Appendix B (Rome 2000 IAS - PCIC Paper 63
Appendix B (Rome 2000 IAS - PCIC Paper 63.4 )
|Refinery Location | |Substation Name | |
|Substation Number | |Circuit Designation | |
|Switchgear Make | |Switchgear Type | |
|Serial No. | |Year of Manufacture | |
|Date of Assessment | |Assessor | |
KEY TO GUIDANCE TABLE / PROFORMANCE
|Potential to Become Safety | |Diagnostic Techniques | |Assessment |
|Integrity Issue | | | | |
|H = |high | |PD = |Partial Discharge Monitor/Locator | |P = |Pass |
|M = |medium | |TH = |Thermographic | |D = |Deteriorating |
|L = |low | |US = |Ultrasonic scan | |F = |Fail |
| | | |MT = |Mechanism Timing | |U = |Unknown |
| | | |OT = |Oil Testing | |N = |Not applicable |
| | | |CD = |Continuity or Ducter Measurements | | | |
| | | |IR = |Insulation Resistance Measurements | | | |
Note- "EVIDENCE" CAN BE EITHER BY DIRECT INSPECTION OR FROM PREVIOUS MAINTENANCE / INSPECTION REPORTS
MV SWITCHGEAR INTEGRITY ASSESSMENT
GUIDANCE TABLE 1 - OCB TRUCK RELATED ITEMS
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
| | | | | | | |
|1.1 |Racking mechanism |a) |Is racking mechanism stiff or binding |L | | |
| |and mechanical interlocks |b) |Is there evidence of wear in racking drive box and associated drive train |L | | |
| | |c) |Is it difficult for the "truck to housing" shoot bolt to enter when the CB is|L | | |
| | | |fully racked into the housing | | | |
| | |d) |Is it easy to over travel when racking into the Service or Earth position |M | | |
| | |e) |Can the CB to be racked out of service when it is carrying current |H | | |
| | |f) |Can a closed CB to be racked into the service position |H | | |
| | |g) |Can a CB to be racked into service with the tank lowered |H | | |
| | |h) |Can the CB to be closed before the shoot bolt is fully home |M | | |
|1.2 |Truck Movement |a) |Can the truck be moved freely into and out of the housing |L | | |
| | |b) |Does the truck travel into housing causing misalignment of CB isolating |M | | |
| | | |contacts | | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|1.3 |Truck to Housing |a) |Is there evidence that the Earthing wiping contacts or plug-in "truck to |L | | |
| |Earthing | |housing" contacts are functioning correctly | | | |
|1.4 |Gas Venting System |a) |Does the CB tank spring loaded or plug in system mate and seal correctly |M | | |
| | |b) |Is there evidence of poor or damaged sealing between the fixed and truck |M | | |
| | | |mounted arrangements | | | |
|1.5 |CB Isolating |a) |Is there evidence of discharge activity in the form of copper nitrate |M | | |
| |Contacts | |deposits ("greening") | | | |
| |and Arms |b) |If a contact cluster is present on the CB truck, are the contact pressure |M | | |
| | | |springs rusting | | | |
| | |c) |Is there evidence of contact overheating, discolouration or arcing |H | | |
| | |d) |Is the contact support ring intact |M | | |
| | |e) |Is there evidence that the contacts are fouling or have fouled the spout |M | | |
| | | |shutters | | | |
| | |f) |Is contact cluster designed to tolerate some misalignment |M | | |
| | |g) | Are CB arms sufficiently insulated |H | | |
|1.6 |CB Tank |a) |Is the gasket complete and making a correct seal |M | | |
| | |b) |Are the tank bolts in good condition and all present |M | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|1.7 |CB Arc Control |a) |Are the labyrinth openings in the correct direction |H | | |
| |Devices |b) |Is there evidence of erosion of the assembly |M | | |
| | |c) |Has the interior been mechanically damaged by the moving contacts |M | | |
|1.8 |CB Moving Contacts |a) |Is there evidence of excessive burning and pitting of the contacts in |H | | |
| | | |relation to the duty performed since last maintenance | | | |
| | |b) |Is there evidence of separation of the arcing tips (where fitted) from the|H | | |
| | | |main contact | | | |
| | |c) |Is the moving contact making correct contact with the fixed contact(s) |H | | |
| | |d) |Is there evidence of moving contact overtravel and impact with the fixed |M | | |
| | | |contact base | | | |
|1.9 |CB Fixed Contacts |a) |Is there evidence of excessive burning and pitting of the arcing contact |H | | |
