Switchgear Solutions

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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

Confidential Property of Schneider Electric

Schneider Electric Services Our team serving your business…..

•  Over 1,500 Employees operating in

42 states across the US

•  25 Service Field Offices and 3

Customer Contact Centers

•  Our field service representatives

are qualified as defined by OSHA

and NFPA 70E.

•  Over 150 strategically-located

professional engineers collectively

registered in every state to meet

state licensing requirements.

Confidential Property of Schneider Electric |

Confidential Property of Schneider Electric | Confidential Property of Schneider Electric |

•  Eaton/Cutler-Hammer

•  General Electric

•  Westinghouse

•  ITE / ABB / BBC

•  Square D

•  Federal Pacific

•  Federal Pioneer

•  Allis Chalmers

•  and more!

Any Brand. Any Industry. Any Time. •  Data Centers

•  Industrial

•  Healthcare

•  Government

•  Utilities

•  Oil & Gas

•  Water / Wastewater

•  and more!

•  Emergency Services

•  National Network

•  24 Hours a Day

•  7 Days a Week

•  888-778-2733

Always there for you…


Aging facilities and budget gaps forcing organizations to maintain with fewer resources

Increasingly difficult to hire, develop, and retain qualified staff

Businesses choosing to outsource services and engage in strategic partnerships

Awareness & accountability of facility risks and worker safety is increasing and becoming more complex

Technology impacting how facility managers do their jobs and buildings operate

Demand escalating for sustainable solutions

Key Trends Impacting All Industries


Power System Assessments


Assessment services are customized based upon the need to reduce risk to a facility from:

Risk to a facility is determined by the combination of the following factors:


•  Reliability issues •  Process disruptions •  Code violations •  Outdated workplace safety requirements

•  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)

Risk Assessment Report Deliverable


Advantage Service Plans

Predictive Maintenance Solutions

Preventive Maintenance and Testing

Additional Services

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%.

•  Insulation breakdown

– Presence of moisture

– Dust and dirt accumulation

– Voltage stresses

•  Overheating

– Overloading

–  Loose connections

•  Friction of moving parts

•  Water

•  Breaker racking

Causes of Electrical Equipment Failure


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”


• 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

Approaches to Electrical Maintenance

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)

•  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)

•  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

•  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

Predictive Maintenance Solutions


Predictive maintenance techniques safely provide condition status to help anticipate and plan maintenance activities.


Partial Discharge Monitoring Detects impending insulation breakdown in MV equipment, which can lead to costly equipment damage and downtime.

Wireless Temperature Monitoring System Allows 24/7 monitoring of critical connection points and areas not seen by infrared cameras.

Infrared Viewing Windows Enhances safety by allowing infrared inspections without the need to remove equipment covers.

Predictive maintenance solutions detect early warning signs and help prevent downtime.



Advantage Service Plans help you comply with NFPA 70E standards and mitigate risks by ensuring that regular maintenance is performed on your equipment.


•  Power equipment

•  Monitoring systems

•  Automation and control equipment

•  Hospital isolation panels

•  Emergency management

•  Facility management software

Advantage Service Plans cover:



Advantage Service Plans provide peace of mind by mitigating your risk of downtime and unexpected repair costs.


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

Get started in three easy steps:

Optional Upgrades: [1] After-hours preventive maintenance. [2] 7x24 priority response and 4-hour response (where available).

• Eaton/Cutler-Hammer

• General Electric

• Westinghouse

Modernization and Upgrade

Cost-effective modernization solutions upgrade your existing equipment to current technology and save time and money.

MODERNIZATION SOLUTIONS FOR ANY BRAND.*

• Federal Pioneer

• Allis Chalmers

• and more!

Motor Control Center Upgrades

Switchgear Modernization: Low Voltage

Switchgear Modernization: Medium Voltage

Direct Replacement or Retrofill?

