Professional Documents
Culture Documents
OBJECTIVES
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 large range 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 specific needs 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 investment plan, 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 maintenance management, which can extend the equipments useful life.
INSTALL MAINTAIN
OPERATE VERIFY
FIVE EXCELEC
LEVELS
LEVEL 1
Routine maintenance Maintenance operations are generally described in the maintenance guide given by the manufacturer. For example: adjustment, level checks, replacement of consumable parts.
LEVEL 2
Actions 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.
LEVEL 3
Operations 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.
LEVEL 4
Operations 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.
LEVEL 5
Operations 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.
NB: Extracts from Afnor Standard FDX 60-000, Industrial Maintenance, dated May 2002. Determination of maintenance levels.
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
EXCELEC LEVEL
Electrical room: - Levelness of support/Alignment Upgrade: - Extension according to TTA/PTTA definition - Updating of software
4
According to manufacturers instructions
Indications: - Check on indicators (indicator lights, mechanical indicators, etc...) - Check on values indicated by measuring equipment
Every month
Enclosure: - Efficiency and presence of interlocking devices - Cover panel and partition (doors, form covers, automatic shutters, screws, keys, etc...) - General appearance: cleanliness, presence of humidity, oxidation - Strain - Dedusting of switchboard
Every year
Every year
Every year
LV
EXCELEC LEVEL
Connections: - Heating - Power connection checks (busbars, terminations and busbar supports) - Downstream power connection checks (connecting pads, cable mechanical strength) - Earth connection checks - Clamp connection checks (wear and greasing) - Auxiliary connection checks
3 3
Every year
3
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3 3 2
Every year
Switchgear and controlgear: - Dedusting - Protection setting according to discrimination study - Check on switchgear wearing parts (main contacts, arcing chamber) - Opening/closing checks
1 2 3
Every 3 years
Every year
MV/LV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
Every year
2 2 2 2 2 2 2 2 2 5 5 4 4
Every year
Every year
Event log analysis and checking Connection checking Cabling check Battery check / replacement (CPU, SRAM) Checking and tightness of test and connection units Electronic components aging study (where applicable) Electrical network setting checking and modification Software upgrade
Every year
Every 5 years
Every 10 years
Hardware upgrade
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Every year
PROTECTION RELAYS
Distance, line differential, Busbar, feeders, motors, generators
MV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
PROTECTION RELAYS
2 2 3
to
Checking and tightness of test and connection units Electronic components aging study (analogue relays) Electrical network settings, checking and modification Software upgrade (digital relays) Equipment upgrade
Every 5 years
Every 10 years
Upon any electrical network change According to manufacturers instructions On change request or according to manufacturers instructions
5 4 4
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Every 5 years
MV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
CIRCUIT BREAKERS
General state visual checking, cleanliness, insulator condition, oxidation, no corrosion of supporting structure, etc. Reading operating counter Tightness checking of: - Screws of supporting structure - High Voltage (HV) connections Check on general state and absence of traces of overheating on earthing connections Oil level checks; Tightness testing Check on operating times and synchronization Insulator cleaning
1 2
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2 3 2 4
Measurement of dielectric losses (poles, dielectric oil, insulating transmission oil if necessary) Measurement of main contact resistance Replacement of dielectric oil Wear checks on arcing contacts
4 2 4 4
MV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
CIRCUIT BREAKERS
General state visual checking, cleanliness, insulator condition, oxidation, no corrosion of supporting structure, etc... Reading operating counter Tightness checking of: - Screws of supporting structure - High Voltage (HV) connections Checking of overall condition and earthing connections (no sign of overheating) SF6 pressure checking Cleaning of insulators (Particular risk: under-pressure insulators) Check on operating times and synchronization Checking of density meter operation and gas quality Resistance measurement on main contacts Replacement of capacitors
1 2
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Every 3 years
2 2
4 5
HV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
ALL MECHANISMS
Reading operating counter Checking of Low Voltage terminals and Low Voltage connections
1 2
HYDRAULIC MECHANISMS
Checking of the oil level and the absence of leakages Reading of pump counter Visual checking of electrical equipment and safety devices Checking of hydraulic safety devices (valves, discharge valves) Checking of pressure switch thresholds and local/remote indicators Oil filter replacement Cleaning of tanks and circuits, oil replacement Accumulator replacement and/or requalification Change of flexible pipes and check on connections Upgrading and/or replacement of control units, cylinders, hydraulic pumps
Every year
2 2 3 4 4 5
Every 15 years
Every 15 years
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DISCONNECTORS
HV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISCONNECTORS
General state visual checking, cleanliness, insulator condition, oxidation, no mounting corrosion, etc... Check on overall condition and earthing connections (no sign of overheating) Tightness checking on: - Screws of supporting structure - HV connections Check on operating mechanism; check on low voltage components Complete operating cycle for each equipment Infrared thermography Check on safety devices (locking, indications) Wiring state, tightening of terminal blocks, checking of heating resistor and indications Cleaning and checking of post insulators, greasing of moving components and connecting rod assemblies Check on operating parameters and mechanical torque Measurement of main contact wear Repair and/or replacement of wearing parts (elastomer thrust stops, joint pins, plastic bearings, propulsion, etc.)
