How to Create an

Effective and Safety

Compliant Electrical
Maintenance Program
Douglas McNeill
Business Development Manager- Asia Pacific
Electrical Systems Are Critical

• Energy
• Control
• Communications

Any error or disruption in these critical electrical systems can have a HUGE cost to your business!
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How do we start?
Critical Asset Surveillance
Technologies (CAST)
Tools Used to Measure Equipment Condition

Ultrasonic / Partial Motor Current Infrared EMSD’s & Critical

Discharge Testing Analysis (MCA) Thermography / Asset Surveillance
Ultraviolet Camera

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Identify the Components you wish to inspect

Cable Connections Bus Bar Connections Isolator or Circuit Breaker

Connections
Good Electrical Connection and Circuit

Test Equipment Results

Infrared Scan Ultrasound Scan Partial Discharge Motor Current Ultraviolet Scan Visual Inspection
Analysis
Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results
No Issues Found No Issues Found No Issues Found No Issues Found No Issues Found No Issues Found
(Voltage Related, (Voltage Related,
Usually used in 5kV Usually used in 5kV
Systems or Above) Systems or Above)
Overloaded Electrical Connection and Circuit

Test Equipment Results

Infrared Scan Ultrasound Scan Partial Discharge Motor Current Ultraviolet Scan Visual Inspection
Analysis
Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results
Uniform heating of No Issues Found No Issues Found No Issues Found No Issues Found In extreme cases we
completed Circuit (Voltage Related, (Voltage Related, may see heat damage
Usually used in 5kV Usually used in 5kV on cables, etc….
Systems or Above) Systems or Above)
High Resistance Or Loose Electrical Connection

Test Equipment Results

Infrared Scan Ultrasound Scan Partial Discharge Motor Current Ultraviolet Scan Visual Inspection
Analysis
Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results
Localized heating at May find Arcing or No Issues Found Inspections should No Issues Found In extreme cases we
bolted connection tracking depending on (Voltage Related, show elevated (Voltage Related, may see heat damage
severity of the fault Usually used in 5kV resistance reading in Usually used in 5kV on cables, etc….
Systems or Above) tested circuits. Systems or Above)
High Resistance Or Loose Cable Lug Connection

Test Equipment Results

Infrared Scan Ultrasound Scan Partial Discharge Motor Current Ultraviolet Scan Visual Inspection
Analysis
Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results
Localized heating at May find Arcing or No Issues Found Inspections should No Issues Found No Issues Found
Lug/cable connection. tracking depending on (Voltage Related, show elevated (Voltage Related,
severity of the fault Usually used in 5kV resistance reading in Usually used in 5kV
Systems or Above) tested circuits. Systems or Above)
Partial Discharge or Cable Insulation failure

Test Equipment Results

Infrared Scan Ultrasound Scan Partial Discharge Motor Current Ultraviolet Scan Visual Inspection
Analysis
Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results Inspection Results
Depending on severity Should produce corona TEV will be present but No Issues Found Corona will be present In extreme cases the
level this may not but is voltage results are voltage but results are voltage Partial Discharge can
produce heat…. defendant Related, Usually used in Related, Usually used in be seen as a white
5kV Systems or Above 5kV Systems or Above residue
Equipment Failure Patterns

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 Critical Asset Surveillance Technologies
Summary

Critical Asset Surveillance Technologies

Risk Exposure Reductions Utilizing CAST
Programs

The blue area is the potential expense to perform repairs upon failure This amounts
to millions of dollars per year not counting production losses, collateral damage or
injury. The red area is the costs associated with CAST / PM programs
Cost exposure is 66% less when utilizing CAST / PM (source IEEE)
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Common Ways to Interact with Equipment
An arc flash hazard is a state that occurs when exposed parts are present OR when you are
interacting with a piece of equipment in such a way that you could cause an arc flash.

• Opening or closing doors

• Removing or replacing a cover
• Reaching into or leaning into equipment
• Removing or replacing internal barriers
• Operating switches or circuit breakers
• Racking a circuit breaker
• Using tools or test equipment
 Hierarchy of Control: Controlling Risk

1. Eliminate Hazards
2. Reduce the Risk by Design
3. Apply Safeguards
4. Implement Administrative
Controls Before
5. Use Proper PPE

After
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Multi Technology EMSD & Inspection Portal

Impact & Load Resistant Design Infrared Viewing Window

IP2X Electrical Failsafe Visual Viewing Window

Unconditional Lifetime Warranty Ultraviolet Viewing Window

Environmentally Sealed to
Insoluble Lens Materials
IP67 / NEMA 4X

Partial Discharge / Ultrasound

Port OR Ultrasound Sensor

E Sentry Connect Asset

Management Systems Arc Containment Tested to
IEC 62271-200
Inspecting your equipment twice
a year using CAST results in your
critical assets being left unchecked
for 99.997% of their annual
running time…
 A Recent Emerson Study on The Effect of Regular, Skilled
Preventive Maintenance and Remote Monitoring of Critical
Power system Reliability on Mean Time Between Failures
(MTBF) showed the following Results: 23
The Asset MTBF is
increased by 51
times by inspecting
once per quarter

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Source: The Effect of Regular, Skilled preventive Maintenance and Remote Monitoring on Critical Power system Reliability
 Direct (Visible) Costs
• Acquisition
• Research
•
•
Design
Production and Test
15%
• Construction

Indirect (Invisible) Costs

• Operations (Personnel, Facilities, Utilities)
• Maintenance, Testing and Support
• Spares and Inventory
• Training
• Software
• Disposal Up to 75%
Total Cost of Asset Ownership
Prioritizing Assets for EMSD / CAST Implementation

Dry type Variable

Low Voltage Speed Drive
Transformer
Switchgear

Oil Filled AC Motor /

Switchboard Transformer DC Motor

Motor Medium
Panelboard Control Voltage
Center Switchgear

11/18/2019 26
Summary:
The Use of EMSD CAST Programs Deliver the Following:
• Repair Cost exposure is 66% less when utilizing CAST /
PM programs
• Significant impact on the TCO by reducing indirect costs
associated with Maintenance & Spares
• Up to 95% reduction of man-hours required for
energized inspections
• MTBF is significantly improved adding to increased
uptime and decreased downtime
• Return On Safety maximized and comply with NFPA70E
• Remove maintenance induced failures by simplifying
energized maintenance inspection processes
• Increased ROI On CAST equipment and training 27
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