Electrical switchboard review.

Risk management
Seeing the unseen
electrical and mechanical issues
Risk and Electrical Switchboards and Infrastructure
The key objectives in risk fall into two categories
• Staff welfare and safety – identifying issues in
electrical switchboards
• Continuous supply of power – ensuring equipment
does not fail creating risks.
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Common Approach
What lies behind the door ?
Always been there – no issues to date
No Issues as I am aware
Our electricians address issues
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Inside the switchboard all ok ?
Above cable heat acceptable tolerances
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Required by legislation to check
But not
Operation- Signage – Access – Opening – Listing
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Required by legislation to check
Operation- Signage – Access – Opening – Listing
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Consequences of electrical switchboards
faults and issues
Fire – Electricity major factor in fire cause.
Safety – incidents with electrical injury is often higher
than perceived.
Service delivery interruption.
Energy Costs – if power factor units and other vital
components not performing correctly.
Major Issue – Publicity - Impact on, share
holders/members.
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Electrical assets to be surveyed
Main Switch Boards
Motor Control Centre
Distribution Boards
Electrical Motors
Mechanical Services S/board
Transformers
Uninterrupted Power
Supply
Bus bars
Control Panels
Power Factor Correction
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Vodaphone UK Business Continuity Study
Of greatest concern is technology-related risk,
being a tier one risk.
59% of managers are concerned about IT systems
failure – related to power supply
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The Asset Life Cycle Management Process
Risk in Commissioning and Performance
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Installation of Asset Upgrade – New project
Commissioning of Asset - Baseline - Warranty
Maintenance of Asset – Predictive or Reactive
Condition Monitoring within Maintenance – Thermography
Life Cycle assessment. Linking condition monitoring information.
Compliance – OH&S comprehensive
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Disconnect between condition monitoring Asset Management
Dr Lin Ma U of Q –
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Standards for Switchboard Maintenance
AS3439.1:2002 Clause 5.3
It is the responsibility of the owner of the ASSEMBLY
to institute a system of maintenance.
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Mark Betcher
Blacktown City Switchboards
National Electrical Switchboard Manufacturers Association
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Switchboard Maintenance
Non-routine maintenance
Preventative maintenance
Post fault maintenance
Repair or corrective maintenance
Routine maintenance
Standard AS 2467 clauses 4.4.3, 4.4.4 & 4.4.5
Inspect – 12 months
Examine – 5 years
Overhaul – 15 years
Mark Betcher
Blacktown City Switchboards
National Electrical Switchboard Manufacturers Association
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Thermography General
Requirements
 Cost Benefit
Hartford Steam Boiler Inspections and Insurance Company completed a ten year study
evaluating the cost/benefits of infrared, in which it was determined a proper infrared
predictive maintenance program produces hard cost savings of $4:1.
 Trends
NFPA 70 USA Section 20.17.5 Inspection Frequency and Procedures
Annually – unless loss experience , New Equipment – Operation Load condition
Arc Flash – listing assets that have arc flash potential
Complete manual
 Australian Thermographers Association
Creating standards and methods
 Canadian Government Master Specification
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• What is a Thermographic survey?
• Using infrared images to measure temperature
differential and graphically illustrate issues
such as electrical anomalies, overheating,
metal wear, insulation degradation, identifying
leaks , observing air conditioning blockages are
a few of the applications.
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The issues below if addressed will ensure that your survey if required
for legal, warranty or insurance claim purposes is not compromised.
•Specialised equipment regularly serviced and calibrated.
•Trained consultants with thermography qualifications and significant experience
in electrical, mechanical and building industries
•Operating to appropriate standards and guidelines. Australia / International .
•Conduct surveys with due diligence to safety and addressing risk issues.
•Reporting completed to a high standard that shows asset condition
insights and issues to be addressed.
•The thermography service company can show evidence of
continued research and peer review, with ongoing professional development.
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Board, Director and Senior Management level.
Risks that an effective thermographic
survey can address for organisations.
Ensure all assets are checked
•Survey is independent
•Monitor faults to check for ongoing issues.
•High Voltage Low Voltage
•Expectation of Insurance objectives
or addressing issues that are to be investigated.
•Critical and high risk assets.
•Performance of Assets
Power Factor Correction unit – not operating creating costs
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SWITCHING AND FUSES ABOVE TRANSFORMERS
Visible Light Image
Infrared Thermal Image
These crimped connections between these transformers appear to be loose.
They should be checked. A failure here would shut down the entire system.
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OVERLOADED CIRCUITS
Visible Light Image
Infrared Thermal Image
Circuits show overloading of current
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OVERLOADED CIRCUITS
Visible Light Image
Infrared Thermal Image
Circuits show overloading of current
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MOTORS – maintenance and performance
Visible Light Image
Infrared Thermal Image
This motor is running too hot. Most motors are rated at 40C (104°F) over
ambient for a maximum heat rise. Once a motor reaches that maximum for any
length of time, the life expectancy of the motor is cut in half. For every 10° above
that maximum heat rise, the life expectancy is cut in half again. Heat could take a
20 year motor and turn it into a 5 year motor pretty fast. This motor is probably
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overloaded or over greased.
Thermography Key Points
Training
Competence
Calibrated Equipment
Suitability of the equipment
Standards
Anecdotes – misdiagnosis – equipment – reporting.
