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Optimized Design and Maintenance For Low Voltage MCCs PDF
Optimized Design and Maintenance For Low Voltage MCCs PDF
Authorized licensed use limited to: CURTIN UNIVERSITY. Downloaded on January 07,2022 at 01:07:37 UTC from IEEE Xplore. Restrictions apply.
II. POSSIBLE CAUSES OF MCC FAILURES III. HOW TO PREVENT MCC FAILURES
Most MCC failures occur after poor maintenance or The basic principles to avoid failures are the same ones
improper modifications. Fewer failures are due to original as you would apply to your car:
design or aging of the LV MCC.
1. Do it right first time.
Some examples of short-circuit failures (including Good quality lasts longer
internal arcing) during maintenance or when performing
2. Do not repair what is not broken
modifications:
Often a failure occurs when you leave the
1. Frequent racking in/out of starters and circuit garage
breakers 3. Do not touch what is working well
2. Poor workmanship Only replace when ageing is involved,
3. Modifications, not per design e.g. tyres, oil (only about 14% of failures
4. Poor commissioning relates to ageing).
5. Poor maintenance.
6. Operating outside design envelope These principles are included in the equipment
7. inadequate control of engineering changes strategies for LV MCCs to achieve high reliability,
availability and safety figures.
Ad 1. FREQUENT RACKING IN/OUT
To eliminate failures it is necessary to consider all
Starters and circuit breakers are designed for a limited phases of the MCC selection, installation and operation:
number of racking operations. Racking out for every 1. Selection of vendors
isolation can exceed this limit after a number of years 2. LV MCC specification
service. 3. Installation and commissioning
4. Personnel and training
Ad 2. POOR WORKMANSHIP
5. Ambient conditions and operating window
Loose connections, open or incorrectly closed covers 6. Preventive maintenance plan
(typically with missing screws/bolts) or worse 7. Management of change
unintentionally left parts or tools while re-commissioning 8. Repair standards
the switchgear.
Ad 1. SELECTION OF VENDORS
Ad 3. MODIFICATIONS NOT PER DESIGN
Vendors should be evaluated for the ability to meet the
Increases in load and/or increases of short circuit current. customer’s requirements. The selected vendors should
Changes in protective relay co-ordination. have at least successful track record in similar projects.
Typically this should include at least three recent
Ad 4. POOR COMMISSIONING examples.
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Ad 3. INSTALLATION AND COMMISSIONING
IV. MAINTENANCE STRATEGIES
Ensure that installation is in line with vendor
requirements. Ad 6. MAINTENANCE
The installation contractor should be familiar with make
and type of the LV MCC. Visual inspections are a key element in the
Ensure that all penetrations are closed. Especially maintenance strategy. Often abnormalities can be
unused cable entries, as ingress of foreign object, sensed by simply looking, smelling, or touching (after
rodents, moisture etc. are known causes for MCC's proving dead). In addition there are quantitative
failures. measurements such as comparison of load current of
Ensure that all main protective relays are tested with starter against its nominal rating, examination of counters
primary injection. Primary injection checks current showing the number of operations and hot spots (IR
transformer orientation and all the wiring, which can be scans) in cable compartments.
missed if only secondary injection testing is carried out. A more detailed inspection should be performed every
When the equipment is in use tests of protective relays Turn Around (typical interval 4-6 years), where starters
using secondary injection will be sufficient as no changes require a visual inspection and stabs are greased. The
in the LV MCC wiring or CT connections are expected. visual inspection should include looking for signs of
Ensure that maintenance personnel are involved during overheating, cracks, dust, condensation and similar
the installation works. Maximum benefit is gained if they abnormalities. The starter isolator (if fitted) is a safety item
are present during commissioning, ideally assisting the and should also be checked for correct operation.
commissioning engineer so they are involved and get an As the incoming circuit breakers or switches are
in depth understanding of the equipment. generally only accessible during Turn Arounds, an
For future reference and bench marking the test reports inspection of their mechanical parts is recommended.
should be available for maintenance personnel and site Every 10-12 years a check on busbar and cable
engineering. connections should be performed, e.g. by checking
torques. Checking torques more frequently will overstress
the connections and will introduce potential failures. An
alternative is low ohmic impedance testing of the busbar
systems.
Thermo-graphics can be a valuable tool to address hot
spots in a LV MCC. Undoubtedly valid for cable
compartments, where easy access helps to make a
proper inspection. Opening of live starters or feeders
requires safety precautions.
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mark should be the commissioning reports (FAT and such a system could be useful in identifying those drives
SAT). which are under the greatest stress from loading or
numbers of operations, hence those which deserve closer
Ad 7. MANAGEMENT OF CHANGE attention during Turn Around inspections.
