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: