NFPA 70B and the Importance of Electrical Predictive Maintenance

Transcription

1 NFPA 70B and the Importance of Electrical Predictive Maintenance PRESENTED BY Bhanu Srilla Director of Product Marke0ng Grace Engineered Products, Inc.

2 Learning Objectives 1. Review NFPA 70B Maintenance Requirements 2. Identify various failure points in electrical systems 3. Observe temperature monitoring in critical applications 4. Compare IR inspections vs. continuous monitoring

3 Downtime Costs by Industry Sector Average Revenue Loss: ~$1.0 Million/Hour Predic0ve Maintenance can o>en be the lower- cost op0on Predic0ve Maintenance o>en results in longer intervals between maintenance

4 Fires triggered due to Electrical faults/malfunction Non- Home structures involving electrical equipment malfunc0on or failure ~37% of the accidents between midnight- 8 AM March and November months

5 Fires involving Lighting and Power Distribution Equipment 5

6 Key Drivers for Electrical Maintenance Programs Regulatory Safety Cost Management Service Con0nuity

7 OSHA & NFPA 29 CFR , Subpart: K NFPA 70B 29 CFR , Subpart: S - NFPA 70E OSHA training requirements have maintenance component OSHA defers to manufacturers required maintenance schedules

8 NFPA 70B: Personnel Safety Personnel safety is very important when performing maintenance Some of the considera0ons in Ar0cle110 of NFPA 70E: (1) Training requirements (see 110.2) (2) Electrical safety program (see 110.1) (3) Use of electrical equipment (see 110.4) Some Considera0ons in Ar0cle 120 of NFPA 70E: (1) Verifica0on of an electrically safe work condi0on (see 120.1) (2) De- energized electrical equipment that has lockout/ tagout devices applied(see 120.2) (3) Temporary protec0ve grounding equipment (see 120.3)

9 NFPA 70E: Properly Installed and Maintained Ar8cle 130.1(A)(4) Normal Opera8on. Normal opera0on of electric equipment shall be permieed where all of the following condi0ons are sa0sfied: (1) The equipment is properly installed. (2) The equipment is properly maintained. (3) The equipment doors are closed and secured. (4) All equipment covers are in place and secured. (5) There is no evidence of impending failure.

10 Preventive Vs Predictive Maintenance Based on Periodic checks and inspec0ons Doesn t consider the asset wear Availability of 0me and trained personnel Full asset Visibility Cost Effec0ve Predict failures using data Increase asset life cycle Planned Down0me Increase Reliability 10

11 Predictive Maintenance Risk reduc0on is the primary driver Predic0ve Maintenance can o>en be the lower- cost op0on Predic0ve Maintenance some0mes results in longer intervals between maintenance

12 NFPA 70B 2016 Edition Highlights Torque Recommenda0ons Loose connec0ons Proper termina0on torque values Overhea0ng, Intermieent Open Circuits and electrical arcs Baeery Tes0ng and Maintenance Greater detail on baeery tes0ng Safety considera0ons for persons performing maintenance

13 Critical Facility Electrical Equipment Generators UPS & Baeeries Transformers Busways HVAC systems Transfer Switches MV/LV switchgear

14 Risk Control Hierarchy Our Goal must be: 1. Elimina0on 2. Engineering Controls PPE must be your last line of defense

15 Loose Connections & Temperature Rise Load Condi0ons Duty Cycles Mechanical wear and stress Incorrect crimping of connec0ons Improper cable training Thermal expansion & contrac0ons Vibra0ons and Harmonics

16 NFPA 70B Code Reference Loose Connec8ons & Temperature Rise: Sec8on 17.9: Loose Connec8ons. Loose connec0ons are the most common cause of excessive heat. Periodic maintenance checks should involve checking for loose connec0ons or evidence of overhea0ng Section : Temperatures over design levels for prolonged periods can reduce the electrical life of organic insulating materials Section : Localized heating (hot spots) can sometimes occur and can be masked because the overall temperature of the surroundings Section : Section 9 and table of the ANSI/NETA/MTS, Standard for Maintenance Testing Specifications for Electrical power distribution equipment and systems suggests temperature benchmark. Temperature differences of 1 C to 3 C indicate possible deficiency and warrant investigation Temperature differences of 4 C to 15 C indicate deficiency; repairs should be made as time permits Temperature differences of 16 C and above indicate major deficiency; repairs should be made immediately. 16

