Maintenance Considerations for Emergency Power Systems Ben Thomas Customer Services Manager

1. Maintenance Considerations for Emergency Power SystemsBen ThomasCustomer Services Manager

2. Long term system reliability is dependent upon a rigorous preventative maintenance plan.

3. Preventative Maintenance “High-frequency, fixed-interval, planned activities including well-defined service routines, proactive defect detection, and repair execution that support the goals of equipment reliability and availability.”

4. General Maintenance Considerations • We all know about the most common causes of failure to start: • Discharged batteries • Not in Auto / E-stop • No fuel / bad fuel • Low fluid levels / filter contamination

5. General Maintenance Considerations • Shipping Maintenance • Storage Maintenance • Regular, Periodic, & Annual Maintenance • Condition Monitoring: Scheduled Repairs Versus Unscheduled Downtime • System Testing Maintenance occurs across the entire product lifecycle!

6. General Maintenance - Shipping • Packaging • Proper generator set cover protection needs to be in place for the environment. • Handling • Proper lifting of generator sets using lifting eyes and fixtures. • Refer to respective manual for more information. Example of generator foot damage from shipping Example of grease deterioration after improper shipping and storage

7. General Maintenance - Storage Generator sets should be properly covered from the elements when stored. Coastal Insulation Protection provides increased reliability in harsh applications. BAD BETTER Tight wrapping is good for shipping and short storage times. If longer storage is required, make sure to cover the package loosely. BEST BAD

8. General Maintenance - Storage • Dry Location • Cover for protection • Loose to allow generator to breathe • Turn rotor ten (10) revolutions every sixty (60) days • Maintain winding temperature • At least 5 °C higher than the ambient temperature • Space heaters • Insulation test – • Insulation test must be done when generator is received • Insulation test must be repeated prior to start-up. Make sure to complete when package is not installed and there is no intention of installing in the near future. Make every effort to complete when package is in storage and make sure to complete when package is being installed or is installed and not running (i.e., standby). Example of condensation inside the generator. Example of hot spot created on bearing race after long storage period without rotor turning.

9. Regular, Periodic & Annual Maintenance • What we typically think of as PM • Document and trend data for future reference! • Follow the manufacturer’s recommended maintenance interval schedule

10. Condition Monitoring “Processes that facilitate timely and accurate detection of changes in equipment health, operation and application severity in support of a repair before failure maintenance strategy.”

11. Condition Monitoring • Understand the monitored process • Normalized readings • Focus on changes occurring over time and trend • End State: Scheduled repairs instead of unplanned downtime! Time to schedule downtime and repair of the generator.

12. Importance of System Testing • Test the entire system to ensure proper functioning and sequence of operations • Test at loads needed during a potential outage • Avoid under loading, overloading, or running an engine at idle for extended periods • Load bank generators on regular basis

13. Maintenance in the Event of an Outage

14. Maintenance in the Event of an Outage • Mission Critical Standby rating definition: • “the generator set is capable of providing emergency backup power at the nameplate rating for the duration of an outage. The average load factor of a standby rated generator set should be no more than 85% of the nameplate rating and applied to varying loads.” *LEXE0244-01

15. What Is the Duration of an Outage? • Outages can last from minutes to weeks • Mt. St. Helens, 18 May 1980 • Hurricane Ike, 13 Sep 2008 • 1 million outages in Texas one week after landfall, power fully restored on 6 October* • Hurricane Sandy, 29 Oct 2012 • 8.5 million outages at peak • Power fully restored on 19 November* *US Department of Energy Office of Electricity Delivery & Energy Reliability

16. Maintenance in the Event of an Outage • Assume 2 weeks on generators, what is required maintenance? Oil and coolant life is NOT linear! What is YOUR plan to conduct maintenance during an extended outage? Parts on hand? Sampling available? Redundancy? *SEBU8479-01: Standby MIS for 3516C Generator Set

17. Emergency Power Systems Maintenance Plan Considerations

18. “A good plan, violently executed now, is better than a perfect plan next week.” General George S. Patton, Jr.

19. Plan, Prepare, Execute, & Assess • Hope is not a method! • Developing a maintenance plan is an iterative process • Challenge the plan by providing alternatives through critical thinking in order to improve decision making and achieve the end state (e.g., Red Teaming) *Army Doctrine Publication (ADP) 5-0, The Operations Process, May 2012

20. Emergency System Maintenance Practices Maintenance and Repair Process: 10 Sub Processes Planning & Scheduling Preventative Maintenance Condition Monitoring Backlog Management Parts Management Component Management Repair Management Human Resource Mgmt. Performance Evaluation Continuous Improvement Preventive Maintenance Condition Monitoring HR Management Repair Management Planning & Scheduling Backlog Management Component Management Parts Management M&R Core Processes

21. Considerations of a Maintenance Plan • Establish the Major Components In Systems • Fuel system, cooling system, breakers, generator system, etc. • Gather equipment information and descriptions (model numbers, serial numbers, points of contact) • Identify the Manufacturer’s Maintenance Interval Schedule • Have service literature and updated drawings available • Frequency of checks can change due to operating conditions • Identify the Manufacturer’s Recommended Maintenance Practices • Fluid Management: change periods, sampling, reporting, monitoring, procurement (regular and emergency) • Spare Parts Management: maintenance, protective and emergency spares – what and where stored • Tooling Requirements: maintenance (site) vs. diagnostic (service provider)

22. Considerations of a Maintenance Plan • Create a Plan to Execute Inspection & Maintenance • Who is responsible? Does this change during an outage? • Periodic testing of system • Define Repair Strategy – Planned & Emergency • Special considerations: remote site, freight limitations, disaster • Response plan: unscheduled repairs, parts delivery to site • Repair options: replace with new, remanufactured, rebuild? • Define Maintenance Data Management Process • Train Staff on Plan and Equipment • Define Roles and Responsibilities Between Site Staff, Manufacturer, and Service Providers • Infrastructure to Support System – Internal & External

23. Safety • The most important piece of the maintenance plan • Establish a safety training culture • Review the work procedures • Qualified personnel • Training • PPE

24. Design for Maintenance & Repair • Is there adequate space to conduct maintenance? • Does the site have overhead lift or crane access? • Is there ease of access to remove or replace major components (e.g., doors and floors)? • Is there ease of access to connect power modules if necessary?

25. Lessons Learned • Long term system reliability is dependent upon a rigorous preventative maintenance plan • Maintenance occurs across the lifecycle of the product • Test the entire system to ensure proper operation • What is your maintenance plan for normal and emergency operations? • Does the facility incorporate design for maintenance and repair?

26. Thank You!