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HVIR Inspection Windows
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Thermographic Reporting
Objectives
•Approach asset surveys – Compliance or proactive.
- How often to inspect.
•Reporting – Your level of requirements
•Maintenance – Overview of asset health
What needs to be addressed with issues discovered?
•Cumulative overview – Comparison online or hard copy showing past reports.
•Management Overview – History of issues accessible, summary of compliance
•Asset Management –Trending of individual asset performance under loading.
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Condition Asset Knowledge is required that services the
requirements of Board, Senior Executives, Maintenance
Managers , Facility managers, and operation staff.
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Overview of Reporting system.
Initial Step Asset Register
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Overview of Reporting system.
Bar-coding – Full asset Register on site.
Details of each asset and previous reports.
Allows discussion with Client maintenance staff
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Reporting system - Asset Performance.
Trending of asset after a number of surveys or focused study
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Work with the Intuitive User Interface
Thermal Trends intuitive user interface allows you to drill
down to all of the relative information you need.
Webs based access.
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Overview of Reporting system.
Routes of locations and equipment are bar coded
for the automatic retrieval of each asset’s past inspection history.
Reports – Options that can be generated by Thermoview
• Historical Test Status Matrix for every survey completed.
• Infrared Documentation pages – Issues to be addressed by priority.
• Before vs. After repair function if required.
• Problem Trending
• Prioritized List of Problems
• Cost Benefit Analysis –
• Inventory Test Status
• Problem Status/Aging and trends.
• Visual Problems • Equipment Baseline Trending
Saving you time in analysis and asset review.
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Risk and Maintenance
Insurance companies require thermographic study.
Loss of Business Insurance requires Condition Monitoring
Independent Assessment
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BUILDING AND PROCESSING SYSTEMS
Retrofit – New Construction – Tune Up – Commissioning
Government funded study of facade of CBD building
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Building Applications Thermography
Trend toward developing professional methods
•Windows – Glazing – poor seals – facade performance
•Insulation –
•Walls and Frames – Thermal Bridging
•HVAC
•Cold Room
•Plumbing – leaks blockages
•Insulation lagging
•Moisture
•Electrical
•Mechanical
Energy rating
Rating against international standards. Canadian Government
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Government Funded Study with Cundall
and UNISA to create a method to
evaluate the facades of CBD Buildings
– 22 King William Street
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Visible Light Image
FLAT ROOF LEAK DETECTION
Infrared Thermal Image
Interior infrared survey conducted during daytime hours reveals central area
saturated with moisture and in need of immediate repair.
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MOISTURE CONTAMINATION
Visible Light Image
Infrared Thermal Image
The thermogram of this vinyl-sided 3-floor apartment house clearly shows the path
of a serious leak from a washing machine on the third floor, which is completely
hidden within the wall.
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PARTIALLY BLOCKED DRAIN PIPES
Visible Light Image
Infrared Thermal Image
Image shows pipes becoming blocked. Further build up has likelihood of a
serious blockage and consequent damage.
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WATER LEAKS
Visible Light Image
Infrared Thermal Image
Water logged cool room insulation.
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STRUCTURAL STEEL
Visible Light Image
Infrared Thermal Image
This is usually where the bars are joined in a bolted splice. Over time the
expansion and contraction from heating and cooling along with vibration from the
plants daily routines, will cause the bolts to become loose. There is no way to see
this without Infrared Thermal Imaging. This was done from the floor, without
climbing up and opening the boxes.
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CONCRETE DETERIORATION
Visible Light Image
Infrared Thermal Image
Note the de-bonded concrete layer on viaduct parapet wall. The thermographic
image has made it possible to efficiently and accurately detect the precise
development of loosening or cracking concrete that can lead to concrete
exfoliation in future. The safeguarding of third parties against potential
disasters is dramatically improved through thermal imaging.
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• Refrigeration – Maintenance – Energy Studies
In alliance with Cundall Sustainability Consultants
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Air Leakage in cold stores, trucks, containers and refrigerated equipment.
Degradation of insulation in panels.
Poor door seal performance.
Electrical switchboard review.
Electric Motor heating.
Moisture build up.
Roof leakage
Thermal bridging.
Insurance – risk management validation.
Cost Benefit Analysis
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PROCESSING
Visible Light Image
Infrared Thermal Image
Here we used Infrared Thermal Imaging to see the level of liquid in the tank.
The vapour space above the liquid is warmer than the liquid and thus we see
the temperature differential. The liquid will have a higher thermal capacitance
(ability to store energy) than the vapour space, and that is why we can see the
difference.
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Summary
Review your switchboard risk profile.
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 Established since 1989 -National operations based in Adelaide
 Servicing blue chip clients in Property, Mining, Manufacturing ,
Government
 Independent Thermography Auditors
 Highly qualified and experienced staff
 Adhere to industry best practices and standards
 State of the art Flir cameras, equipment and technology
 Strong alliances and strategic partners
Cundall, Green Ochre, CBC and overseas groups.
 Member of Aust Institute of Non Destructive Testing
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Thank You for your participation
Ken Burt
Thermoview Pty Ltd
22 The Parade West
Kent Town SA 5067
kburt@thermoview.com.au
Telephone 08 83636886
Mobile 0448 920 007
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