If a facility was constructed in the 1980s and its electrical system is at least 30 years old, it is time for business owners to start assessing their options for replacement. Transformers, switchgears and cable systems are typically designed for a lifecycle of 20-40 years, with a usual assumption of expected and/or stable operating conditions. Safety, reliability and efficiency risks must be evaluated and addressed. In addition to the improved safety, the benefits of addressing immediate risks in a timely manner include improved reliability and energy efficiency, long-range planning for turnarounds, competitive bidding by suppliers and an array of technological advancements.
Facility electrical loads, configurations and needs change over time, and industry regulations, practices and standards are constantly evolving. This requires periodic review and evaluation by knowledgeable personnel and potential upgrading of equipment and processes. The physical condition of electrical assets and the practices utilized to maintain them in proper condition have serious implications in terms of safety, reliability, productivity and efficiency, and are critical factors in any discussion on aging electrical systems.
Business owners and those responsible for electrical system upkeep must be provided with the basic knowledge and awareness of risks, regulations and maintenance best practices associated with their own aging electrical systems, allowing for informed and prudent decision making regarding long-range planning and budgeting.
A two-pronged approach is required, consisting of: 1. Concurrent electrical systems/ equipment conditions assessments, and 2. Analyses to evaluate the design and condition of the current electrical system as well as the supporting maintenance and reliability practices to develop corrective actions and improvements.
1. The current electrical system design and condition must be assessed for deficiencies in safety, reliability, capacity, efficiency and compliance with current regulations. Only after a thorough assessment can corrective actions be identified and evaluated to meet regulatory requirements and long-term business goals. The condition assessments must include the following evaluation points:
- Immediate and potential safety concerns
- Regulatory compliance, including arc flash
- Capacity and performance requirements
- Lifecycle performance and risks
- Efficiency improvement opportunities
- Restoration scope
- Business case for repair, replacement and restoration
2. Experienced reliability engineers will be required to conduct an extensive review of a facility's electrical system maintenance program and practices, as well as the reliability engineering processes and technologies being utilized. This allows for comparison of present facility practices to proven industry maintenance and reliability standards and best practices as well as alignment with business policies and long-range objectives. From this analysis, detailed recommendations can be derived to meet present regulatory and capacity requirements; upgrade the condition, reliability, efficiency and longevity of present assets; and preserve the condition of any newly restored or replaced equipment. The maintenance and reliability process analyses include the following evaluation points:
- Organization asset management practices
- Site reliability engineering functions
- Implementation of condition monitoring technologies
- Current electrical maintenance practices and capabilities
- Coordination and execution of maintenance and corrective actions with operating schedules
By addressing the safety, reliability and production risks posed by aging and degraded equipment conditions and a deficient reliability process early on, owners can decide proper courses of action on their terms in a proactive rather than reactive manner.
For more information, contact David Hicks with Stork, A Fluor Company, at david.hicks@stork.com or (832) 331- 6316, or Ric Bryant with Fluor at eric. bryant@fluor.com or (864) 281-5079.
