HECS-130XXLp

GCB Customer Training (light version after Commissioning)

HECS-Systems (Standard execution)

Customer Training Light
© ABB Group
June 20, 2011 | Slide 2
© ABB Group
June 20, 2011 | Slide 3
Customer Training Light
Preface & Contents
Dear GCB user,
this customer training session given from our ABB Field Service Engineer gives you an overview of your GCB and makes you
familiar with the following main topics:
■ Product description & design
■ Operating modes & alarms
■ Interlocking system (only circuit-breaker)
■ Operating mechanism HMB-4 (only overview)
■ SF6 Gas handling
■ Maintenance concept
■ Identification & documentation
For your better comprehension of this document you will need the corresponding Breaker “Operation manual”.
Please note that this training doesn’t allow you to open the protection cover of the hydraulic drive HMB-4 and of the system.
ABB recommends a full GCB customer training session (two days) to enable you to handle the drive safely.
We will not accept any liability whatsoever for damage arising either directly or indirectly from incorrect operation of our
products.

Please contact the GCB Training Team for more information as given: GCB_Training@ch.abb.com

This training documentation is an extract of the corresponding product “Operating manual”. The “Operating
manual”, given to you with the product, overrides the instructions in this document.

© ABB Group ABB reserves all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without
June 20, 2011 | Slide 4 express authority are strictly forbidden. Subject to technical modifications without notice.
© ABB Group
June 20, 2011 | Slide 5
 HECS-130XXLp

GCB Customer Training (light version after Commissioning)

HECS-Systems (Standard execution)

Product overview
© ABB Group
June 20, 2011 | Slide 6
 Product description & design
Overview

Cover
SF6 Density indicator
& fill connection
(on pole frame)

Local control panel

(on control cubicle)
Main current path

Enclosure

Operating mechanisms
- Hydraulic spring drive HMB-4
Pole frame
- Slow drives

© ABB Group
June 20, 2011 | Slide 7
Product description & design
Operating mechanisms

Q82 Q91
Q81
Q0
Q9

Starting switch (Q91) Earthing switch, transformer side (Q82)

Disconnector (Q9) Earthing switch, generator side (Q81)
Circuit-Breaker (Q0)

© ABB Group
June 20, 2011 | Slide 8
Product description & design
Components inside the enclosure
Surge arrester

Current transformer

Voltage transformer

Disconnector

Arcing chamber

Capacitor

Starting switch Earthing switch

© ABB Group
June 20, 2011 | Slide 9
Product description & design
Components filled with SF6-Gas

 Circuit breaker
 Gas pipe
 Density monitor
 Density indicator

SF6 gas functions are: - insulation and quenching

- damping of mechanical forces
© ABB Group
June 20, 2011 | Slide 10
Product description & design
Protective earthing

 Two (2) possible earthing points: - 2 on the control cubicle (pos.1)

- 2 on the pole frame (pos.2)

Both, the pole frame and the control cubicle must be earthed separately.
Correct earthing of the product:
 Only one (1) earthing point of the control cubicle must be connected to protective earthing.
 Only one (1) earthing point of the pole frame must be connected to protective earthing.
© ABB Group
June 20, 2011 | Slide 11
 HECS-130XXLp

GCB Customer Training (light version after Commissioning)

HECS-Systems (Standard execution)

Operating Modes & Alarms
© ABB Group
June 20, 2011 | Slide 12
Operation mode, controls & alarms
Control panel

 Key operated interlocking switches

 Event counters

 Indicators for events & alarms

 LOCAL operating mode pushbuttons

© ABB Group
June 20, 2011 | Slide 13
Operation mode, controls & alarms
Mimic diagram of the control cubicle (standard execution)

LOCAL operating
mode pushbuttons

Key operated interlocking

switches S2
(LOCAL/REMOTE/LAMP TEST)
Operation counter Q0
(C-O cycles !)

Pump operation Indicators for

counter Q0 events & alarms
(motor starts)
© ABB Group
June 20, 2011 | Slide 14
Operation mode, controls & alarms
Alarms source (O&M, Chapter fault recognition)

SF6 – Gas equipment

Hydraulic drive

Control cubicle SDM drives (protections)

© ABB Group
June 20, 2011 | Slide 15
Operation mode, controls & alarms
Gas equipment

■ green zone (dot point): nominal SF6 pressure (620 kPa abs.@20°C)

■ yellow zone: alarm SF6 low density at 560 kPa abs.@20°C

■ red zone: alarm SF6 Blocking at 540 kPa abs.@20°C

Which alarm(s) could you get from the Gas equipment ?

 Density of the SF6 gas is correctly displayed if there are no temperature differences
between interrupting chamber and density indicator

© ABB Group
June 20, 2011 | Slide 16
Operation mode, controls & alarms
Hydraulic springs operating mechanism

Which alarm(s) you could get from the Hydraulic spring drive ?
Remark: supervision relays circuits are optional

 Blocking Close : The circuit-breaker can only perform only one opening operation.
 Blocking C & O : The circuit-breaker can not perform any operation (incl.protection trip II)

© ABB Group
June 20, 2011 | Slide 17
Operation mode, controls & alarms
SDM drives (protections)

Which alarm(s) you could get from the SDM drives (protections) ?

 The motor of an SDM drive has been overloaded.

 Possible reasons: -failure of power supply , -mechanical defect of operating linkage -motor defective

© ABB Group
June 20, 2011 | Slide 18
Operation mode, controls & alarms
Control cubicle

Which alarm(s) you could get from the Control cubicle ?

© ABB Group
June 20, 2011 | Slide 19
Operation mode, controls & alarms
Interruption and grounding (generator side)

 Interruption

1. Open Q0

2. Open Q9

3. De-energize the generator

4. Close Q81
G

Transformer side still alive

Q81

© ABB Group
June 20, 2011 | Slide 20
Operation mode, controls & alarms
Work on GCB system

Q81 Q82

1. Generator down and de-energized!

2. Transformer high voltage site disconnected and grounded
3. Close earthing switches Q81 & Q82

© ABB Group
June 20, 2011 | Slide 21
Operation mode, controls & alarms
SDM control panel

 Normal operation
- Access key: removed
- locking key for OFF position: inserted
- locking key for ON position: inserted
- switching position: ON or OFF
- hand-crank: looked
- knob: motorised operation

 Before any manipulation

- Generator: disconnected or shut down
- Transformer: disconnected or earthed
- SFC: disconnected or earthed
- Access key: required
- Work permit: required
© ABB Group
June 20, 2011 | Slide 22
© ABB Group
June 20, 2011 | Slide 23
 HECS-130XXLp

GCB Customer Training (light version after Commissioning)

HECS-Systems (Standard execution)

Interlocking System
(Only Circuit-Breaker)
© ABB Group
June 20, 2011 | Slide 24
Customer control & protection
Interlocking diagram

Q9 Disconnector Q0 Circuit-Breaker
Q82 Earthing switch T.side Q81 Earthing switch G.side
Q91 Starting switch

© ABB Group
June 20, 2011 | Slide 25
Customer control & protection
Circuit-breaker protection, Close operation

S2 in position REMOTE
Q9 Close
Q81 OPEN
Q82 OPEN &
Q91 OPEN (and)
Remote signal CLOSE
Q0 OPEN
Q0
>1 &
(or) (and) CLOSE
Hydraulic spring drive O.K.
(Blocking close not set)
S2 in position LOCAL
Q9 Open SF6 Pressure O.K.
Ext. Interlocking FREE & (SF6 Gas-blocking not set)
Push button SH11 (and)

© ABB Group
June 20, 2011 | Slide 26
Customer control & protection
Circuit-breaker protection, Open operation TRIP I

S2 in position REMOTE
&
Remote signal OPEN
(and)
Q0 CLOSE
Q0
>1 &
(or) (and) OPEN
Hydraulic spring drive O.K.
(Blocking open not set)
S2 in position LOCAL
&
Push button SF6 Pressure O.K.
(and)
(SF6 Gas-blocking not set)

© ABB Group
June 20, 2011 | Slide 27
Customer control & protection
Circuit-breaker protection, Open operation TRIP II

S2 in position REMOTE*
Remote signal OPEN &
(Protection trip) (and)
Q0 CLOSE
Q0
>1 &
(or) (and) OPEN
Hydraulic spring drive O.K.
(BLOCKING-O not set)

SF6 Pressure O.K.

(SF6 GAS-BLOCKING not set)

* The circuit-breaker is capable of performing opening operation TRIPII

independent from mode selection

© ABB Group
June 20, 2011 | Slide 28
© ABB Group
June 20, 2011 | Slide 29
 GCB Customer Training (light version after Commissioning)

Operating mechanism HMB-4

Overview
© ABB Group
June 20, 2011 | Slide 30
Components & function
Overview

Position indicator of the circuit-breaker

Inspection window for the filling

level of hydraulic oil
(max: middle, min: visible)
(Springs are tensioned !)

