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 1. Home
 2. Arc Flash & Electrical Safety
 3. How state-of-the-art predictive maintenance best practices can achieve
    electrical safety 


HOW STATE-OF-THE-ART PREDICTIVE MAINTENANCE BEST PRACTICES CAN ACHIEVE
ELECTRICAL SAFETY 


PREDICTIVE MAINTENANCE CAN ENSURE ELECTRICAL SYSTEMS ARE DESIGNED CORRECTLY AND
OPERATED SAFELY 

By Carsten Baumann August 1, 2023
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Courtesy: Schneider Electric

 

LEARNING OBJECTIVES

 * Learn how to tap into the power of digital twins to run “what if” safety
   scenarios.
 * Know how to use audits and smart sensors to improve safety and electrical
   system performance..
 * Review methods to proactively reduce arc flash threats.




ELECTRICAL SYSTEM INSIGHTS

 * Electrical system safety is always the No. 1 priority and engineers are aware
   of the four basic tenets of achieving it: reduction, avoidance, prevention
   and containment.
 * What if engineers were equipped with a crystal ball that could tell them how,
   why and when that safety would be jeopardized? Predictive maintenance can be
   the answer.

--------------------------------------------------------------------------------

Managing maintenance and operating electrical systems in facilities without
proper controls can lead to safety and financial risks, including unplanned
outages that can cause harm to on-site personnel and equipment damage. Such
outages can also cause excessive financial losses to businesses. Uptime
Institute research data found that around a third of all reported outages cost
more than $250,000, with many exceeding $1 million. Data center outages are some
of the costliest, with a quarter of respondents in a survey indicating that
their most recent outage cost more than $1 million in direct and indirect costs.





Power systems engineers working in plants often rely on static paper or
PDF-based electrical single-line diagrams to prevent these outages and maintain
their facilities. This introduces limitations that increase operational risks
and create challenges in maintaining and updating the documentation for
electrical systems. Adopting predictive maintenance best practices to mitigate
these risks, such as digital twins, safety audits, smart sensors and arc flash
solutions, can help ensure electrical safety and reduce unplanned downtime.


TAPPING INTO THE POWER OF DIGITAL TWINS

Digital twins are virtual replicas of physical objects, processes or systems
that are created using real-time data and simulations. These digital
representations can help improve complex systems’ understanding, design and
operation by providing insights into their behavior, performance and potential
problems.



For example, a digital twin of a power distribution system could monitor the
flow of electricity through various components, identify potential areas of
overload or overvoltage and predict the likelihood of equipment failure.

Digital twin technology can be employed during the design phase of an electrical
system and the life cycle’s operations and maintenance phases to increase safety
significantly. Intelligent single-line diagrams using digital twin technology
can create active blueprints of single- and three-phase power systems. These
tools facilitate seamless collaboration and the application of real-time
insights, which can streamline diagnostics and troubleshooting.

Operators and engineers can improve their understanding of existing electrical
systems by using digital twins as a comprehensive digital learning environment.
New-generation predictive tools use real-time and archived data as a simulation
platform that enables power systems engineers to run “what if” scenarios. This
online predictive simulation is a potent analytical tool that allows engineers
to anticipate the system’s response to operator actions.

Such an approach offers several advantages, including the ability to experience
emergencies and precarious situations without actual danger, resulting in fewer
safety exposures. Additionally, precise “what if” scenarios can illustrate how
to improve operational efficiency and enhance decision-making. The practical
post-mortem analysis and event playback capabilities facilitate faster incident
response times.


USING AUDITS TO IMPROVE SAFETY AND ELECTRICAL SYSTEM PERFORMANCE

Audits can be another valuable tool for promoting safety and enhancing the
performance of electrical systems. Having the capability to identify technical
deficiencies and anticipate potential failure risks in a facility’s electrical
system is vital. By conducting audits, organizations can identify potential
hazards and areas for improvement, allowing them to implement corrective actions
before accidents or failures occur. Audits can also help ensure that electrical
systems are operating efficiently, identify areas of noncompliance and verify
that maintenance programs are being executed effectively. This proactive
approach can improve safety, reduce downtime, extend equipment life span and
save costs.

