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  • 1. Flanders Electric – Engineering Division Welcomes You to an Overview of Reconditioned Switchgear
  • 2. Reasons for Reconditioning Switchgear Cost Savings Reuse material Buswork Building/enclosure Components Energy Efficiencies Shorter Production outages often required with switchgear upgrades
  • 3. Technology Upgrade Obsolete Parts Replacement Vacuum Contactors/Breakers Solid State Protection Web Enabled Power Monitoring Equipment (wireless Ethernet) Reasons for Reconditioning Switchgear – con’t Environmental Considerations Removal of Equipment From Old Mines More Energy Efficient Components
  • 4. Meggar/Hi Pot Line and Load Conductors Visually inspect for hot spots/fluid leaks etc. Thoroughly Clean Compartment Remove: Dirt, Rocks, Excess oils, Rodent infestation Inspect all components for excess wear and damage Basic inspections/cleanings on all components Visually inspect all Connections – i.e. Power Cable Clamps (draglines) Fuse Clips (loose, corrosion) Inspect Insulators, Bushings and Surge Arrestors
  • 5. For Load Break Switches Adjust and lubricate linkages as necessary Clean and Calibrate Electro-Mechanical Protection Devices (if not being replaced) Oil Analysis where necessary Basic inspections/cleanings on all components (con’t)
  • 6. Technology Upgrades Typically Recommended Change OCB’s (Oil Filled Circuit Breakers) to Vacuum Circuit Breakers Replace Capacitive Trip Devices – Depending upon Age Change Electro-Mechanical Overload protection devices to Solid State – Improve Repeatability and Accuracy
  • 7. Replace low voltage, air contactor size 4 and above with vacuum contactors and any medium voltage with vacuum contactor -Improves contactor life (number of cycles) -Minimizes effect of environmental elements on contacts Replace old lighting with more energy efficient lighting -High pressure sodium or Metal Halide on outside -Replace incandescent lights with fluorescent bulbs in sockets Technology Upgrades Typically Recommended (con’t)
  • 8. Safety Related items – must do Upgrade all receptacles to GFCI type Install new safety signage/warning labels Simulate all Ground Faults Repair all door interlocks per MSHA Check Ground Monitor (Coal Mines)
  • 9. Standards Followed National Electrical Code Mining Safety and Health Administration UL/c UL – Underwriters Laboratory ANSI – American National Standards Institute NFPA 79 – Electrical Standard for Industrial Machinery EIA RS821 – Electronics Industries Assoc.: Construction Standards
  • 10. Just a few examples
  • 11. EXAMPLES – 1 BEFORE
  • 12. EXAMPLE - 2
  • 13. EXAMPLE -3 INSTALLATIONS
  • 14. EXAMPLE 4
  • 15. EXAMPLE -5
  • 16. EXAMPLE – 6 BEFORE
  • 17. EXAMPLE – 7 AFTER
  • 18. Example # 1 Medium Voltage Pump Sub Specifications 7200/480Y, 225KVA Description of operation - Transformer and Breaker to Feed Pumps for Water Removal
  • 19. Material Cost $6,500.00 Repair Load Switch Replace two 480VAC Breakers Labor cost $1,200.00 Total Cost $7,700.00 Example # 1 Medium Voltage Pump Sub Summary Estimated Cost of new $30,000
  • 20. Example # 2 OCB – Vacuum Retrofit Specifications Voltage: 7200VAC Current: 400 Amp Description of Operation – Dragline Contactor for Motor Starting with Overload and Ground Fault Protection
  • 21. Material Cost $9,000.00 Labor cost $1000.00 Total Cost $10,000.00 Example # 2 OCB - Vacuum Retrofit Summary Other Savings/Benefits: Installation of new contactor during normal outage time. Estimated Cost of new Switchgear: $55,000.00
  • 22. Example # 3 Portable Breaker House Specifications Voltage: 4160 VAC Current: 1200 Amps Description of operation – Converted 7200VAC Portable Breaker House to 4160 Line Drop Station
  • 23. Items Replaced (2) Potential Transformers (PT’s) (3) 5kV Bushing Assemblies Labor cost $8,000.00 Total Cost $13,000.00 Example # 3 Portable Breaker House Summary Estimated Cost of new $50,000.00 Material Cost $5,000.00
  • 24. Example # 4 - 3 Way Switch House Specifications Voltage 7200 VAC Current 400 amps Description of operation - Switches to Provide Alternative Feed for Distribution. Single Main to 3 feeds
  • 25. Material Cost $900.00 Mechanical Interlocks Calibration Labor cost $1,000.00 Total Cost $1,900.00 Example # 4 3 Way Switch House Summary Estimated Cost of new $25,000.00
  • 26. Example # 5 Large Portable Substation Specifications Voltage 23,000VAC Current 1000 amps Description of operation - Power Feed and Distribution to Dragline
  • 27. Items Replaced Replaced 25KV OCB Contacts and Changed Oil Ground Monitor GE Potential Transformer Labor cost $11,000.00 Total Cost $27,000.00 Example # 5 Large Portable Switchgear Summary Estimated Cost of new $75,000.00 Material Cost $16,000.00 (includes purchase of used skid)
  • 28. Questions ???