SECTION 6 6.

0 Guidelines for Renovation and Modernisation(R&M) and Residual Life Assessment (RLA) studies of Sub Transmission and Distribution Equipment 6.1 Introduction. Predictive maintenance is gaining popularity as a productivity tool because it helps eliminate unscheduled downtime of expensive equipment and reduce the overall cost of maintenance. This approach, sometimes called condition-based maintenance, relies on planned inspections, testing, analysing and trending of the relevant equipment parameters which in most cases can non-intrusively determine a equipments health and must be followed by proactive actions that change the way equipment is operated to reach the goals set out above. In other words, the performance of equipment is analyzed to determine its condition and predict when it will need attention. The concept of simple replacement of power equipment in the system, considering it as weak or a potential source of trouble, is no more valid in the present scenario of financial constraints. Today the paradigm has changed and efforts are being directed to explore new approaches/techniques of monitoring, diagnosis, life assessment and condition evaluation, and possibility of extending the life of existing assets(i.e. generator, circuit breaker, surge arresster, oil filled equipment like transformers, load tap changer etc., which constitute a significant portion of assets for generation, transmission and distribution system).

Renovation and modernization and life extension of existing substation of sub transmission and distribution network and field equipment outside substation is one of the cost effective option for maintaining continuity and reliability of the power supply to the consumers. R&M is primarily needed to arrest the poor performance of the substation equipment mainly transformers and switchgears which are under severe stress due to poor grid conditions, poor and inadequate maintenance and polluting environment. The methology of implementation of R&M and life extension schemes and the essential inputs required for its successful implementation have been suggested. 6.2 Need for Renovation and Modernisation The need of R&M of Electrical Equipment arises on account of : a) Deterioration in performance due to aging, poor maintenance etc. b) Deterioration in performance due to design deficiencies, pollution etc c) Non-availability of spares due to obsolescence. 6.3 Objective of Renovation and Modernisation. a) To arrest the deterioration in performance. b) To improve the availability, reliability, efficiency and safety of the equipment. c) To regain lost capacity d) To extend the useful life beyond designed life of 25 years. e) To save investments on new equipment f) To meet environmental pollution norms and to have more effective pollution control.

6.4 Methodology suggested for Implementation of R & M/Life Extension Schemes. The main steps involved in R&M and Life Extension of equipment are as under : a) Study of past performance data and review of O&M records e.g. loading conditions, number of trippings, failures, repairs/replacements etc. b) Assessment of present condition of the equipment to know the present health e.g. efficiency and other operating parameters. c) Assessment of remaining life of various components of the plant by conducting Residual Life Assessment (RLA) studies. d) Identification of components requiring replacements, repairs, upgradations/retrofitting. e) Formulation of R&M/Life Extension scheme covering complete scope of works. f) Implementation of R&M and Life Extension Programme on equipment to equipment basis. g) Replacement of equipment with latest state of art making new provisions as a modernisation process 6.5 Methodology for R & M 6.5.1 Electrical distribution equipment are generally designed for service life of about 25 years. Average life span of a distribution transformer and Circuit Breaker (CB) is about 25 years. Beyond this period they are not expected to render their services up to expectation with desired efficiency. However, certain equipment are found to operate satisfactorily even after the expected life span which may be attributed to good site conditions and good maintenance. But generally due to poor quality of raw material,

