SWITCHGEAR SOLUTIONS WHAT CAN I DO TO INCREASE THE LIFE OF MY EXISTING SWITCHGEAR AND BRING IT IN TO CODE COMPLIANCE?
Presented by: Rich Hicks – Schneider Electric Services 1 Confidential Property of Schneider Electric
Schneider Electric Services Our team serving your business…..
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Over 1,500 Employees operating in 42 states across the US
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25 Service Field Offices and 3 Customer Contact Centers
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Our field service representatives are qualified as defined by OSHA and NFPA 70E.
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Over 150 strategically-located professional engineers collectively registered in every state to meet state licensing requirements.
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Always there for you…
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Any Time.
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and more!
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Key Trends Impacting All Industries
Aging facilities and budget gaps forcing organizations to maintain with fewer resources
Awareness & accountability of facility risks and worker safety is increasing and becoming more complex
Increasingly difficult to hire, develop, and retain qualified staff
Technology impacting how facility managers do their jobs and buildings operate
Businesses choosing to outsource services and engage in strategic partnerships
Demand escalating for sustainable solutions
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Power System Assessments
Assessment services are customized based upon the need to reduce risk to a facility from:
• Reliability issues • Process disruptions • Code violations • Outdated workplace safety requirements Risk to a facility is determined by the combination of the following factors:
• The impact of the occurrence to key processes • The safety hazard to electrical workers • The probability of an occurrence • The ability to respond quickly to correct the negative effects of the occurrence (vulnerability)
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Risk Assessment Report Deliverable
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Maintenance and Testing To help ensure reliable power, periodic maintenance, cleaning and testing is required.
HAVING A PREVENTATIVE MAINTENANCE PROGRAM IN PLACE CAN REDUCE THE RISK OF UNPLANNED DOWNTIME BY AS MUCH AS 66%.
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Preventive Maintenance and Testing
Predictive Maintenance Solutions
Advantage Service Plans
Additional Services
Causes of Electrical Equipment Failure • Insulation breakdown – Presence of moisture – Dust and dirt accumulation – Voltage stresses • Overheating – Overloading – Loose connections • Friction of moving parts • Water • Breaker racking
What is Maintenance?
• A regularly scheduled preventative maintenance program is intended to detect, correct, or replace affected components parts or equipment before they lead to a catastrophic failure and significant power interruptions. • Article 200 of NFPA70E defines maintenance “as preserving or restoring the condition of electrical equipment and installations, or parts of either, for the safety of employees who work where exposed to electrical hazards”
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Approaches to Electrical Maintenance
• Reactive Maintenance • Repair work conducted after a failure or breakdown, often completed as an emergency
• Preventive Maintenance • A specified list of inspections, cleaning, testing and part replacement during a pre-defined, time-based schedule
• Predictive Maintenance (or Periodic Diagnosis) • Scheduled based on diagnostic evaluations. Also factors in equipment age, environmental stresses, criticality of equipment etc. to decide on schedule
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ARC Advisory Group
Maintenance Plan Development • NFPA 70B states… • Maintenance requirements vary by equipment class • Frequency should consider criticality, condition and environment • Consider the Manufacturer’s recommendations
• NFPA 70B - Annex L (frequency) • Indoor switchgear • Infrared - annually • Visual - 6 months • Test Insulation - 2 years
• Low voltage air circuit breakers • Inspect/Clean/Adjust - Annually • Test - 3 years
Important Preventive Maintenance Tasks
• Infrared Scanning • Molded-Case Breakers • Should be operated periodically (Keeps contacts clean, helps operating mechanisms move freely)
• MV Breakers • Should be removed from service and inspected at least once per year • Clean, lubrication, exercise • Testing: protective relays, resistance, timing • Bolted Pressure Switches
• LVPCB’s • LVPCB’s not maintained within 5 year period have a 50% failure rate • Cleaning, lubrication, exercise, reconditioning • Testing: primary or secondary current, resistance (current path, insulation)
• Visual inspection and exercising once a year • Cleaning and lubrication should ideally occur annually for current carrying components, but not longer than three years
Types of Predictive Technologies • Power System Assessments • Infrared inspections • Thermal monitoring • Oil analysis • Vibration analysis • Partial discharge monitoring • Circuit Monitor Analysis • Intelligent protective devices – Circuit Breaker electronic trip units – Motor Starter intelligent overloads Confidential Property of Schneider Electric
Predictive Maintenance Solutions Predictive maintenance techniques safely provide condition status to help anticipate and plan maintenance activities.
Infrared Viewing Windows Enhances safety by allowing infrared inspections without the need to remove equipment covers.
Wireless Temperature Monitoring System Allows 24/7 monitoring of critical connection points and areas not seen by infrared cameras.
