Alstom Grid Services. Circuit breaker lifecycle management GRID

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1 Alstom Grid Services Circuit breaker lifecycle management GRID

2 Circuit breaker services A COMPLETE RANGE OF SOLUTIONS In today's complex environment, energy players face growing demands to improve energy efficiency while reducing costs. Energy shortages and increased ecological awareness have resulted in great expectations for grid stability and reliability. Utilities and industries need to find eco-efficient solutions to maintain secure, safe and uninterrupted operations. Circuit Breakers automatically protect installations against phase-to-phase short circuits as well as phase-to-earth short circuits. i Combining the expertise of a global manufacturer with local proximity centres, Alstom Grid is the best partner for High Voltage products asset management all along the circuit breaker's lifecycle. With more than 60 years of worldwide experience dedicated to live tank, dead tank and generator circuit breakers on legacy products, we provide customers with a full range of services on the three different types of insulating technologies: minimum oil, air blast and SF6 circuit breakers. Investing in quality, innovative equipment that optimises your electrical structure and heightens your return-on-investment is essential. Once the equipment is purchased, you need to ensure that it continues to function optimally throughout its lifetime. " 2 Who better to trust than the manufacturer you purchased the equipment from in the first place? " PRODUCT LIFECYCLE MANAGEMENT - p.4 Condition based maintenance Technical training and competence development SF6 management Based on our manufacturing expertise and time-proven refurbishment experience, Alstom Grid offers the most cost-effective and efficient solutions to increase the life span of your circuit breakers and generator circuit breakers. From onsite assessments, periodic inspections, mid-life overhauls through to complete life-extensions, we can customise the most appropriate program for your circuit breaker type, age and ratings. Our technical specialists take care of your assets and we make sure that all quality and safety regulations are met and respected. Our services include: Network consulting Erection, commissioning and supervision Long-term operation and maintenance contracts Renovation, modernisation and extension Maintenance, repair, emergency support Spare parts and strategic spare parts management Technical training and competence development program RENOVATION, MODERNISATION & EXTENSION - p.8 Circuit breaker upgrade examples Make your equipment smarter and more sustainable based on fieldproven expertise At Alstom Grid, our mission is to ensure that your energy network is reliable, efficient and environmentally-friendly. We leverage the technical know-how of our equipment design and manufacturing engineers into customised service solutions. An efficient, proactive monitoring system combined with Alstom Grid s expert services team is the best way to prolong equipment life. Our condition monitoring services can drastically reduce the risks of failure. Our global services teams bring you innovative technological solutions to keep your circuit breaker equipment up-to-date, safe, reliable and efficient. Asset management optimises your infrastructure performance while keeping your operating costs under control. Alstom Grid local services units around the world are managed by strict quality management systems and fulfil the requirements of ISO 9001, environmental standard ISO and OHSAS LONG TERM MAINTENANCE - p.10 Maintenance recommendations per type of circuit breaker Outage and maintenance durations

3 Circuit breaker models Alstom Grid is one of the top three circuit breaker suppliers with its live tank, dead tank and compact modules, ranging from 36 kv to 1200 kv. The complete product portfolio can answer any customer need, including power generation with our generator circuit breakers for installations up to 50 kv MW. Alstom Grid offers services for all legacy circuit breakers and third party. Live tank (LT) Live tank circuit breakers benefit from three-pole application and one interruption chamber arranged in the insulator, which can be either porcelain or of a composite material. The enclosure that houses the contacts is energised. Live Tank design includes three main types: Air: pneumatic mechanism Oil: Spring or hydraulic mechanism SF6: Spring or hydraulic mechanisms Models: FG1, FL, FX, FXT, GL, H, HGF, HPF, HPGE, S1, S2, S4, PK Dead tank (DT) Dead tank circuit breaker's contact enclosures are not energised and are connected to the ground grid. The live parts are located in a metal tank filled with SF6. The gas plays the role of quenching agent as well as insulation of the live parts. Models: DT, FK1, FL1, HGF Generator circuit breaker (GCB) Generator circuit breakers for power plants are designed to be connected directly to the bars linking the generators to the step-up transformers. They use the proven technique of compressed air or SF6 gas. They are equipped with a fully natural cooling system, ensured by an external heat exchanger using natural convection phenomena for SF6 cooling. Generator circuit breaker's design includes two main types: Air: pneumatic mechanism SF6: Spring or hydraulic mechanism Models: FKG1, FKG2, PKG Compact SF6 Alstom Grid's compact module is named HYpact. This hybrid compact switchgear assembly is composed of three separate gas tanks with all switching devices located in the SF6 gas compartment. It offers optimum interference protection, a highly reliable spring-operated mechanism and space savings. Different configurations are available from circuit breaker alone to circuit breaker and disconnectors, voltage and current transformers. Models: HYpact 3

4 PRODUCT LIFECYCLE MANAGEMENT Taking care of your equipment components is essential to keep your assets safe and reliable. Alstom Grid offers comprehensive services to support you in getting the most of your assets. Customer challenge Circuit breakers have been designed to optimise the reliability and efficiency of operating networks. Operators require efficient solutions to avoid unscheduled downtime, major failure and the subsequent penalties. Alstom Grid solution Alstom Grid offers complete services to cover all operation and maintenance needs for their customers to get the most of their assets and investment. Based on our manufacturing experience, Alstom Grid proposes efficient and customised solutions to increase the life of the circuit breaker according to the type, age and ratings. From network consulting and planning to operational implementation From asset diagnostic to condition-based maintenance From emergency support to full operation and maintenance From training your engineers to customised competence development programme Project design Whether for new installations or to improve the efficiency and performance of existing equipments, Alstom Grid offers an integrated range of consulting services: System planning and analysis Transient stability analysis Dynamic interaction assessment and reliability studies Our network consulting experts allow you to anticipate future challenges, for a sustainable network as well as equipment reliability and performance. Erection and commissioning Our local teams ensure that the asset is erected, tested and commissioned according to our state of the art standards. Our certification process, based on on job coaching guarantees the same high level of quality anywhere the asset is installed. Maintenance and repair In order to optimise equipment uptime, Alstom Grid offers maintenance and repair operations. Our local teams cover all needs: From single inspection to long term operations and maintenance partnership From emergency support to predictive maintenances Maintenance and repair plans must be carried out by a qualified Field Service Engineer with the prerequisite technical level. Our local teams support customers in emergency repairs, in time-based, predictive and corrective maintenances. According to the situations, necessary repairs are conducted. When a replacement of the current asset is the best available solution, our specialists can propose replacement by the very same equipment. Service teams can also provide equipment-upgrading solutions to keep assets up-to-date with the latest technological benefits. Spare parts management Although some parts have a mainly supporting role, they are vital for optimal operation. Any problem associated with any pieces of equipments can result in damage or failure of the equipment. Alstom Grid proposes strategic spare parts to avoid risks. It is also necessary because urgent corrective maintenance is very costly, due to rush production and transportation costs. Replacement lead times can sometimes take months, causing penalties or loss of revenue. A strategic spare part stock focuses on main and critical components, such as hydraulic rams, interrupting chambers, supporting column, spring mechanisms... 4