workmanship and manufacturing techniques or due to frequent system faults, over loading, environmental effect, unexpected voltage swings and over voltage stresses on the system during the operation, many equipment fail much before their expected life span. Moreover, due to the above cited reasons, the failure of vital equipment in Indian installations has become a regular feature and the high rate of failure has become a cause of concern for electrical utilities. 6.5.2 Hence the condition monitoring of electrical equipment in a substation is gaining importance. Assessing the condition of equipment is key to improving reliability. The knowledge of equipment condition helps to target the maintenance efforts to reduce equipment failures. Reduction of failures of equipment improves reliability and effectively extends the life of equipment. Hence utilities are continuously in search of ways and means other than conventional methods/techniques to assess the condition of equipment in service so that remedial measures can be taken in advance to avoid disastrous consequences thereby saving lot of valuable resources. Researchers and manufactures have come out with various condition assessment, monitoring and diagnostic techniques for various equipment to overcome the challenges faced by electrical utilities. The techniques so developed are grouped under Residual Life Assessment (RLA) techniques. The potential of such techniques is tremendous and their benefits are so much that utilities cannot ignore their importance in the present scenario. 6.5.3 The main objective of RLA is to determine the condition of a set of equipment (e.g. transformers) in order to identify the most vulnerable component/equipment. Based on the evaluation, utilities can develop a strategic replacement plan for a particular population of equipment in such a way so as to maximize the availability and utilization by avoiding

unexpected failures and at the same time minimizing risk. Strategies for life assessment are quite complex and involve many aspects(both user oriented and manufacturer oriented). 6.5.4 For assessing normal operation, strategic planning and scheduling, three major tasks need to be identified: Incipient failure detection and prevention-supervisory function, monitoring. Identification of malfunction or fault state- offered by diagnostic techniques. Planning for repair, replacement and upgrading-life assessment and condition evaluation techniques. 6.5.5 Basically electrical component deterioration phenomena are related to electric, thermal, mechanical, chemical, environmental and combined stresses. Hence, failure of equipment could be due to insulation failure, or thermal failure, or mechanical failure or any combinations. Technologies for condition assessment, diagnostic monitoring, preventive maintenance, predictive maintenance (PDM) have been developed for various equipment to reduce the risk of failure and to extend their effective life. Various condition assessment tools are used to establish the health of equipment using latest on line and off line diagnostic testing techniques/technologies. Some of the techniques/tools being used for detection of incipient faults in some of the vital equipment in transmission system are furnished below: There are no established guidelines for the time interval during which R&M and life extension studies must be carried out. The R&M and life

extension studies must be done when the performance of the equipment is noticed as deteriorating but not later than two years from the previous such study. Diagnostic Tools/Techniques for Distribution Equipment/material. (i) Distribution Transformers : Advanced techniques for transformer oil analysis e.g. Dissolved Gas Analysis (DGA)-can be an on line, Oil quality assessment- e.g. moisture content level, particle profiling(no. of particles), vibration measurement, infrared camera inspection(for detection of hot spot), turns ratio measurement, Recovery voltage Measurement(RVM) for monitoring of moisture level in paper insulation, resistance,Tan delta, and capacitance measurement of winding. (ii) Circuit Breaker: Contact resistance measurement, measurement of closing /opening time. (iii) Surge Arrester: Detection of 3rd harmonic component of arrester leakage current (iv) Cable: Built in microscopic sensors to locate an incipient fault before it happens. (v) Bushing: Dielectric loss angle measurement (Tan delta), leakage current measurement, capacitance measurement. (vi) Current transformer: Dielectric loss angle measurement (Tan delta), leakage current measurement (vii) Over head line insulation condition:

Leakage current measurement. (viii) Compression joints of conductor for over head conductor: Measurement of temperature by thermovision camera. (ix) Metal enclosed Gas Insulated switchgear: Opto-electronic arc detection, Partial Discharge measurement, measurement of temperature rise. 6.6 Renovation/Refurbishment of Energy Meters The energy meters can be restored back to near original condition by following process : Removal of rust, dirt and grime from the meter cover and base Painting, polishing and burnishing Replacement of broken or damaged terminal blocks/terminals burnt terminal blocks /terminals Insertion of missing screws Checking for the loose connections Testing of insulation of terminal blocks with 500 V DC Testing for dielectric properties with 2 kV a.c voltage test Replacement of all old worn out bottom bearings Checking the gear ratio of the register for tamper and replacement of tampered /damaged registers. Oiling of registers Checking the anti creep device and reverse stop device for proper operation Checking of brake magnets for alignments and loose magnets Recaliberation of meters Replacement of broken glass windows

