richard blakeley - options for managing safety with elderly switchgear
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OPTIONS FOR MANAGING SAFETY WITH ELDERLY SWITCHGEAR
Richard Blakeley, R.P.S. Switchgear,
SWITCHGEAR – WHAT DOES IT DO? MAKE AND BREAK NORMAL LOAD CURRENTS
OPERATE CONTINUOUSLY UP TO NORMAL RATINGS
WITHSTAND THE PASSAGE OF THROUGH-FAULT CURRENT FOR SUFFICIENT TIME TO ALLOW THE DOWNSTREAM PROTECTION TO OPERATE
SAFELY SWITCH ON TO FAULT, HANDLING THE ENERGIES INVOLVED
SAFELY INTERRUPT FAULT CURRENT AND THEREBY REMOVING THE FAULTED EQUIPMENT FROM THE SOURCE OF ELECTRICAL SUPPLY
ACT AS A POINT OF ISOLATION AND EARTHING TO ENABLE WORK TO BE DONE SAFELY
Reyrolle, Type ‘AR’ 33kv, 800A Switchgear,
PRIMARY CONTACTS -- FIXED AND MOVING.
ARCING CONTACTS -- FIXED AND MOVING.
CLOSING MECHANISM -- (Stored Energy, MO or Manual),
OPENING MECHANISM -- STORED ENERGY
PRIMARY INSULATION SYSTEM,
ENCLOSURE,
MEANS OF ISOLATION FROM THE SYSTEM.
CIRCUIT BREAKER DESIGN -- TRADITIONAL
COMPONENTS
Risk Factors with Elderly Switchgear
AGING SWITCHGEAR – RISKS & ISSUES
Lack of knowledge/training
Network changes resulting in the switchgear being overstressed
Not being modified as per manufacturer’s advice/updates
Not being maintained or operated properly
Dependent-manual switchgear
Spares & Technical Support not being available
Age related failure,
Switchgear is normally ‘quiescent’
Continuous assessment not justifiable
True condition difficult to determine
ELDERLY SWITCHGEAR – TRUE CONDITION??
“In on-site evaluation tests carried out by Reyrolle on aging oil switchgear worldwide, it was found that on more than 50% of oil switchgear thought to be in good condition, the circuit breakers had faults or were operating outside of their design envelope and in some cases would have failed to operate correctly under system fault conditions”
SWITCHGEAR FAULT CLEARANCE – KEY FUNCTION FOR SAFETY
ISSUES WITH ELDERLY SWITCHGEAR
ELDERLY OIL SWITCHGEAR PRESENTS INCREASING RISK , (Consequences of a flashover can be severe)
CONDITION ASSESSMENT OF DISTRIBUTION SWITCHGEAR IS DIFFICULT
SPARES ARE NOT AVAILABLE FOR MOST ELDERLY SWITCHGEAR,
NOT UPGRADED TO LATEST REVISION,
NOT COMPLIANT WITH MODERN SAFETY STANDARDS,
SWITCHING PERFORMANCE OF OIL CB’s NOT GOOD AT LOWER FAULT LEVELS,
Internal Arc/Arc Flash Faults
ARC FLASH FAULTS
HOW OFTEN DO THEY HAPPEN?
“EVERY DAY, 1 TO 2 ARC FLASH RELATED FATALITIES OCCUR ACROSS NORTH AMERICA”
INTERNAL ARC FAULTS – CAUSES
Badly Designed Switchgear Incorrect Installation Insulation Failure
▫ Contamination
▫ Age Deterioration
▫ Overstressing
▫ Human Intervention
▫ Vermin Ingress
Lack of/Inadequate Maintenance Human Error or Misuse Over-stressing
ENERGY RELEASED BY ARC FAULT
PRESSURE RISE
VISUAL & ACCOUSTIC
PHENOMENA
TEMPERATURE RISE
EFFECTS OF FAULT ARC
CONSEQUENCES FOR PLANT
MECHANICAL STRESSING OF ENCLOSURES
THERMAL STRESSING, MELTING, VAPOURISATION
CONSEQUENCES FOR PERSONNEL
SHOCK WAVE, FLYING DEBRIS, OPENING PANELS
EJECTION OF FLAMES & HOT GASES, METAL
VAPOUR
EFFECTS AND CONSEQUENCES OF AN ARC FAULT IN HIGH VOLTAGE SWITCHGEAR
THE CONSEQUENCES OF AN INTERNAL ARC
FAULT IN HV SWITCHGEAR
THE CONSEQUENCES OF AN INTERNAL ARC
FAULT IN HV OIL SWITCHGEAR
ARC-FAULT IN NON-VENTED SWITCHGEAR
SOME INTERESTING DATA FROM RPS TESTING OF ELDERLY SWITCHGEAR
Current starts: 0 Pressure starts: 0.4 ms Pressure peak: 4.7 ms Pressure duration: 6.6 ms Current peak: <10 ms
Data & Test evidence supports that the covers will be flying off in 5 – 10 ms
Maximum pressure on switchgear panels/doors can be 1-2 bar
Safety Solutions & Improvements for Existing Switchboards
TO IMPROVE SAFETY FOR OPERATORS AND STAFF,
TO REDUCE MAINTENANCE AND LIFETIME OWNERSHIP COSTS,
TO IMPROVE THE RELIABILITY AND THE SERVICE-ABILITY OF THE CIRCUIT BREAKERS.
