Hunting “the ghost in the machine”
For some, the phrase “ghost in the machine” conjures up dark implications of paranormal malice. In the electrical industry, it refers to difficult to diagnose issues that have the potential to cause damage to electrical equipment and an organization’s bottom line as well.
Power management company, and Sarnia Lambton Industrial Alliance member, Eaton, is positioned through its global solutions to answer today’s most critical electrical power management challenges. Its experienced and expansive team of power systems engineers and specialists, which are part of Eaton’s Electrical Engineering Services and Systems (EESS) division, provide the knowledge and on-the-ground support to keep processing running efficiently and enhance personnel safety. The management at the Praxair Inc. facility in Chatham, Ontario tapped into Eaton’s expertise and one of the largest field service organizations in the industry to help identify and remedy a recurring electrical issue that caused unpredictable downtime and significant expense.
When the company that usually did the Chatham plant’s regular electrical inspections was unable to deliver the services in the required time, Eaton was called in to help. Eaton’s senior field service representative from Sarnia, Ontario, Robert Chwiecko responded to the call and while he was there, Plant Manager David Ryan decided to have him look into an unknown and recurring problem. The Chatham plant had been plagued for years by a yet-to-be- diagnosed issue that presented itself as a “non-PLC shutdown event”. The plant was subject to shutdowns when some of the medium voltage motor starters would suddenly shut off, and the apparent problem defied all attempts at being identified and resolved. Ryan indicated that the shutdowns were frustrating and harmful to the plant. “It took its toll on the equipment and machinery” he said, “There was no dollar value established but it was considerable.”
Chwiecko saw that the station PLC rack used a UPS as its power supply and monitoring system voltage source. Adding complexity to troubleshooting, the existing UPS incorporated a self-test setting, which was activated every two weeks, and contributed to the frequency of the outages; it also made it seem as if the problem could be related to the utility supply power to the plant. Chwiecko speculated that the “ghost” fault was caused by a transient that occurred during the switching cycle when the UPS transferred from utility-to-battery, as well as in reverse. Such transients would cause the control systems to misinterpret real conditions and suddenly force the unwanted equipment operation. Chwiecko demonstrated that the unscheduled shutdowns were due to the existing UPS and installed an Eaton 9130 to resolve the issue.
Eaton expertise and industry-leading technology helped to improve power reliability and reduce downtime for Praxair. Since Eaton addressed the issue, Ryan indicated the equipment has operated reliably. Further, he says Eaton is now providing ongoing support and expertise for the Chatham facility.
The Praxair “ghost” is an example of the type of difficult and costly problems Eaton helps to solve on a day-to-day basis. Robert Chwiecko is just one of the many Eaton field service personnel in Ontario who bring their superior skills and problem-solving acumen to each customer. Ali Mankal, Eaton business development manager, indicates that the organization provides a comprehensive portfolio of services tailored for every stage of a power system’s life cycle. “Eaton’s Electrical Engineering Services and Systems team has the expertise for a broad range of applications and are highly qualified and proficient in troubleshooting a range of electrical issues,” he said. “We have the experience and depth to diagnose and trouble-shoot and resolve customer’s most challenging electrical problems.”
However, Mankal notes the goal is always to deliver the optimum solution for our customers. “We do our utmost to provide the best solution for the customer, so that they get their system up and running reliability as quickly as possible.”
Eaton also provides arc flash safety training to help its customers enhance personnel safety. “It is critical that personnel are aware of the dangers of arc flash, how to reduce risks and the industry-leading technologies, best practices and the latest electrical codes that are helping enhance safety,” he said. Eaton provides a range of expertise and solutions to help enhance safety, arc flash analysis, training and equipment labelling, as well as an extensive range of safety solutions.
Another area of expertise that Eaton brings to each customer is life cycle extension program. Mankal says installing new equipment is not always the right option. Through life cycle extension work such as reconditioning, retrofitting and upgrading, making custom bus modifications and bracing upgrades and using non-black-market equipment, many systems can carry on providing dependable service well into the future.
Since the nature of the electrical business resolves around elements that can’t be seen, the problems caused by aging equipment, lack of proper maintenance and inspection and poor design can be difficult to diagnose and seem like there is “ghost in the machine,” causing downtime and impacting personnel safety. Given proper attention and skill, the potential for problems can be identified and remedied. Rely on the industry experts to keep your facility operating reliably and profitable.