSHA Violations w/ Fines.
12,470 volts explosion on a Main Switch
Junction box rusted out from water leak from
above for years
480 volt switchboard
disaster
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
Be Knowledgeable about your Electrical System: Know your Components Know what should be
serviced?
Knowing where to Start? Begin with Critical Areas and
branch out as budget allows.
PMS Checklist:9 Budgeted Maintenance9 Planned Shutdown
vs. Forced Shutdown
9 Yearly Service Plan9 Emergency Protocols
Electrical After hours Contract?
9 Trending Problem AreasTracking Improvement on yearly basis
Preventing Costly Business Interruptions?
Implement Structured PMS Program:
1. Infrared Inspections2. Ultrasonic Inspections 3. Voltage/Current Testing4. Torque/Clean/Lubricate5. Power Quality Analysis6. Code Compliance Issues7. Know Your System!
Step:1 Infrared: Loose Connections Overloaded Circuits Hot Spots Worn Contacts
7.8C
127.1C
20
40
60
80
100
120
Reference
Problem
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.
Infrared interpretation is key:
2. Ultrasonic:1. Arching2. Tracking3. Corona
1. Ultrasonic can pick up areas that Infrared cannotsee.
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.
Ultrasonic complements Infrared!
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 voltage system with a 155 volt voltage sag
277/480 Volt Switchboard
Care on your EDS is Critical Because the Way We Use Power Today is
Different From our Past Usage..
9More Computers9More Electronic Devices9Constant 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-UnionOld wiring cut but not removed is it live ?
Wheres all the support for all
these conduits ?
Whats this doing here ? & where is the grounding ?,
where is the bonding ?
How are you going to reach this ?
Know Your Code? Facility Engineers is
this Better ?Union
7. Know Your System !
PMS Can-Increase the Life & Efficiency of your Electrical Distribution System:
E
D
S
V
A
L
U
E
TIME
$AVING$$AVING$
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 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 Actual Total Cost = $ 75,162.16
Annual PM Costing = $ 700.00
You Decide Which is Better
Typical buildings have 1-2 Main Transformers 500 2500 KVA for Switchgears that are very critical points for operation!
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 !!!
Man how much is this going to cost
us ??
Its a good thing I can leave after this transformer is in placeThey smell
We sure are going to make money off
this job !
"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, time-consuming 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:Cardboard InsulationNo Insulation 480v Wire
Feeder Cables in Salt WaterMissing Switchboard Covers
Be Observant:Capacitor Wire Burnt Off480v Panel rust falling down
Feeder Cables Bypass BreakerSwitchboard Bus Bolts Loose !!!
Visual Highlight:
148 degrees-w/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
Castle Medical Center Manele Bay Hotel
Hawaii Prince Hotel
9Reduce Your Risk of Business Interruptions
9Increase the Life and Efficiency of YourElectrical Distribution System
9Increase and Assure The Safety of Your Facility
9Minimize Electrical Utility Costs
9Increase Your Peace of Mind
How Preventive Maintenance Can Help You:
PCEA: Electrical Preventive Maintenance - SPEND A LITTLE SAVE A LOTIndustry Trends:Why Should I Spend Money on PMS ?Why Should I Spend Money on PMS ?Characteristics of Preventive Maintenance:Preventing Costly Business Interruptions?1. Hot Spots are not always problem areas.2. Many Problem areas are due to loose connections, which can be fixed on1. Ultrasonic can pick up areas that Infrared cannot see.2. Ultrasonic gives us additional insight.3. We have the 3. Voltage & Current TestingPower Quality277 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..Step 6: Know Your Code?Know Your Code?Know Your Code?7. Know Your System !PMS Can-Increase the Life & Efficiency of your Electrical Distribution System:PMS can help in Reducing overall Operating Costs:June 2005 - Actual Transformer Failure at Facility Show & Tell:Be Observant:Be Observant:Visual Highlight:How Preventive Maintenance Can Help You: