A3-305 EVALUATION OF FAILURE DATA OF HV CIRCUIT-BREAKERS FOR CONDITION BASED MAINTENANCE. F. Heil ABB Schweiz AG (Switzerland)
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1 21, rue d'arois, F Paris hp:// A3-305 Session 2004 CIGRÉ EVALUATION OF FAILURE DATA OF HV CIRCUIT-BREAKERS FOR CONDITION BASED MAINTENANCE G. Balzer * D. Drescher Darmsad Universiy of Technology (Germany) F. Heil ABB Schweiz AG (Swizerland) P. Kirchesch Alsom Energieechnik GmbH (Germany) R. Meiser EnBW Regional AG (Germany) C. Neumann RWE Transpornez Srom GmbH (Germany) SUMMARY Permanenly new ideas are invesigaed o opimize mainenance sraegies and measures o reduce expenses wih consan qualiy of power supply. Therefore mos German nework operaors aemp o expand he ime inerval of mainenance. The overall quesion is how long such inervals for elecrical equipmen can be expanded wihou reducing he qualiy of power supply? In his repor a new mehod is presened which evaluaes he fuure failure frequency coming from disurbance saisics of equipmen. I is a direc anicipaion from resuls, how long mainenance inervals can be exended by a oleraed failure frequency. In a firs sep high vol circui-breakers are assessed and he daa base consiss of abou 8600 iems. The hisory of he circui-breakers are recorded over he complee life ime, so he mainenance measures and he failures could evaluaed. Keywords: Circui-breaker, failure rae, mainenance 1. INTRODUCTION Elecrical equipmen in power ransmission and disribuion sysems are essenial for he load flow, o proec oher equipmen and persons in case of failures. Therefore high requiremens for performance and availabiliy are mandaory for hese equipmen. To secure hese properies during oal lifeime, exensive mainenance sraegies have o be applied. The erms from area of mainenance follow he definiions in he German sandard specificaion DIN The mos imporan erms for his repor are explained again: - Inspecion: Measures of ascerainmen and esimaion of acual sae of echnical equipmen - Service: Measures of preservaion of arge sae of echnical equipmen - Replacemen: Measures of resoraion of arge sae of echnical equipmen - Mainenance: Measures of preservaion and resoraion of arge sae as well as measures of ascerainmen and esimaion of acual sae of echnical equipmen There is a rend since some years o change he mainenance sraegy: Saring wih he ime based sraegy wih fixed and shor mainenance inervals and for example an assumed ime of replacemen of 35 years, he uiliies ry o apply he condiioned based sraegy or in he opposie o his o exend he ime inervals of he inspecion or service depending on he ype of circui-breaker or drive. The * Landgraf-Georg-Sr. 4, D Darmsad; gerd.balzer@eev.u-darmsad.de
2 overall problem is o ge he experience of he opimum ime inervals wha is he bes suied measure wihou acceping a higher risk of failures. Mainenance measures can only be opimized and special sraegies can be creaed, if daa abou previous evens (disurbances and/or mainenance measures) are known. These evens should be colleced in disurbance saisics by each nework operaor. These disurbance saisics should conain ime of he failure even, ype and reason of he failure. This repor presens a mehod o handle he colleced disurbance daa so ha no only he previous ing behavior of equipmen bu also he fuure ing behavior can be shown. This new mehod is exemplary applied o abou 8600 HV circui-breakers (U r > 100 kv) wih abou 6800 failures. 2. FAILURE FREQUENCIES OF EQUIPMENT The failure frequency of various equipmen classes is an imporan crieria besides he analysis of he failure locaion. The failure frequency of equipmen classes allows comparisons of failures of differen equipmen and makes reference o several crieria like, number of operaions, ime beween evens ec. Whaever crieria for evaluaion is chosen, differen saemens abou previous and fuure mainenance aciviies can be achieved. For he esimaion of ing behavior of differen equipmen, as crieria is chosen, i.e. all failure frequencies are calculaed and illusraed versus. In general various ing paerns can be differeniaed according o Figure 1 [1]: Teehing: describes pure eehing problems or burn-in problems which are reduced by progressed operaing ime Wearou: describes wearou problems which are increased by progressed operaing ime Operaional: describes problems which appear due o operaion Ageing: describes common ing phenomena independen of operaion Random: describes problems which do no depend on or operaion Bah-ub: is a combinaion of eehing problems and wearou bah ub eehing problems wearou ing operaional Figure 1: Differen paern of failure frequency The aim of he mehod for he evaluaion of he ing behavior of elecrical equipmen is o find a combinaion of he five elemenary and independen behavior paerns, he summaion of which mus have he minimum deviaion (leas square mehod) from he disurbance daa. Figure 2 shows he main principle of his mehod, which is described in deail in [2]. 2
