guide excelec en

A GUIDE TO BEST PRACTICE

PRESERVING &MAINTAININGYOUR ELECTRICAL EQUIPMENT

OBJECTIVESOF THE EXCELEC GUIDE

This professional guide is aimed at aiding the maintenance manager of an electrical installation, as well as the buyers of these services, to optimise maintenance in terms of both costs and quality.

It provides a tool for optimal implementation of maintenance services taking into account the potential risks and industry know-how.

Focused on the entire life cycle of the equipment, the Excelec Guide describes a largerange of operations aimed at checking and preserving the life of an electrical installation, and establishing the level of complexity of each maintenance operation.

The Guide also recommends the optimal frequency of the various operations, adapted to the corresponding phase of the equipment life cycle, to anticipate specificneeds and allow overall cost optimisation.

This Excelec Guide is, above all, an aid for a dialogue between the maintenance provider and the client, intended to clarify the discussion and to establish basic reflexes concerning maintenance.

It also allows the client to build up a maintenance plan and to take advantage of regular servicing operations by a maintenance specialist to assess his installation.

Thanks to the product knowledge and long-term vision of the maintenance specialist, the client can also get advice on how to develop or update his investmentplan, based on expert recommendations, and thereby be able to control his overall operating costs.

The maintenance specialist, based on his know-how and perfect familiarity with the equipment, is able to offer the appropriate operation corresponding to the life-cycle stage of the equipment, and can give guidance on optimised maintenancemanagement, which can extend the equipments useful life.

INSTALL

OPERATE

VERIFY

MAINTAIN

FIVE EXCELECLEVELS

LEVELRoutine maintenanceMaintenance operations are generally described in the maintenance guide given by the manufacturer.For example: adjustment, level checks, replacement of consumable parts.

LEVELActions requiring simple procedures and/or support equipment (integrated into the equipment or outside it) simple to use or to implement.Maintenance operations are generally described in the maintenance guide given by the manufacturer.For example: Replacement/exchange of components, simple inspections.

LEVELOperations requiring complex procedures and/or support equipment which are either complex to use or to implement.For example: replacement of manufacturer's original parts, complex adjustments, realignment.

LEVELOperations involving procedures which imply the mastery of a particular technique or technology and/or the implementation of specialized support equipment.For example: Technical upgrading, change of function performance, change of use.

LEVELOperations involving procedures which imply expertise, requiring particular techniques or technologies, processes and/or industrial support equipment.For example: general overhaul with complete dismantling of equipment, replacement of obsolete or worn-out equipment.

5

4

3

2

1

NB: Extracts from Afnor Standard FDX 60-000, Industrial Maintenance, dated May 2002. Determination of maintenance levels.

EXCELEC DATA SHEETS

PRESERVING & MAINTAINING YOUR ELECTRICAL EQUIPMENT

TECHNICAL DATA SHEETSJuly 2007

Low voltage power distribution schwitchboards and motor control centres

Monitoring and measurement equipment

Protection relays

Cubicle with circuit breaker and MV associated protection

MV Circuit-breaker operating mechanisms

MV circuit switch cubicle

Distribution transformer

Minimum oil circuit breakers

SF6 Circuit breakers

Circuit-breaker operating mechanisms

Disconnectors

Surge arrestors, CTs, VTs

GIS equipment

Power transformer

LV : Low VoltageMV : Medium VoltageHV : High Voltage

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EXCELEC DATA SHEETS


* in normal operating conditions

LOW VOLTAGE POWER DISTRIBUTION SCHWITCHBOARDS AND MOTOR CONTROL CENTRES

LV

EQUIPMENT DESCRIPTION RECOMMENDED EXCELEC OF THE OPERATION FREQUENCY* LEVEL

Electrical room: In case of switchboard 2- Levelness of support/Alignment extension

Upgrade: According to upgrade- Extension according

to TTA/PTTA definition 4

- Updating of software According to manufacturers instructions

Indications:- Check on indicators Every month 1

(indicator lights, mechanical indicators, etc...)

- Check on values indicated Every two years 2by measuring equipment

Enclosure:- Efficiency and presence Every year

of interlocking devices

- Cover panel and partition Every year(doors, form covers, automatic 1shutters, screws, keys, etc...)

