PowerChain Management Audit Service Focus Professional Engineering Services

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1 PowerChain Management Audit Service Focus Professional Engineering Services

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3 The power chain. It s time to understand the electrical system as a manageable single entity. Productivity losses from power outages and power quality issues are astounding. The price of continuity disruption is huge, and major safety issues loom. Regardless of the industry, every enterprise needs to find a better way to manage its electricity. Electrical products are purchased, maintained, and repaired separately, often from several different suppliers with fragmented accountability and virtually no system responsibility. Eaton has created a better way, a breakthrough advance in enterprise electricity management. It s called PowerChain Management solutions. Eaton has a new vision of electricity within the enterprise. Just as the supply chain feeds the enterprise, and the demand chain feeds the marketplace, electricity is a critical entity that sustains all activity within a facility. This electricity is not a jumble of products, suppliers, tasks, and risks. It is a single system, a power chain sourced, managed, monitored, maintained, and evolved as a unit unique to every enterprise. Eaton s PowerChain Management solutions encompass power audits, system design and installation, predictive monitoring, and life-cycle management to address complete power chain needs. Every facility in every industry data centers, healthcare facilities, petrochemical plants, ships, homes, developments, office buildings has a power chain. And for every one, there are PowerChain Management solutions from Eaton. Perhaps the most strategically important solution is the initial PowerChain Management Audit

4 A new way to minimize risks and quickly reduce the high costs of power disruptions and inefficiencies inside your facility. Electrical System Reliability, Safety, and Energy Efficiency The effective management of electrical systems is critical to the success of businesses and facilities. The electrical problems facing businesses today can often seem overwhelming, especially knowing that key elements of electrical systems are susceptible to failure. It can be costly and difficult to design a system that predicts failure and minimizes risks of dangerous hazards such as arc flash. Reliability Downtime is one thing. Downtime as a result of power disturbances is another. The typical downtime of the utility grid is 8 hours, 45 minutes per year in the United States. According to the Electric Power Research Institute s estimates, the U.S. economy is losing between $104 billion and $164 billion to outages and another $15 billion to $24 billion to power quality phenomena. 1 With on-site generation equipment and uninterruptible power system (UPS) protection, downtime can be reduced to the equivalent of 5 minutes, 15 seconds per year. Regardless of utility reliability, nearly 80% of power disturbances that interrupt business occur due to problems within the facility itself. 2 Retail, Hotels Paper, Printing Hospitals, Banks Textiles, Metal Fab. Rubber, Plastics Food Processing Petrochem Glass Automobile Mfg. Comm/Info Processing Electronics Mfg. Pharmaceuticals Semiconductor Mfg. Data Centers/Telecom Safety The risk of contact with energized electrical components is something that most people learn about from an early age. A potentially more dangerous situation arc flash exists for personnel working on or near energized electrical equipment. Arc flash is a hazardous condition associated with the release of energy during a fault and can cause serious injury or even death. Losses can be devastating both financial and physical. Arc flash incidents are costly and may cost upwards of $1 million per event. NFPA 70E and IEEE 1584 offer methods to calculate the safe approach distance, risk category, and personal protective equipment requirements to avoid safety hazards. Eaton s expertise in this critical area ensures you stay in compliance and your workers remain safe. Power Chain Criticality Cost Per Year Due To Power Interruptions Normalized to 1000 kw Facility $0 $50 $100 $150 $200 $250 Amount spent in thousands (per 1000 kw Load) Maximum $ per 1000 kw Load Minimum $ per 1000 kw Load $680K $760K $1200K Energy Efficiency The cost of electricity is based on usage, demand, and available supply. Utility companies have multiple rate structures based upon the amount of energy consumed, the time of use, and the type of loads that are supplied. In many cases, only one particular rate structure applies to a given load or customer. Generally, the limiting factors are the load size (kva or kw) or industry type. If a customer is limited to a single rate based on a load size or service type, there may be other methods for changing to a different rate structure. Buying energy at a higher voltage level may prove to be very cost-effective. Partially supplying some of the required energy with local generation is another method of savings by allowing a change to a different class of service. With a system-wide approach, Eaton addresses all decision points and life-cycle impacts to the power chain, enabling businesses to focus on core capabilities. With skilled Eaton engineers addressing your power chain needs and the most up-to-date service for your power systems equipment, you have the resources available that deliver peace of mind. A single point of accountability offers businesses more effective management of the project, a greater ability to anticipate and resolve problems, and more comprehensive preventive maintenance. 2 EATON CORPORATION PowerChain Management Audit

