66

TABLE 1.8
Failure Modes, Stressors, and Effects of Medium-Voltage Switchgear Relays
Component Material Stressors Failure Modes Effects
Enclosure Phenolic, Lexan, Elevated temperature Corrosion Loss of structural integrity
aluminum, steel
Moisture/humidity Oxidation Dirt/moisture intrusion into
internal components
Mechanical stress Cracking of welds
Seismic/vibration-induced
damage
Coil wire Polyamide/polyimide Elevated temperature Embrittlement/cracking of Loss of dielectric integrity
insulation, copper insulation
magnet wire
Ohmic heating Corrosion/oxidation
of wire
Moisture/humidity
Coil spool Zytel, Nylon, Lexan Elevated temperature Aging/cyclic fatigue, Improper operation of relay
wear/loosening
Mechanical stress due to
cycling
Coil coating Polyester or fiberglass Elevated temperature Embrittlement/cracking Improper operation of relay
tape varnish
Ohmic heating
Contacts Silver Electrical arcing/cycling Pitting Increased temperature due
to high resistance
Electrical overload Corrosion/oxidation Improper operation due to
misalignment of contacts
Moisture/humidity Chatter-induced damage
Electrical Power Equipment Maintenance and Testing
 Vibration Bending/twisting of
linkage
Mechanical stress
Contact Phenolic, Zytel, Mechanical stress due to Embrittlement/cracking Improper/loss of relay function
carrier/arm Delrin, Nylon cycling
Distortion
Coil lead wires Teflon, silicon rubber, Electrical cycling Embrittlement/cracking of wire Improper/loss of relay function
capacitors Tefzel, insulation insulation
Electrical overload Degradation of fuses
Elevated temperature Wear/loosening of
connections
Moisture/humidity
Vibration induced
Slip motor Bronze, copper Moisture/humidity Corrosion/oxidation Improper/loss of relay function
rotor/bearings
Maintenance Strategies, Dielectric Theory

Mechanical stress Bending/twisting

Damping Magnetic steel Moisture/humidity Corrosion/oxidation Improper/loss of relay function
magnet
Mechanical stress
Timing motor/ Magnet wire with Elevated temperature Embrittlement/cracking Loss of relay function due to
bearings formal varnish of winding insulation shoring of motor windings
Moisture/humidity
Cams Delrin, Metal Moisture/humidity Corrosion/oxidation Improper/loss of relay
function
Timing Silicon rubber Elevated temperature Embrittlement/cracking Improper/loss of relay
diaphragms function
Mechanical stress due to
cycling
67
 68

TABLE 1.9
Failure Modes, Stressors, and Effects of Medium-Voltage Switchgear Bus
Component Material Stressors Failure Modes Effects
Conductor Aluminum copper Moisture/humidity Corrosion Loss of structural integrity
Elevated temperature Oxidation Loss of electrical continuity
Vibration Cracking of welds Reduced electrical clearance
Electrical transients Seismic/vibration-induced
damage
Distortion and displacement
Enclosure Aluminum polymers Moisture/humidity Corrosion/oxidation Loss of structural integrity
Vibration Cracking of welds Short circuit to ground
Degraded cooling capacity
Insulators Porcelain polymers Humidity/moisture Oxidation Loss of structural integrity
Elevated temperature Embrittlement/ Fault to ground
cracking
Vibration Displacement
Electrical transients
Electrical connections Copper, aluminum Elevated Corrosion and Fault to ground
phenolic, porcelain, temperature oxidation
polymer insulators
Ohmic heating Cracking of insulators and Loss of function of load
welds
Moisture/humidity Seismic/vibration-induced
damage
Vibration Loosening of parts
Electrical transients
Electrical Power Equipment Maintenance and Testing