Generator Circuit Breaker He Overhaul Procedure

ABB GCB Service Department

ABB Switzerland Ltd Telephone: Telefax: www.abb.ch High Voltage Products +41 58 58 83300 +41 58 58 81188 VAT No.: 101 401 Brown Boveri Strasse 5 CH-8050 Zürich / Switzerland

Author: Volkan Uzakgoeren

Department: PPHV-GZ Phone: +41 58 588 38 63 Mail: [email protected] Document: GCB HE overhaul v1 Type: External document Date: 28th October 2014 /9

Generator Circuit Breaker (GCB) HE Overhaul Procedure

Aim of the following “GCB HE-Overhaul guide” document is to simplify the work be-tween Product Service Centre (PSC), Local Service Centre (LSC) and End-user during the mentioned job/project. Misunderstanding and/or missing information flow during the project can result in time and/or money lost for every one of the “involved parties”.

The document will in addition guaranty a worldwide standardized GCB HE-Overhaul procedure and offer the customer an understandable and transparent description of the HE-Overhaul job/project.

Involved parties The document addresses to the following person(s):

- Project coordinator, Product Service Center (PSC), - Project coordinator, Local Service Center (LSC), - Power Plant project responsible and/or authorized customer representative, - ABB Field Service Engineer(s) (FSE). Products This document is valid for the following ABB GCB Product:

HEI (open breaker type with pneumatic drive SADHE) HEK (enclosed breaker system with pneumatic drive type SADHE) HECK (enclosed breaker system with pneumatic drive type SADHE) HEF (enclosed breaker system with enclosed pneumatic drive type SADHE) HEC-3/6 (enclosed breaker system with hydraulic drive type AHMA-4 or HMB-4) HEC-PS (Pump storage application with HEC-3/6 technology)

Service criteria The herewith described Service (resp. Overhaul) criteria’s are based on the operation and maintenance manual of the mentioned breaker

Breaker type Service criteria

Aging Mechanical Electrical

HEI 10 years 5’000 CO

k (I rms) > 20’000 HEK / HECK / HEF 10 years 5’000 CO

HEC-3/6 / HECPS 15 years 10’000 CO

Manpower

ABB will provide one (1) certified Field Service Engineer (FSE). End-customer has to guaranty the presence of three (3) skilled helpers.

HEF

HEK

HEC-3/6

HECK

HEI

ABB Generator Circuit Breaker (GCB) HE Overhaul

ABB Switzerland Ltd ABB Switzerland Ltd Telephone: Telefax: www.abb.ch High Voltage Products +41 58 58 83300 +41 58 58 81188 VAT No.: 101 401 Brown Boveri Strasse 5 CH-8050 Zürich / Switzerland 2/9

Duration (needed shortage) The below described job/project durations refer to the on-site “technical job” only as described in the section “Scope of work”. Bad project- and/or site preparation will directly influence the whole duration of the technician’s site stay and affect the final job/project costs.

Breaker type Normal time [hours]

Over time [hours]

Total [hours]

Remark

HEI 64 16 80 (8 days)

▪ Pneumatic drive SADHE included

HEK / HECK / HEF 88 22 110 (11 days)

▪ Pneumatic drive SADHE included ▪ Earthing switch + 20 hours ▪ Disconnector + 20 hours ▪ Starting switch + 20 hours

HEC-3/6 / HEC-PS 72 18 90 (9 days)

▪ AHMA/HMB drive + 30 hours ▪ Earthing switch + 10 hours ▪ Disconnector + 10 hours ▪ Starting switch + 10 hours

Remark: due to PSC operational experiences overhaul working days are based on a 10 hours day

Manpower The above estimated man-hours have to be considered as reference for future HE overhaul quotations. Any evident discrepancy between the herewith listed hours and the one given by any other Local Service Center will be checked exactly and discussed between the involved parts.

Task HEI [hours]

HEK / HECK / HEF [hours]

HEC-3/6 / HEC-PS [hours]

Preparation 4 4 4

Travel to site 10 10 10

Normal time 64 88 72

Overtime 16 22 18

Travel from site 10 10 10

Reporting 4 4 4

Total [hours] 108 138 118

Other expenses Overhaul pricing is in addition to the manpower completed from the following expenses. - Daily allowances (meal and accommodation according ABB travel rules document) - Car - Taxi - Fuel and road taxes - Flight - Excess luggage - Tools (charged from the moment where are living the tools shop until their return in the shop) - Customs documents for tools (i.e. Carnet ATA) - Handling fees

Man power- & costs adjustment Every GCB service network member reserves the right to adjust the costs in the event of any inconsistency be-tween the assumptions upon which his quotation is based and the actual circumstances under which the work is to be provided, or in the event of any unforeseen circumstances. The prices during the quotation phase are only estimated, final costs will be as per signed timesheets and associ-ated expense receipts.



Tools (1/4) The following list describes all needed tools for the mentioned work on site. Name Reference ID (Int. reference)

Picture

Name Reference ID (Int. reference)

Picture

General tools case --- (HS21291)

HE special tools box HAGG404547R0010 (HEI, HEK, HECK, HEF: HS21292) (HEC-3/6: HS21297) (For contacts replacement: HS21298)

Torque wrench 60 QL 1HC6023151P0051 (HS22007)

Torque wrench 730R/40” 1HC6023151P0053 (HS22019)

Torque wrench 225 QL 1HC6023151P0052 (HS22009)

Combination wrench 27 --- (HS28027)


Combination wrench 32 --- (HS28032)


Open-end torque wrench 32 --- (HS28633)

Remark: uncalibrated tools can cause wrong evaluation of the system during the commissioning with possible dra-matical results for the safety of the installation. Calibration of the on-site delivered tools is under responsibility of the tools owner.




Picture


Picture

Helicoil thread repair (Set M5-M12) 1HC6021620P0001 (HS18955)

Angular transducer 1HC6022881P0003 (HS31344)

Hot air blower “Electron” 1HC6023151P0003 (HS11400)

EGIL measurement device HAGG301932P0041 (HS31364)

Remark: the TM 1600/1760 are other suit-able solutions

Leak Seeker “GIR-10” --- (HS21401)

SDRM-202 GCB HAGG301932R0020 (HS31373)

µohm-meter Mjölner 600 --- (HS21414)

SF6 Analyzer “973” --- (HS31033)

Multimeter 18S --- (HS30218)

Pressure gauge Leo-2 with adapters 1HC6027221R0001 (HS31393)

Remark: necessary for the “pressure drop test” on the air receiver of the SADHE drive on HEK, HEI, HECK and HEF breakers





Picture


Picture

SF6 Filling device DILO HAGG401003R0002 (HS41427)

Particles vacuum cleaner (WAP SQ450-3H) --- (HS46206)

Vacuum pump 10M3/H “mini” --- (HS41601)

Aluminum case “A10” --- (HS63910)

Vacuum compressor “mini” --- (HS41603)

Chain block 0.5t “LX005” --- (HS54233) Remark: not necessary if crane is availa-ble on site

Compressor “mini” --- (HS41602)

2x Round sling “1m / 1000 kg” --- (HS56501)

2x Round sling “2m / 2000 kg” --- (HS56513)

Control console “mini” 1HC6021612P0001 (HS41604)

4x Shackle “1.0t” --- (HS56604)

Strap “50mm/5m” --- (HS66322)




“Special” Tools (4/4) The following list describes all needed tools for the mentioned work on site. Name Reference ID (Int. reference)

Picture


Picture

For contacts replacement AHMA-4 Special tools

Industrial press “HWPEP/1 30” with pressure plate Ø400x60mm Industrial oven “Series ED” --- (HS49709)

Tools kit AHMA-4 1HC0085002R0001 (HS48934)

Spring press “clamping tool” 1HC6023151P0017 (HS48948)

General Hydraulic drive tools HMB-4 Special tools

Depth gage 300mm 1HC6022881P0006 (HS36253)

Tools kit HMB-4 1HC0085112R0001 (HS48964)

Vacuum pump “HA” 1HC6009652P0001 (HS41457)

Special coupling wrench --- (HS21305)




Scope of work Overhaul is required when one of the associated Service criteria’s is reached. Overhaul is a sum of works per-formed with the objective of restore, repair or replace parts which are found to be out of tolerance by analysis in-spection, test, examination, or as required by manufacturer's operation and maintenance manual. Overhaul activities include partial dismantling of the product and the replacement of electrical contacts, sealing’s, guide rings, screws, bolts, insulators, etc. as defined from the related service criteria. The needed overhaul documents (i.e. electrical scheme, arc.file, last available object report and dimension draw-ing) have to be required via mail to [email protected] at least one (1) week prior the travel on site. Other needed documents and files (i.e. test plan, reports, overhaul- and O&M manuals, etc.) can be find and down-loaded from the GCB-FSE Server. The following described overhaul tasks are based on checks and measurements according the related “Overhaul report”. - Power Plant Health and Safety introduction (if applicable)

- Work environment visual check at beginning (recognition of possible dangerous scenario)

- Health and Safety condition on site (work permit, working area secured and marked, H&S check list completed, the 7 safety rules followed)

- General visual check of the GCB, mechanical installation and “external” cabling (Pole frame, oxidation, rust, condition of supporting bracket(s), mechanical linkage(s), control cubicle- and system grounding)

- Visual check of the components inside the enclosure (Verification of torques and cablings, component(s) (VT, CT, MO and C) connection(s) to current path, presence of humidity)

- Dynamic Resistance Measurement (DRM) measurement (if applicable) (Measurement of the contact overlapping before the overhaul)

- Arcing chambers overhaul (Replacement of the parts according the related product overhaul document and the reached service criteria)

- Maintenance works on disconnector, earthing switche(s) and starting switch (if applicable) (Contacts cleaning and lubrication)

- Operating mechanism overhaul (Overhaul of the related drive: SADHE pneumatic drive or AHMA/HMB drive if applicable)

- Compressor and air receiver overhaul (Applicable for the pneumatic drive SADHE only)

- Maintenance works on slow drive motor and on electrical control (Lubrication and checks of shaft joints, pins, sliding surface of mechanical linkages, etc.)

- Re-commissioning of the breaker: Timing and motion test (Comparison with the equipment factory limit)

- Dynamic Resistance Measurement (DRM) measurement (Measurement of the contact overlapping after the overhaul and definition of the new breaker footprint)

- Static Resistance Measurement (SRM) measurement (Measurement of the contact overlapping after the overhaul and definition of the new breaker footprint)

- SF6 gas analysis (according IEC 60480) and –equipment (Concentration, dew point, decomposition product, density gauge and leakage test on SF6 circuit, refilling gas if necessary)

- Operation and Maintenance training (if applicable) (Maximum 4-5 people from the customer crew during 2 hours)

- To do’s and remarks (Communicated to customer and described in the Analysis inspection report)

- Overhaul report to customer (Including signature of the customer representative)

After the completion of the job on site all job relevant documents (updated arc.file, taking over certificate in “.doc” and “.pdf” version with signatures, IFSR, endurance file, etc.) have to be sent back to the Product Service Center (PSC) via mail to [email protected].



Site preparation The following “Site preparation page” is mandatory for overhaul job/project on Generator Circuit Breaker (GCB) type HEI, HEK, HECK, HEF and HEC-3/6. The herewith requested information and site preparation tasks are essential for the execution of the mentioned job, without the complete form the organising LSC and/or the PSC reserve the right to cancel the job. Please fill out the below listed points and return it to the PSC five (5) weeks prior the start of the overhaul activity on site. - Customer responsible and -authorized representative for the signature of the “Job Report” on site

First- and family name …………………………………………………….