- General appearance: cleanliness, Every yearpresence of humidity, oxidation

- Strain Every year

- Dedusting of switchboard Every year

LOW VOLTAGE SWITCHBOARDS

LOW VOLTAGE POWER DISTRIBUTION SCHWITCHBOARDS AND MOTOR CONTROL CENTRES


Connections:- Heating Every year 3

- Power connection According 3checks (busbars, to manufacturers terminations and busbar instructionsupports)

- Downstream power connection Every year 3checks (connecting pads, cable mechanical strength)

- Earth connection checks Every year 3

- Clamp connection checks Every year 3(wear and greasing)

- Auxiliary connection checks Every year 2

Switchgear and controlgear:- Dedusting Every year 1

- Protection setting according During commissioning 2to discrimination study

- Check on switchgear Every 3 years 3wearing parts (main contacts, arcing chamber)

- Opening/closing checks Every year 1

Electrical environment:- Harmonic content checks Depending on changes 1

in downstream loads

LOW VOLTAGE SWITCHBOARDS


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LV

MONITORING AND MEASUREMENT EQUIPMENTDigital Control Systems, Remote Terminal Units, Event Recorders, Fault Recorders, Transducers, Meters


Fan filter replacement Every year 2

Fan/drive system Every year 2rack checking

Computer fan checking Every year 2

Power supply checking Every year 2(noise level)

Event log analysis Every year 2and checking

Connection checking Every year 2

Cabling check Every year 2

Battery check / replacement Every 5 years 2(CPU, SRAM)

Checking and tightness of test Every 5 years 2and connection units

Electronic components Every 10 years 5aging study (where applicable)

Electrical network setting On any electrical 5checking and modification network change

Software upgrade According to manufacturers 4instructions

Hardware upgrade On change request 4

MONITORING AND MEASUREMENT EQUIPMENT

EXCELEC DATA SHEETS



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MV/LV

PROTECTION RELAYSDistance, line differential, Busbar, feeders, motors, generators


Connexion check Every year 2

Cabling check Every year 2

Secondary injection testing Every year to

Backup battery Every 5 years 2checking / replacement (digital relays)

Checking and tightness Every 5 years 2of test and connection units

Electronic components Every 10 years 5aging study (analogue relays)

Electrical network settings, Upon any electrical 5checking and modification network change

Software upgrade According to manufacturers 4(digital relays) instructions

Equipment upgrade On change request or 4according to manufacturers instructions

43

PROTECTION RELAYS

(according to type of protection)

EXCELEC DATA SHEETS



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MV

OIL CIRCUIT BREAKERS


General state visual checking, Every year, energized 1cleanliness, insulator condition, oxidation, no corrosion of supporting structure, etc.

Reading operating counter Every year 1

Tightness checking of: Every year, 2- Screws of supporting structure - energized- High Voltage (HV) connections - de-energized

Check on general state and absence Every year, energized 2of traces of overheating on earthing connections

Oil level checks; Every year, energized 2Tightness testing

Check on operating times Every 3 years, de-energized 3and synchronization

Insulator cleaning Every 3 years, 2energized or de-energized

Measurement of dielectric losses Every 3 years, de-energized 4(poles, dielectric oil, insulating transmission oil if necessary)

Measurement of main Every 3 years, de-energized 4contact resistance

Replacement of dielectric oil Every 5 years, de-energized 2

Wear checks on arcing contacts Every 5 years, 4depending on use

Renovation and upgrading Every 20 years 4

CIRCUIT BREAKERS

EXCELEC DATA SHEETS



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MV

SF6 CIRCUIT BREAKERS


General state visual checking, Every year, energized 1cleanliness, insulator condition, oxidation, no corrosion of supporting structure, etc...


