1. One powerful future. Maintenance Considerations for Emergency Power Systems Ben Thomas Customer Services Manager

2. One powerful future. Page 2 Long term system reliability is dependent upon a rigorous preventative maintenance plan.

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

8. One powerful future. Page 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. Example of condensation inside the generator. Example of hot spot created on bearing race after long storage period without rotor turning. 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).

9. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Maintenance in the Event of an Outage

14. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Emergency Power Systems Maintenance Plan Considerations

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

19. One powerful future. Page 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. One powerful future. Page 20 Emergency System Maintenance Practices Maintenance and Repair Process: 10 Sub Processes 1.Planning & Scheduling 2.Preventative Maintenance 3.Condition Monitoring 4.Backlog Management 5.Parts Management 6.Component Management 7.Repair Management 8.Human Resource Mgmt. 9.Performance Evaluation 10.Continuous Improvement M&R Core Processes Preventive Maintenance Planning & Scheduling Parts Management Component Management Backlog Management Repair Management Condition Monitoring HR Management

21. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Page 23 Safety The most important piece of the maintenance plan Establish a safety training culture Review the work procedures –Qualified personnel –Training –PPE

24. One powerful future. Page 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. One powerful future. Page 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. One powerful future. Thank You!