Inspection window for the spring travel

© ABB Group
June 20, 2011 | Slide 31
Components & function
Mechanical interlocking

The Close-position interlock, which in installed as an option, serves as protection of the circuit
breaker in on-position in case of a complete pressure loss by a defective drive.

The close-position interlocking must be activated, when the Circuit Breaker

is in operation

The mounting of the drive, manual switching during commissioning resp.

maintenance or repair and also tests for protection of the switching
device represent an exceptional state of operation.

© ABB Group Please pay attention during hand operation with the emergency lever.
June 20, 2011 | Slide 32
Components & function
Preventive maintenance (O&M HMB4 Drive, chapter 4.3)

Extended checks
It can be combined and executed during functional checks of the GCB System

- Pump motor counter (on control cubicle)

(Up to 10 pump starts per 24 h are permissible, even when the breaker is not triggered)

- Oil level

- Charging time of springs after Close-Open operation

(it can be compared with the Factory Acceptance Test value)

© ABB Group
June 20, 2011 | Slide 33 manipulation by trained personnel only
 GCB Customer Training (light version after Commissioning)

SF6 Gas
Handling & Safety instruction
© ABB Group
June 20, 2011 | Slide 34
SF6 Gas
Characteristic

SF6 Gas is under standard condition:

 Colourless

 Odourless

 6-times heavier than air

 Non toxic (in pure form)

 Dielectrically strength 3-times better than air

 Greenhouse Gas with a Global Warming Potential of 22’900

times than CO2 (compared on 100 years)

 Estimated atmospheric lifetime 800 - 3’200 years

 Working with SF6 section 3.5.2 of O&M

© ABB Group
June 20, 2011 | Slide 35
SF6 Gas
Declaring

Professional handling starts with correct declaring of the used bottles and container

New SF6 Contaminated SF6 C (>50ppm SO2)

© ABB Group
June 20, 2011 | Slide 36
SF6 Gas
Contamination

 Contaminated SF6 occurs under:

- Arcs (high temperature, > 500°C)
- Corona effect (partial discharges)

 Classes of gas quality

- Lightly arced SF6 - PD only
- Normally arced SF6 - normal operation (load switching)
- Heavily arced SF6 - interruption of rated or short circuit

© ABB Group
June 20, 2011 | Slide 37
SF6 Gas
Couplings
DILO-couplings are manufactured with nominal diameters DN 6, 7, 8, 12 and 20

Spring part Groove part

Coupling coupled
© ABB Group
June 20, 2011 | Slide 38
SF6 Gas
Gas re-filling device

(1) Pressure reducer

(2) Adapter DN8 / DN20
(3) 5 Meter tube
(4) Coupling DN 8
(5) Aluminium case

Case dimensions:
LxWxH: 475x380x125mm
Weight: 7,5kg
(3) (4) (1) (5) (2)
© ABB Group
June 20, 2011 | Slide 39
SF6 Gas
Re-filling during operation
3 1
ON
8  Due to cool down effect of
expanding gases the re-filling
process has to be done slowly till
the alarm “SF6 low density”
disappears.

6
4

 By “SF6 Low Density” signal ABB suggests to contact the manufacturer.

© ABB Group
June 20, 2011 | Slide 40
SF6 Gas
Disconnect the filling device
6

2
5

7
1

© ABB Group
June 20, 2011 | Slide 41
Avoid SF6 losses, leave SF6 inside the tube hose
SF6 Gas
Information

 As any pressurised gas, a sudden volume expansion results in a

local temperature drop and may cause freezing.

 Suitable gloves and protective goggles should be worn in case of

working with SF6 decomposition product

 All equipment and tools used during SF6 handling potentially

contain gaseous or liquid SF6 under high pressure. They should
be handled with care.

 Personal safety and protective equipment see IEC 62271-303

© ABB Group
June 20, 2011 | Slide 42
SF6 Gas
EU standard

 EC 842/2006 and EC 305/2008

 All people reclaiming and storing SF6 in the EU zone must

be certified according to EC 842/2006 and EC 305/2008.

