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iCAST Introduction to Critical Asset Surveillance Technology Rudy Wodrich – VP Engineering Services Drew Walts – Training Manager IRISS Inc.
iCASTIntroduction to Critical
Asset Surveillance Technology
Rudy Wodrich – VP Engineering Services
Drew Walts – Training Manager
IRISS Inc.
iCAST: Agenda
• How to Create a Safe & Effective Electrical Maintenance Program
• Ultrasound / Partial Discharge
• Infrared / Thermal Monitoring
• Electrical Maintenance Surveillance Systems• Spot testing methods
• Online Monitoring
• Asset Tagging Technology
How to Create an Effective and Safety Compliant Electrical
Maintenance ProgramRudy Wodrich
VP Engineering Services, IRISS Inc.
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
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Ultrasonic / Partial Discharge Testing
Motor Current Analysis (MCA)
Infrared Thermography / Ultraviolet Camera
EMSD’s & Critical Asset Surveillance
Cable Connections Bus Bar Connections Isolator or Circuit Breaker
Connections
Identify the Components you wish to inspect
Infrared Scan Ultrasound Scan Partial Discharge Motor Current Analysis
Ultraviolet Scan Visual Inspection
Inspection Results
No Issues Found
Inspection Results
No Issues Found
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
No Issues Found
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
No Issues Found
Good Electrical Connection and Circuit
Test Equipment Results
Infrared Scan Ultrasound Scan Partial Discharge Motor Current Analysis
Ultraviolet Scan Visual Inspection
Inspection Results
Uniform heating of completed Circuit
Inspection Results
No Issues Found
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
No Issues Found
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
In extreme cases we may see heat damage
on cables, etc….
Overloaded Electrical Connection and Circuit
Test Equipment Results
Infrared Scan Ultrasound Scan Partial Discharge Motor Current Analysis
Ultraviolet Scan Visual Inspection
Inspection Results
Localized heating at bolted connection
Inspection Results
May find Arcing or tracking depending on
severity of the fault
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
Inspections should show elevated
resistance reading in tested circuits.
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
In extreme cases we may see heat damage
on cables, etc….
High Resistance Or Loose Electrical Connection
Test Equipment Results
Infrared Scan Ultrasound Scan Partial Discharge Motor Current Analysis
Ultraviolet Scan Visual Inspection
Inspection Results
Localized heating at Lug/cable connection.
Inspection Results
May find Arcing or tracking depending on
severity of the fault
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
Inspections should show elevated
resistance reading in tested circuits.
Inspection Results
No Issues Found(Voltage Related,
Usually used in 5kV Systems or Above)
Inspection Results
No Issues Found
High Resistance Or Loose Cable Lug Connection
Test Equipment Results
Infrared Scan Ultrasound Scan Partial Discharge Motor Current Analysis
Ultraviolet Scan Visual Inspection
Inspection Results
Depending on severity level this may not produce heat….
Inspection Results
Should produce corona but is voltage
defendant
Inspection Results
TEV will be present but results are voltage
Related, Usually used in 5kV Systems or Above
Inspection Results
No Issues Found
Inspection Results
Corona will be present but results are voltage
Related, Usually used in 5kV Systems or Above
Inspection Results
In extreme cases the Partial Discharge can
be seen as a white residue
Partial Discharge or Cable Insulation failure
Test Equipment Results
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Equipment Failure Patterns
SummaryCritical Asset Surveillance Technologies
Critical Asset Surveillance Technologies
Risk Exposure Reductions Utilizing CAST
Programs
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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)
Equipment Condition Can Seriously Impact
Energy Efficiency
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Loose Connections have higher resistance and generate energy losses in the form of Heat
Resistance (R) in Ohms can be calculated via Voltage Drop Measurement across the connection and Current Measurement of the circuit (Vd = I x R)
Find the Voltage drop on a “normal” tight connection for comparison (Vdn) and the normal resistance Rn (Vdn = I x Rn)
Power Loss in KW: P = [I2 x (R – Rn)] / 1000
Energy Loss Cost: P x Annual Operating Hours x Energy Price ($/kWh)
Example:Circuit breaker with 250A load current.Normal Connection shows Vdn = 2 Volts
Rn = 2 / 250 = 0.008 OhmsLoose Connection shows Vd = 4.5 Volts
r = 4.5 / 250 = 0.018 OhmsPower Loss in KW
p = [2502 x (0.018 – 0.008)] / 1000 = 0.625 KW
Operation runs 8 hours per day x 240 days per year. Electricity cost is 6c/kWh
Annual Energy Loss Cost: 0.625KW x 240 x 8 x $0.06 = $309 per year
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Reducing Maintenance
Induced Failures
Common Ways to Interact with Equipment
• 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
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.
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Ports
Ultrasound
External Voltage Indicators
MCA
Power Quality
Online Monitoring
Temperature Monitoring
Asset Tags & Monitoring
Vibration Analysis
Partial Discharge
Power Quality
Types of Electrical Maintenance Safety Devices (EMSD)
Infrared (IR) Windows
Round / Rectangular IR
Windows
Visual / IR / UV spectrums
Custom designed IR
Windows
Hierarchy of Control: Controlling Risk
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1. Eliminate Hazards
2. Reduce the Risk by Design
3. Apply Safeguards
4. Implement Administrative Controls
5. Use Proper PPE
Before
After
Infrared Viewing Window
Visual Viewing Window
Ultraviolet Viewing Window
Impact & Load Resistant Design
IP2X Electrical Failsafe
Unconditional Lifetime Warranty
Insoluble Lens Materials
Multi Technology EMSD & Inspection Portal
E Sentry Connect Asset Management Systems
Partial Discharge / Ultrasound Port OR Ultrasound Sensor
Environmentally Sealed to IP67 / NEMA 4X
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…
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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:
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The Asset MTBF is increased by 51
times by inspecting once per quarter
Source: The Effect of Regular, Skilled preventive Maintenance and Remote Monitoring on Critical Power system Reliability
Total Cost of Asset Ownership
Direct (Visible) Costs• Acquisition• Research• Design• Production and Test• Construction
Indirect (Invisible) Costs• Operations (Personnel, Facilities, Utilities)• Maintenance, Testing and Support• Spares and Inventory• Training• Software• Disposal
15%
85%
Total Cost of Asset Ownership
Direct (Visible) Costs• Acquisition• Research• Design• Production and Test• Construction
Indirect (Invisible) Costs• Operations (Personnel, Facilities, Utilities)• Maintenance, Testing and Support• Spares and Inventory• Training• Software• Disposal
15%
Up to 75%
Prioritizing Assets for EMSD / CAST Implementation
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Low Voltage Switchgear
Panelboard
Switchboard
Dry type Transformer
Oil Filled Transformer
AC Motor / DC Motor
Motor Control Center
Variable Speed Drive
Medium Voltage Switchgear
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• 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
Summary:The Use of EMSD CAST Programs Deliver the Following:
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