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 Integrity Issue / Diagnostic Techniques / Assessment
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

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MV SWITCHGEAR INTEGRITY ASSESSMENT

GUIDANCE TABLE 1 - OCB TRUCK RELATED ITEMS

Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 fully racked into the housing / L
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 contacts / M
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
1.3 / Truck to Housing
Earthing / a) / Is there evidence that the Earthing wiping contacts or plug-in "truck to housing" contacts are functioning correctly / L
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 mounted arrangements / M
1.5 / CB Isolating
Contacts / a) / Is there evidence of discharge activity in the form of copper nitrate deposits ("greening") / M
and Arms / b) / If a contact cluster is present on the CB truck, are the contact pressure springs rusting / M
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 shutters / M
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
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 relation to the duty performed since last maintenance / H
b) / Is there evidence of separation of the arcing tips (where fitted) from the main contact / H
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 contact base / M
1.9 / CB Fixed Contacts / a) / Is there evidence of excessive burning and pitting of the arcing contact in relation to the duty performed since last maintenance / H
b) / Is the contact support ring and contact pressure spring assembly intact / H
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
1.10 / CB Bushings / a) / Is there evidence of delamination, cracks, mechanical damage or discharge activity / H
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 stops / b) / Is there evidence of deterioration of resilient travel stops / L
1.12 / CB Opening and closing Spring Assemblies / a) / Is there evidence of misalignment or mechanical deterioration of the groups of coil springs / M
b) / Is there historical evidence of delayed opening or closing (either through operation of upstream CB or from timing tests) / M
1.13 / CB Tank Linings / a) / Is the assembly mechanically damaged or delaminating / H
and Phase Separators / b)
c) / Is there evidence of moisture absorption
Is there evidence of damage due to arcing or arc products / H
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 since the last oil change / H
b) / Is there evidence of any sludging or fungus growth in the oil tank / M
1.16 / CB Operating Mechanism Stability / a)
b)
c)
d) / Has the mechanism suffered from failure to latch
Is the mechanism difficult to re-adjust
Has the CB been tripping through
Have measured tripping times been satisfactory (after CB being closed for extended time) / M
L
M
M
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 operation / L
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
1.18 / Trip Coil / a) / Has a Trip Coil ever burnt out due to inaction of the clearing contact / L
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 Connecting withdrawn CB to Housing / a)
b) / Are the end connections in good condition
Are the interconnections complete / L
L
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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)
b) / Are the bushing extensions in good condition
Are the contact assemblies in good condition / L
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 spout shutters / L
f) / Has the equipment been modified or had lost parts replaced by local manufacture / L
g) / Is the assembly fully rated for duty / M

GUIDANCE TABLE 2 - OCB HOUSING RELATED ITEMS

Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 sweated is there evidence of moisture on the cores / M
h) / Is there evidence of inadequate earth bonding / L
i) / If the termination is of the dry type, phase segregated, are the inter-phase and phase to earth barriers in good condition / M
j) / Is the cable compartment adequately segregated from other compartments and externally (i.e. IP rating) / M
2.2 / Earthing and Bonding / a) / Are the truck, tank to housing and inter panel earth bonds functioning correctly / L
b) / Is the earth applied via fault rated earthing device. / L
c) / Are the earthing interlocks adequate / L
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 mounted arrangements / M
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 atmosphere does the system function correctly / M
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
Heaters / b) / Are they adequate for the environmental duty at the site / M
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 copper nitrate deposits ("greening") on the isolating contacts / H
c) / Is there any evidence of busbar insulation deterioration or metal corrosion / H
d) / Is there evidence of deterioration of the connection profile wrapping/insulation / M
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 spouts / H
h) / Is there evidence of build up of contamination on the surface of support insulators and the exterior and interior of spout bushings / M
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 or moisture / H
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 Bushing / H
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
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
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 Bushings / H
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 discharge activity / H
h) / Is there evidence of electrical discharge or overheating associated with the HV fuse pressure contacts / H
i) / Is there evidence that the VT fuse is open circuit or displays internal corona discharge problems / M
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

Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
3.1 / Switchroom Environment / a) / Is the heating/dehumidification/ ventilation system in working order and adequate for the application / M
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 pollutants / M
f) / If close to the sea, is switchroom adequately sealed against ingress of salt laden atmosphere / M
Item / Item Description / Assessment Check / Integrity
Rating / Assessment
P/D/F/U/N / COMMENT
3.2 / Maintenance Practice for Switchboard / a) / Are there records of regular inspections and maintenance examinations being carried out / M
b) / Do specifications exist that describe the extent of these inspections and maintenance examinations / M
c) / Is replacement oil tested for moisture and electric strength before maintained OCB is returned to service / H
d)
e)
f) / Are liquid vacuum cleaners/spray equipment used to clean contaminated tanks
Is it the practice to check that oil is free from air bubbles after refilling the OCB tank and before energising the circuit
Are mechanism operating times measured / M
M
M
g) / Have the manufacturer's recommended lubricants (or equivalent) been used throughout the life of the mechanism / L
h) / Has the standard of maintenance practice ever been audited / M

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SUMMARY OF INTEGRITY ASSESSMENT FAILED ITEMS

Integrity
Priority
Rating / ITEM / Reason For Failure / Potential Consequences / Options to Rectify / Order of
Cost

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