TO INCREASE THE RATING OF THE SWITCHBOARD, (X/R, Normal & Short cct)
TO FURTHER EXTEND THE REMAINING LIFE OF THE ASSET BY REPLACING KEY COMPONENTS AS REQUIRED, (BUSHINGS, CT’S, VT’S ETC)
TO MODERNISE THE CONTROL & PROTECTION EQUIPMENT.
TO ACHIEVE THE ABOVE WITH MINIMUM SYSTEM DISRUPTION.
KEY STRATEGIC OBJECTIVES FOR LIFETIME SUPPORT OF AGING SWITCHGEAR ASSETS.
SUMMARY OF SWITCHGEAR SOLUTIONS,
SAFETY RETROFITS,
CIRCUIT BREAKER RETROFIT,
ARC DOOR + END SHIELD RETROFIT,
3-SIDED ‘CONTAINMENT’
‘REMOTE OPERATION’
UPGRADES & LIFE EXTENSION,
CURRENT TRANSFORMER REPLACEMENT,
CABLE BOX RETROFIT,
REPLACEMENT OF ORIFICE BUSHINGS,
REPLACEMENT OF VT’s
PROTECTION & CONTROL UPGRADE,
Circuit Breaker Retrofit
CIRCUIT BREAKER RETROFIT
Existing LMT panel
Oil Circuit Breaker out
Vacuum Circuit Breaker in (Brand new unit)
OCB TO VCB REPLACEMENT ABOUT A DAY PER CIRCUIT
MINIMAL DISRUPTION
SIGNIFICANT SAFETY IMPROVEMENT
>6,000 units in service world-wide
RETROFIT CIRCUIT BREAKER FOR REYROLLE ‘LM’ SWITCHGEAR
SIMPLE MODULAR DESIGN
PROVEN CAST EPOXY RESIN INSULATION SYSTEM
CAPABLE OF MORE THAN 10,000 LOAD CURRENT OPERATIONS
PROVEN LONG LIFE, LOW MAINTENANCE MECHANISM
LESS THAN 30% OF THE PARTS OF LMT
CAPABLE OF OVER 50 SHORT-CIRCUIT OPERATIONS AT 25KA AT 12KV
EXCELLENT SWITCHING PERFORMANCE, (25ms opening, >45% dc component)
DIRECT REPLACEMENT FOR LM RANGE,
SIGNIFICANTLY IMPROVES SAFETY IN THE SUBSTATION,
LESS THAN 1 DAY PER CIRCUIT, (Fast Implementation, minimum disruption)
SHORT CIRCUIT WITHSTAND RATING OF THE SWITCHBOARD CAN BE INCREASED UP TO 31.5kA ,
REMOVES OIL HANDLING,
REPLACES CB WITH LONG LIFE, LOW MAINTENANCE UNIT,
LOW COST W.R.T. COMPLETE SWITCHBOARD REPLACEMENT, (<30%)
ALLOWS SUBSTATION ASSETS TO BE RENEWED & REVALUED COST EFFECTIVELY,
RPS LMT SWITCHGEAR RETROFIT -- SUMMARY
FURTHER SAFETY FOR EXISTING SUBSTATIONS
“REPLACEMENT OF THE O.C.B. WITH OUR VACUUM UNIT IS A SIGNIFICANT
IMPROVEMENT IN OPERATOR SAFETY”
BUT THERE ARE OTHER IMPORTANT SAFETY FEATURES THAT ARE AVAILABLE TO
SIGNIFICANTLY IMPROVE SAFETY AND BRING THE EXISTING SWITCHBOARD TOWARDS
62271-200 FOR INTERNAL ARC SAFETY”
FURTHER SAFETY FOR EXISTING SUBSTATIONS
SWITCHGEAR SAFETY UPGRADES:
Arc-proof doors + end shields
3 sided containment
Electrical operation ‘not-in-front’
EXISTING SWITCHGEAR & INTERNAL ARC SAFETY
EXISTING SWITCHBOARDS HAVE NO INTERNAL ARC WITHSTAND OR PRESSURE RELIEF DESIGN,
HUMAN PRESENCE IN FRONT OF THE LIVE SWITCHBOARD IS UNAVOIDABLE
SAFETY FOR OPERATORS, STAFF AND VISITORS IN FRONT OF THE EXISTING SWITCHBOARD IS ACHIEVABLE,
RACKING THROUGH A CLOSED ARC-PROOF DOOR IS ESSENTIAL.
TYPICAL EXISTING LMT SWITCHBOARDS
WHY HAVE AN ARC-PROOF DOOR?
WHY HAVE RACKING THROUGH AN ARC-PROOF DOOR?
TWO IMPORTANT QUESTIONS:-
EXISTING SWITCHGEAR & INTERNAL ARC SAFETY
WHY HAVE AN ARC-PROOF DOOR?