Every year
1 3 2 1
Every 3 years
Every 3 years
Every 3 years
3 4
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HV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
ALL
Visual check: general appearance, cleanliness, cracks, corrosion on supports, etc... Insulator cleaning
Every 3 years, energized or de-energized Every year energized de-energized Every year, energized
2 2
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Tightening checks: support structure bolts, HV and LV circuit connections IR thermographic checks
SURGE ARRESTOR
1 1 4
Oil level check and leakage identification and pinpointing Oil sampling for analysis Secondary loads & load factor measurement
Every year
1 1 3
SF6 pressure check, leakage pinpointing and tapping-off Secondary loads & load factor measurement
2 3
Every 5 years
MV
EXCELEC LEVEL
Cleaning of cubicle and internal equipment (voltage and current transformers) Checking of busbar connections, tightening according to value recommended by manufacturer Cleaning and greasing of earthing switch Checking of earthing switch mechanism Opening and closing of earthing switch Checking of voltage and current transformers (overheating marks, cracks, etc...) Checking of withdrawal mechanism and shutters Checking of locking mechanism function Checking of the position indicators and signalling switches
2 3 1 4
3 3 1
MV
EXCELEC LEVEL
CIRCUIT BREAKER
Checking of opening and closing times, contact synchronization, closing and tripping speed, measuring of contact resistance Checking, cleaning and greasing of fixed and moving contacts of withdrawable parts Checking of the components in the latching mechanism, replacement if necessary Visual inspection of mechanism and electrical equipment, and safety devices Visual checking of external coupling rods Cleaning and greasing Replacement of wearing parts
After 10 years or 10 000 operations whichever occurs the earlier, then every 3 years Every 3 years, de-energized
Every 3 years
Every year
Every year
1 3 3
ASSOCIATED PROTECTION
Equipment opening and closing cycle Checking of protection relay Checking of upstream and downstream selectivity
1 4 4
MV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
MV CIRCUIT-BREAKER MECHANISMS
Visual examination of mechanism, electrical equipment and safety devices Visual examination of external coupling rods Cleaning and greasing
Every year
Every year
1 3 3
to
Every 3 or 5 years
4** 4**
Every 3 or 5 years
to
4 4 4 2
Replacement of operation counter Replacement of closing and tripping springs Check on fastening of nuts and bolts and presence of safety devices
Every 3 years
MV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
Visual examination and cleaning Cleaning and greasing of main contacts Check on active part and resin enclosures (overheating marks, cracks, dust, etc...) Visual inspection of busbars and tightening Check on the absence of corona traces on the MV cable ends Removal, cleaning and greasing of mechanism Cleaning and greasing of earthing switch where applicable Check on earthing switch mechanism Check on MV fuses and comparison with manufacturer's data Check on system for tripping by MV fuses Mechanical test (closing, tripping, locking mechanism) Electrical and operating tests
1 2 2
4 3 2 4
3 4 3 2
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LEVEL 1
Routine maintenance Maintenance operations are generally described in the maintenance guide given by the manufacturer. For example: adjustment, level checks, replacement of consumable parts.
LEVEL 2
Actions 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.
LEVEL 3
Operations 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.
LEVEL 4
Operations 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.
LEVEL 5
Operations 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.
NB: Extracts from Afnor Standard FDX 60-000, Industrial Maintenance, dated May 2002. Determination of maintenance levels.
DISTRIBUTION TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISTRIBUTION TRANSFORMER
Commissioning of transformers: - Preparation for shipment - Shipment Unloading - Erection Installation - Other operations (oil filling) - Checks (protection systems, automatic controls) - Commissioning Repair/refurbishment in factory: - On-site diagnosis - Preparation for shipment - Shipment - Unloading - Untanking - Expert appraisal - Active part dismantling - Calculation and design - Repair of accessories - Coil winding - Connections
At commissioning
1 1 3 4 3 4
5 1 1 4 4 5 4 4 5 4
DISTRIBUTION TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISTRIBUTION TRANSFORMER
Repair/refurbishment in factory: (continued) - Work on magnetic core - Active part reassembly - Tanking - Oil filling - Oil filtration in factory During repair/ refurbishment in factory
5 5 5 4 4 5 3 2 5
During repair/ refurbishment in factory
- Electrical tests in factory - Painting and coating - Preparation for shipment - Oil purification or regeneration On-site repair/refurbishment: - On-site diagnosis - Preparation for untanking - Untanking - Expert appraisal - Active part dismantling - Calculation and design
4 4 4 5 5 4
DISTRIBUTION TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISTRIBUTION TRANSFORMER
Repair/refurbishment in factory: (continued) - Refurbishment of accessories - Coil winding - Shipment of windings to site - Connections - Work on magnetic core - Active part assembly - Tanking - Oil filling operations - Protection system checking - Commissioning - Oil purification and regeneration - Destruction of polluted transformers During repair/ refurbishment in factory