Partial Discharge Monitoring Detects impending insulation breakdown in MV equipment, which can lead to costly equipment damage and downtime.
Predictive maintenance solutions detect early warning signs and help prevent downtime. Confidential Property of Schneider Electric Confidential Property of Schneider Electric | | Page 14
Advantage Service Plans
Advantage Service Plans help you comply with NFPA 70E standards and mitigate risks by ensuring that regular maintenance is performed on your equipment. Advantage Service Plans cover:
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Power equipment Monitoring systems Automation and control equipment Hospital isolation panels Emergency management Facility management software
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Advantage Service Plans Advantage Service Plans provide peace of mind by mitigating your risk of downtime and unexpected repair costs. Get started in three easy steps: 1) Select your plan - Advantage Plus - Advantage Prime - Advantage Ultra 2) Select the term - 12-month / 36-month / 72-month 3) Call 888-778-2733 Optional Upgrades: [1] After-hours preventive maintenance. [2] 7x24 priority response and 4-hour response (where available).
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Modernization and Upgrade Cost-effective modernization solutions upgrade your existing equipment to current technology and save time and money. Direct Replacement or Retrofill? Switchgear Modernization: Low Voltage
MODERNIZATION SOLUTIONS FOR ANY BRAND.*
Switchgear Modernization: Medium Voltage Motor Control Center Upgrades
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• Eaton/Cutler-Hammer • ITE/ABB/BBC • Federal Pioneer • General Electric • Allis Chalmers • Square D • Westinghouse • Federal Pacific • and more!
Electrical Distribution Equipment Electrical Distribution Equipment is composed of both Active and Passive Components • Active Components • Circuit Breakers • Trip Units • Relays • PLC’s, TVSS • Fuses • Racking Mechanisms • Monitoring Components
• Passive Components • Structure • Bussing • Lugs/Lug Pads • Bracing Confidential Property of Schneider Electric
Electrical Distribution System Active Components include mechanical or solid state features and many times both • Mechanical Components • Involve moving parts, therefore they must be maintained in order to operate as intended • Will wear out over time • Some components require replacement upon use • Electronic Components • The rise in utilization of solid state components gives rise to another mode of failure that cannot be easily detected • Typically cannot be maintained and must be replaced upon failure • Obsolescence is a key consideration
Electrical Distribution System Passive Components include the non-moving and non-solid state components Structural Components • Require minimal maintenance • If properly cleaned and monitored in a controlled environment, the passive components may last a long time, however: – Dust, dirt and moisture build-up can affect the insulation system – Loose connections due to improper torque and/or vibration over time can lead to excessive heat and failure • If well maintained, these components substantially outlast the life span of the Active Components in a piece of electrical distribution equipment
Electrical Infrastructure Failure Tangible Costs • Equipment replacement costs • Contractor costs • Loss of production • Fines (for spill or backup) • Impact to personnel/medical costs/lawsuits Intangible Costs • Fixed and variable costs wasted during downtime • Possible loss of customer revenue • Internal and external meetings • Human resources allocated to the repair
Direct Replacement or Retrofill?
When considering whether to replace or upgrade existing equipment, there are a number of factors to consider.
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Operating environment
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Availability of spare parts
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Impact of downtime
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Cost of ongoing maintenance
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Need to increase fault or continuous current rating
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Desire to upgrade to current technology
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Our direct replacement and retrofill solutions modernize any manufacturer’s existing switchgear to current technology.
Direct Replacement or Retrofill? Our direct replacement and retrofill switchgear modernization solutions will expand the capabilities of your electrical system with minimal downtime. Direct Replacement
Retrofill
Circuit breakers are designed to fit into the existing cubicle with little-to-no modification to the switchgear cell. Reduces downtime since there is minimal (if any) outage on the equipment bus.
The existing switchgear cell and bus are modified to accept the new circuit breaker. This option requires a longer bus outage (compared to the direct replacement option), during which time the internal circuit breaker cell is modified to accept the new circuit breaker.
A Masterpact cradle-in-cradle design is utilized for LV direct replacement solutions
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Before and after photos of MV retrofill upgrade
Switchgear Modernization: LV
Direct Replacement (Low Voltage)
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A MasterpactTM cradle is installed into an adapter cradle, which is then installed into the switchgear cubicle.
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This cradle-in-cradle assembly locks into place and remains in the switchgear cell after installation.
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The new Masterpact circuit breaker racks in and out of the adapter cradle.
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A new door is installed, however cell interlocks, the racking mechanism and the switchgear structure are not modified.
Masterpact circuit breakers are installed, tested and commissioned by qualified field service personnel and are backed by a one-year warranty. Extended warranties are available.
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Switchgear Modernization: LV
Retrofill (Low Voltage) Features a Masterpact cradle and circuit breaker and includes:
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New racking mechanism and primary and secondary connections.