| | | |in relation to the duty performed since last maintenance | | | |
| | |b) |Is the contact support ring and contact pressure spring assembly intact |H | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|1.10 |CB Bushings |a) |Is there evidence of delamination, cracks, mechanical damage or discharge |H | | |
| | | |activity | | | |
| | |b) |Is the surface finish in good condition |M | | |
| | |c) |Is there evidence of mechanical damage within the CB tank |M | | |
| | |d) |Is there evidence of bushing cement crumbling into the tank |M | | |
|1.11 |CB Travel limit |a) |Is there evidence of oilway blockage in the dashpots |L | | |
| |dashpots and resilient |b) |Is there evidence of deterioration of resilient travel stops |L | | |
| |stops | | | | | |
|1.12 |CB Opening and closing |a) |Is there evidence of misalignment or mechanical deterioration of the |M | | |
| |Spring Assemblies | |groups of coil springs | | | |
| | |b) |Is there historical evidence of delayed opening or closing (either through|M | | |
| | | |operation of upstream CB or from timing tests) | | | |
|1.13 |CB Tank Linings |a) |Is the assembly mechanically damaged or delaminating |H | | |
| |and Phase Separators |b) |Is there evidence of moisture absorption |H | | |
| | |c) |Is there evidence of damage due to arcing or arc products | | | |
|Item |Item Description | |Assessment Check |Integrity |Assessment |COMMENT |
| | | | |Rating |P/D/F/U/N | |
|1.14 |Insulated Drive |a) |Is there evidence of mechanical fatigue at the fixings |H | | |
| |Links |b) |Is there evidence of electrical distress (tracking) |H | | |
| | |c) |Is there evidence of surface contamination |H | | |
|1.15 |Oil Condition |a) |Is the oil severely carbon contaminated in relation to the duty performed |H | | |
| | | |since the last oil change | | | |
| | |b) |Is there evidence of any sludging or fungus growth in the oil tank |M | | |
|1.16 |CB Operating Mechanism |a) |Has the mechanism suffered from failure to latch |M | | |
| |Stability |b) |Is the mechanism difficult to re-adjust |L | | |
| | |c) |Has the CB been tripping through |M | | |
| | |d) |Have measured tripping times been satisfactory (after CB being closed for |M | | |
| | | |extended time) | | | |
|1.17 |CB Operating |a) |Has the CB been slow to trip |M | | |
| |Mechanism Trip |b) |Does the trip coil plunger travel freely |M | | |
| |Bar and Trip Prop |c) |Are the trip bar bearings free and correctly lubricated |M | | |
| | |d) |Does the trip prop correctly support the trip latch |M | | |
| | |e) |Has the mechanism been persistently difficult to adjust for correct |L | | |
| | | |operation | | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|1.18 |Trip Coil |a) |Has a Trip Coil ever burnt out due to inaction of the clearing |L | | |
| | | |contact | | | |
| | |b) |Is the insulation of the coil adequate |L | | |
| | |c) |Does the plunger fully travel to lift the trip bar |L | | |
|1.19 |Auxiliary Switches |a) |Are these switches all correctly set |L | | |
| | |b) |Are these switches correctly lubricated and free moving |L | | |
|1.20 |Auxiliary Switch |a) |Are all the male and female contacts complete |L | | |
| |Isolating Contact |b) |Do the contacts engage correctly |L | | |
| |board |c) |Are the contacts correctly lubricated | | | |
| | |d) |Does the contact self aligning system function correctly |L | | |
|1.21 |Umbilical Loose Trunk for |a) |Are the end connections in good condition |L | | |
| |Connecting withdrawn CB to|b) |Are the interconnections complete |L | | |
| |Housing | | | | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|1.22 |Mechanism Lubrication |a) |Is there evidence of all bearings being correctly lubricated |L | | |
| | |b) |Is the mechanism sticky with old congealed lubricant |L | | |
|1.23 |Loose Earthing Equipment |a) |Are the bushing extensions in good condition |L | | |
| | |b) |Are the contact assemblies in good condition |L | | |
| | |c) |Is the Star point assembly complete |L | | |
| | |d) |Are the shutter advancing components complete, including fixings |L | | |
| | |e) |Has the equipment been damaged by inadvertent contact with the |L | | |