 Replacement of terminal covers and sealing screws if found missing/broken Checking of gasket between base and cover and replacement Sealing of meters Replacement of meter itself, if found, unrepairable. 6.7 The second process of R&M activity is the modernisation. This includes replacement of equipment with latest state of art. Some of the modernisation activities are: Replacement of old conventional transformers with CSP transformers Provision of remote control in circuit breakers Replacement of MOCBs with SF6 type circuit breakers Conversion of old sub-station into GIS in densely populated area Replacement of electro-mechanical meters to high accuracy electronic meters Reduction of LT lines to bare minimum etc Use of Auto Reclosures Use of Sectionalisers Use of Automatically Switched Capacitor banks Use of Automatic Voltage Boosters Use of SCADA system Creation of data base for call management service Envisaging remote metering Use of Management Information System (MIS) Automation of the sub-station for load shedding However, cost of such modernisation activity is to be kept in view.

6.8 Essential Schemes.

Inputs for Implementation of

R& M/Life Extension

a) The officers and staff at sub stations normally remain busy in their day-to-day works. As a result, the R&M activity has not been taken up by any of the utility for distribution equipment. There is a need to set up separate dedicated R&M unit in each organisation with staff at their Regional office to deal exclusively with the R&M schemes. This will ensure timely completion of implementation of R & M programme. b) It is desired that a separate committee(Task Force) headed by a senior level officer of the rank of Member is formed in each SEB/Utility for expeditious implementation of the R&M Schemes . The Committee needs to be delegated adequate financial powers to place orders and take all policy decisions. This procedure will cut short the delays in taking decisions and thus reduce the time and cost overruns. c) In order to achieve the optimal utilisation of funds and efforts, it would be prudent if the sub station /Equipment wise approach is adopted i.e. all the works required to be carriedout on a substation /Field equipment to bring the equipment to its designed capacity and efficiency are planned together and implemented rather than taking up activities in a piecemeal manner. d) As far as possible, the overhauls/shutdown of the equipment should be planned in such a way that RLA studies and execution of works are carried out during overhauls so as to avoid separate shutdowns for carrying out these works. Proper planning of resources(man and

material) should be made to match with the planned shutdown of equipment for R&M works. e) In the event of unavoidable replacement of obsolete equipment, instead of replacing the whole lot, a part quantity of the equipment may be replaced with that of modern and better design equipment. The old equipment may be utilised as spares for balance equipment in service. f) Wherever possible, orders for a particular system with defined boundary conditions may be placed on turn-key basis so as to have single point responsibility on the bidder and to avoid problems of coordination/interface etc. g) In case a similar R&M activity is implemented at more than one power station of a particular Utility, centralised action for procurement of equipment could be taken to reduce the time and cost overruns as well as to avail concessional price for bulk order. h) Only well qualified and trained staff should be posted at the power stations. Also periodical training need to be imparted to the officers/staff for upgradation of their skill and knowledge in the technology being adopted in R&M/Refurbishment of the equipment and its O&M. 6.9 The importance of life assessment and condition evaluation techniques cannot be ignored in the present scenario. The techniques would help in taking remedial action before occurrence of fault, thus avoiding the costs associated with down time. In the process, the reliability of installations would improve and the failure rate would be reduced leading to saving of money and material (i.e. reduction of financial burden on utilities) This

would also help in extending the life of the equipment beyond their expected life span. Evaluation of the possibility of extending the service life of electrical equipment/machinery is a techno-economic compromise which must lead to run-refurbish-replace decisions. Once the expected service life period has expired, rehabilitation of such equipment falls within the life extension programme. The investment at the initial stage would definitely be very much pinching to the utility concerned as the devices to be installed in the system for RLA/condition evaluation purpose are very costly, but its intrinsic benefit is so much and the pay back period is so short that utilities would be encouraged to adopt the techniques in their installations at the earliest possible time on a wider scale.