Although it is outside the scope of this article, there are
A management of change procedure is essential for a other areas where intelligence can be made to work
reliable and safe operation of the LV MCC. harder by including monitoring of the motor as well as the
Any replacement which is not "like for like" should be starter.
subject to an engineering assessment. There are many A system combining both switchgear and motor
examples where even minor changes led to component monitoring with reliable indications would be a great step
failure or a failure to operate as intended. forward in allowing targeted and condition based
Any change in load should be reviewed as to whether maintenance rather than being mainly time based.
the change still fits within the operating window of the LV Currently such capabilities are only available from
MCC. If the knowledge to make this assessment is not limited number of vendors. Users should encourage their
available at site, then the original manufacturer should be preferred vendors to consider how they can apply
consulted to confirm loading will still be acceptable leverage from the presence of intelligence in the
Note that changes can also be procedural changes or a compartment to aid early identification of developing faults
change to the preventive maintenance interval. Both so there is a competitive market for this type of
should fall under the management of change process. technology.
Repairs or modifications should only be done by skilled An MCC reaches its end of life when spare parts are
personnel, usually from the manufacturer. not available and servicing is either impossible or
Modifications should follow the site management of prohibitively expensive. Typically it is when the mean time
change procedure. to repair becomes unacceptably long that action is forced
Prior to a repair the cause of failure should be upon the user.
addressed. The repair/modification should avoid a re- Provided that this condition is recognized, the low
occurrence of the failure. A root cause analysis of a failure failure rate normally experienced with LV MCC’s allows
might highlight the need to make multiple modifications sufficient time for alternatives for switches, circuit
not only on the directly affected LV MCC but also similar breakers, contactors and protective devices to be
switchgear elsewhere on the site. identified. However if attention is not paid to the
availability of spares, then it is possible to be caught out
and suffer extended outages or loss of service from a
FUTURE DEVELOPMENTS compartment.
With proper maintenance the copper, cabinets and
The introduction of intelligent motor protection relays insulation materials should remain in good condition and
offers the possibility of providing additional on-line do not suffer from age related defect mechanisms.
monitoring of the status of starters through trending However this statement is subject to caveats regarding
temperature rises and giving an alarm when these exceed heat and environment. Extended operation at or close to
expected values. Although an absolute temperature value the nominal rating of equipment will mean that the
may be used as an alarm, this assumes the starter is fully equipment will run “hot” and insulation may well start to
loaded. To pick up deterioration in more lightly loaded degrade once the design lifetime is exceeded. Similarly a
starters it would be necessary for an alarm to be raised simple mechanism such as rust due to extended
when temperature exceeds the normal steady state value, operation in a high humidity environment can fatally
which may well be below the maximum permitted weaken parts of the MCC structure forcing its
temperature in a lightly loaded cubicle. Any such system replacement.
should be capable of being set up to detect such changes As long as the function of the MCC does not change
as well as if the temperature exceeds the maximum significantly and the level of safety of the original design
permitted. is acceptable, the MCC can last at least for another
It is unrealistic to expect maintenance staff to be able to decade after the official obsolescence declaration.
closely monitor the performance of hundred’s of starters Also upgrades can be considered, as more modern
across a plant. So it is important that, in addition to the components tend to be smaller and functionality
measurements themselves, there is software capable of increased.
applying an intelligent filter to the output which only raises
alarms where they are real.
In fact it is the combination of the ability to measure
additional information about starter performance, together
with the ability to identify real problem areas, which will
make this technology really useful. In addition to heat or
voltage drops, other aspects such as number of times a
starter is withdrawn, numbers of starts / abnormal
numbers of starts per hour, number of contactor
operations or increasing levels of earth leakage current
before a trip value is reached, could be included in the
monitoring programme.
Even where alarm conditions have not been reached,
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Upgrade examples, installed at various petrochemical included, a higher safety, reliability and availability level
sites are: will be achieved.
VII. CONCLUSIONS
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In the future we hope there will be improved status VIII. REFERENCES
information available from the boards themselves through
condition monitoring but there will always be a need to PCIC PAPER BA-27 : Imcs versus conventional mcc -
combine this with traditional approaches and skills. are the benefits realised in practice?
After a long life time (exceeding 1,5 – 2 times the Graduated in 1985 from the HTS Hilversum, the
nominal design life time) the MCC will reach the End of Netherlands with a bachelor degree (ing.) in Electrical
Lifetime condition. Now it all starts all over again with Engineering specialization Telecommunications. From
specifying the right replacement material. 1987 he worked for Rossmark Watertreatment as a
process automation engineer and later he managed the
process automation department. In 1997 he joint Eaton
Electric in the role of application engineer/SCADA
specialist. After changing positions to Project Manager
and Export Customer Support Manager his current
position is Product Manager being responsible for the
marketing of LV MCC and Motor Management Systems.
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