However, detecting these shortcomings can be daunting, particularly when faced
with limited resources. Collaborating with expert consultants and the operations
team can help identify critical areas for improvement. Using nonintrusive
state-of-the-art technology, an on-site audit assesses the electrical
installation. It builds a single-line diagram of the devices, quickly
identifying potential weak points that could compromise system safety and
performance. This process helps uncover potential vulnerability hazards and
recommends optimal performance and safety improvements.

Figure 1: ETAP is an analytical engineering solution company specializing in the
simulation, design, monitoring, control, operator training, optimizing and
automating of power systems. ETAP’s integrated digital twin platform offers the
best comprehensive suite of enterprise solutions. Courtesy: Schneider Electric

Experts with specialized software provide a comprehensive modernization plan,
including 10-year maintenance, monitoring and management plans, spare parts and
technical documentation management. Following the audit, debrief sessions with
all stakeholders highlight observations, risks and recommended next steps.
Comprehensive reports relay vital, actionable insights and standardized
deliverables across locations, segments or countries to ensure multisite or
country consistency and develop ongoing monitoring and management strategies for
maintenance plans.


REDUCING THE HAZARDS OF ELECTRICAL SYSTEM ARC FLASH THREATS

Arc flash is one of the most potentially destructive and hazardous forces in
electrical installation, operations and maintenance. It is highly complex,
dangerous and difficult to avoid and contain. An uncontrolled arc has the
potential to generate extreme heat exceeding 35,000°F and a blast force with
pressure waves up to 1,000 pounds per square foot. The resulting noise can reach
160 decibels and high-velocity projectiles from the arc can travel up to 700
mph. The toxic gases produced can expand by a factor of 67,000, posing a
significant risk to workers, equipment and facilities.

Arc flash mitigation and arc flash hazard analyses have been complex until
recently. Although many empirical formulas and significant testing have been
developed, the algorithms and formulas available are still challenging for
engineers to solve without a computing tool and nearly impossible for people in
the field to apply.

However, with an increased industry focus on electrical safety, arc flash
hazards are now more broadly recognized.

Mitigating the risk of arc flash is complex and typically requires collaboration
between multiple parties, including facility owners, electrical system designers
and equipment manufacturers. However, obtaining accurate information can be
challenging, especially in traditional design-and-build project environments.
Information exchange may be limited, such as the system short circuit level, the
composition of electrodes, enclosure sizes or standard operating procedures.
Failure to consider these factors can undermine even the most well-conceived
mitigation solutions.

Figure 2: Screen captures of ETAP Predictive Stimulation Analysis information
shows sequences of operations and time current curves, among other things.
Courtesy: Schneider Electric

Compliance with Title 29 of the Code of Federal Regulations Part 1910 is
required to reduce the risk and severity of arc flash incidents and ensure
worker safety. A proactive approach to electrical system design can eliminate
the risk of arc flash hazards. Engineered solutions can reduce the likelihood of
accidental contact with energized components using a safety-by-design
methodology during a new system’s design and specification stage.

Understanding the arcing current’s magnitude, path and duration is necessary for
effective mitigation. The incident energy level is a parameter used to quantify
the arc flash hazard. Eliminating the risk or reducing the arc flash incident
energy is possible through de-energized work, arc-resistant switchgear or
removing personnel outside of the arc flash boundary.

However, these solutions only sometimes prevent equipment damage. Alternatively,
arc fault detection solutions can clear arc faults by upstream overcurrent
protection devices. However, these solutions can be risky and require auxiliary
power, system design or operator intervention, which introduces the possibility
of human error. Additionally, these solutions are one-time use and require
inspection or replacement of failed components.