3 eehing problems failure saisic of equipmen failure operaional failure wearou failure ing failure Σ mehod of leas square elemenary, independen behavior paern Figure 2: Principle mehod for evaluaing he ing behavior of equipmen 3. DATA BASE OF CIRCUIT-BREAKERS The complee daa base of he evaluaed circui-breakers is lised below regarding ype of insulaion, arc exinguishing medium and drive (absolue values and percen): Type of insulaion: air blas: 1357 (15.9 %) minimum oil: 3014 (35.2 %) SF 6 : 4184 (48.9 %) Type of drives: pneumaic: 1701 (19.9 %) hydraulic: 3985 (46.6 %) mechanic: 2869 (33.5 %) In oal 8555 circui-breakers are considered wih differen insulaion maerial and drives. The disribuion of he circui-breaker is presened in Figure 3. Firs insallaions were in he sixies, mos of he pieces of equipmen were insalled during he sevenies, and since he beginning of he las decade he invesmens were reduced. The aver of he differen ypes of circui-breakers can be esimaed o: air-blas: minimum oil: SF 6 : 38.9 years 31.2 years 14.9 years. During he las fify years 6776 evens are recorded which are relaed o he oal circui-breakers populaion. Table 1 shows he number of disurbances according o he differen componens: high vol/insulaion - drive secondary and auxiliary circuis -ohers. The recorded daa involve major as well as minor failures and he values are received from he daa bases of he ransmission uiliies. I has o be saed ha he porion of high vol/insulaion failures in case of SF 6 circui-breakers are mainly driven by leak problems and no due o failures a he live par componens of he circui- 3
4 breakers. The lised failures in any case led o a reacion of he service deparmen, so hese daa are relevan o esimae he opimal service ime SF6 minimum oil air-blas Figure 3: Age disribuion c.b. secion ype of circui-breaker air-blas minimum SF 6 oil high vol/insulaion drive secondary & auxiliary circuis ohers Table 1: Failure disribuion of differen ypes of circui-breakers as percen 4. FAILURE FREQUENCY OF CIRCUIT-BREAKERS Due o he imporance for mainenance sraegies and he exising daa base circui-breakers wih SF 6 and minimum oil insulaion are considered only. Figures 4 (above, minimum oil) and (below, SF 6 ) shows he failure frequency versus he of he circui-breakers in oal. A clear rend of he failure behavior of minimum oil ype is obvious, ha means afer 10 and up o 25 years of insallaion, he failure rae exceeds he mean value of 1.9 failure/100 c.b. and year. On he conrary o his fac he failures for SF 6 circui-breakers are ly disribued over he oal insallaion ime and in his case he mean failure rae is 6.0 failure/100 c.b. and year, which exceeds he failure rae of he minimum oil ype. For informaion he failure rae of he air-blas c.b.'s is 2.6 failure/100 c.b. and year bu his value is no comparable wih he ohers (see Chaper 5). Due o he fac, ha mainenance aciviies are applied during he insallaion ime, i makes sense o evaluae he failure frequency depending on he "even-free ime" of a circui-breaker. Evens may be failures, ess, services, mainenance measures or commissioning. So here are neiher failures nor any mainenance or live-exension measures during even-free ime. Such ype of illusraion is specially suiable o ge saemens like how long componens can operae wihou mainenance measures, so ha he relaive failure frequency of componen is no influenced by any aciviies [3]. Furhermore he wo mos imporan componens of he circui-breaker are considered separaely according o Table 1: high vol/insulaion and drive. In addiion he evaluaions concenrae only upon SF 6 and minimum oil circui-breakers due o he low number of air-blas circui-breakers. 4
5 failure frequency failure frequency Figure 4: Failure frequency in oal of minimum oil (above) and SF 6 circui-breakers (below) The figures 5 o 9 show on he lef hand side he failure rae of he samples versus even free ime. On he righ hand side he paern curves are ploed separaely, which fi bes o he samples. Finally he differen regression curves are summed up and he resul is ploed in he figures on he lef side again, which shows he overall curve. Due o he reduced number of failures of SF 6 circui-breakers wih mechanic drives hese componens are no considered. The maximum ime range, which is recorded, is for example 17 years (Figure 7), ha means during his ime no aciviy is provided a he circui-breaker. The Figures 5 o 9 presen he following samples: - h.v. componens of 4184 SF 6 circui-breakers wih 3163 failures (Figure 5); - h.v. componens of 3014 minimum oil circui-breakers wih 2206 failures (Figure 6); hydraulic drives of SF 6 circui-breakers wih 1734 failures (Figure 7) hydraulic drives of minimum oil circui-breakers wih 674 failures (Figure 8) mechanic drives of minimum oil circui-breakers wih 95 failures (Figure 9) The principle procedure is explained using Figure 7: In his case here are hree overall curves o derive he leas deviaion from he mean value of he samples: - combinaion of eehing, and wearou behavior. The final resul of he evaluaion is, ha eehing problems seem o be he main reason for he failure rae of componens. Tha means he probabiliy of a failure even is high in he same year as mainenance aciviies have aken place. This disinc behavior can obviously be seen in case of hydraulic drives in he opposie o mechanic drives. The same failure frequency paern can be deduced from he behavior of he high vol componens of circui-breakers. The hydraulic drives of SF 6 circui-breakers show a wearou problem afer 13 years due o he long recorded ime period of 17 years, bu no ing phenomena can be deeced. In conras o his a clear ing and minor eehing prob- 5