- Punishment up to 50.000- € for the FS-man

- Plus a fine for the company

© ABB Group
June 20, 2011 | Slide 43
 HECS-130L

GCB Customer Training (light version after Commissioning)

Maintenance Concept
Periodic checks
© ABB Group
June 20, 2011 | Slide 44
Maintenance concept
Policy, principles, targets & benefits

Targets
 Retain or restore the product in its safe and functional condition
 Ensure the availability of the wear and tear parts for the life
time of the breaker (or beyond it) and the relevant service
knowledge

Benefits for customer

 A safe, reliable breaker in good condition
 Reduced risk of unexpected downtimes of the plant
 Reasonable costs for the maintenance

© ABB Group
June 20, 2011 | Slide 45
Maintenance concept
Maintenance Plan

Periodic checks Customised service

(Preventive Maintenance) (Preventive maintenance)

 Supervisory tasks  Mechanical & Electrical Inspection

 Routine checks  Analysis inspection (Travel-time, DRM)

 Functional checks  Check of logbook

 Prediction of remaining lifetime

Overhaul
(Preventive maintenance)

 Exchange parts
 Reconditioning

Repair
(Corrective maintenance)

Damage  Restore breaker functionality

Failure  Reconditioning
Other Events

© ABB Group
June 20, 2011 | Slide 46
 Maintenance concept
Service criteria

Mechanical based Time based

- Abrasion moving parts (slide bearing) - Aging (seals, isolators, guide ways)

- Wear (contact rings, contact fingers) - Diffusion (loss of grease or gas)

- Relaxation (spring, contact fingers)
- Vibration, shock, seismic
- Measuring accuracy (fuses, rupture disc)
- General expendable items
- Corrosion
- Mechanical friction parts

Cumulated current
- Burn off of contacts
- SF6 decomposition products

© ABB Group
June 20, 2011 | Slide 47
Maintenance concept
Service criteria HECS

 Mechanical based: 20’000 CO Operations (Circuit-breaker)

 Time based: 20 years

 Cumulated current: Σk factor (Irms) ≤ 20’000

© ABB Group
June 20, 2011 | Slide 48
Maintenance concept
Periodic checks, supervisory tasks
 Interval 1 day to …. interval (depends on operation)
 Group Operator (s)
 Unit in operation

 Tasks - Visual check of outside

- Alarm signals on control cubicle
- Counters reading (C-O operation, pumping & cooling system)
- Effective value of switched current (RMS-value)
- Calculation of corresponding ablation coefficient k
- Accumulated sum of k (Σk)

 Record findings in logbook or report form

 Compare results with criteria for overhaul
 Depending on results or, if queries arise:
- Contact manufacturer for advice
- Report deviations with report and photos to manufacturer

© ABB Group
June 20, 2011 | Slide 49
Maintenance concept
Calculation of ablation coefficient k (Example with HECS-80S)

 with k =
-1 if 0 kA rms ≤ I < 0.847 kA rms
- f (I)* if 0.847 kA rms ≤ I ≤ 150 % IC*
- 5000 if 150 % IC < I over-current

*IC: maximum operating current of system at 40°C

 As long as the sum Σk(I) is smaller or equal to

20’000 at least one (1) additional
over-current switching operation is possible.

Example!  As soon as Σ k(I) reaches a value greater than

20’000 the circuit-breaker must not be operated any
longer and an overhaul must be performed

 k = f (Irms) = 0.001298 • I 3 + 0.02846 • I 2 + 1.180 • I − 0.2056

© ABB Group
June 20, 2011 | Slide 50
Every breaker has his own k factor table !
Maintenance concept
Measuring of the switched current

 It is important to measure the rms-value of the switched current correctly

 Shortly before contact separation, the current may rise or decrease
 Therefore, the current must be measured just before contact separation takes place, typically during the last 2 cycles
before contact separation.
Instantaneous current

1 - Continuous current
2 - Interval for measuring
3 - Trip signal
4 - Contact separation
5 - Current interruption
Time

© ABB Group
June 20, 2011 | Slide 51
Maintenance concept
Logbooks

 Calculation of ablation coefficient k

 Accumulated sum of k (Σk)
 Evaluation of the remaining electrical life time of the contact system
(This file could be demanded to the ABB FSE)

 As events and checks log book an excel spread sheet is

recommended
 This enables everybody to find by graphical presentation in an
easy way any undue chance or increase of values before
reaching a critical situation
 Get the opportunity to plan an overhaul well in advance

© ABB Group
June 20, 2011 | Slide 52
Maintenance concept
Periodic checks, routine checks
 Interval 1 month to 1 year (depends on operation)
 Group Operator (s)
 Unit in operation

 Tasks - Repeat supervisory tasks

- Check SF6-gas density indicator
- Check oil level on hydraulic springs operating system
- Perform lamp test on control cubicle