A straightforward and reliable solution for controlling arc flash hazards can be
achieved with a passive, repeatable, always-on system that does not require
complex engineering. An always-on arc flash prevention and containment system
works to minimize the chances of an arc occurring. If a sustained arcing current
does occur, the system will extinguish it within one cycle or less, which is
faster than any other active or reactionary protection system.

This approach eliminates the need for operator intervention, does not rely on
auxiliary power and significantly reduces the risk of harm to people and
electrical equipment. With the implementation of a passive arc flash protection
system, managing arc flash hazards becomes more straightforward and mitigation
strategies become more accessible. Unlike many active solutions, an always-on
arc flash prevention and containment system does not cause tripping, leading to
zero downtime or disruption of upstream devices while still containing the arc
fault.

The initial cost of implementing a passive, repeatable, always-on arc flash
control solution may be approximately 15% more than standard equipment. However,
the return on investment over the equipment life cycle is significant. The
benefits of this system include a reduction in additional arc flash engineering
controls, lower installation, commissioning and ongoing maintenance costs,
decreased need for personal protective equipment and associated costs.
Furthermore, businesses can avoid direct and indirect arc flash-related
expenses, such as medical and legal costs, fines, increased insurance premiums
and business continuity interruptions.


USING SMART SENSORS FOR GREATER OPERATIONAL CAPABILITIES

Smart sensors, breakers and electrical panels with shared visibility benefit
various stakeholders along the risk-management value chain. Smart sensors can be
used to monitor plant conditions and alert engineers to potential safety hazards
by monitoring air quality, temperature, humidity and other environmental
conditions in the plant. If levels exceed safe limits, alerts can be sent to
engineers or safety personnel, allowing them to take appropriate action. Smart
sensors can also detect the presence of gases that can be hazardous to human
health or safety and detect the presence of smoke or fire in the plant.

When circuit breakers and electrical panels are equipped with built-in smart
sensor monitoring capabilities, they can provide operational data right from the
moment they are installed. These novel capabilities have numerous advantages,
such as reducing risk for insurers and supporting testing, inspection and
certification providers to offer value-added services to their clients
throughout the year, not just during annual inspections.

Smart sensors can be used to monitor critical plant equipment and processes in
real-time, allowing engineers to quickly detect any anomalies or potential
problems and take corrective action before they escalate into more serious
issues. By analyzing data from smart sensors, engineers can predict when
maintenance is required for plant equipment. This allows maintenance to be
scheduled in advance, minimizing downtime and reducing costs. These capabilities
are continually evolving and hold the potential to provide even more
comprehensive insights into electrical operations in the future.


PREDICTIVE MAINTENANCE AS A BEST PRACTICE FOR PROACTIVE SAFETY MEASURES

Ultimately, state-of-the-art predictive maintenance best practices are all about
accomplishing the four broad dimensions of safety: reduction, avoidance,
prevention and containment. Ensuring safety and reducing unplanned downtime in
electrical systems is essential to minimize financial risks and safeguard
personnel and equipment. Adopting predictive maintenance best practices such as
digital twins, safety audits and arc flash solutions can significantly enhance
safety and reduce unplanned downtime.

Digital twin technology can be employed during the design, operations and
maintenance phases to streamline diagnostics and troubleshooting. Audits can
identify potential hazards and areas for improvement, allowing organizations to
implement corrective actions before accidents or failures occur. Mitigating the
risk of arc flash is necessary to reduce the risk and severity of arc flash
incidents and ensure worker safety. Adopting these proactive measures to ensure
electrical safety and prevent unplanned downtime can lead to financial benefits,
increase safety and extend equipment life span.

Do you have experience and expertise with the topics mentioned in this content?
You should consider contributing to our CFE Media editorial team and getting the
recognition you and your company deserve. Click here to start this process.

--------------------------------------------------------------------------------

Carsten Baumann
Author Bio: Carsten Baumann is Director Strategic Initiatives and Solution
Architect at Schneider Electric.



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