6 lems are observed in case of he mechanic drives of minimum oil circui-breakers, bu he observed even free ime is reduced compared o hydraulic drives. The second class of failure behavior is he paern, ha means he failure occur consanly over he considered ime period. eehing 1 values eehing/ even free ime/years Figure 5: High vol componens of SF 6 ype circui-breakers 1 eehing values eehing/ even free ime/years Figure 6: High vol componens of minimum oil circui- breakers 1 1 values eehing/wearou/ 1 eehing wearou even free ime/year Figure 7: Hydraulic drives of SF 6 circui-breakers 6
7 values eehing/ 1 eehing even free ime/year Figure 8: Hydraulic drives of minimum oil circui-breakers eehing 1 values eehing/wearou/ing wearou ing even free ime/years Figure 9: Mechanic drives of minimum oil circui-breakers 5. ASSESSMENT OF THE RESULTS Comparing minimum oil and SF6 breakers he differen echnical boundary condiions should be considered: - Minimum oil circui breakers reached heir maximum performance per inerruping uni in he mid sevenies wih approximaely 145kV/31.5kA. Major manufacurer sopped hen developmen aciviies and minimum oil echnology was replaced by SF6 echnology. - SF 6 unis reach now 300kV/63kA or even more. From he mid sevenies on SF6 echnology is he dominaing echnology. - In addiion o ha requiremens from he grid and consequenly from he sandard side have increased: shor circui curren, capaciive curren swiching, elecrical and mechanical endurance, ype esing and so on. These addiional requess may lead o higher sresses for componens of SF6 circui breakers compared o hose of minimum oil devices. Mechanic and hydraulic drives can be characerized by following aspecs, which can be described as follows: 7
8 - Hydraulic drives are complex; require high qualiy and perfec maerial. These aspecs are some imes difficul o check during producion and commissioning. On he oher hand only a few pars are moving ones and because of naural greasing by hydraulic oil wear is low. - Mechanic drives are easier o check during producion and commissioning. Neverheless he high number of pars (many of hem moving), grease ha may disappear, increasing fricion, and mechanical deformaion, may increase wear over. - As a consequence hydraulic drives have more eehing problems and show less ing behavior - In addiion i has o be menioned ha in many applicaions hydraulic drives are used o operae heavy SF 6 breakers e.g. puffer breakers for ka, whereas mechanic spring drives are mainly used o operae breakers which need less drive energy like SF 6 self blas breakers. As a resul of he evaluaion i can be saed ha in many cases he mainenance inerval can be exended depending on he ype of circui-breaker, especially on he ype of drives in use. Due o he eehing problems, which are relevan for high vol componens as well as for hydraulic drives, he mainenance measures should be performed more carefully. Furhermore i is recommended o monior he condiion of componens. As a consequence he possibiliies of manual inervenions on he circuibreakers hus increasing he risk of eehing problems can considerably be reduced. Regarding he hydraulic drives i is obvious ha he mainenance inervals can be exended up o 12 or 15 years. Whereas he inerval of a mechanic drive should be abou 10 years. Bu due o he low number of recorded failures his value is a rough esimaion. In principle he nework operaor has o make sure ha he failure rae does no exceed he level he is willing o accep. The main goal is o observe he failure behavior coninuously and buil up a proper daa collecion i is also necessary o define levels of imporance a any poin where a circui breaker is insalled [4]. From he correlaion beween failure behavior and menioned levels he nework operaor can define he risks depending on he ime inerval of mainenance and can decide which risk level a he differen sysem poins is accepable. Togeher wih he relaion beween mainenance coss versus new equipmen coss i will be possible o find a reasonable ime for replacemen. 6. CONCLUSION By using he discussed evaluaion mehod i is possible o recommend mainenance inervals for condiion based mainenance. This mehod was applied o calculae he inervals for high vol circuibreakers of SF 6 and minimum oil ype wih hydraulic and mechanic drives. Teehing problems are he mos ofen observed failure paern whereas ing phenomena of he high vol componen could no be deeced up o 15 years. In a nex sep his procedure will be applied für power ransformers. 7. REFERENCES [1] Moubray, J.: Reliabiliy-cenered mainenance. 2 nd ediion. New York, Indusrial Press Inc., 1997 [2] Drescher, D.; Balzer, G.: A new mehod for qualiaive evaluaion of ing behavior of elecrical equipmen. ISH 2003, Delf, Augus 25-29,2003 [3] Drescher, D.; Balzer, G., Neumann, C.: Preparing failure daa o evaluae elecrical equipmen and resuls. ISH 2003, Delf, Augus 25-29,2003 [4] Balzer, G; e. al.: Life Cycle Assessmen of Subsaions: A Procedure for an Opimized Asse Manmen. Cigre 2002, Paris 2003, Repor
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