Maintenance Electrical System - ASET

2020-09-18

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Electrical System

Maintenance

Magna IV Engineering

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Magna IV Engineering is a privately-owned electrical engineering and technical field service firm.

Established in 1982 in Edmonton Alberta

Currently many office locations in North and South America

Offers many services in:

• Engineering (Power System Studies, Design)

• Project Management

• Testing, Commissioning and Maintenance

• Electrical Safety Training, Electrical Program and Safe Work Procedure Development

To find out more visit www.magnaiv.com

Magna IV Engineering

1. Evaluating System Performance

2. Identifying Equipment for Repair, Upgrade and Replacement

3. Budgeting and Planning for Maintenance

4. Types of Maintenance Plans

Table of Contents

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1. Evaluating System Performance

Electrical System Maintenance

Electrical systems are made up of numerous electrical components that work in an integrated manner to safely supply power to system loads.

These components have their own specific operational

limitations and maintenance requirements.

Evaluating System Performance

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• How do you know what maintenance requirements exist?

• How reliable is your electrical distribution system?

• How safe is your electrical distribution system?

• Does your electrical maintenance plan exist only in the heads of a few staff?

• How do you know your maintenance dollars are being spent effectively?


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Proper maintenance is critical to the safe operation of electrical systems

Evaluating Equipment Performance

Electrical Equipment Failures

Fires Caused byLack of Maintenance

Evaluating Equipment Performances

Source: NFPA 70B

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A NETA study done in October 2007, indicated that 22% of service-aged circuit breakers had some type of malfunction and 10.5% did not operate at all during maintenance testing.

» 340,000 protective devices surveyed

Heid K & Widdup R, Total Clearing Time of Protective Devices and Its Effect of Electrical Hazards


Equipment failures can result in not only equipment damage but personnel injury.

As per CSA Z462, electrical power systems equipment operated when its in poor condition because of lack of maintenance presents a higher risk of personnel exposure to electrical shock and arcing faults.


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CSA Z462 – Workplace Electrical Safety

Addresses workplace electrical safety requirements

Released January 2009, new revisions 2012, 2015, 2018

Technically harmonized with the Canadian Electrical Code, NFPA 70E and other standards

Toolkit of work practices, definitions, equipment requirements, equations, look-up tables and sample forms


The incident energy analysis and selection of PPE are completely dependent on the protective devices functioning exactly as designed

Protective devices shall be maintained to adequately withstand or interrupt the available fault current and to function in accordance with their designed operating times

*Note: Improper or inadequate maintenance can result in increased opening time of the overcurrent protective device, thus increasing the incident energy


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Arc flash levels are the product of time and energy

Proper equipment operation is essential to the control of the time component of the equation

Set and forget = misoperation, danger and negligence


An arc flash incident is not likely to occur under normal operating conditions when enclosed energized equipment

has been properly installed and maintained. CSA Z462-18 Definitions

A Normal Operating Condition exists when all of the following conditions are satisfied:

• The equipment is properly installed

• The equipment is properly maintained


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Normal Operating Condition cont.

• The equipment is used in accordance with instruction included in the applicable Canadian Electrical Code, Part II Standard and in accordance with the manufacturer’s instructions

• All equipment doors are closed and secure

• All equipment covers are in place and secured; and

• There is no evidence of impending failureCSA Z462-18


Electrical equipment maintenance is one aspect of electrical safety. Other aspects include:

• Equipment design

• Systems engineering

• Instructions for use

• Safety-related work procedures

• Worker training and experience


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The workplace safety program shall cover the essentials necessary:

• For the safe functioning of electrical equipment and systems

• And support an electrical maintenance strategy critical to worker safety

Understanding the risk associated with equipment failure is key to knowing how to protect personnel.


Risk Assessment: an overall process that identifies hazards, estimates the likelihood of occurrence of injury or damage to health, estimates the potential severity of injury or damage to health, and determines if protective measures are required

Risk Assessment process – identify electrical equipment and system failures with the potential to cause harm

Establish maintenance practices to prevent electrical equipment failures with the potential to cause harm


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Assess risks:

Risk assessment: sources, causes and potential consequences are analyzed

Risk is a combination of the:

• Likelihood of occurrence of injury or damage to health

• Severity of injury or damage to health that results from a hazard


Risk Controls:

Take action to eliminate or reduce risk using the Hierarchy of Risk Control Methods as per CSA Z1002


Use risk assessment results to select maintenance strategies

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Assessing Equipment Condition

» Maintenance history

» Records

» Failure history

» Operational familiarity

» Where is equipment in its lifecycle


Component Failures The bathtub curve describes the relative

failure rate of products. Some will fail

relatively early (infant mortality failures),

some will fail during the relatively long

period typically called normal life others

will last until wear-out.