Tightness checking of: Every year, 2- Screws of supporting structure - energized- High Voltage (HV) connections - de-energized

Checking of overall condition Every year, energized 2and earthing connections (no sign of overheating)

SF6 pressure Every 3 years 2checking

Cleaning of insulators Every 3 years, 2(Particular risk: energized or de-energizedunder-pressure insulators)

Check on Every 3 years, de-energized 4operating times and synchronization

Checking of Every 5 years, de-energized 4density meter operation and gas quality

Resistance measurement Every 5 years, de-energized 4on main contacts

Replacement of capacitors Every 5000 operations 5or 25 years de-energized

Renovation and upgrading Every 20 years 5

CIRCUIT BREAKERS

EXCELEC DATA SHEETS



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MV

CIRCUIT-BREAKER OPERATING MECHANISMS



Checking of Low Voltage terminals Every 5 years 2and Low Voltage connections

Checking of the oil level Every year, energized 1and the absence of leakagesReading of pump counter

Visual checking Every year 1of electrical equipment and safety devices

Checking of hydraulic Every 40 months 2safety devices as per regulation(valves, discharge valves)

Checking of pressure switch thresholds Every 5 years, energized 2and local/remote indicators

Oil filter replacement Every 5 years 2

Cleaning of tanks and circuits, Every 10 years, 3oil replacement de-energized

Accumulator replacement Every 10 years 4and/or requalification

Change of flexible pipes Every 15 years 4and check on connections

Upgrading and/or replacement Every 15 years 5of control units, cylinders, hydraulic pumps

ALL MECHANISMS

HYDRAULIC MECHANISMS

EXCELEC DATA SHEETS



HV

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DISCONNECTORS


General state visual checking, Every year, energized 1cleanliness, insulator condition, oxidation, no mounting corrosion, etc...

Check on overall condition and Every year, energized 2earthing connections (no sign of overheating)

Tightness checking on: Every year, 2- Screws of supporting structure - energized- HV connections - de-energized

Check on operating mechanism; Every year 1check on low voltage components

Complete operating cycle Every year, de-energized 1for each equipment

Infrared thermography Every year, energized 3

Check on safety devices Every year 2(locking, indications)

Wiring state, tightening of Every 3 years 1terminal blocks, checking of heating resistor and indications

Cleaning and checking of post insulators, Every 3 years, de-energized 2greasing of moving components and connecting rod assemblies

Check on operating Every 3 years 3parameters and mechanical torque

Measurement of Every 3 years 3main contact wear

Repair and/or replacement of wearing Every 15 years, 4parts (elastomer thrust stops, depending on joint pins, plastic bearings, conditions of usepropulsion, etc.)

DISCONNECTORS

EXCELEC DATA SHEETS



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HV

SURGE ARRESTORS, CTS, VTS


Visual check: general appearance, Every year, energized 1cleanliness, cracks, corrosion on supports, etc...

Insulator cleaning Every 3 years, energized 2or de-energized

Tightening checks: Every year 2support structure bolts, HV and energized LV circuit connections de-energized

IR thermographic checks Every year, energized 3

Reading of discharge counters Every year 1

Earthing connection check Every year 1

Leak current check Every 3 years 4

Oil level check and leakage Every year 1identification and pinpointing

Oil sampling for analysis Every 5 years, de-energized 1

Secondary loads & load Every 5 years 3factor measurement

SF6 pressure check, Every year, energized 2leakage pinpointing and tapping-off

Secondary loads & load Every 5 years 3factor measurement

ALL

SURGE ARRESTOR

OIL INSULATED CTS AND VTS

SF6 INSULATED CTS AND VTS

EXCELEC DATA SHEETS



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HV

CUBICLE WITH CIRCUIT BREAKER AND MV ASSOCIATED PROTECTION


Cleaning of cubicle and internal Every 3 years, de-energized 1equipment (voltage and current transformers)

Checking of busbar connections, Every 3 years, de-energized 2tightening according to value recommended by manufacturer

Cleaning and greasing Every 3 years, de-energized 2of earthing switch

Checking of earthing Every 3 years, de-energized 3switch mechanism

Opening and closing Every year if possible, 1of earthing switch or every 3 years

Checking of voltage and Every 3 years, de-energized 4current transformers (overheating marks, cracks, etc...)

