reliability management services

MARCH 2017

Reliability Management ServicesSubstation Risk Assessment & LifeStretchTM

Peter Lokang, Regional Business Development Manager

Reliability Management ServicesAgenda– Background– Reliability Management

– Substation Risk Assessment– Substation LifeStretch™

– Case study– Summary & Conclusion

Typical economical lifespan of major HV electrical equipment

Substation establishment 50-60 years

Power transformers 45-50 years

Capacitors 40 years

Circuit breakers 45 years

Instrument transformers 45 years

Control & Protection systems 15-30 years

SCADA systems 15 years

Telecommunication 10-12,5 years

Transmission lines 45-60 years

Transmission cables 40-45 years

April 18, 2017 Slide 3

The greatest challenges that utilities faceCredit: Utility Dive

Reliability Management ServicesBackground

Source: Sinclair Knight Merz (SKM)Economical lifespan: Period over which an asset (machine, property,computer system etc.) is expected to be usable, with normal repairs andmaintenance, for the purpose it was acquired, rented or leased for – usuallyless than the asset’s physical lifetime.


Deferred maintenance is a global phenomenon. Life goes on, but expected lifetime is not likely to be reached…Deferred maintenance is a global phenomenon. Life goes on, but expected lifetime is not likely to be reached…

Reliability Management ServicesBackground

Asset Management is a balance act where different factors needs to be considered

– New expected lifetime

– Health and Safetyaspects

– Functional specification

– Remote monitoringfeatures

– …

– Substation risk profile

– Expected mean timebetween failures

– Expected mean time torepair

– Unplanned outagesduration

– Unplanned outagesfrequency

– Substation availability

– Initial investment

– Substation Lifecyclecost

– Cost of powerinterruption

– Operation andMaintenance cost

Reliability Management Services

Overview


Substation Risk Assessment

Substation assessment is essentially a risk assessment ofsubstations based on component condition evaluation andimportance analysis

Substation assessment is a visual inspection only, and doesnot require equipment outage

Objective is to provide owner a decision base for planningfuture investments

The result is presented in a technical report, outlining thefollowing:§ Current situation

§ Identified risks and related consequences

§ Recommended actions, e.g. diagnostics, maintenance, upgrading,replacement, etc.

§ List of priorities, based on calculated risks

The process in RISE (Reliability Improvement through Substation Enhancement)



Modeling of the current Substation



Risk evaluation in RISE



During the site visit:

q Conduct visual inspectionof each components

q Interview the client about:

- Maintenance practices

- Reliability issues

- Historic events

- Availability of spares

- Impact of equipmentoutage

q Complete conditionassessment of eachcomponent using thetablet software



Visual Inspection

Tablet app for data collectionand condition assessment

- Guided process to performassessment

- Data collection based ontablet app:

Tablet-PC

Risk Calculation

Risk calculation based oncondition assessment and

reliability analysis

- Condition assessment basedon ABB Assessment criteria

- Components importancecalculated according itscontribution to outages rate

- Risk calculation based onpublic reliability libraries

Risk analysis

Technical Report

Automated report generator

- Value protection via reportcontent management

- Report auto generated

Report Generation

ResultSpecific

conclusion

- Riskassessmentresult

- Recommendedactionsprioritized

Report

LifeStretch™ - trademarked product of ABBCustom tool with proprietary algorithms developed to supportABB’s systematic approach to economically improving substationreliability

LifeStretch™ utilizes information gathered during SubstationAssessment to provide structured customer support to selectoptimal substation life extension solution

Reliability Model for Existing Substation Based On:

ABB developed algorithm for adjusting equipment reliability data– Utilize reliability data from open sources (CIGRE, IEEE, CEA,

and local data if available from customer)

Create reliability model for existing substation as basis forevaluation– Rank substation components using the following criteria:

1. Contribution to overall reliability2. Contribution to reliability of specific feeders/loads3. Economic impact of lost revenues

Substation LifeStretch™

Single line diagram

Equipment lists

Manufacturer, type

Year of installation

Identification no.

Failure & Service history

As preparatory measure, the scope must be clearly defined and relevant information received

Substation info.

Substation LifeStretchTM

More accurate information at this stage will enable higher efficiency on siteMore accurate information at this stage will enable higher efficiency on site

Cond

ition

Importance

Importance is calculated based on:

– Economical factors for the user– Loading, connection, topology– Equipment failure mode and effect analysis– Reliability modelling of the substation

(MTBF, MTTS, MTTR, … )– Data from Open Sources – CIGRE, IEEE, CEA

Condition is evaluated based on:

– Application and design– Environment– Number of operations and short circuits– Operational experience– Maintenance program– Availability of spare parts and expertise– Personal safety

Risk Matrix is a combination of Equipment Condition and calculated Importance (FMEA)Risk Matrix is a combination of Equipment Condition and calculated Importance (FMEA)


18 April 2017

Multi-objective tailored criteria to be modelled to fit specific needs.

