JANUARY 6, 2017

Substation Inspection and Maintenance

ABB Workforce Management System
Edwin Pak
Agenda

What is a Substation?
Connected Asset Lifecycle Management
ABB’s Workforce Management System
 Challenges
 Inspection
 Maintenance
 Repair
Target Customer Profile
Glossary

May 11, 2017 Slide 2

What is a Substation?
Wikipedia

Wikipedia “Electrical Substation”

“A substation is a part of an electrical generation,
transmission, and distribution system. Substations
transform voltage from high to low, or the revers, or
perform any of several other important functions.
Between the generating station and consumer, electric
power may flow through several substations at
different voltage levels. A substation may include
transformers to change voltage levels between high
transmission voltages and lower distribution voltages,
or at the interconnection of two different transmission
voltages.” –

May 11, 2017 Slide 3

What is a Substation?
Example of a digital substation

Substation automation protection and Advanced system and equipment supervision for
control system with IEC 61850 station bus efficient asset management Non-conventional instrument
transformers increase safety and
reduce footprint

IEC 61850 process bus,

connecting the switchyard to the
protection and control system Stand-alone merging units, bridging
the gap between analog and digital
world. Compliant to IEC 61850

May 11, 2017 Slide 4

What is a Substation?
Type of Substations

– Transmission Substation
• > 170 kV – Convert Substation
– Sub-transmission Substation • Convert currents: AC to DC or DC to AC
• 60 – 170 kV • Rare
• US: 138 kV / 230 kV / 356 kV / 500 kV – Switching Substation (Switchyard)
• Canada: 110 kV / 220 kV / 400 kV • Substation without transformers operating only at a single voltage level
• Different voltages have different safety considerations • Used to switch lines or parallelizing circuits
– Distribution Substation – Railways
• < 60 kV • Electrified railways also use substations
• End users are consumers • Often distribution substations
– Collector Substation
• Substation that collects from generation projects like a wind farm

May 11, 2017 Slide 5

What is a Substation?
Components

✓ Arresters ✓ Station load boards

✓ Batteries ✓ Switchgear
✓ Cables and terminators ✓ Switchgear houses
✓ Capacitors ✓ Transformers
✓ Circuit breakers ✓ Voltage regulators
✓ Disconnect switches ✓ Yards
✓ Instrument transformers
✓ Line traps and reactors
✓ Overhead Transmission Lines (OHTLs)
✓ Pump houses
✓ Relay house and control rooms
✓ Re-closer Circuit Breakers / Fuses
✓ Station bus
✓ Station equipment

May 11, 2017 Slide 6

Agenda

What is a Substation?
Connected Asset Lifecycle Management
ABB’s Workforce Management System
 Challenges
 Inspection
 Maintenance
 Repair
Target Customer Profile
Glossary

May 11, 2017 Slide 7

Connected Asset Lifecycle Management

Asset Health Center

May 11, 2017 Slide 8

Connected Asset Lifecycle Management
Components involved in CALM

Assessment Analytics System (Asset Health Center – AHC)

• Provides information and metrics to make decisions for maintenance work and their priorities

Enterprise Asset Management System (Ellipse)

• Provides a holistic way to view and manage assets and plan for work required to maintain the assets

Workforce Management System (Hancock)

• Provides a way to manage the mobile workforce efficiently and optimally

May 11, 2017 Slide 9

Connected Asset Lifecycle Management
End-to-End Scenario

– Sensors (Grid Sentry) collects asset information • Work Order released to WFM • Crew updates readings / repair information
– Assessment Analytics (Asset Health Center) – WFM (Hancock) • Crew updates Labour / Equipment information
• Identify problems using a variety of methods • Work Order is sent to a Crew • Crew identifies repair required and sends a
(trending, thresholds, rate of change, statistical • Crew arrives at the Substation Work Request to the EAM
correlation and probabilistic theory) • Crew completes the Work Order
• Crew views a Substation Hazard Report WFM-
• Provide recommendations for corrective action >AHC • Work Order status is sent to Ellipse
/ preventative maintenance (Including
Timeframe) • Crew views all Substation issues WFM->AHC – Ellipse

• Sends Work Requests to Ellipse • Crew views current asset information WFM- • Updates the status of the Work Order
>AHC – Asset Health Center
– EAM (Ellipse)
• Crew views asset maintenance steps WFM- • Data points sent to AHC
• Creates a Work Order associated with the asset >EAM
• Requisitions materials, resources and • Crew views schematic from LinkOne WFM-
equipment >EAM

May 11, 2017 Slide 10

Agenda

What is a Substation?
Connected Asset Lifecycle Management
ABB’s Workforce Management System
 Challenges
 Inspection
 Maintenance
 Repair
Target Customer Profile
Glossary

May 11, 2017 Slide 11

ABB’s Workforce Management System
Categories: Substation Inspection, Maintenance, Repair