Checking of withdrawal Every 3 years, de-energized 3mechanism and shutters

Checking of locking Every 3 years, de-energized 3mechanism function

Checking of the position indicators Every year, energized 1and signalling switches

AIR INSULATED MV CUBICLE

EXCELEC DATA SHEETS



MV

CUBICLE WITH CIRCUIT BREAKER AND MV ASSOCIATED PROTECTION


Checking of opening and closing times, After 10 years or 4contact synchronization, closing 10 000 operations and tripping speed, measuring whichever occurs the earlier, of contact resistance then every 3 years

Checking, cleaning and greasing Every 3 years, de-energized 2of fixed and moving contacts of withdrawable parts

Checking of the components Every 3 years 4in the latching mechanism, replacement if necessary

Visual inspection of mechanism Every year 1and electrical equipment, and safety devices

Visual checking Every year 1of external coupling rods

Cleaning and greasing Every 5 years 3

Replacement of wearing parts Every 5 years 3

Equipment opening Every year, de-energized 1and closing cycle

Checking of protection relay Every year, de-energized 4

Checking of upstream Every year, de-energized 4and downstream selectivity

CIRCUIT BREAKER

ASSOCIATED PROTECTION


MV

MV CIRCUIT-BREAKER OPERATING MECHANISMS


Visual examination of mechanism, Every year 1electrical equipment and safety devices

Visual examination Every year 1of external coupling rods

Cleaning and greasing Every 3 or 5 years to

Replacement Every 3 or 5 years toof wearing parts and check on latching

Replacement of motor After 10 000 operations 4

Replacement of operation After 10 000 operations 4counter

Replacement of closing After 10 000 operations 4and tripping springs

Check on fastening of nuts Every 3 years 2and bolts and presence of safety devices

43

43

MV CIRCUIT-BREAKER MECHANISMS

* in normal operating conditions** according to the type of circuit-breaker

EXCELEC DATA SHEETS


MV

**

**

MV CIRCUIT SWITCH CUBICLE


Visual examination and cleaning Every year 1

Cleaning and greasing Every 3 years, de-energized 2of main contacts

Check on active part and Every 3 years, de-energized 2resin enclosures (overheating marks, cracks, dust, etc...)

Visual inspection Every 3 years, de-energized 3of busbars and tightening

Check on the absence Every 3 years, de-energized 2of corona traces on the MV cable ends

Removal, cleaning Every 3 years, de-energized 4and greasing of mechanism

Cleaning and greasing Every 3 years, de-energized 3of earthing switch where applicable

Check on earthing Every year if possible 2switch mechanism or every 3 years

Check on MV fuses Every 5 years, de-energized 4and comparison with manufacturer's data

Check on system Every 3 years, de-energized 3for tripping by MV fuses

Mechanical test (closing, tripping, Every 3 years, de-energized 4locking mechanism)

Electrical and operating tests Every year, energized 3

Check on auxiliary contacts Every year, energized 2and position indicators


MV

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EXCELEC DATA SHEETS


A GUIDE TO BEST PRACTICE


23 rue Galile - 75116 PARIS | Tl/Fax +33 (0)1 40 70 07 [email protected] | www.gimelec-promotion.fr

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LEVELRoutine maintenanceMaintenance operations are generally described in the maintenance guide given by the manufacturer.For example: adjustment, level checks, replacement of consumable parts.

LEVELActions requiring simple procedures and/or support equipment (integrated into the equipment or outside it) simple to use or to implement.Maintenance operations are generally described in the maintenance guide given by the manufacturer.For example: Replacement/exchange of components, simple inspections.

LEVELOperations requiring complex procedures and/or support equipment which are either complex to use or to implement.For example: replacement of manufacturer's original parts, complex adjustments, realignment.

LEVELOperations involving procedures which imply the mastery of a particular technique or technology and/or the implementation of specialized support equipment.For example: Technical upgrading, change of function performance, change of use.

LEVELOperations involving procedures which imply expertise, requiring particular techniques or technologies, processes and/or industrial support equipment.For example: general overhaul with complete dismantling of equipment, replacement of obsolete or worn-out equipment.

5

4

3

2

1

NB: Extracts from Afnor Standard FDX 60-000, Industrial Maintenance, dated May 2002. Determination of maintenance levels.