• ITE/ABB/BBC

• Square D

• Federal Pacific * Confidential Property of Schneider Electric |


Electrical Distribution Equipment

•  Active Components • Circuit Breakers

• Trip Units • Relays

• PLC’s, TVSS • Fuses • Racking Mechanisms

• Monitoring Components

•  Passive Components • Structure • Bussing

• Lugs/Lug Pads • Bracing

Electrical Distribution Equipment is composed of both Active and Passive Components

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

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

Passive Components include the non-moving and non-solid state components

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



When considering whether to replace or upgrade existing equipment, there are a number of factors to consider.


•  Operating environment

•  Availability of spare parts

•  Impact of downtime

•  Cost of ongoing maintenance

•  Need to increase fault or continuous current rating

•  Desire to upgrade to current technology Our direct replacement and retrofill solutions modernize any manufacturer’s existing switchgear to current technology.



Our direct replacement and retrofill switchgear modernization solutions will expand the capabilities of your electrical system with minimal downtime.


Before and after photos of MV retrofill upgrade

Retrofill 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

Direct Replacement 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.

Switchgear Modernization: LV


Direct Replacement (Low Voltage)


•  A MasterpactTM cradle is installed into an adapter cradle, which is then installed into the switchgear cubicle.

•  This cradle-in-cradle assembly locks into place and remains in the switchgear cell after installation.

•  The new Masterpact circuit breaker racks in and out of the adapter cradle.

•  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.

Switchgear Modernization: LV


Retrofill (Low Voltage)


•  New racking mechanism and primary and secondary connections.

•  Custom-engineered connection between the switchgear line and load side.

•  New cubicle doors to match the existing equipment and new circuit breaker face.

The existing switchgear cell and bus are modified to accept the new circuit breaker.

Features a Masterpact cradle and circuit breaker and includes:

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 .

Switchgear Modernization: MV


Direct Replacement (Medium Voltage)


•  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.

•  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.

Magnum designs are available for any brand of medium voltage switchgear.

Our Magnum™ direct replacement circuit breaker is designed to fit directly into the existing OEM switchgear. An adapter cradle is not utilized.

Switchgear Modernization: MV


Retrofill (Medium Voltage)


•  All-new racking mechanism

•  Primary and secondary disconnections

•  Customized connections

•  New doors to match the existing equipment and circuit breaker face

Switchgear Line-up after Retrofill

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:

A retrofill solution is often used in lieu of the direct replacement option for larger devices, such as main breakers and tie breakers.

Designs are available for any manufacturer’s switchgear and include:

•  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

Motor Control Center Upgrades


• 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.

Direct Replacement and Retrofit Upgrades for Low Voltage Motor Control Centers

Both motor control center upgrade options are designed to improve reliability, reduce maintenance and increase equipment capabilities.

The TeSys motor management system reduces costs as well as the complexity of your equipment.

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

Regardless of the application or location, our engineering, manufacturing, field service and project management teams can deliver a cost-effective turnkey solution that will minimize downtime or lead times.

Custom Solutions

DO YOU HAVE UNIQUE PRODUCT REQUIREMENTS

OR COMPLEX POWER ISSUES?

Custom Equipment: Non-Standard Dimensions and/or Ratings


On Demand and Emergency Response Services

Temporary Generator Connection

Emergency Action Plan

On Demand and Emergency Services

In case of emergency, call 1-888-778-2733. Our nationwide network of professional engineers and qualified field representatives is available any time, for any brand of equipment.

NATIONAL NETWORK OF OVER 400 QUALIFIED

FIELD SERVICE REPRESENTATIVES.


Temporary Generator Connection


We offer a turnkey solution for a temporary generator connection to your normal or emergency power system.


•  The authority having jurisdiction requires portable generator connection provisions in addition to the fixed-mounted emergency generators per NEC® article 708.20(F)(6).

•  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.

•  The facility can withstand short-term disruptions to electrical power but a long-term disruption will jeopardize the business.

Improves electrical system reliability.

A temporary generator connection is recommended where one of the following applies:

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.


•  Have a current single-line drawing of the electrical distribution system.

•  Identify which electrical equipment is critical to the electrical infrastructure.

•  Determine which equipment must be replaced and that which can be reconditioned, if water damage has occurred.

Components include:

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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Our technologies ensure that everywhere, for everyone and at every moment.


THANK YOU

Switchgear Solutions

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