MV Switchgear Maintenance

Basic Requirements for Developing a Condition Based Maintenance (CBM) Plan. Hardanjit S. Gosal
hardanjit@tnb.com.my
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Why do we need to maintain a switchgear?

To preserve its primary functions To improve its availability To extend its life or the lead time to the next failure To reduce the frequency of service interruptions and the undesirable consequences
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Maintenance has a major impact on Component and System Reliability

If too little is done
Higher number of failures Poor system reliability

If done regularly at fixed time intervals

Reliability will improve Cost will increase sharply

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Maintenance of Switchgears Deserves Special Consideration

Importance for routine switching Protection of other primary equipment & components under abnormal conditions May remain idle in either OPEN or CLOSED positions for long periods of time

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Examples of switchgear failures

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Examples of switchgear failures

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Examples of switchgear failures

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Examples of switchgear failures

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What is Condition Based Maintenance?

Also known as Predictive Maintenance It relies on knowing the condition of individual pieces of equipment It includes:
monitoring equipment parameters testing on a periodic basis and/or when problems are suspected Data analysis and data management
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What is Condition Based Maintenance?

Results in knowledgeable maintenance decisions which would reduce overall costs by focusing only on equipment that really needs attention

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Drawbacks:
Some parameters are very difficult and expensive to monitor It requires knowledgeable and consistent analysis to be effective Condition monitoring equipment and systems need to be maintained and calibrated
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In summary, CBM is:

A cost-effective maintenance scheme where System Reliability and Maintenance Cost are balanced. A methodology that comes under the broader approach of RCM
In RCM approach, various alternative maintenance policies are compared and the most cost-effective for sustaining equipment reliability is selected.

It is nearly impossible to apply a condition based maintenance program to the entire distribution network.
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Asset Maintenance Strategy

TNB Distribution Division strategy is a practical approach. It is a hybrid i.e. a combination of Condition Based Maintenance (CBM) and Preventive maintenance (PM). CBM will be applied to key and critical primary equipment that has an impact on system reliability such as:
1. 2. 3.

Power Transformers Switchgears MV UG Cable Feeders

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Asset Maintenance Strategy

PM will continued to be applied to:
1. 2. 3. 4. 5.

LV UG Cable Feeders LV Equipment LV OH Line Feeders MV OH Line Feeders DC Battery Banks

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How to initiate a CBM Program?

The migration from a purely PM program to CBM is not an easy one. Listed below are some basic steps that are required to initiate a CBM program: 1. Develop a master list of all primary equipment in your network 2. Prioritize the primary equipment based on their importance to system reliability 3. Group them according to voltage rating, type, manufacturer, age, etc
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How to initiate a CBM Program?

4. Determine the type & number of maintenance activities required and frequency using:
a. Manufacturer technical manuals b. Maintenance history c. Root cause analysis findings - Why did it fail? d. Good engineering judgment

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How to initiate a CBM Program?

5. Assess the size of your maintenance staff. 6. Identify tasks that may be performed by your operations maintenance personnel and those that can be outsourced to service providers. 7. Analyze equipment failure modes and effects (FMECA). 8. Identify effective maintenance tasks or mitigation strategies.
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FMECA
The FMECA (Failure mode, Effects and Criticality Analysis methodology is employed in TNB Distribution to identify potential failures. For the switchgear or system, assess the risk associated with those failure modes, rank the issues in terms of importance and identify and carry out corrective actions to address the most serious concerns: All potential failure modes of the various components of a system The effects these failures may have on the system How to avoid and/or mitigate the effects of the failures on the system

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Standards Related to FMECA

FMECA standards are: MIL-STD 1629 Procedures for performing a failure mode and effect analysis IEC 60812 Procedures for failure mode and effect analysis (FMEA) BS 5760-5 Guide to failure modes, effects and criticality analysis (FMEA and FMECA)
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Pre-requisites of FMECA
1. 2.

3.

Defining the system to be analyzed and dividing it into manageable units called functional elements. Collecting available information that describes the system to be analyzed; including-drawings, specifications, schematics, component lists, interface information and functional descriptions. Collecting information about previous and similar designs through interviews with design personnel, operations and maintenance personnel and component suppliers.

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Limitations of FMECA
In spite of being so popular FMECA also has downsides and they are: It is a tedious, time-consuming and expensive process. It is not suitable for multiple failures.

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Sample of FMECA
From FMECA: We identified the test techniques and technologies to be adopted for CBM of switchgears Developed Acceptance Criteria Developed a Switchgear Maintenance Manual Developed a Frequency & Maintenance Matrix

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What is in the manual?

Maintenance Management Categorisation of Assets Safety Procedures Life-cycle Maintenance Matrix Commissioning Procedures Maintenance Servicing Procedures Post-breakdown Procedures Test Equipment Requirements Data Analysis & Trending
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Application
Air Insulated Switchgear (AIS) VCB, OCB, GCB. Gas Insulated Switchgear (GIS) Ring Main Units (RMU) Oil , SF6. Outdoor Switchgear OCB, VCB.

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Servicing Matrix
No. Test Routine Diagnostic 1 Physical Audit Classification Advance Diagnostic In-house Out-sourced 2 IR Thermography

Ultrasound

PD Measurement

Gas Purity

TNBR Lab

Gas Dew-point

Gas Leakage

Contact resistance

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Servicing Matrix
No. Test Routine Diagnostic 9 Timing & Travel inclusive of first trip Vacuum Check Classification Advance Diagnostic In-house Out-sourced 10

11

Contact Erosion & Adjustment

OEM

12

Oil Dielectric

13

HV Dielectric Test

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Insulation Resistance

15

Tan Delta (DDF)

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CT & VT Test

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Servicing Matrix
No. Test Routine Diagnostic Classification Advance Diagnostic In-house Out-sourced 17 Mechanical Functional Check

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Electrical Functional Check

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Interlocks

20

Gas Pressure

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Temperature Scan

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CMMS
A computerized maintenance management system (CMMS) is a type of management software that performs functions in support of management and tracking of O&M activities. CMMS systems automate most of the logistical functions performed by maintenance staff and management. CMMS systems come with many options and have many advantages over manual maintenance tracking systems. A CMMS is being developed by TNB Research for TNBDistribution Divisions CBM Program.

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tnb distribution division : condition

based maintenance program

Module 1

Maintenance Action

Tracking and recording of all maintenance actions on each equipment

Module 2

Maintenance Manual

Repository of all maintenance procedures, manuals, guidelines etc.

Module 3

Test Results

Collation of all maintenance test results of all equipments

Module 4

Decision Support

CBM actions, determining maintenance intervals

Module 5

Maintenance Planning

Levels of authority
2

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Maintenance work orders (generated thru ERMS) Date / Time start / end Responsible person Standard templates for prescribed maintenance actions (maintenance test sheets) Findings Closing of maintenance work orders
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Related PSI documents Equipment Manuals Procedures Guidelines Standard maintenance practices across Distribution Division Stored in a central server and available on demand Linked to Maintenance Action Module
4

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Similar to Patients Medical Record Linked to Maintenance Action module Able to list categories, tabulate results Generate charts and graphs, look for underlying trends Used for technical analysis

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High level prognostic and diagnostic capability Evaluate what next scenarios Incorporate risk-based analysis Expert system capability Prioritise maintenance actions Make use of database of maintenance experience, previous test results, previous failures, maintenance costs etc.
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Linked to current ERMS SAP-PM Module List of possible maintenance actions Accept / Reject output from Decision Support Module Add maintenance actions (if required) Prioritise Maintenance Action Generate work order via ERMS

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azrin@tnb.com.my
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