DISTRIBUTION TRANSFORMER


Commissioning of transformers: At commissioning- Preparation for shipment 1

- Shipment Unloading 1

- Erection Installation 3

- Other operations 4(oil filling)

- Checks (protection systems, 3automatic controls)

- Commissioning 4

Repair/refurbishment in factory: During repair/ - On-site diagnosis refurbishment in factory 5

- Preparation for shipment 1

- Shipment - Unloading 1

- Untanking 4

- Expert appraisal 4

- Active part dismantling 5

- Calculation and design 4

- Repair of accessories 4

- Coil winding 5

- Connections 4


EXCELEC DATA SHEETS





Repair/refurbishment in factory:(continued)- Work on magnetic core 5

- Active part reassembly 5

- Tanking 5

- Oil filling 4

- Oil filtration in factory During repair/ 4refurbishment in factory

- Electrical tests in factory 5

- Painting and coating 3

- Preparation for shipment 2

- Oil purification 5or regeneration

On-site repair/refurbishment: During repair/ - On-site diagnosis refurbishment in factory 4

- Preparation for untanking 4

- Untanking 4

- Expert appraisal 5

- Active part dismantling 5

- Calculation and design 4





Repair/refurbishment in factory:(continued)- Refurbishment of accessories 3

- Coil winding 5

- Shipment of windings to site 3

- Connections 4

- Work on magnetic core 5

- Active part assembly During repair/ 5refurbishment in factory

- Tanking 5

- Oil filling operations 3

- Protection system checking 3

- Commissioning 4

- Oil purification 5and regeneration

- Destruction of 3polluted transformers



EXCELEC DATA SHEETS




Oil analyses: Every year- Oil sampling 2

- Basic analyses 3

- PCB content analysis 5

- Dissolved gas 5and furanic analyses

- Results interpretation 5

Maintenance: Every year- Visual check (endoscopy) 2

- Oil sampling and analysis 2

- LV electrical testing 3

- Environmental checks 3(pollution and fires)

- Partial discharges 5

- HV electrical testing 5

- Noise test 3

- Infrared thermography 3

- Oil level (except for integral-filling devices) 2

- Air dryer maintenance 2

- Air dryer replacement 4

- Dessicant breather replacement 2





Maintenance (continued): Every year- Check of transformer's 3

protection systems

- Bushing cleaning Every year 2

- Transformer compartment Every year 2cleaning

- Visual check for leakage Every year 2

- Leakage repair if necessary 2

- Gasket replacement if necessary 4

- Bushing replacement if necessary 4

- Accessories check Every year 4

- Accessories replacement if necessary 3

- Refurbishment of auxiliary equipments if necessary 2

- Oil filtration if necessary 3

- Installation of retention tanks if necessary 4

- Installation of if necessary 3fire protection systems

- Transformer moving if necessary 3

- Painting if necessary 3

- Coating if necessary 3

- Oil retrofilling, purification if necessary 5and regeneration



EXCELEC DATA SHEETS


GIS EQUIPMENT


Erection & Commissioning In case of re-assembly of 4supervision a component (circuit breaker,

disconnector, ) after repair

Erection: In case of re-assembly of 2- GIS assembly under a component (circuit breaker,

responsibility of supervisor disconnector, ) after repair

Dielectric tests/detection In case of re-assembly of 5of partial discharges: a component (circuit breaker, - To validate re-assembly disconnector, )

after repair after repair

IR thermographic check Every 5 years, energized 3

Optical indicators Every 5 years, de-energized 1operating check

SF6 filling valves Every year, de-energized 1& operating mechanisms labeling check

Cubicle heating resistors Every year, de-energized 1operating check

LV wiring connections Every 5 years, de-energized 2check

Mechanisms and alarms Every 5 years, de-energized 2check

Cubicle tightness Every 15 years, de-energized 1check

GENERAL


HV

GIS EQUIPMENT


Pressure check with Every year, when energized 1permanent pressure gauge (if applicable)

Pressure check with Every 5 years, de-energized 1appropriate tool

SF6 quality check Every 5 years, de-energized 2

SF6 leakage pinpointing Every 5 years, de-energized 2

Density switch checking Every 5 years, de-energized 2(including wiring connections), check from control room