5 Condition-based maintenance Transmission equipment constitutes an important capital investment and is critical to network stability. To prolong assets life and ensure their reliability, Alstom Grid offers condition-based maintenance. Customer challenge Transmission systems and their equipment have been designed for reliability. Energy managers require cost-effective applications and solutions to avoid unscheduled downtime, major failure and the subsequent penalties. Alstom Grid solution Continuous condition monitoring Alstom Grid has designed monitoring products to keep a constant watch over assets. Continuous condition monitoring allows shifting from a time-based maintenance to a conditionbased maintenance strategy, providing a more cost effective service while improving capability to predict and prevent failures. On-line technology enables remote technical assistance and diagnosis for better customer support in the decision making process of operations and maintenance. Condition monitoring devices embed capabilities of generating alarms, on settable thresholds, in absolute value and time trend. The monitoring tool records SF6 densities and other circuit breaker's conditions (speed recording, trends, coil current...) allowing predictive analysis for preventive maintenance. Stress assessment analysis For SF6 circuit breaker equipped with spring mechanisms, Alstom Grid has developed a simple tool to evaluate the stress condition of the circuit breaker. According to the result, a maintenance plan can be set, enabling the switch from time-based maintenance to condition-based maintenance. The table below presents stress assessment analysis and resulting maintenance plan recommendations. Synchronisation Alstom Grid designed synchronisation relays for circuit breaker to increase equipment's reliability. Synchronising circuit breaker for some operations such as shunt reactor, capacitor banks are critical. Overvoltage and over current generated by these operations can seriously damage the asset and its neighbouring equipments. To avoid overvoltage and over current, and to increase asset life, service teams study the possibility of installing a RPH relay on your circuit breaker. The relay will synchronise the circuit breaker's operations according to network voltage, avoiding stress to the substation's equipments. Data analysis expertise Armed with the proper information received from our installed monitoring tools, we can provide a full assessment to evaluate the equipments in real time, define the scope of maintenance operations and plan actions for future execution (planning, operations, repair, replacement). This enables a better match of intervention teams, spare parts replacement and special tools management, saving downtime and costs, avoiding unexpected situations and maximising your electrical system s availability and performance. Alstom Grid can provide a 24/7 asset management. 5

6 Technical training and competence development Training is power To face electrical incidents, operations outages, blackouts, and the costs that go with these, there is one logical solution: Training. Training has the quickest and the strongest return-on-investment rate when it comes to increasing your company s personnel competencies and enhancing your current electrical installation performance. Alstom Grid offers over 200 training courses in its 15 Technical Institute centres. Discover our training offer on Customer challenge Expertise on circuit breaker operations and SF6 handling are key to avoid errors, accidents. Alstom Grid solution Alstom Grid Technical Institute offers a full range of training in electrical grid safety, operations, maintenance, protection, control and management. This high-value-added selection of training courses encompasses all aspects of electricity, with an offer ranging from fundamentals to competence development. Whether maintenance is carried out by your company's site personnel or subcontracted, power service continuity is your remit. Your electrical installation may already be designed but in-depth product knowledge is vital. When it comes to equipment operation and maintenance, theoretical study is necessary but not sufficient to optimise site personnel reactivity. What makes a real difference is the experience site personnel can gain through practice, over the years, or... through training. Technical Institute Centres provide training on all circuit breakers and condition monitoring tools. Standard training courses: Oil circuit breakers, Air blast circuit breakers, SF6 circuit breakers, SF6 dead tank circuit breakers, CAIS AIM Hypact 72,5 kv to 170 kv, SF6 GCB type FKG1/2, Air blast GCB type PKG, Spring operating mechanism type FK1/2/3, Monitoring CBWatch operation, synchronising relay RPH range operation. Competence development: a turnkey approach to performance Needed when... Competence level is required "Competence assumption" is not sufficient! e.g. safety issues and certification Competence creation is necessary Growth leads to an important increase in young or new recruits Health, Safety and Environment policy contributes to leading position ANALYSING Needs analysis Evaluation quiz To evaluate trainees' knowledge level PREPARING Course design e-learning Planning To optimise the course TEACHING Teaching Learning Application at site To learn required skills QUALIFYING Evaluation quiz Knowledge validation To check knowledge acquisition & deliver competence certificate CERTIFICATION Companies have to face competence losses Massive departure of senior generations To know more... 6