| | | |spout shutters | | | |
| | |f) |Has the equipment been modified or had lost parts replaced by |L | | |
| | | |local manufacture | | | |
| | |g) |Is the assembly fully rated for duty |M | | |
GUIDANCE TABLE 2 - OCB HOUSING RELATED ITEMS
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|2.1 |Cable Termination |a) |If termination box is compound filled, is compound leaking from box |M | | |
| | |b) |Is there evidence of Discharge Activity on dry terminations |H | | |
| | |c) |Is there evidence of overheating |M | | |
| | |d) |Are the bushings in good condition |M | | |
| | |e) |Is there evidence of cable plumb deterioration |L | | |
| | |f) |Is there evidence of cable papers drying out in the region of the crutch |M | | |
| | |g) |If the cable cores are brought through the cable box turret insulators and damp|M | | |
| | | |sweated is there evidence of moisture on the cores | | | |
| | |h) |Is there evidence of inadequate earth bonding |L | | |
| | |i) |If the termination is of the dry type, phase segregated, are the inter-phase |M | | |
| | | |and phase to earth barriers in good condition | | | |
| | |j) |Is the cable compartment adequately segregated from other compartments and |M | | |
| | | |externally (i.e. IP rating) | | | |
|2.2 |Earthing and Bonding |a) |Are the truck, tank to housing and inter panel earth bonds functioning |L | | |
| | | |correctly | | | |
| | |b) |Is the earth applied via fault rated earthing device. |L | | |
| | |c) |Are the earthing interlocks adequate |L | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|2.3 |Shutters and |a) |Does the truck correctly drive the shutter operating mechanism |M | | |
| |Interlocks |b) |Are the shutters damaged |M | | |
| | |c) |Do the shutters correctly cover the spouts when the truck is withdrawn |M | | |
| | |d) |Do the shutters have a facility for safety locking |H | | |
| | |e) |Does the truck to housing interlock function correctly |M | | |
| | |f) |Is it possible to overrun with the truck raising system |L | | |
|2.4 |Gas Venting |a) |Does the CB tank spring loaded or plug in system mate and seal correctly |M | | |
| | |b) |Is there evidence of poor or damaged sealing between the fixed and truck |M | | |
| | | |mounted arrangements | | | |
| | |c) |Is the pipe for venting gas to atmosphere clear of debris and complete |M | | |
| | |d) |If the gas venting system relies on non return valves to ensure venting to |M | | |
| | | |atmosphere does the system function correctly | | | |
| | |e) |Is it possible for water to enter the gas vent pipe if the roof leaked |H | | |
|2.5 |Internal Anti- |a) |If internal heaters are fitted, do they function correctly |M | | |
| |Condensation |b) |Are they adequate for the environmental duty at the site |M | | |
| |Heaters | | | | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|2.6 |Busbars and |a) |Is there evidence of overheating of any connections |H | | |
| |Spouts |b) |Is there evidence of discharge activity within spout bushings as indicated by |H | | |
| | | |copper nitrate deposits ("greening") on the isolating contacts | | | |
| | |c) |Is there any evidence of busbar insulation deterioration or metal corrosion |H | | |
| | |d) |Is there evidence of deterioration of the connection profile |M | | |
| | | |wrapping/insulation | | | |
| | |e) |Is there any evidence of compound leakage in compounded busbar systems |M | | |
| | |f) |Is there evidence of contamination of compound or liquid filled busbar chambers|M | | |
| | |g) |Is there evidence of discharge activity on the surface of support insulators or|H | | |
| | | |spouts | | | |
| | |h) |Is there evidence of build up of contamination on the surface of support |M | | |
| | | |insulators and the exterior and interior of spout bushings | | | |
| | |i) |Is there evidence of mechanical distress of support insulators or spouts |H | | |
| | |j) |Is the busbar compartment adequatley protected from ingress of foreign bodies |H | | |
| | | |or moisture | | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description| |Assessment Check |Rating |P/D/F/U/N | |
|2.7 |CT Chamber |a) |Is there evidence of surface contamination of the CT Primary Bushing |M | | |