Economic Analysis Substation Reliability Technical Quality

The comparison criteria must be done prior to the identification of potential technical solutionsThe comparison criteria must be done prior to the identification of potential technical solutions


Description of Solution #1: Description of Solution #2:

Replace components presenting poor condition to reduce MTBF.

Spare parts acquisition for critical HV CBs to impact MTTR

MV SS configuration change to increase redundancy and reducecriticality of MV components.


Existing Substation Solution #1 Solution #2

Current installation risk snapshotenables asset risk management.

High risk components replaced toreduce risk and improve reliability

MV component importance reduced byadding redundancy into the system.

Methodology provides collaborative approach to make the right investment choice.Methodology provides collaborative approach to make the right investment choice.




Requirements analysis

Substation risk analysis Definition of alternatives ConclusionsReliability analysis

Substation Assessment

Design comparison criteria

Identify technical solutions

Design reliability models

LifeStretch result analysis

Selecting the optimal solution

Action plan agreement

Tailored Benchmark criteria

Condition AssessmentABB assessment criteria toevaluate the condition ofthe substation components

Importance calculationAnalysis of the impact of acomponent malfunction

Recommended riskmitigation plan developedaccording the assessedsubstation risk

Substation Risk Analysis

Prioritization of therecommendedactions to optimizeinvestments

ABB technicalrecommendations

- Life cycle cost- MTBF- O&M Cost- Initial investment- Interruption cost

Technical solution #1



Selecting the optimal solution

Compare the solutionsaccording a multi-objectivecriteria focused on yourdecision process.

Selecting the optimal solutionbased in a quantitative analysisof pros and cons of thealternatives

Technical benchmarkingConclusion and Recommendation

Comparison oncriteria

Substation LifeStretch™

Case study



Customer NeedsDecision base for the future of an aged and worn-out substation havingobsolete equipment – rehabilitation or scrap and build new

ABB’s ResponseRisk assessment to define current status, identify risks and giverecommendations of improvement actions, reliability calculation and LifeCycle Cost comparison of five alternative solutions resulted in:• Major rehabilitation program, e.g. overhaul/retrofit of GIS,• Overhaul of power transformers,• Replacement of AIS components,• Modernization of protection and control etc.

Customer Values and Benefits• LifeStretchTM analysis proved rehabilitation program to be the totally

most favorable solution• Comprehensive technical screening of the entire substation• Customer was given five possible solution and could the most optimal• Sustainability and reduced CAPEX – Lifetime extension of substation

through adequate and right on time maintenance actionsCustomer: Ministry of Electricity, IraqSubstation: Babil 400/132/11kV S/SYear of construction: 1987 by ASEA

Case study



Customer: Substation, USASubstation: 34,5/4.16kVYear of construction: 1996

Customer NeedsDecision base for the future demand and challenges to improve boththe availability and Reliability of the power distribution system.

ABB’s ResponseRisk assessment to define current status, identify risks and giverecommendations of improvement actions, safety related andreliability study on the entire power system

Customer Values and BenefitsComprehensive technical screening of the entire power systemSustainability and reduced CAPEX – Lifetime extension of substationthrough adequate and right on time maintenance actions

Case study



Component Risk MatrixThe risk of each component type is shown both in a risk matrix and apriority list in xl. The priority list can be used to filter each componenttype with the highest risk, condition or importance depending

RecommendationPerform a reliability study on the entire power system.Condition monitoring on key assetsTrainingSpare partsEtc.

34.5/4.16kV PowerTransformers

34.5kV Circuit Breakers 34.5kV Disconnect Switchesand Earth Switches

34.5kV VoltageTransformers

34.5kV Surge Arresters 34.5kV Cable Circuits

© ABB GroupApril 18, 2017 | Slide 26

Extending substation life based on:

ØEvaluation of the current substation conditionfrom equipment and system perspectivesØProposing different solution for substation life

extensionØEvaluating reliability for each of the proposed

solutionsØEvaluating the cost related to each of the

proposed solutionØSelecting an optimal customized solution

depending of the specific customerrequirementsØMake a decision based on reliability and related

cost

Summary & Conclusions

Collaboration process to find the optimal solutionCollaboration process to find the optimal solution

© ABB GroupApril 18, 2017 | Slide 27

Substation LifeStretchTM includes:– Low cost investment with high value

to asset owners

• Offering clear options for planningand improvement

– Short turnaround time for service

• Including data gathering, site visit,and meetings to finalize thereports

– Visual inspection of all substationequipment & key components

• No equipment outages necessary

– Final report describing the optimalsolution considered

• Multiple criteria's based onreliability and economical analysis

Summary & Conclusions

Comprehensive report provided including explanation of results achievedComprehensive report provided including explanation of results achieved

reliability management services

Documents