7 SF6 management According to potential environmental, health and safety impacts of SF6 use, Alstom Grid supports its customers in efficiently managing SF6 and shares its best handling practices for a permanent reduction in SF6 emissions. For Alstom Grid, the goal is to offer customers the most economical and simple solution for the management of SF6 in their installed park. SF6 leak detection and repair Alstom Grid proposes a gas density monitoring system that detects leaks as soon as they start and measures the leak rate. Once a gas leak is detected, gaskets can be sealed off or exchanged. The Alstom Grid leak detection and repair service can be performed on any equipment containing SF6, including circuit breakers. Customer challenge SF6 makes equipments more resistant to the effects of pollution and climate and more reliable over the long-term. The resulting size reduction allows equipment to fit better with customers' needs in specific environment constraints. Operators have the responsibility to efficiently manage SF6 in order to limit environmental impacts, as well as health and safety risks. Alstom Grid solution Alstom Grid offers service solutions for the customer to better manage SF6. Local experts can support you in all SF6 operations. SF6 lifecycle management To ensure circuit breakers function efficiently, SF6-filled devices need to meet gas pressure and gas quality standards. Both of these standards tend to lessen throughout equipment lifecycles, which ultimately will compromise reliability. Alstom Grid proposes services to manage SF6 quality and pressure levels for all Alstom Grid products and equipments. This offer includes: A gas pressure check Topping-up when required A gas quality check Decontamination Many overhaul or maintenance operations involve opening SF6 insulated switchgear. Clean, dry work conditions are necessary to accomplish these operations, so the Alstom Grid services team has designed a mobile decontamination workshop, which can be taken to the customer s site. Alstom Grid teams are able to retrofit, maintain, overhaul or upgrade any gas-insulated equipment in safe, clean and environmentally friendly conditions. The mobile workshop is fully functional on-site within one day. It is equipped with state-of-the-art devices to ensure the highest service quality. SF6 recycling To perform SF6 recycling, Alstom Grid uses a mobile recycling cart to proceed with recuperation and recycling at the customer s site. Gas recovery is performed with state-ofthe-art reclaimers, with a recovery capacity of 1mbar, thus losses are insignificant. Alstom Grid team manages the whole SF6 recycling process meaning that gas must be handled only by trained and certified workers. 7

8 RENOVATION, MODERNISATION & EXTENSION Alstom Grid provides condition assessment of substations including third party Original Equipment Manufacturers. Based on the situation, services experts offer Renovation, Modernisation and Extension solutions to improve performance or to resolve some obsolescence issues.. Customer challenge High Voltage substations are key contributors of the Grid assets value while they are critical for Grid reliability and availability. After decades of operations, Grid operators may foresee risks of increasing failure rate according to electrical and environmental stress. They may also address the needs for evolving power performance or the needs for standard or technological enhancement. Alstom Grid solution Alstom Grid services experts support the decision-making process providing the most cost efficient solution for substation and circuit breakers renovation, modernisation or extension based on condition and life assessment. Renovation Alstom Grid offers solutions to expand the life of ageing equipments by replacing worn circuit breakers, switches, control and protection. Services experts conduct for example circuit breaker mid-life overhauling or GCB forklift upgrade. Modernisation Modernisation of equipments is a way of getting benefits of new design and technology on equipments already in operation as well as solutions for obsolescence issues on old equipments. Alstom Grid provides circuit breaker modernisation, add-on condition monitoring system allowing optimised asset management. Extension Increasing electrical ratings such as nominal current, short-circuit current, breaker tripping time, protection performances, nominal power and adding bays in existing substation are common demands addressed by the Alstom Grid Engineering team. Service teams can extend the life of equipments and their performance. 8