3 5 3 4 5 5 5 3 3 4 5 3
DISTRIBUTION TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISTRIBUTION TRANSFORMER
Oil analyses: - Oil sampling - Basic analyses - PCB content analysis - Dissolved gas and furanic analyses - Results interpretation Maintenance: - Visual check (endoscopy) - Oil sampling and analysis - LV electrical testing - Environmental checks (pollution and fires) - Partial discharges - HV electrical testing - Noise test - Infrared thermography - Oil level (except for integral-filling devices) - Air dryer maintenance - Air dryer replacement - Dessicant breather replacement
Every year
2 3 5 5 5
Every year
2 2 3 3 5 5 3 3 2 2 4 2
DISTRIBUTION TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISTRIBUTION TRANSFORMER
Maintenance (continued): - Check of transformer's protection systems - Bushing cleaning - Transformer compartment cleaning - Visual check for leakage - Leakage repair - Gasket replacement - Bushing replacement - Accessories check - Accessories replacement - Refurbishment of auxiliary equipments - Oil filtration - Installation of retention tanks - Installation of fire protection systems - Transformer moving - Painting - Coating - Oil retrofilling, purification and regeneration
Every year
3 2 2 2 2 4 4 4 3 2 3 4 3 3 3 3 5
Every year if necessary if necessary if necessary Every year if necessary if necessary if necessary if necessary if necessary
GIS EQUIPMENT
HV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
GENERAL
In case of re-assembly of a component (circuit breaker, disconnector, ) after repair In case of re-assembly of a component (circuit breaker, disconnector, ) after repair In case of re-assembly of a component (circuit breaker, disconnector, ) after repair Every 5 years, energized Every 5 years, de-energized
Dielectric tests/detection of partial discharges: - To validate re-assembly after repair IR thermographic check Optical indicators operating check SF6 filling valves & operating mechanisms labeling check Cubicle heating resistors operating check LV wiring connections check Mechanisms and alarms check Cubicle tightness check
3 1 1
1 2 2 1
GIS EQUIPMENT
HV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
SF6
Pressure check with permanent pressure gauge (if applicable) Pressure check with appropriate tool SF6 quality check SF6 leakage pinpointing Density switch checking (including wiring connections), check from control room
1 2 2 2
CIRCUIT BREAKERS
Operating time checks (main and auxiliary contacts) Contact wear check
Every 5000 operations, de-energized Every 5000 operations or 25 years, de-energized Every 15 years, de-energized
4 5 3
Capacitor replacement
Circuit-breaker control rod adjustment check (if applicable) Renovation and upgrading
GIS EQUIPMENT
HV
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
DISCONNECTORS
1 4
Contact inspection
EARTHING SWITCHES
3 1
POWER TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
POWER TRANSFORMER
Switching of off-load tap changer Overall look: cleanliness, moisture content and oxidation. Frequency: yearly Search for leaks, unusual noises, hot spots Visual check on HV-MV-LV bushings Air dryer check Visual check on electrical auxiliary cabinet Oil level check Check of the dessicant breather condition Maintenance of air coolers / water coolers: - Heat exchanger cleaning - Beam cleaning - Motor-powered fan Dielectric oil analysis : - Physico-chemical - Dissolved gas analysis - Particles counting, search for furfural and its derivatives
1 1 1 1 1 1 1 1
Every week
Every year
2 2 2 3 3 3
POWER TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
POWER TRANSFORMER
Check on HV and LV connections On-load tap changer: - Operating and safety checks - Oil analysis - Complete overhaul of OLTC including 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 - Cooling system check - Filter clogging - Oil circuit check - Thermostat - Buchholz relay - RS 2000 and 2001 relays - Protection relays for transformer and OLTC
Every year
3 2 3 4
Every year
Every year Every year Every year Every year Every year Every year Every year Every year
1 2 2 2 2 3 3 3
POWER TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
POWER TRANSFORMER
Every year and maintenance work if necessary Every 5 years according to oil analyses According to results, dissolved gas analyses Every 5 years or on incident As per Tan delta results According to insulation results
2 3
- Oil filtration
4 3 3 3 3 3 3 4 4
- Replacement of motor-powered fan - Change of circulation pump - Change of oil circulation indicator - Replacement of thermometers - Replacement of relief valve - Replacement of Buchholz relay Expert appraisal upon failure: - Nature and origin of the failure - Operating background analysis
Upon failure - Oscilloperturbograph analysis - Oil analyses (Buchholz gas, DGA, furfural, PCB
4 3
POWER TRANSFORMER
EQUIPMENT
RECOMMENDED FREQUENCY*
EXCELEC LEVEL
POWER TRANSFORMER
On-site repair: - Without untanking Upon failure - With untanking and expert appraisal of active part Repair in factory (with untanking) - Disassembly to view the fault + validation of the repair process - Expert appraisal (causes and origin of fault) - Reassembly and tests Upon failure
4 5
5 5
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Expert appraisal upon failure (continued): - Electrical measurement: Ratios Resistance Impedance Insulation - Endoscopy - On-site expertise: Results interpretation Definition of the type of repair (on site, in workshop) and operating process
Upon failure
3 5 4