8 Maintenance 8 Maintenance 8.1 Introduction General Instructions ‘These maintenance instructions give recommendations for care and guidelines for ‘maintenance of high-voltage circuit breakers, The instructions are divided into: + Inspection intervals + Instructions for preventive maintenance of circuit breakers + Instructions for preventive maintenance of operating mechanisms ‘The periodic maintenance is to be carried out at specified time intervals or number of ‘operations. Equipment is to be overhauled in line with specified criteria such as a certain number of operations. Overhauls are to be made by authorized service personnel. TASBIDOET Gen oID0S 7078 Maintenance 8.2 Description of maintenance categories Maintenance categories Action/explanation Interval Condition of Requirement Circuit breaker 'B Preventive maintenance i + General overhaul of circuit 15 years or 5 000 breaker and operating mechanism Perations + _ Heat measurement Overhaul of breaking chamber ct a Overhaul of line and transformer circuit Enxi2=20 000 breaker ‘Overhaul of capacitor bank circuit breakers, reactor cicult breakers and fiter circuit breakers + Without pointion-wave control 2,500 operations + With point-on-wave control ) General overnaul ‘After 30 years or dt a 40 000 operations 7) Explanations Maintenance, circuit breaker pole on page 116 . 2) Special requirements for resistance checks for circuit breakers; executed >100 Close and tripping operations per year. Condition of circuit breaker The following specifies the condition in which the circuit breaker should be for the various, maintenance activities. + al) circuit breaker in operation. + 1) Closing spring discharged, circuit breaker open, disconnected and earthed. If heat ‘measurement is part of the maintenance activity, this should be done during normal load before the circuit breaker trips. + cl) Closing spring discharged, circuit breaker open, disconnected and earthed. The circuit breaker poles/breaking units are dismantled and transported to the workshop. + dl) Closing spring discharged, circuit breaker open, disconnected and earthed. The entire circuit breaker with operating mechanism is transported to the workshop. Competence requirements ‘The following describes the necessary requirements for personnel carrying out maintenance work. *+ a2) substation personnel without special training. + b2) personnel authorized by ABB to carry out assembly, commissioning and maintenance work. + ¢2) personnel authorized by ABB to carry out assembly, commissioning and ‘maintenance work. In some cases support may be necessary from ABB. oo) D2OET THSBADOOSE Sen NOAA AAA AAA Ae.8 Maintenance 8.3 Maintenance schedule General The following inspection schedule includes important control points, acceptable tolerances, functional values for certain adjustments and recommended inspection intervals. In corrosive or polluted air and in climates with high humidity, it may be necessary to half the inspection interval. The specified inspection intervals are o be regarded as recommended guidelines that er be extended or shortened depending on local conditions. ficance of the various categories are explained in section Description of maintenance categories on page 108. Category A Maintenance category A takes place at an interval of 1-2 years Inspected Action | circu breaker ‘Check: : | Exterorcleaningon page 118 and Gas nal cleanin | == Bene teenies | systom and density moniter on page + Heating element function | 10 | + Gas pressure No special tools needed +_Valves and draining holes Category B Maintenance category B takes place at an interval of 15 years or 5,000 mechanical close/open operations. Inspected ‘Action Instructions/Tools ‘ireut breaker ‘Check: This is covered in section: ‘ Exterior cleaning on page 118 and Gas nin | External cleanness system and densily monitor on page 10 + Gas pressure [No special tools needed. + _Valves and draining holes Operating ‘Check: mechanism eden + Heating element function + _Oilleaksfror Rating plates Note serial number. — ‘Operation counter | Note the number of operations. ‘SF 988 ‘Check ean ‘See Gas fling with SF6-goson page 91 necessary) Dew point meter. + Dew pint fornorna ges |D2W/Pont ma, °C at specie ng pressure in the circuit | Pressure an breaker. insulators | Check: Wash and dry the insulators. pris andais Rinsing equipment, drying cloths, torque wrenches. This is described in Exterior cleaning on age 118 THSBADBOEE Sen 201205 7058 Maintenance Inspected ‘Composite insulators Main circuit Heat measurement Mechanism Function times Action Check: Check: Check: (Check: Resistance measurement Resistance bridge, using a test current of 200-400 A oc Instructions/Tools Resisiance values as epedfedin secon Operating values on age 4, Intho case of