Infant Mortality

• Caused by defects and mistakes• Material defects• Poor design • Assembly/Installation errors


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Lifecycle of Electrical Equipment:

Field life up to 50 years

Some equipment based on number of operations

Factors such as environment, use (as designed), and maintenance can have an impact on equipment lifecycle


CSA Z462 5.1: Maintenance shall be defined as preserving or restoring the condition of electrical equipment and installations, or parts thereof, for the safety of workers who work where exposed to electrical hazards.

Individual parts of equipment may be repaired or replaced without the need for modification or replacement of parts that are in a safe condition.


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Maintenance of Electrical Equipment

» Increases reliability

» Satisfactory operation for the entire life-cycle of the equipment

» A cost effective approach


The Cost of Neglecting Maintenance

FM Global looked at 617 electrical loss incidents between the years of 2001 and 2011 totalling US$3.3 billion. In 84 of the 617 incidents (~13.5%), lack of maintenance was identified as a major contributing factor. This represents US$800 million (average loss/incident ~9.5 million).

Source: CSA Z463 A.8


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The Cost of Neglecting Maintenance

Switchgear accounted for 44% of all losses

Transformers – 25%

Generators – 18%

Source: CSA Z463 A.8



2. Identifying Equipment for Repair, Upgrade and Replacement

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Maintenance Planning

» How much, how often?

• Use performance test results and findings as a guide

• Categorize critical items

• Shutdown opportunities

• Budgets!!

» Applicable guides, standards

Identifying Equipment for Repair, Upgrade and Replacement

Process and Procedures for Maintenance

Sites shall have procedures and practices in place to manage the integrity of electrical equipment – CSA Z462

CSA Z462 recommends referring to CSA Z463 for guidance related to electrical strategies


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CSA Z463 – Maintenance of Electrical Systems:

» Strategies on electrical maintenance

» Practical applications to integrate electrical maintenance into quality management systems

» Guidelines on electrical safety and specific equipment related maintenance practices

» Analysis of inspections, testing and failure results


CSA Z463 states

» The asset owner shall develop a detailed maintenance plan

» The maintenance plan should identify all the maintenance activities required to confirm the safety, reliability, and integrity of the electrical system and equipment

» The maintenance plan should identify the frequency of inspection and comply with the equipment manufacturers recommended maintenance intervals and tasks


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Application of this standard can range from enhancing existing QMS, safety systems to providing practical guidance and specific examples for the development of electrical maintenance programs.

Is my equipment within ‘spec’?

Normal Operating Condition


NETA (International Electrical Testing Association)

Sets out standards for:

» Maintenance intervals

» Scope of inspections and electrical tests

» Expected results and acceptance criteria

» Technician qualifications

» Testing company qualification

» Test equipment calibration


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NETA

» Specific to electrical Industry

» Promote competence in electrical testing and electrical system maintenance

» Focuses on what tests to perform, rather than how to perform them

» Accrediting body – two-fold accreditation process:

• Company certification

• Technician certification


Document standards

Accredited standards developer for American National Standards Institute (ANSI)

» Maintenance Testing Specifications (MTS)

» Acceptance Testing Specification (ATS)

» Standard for Electrical Commissioning Specifications (ECS)

» Standard for Certification of Electrical Testing Technicians (ETT)


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ANSI / NETA MTS 2019 – Standard for Maintenance Testing Specifications for Electrical Power Equipment and Systems

• Comprehensive field tests and inspections to assess the suitability for continued service, condition of maintenance, and reliability of electrical power distribution equipment and systems

• Ensure that the electrical power equipment and systems operate reliably and safely in conformance with industry and manufacturer standards and tolerances


Testing and Inspections

» What is it suppose to do?

• Design consideration

» Environmental considerations

» Criticality of system

» Current condition of equipment

» Trending results – good, bad, normal wear and tear?

» Budgets for upgrades and replacements


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3. Budgeting and Planning for Maintenance

» All equipment will eventually reach end of life

» Sound maintenance strategies can help plan for this inevitability

» Finding a balance between reliability, cost and safety is key to having a successful maintenance plan

Budgeting and Planning for Maintenance

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A good maintenance plan will get the best life out of your equipment and provide the best value for that investment.

Good maintenance practices and strategic upgrades can extend the life of equipment, improve performance, safety and prolong the equipment replacement as long as practical.


Budgeting:

A good maintenance plan helps predict your replacement budgets. Knowing your equipment will reach end of life in 10, 5 or 2 years allows you to budget properly and affords the time to get the most competitive replacements in a non-urgent timeframe.