5 Benefits of Power Chain Analysis By examining and managing an enterprise s power infrastructure, businesses can expect greater reliability, cost efficiencies, effective use of capital, a safe environment, and risk mitigation. A PowerChain Management Audit will help alleviate the strains that currently reside in many electrical systems in three specific areas: Power Quality and Reliability Reputation. Eliminate power system disturbances that disrupt processes and data flow as well as severely impact the reputation of a company even so far as to affect stock prices and market value. Warranty Costs. Reduce unpredictable product quality that can contribute to significant warranty issues. Future Business. Turn around a history of unreliable operations, poor product quality, and significant warranty repairs that are detrimental to potential future business. Customer Satisfaction. Ensure favorable customer satisfaction and repeat business with a reliable power chain. Arc Flash Safety. Avoid personal injury or death resulting from arc flash incidents. Compliance. Ensure employees working in areas where electric hazards are present are provided with and use protective equipment designed to protect specific exposed body parts. Labeling. Prevent regulatory fines by utilizing appropriate labeling standards warning personnel of potential arc flash hazards. Procedures. Document safety guidelines and safe work practices and train personnel to abide by these procedures to avoid hazards. Energy Management Supply-Side Management. Save money through rate structure optimization, penalty avoidance, and utility bill accuracy verification. Enterprise Monitoring. Manage the facility s energy usage through meters and software to identify savings opportunities. Demand-Side Management. Reduce energy consumption and save money by controlling loads. Energy-Efficient Devices. Conserve energy through installation of energy-efficient devices. Eaton s Expertise As a premier industrial manufacturer, Eaton is uniquely qualified to provide PowerChain Management solutions including electrical distribution, distributed generation, power quality, controls, monitoring, and life-cycle management services. By having access to all of these products, Eaton provides customers with the right solution, and our engineers have the knowledge to analyze and correctly apply this equipment. With many of the United States leading Professional Power Systems Engineers, Eaton has the expertise to most effectively identify, address, and correct power-related problems. Not only does Eaton address the various industry standards for electrical equipment IEEE, NFPA, UL, ANSI, IEC, and NEMA but we also contribute to the standards with employee representatives serving on the committees that write the codes. Eaton s Power Systems Engineers bring a system-wide approach to addressing power irregularities, looking at all aspects of a facility s electrical system planning, design, finance, engineering, construction, installation, upgrades, and monitoring enabling businesses to focus on their core capabilities