reat breakers wih a lood Curent of ss than 400 A reltance | ate of upto 1000 uOhm is permite per [Beata | Caries out at ced pir to | disconnection of the circuit breaker. The temperature increase | In the outer parts of the breaking unit, Reference hole in outer lever and mechanism housing Opening time Closing time Close-Open time Deviations betwee. phases Auxiliary switch Travel curve Contact damping The highest permitted temperature difference between the phases is 5°C. Thermal camera. Consideration must be taken to the load Current during measurement, both to the larger variations ofthe load current 3-4 hours prior to measurement. See the ‘manual forthe thermal camera, ‘Measuring with electronic timing, [Nominal control voliage For times, see Operating values on page 44, ‘Maximum time deviation between the phases, 4 ms at closing and 3 ms at opening, 70 DODO THSBADGOGE Ten QANNNNNNANNNRAANNANNKHNANHRNAANNnANNnnnnnnnnnen.8 Maintenance [Action | Instructions/Toots Rod aystem oe Check ot hteing torque for nus inthe tod eyo * Control safety ‘See Fitting of rod system on page 71. + Astipumping relay Control satety: Measurement of minimal contel votage Closing cot < 85% IEC (<72% ANS) of nina value Tepping ol < 70h ee (£864 ANSI) of anal value Variable Deswotage unt _antipumpng rte: Wit he cut breaker in Open poston andthe operating mechanism charged, 8 Simultaneous Close and Open operon s produced (Chae buon presse), |The cic breaker aries outa Closer | | Open operation and must not Close when | the operating mechanism is charged. The ant-pump funeton must be activated along asthe dose impulse lasts, The ‘owes contol vatiag stobe measured for the rely (85 of tomna) FT motor eurent must be measured towards to ond of he charging process The maximum permite motor currents 110 %oftremaasuroment valves recoved dhtng route lots, “The permitted variation in charge ie is 30% ofthe measurement valve obtaned ding routine tests. The moto must be abet charge the Sorings aa minimum of 85% of nominal votage (as par IEC) | | see inspection o dive unt on page 123 Lath doco Vaal inepesionfestinas For vetioatgan te a even ae ‘Soriaces on Shas and atsne te ‘overs ving renner See wean "Types of graze on page 37 oa ~The col resistance and curentsalowed Col Check The col resistance and curtis ol to vary £10% ofthe measurement vale Obtained during rouine test init eich Function contol Inthe final phase ofthe charging proces of ue the spring, the closing circuit must be Cloeed before cating the motor curt See Check oft atch end aury contact on page 128. “Motor current + Motor current + Coil resistance and current + Rasistence measiremant [spercabie. ‘See fspection orheadng efementon page 122, , THSBAT05- Sen 2012-05-11 Tr8 Maintenance Instructions Tools Small cabinet: 48 W, HOV R= 330 ohm 210% |48.W, 220 Re 1000 ohm 210% “Medium-sized or large cabinet: | 140 W, 110V R= 86 ohm 210% Inspected Central control cabinet (f applicable) + Resistance measurement ‘Check that the thermostat is adjusted to ‘comply with the set value Pre-commissioning check lston page Thermostat (if applicable) 104. ‘Check that bolts and clamps are property tightened. “Terminal blocks | Check the signal for voltage drop, if any. switch ‘Check the density monitors as regards pressure indicator and signal/break contacts. + Signal for voltage drop ‘Check: + Density monitoring SealsiSFe gas NoTE! ‘The test must take place in normal ‘conditions, +20 °C and 101.3 KPa (1,013 mbar), | Remove the density monitor from the | Sreut eater check he tuncton, Minimum permed voltage when | hocking 20 See Assen of gas montoringsysomon eo _|page 78 Blocking relays ‘Check: | |The relays must break when a denaty |Inontor's moved fom a creat breaker pote, pressured a ling pressure, Nore! May ony be cared out when te ccut + Relays Corrosion Check: : a Make a special check ofthe protected Operating mechanism | components inthe unheated areas, pull- rod system, forks and springs Treat wih ane-ust agent where necessary. See Cleaning, ubvicaton, and rust protection of operating mechanism on page 121 Lubrication Cheek: Chock and ubriate the latches using | | grease“ | CCheck and lubricate the worm gear using | + Worn gear grease "M" i Dae TASBADGS Sen DAHAHAAHANAAANHAAAAAAANDRAAAAANAnnnnAction Inspected Tightening torque | Check: ‘Cheek ‘Operation Al bot joints 8 Maintenance InstructionsrTools | Check the tightening torque on all bot |ioints See Tight 40. ‘Operation ination (if possible) with operating time measurement (inc ee eat ‘open/close operation time). + Operating time measurement Category C Intra Instructionsools “Overhaul of Breaking un Instructions: = Line and transformer circuit 0.000 | Evacuate the gas, dismante the cuit breaker breaker poles and transport to clean | workshop. Dismant the breaking chamber | “insulator ft anew contact set and new PTFE - Capacitor, reactor and fiter “components. circu breaker | equipment: + without pointonave |2,500 operations. | Standard equpment ht ting face mask or contol dust protection, long sleoved overal, «ain peanton-wio = [1p protective gloves of plastic or rubber. contol See Ovortaulof breaking unit on page 151. AAltypes of maintenance During diagnostic testing with non- | oe [contortion e - Overhaul of complete creut | 80 years or 10,000 | Dismanting of cru breaker pole and breaker and operating mechanical lose! | mechanism. Assembly of nw contact set mechanism ‘Open operations | Replacement o ther worn components, [ihe cet breaker andthe operating | mechanism are being overhauled fora further 2,000 operations, all wear parts must be replaces | Ifthe circuit breaker and the operating mechanism are overhauled fora further 40,000 operations, the entre cel breakeris | to be reconditioned [Protection against crevice products as per standard equipment above Instructions: See chaptor Overhaul on page 196. For operating mechanism, with instructions 4 guidance from ABB ” See Maintenance, circuit breaker pole on page 116. FSET Ten WET 738 Maintenance 8.4 Maintenance, circuit breaker pole 8.4.1 The service life of the circuit breaker General Assuming that the recommended inspection intervals and actions have been observed, the circuit breaker will have a service life greater than 30 years or 10,000 mechanical operations. Maintenance points ‘The following points ensure a long service life Maintenance points breaker Bearings in the 4 [The seals are designed with a double sealing ring Opening the breaking unit In general there are only two reasons for opening the breaking units: 1 Ifthe number of shor-circults x short-circuit current (KA) approaches the curve, see figure No. of __operations on page 117. 2 Ifthe number of operations atthe line, reactor or capacitor connection, as well as the switching of load current’) has reached the number under the heading "Interval in Description of maintenance categories on page 108. ') The load currents from normal Close and Open operations are not calculated in the formula. ‘These are only calculated when counting the total number of mechanical Close and Open operations. ‘Another reason for opening the breaking units is limited to mechanical faults/faulty adjustment of the drive system, that could damage the components inside the breaking units. NoTe! A Opening the breaking unit calls for special instructions and may only be carried out by qualified and authorized personnel. Calculations ‘The graph that shows the restriction to the number of permitted short circuits can be given roughly as Formula Explanation Enx l= 20000, ‘n= number of short circuits |= short-circuit current KA (RMS) In the formula, all levels of short-circuit current are included. E.g. 10x307+20x207+20x10" = 19,000. WT Dia THSBA20054-G0n ONAAAOAAAAAADAAAAAAnnnnen Nannnnnnnnnn8 Maintenance 8.4.2 The service life of the arcing contacts in the event of short circuit breaking The diagram shows the number of breaks asa function of the breaking current that the contacts {n a circuit breaker can undergo before burn-off is so great that they must be replaced. Wo. of operations — 5000 2000 1000 500 20 30 4050 63 c002855 1n__|No.of operations Short-circuit current TASBAROS en DODO TS8 Maintenance 8.4.3 Cleaning and lubrication of circuit breakers Exterior cl The circuit breaker's porcelain insulators are to be cleaned of salt and dirt deposits in connection with cleaning of other insulators in the substation. The time interval for this cleaning depends on local conditions, ie. the degree of air pollution. ‘Wash and dry the insulators using rinsing equipment and drying cloths. WARNING! A Work on the circuit breaker when there is a risk for mechanical damage to the insulators is to be executed at reduced gas pressure, 0.125 MPa (abs) NoTe! FD acest wit ein ints complet west ite ii breakers in use can be cleaned using water without any tisk of moisture penetrating and damaging important parts. Composite insulators do not normally require cleaning. Solvents or water rinsing with high pressure could damage the silicone surface on the insulator. Cleaning the mechanism hou: 9 Clean the mechanism housing where necessary through vacuuming. The time interval for this cleaning depends on local conditions, i.. the degree of air pollution. Lubricant Only use lubricants recommended in section Types of grease on page 37. This important at temperatures below -25°C. particularly Lubrication of circuit breakers The circuit breaker bearings are lubricated with grease on delivery and do not normally need to be lubricated other than for larger overhauls. See