– Three categories of scenarios

• Planned: Inspection – Reliability is a secondary concern
• Planned: Maintenance • Ensure the assets are performing reliably
• Unplanned: Repair – Manuals: http://electrical-engineering-portal.com/download-center/books-
– Coordination is required among many business groups and-guides/power-substations

• Especially when an outage is required

• Information regarding switching to the technician / crew is beneficial
• In order to do maintenance or repair, lockout / tagout procedure is
required to de-energize the bay in which work is required
– Safety is a primary concern
• Information of procedures to de-energize and re-energize bays
• Communication with the back office in cases of emergency

May 11, 2017 Slide 12

ABB’s Workforce Management System
Challenges

Crew types Forms

– GIS / AIS may require different crews because of the different skill sets – There are different forms that are required for different conditions
required (GIS – mainly Europe / AIS – mainly North America) – There are also different responses / directions for different situations
– Example 1: A reading is taken from sensor 1
Crew gear • Section A is filled out and the reading is entered into field Y
– Higher voltage requires different safety gear • Since field Y is filled out in Section A, Section C is required.
– Different gear would be required for a 33 kV vs a 500 kV Substation • However, the reading if field Y didn’t reach the threshold so Section B is
not required
Procedures – Example 2: There is a transformer leak on site
– Different procedures are required for different Substations • Environmental for is required to be filled out with the amount of leak
– Safety is more rigorous for a 500 kV vs a 33 kV Substation
– GIS maintenance and repair procedures would be different than an AIS Complex Forms
procedure – Conditional evaluation is required, similar to the examples above

May 11, 2017 Slide 13

ABB’s Workforce Management System
Considerations

– Clearances
• Tagout/lockout procedures. Access to equipment isolation, work status, – Switching
and schedule information required. • Critical systems have parallel breakers
• To perform maintenance, a certain bay is re-routed and then shut down
– Inspection
• Collecting and storing information. – Utilities don’t always inspect substations as a whole
• Coordinate multiple feeders
– Personnel Qualifications • Certain breakers, group inspections / maintenance in to one work order
• Due to the various substation requirements, qualifications need to be • Switches and transformers do not have much change
considered.

– Equipment
• Equipment required should be identified.

May 11, 2017 Slide 14

ABB’s Workforce Management System
Substation Inspection
Example 1: http://electrical-engineering-portal.com/download-center/books-and-guides/power-substations/installation-mps-
transformers
– Periodic Tests and Inspections – Sampling of Insulating Fluid
• Gauge readings – Gaskets
• Ambient temperature
• kVA load
• Pressure/Vacuum Guage
• Fluid level Gauge
• Cooling fans
• Control wiring
• Paint finish
• Fluid dielectric test
• Bushing and surge arrester insulators
• Bushing terminals

May 11, 2017 Slide 15

ABB’s Workforce Management System
Substation Inspection
Example 2: http://electrical-engineering-portal.com/download-center/books-and-guides/power-substations/substation-condition-
monitoring
Service Inspection & Condition Monitoring Guideline • Battery Charger
– Painting and Galvanizing – Compressor
– Grounding System – Substation area – General
– Structure – Transformer
– Civil work-Foundation and Control Room – Circuit Breakers
– Buses and Shield wire – Current Transformer
– Porcelain Insulators and Bushings – Potential transformers
– Cable – Capacitance Voltage Transformers
– LT Cable & Metal clad switchgear – Coupling Capacitors
– Battery and battery charger – Disconnectors and Earth Switches
• Batteries – Surge Arrestors
• Racks – Wave Traps

May 11, 2017 Slide 16

ABB’s Workforce Management System
Substation Inspection

Substations: http://electrical-engineering-portal.com/download-center/books-and-guides/power-substations

• Each Asset comes with an Installation Manual

• Within each manual, there are instructions for the owners on
• When to inspect
• What to inspect
• How to maintain the equipment
• What the safety procedures
• How to troubleshoot common problems

May 11, 2017 Slide 17

ABB’s Workforce Management System
Substation Maintenance / Inspection / Repair (Equipment)

Under ABB PGGI Service, there are 3 types of work performed on Substations Maintenance Contract
• Service Calls (Warranty Calls) • Calls are first forwarded to Raleigh, NC
• Maintenance Calls • Work order is then manually assigned to the nearest Service Tech
• Testing and commissioning (Inspection)
Testing and commissioning
Service Calls • Equipment Tested (example):
• Equipment under warranty • Static VAR compensators
• 24 / 7 maintenance contract • Capacitor Stations (300 kV / 500 kV)
• Calls are first forwarded to Montreal • Schedule depends on customers
• Work Order is then manually assigned to whoever is free and nearest to • 2 – 3 months per station
the call • 10 hrs / 6 days a week

