7 Predictive Maintenance Techniques for Boosting Power

Equipment Reliability

Dennis Bouley | August 31, 2016 | 11,457 views

7 Predictive Maintenance Techniques for Boosting Power Equipment Reliability eMail1644inShare70

According to the Hartford Steam Boiler Insurance Company, businesses can expect a
minimum of six hours of electrical distribution system-induced business interruption per year.
Statistics from the Institute of Electrical and Electronics Engineers (IEEE) show that an
effective electrical maintenance program can reduce risk of these types of outages by as much
as 66 %.

Predictive or condition-based maintenance offers companies the least expensive, most

efficient method of reducing equipment-related downtime. In a predictive maintenance
model, maintenance work is scheduled based on diagnostic evaluations that determine when
to perform service. The monitoring of equipment conditions provides trending data to help
anticipate future maintenance needs.

Over time, electrical equipment can break down for several reasons. One is mechanical
failure. This can occur as a result of loose connections, overheating, and changes or additions
to load changes. Environmental conditions, including high humidity, corrosive environments,
and high dirt and dust levels, also lead to more frequent instances of downtime. Human error
is a third important element of unanticipated downtime, and it often occurs when hands-on
maintenance is performed.

In order to avoid costly disruptions, many organizations are now shifting from a preventive
maintenance model to the predictive maintenance approach. New advances in software and
sensor technology (e.g. smart panels) allows for this highly effective monitoring method to be
both affordable and precise.

Below are 7 predictive maintenance approaches that inspect, monitor, assess, and analyze
electrical equipment:

1. Power System Assessments – These are conducted by professional electrical engineers

trained in power system analyses. Power system assessments provide visual inspections of
the existing power distributionsystem. Defects, deficiencies, deteriorations, hazards, or
weaknesses in existing system installations are identified as part of the assessment.
2. Infrared (Thermographic) Inspections – Infrared inspections use a specialized camera
to detect anomalies not noticeable to the naked eye. In an electrical setting, infrared
inspections identify hot spots, which can be a precursor to equipment malfunction, which
leads to unplanned downtime.
3. Online Temperature Monitoring – This technology provides 24/7 access to critical
connection points where traditional thermography cannot be used. Continuous monitoring
provides the means to evaluate the equipment’s current condition and detect abnormalities
at an early stage. During a planned outage, wireless temperature sensors are installed in
low-voltage and medium-voltage equipment areas not accessible to an infrared camera.
4. Insulating Fluid Analysis – This approach measures the physical and chemical properties
of oil in an oil-filled transformer. An oil analysis can detect the breakdown of the oil paper
insulating system. Common tests performed on electrical insulating oils include readings
 for moisture content, acid levels, dielectric strength, power factor, and dissolved gas
analysis.
5. Partial Discharge Monitoring – A partial discharge is a localized electrical discharge in
an insulation system that does not completely bridge the electrodes. As insulation systems
age, they become more susceptible to these types of breakdowns.
6. Circuit Monitor Analysis – Circuit monitors record data relating to voltage, current, and
power. They help facility managers and engineers understand where and when dangerous
and destructive transients, sags and swells occur.
7. Intelligent Protective Devices – Circuit breakers and motor control centers are two
examples of intelligent protective devices. Monitoring of circuit breakers provides
advanced information regarding identification and position, number of operations,
cumulative interrupted currents, operating times, charging time, travel-time curve, excess
closing energy, and wear of contacts. Motor control centers are monitored for readings of
motor current and power, thermal capacity, line currents, average current, ground current,
motor temperature, current phase imbalance, voltage frequency, line to line voltage, and
line voltage imbalance.