6 The PowerChain Management Audit Many facilities have gone through upgrades and changes over the years. Electrical loads have been added to automate processes, computer loads have been added to the facilities, harmonics have been introduced to the system, and the loads are often much more susceptible to power quality issues. Dealing with these issues is most efficiently done systematically by performing a site audit looking for specific problems and potential areas of improvement. By using proven techniques and strategic monitoring, Eaton will identify the areas of greatest vulnerability and will address the options for providing protection from utility issues as well as system protection from new and ever-changing load requirements. Eaton offers PowerChain Management Audits to evaluate power system designs and improve the availability and reliability of the power system. This method uses proven IEEE Gold Book methods for analysis and helps determine whether upgrading critical elements of the power system, modernizing the system, or simply rehabilitating the system is the most cost-effective method of improving reliability prior to a failure. Eaton s PowerChain Management Audits consist of visual inspections, electrical measurements using power quality monitoring equipment, interviews with on-site personnel, and reviews of utility bills and data. Specifically, Eaton will address interruptions, voltage sags, harmonics, surge protection, grounding, energy management, and arc flash safety. Eaton will investigate methods of improving the reliability of the power system to help you avoid costly downtime and repairs. The present state of the existing personal protective equipment is also evaluated. Cost and payback information will be presented where appropriate. Eaton reviews energy consumption to determine possible savings with utility rate structures, energy usage, time of use (on- or off-peak), power factor correction, and various methods of metering. By monitoring trouble areas of the facility, Eaton will identify other potential areas for improvement and savings. Eaton s electrical group recognizes the criticality of addressing the entire power chain to give organizations the benefits of greater reliability, operating cost efficiencies, effective use of capital, safety, and risk mitigation. With a PowerChain Management Audit, power management problems can be resolved through a single, integrated solution at every level in a facility, delivering products, services, expertise, and exceptional performance to address your complete power chain needs. The purpose of this audit is to show areas of improvement in the electrical infrastructure and to point out areas that are well designed, maintained, and operating at or above expectations. PowerChain Management Audit Features Evaluate wiring and grounding methods. Evaluate backup protection including the use of UPS power, backup generation, sag correction, and power conditioning. Review energy management processes to determine demand-side management opportunities and analyze energy-efficient electrical loads. Evaluate surge protection at the utility connection point and at the downstream loads. Evaluate the use of harmonic solutions including tuned filters, line reactors, and phase shifting transformers. Evaluate and review present arc flash safety compliance status. Evaluate the quality of the voltage and current at the main service equipment. Interview key electrical personnel on site to determine the type of operating problems, the equipment affected, and time of occurrences. What will you do?* Have a preliminary meeting with Eaton to discuss your potential power quality, energy management, and electrical safety concerns. Complete a simple power chain questionnaire. Participate in a pre-site conference call with one of our engineers. Walk the power chain with our engineer, providing access to your electrical equipment as required. What will we do?* Analyze existing system data and prepare a test plan for your site. Monitor critical processes or loads where possible. Evaluate power quality concerns related to your loads or caused by external events. Evaluate electricity usage. Ensure safe work practices using NFPA 70E and IEEE 1584 arc flash guidelines. What can you expect?* A detailed engineering summary and evaluation of your electrical system. ROI evaluations for suggested solutions, where appropriate. Courteous, professional, and safe work practices by our highly qualified staff. Access to our engineering services group through your PowerChain Management Audit engineer. What will we deliver?* Energy management solutions. A detailed plan to ensure compliance with NFPA 70E s arc flash safety standard. A detailed engineering report with specific conclusions and recommendations. A peer review of your report by one of our Power Systems Engineers on staff. A report presentation to you and your staff with a review approximately three (3) months post-audit to ensure complete satisfaction. *See chart on page five for specific PowerChain Management Audit offerings. 4 EATON CORPORATION PowerChain Management Audit

7 Eaton s PowerChain Management Audits offer varying levels of service depending on your electrical power chain management needs and the level of detail you seek for problem resolution. All audits are conducted by a highly qualified Power Systems Engineer and include a detailed analysis of the audit results and a comprehensive report. The PowerChain Tactical Audit is a baseline audit with on-site visual inspections and evaluation of the key safety, energy management, and compliance standards and ongoing support for six (6) months following the site visit. The PowerChain Operational Audit offers a more robust audit including on-site visual inspections, overnight metering of problem areas, IEEE analysis, and one year of support from a Power Systems Engineer. The PowerChain Strategic Audit is a three-year partnership evaluation of the electrical power chain, including continuous metering at the main service entrance point with quarterly data summaries, ongoing support for the duration of the study, and an annual report summarizing all of the study data. PowerChain Management Audit Offerings Tactical Operational Strategic Preliminary analysis of the power system Site meeting and project overview One day on-site system evaluation Level 1 IEEE Power Quality Audit Electrical Energy Management Audit Arc flash needs assessment Preliminary, on-site presentation of initial results Off-site analysis and evaluation of site data Formal report and web-based presentation Ongoing telephone and support for six (6) months following site visit Follow-up call with facility three (3) months following site visit Level 2 IEEE Power Quality Audit Overnight monitoring of critical location Reliability analysis per IEEE Gold Book Power quality and arc flash training On-site formal presentation of results and recommendations Ongoing telephone and support for twelve (12) months following site visit Installation of Cutler-Hammer power quality and energy meter at main service connection point Quarterly summary of captured data Yearly report summarizing power quality and energy data 1 The Cost of Power Disturbances to Industrial & Digital Economy Companies. Electric Power Research Institute, Energy Expertise-Power Quality. Alliant Energy Corporation, posted at

8 Eaton Electrical Inc Cherrington Parkway Moon Township, PA tel: Cutler-Hammer and PowerChain Management are trademarks of Eaton Corporation. All other brand and product names are trade names, trademarks, and/or service marks of their respective companies or subsidiaries and affiliates Eaton Corporation All Rights Reserved Printed in USA BR E October 2005