17 NFPA 70B Code Reference Thermography Programs: Section: : Infrared inspections should be performed by qualified and trained personnel who have an understanding of infrared technology, electrical equipment maintenance Sec8on : Infrared inspec0ons require special measures and analysis. Equipment enclosed for safety or reliability can be difficult to scan or to detect radia0on from within. Special precau0ons, including the removal of access panels, might be necessary for sa0sfactory measurements Sec8on : Inspec6on frequency and procedures Rou6ne infrared inspec6ons of energized electrical systems should be performed annually prior to shut down. More frequent infrared inspec6ons, for example, quarterly or semi- annually, should be performed where warranted by loss experience, installa6on of new electrical equipment, or changes in environmental, opera6onal or load condi6ons. Sec8on : Inspec0on frequency and procedures Rou0ne infrared inspec0ons of energized electrical systems should be performed annually prior to shut down. More frequent infrared inspec0ons, for example, quarterly or semi- annually

18 NFPA 70B Code Reference Sensing, Indica8ng & Control Systems in Maintenance of Electrical Equipment Subject to Long Intervals Between shutdowns: Applies to both low and medium voltage systems Sensing, Indica0ng and Control Systems Sec8on : The need for and frequency of inspec0on and maintenance are determined by the effect on safety, plant opera0ons, and the severity of service. Also, some components can be readily isolated, while others can be inspected only during plant or process shutdowns. Sec8on : Visual inspec0on either by plant operators during normal opera0ons or as part of a scheduled inspec0on can assist in detec0on of deficiencies such as loose connec0ons, overhea0ng, and excessive vibra0on. Sec8on : Sensing, indica0ng, and control devices can be divided into two categories: primary elements and secondary elements. (1) Primary elements are elements in contact with the process medium directly or indirectly and that might or might not be isolated from the process medium. (2) Secondary elements are transminng, recording, or controlling devices. Some are normally in use and thus receive an automa0c day- to- day check. Some are remotely located or infrequently used and require a check at regular intervals.

19 NFPA 70B Code Reference Busways & Electrical Joints Low Voltage Busway (600 Volts) Section Feeder Busway Section Plug-in bus way Section Metal-Enclosed Busway (5 kv to 15 kv) Section Electrical Joints Section Infrared inspection of busway joints can reveal loose connections 19

20 Thermography and it s challenges Thermography Programs Open- door Thermography Annually/ Semi- annually Closed- door Thermography IR windows More frequent (Monthly)

21 Trends in temperature monitoring Con0nuous monitoring Fixed IR Cameras RFID Sensors Magne0c sensors

22 Fiber-optic Non-Conductive Sensing LED tunnels through polymer fiber, reflects off probe 8p compound and a]enua8on is measured at the HSM module. 22

23 Ease of Installation Ability to perform concurrent maintenance Perform maintenance on redundant systems Aeain the reliability/availability criteria

24 Potential Failure Points Example Visibility Barriers Low Voltage Compartment All Poten8al Failure Points (PFP s) should be known for op8mal predictability Infrared imaging has limita8ons with Field of View (FOV) 24

25 Application Ideas Main Incoming Termina8ons Low Voltage MCC MV MCC

26 Other Application Ideas Ambient Space Heater

27 Open Door Thermography vs Continuous Monitoring Scenario: Industrial facility using thermography contractors on a semiannual basis for open door inspec8ons to meet insurance requirements. For this example, we considered a manufacturing facility required to inspect ten electrical panels with six cri0cal connec0ons in each panel totaling sixty inspec0on points. A typical open door inspec0on of this magnitude requires two thermographers and a facility electrician. Electrical Panels: 10, Cri8cal connec8ons in each panel: 6, Total points inspected: 60 No. of Electricians: 1, No. of Thermographers: 2, No. of inspec8ons: 1

28 IR Windows vs Continuous Monitoring Scenario: Industrial facility has iden8fied cri8cal panels to be inspected and is evalua8ng the installa8on of IR windows and using in- house personnel to minimize the exposure to high incident energy and reduce outsourced thermography contractor costs. For this example, we considered a manufacturing facility that iden0fied nine electrical panels with three cri0cal connec0ons in each panel totaling to twenty seven inspec0on points. A typical closed door inspec0on requires at least one 3 round IR window installed in every panel to inspect three connec0ons that result in installa0on of nine IR windows. Electrical Panels: 9, Cri8cal connec8ons in each panel: 3, Total points inspected: 27, No. of inspec8ons: 4

29 Networking Stand Alone Unit TCP/IP Serial Topology (Daisy Chain) Modbus RTU Plant-wide Integration SCADA/ DCS Systems Local Power Management System Star Topology Ethernet IP Plant-wide Integration SCADA/ DCS Systems Local Power Management System

30 Comparison of Open Door / IR Windows / Continuous Monitoring

31 Summary

32 Questions? Thank you!