9 Circuit breaker upgrade examples 9

10 LONG TERM MAINTENANCE Maintenance of assets is critical to achieve reliability of electricity supply and to comply with current regulations. With the goal of improving efficiencies and downtimes while lowering costs, utilities and industries have to get the most of their equipments over the long term. We support our customers in their challenges by providing Long Term Maintenance, a set of tailored expert services executed on a multi-year partnership. Customer challenge Lack or absence of maintenance can generate deterioration or severe failures (Electrical: hardware failure, coil, relay Mechanical: peeling, loosening, parts breaking Dielectrics: leaks, moistures, electric heating ). Energy players need to make efficient decisions on equipments management to ensure their reliability and maximise their long term performance in a cost-effective way. Alstom Grid solution To support customers in the long term, Alstom Grid offers incremental tailored maintenance levels to answer customers' needs. 10

11 Air blast circuit breaker Alstom Grid advises the following maintenance recommendations for circuit breakers' models: PK (1) Operation counters (mechanical or electrical) record 1 CO cycle (Closing + Opening) (2) Number of trip operations to be applied to guarantee interrupting capabilities from 30 to 63kA (3) Recommended yearly inspections for PK circuit breakers, associated with power units or reactors (4) In case of wearing or air leakage (5) Replace friction rings and springs of auxiliary switch control device 11

12 Minimum oil circuit breaker Alstom Grid advises the following maintenance recommendations for circuit breakers' models: HPGE, HPF 12

13 13

14 Gas live tank circuit breaker with spring mechanism Alstom Grid advises the following maintenance recommendations for circuit breakers' models: FG1, FXT, GL, S1 14

15 Gas live tank circuit breaker with hydraulic mechanism Alstom Grid advises the following maintenance recommendations for circuit breakers' models: FL, FX (1)The operation counters (mechanical or electrical) record 1 CO cycle (Closing + Opening) (2)Number of trip operations to be applied for guaranteed interrupting capabilities from 30 to 63kA (3)Recommended yearly inspections for PK circuit-breakers, associated with power units or reactors (4)In case of wearing or air leakage (5)Replace friction rings and springs of auxiliary switch control device 15

16 N.B.: To safely set up these operations, SF6 gas contained in the poles must be drained and the effective pressure reduced to 0.03 Mpa (20 C). The quality of the recovered gas must be controlled before being reintroduced into the poles. If the quality does not conform, new gas must be used. 16

17 Dead tank circuit breaker Alstom Grid advises the following maintenance recommendations for circuit breakers' models: HGF, DT (1) One year after commissioning (2) If none have been performed during the year (3) Six months after commissioning 17

18 Air blast generator circuit breaker with pneumatic mechanism Alstom Grid advises the following maintenance recommendations for circuit breakers' models: PKG (1)The operation counters (mechanical or electrical) record 1 CO cycle (Closing + Opening) (2)Number of trip operations to be applied for guaranteed interrupting capabilities from 30 to 63kA (3)Recommended yearly inspections for PK circuit-breakers, associated with power units or reactors (4)In case of wearing or air leakage (5)Replace friction rings and springs of auxiliary switch control device 18 (1) Mechanical and electrical operations are recorded by counters as close or open, not both

19 Gas generator circuit breaker with hydraulic mechanism Alstom Grid advises the following maintenance recommendations for circuit breakers' models: FKG1 19

20 20

21 Gas generator circuit breaker with spring mechanism Alstom Grid advises the following maintenance recommendations for circuit breakers' models: FKG2 21

22 Gas compact circuit breaker Alstom Grid advises the following maintenance recommendations for circuit breakers' models: HYpact 22

23 Outage and maintenance durations Below durations (in man-days) are given for information. The final duration will be determined after site's audit by service experts and according to the number of field supervisors for maintenance.maintenance & repair levels: M2 - minor maintenance: basic commissioning tests and replacement of few parts, every 3-5 years, M3 - partial refurbishment (replacement of some sub-components) and/or advanced testing and analysis, every 8-12 years, M4 - major maintenance/overhaul: refurbishment of complete equipment, every 15 to 25 years. 23

24 ALSTOM Grid Worldwide Contact Centre Tel: +44 (0)

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