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FM Global

FM Global. Switchgear and Circuit Breakers Failures and Case Studies. UE Systems 2015 Reliable Asset Conference June 4 th Dan Crawford, Group Manager Field Engineering, FM Global. FM Global. 180 years of expertise. Mutuality Single focus – commercial property. FM Global.

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FM Global

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  1. FMGlobal Switchgear andCircuit Breakers Failures and CaseStudies UE Systems 2015 Reliable Asset Conference June4th Dan Crawford, Group Manager Field Engineering, FMGlobal

  2. FMGlobal 180 years ofexpertise Mutuality Singlefocus – commercial property

  3. FMGlobal FMGlobal-Engineering • ~1,800 engineers • 148countries • Loss PreventionSolutions • Consistent • Practical and costeffective • Scientificproven

  4. FMGlobal Switchgear and Circuit BreakerFailure What canhappen? Switchgear/circuit breakers fail to operate with severe consequences

  5. FMGlobal What can happen- Switchgear and Circuit BreakerFailure

  6. FMGlobal What can happen- Switchgear and Circuit BreakerFailure

  7. FMGlobal What can happen – worstcase Switchgear and Circuit BreakerFailure

  8. FMGlobal Switchgear and Circuit BreakerFailure • Beyond the loss of the CBs andSwitchgear • Ignitionsource • Catastrophic failure of controlledequipment • BusinessInterruption

  9. FMGlobal Switchgear and Circuit BreakerFailure FMexperience

  10. FMGlobal VeryHigh RiskFactors F R E Q U E N C Y • Environment • Operating conditions • Age/history • Maintenance • Operatortraining Very Severe Low SEVERITY Operator training, contingency plan, safetydevice

  11. FMGlobal Contingency Plan – What to askyourself. • Is a needed spare on hand and ready to install • Criticalequipment • Long leadtime • Obsolete • Is re-configuring the electrical systempossible • Is redundant equipmentinstalled • double-endedsubstation • Has an alternative supply beenidentified • Rental diesel engine-driven generatorunits

  12. SafetyDevice FMGlobal

  13. FMGlobal • Electrical protection - a system of manycomponents • Instrument • Relay • Controlwire • Trip coil • Battery • Etc. Preventive MaintenanceProgram

  14. Preventive Maintenance ProgramExamples FMGlobal

  15. FMGlobal Preventive Maintenance ProgramExamples 2.1.3.4.2 Perform a capacity test ( also called performance test or discharge test) every 5 years for flooded lead acid and flooded Ni-Cd batteries, and every 2 years for sealed lead acid (VRLA)batteries. Sources: DS 5-19: Switchgear and Circuit Breakers DS 5-20: ElectricalTesting

  16. FMGlobal Case Study#1 • Site Information • A simple manufacturingfacility • 24/7 operation • Utility power is the single electric poweresource

  17. Case Study#1 Utility line 69kV FMGlobal 12kV 480V

  18. FMGlobal Case Study#1 • DamageInvestigation • Explosion & fire involving • 480Vcabinets • Tank rupture of the mineral oil-filled 12 kV/480V transformer • Minimum business interruption: contingency plan inplace

  19. FMGlobal • Damageinvestigation • Key contributing factor: Lack of adequatemaintenance • 12 kV switchgear’s battery -discharged • 480 V circuit breaker:seized • 12 kV fuse for transformer had a knownproblem Case Study#1

  20. FMGlobal • Conclusion • Overall maintenance program needs improvement • Contingency plan minimized theBI • No fire following: no combustible load in the electricalroom Case Study#1

  21. FMGlobal Case Study#2 • Site Information • A simple manufacturingfacility • 24/7 operation • Utility power is the single electric powersource

  22. FMGlobal Case Study#2 • Site Electricalsystem: • Utility power: 69kV • 480Vfeeder • Solid groundedsystem • Fused switch with ground faultprotection • >100 ft. bus bar above the productionarea • 40 yearsold

  23. FMGlobal Case Study#2 • ElectricalPM • Annual IRscan • Annual transformer oil sample – screen &DGA • 3 year switchgearPM

  24. FMGlobal Case Study#2 • Theincident • Bus bar failed (close to the plug-in) • Auminum bus & enclosure steel frame vaporized • Suspended ceiling above blewoff • Hot particles from the bus duct explosion ignited the combustible material above the ceiling and a firefollowed

  25. FMGlobal

  26. FMGlobal Case Study#2 • Damageinvestigation • Ground fault protection did notoperate • Fuses of two phasesmelted • Entire busdamaged • Significant smoke/water damage to foodproduct • 100% productionshutdown

  27. FMGlobal Case Study#2 • Damageinvestigation • GFP • Unknown setting ofGFP • No electrical study to identifysetting • No recorded testing/maintenance • The 480 V busbar • No documented maintenanceactivities

  28. FMGlobal Case Study#2 • Conclusion • Coordination study needed forGFP • Test GFP during 3 yearPM • Improve busPM • Fire relatedissues • Automatic sprinklerinstallation • FD pre incidentplanning

  29. FMGlobal Questions

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