Maintenance Program

1. CUSTOMER
LOCATION
Maintenance Program

2. Industry Trends & Technology Solutions
• Energy Deregulation
• Turnkey Solutions
• Plant Life Extension Capability
• Outsourcing of Maintenance and Service
• Preventative and Predictive Maintenance
• Remote Monitoring & Communications

3. Alliance Partner Expectations
What Do we expect from each other?
– Customer/Cutler-Hammer - One Team
– Shared Work Processes
– Enhanced Employee Time Effectiveness
– Elimination of Redundant Engineering
– Project Cycle Time Reduction
– Focus on Joint Cost Reduction
Creating a Competitive Advantage for each
Partner

4. Effect of Maintenance Quality on
Failure Rates
Equipment
Poor
Maintenance
Failure
Rates
Perfect
Maintenance
Failure Rates
Decrease in
Failure Rates
Transformers 1.51 0.89 41.06%
Circuit /Breakers 1.28 0.79 38.28%
Motors 1.97 0.84 57.36%
IEEE Gold Book Std 493-1997 Published August 1998

5. Effect of Maintenance on Failures
Maintenance Quality & Time
Between Maintenance
Percentage of
failures due to
quality of
maintenance
Excellent 11.60%
Fair 18.10%
Poor 32.80%
Total 16.40%
Less than 12 months ago 7.40%
12-24 months ago 11.20%
More than 24 months ago 36.70%
IEEE Gold Book Std 493-1997 Published
August 1998

6. Long Term Maintenance Contracts
• Sony Corporation
• J&L Specialty Steel
• Westinghouse Nuclear
• University of Pittsburgh Medical Center
• BASF Corp
• NOVA Chemical

7. Predictive Maintenance Testing
– Infrared Inspection
– Partial Discharge
• Transformer
• MV Switchgear
• Motors / Generators
– Vibration Analysis
– Vibro-Acoustic Analysis
– Oil Analysis
– Gas in Oil Analysis

8. Preventative Maintenance
Testing

9. Cables
• Cable Test Findings
 Review Report
 Prioritize
 List and address most critical problems
 Doble test non-destructive / trending
 Compare to Customer sample tests.
 CHESS will Doble and Megger
 C-HESS held accountable to schedule

10. Transformers
• Oil Testing Transformers
 PCB Inspection
 General & Gas Tests
 Compare to Customer sample tests
– Miscellaneous Special Tests
• Oxidation Inhibitor
• Furanic Compounds
• Fault Metals
– C-HESS held accountable to schedule
– Prioritize Recommendations

11. OCB's / Relays
 Routine scheduled inspections
 Routine scheduled testing
 Oil levels, oil tests
 Internal inspection
 Doble tests / trending

12. HV Switchgear
• High Voltage Switchgear / PT's / CT's
 Assess previous tests and schedules
 Perform visual walk-through
 Inspect for leaks, oil levels

13. Partial Discharge
• Partial discharge testing
– Transformer Bushings
– MV Switchgear
– Cable Terminations
– Motors

14. MV Switchgear
• Medium Voltage / Switchgear / Breakers
/ PT's / CT's
 Assess previous tests and schedules
 Perform visual walk-through inspection
• Partial discharge testing
• Establish Routine Testing Schedule:
 Breakers, starters
 Relays
• Vacuum replacement

15. Low Voltage/Switchgear/Breakers
• Switchgear inspection
• Inspect Switchgear:
 Breaker Testing
 Retrofits
 Reconditioning
• MCC Rebuilds

16. Post Testing Recommendations
After Maintenance Outage, CHESS will
Provide:
• Reports on Condition on each piece of
equipment tested
• Engineering Recommendations
• List of equipment that needs repair or
recondition.

17. Power Systems
• Power System Measurements
 Primary system requirements
 Measurements on-going
• AK Technicians to Assist
• System reliability
• Harmonics

18. Power System Studies
– Short Circuit Protective Device Evaluation
Study
– Protective Device Coordination Study
– Load Flow Power Factor Correction Analysis
– Energy Management Audit
– Harmonic Analysis
– Grounding Grid Design & Analysis
– Switching Transient Analysis

19. Specialized Studies
– Voltage Regulation
– Transient Stability / Load Shedding Study
– Voltage Flicker
– Ferroresonance

20. Power Quality “STUFF”

21. Power Quality
• Site Survey’s
• Monitor system for Harmonics / Sags /
Flicker
• Make recommendations for improving
Power Quality

22. Power System Automation
• Automation
• Load Shedding
• Cost Allocation
• Monitor Device Status
• Power Net / Control
• Power Net Monitoring
 Transformer alarm status
 Power monitoring status
 Breaker trip status and Ground Detection

23. Cost Allocation
• Allocate actual energy costs to each
department via automatic bill/report
generation
• Measurable targets can be set for each
department - incentive & accountability
• Can be extended down to each machine
• Payback in less than 2 years if no other
action taken

24. Training
• Maintenance Training
• Safety Training
• Custom designed with On-site
Instruction

25. Other Service
• Oil Processing Trailer

26. Maintenance Program and Monitoring
• Value Based Reliability Centered
Maintenance
• Instant Response Center

27. • Unique C-H Approach
• Criticality based system,
• Equipment/process ranked by criticality
• Determines priority ranking for PM & PdM activities
• Identifies where PdM sensors would give the best return.
• Identifies which pieces of equipment should be run to
failure, i.e. cost of maintenance > replacement cost.
Reliability Centered Maintenance (RCM)

28. • Choose the right Maintenance Program using Value-
Added RCM
Critical system based
• Criticality 1 - MUST NOT FAIL - by default all service
transformers, MCC’s, etc. are in this group
• Failure would shut the plant, production line, or
cause great financial loss
• Failure would cause bodily harm to employees,
major equipment, or environmental penalties
• Criticality 2 - should Not Fail
• Equipment still important, but failure will not have a
serious impact on the plant. (redundant equipment,
little impact on production)
• Criticality 3 - all the rest
Reliability Centered Maintenance (RCM)
Cont’d

29. Life Extension
• Class I Reconditioning
• LV Breaker Retrofits
• Spare or Loaner Breakers
• Medium Voltage Roll in Replacement
Breakers
• MCC Bucket Retrofits

30. Cutler-Hammer VR Breakers
• Solid design by the industry
leader
– >34% of overall market
– >75% of vacuum interrupters
market in US
• IEEE/ANSI certification
• Dedicated facility
– Largest investment in replacement
breaker industry

31. Next Step for Long Term Maintenance
Contract
• Generate a List of Equipment to be
Maintained
• Edit Workscopes to fit Requirements
• Establish the Frequency of Testing
• Establish Work Team
– Who Does What

32. C-H ESS Strategy
Be the preeminent solutions
provider of electrical
distribution and control
systems to our key customers.