Evolution of technology in low voltage power distribution is very dynamic. The developmental changes are in fast pace. As a customer it becomes very important in ensuring following points are taken care prior to selection of products which they wish to use in their projects.

– Product life cycle– Common spare parts– Product upgradability– Strategy to extended system lifetime– Retrofit solution for obsolete systems/any other

manufacturer’s installation

In this paper we will analyze critical aspects of product life cycle and retrofit solutions that can improve system efficiency with less down time.

When an air circuit breaker is selected, one needs to check the life of the product. It is very important factor to check both mechanical and electrical life of the circuit breakers. These two parameters play an important role in ensuring return on investments. These data can be obtained from published technical catalog of the manufacturer.

One of the important aspects here is to analyze the life of the circuit breakers which is published in the catalog with some preconditions. In case there are no preconditions, it is always advised that the user demands an installation manual where life expectancy of products is clearly defined with all necessary conditions. The same may be missing in the published catalog due to space constraints.

When detailed analysis is done with installation manual, one can easily tabulate the actual life of the circuit breaker. Normally when life is declared, installation manual also carries information on list parts which needs to be replaced at a specific interval. There is possibility that lot of parts needs to be replaced (indicated in installation manual) to reach life indicated in catalog. What is important is to consider life without replacement of parts when typical product comparison is being done. In case of similar comparison is not carried out, there is possibility that one will be paying higher price for circuit breakers with average performance.

Another important aspect to be considered during the product selection process is common spare parts (like arc chambers, main contacts). This is due to fact that manufacturers might

have different range of circuit breakers. Each type may have different type of spare parts. When two different series of products are used in same project, increases burden on user to keep different set spare parts and maintenance team needs to be trained two or three series of circuit breakers.

Product upgrading is another important parameter which is to be taken into consideration. With modularity, it will be possibility to upgrade protection functionality of the circuit breakers.

Strategy to extend system efficiency and system lifetime is key element which needs to be addressed at the right time. It is important to limit in-panel temperature within prescribed values (preferably well below this value) in low voltage systems.

Temperature effects the life time of switching devices. Thermo graphic analysis in regular intervals (as recommended bymanufacturer) provides insight into expected problem and enables user to take preventive measure.

Harmonics due to nonlinear loads is one key factor which influences heating of equipment and cables. It is advisable to ensure right solution is used in rich harmonic environment. Selection of harmonic filter can only be done once the harmonic study of electrical system is completed. It is not advisable to install any harmonic filters without harmonics analysis.

Product Life cycle and Retrofit solutionsTechnical journal – April, 2013

The service teams in ABB’s low voltage breakers and systems focus on keeping your breakers in optimum condition, ensuring maximum reliability and up-time. ABB’s retrofit service improves the electrical and mechanical performance of breakers by replacing obsolete components with modern equivalents. All of which is carried out using special replacement kits or bespoke engineered solutions. A retrofit preserves the existing switchboard’s condition and reduces the breakers’ downtime. Utilizing life cycle management practices, installations can have their serviceable lifespans significantly increased.

Any replacement of obsolete equipment can be made using retrofit kits, specifically designed by ABB to preserve the existing frameworks and to minimize downtime. The use of the retrofitting kits provides several advantages:– restoring the status of the life cycle of the switchboard– maintaining the original configuration of the switchboard

equipment and installation– Improvement of safety and reliability– Ease of maintenance and functionality of the system– Low investment costs compared to those required for the

installation of a new switchboard– Planned scheduling and implementation with minimum

downtime– Cost reduction of maintenance and repairing– Full interconnectivity with the existing distribution systems– Easy and safe replacement– No structural changes– Adaptations to auxiliary circuits– Greater control of plants with new electronic protections– Upgrading of the switchboard with new technology implies

economic benefits as regards maintenance and spare part costs

Typical retrofit solutions includes1.RetrofillThe “simple” solution: the existing fixed part is removed from the switchboard and the new one is installed using a pre-designed bus bar connection and protection shields.

2. Cradle in cradleThe existing fixed part remains in place and the new one is installed inside it.

3. ReplacementRetrofit new range of moving part into fixed part of old series of circuit breakers (possible with few series of old range of ACB’s)

The new moving part is modified to fit the existing fixed part, that remains unchanged. This is the faster solution for the installation, but the most elaborate one.

Retrofit of old series of ABB / Non ABB circuit breakers with new range circuit breakers including bus bar fabrication.

Existing fixed part

Emax X1 fixed part

4. Fault prevention with Thermo graphic solutions Why ABB?It is natural for any administrator / manager that the investment made in equipment would last long without requiring the need for frequent modification / changes. Uninterrupted long term service would lead any industry to profitability and reputation and this has bearing on the switchgears / equipment employed in the plant. It’s our goal to protect investments of our customers beyond the ordinary Life Cycle of the installed products; for this reason we inform you that ABB’s Products Group for low voltage breakers has decided to join the ABB Life Cycle Management Policy.

Product Life Cycle Management (LCM) is a term used for the process of managing the entire lifecycle of a product from its conception, through design and manufacture to service. LCM is a set of capabilities that enable an enterprise to effectively and efficiently innovate and manage its products and related services throughout the entire business lifecycle.

In a process industry where power blackout is very expensive, periodic thermo graphic analysis can be carried out to analyze critical hot spots. With this analysis, preventive maintenance planning can be done.

5. ABB’s retrofitting solutions ABB offers retrofitting solutions for complete panels in old installation new panels. ABB is fully equipped with all necessary tools to carry major activities at site with clear focus on least down time.

The solution of switchboard offered complies with international standards IEC 60439 for type tested assembly. The switchboard also complies with internal arc containment in accordance to IEC 61641.

ABB provides retrofit solutions for old LV installations of any other manufacturer. Tailor made solution provides significant benefits in terms less down time and expensive spare parts of old products.

Customer support over the lifecycle and beyond

Active Classic Limited Obsolete

Selection

Dimensioning

Installation

Commissioning

Training & e-Learning

Technical Support & remote service

Parts & repair

Maintenance

Replace & recyclingRebuildor replace

Operate andmaintain

Start-up

............................................ Lifecycle Services .............................................

Availability of service offerings is subject to local market conditions.

Contact us Toll-free number: 1800 420 0707Email: lp.contactcenter@in.abb.com