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CSA Z463 – Maintenance of Electrical Systems:

An organization that is responsible for the state of maintenance of electrical equipment shall establish, implement, and maintain a documented electrical maintenance program.


The Maintenance Program shall address:

• Worker and public safety;

• Prevention of losses and property damage;

• Electrical system performance and reliability;

• Reduction of risk; and

• Compliance with applicable Federal, Provincial or Territorial regulation.


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Maintenance frequency must be adequate:

• To maintain the design criteria of equipment

• For devices to function safety

• References such as manufactures specifications, ANSI/NETA MTS can provide guidance for maintenance frequency intervals


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POOR AVERAGE GOOD

LOW 1 2 2.5

MEDIUM 0.5 1 1.5

HIGH 0.25 0.5 0.75

MAINTENANCE FREQUENCY MATRIX

EQUIPMENT CONDITION

EQ

UIP

ME

NT

RE

LIA

BIL

ITY

RE

QU

IRE

ME

NT

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Inspections

» Routine periodic inspections should be included in the electrical maintenance program

• Environmental conditions

• Visually good condition, dry and free from mechanical damage, overheating, corrosion,

• Abnormal noise/odor

• Indicating alarms, relays, gauges



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Electrical Tests

» Insulation resistance

» Timing tests

» Winding resistance

» Turns ratio

» Breaker operation

» Protection scheme operation


Repairs

» What items are in need of repairs or replacement during a shutdown?

» Are additional resources needed to execute the repairs?


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Replacement and Upgrades

» Are the parts available?

» What information is needed to specify a replacement or upgrade?


Personnel

» Are the required skills available to preform all of the maintenance activities?

» What are the specific duties of maintenance personnel?

» What are the specific training requirements for maintenance personnel?

» Are staff qualified to perform the required tasks?


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Planning a Maintenance Shutdown:

• Equipment/maintenance history

• Inspections/Electrical Tests

• Manufacturers recommendations

• Procurement and Engineering support for replacement or modification required

• Execution plan including schedules, worker competency, documentation, safety plan


There are numerous maintenance strategies.

Talking to a professional can assist in proper development of a maintenance program based on equipment, performance needs and budget.


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4. Types of Maintenance Plans


Planned Maintenance: Any maintenance activity for which a pre-determined job procedure has been documented and for which all labour, material, tools and equipment required to carry out the task has been estimated.

Types of Maintenance Plans

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Maintenance approaches fall into two basic categories; reactive and proactive.

Proactive Maintenance: Maintenance work that is completed to avoid failures or to identify defects that could lead to failures (failure finding).• Includes preventive and predictive maintenance activities

and work task identified from them.


Predictive Maintenance (condition-based): An equipment maintenance strategy based on equipment condition which looks for signs of impending failure so that maintenance can be done before failure.

Performing periodic or continuous equipment monitoring, once equipment gets to an unacceptable level, then repair or replacement.


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Predictive Maintenance (condition-based):

Oil Analysis

Insulation Resistance testing

Human Senses (look, listen, feel, smell)

Examples:

• Changing a bearing based on vibration analysis

• Changing lubricant based on oil analysis showing excess wear particles


Preventative Maintenance (PM) (time-based): An equipment maintenance strategy based on replacing or restoring an asset at a fixed interval regardless of its condition. (Time-based)

Preventative maintenance task is worth doing if it reduces the probability of failure enough to justify the cost of doing that task.


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Run to fail – an approach that allows equipment to run until it fails to deliver its intended function, then reactive maintenance occurs with repair or replacement.

Selected when the cost and impact of failure is less than the cost of preventative actions.

Not suitable for critical equipment


Different maintenance strategies for different equipment

» A record of electrical equipment assets shall be documented and maintained;

» A maintenance strategy shall be selected for each electrical equipment asset; and

» The maintenance strategy shall address:

• Manufacturers maintenance requirements; and

• Requirements of applicable codes and standards


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Because of the almost catastrophic consequences of electrical equipment downtime, it is important to select a strategy that balances the needs of the operation or end-user, with a practical and cost-effective approach to asset preservation.

Size of the operation may be a factor is selecting the appropriate maintenance strategy.


Summary

» Maintenance, regulatory compliance, safety and reliability are inter-related concepts that all need to be addressed together

» Owners need to understand the risk relating to electrical equipment failure

» Safety considerations when assuming equipment will operate within design tolerances

» Electrical equipment requires routine maintenance to function properly

» All equipment will eventually reach end-of-life

» Proper maintenance leads to the longest equipment service life, highest safety for personnel and best value for owner

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Questions?

Virginia Balitski

[email protected]

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Documents

Maintenance Electrical System - ASET