LMT TEST ARRANGEMENT
STANDARD LMT PANEL
FAULT IN BREAKER COMPARTMENT
25KA, 1S DURATION
OCB WOULD BE MUCH WORSE
WHY HAVE AN ARC-PROOF DOOR?
...from a different angle
WHY HAVE RACKING THROUGH AN ARC-PROOF DOOR?
BEHIND CLOSED DOOR RACKING
RETROFIT ARC-PROOF DOOR – OPERATOR SAFETY
Behind Closed Door Racking
RETROFIT END SHIELDS – OPERATOR SAFETY
PREVENTS BURN-THROUGH,
PROVIDES LATERAL SAFETY
SIMPLE INSTALLATION
NO BUS OUTAGE REQUIRED
END PANEL CCT OUTAGE ONLY
RETROFIT OF , 25kA, 1s ARC WITHSTAND FRONT DOOR & END SHIELDS FOR OPERATOR SAFETY`
LMT SWITCHBOARDS RETROFITTED WITH ARC DOORS & END SHIELDS. END SHIELD.
RETROFIT OF ARC-WITHSTAND FRONT DOOR
Brunei Australia
South Africa
United Kingdom
ARC DOORS REDUCE THE HRC – NFPA 70E
Activity Existing switchgear
With arc-doors & end shields
Circuit breaker operation 4 0/1
Circuit breaker racking 4 0/1
Instrument cubicle work/inspection 4 0/1
Maintenance work in front of switchboard 4 0/1
Relay inspection/testing 4 0/1
General presence in the switch-room in front of the switchboard 4 0/1
3-SIDED CONTAINMENT SYSTEM
3-SIDED CONTAINMENT SYSTEM
TEST ARRANGEMENT
LMT PANELS FITTED WITH ARC WITHSTAND KIT
FAULT IN BREAKER COMPARTMENT
25KA, 1S DURATION
CERTIFIED TO IEC 62271-200
3-SIDED SAFETY, 2.8M ROOF
ARC DOOR TEST TO LATEST STANDARD
‘REMOTE’ OPERATION
Option 1 – Remote Control Panel • Dedicated control for each panel • One set of trip & close operators with key to
determine panel
Option 2 – Remote Control Pendant • Lead length: 10m, 15m or request • Plugs into panel to be operated
Other Retrofit & Upgrade Solutions
RETROFIT OF CT CHAMBER & CABLE BOX
PITCH-FILLED CABLE BOX REPLACED WITH AIR
CABLE BOX.
ENCAPSULATED CAST RESIN CT’s REPLACED WITH SLIP-OVER TYPE
RETROFIT OF CT CHAMBER
SLIP-OVER CT RETROFIT KIT FOR LMT
ASSEMBLED, JIGGED AND POURED IN THE FACTORY
COMPLETE INSTALLATION
REPLACES THE CABLE BOX & CABLE BOX BUSHINGS ONLY, -- OR
ALSO REPLACES THE EXISTING CAST RESIN CT’S WITH SLIP-OVER TYPE,
INCLUDES NEW CT ORIFICE BUSHINGS AND CT BUSHINGS,
IMPROVED FUTURE PROTECTION FLEXIBILITY,
LIVE LINE INDICATION & PHASING AVAILABLE,
CONVERTS EXISTING CAST PITCH-FILLED BOX TO AIR TERMINATION,
EASY TO IMPLEMENT, -- PER CCT OUTAGE ONLY,
CABLE BOX REPLACEMENT 400A/800A FEEDER PANEL CONVERTED TO AIR BOX.
400A/800A FEEDER PANEL BEING CONVERTED TO AIR
BOX.
VT REPLACEMENT – MOVING PORTION
RPS manufacture & supply a direct replacement truck for the existing Reyrolle LMT VT’s
Fast replacement – no bus-bar outage required Isolating and Engaging the VT through the Instrument
cubicle is available for the new VT arrangement
Replacement VT trucks for LMT
PROTECTION & CONTROL UPGRADE
Replaces the existing RMI “top-box”
Complete new RMI modernisation
Equipped, wired & tested in the factory
Customised to specific customer requirements
Simplifies site work
LMT SWITCHBOARD FITTED WITH SAFETY, PROTECTION & CONTROL IMPROVEMENTS
LMT SWITCHBOARD FITTED WITH RPS IMPROVEMENTS
RETROFIT VCB’S,
RETROFIT ARC DOORS
PROTECTION & CONTROL UPGRADE,
RETROFIT RMI CUBICLES,
CT & VT UPGRADES,
SWITCHBOARD FAULT RATING INCREASED FROM 13.1kA UP TO 31.5kA.
“Upgraded to modern standards for 40% of the cost of switchboard replacement”
SUMMARY – ELDERLY SWITCHGEAR RETROFIT OPTIONS
SAFETY UPGRADES: OCB to VCB upgrade Arc-proof doors + end shields 3 sided containment Electrical operation ‘not-in-front’
ADDITIONAL RETROFITS: RMI cubicles Busbars VT’s – bus and circuit CT’s Cable boxes
Existing aged switchgear can be made safer & upgraded
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