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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

10/19/2018 33

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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