Operating time checks Every 5 years, de-energized 3(main and auxiliary contacts)

Contact wear check Every 5000 operations, 4de-energized

Capacitor replacement Every 5000 operations 5or 25 years, de-energized

Circuit-breaker control Every 15 years, de-energized 3rod adjustment check (if applicable)

Renovation and upgrading Every 20 years, de-energized 5

SF6

CIRCUIT BREAKERS


HV

GIS EQUIPMENT


Mechanical function Every 5 years, de-energized 3checks (locking, interlocking, auxiliary contacts)

Lubrication Every 5 years, de-energized 1

Contact inspection Every 5000 operations, 4de-energized

Mechanical function checks Every 5 years, de-energized 2(locking, interlocking, auxiliary contacts)

Lubrication Every 5 years, de-energized 1

Leaking current measurement Every 15 years, de-energized 3

Reading of discharge Every year 1counters

DISCONNECTORS

EARTHING SWITCHES

EQUIPMENT: SURGE ARRESTORS


HV

EXCELEC DATA SHEETS


EXCELEC DATA SHEETS


POWER TRANSFORMER


Switching of off-load tap changer Every year, de-energized 1

Overall look: cleanliness, moisture Every year 1content and oxidation. Frequency: yearly

Search for leaks, Every week 1unusual noises, hot spots

Visual check on Every year 1HV-MV-LV bushings

Air dryer check Every year 1

Visual check on Every year 1electrical auxiliary cabinet

Oil level check Every 6 months 1

Check of the dessicant Every 6 months 1breather condition

Maintenance of air coolers / water coolers:- Heat exchanger cleaning Every year 2

- Beam cleaning Every year 2

- Motor-powered fan Every 5 years or upon failure 2

Dielectric oil analysis :- Physico-chemical Every year 3

- Dissolved gas analysis Every year 3

- Particles counting, search for Every 5 years 3furfural and its derivatives

POWER TRANSFORMER


POWER TRANSFORMER


Check on HV and LV connections Every year 3

On-load tap changer:- Operating and safety Every year 2

checks

- Oil analysis Every year 3

- Complete overhaul of OLTC Every 5 years 4including replacement of parts and oil (to be replaced every 50 000 or 100 000 operations if circuit filtered permanently)

Check on transformer accessories:- Oil level Every year 1

- Cooling system check Every year 2

- Filter clogging Every year 2

- Oil circuit check Every year 2

- Thermostat Every year 2

- Buchholz relay Every year 3

- RS 2000 and 2001 relays Every year 3

- Protection relays for Every year 3transformer and OLTC

POWER TRANSFORMER


POWER TRANSFORMER


Other maintenance work:- Tank and pipes painting-coating Every year and maintenance 2

work if necessary

- Oil filtration Every 5 years 3according to oil analyses

- Replacement or oil According to results,retreatment dissolved gas

analyses

- Tan delta values on transformer Every 5 years or or bushings on incident

- Replacement of HV/LV/N bushings As per Tan delta 4results

- Replacement of motor-powered fan According to 3insulation results

- Change of circulation pump 3

- Change of oil 3circulation indicator

- Replacement of thermometers 3

- Replacement of relief valve 3

- Replacement of Buchholz relay 3

Expert appraisal upon failure:- Nature and origin of the failure 4

- Operating background 4analysis

Upon failure- Oscilloperturbograph 4

analysis

- Oil analyses (Buchholz gas, 3DGA, furfural, PCB

POWER TRANSFORMER


EXCELEC DATA SHEETS


EXCELEC DATA SHEETS


POWER TRANSFORMER


Expert appraisal upon failure (continued):- Electrical measurement: 3

Ratios Resistance Impedance Insulation Upon failure

- Endoscopy 3- On-site expertise:

Results interpretation 5 Definition of the type of repair

(on site, in workshop) 4and operating process

On-site repair:- Without untanking 4

Upon failure- With untanking and expert 5

appraisal of active part

Repair in factory (with untanking)- Disassembly to view the fault 5

+ validation of the repair process

- Expert appraisal (causes Upon failure 5and origin of fault)

- Reassembly and tests 5

POWER TRANSFORMER


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