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Custom-engineered connection between the switchgear line and load side.
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New cubicle doors to match the existing equipment and new circuit breaker face.
Did You Know? New switchgear is usually smaller than the equipment it is designed to replace. The existing conduit may need to be moved and cabling replaced or spliced. Both are expensive and time consuming tasks, often costing more in labor and material than the cost of the new equipment .
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The existing switchgear cell and bus are modified to accept the new circuit breaker.
Switchgear Modernization: MV
Direct Replacement (Medium Voltage) Our Magnum™ direct replacement circuit breaker is designed to fit directly into the existing OEM switchgear. An adapter cradle is not utilized.
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Built with new components and tested to ANSI standards, Magnum circuit breakers interface with the existing circuit breaker compartment components and maintain safety interlocks present in the original equipment design.
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Magnum circuit breakers are installed, tested and commissioned by qualified field service personnel and are backed by a one-year warranty. Extended warranties are available.
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Magnum designs are available for any brand of medium voltage switchgear.
Switchgear Modernization: MV
Retrofill (Medium Voltage)
Designs are available for any manufacturer’s switchgear and include:
Upgrades switchgear by installing a new medium voltage circuit breaker and cell into an existing line-up. Necessary modifications are made to the existing cell and include:
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All-new racking mechanism Primary and secondary disconnections
Air-magnetic to vacuum or SF6 Air-blast to vacuum or SF6 OCB switchgear to vacuum or SF6 switchgear Convert stationary circuit breaker to draw-out, or obsolete air circuit breaker to vacuum or SF6
Customized connections New doors to match the existing equipment and circuit breaker face
A retrofill solution is often used in lieu of the direct replacement option for larger devices, such as main breakers and tie breakers.
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Switchgear Line-up after Retrofill
Motor Control Center Upgrades
Direct Replacement and Retrofit Upgrades for Low Voltage Motor Control Centers
• New direct replacement motor control center units are available for many common vintage and current style motor control centers.
- Upgrade to an intelligent motor control center to increase productivity and save energy.
• If a direct replacement unit is not available, we can retrofit a genuine OEM bucket with all new Square D™ components. - The genuine OEM stab assembly is reconditioned to like-new condition and the bucket is painted white enamel.
The TeSys motor management system reduces costs as well as the complexity of your equipment.
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Both motor control center upgrade options are designed to improve reliability, reduce maintenance and increase equipment capabilities.
OSHA & NFPA 70E Compliance As an industry leader in promoting electrical workplace safety, we recommend that any modernization project should consider the latest technologies available to optimize the safety and performance of your electrical power system: Follow strategies to mitigate and control arc flash hazards, which may include:
• Over-current protective device coordination study • Upgrade switchgear with a Virtual Main Relay • Infrared viewing windows • Remote racking systems • Wireless temperature monitoring system
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Custom Solutions
DO YOU HAVE UNIQUE PRODUCT REQUIREMENTS OR COMPLEX POWER ISSUES?
Regardless of the application or location, our engineering, manufacturing, field service and project management teams can deliver a costeffective turnkey solution that will minimize downtime or lead times.
Custom Equipment: Non-Standard Dimensions and/or Ratings
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On Demand and Emergency Services In case of emergency, call
1-888-778-2733. NATIONAL NETWORK OF OVER 400 QUALIFIED FIELD SERVICE REPRESENTATIVES.
Our nationwide network of professional engineers and qualified field representatives is available any time, for any brand of equipment.
On Demand and Emergency Response Services Temporary Generator Connection Emergency Action Plan
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Temporary Generator Connection
We offer a turnkey solution for a temporary generator connection to your normal or emergency power system. A temporary generator connection is recommended where one of the following applies:
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The authority having jurisdiction requires portable generator connection provisions in addition to the fixed-mounted emergency generators per NEC® article 708.20(F)(6).
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The facility is designated as needing continued operation in the event of a widespread disaster and a temporary connection is acceptable to the governing entity.
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The facility can withstand short-term disruptions to electrical power but a long-term disruption will jeopardize the business.
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Improves electrical system reliability.
Electrical Emergency Action Plan
Our professional engineers can create an action plan to help restore power and return to normal operations as quickly as possible. Components include:
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Have a current single-line drawing of the electrical distribution system.
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Identify which electrical equipment is critical to the electrical infrastructure.
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Determine which equipment must be replaced and that which can be reconditioned, if water damage has occurred.
500-Year Nashville Flood (May-2010)
All of Opry Mills Mall’s electrical rooms were flooded with water levels reaching 10 feet in some areas.
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THANK YOU
Our technologies ensure that everywhere, for everyone and at every moment. 34 Confidential Property of Schneider Electric | Page 34