 Record findings in logbook or report form

 Compare results with criteria for overhaul
 Depending on results or, if queries arise:
- Contact manufacturer for advice
- Report deviations with report and photos to manufacturer

© ABB Group
June 20, 2011 | Slide 53
Maintenance concept
Periodic checks, functional checks
 Interval 1 year
 Group Operator (s)
 Unit - Out of operation
- Generator, Transformer and SFC are disconnected / earthed
- IPB earthed
- Enclosure of product remains closed

 Tasks - Operate the circuit-breaker Q0 electrically from control cubicle

- Operate SDM drives electrically from control cubicle and
manually using the hand-crank from control panel
- Check heating system, illumination inside the control cubicle
and the cooling system (if applicable)

 Record findings in logbook or report form

 Compare results with criteria for overhaul
 Depending on results or, if queries arise:
- Contact manufacturer for advice
© ABB Group
June 20, 2011 | Slide 54 - Report deviations with report and photos to manufacturer
Maintenance concept
Customised services

May be carried out

- as a part of scheduled maintenance
- after the occurrence of an unpredictable event to verify the physical condition of the product

Verification measurement
Travel measurement vs. time
The result of a travel measurement vs. time is to verify the mechanical performance of the product.
The travel measurement vs. time is recommended for rarely switching products and after storage
periods of more than 12 months.

Dynamic Resistance Measurement (DRM)

The dynamic resistance measurement determines the ablation of the arcing contact material. It
can thus be used to verify the degree of ablation calculated by the ablation coefficient k

Extended functional checks

- gas equipment
- hydraulic springs operating mechanism
- heat pipes and temperature monitoring switches

Extended warranty

© ABB Group
Monitoring system
June 20, 2011 | Slide 55
Maintenance concept
Dynamic Resistance Measurement

Why is it important? - At an Overhaul you might see that the arcing contact has tracks of erosion.

- The arc contact is shorter and the nozzle is wider than at new condition.

- We know, that if the erosion is too high, the breaker will fail at interruption of
current.

 we want to know the length (condition) of the arcing contact without opening
the breaker to predict the remaining life time.

© ABB Group
June 20, 2011 | Slide 56
Maintenance concept
Dynamic Resistance Measurement

What is it? The Dynamic Resistance Measurement permits to define the overlap time
between nominal-contact- and arcing-contact system.

Commutation

Nominal current path Arcing current path

© ABB Group
June 20, 2011 | Slide 57
Maintenance concept
Dynamic Resistance Measurement

 The DRM determines the ablation of the arcing contact material

 It verifies the degree of ablation k calculated till this moment
© ABB Group
June 20, 2011 | Slide 58
Maintenance concept
Important

 Contact the manufacturer early enough to synchronize service and/or overhaul of the
product with the maintenance activities in the respective unit of the plant

 Our advisory services and information will help you to accomplish a smooth and rapid
overhaul

 Information to be submitted to manufacturer: - Installation name

- GCB type
- Serial number
- ABB order number
- Counters (GCB/pump)
- Ablation k Factor
Contact us:
24-hour call centre: +41 (0)844 845 845 - Number of short-circuit
Service mail: gcb_service@ch.abb.com

© ABB Group
June 20, 2011 | Slide 59
 GCB Customer Training (light version after Commissioning)

HECS
Identification & Documentations
© ABB Group
June 20, 2011 | Slide 60
Identification and documentation
Troubleshooting

 You can reach us around the clock (24/7)

 Hotline: +41 844 845 845 (Switzerland)

use “GCB” as keyword for the call centre

 The local hotline number you can easily find next to the rating plate of each breaker
- inside of the local control cubicle
- at pole frame

 E-mail: GCB_service@ch.abb.com

© ABB Group
June 20, 2011 | Slide 61
Identification and documentation
Documentation

 Plant specific documents

- Electrical diagram
- FAT 1HC…. – No.: ……..
- Dimension drawing Order - No.: ………..
- Nameplate

 General documents
- O&M Manual
Type and Components
- Erection manual

© ABB Group
June 20, 2011 | Slide 62
Identification and documentation
Rating plate information for identification (on pole frame)

Serial number

GCB Type

ABB Order number

© ABB Group
June 20, 2011 | Slide 63
Identification and documentation
Electrical scheme information for identification

Plant name

GCB Type

ABB Order number

© ABB Group
June 20, 2011 | Slide 64
© ABB Group
June 20, 2011 | Slide 65