Treatment of sealing surfaces and seals on page 161 Rust protection ‘The closing springs are surface treated through manganese phosphating agent and anti-rust protected by being dipped in oil. The trip springs are anti-ust protected with two-component paint. See Rust protection on page 134. Te DOID0S-TT THSBADOSE SER8 Maintenance 8.5 Maintenance, operating mechanism and link system 8.5.1 Preparatory measures and overview of the operating mechanism General This section describes the actions that mustican be made prior to commencing maintenance work. WARNING! A Do not operate the operating mechanism without a load! Operation must not be conducted until the device has been connected and adjusted as appropriate for the associated pressurized circuit, breaker, Operating mechanism ‘The components in the operating mechanism are integrated into a cabinet that also contains an control panel with control equipment. cooert4 1 {Drive unit 2 [Mechanism 3___ [Control pane! 4 [Closing spring ‘5 [Heating element THSBADOEA en DID0S- 78 Maintenance Control panel co076a Control pane! [Control switch, Close/Open Switch, LocalRemote/Disconnected ‘Spring indicator Protective motor switch Before commencing maintenance the following must be done: Action Note 2. Disconnect the motor curent using the [protective motor switch, 3. Perform a close-open operation o ensure that the operating mechanism spring discharges. 4. | Cut the control voltage and where necessary the heater votage os wel 5. Disconne rth, . 1 Move the circuit breaker tothe open position. To facilitate maintenance, the following can be performed: Action Remove te top ofthe operating cabinet. = _ 2. Open the control panel. Tt ie DORIS THSBADSISS Sen8 Maintenance 8.5.2 Cleaning, lubrication, and rust protection of operating mechanism Safety - = 7 WARNING! A ‘Work on the operating mechanism with the circuit breaker in closed position and charged springs always represents a risk. Its therefore important to observe the safety instructions before commencing work, See Hazardous working situations on page 28. Lubricant - - ‘The table below shows the greases and oils that are needed for this maintenance. For suppliers and trade names of oils and greases, see sections Oil types on page 35 and Types of grease on page 37. Lubricant 5316 381-4 [ss 36t - — +HSB875318-C Cleaning _ 7 Clean the operating mechanism and mechanism housing where necessary through vacuuming. The time interval for this cleaning depends on local conditions, ic. the degree of air pollution. (Check thatthe filters in the valves are clean, Replace them if they are overly dirty. Lubrication - - The operating mechanism’s ball, roller, and needle bearings and worm gear are permanently lubricated and require no maintenance. Shafts in latch devices are to be lubricated with grease "L"; see Maintenance schedule on page 108. AS part of the overhaul, the slide surfaces for the damper are to be lubricated with grease "G" ‘The dampers are filled with “S” oil on delivery. Rust protection On delivery, the operating mechanism is treated with desiccant as transport protection against moisture, Despite good anti-rust treatment, minor corrosion may occur, particularly if the circuit breaker is installed in a highly corrosive environment. Rust spots must be polished off and new anti-rust agent applied, see Rus? protection on page 134 Spare parts Spare parts must be stored indoors in an approved storage area!) and in original packaging. ‘This applies especially to rubber components (seals etc.) that must also be protected against sunlight to prevent drying out. Gaskets can be stored only for a limited period, so avoid stocking them. Supports ean be stored outdoors D Approved storage areas: Roof, solid ground, sir huamicity below 50%, temperature 420°C (410°C), TASBA200543en DIRS 78 Maintenance TD DODO THSEA2OGSESen8 Maintenance 8.5.3 Inspection of heating element Operating mechanism is fitted with a heating element to prevent moisture, and this must always be connected. Heating element conaTe6 v 1__|Heating element Instructions Action Note 1 Measure the element's resistance in order 10 element intact 2. | Measure the power supply to the element Data 7 See se Heating element on page 23 for values. ‘The 70 W heating element is always connected, while the 140 W or 2x 140 W heating elements, for temperatures below -25°C, are thermostat controlled. THSBADIOEE en 2OIZ0ETT Tai8 Maintenance 8.5.4 Inspection of drive unit General This section describes how to check the drive unit, and overhaul of the motor. Drive unit cooze19 Closing lever Roller Bolt MGX75 (2 pos), washer 6.4x12x1.5 (2 pes) Drive unit, Requisite equipment Equipment Part number Note “Standard tools : Locking fuid Torque wrench : 269 0014-408 ir DIDO THSBA20GS4 Sen