May 11, 2017 Slide 18

ABB’s Workforce Management System
Substation Maintenance / Inspection / Repair (Equipment) – Testing and Commissioning Workflow

Testing and Commissioning – Note: Cell phone restrictions. Some older sites are not allowed
1. Work Order sent to the Tech via email
2. Tech downloads from ABB’s server the Inspection and Test Plan (ITP) (like
Switch Order)
3. Tech arranges a conference call to sign off on the ITP
4. Each separate apparatus is inspected
– Must be within certain parameters
• w/in parameter – passes
• Trouble shooting and repairs may be required (done on the spot)
• If Union, the trouble shooting request sent to union for repairs
– Inspection performed with a crew
– Currently using paper forms

May 11, 2017 Slide 19

ABB’s Workforce Management System
Substation Maintenance / Inspection / Repair (Equipment) – Service Call Workflow

1. Customer Calls requesting Service/Repair 8. Diagnose problem

2. CSR take down relevant data 9. Repair Performed
– Nature of the problem 10. Site Visit Report completed
– Study data – Nature of the problem
– Attempts to resolve the issue on the phone – Condition of the Asset before repair (picture included)
– If not able to resolve, sent to the service tech – Resulting work
3. Email of the Work Order is sent to the Technician – Condition of Asset after repair (picture included)
4. Prepare a Plan of Action and sent to head office and customer for approval 11. Document stored in the PMDoc (storage location)
– If special tools required, inform customer or contractor ahead of time
5. Fly out to the site • Note: Reporting streamline would assist work.
6. Safety Orientation (Safety procedures)
7. Sit down and discuss plan of action with the customer

May 11, 2017 Slide 20

ABB’s Workforce Management System
Substation Maintenance / Inspection / Repair (Transformer)

• Industrial clients usually have their own maintenance programs (2 – 3 year • Manufactures have recommendations for new installations
inspections • SCADA monitors oil results
• Assessment performed first • Oil condition is an indicator on the health of the transformer
• Oil Sample • Normal Maint schedule 2 – 3 years
• Visual • Oil sample taking every 3 months if transformer is bad
• Electrical and Mechanical Recommendation • While inspecting the transformer
• If in bad shape and will fail w/in 6months • Change / replace bushings
• Usually have 1 spare on site because can take up to 1 year to replace a • Information for the inspector
transformer
• Details
• Inspection cycle
• Location
• Usually have customer guys do regular checkups
• Designation
• Procedures followed:
• History
• IEEE or other testing standards followed

May 11, 2017 Slide 21

ABB’s Workforce Management System
Substation Inspection

Workflow and samples

May 11, 2017 Slide 22

ABB’s Workforce Management System
Substation Inspection

Workflow and samples

May 11, 2017 Slide 23

ABB’s Workforce Management System
Substation Repair

Workflow and samples

May 11, 2017 Slide 24

Agenda

What is a Substation?
Connected Asset Lifecycle Management
ABB’s Workforce Management System
 Challenges
 Inspection
 Maintenance
 Repair
Target Customer Profile
Glossary

May 11, 2017 Slide 25

Target Customer Profile

– Substation owners with:

• Ageing Substations (in need of upgrade or extend lifetime)
• Reliability issues / Unplanned outages (repeating)
• High cost of power interruptions
– Varying environment
• Inclement weather conditions
• Vegetation management
• Regulatory requirements

May 11, 2017 Slide 26

Agenda

What is a Substation?
Connected Asset Lifecycle Management
ABB’s Workforce Management System
 Challenges
 Inspection
 Maintenance
 Repair
Target Customer Profile
Glossary

May 11, 2017 Slide 27

Glossary

AIS – Air-Insulated Switchgear GIS – Gas-Insulated Switchgear

Bay – Substations have multiple bays. (Area within a substation) Back feed HMI – Human Machine Interface
compatibility. When switching need to ensure the bay has the capacity of IED – Intelligent Electronic Device
managing the extra load from another feeder
LTB – Live Tank Breakers
Circuit Breaker – used as a protection device to interrupt fault currents
automatically, and may be used to switch loads on and off, or to cut off a line NCIT – Non-Conventional Instrument Transformers
when power is flowing in the 'wrong' direction PASS – Plug and Switch System (Hybrid)
CT – Current Transformer PT – Potential Transformer
DCB – Disconnecting Circuit Breaker – provides the functionality of a circuit Switchgear – Combination of electrical disconnect switches, fuses or circuit
breaker and a disconnector combined in a single unit (Measurement / breakers used to control, protect and isolate electrical equipment.
Interruption / Isolation) https://en.wikipedia.org/wiki/Switchgear
Disconnector - (disconnect switch / isolator switch) - used to ensure that an VT – Voltage Transformer
electrical circuit is completely de-energized for service or maintenance
FOCS – Fiber Optic Current Sensors

May 11, 2017 Slide 28