Company ……………………………………………………

Cell number ……………………………………………………

- GCB system will be de-energized from: to: Yes No

- Power Plant entry documents are complete (e.g. H&S certificate, medical checks, etc…)

- Confirmation that all ordered ABB spare parts will be on site before the overhaul outage

- Grounding on transformer- and generator side will be carried out

- Accessibility to the GCB System to perform the job is guaranteed

- AC/DC power supply for the GCB system according electrical scheme is guaranteed

- Necessary lighting installation at the GCB System is available

- Enclosure will be already cleaned and opened

- ABB technician can disconnect temporarily the Customer connections (control and interlocking)

- Lockable tool storage is available

- Maintenance lever and hand crank are available

- Interlocking keys of the Slow Drive Motor panel (Q81/82, Q9, Q91) are available

- Control cubicle and remote/local keys are available

- Consumables as protective covers, rags and ethanol for cleaning are available

- Availability of a bench with bench vice and a table to do the paper works

- Skilled labourer (3 persons) from the power plant to assist our technician are available

- Health and Safety aspect are fulfilled (e.g. workplace safety, emergency contacts, scaffolding, etc.)

- * Lifting device (crane) for the GCB components and space to store them temporarily during the job

- * An empty SF6 gas bottle available next to the GCB System (if NO, it’s under LSC responsibility)

- * SF6 reclaiming & storing device and a -fitting re-filling device are available in customer warehouse

- * Particles vacuum cleaner is available in customer warehouse

* The mentioned equipment(s) can in case of need (NO answer) be organised from the PSC respectively LSC Note: Any extension of the overhaul job/project due to wrong information will be at charge to the ABB LSC. With submitting this form, you are requested to provide pictures from site that show the GCB, the relevant preparations at site and the GCB surrounding area.



Common errors during project preparation/execution Every on site activity has to be prepared carefully. Every error during this phase of the project will have financial and/or image loss for our Client and for ABB. Additionally to the usual FSE preparation tasks (i.e. Documents request of the project specific documents like Arc.file, FAT report, electrical schematic, etc.) the project has to be executed carefully from a logistic point of view too. Enclosed a list of the most common problems/errors during the project preparation and/or execution phase. 1. Short-term manpower request Good project preparation needs time. If you are organising a GCB Service job in your country with a Field Service Engineers (FSE) coming from another Local Service Centre (LSC) or from the Product Service Centre (PSC) please consider the following. - FSE from the PSC (Zürich/Switzerland): for the organisation of a service jobs within the European countries a re-quest of at least three (3) weeks prior the job is required. For service jobs organised worldwide (out from the European borders) a request of six (6) weeks prior the job is considered as reasonable if the whole procedure (specially for TIS/Visa countries) is executed without leak of sup-port and communication between the involved parties. 2. Customs procedures The ABB Local Service Centre knows best his local import/export procedures. The local ABB (excluded Carnet ATA countries) has to support every import/export procedures arising from an equipment shipment for an Analysis inspection job. Import/export procedures are in some countries very difficult, that is why the support of the local ABB plays a key role for the success of the project/job. 3. Power Plant preparation Information about the Power Plant (including exact address) where the job has to be executed are under responsi-bility of the local ABB. This information have to be shared and communicated to the ABB project partner at the initial stage of the job/project. Other information like Power Plant contact persons and/or other preparation tasks prior the job/project are listed in the template “Site preparation” contained in this document. The completion of the “Site preparation template” is under responsibility of the local ABB who is responsible for the communication with the end customer. Without completion of the mentioned document the service job on site cannot be initialised by the project manager. Any job delay (and the arising cost of it) due to wrong- and/or missing information will be charged to the End cus-tomer with consequences for the image of ABB. 4. Power Plant entry needed documentations The local ABB is the party who takes care about the contact with the local customer. It is the task of the local ABB to inform about additionally special entry needed documents like “medical check certificate”, “Health & safety certifi-cation”, insurance documents, etc. Every missing document could cause delay (with additional costs) and/or compromise the execution of the job/project. 5. Local ABB leadership during the project A Service job in your country means a new possibility to take care about the relationship with your local customer. The local service unit has to guide and direct his customer before, during and after the whole service work and ad-ditionally to manage the communication between the customer and Product Service Centre (PSC).

Generator Circuit Breaker He Overhaul Procedure

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