| | |b) |Is there evidence of electrical discharge erosion around the CT seating on the Primary |H | | |
| | | |Bushing | | | |
| | |c) |Is there evidence of discharge erosion of the surface of the Primary Bushing |H | | |
| | |d) |Is there evidence of discharge products on or within the wrappings of the wound ring CT |H | | |
| | |e) |Was the CT satisfactory after winding continuity and voltage tests |H | | |
| | |f) |If the CT chamber is oil filled, have the oil tests been satisfactory |H | | |
| | |g) |Is there evidence of moisture on the outside of the chamber |L | | |
| | |h) |Are all the connections from the CT to other components satisfactory |M | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|2.8 |Voltage Transformer |a) |Are the isolating spout shutters free from damage and able to operate correctly | | | |
| | |b) |Is there evidence of mechanical damage to the VT Bushings |M | | |
| | |c) |Is there evidence of surface contamination of the VT Bushings |M | | |
| | |d) |Is there evidence of electrical discharge erosion on the surface or end of the VT |H | | |
| | | |Bushings | | | |
| | |e) |Is there evidence of overheating of the plug-in isolating contact assembly |H | | |
| | |f) |Is there evidence of electrical discharge within the plug-in spout assembly |H | | |
| | |g) |Where the HV fuse is mounted in the VT bushing, is there evidence of internal electrical|H | | |
| | | |discharge activity | | | |
| | |h) |Is there evidence of electrical discharge or overheating associated with the HV fuse |H | | |
| | | |pressure contacts | | | |
| | |i) |Is there evidence that the VT fuse is open circuit or displays internal corona discharge|M | | |
| | | |problems | | | |
| | |j) |Have electrical tests of the HV and LV windings been satisfactory |M | | |
| | |k) |Are the LV terminal rail or fuse connections satisfactory |L | | |
| | |l) |If the chamber is oil filled, did it pass routine oil tests |M | | |
| | |m) |Can the VT fuses be changed safely without de energising |L | | |
MV SWITCHGEAR ASSESSMENT
GUIDANCE TABLE 3 - CARE AND MAINTENANCE
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|3.1 |Switchroom Environment |a) |Is the heating/dehumidification/ ventilation system in working order and adequate for |M | | |
| | | |the application | | | |
| | |b) |Are cable trenches and ducts sealed against moisture ingress |M | | |
| | |c) |Is there evidence of water leakage through the switchroom roof |H | | |
| | |d) |Is there evidence of condensation on walls or on the electrical equipment |H | | |
| | |e) |Is the room adequately sealed against ingress of dust and other external solid |M | | |
| | | |pollutants | | | |
| | |f) |If close to the sea, is switchroom adequately sealed against ingress of salt laden |M | | |
| | | |atmosphere | | | |
| | | | |Integrity |Assessment |COMMENT |
|Item |Item Description | |Assessment Check |Rating |P/D/F/U/N | |
|3.2 |Maintenance Practice |a) |Are there records of regular inspections and maintenance examinations being carried |M | | |
| |for Switchboard | |out | | | |
| | |b) |Do specifications exist that describe the extent of these inspections and maintenance |M | | |
| | | |examinations | | | |
| | |c) |Is replacement oil tested for moisture and electric strength before maintained OCB is |H | | |
| | | |returned to service | | | |
| | |d) |Are liquid vacuum cleaners/spray equipment used to clean contaminated tanks |M | | |
| | | |Is it the practice to check that oil is free from air bubbles after refilling the OCB | | | |
| | |e) |tank and before energising the circuit |M | | |
| | | |Are mechanism operating times measured | | | |
| | |f) | |M | | |
| | |g) |Have the manufacturer's recommended lubricants (or equivalent) been used throughout |L | | |
| | | |the life of the mechanism | | | |
| | |h) |Has the standard of maintenance practice ever been audited |M | | |
SUMMARY OF INTEGRITY ASSESSMENT FAILED ITEMS
|Integrity |ITEM |Reason For Failure |Potential Consequences |Options to Rectify |Order of |
|Priority | | | | |Cost |
|Rating | | | | | |
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