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10. Dependability of an electrical installation

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10. DEPENDABILITY OF AN ELECTRICAL INSTALLATION

The voltage at the terminals of a load is affected by phenomena originating either from the utility's network or the disturbed user's electrical installation. Abnormal operation and the cost of damage undergone depend on the type of loads and the critical level of the industrial process. Thus, a momentary critical load cut can have serious consequences on the industrial process operation without the load itself being affected. In other cases, the same disturbance can damage loads and be tolerated by the industrial process. For the design of an electrical network, a precise analysis of the effects of failures and disturbances which may occur must be carried out. Provisions must generally be taken in order to limit their consequences. Harmonic effects, flicker, voltage unbalance, frequency variations and overvoltages can be reduced by implementing network structures and equipment suitable to each case (see 3; 5 and 8). Power cut immunity also requires specific equipment such as uninterruptible power supplies and electrical energy generator sets (see 4). This equipment is generally not sufficient to solve all the problems. The network structure, the automatic supply restoration systems, the reliability level of equipment, the presence of a control and monitoring system, as well as the maintenance policy, all play an important role in reducing and eliminating power cut times. A complete analysis of the problem requires dependability studies taking into account all of these data as well as the occurrence and duration of power cuts allowed by the industrial process. These studies can be used to determine the structure and equipment most suitable for the needs of the plant. They generally require loads to be classed in relation to their sensitivity level and the following distinctions to be made: - loads allowing prolonged power cuts: 1 hour or more - loads having to be re-supplied after several seconds - loads unable to withstand any power cuts.

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Figure 10-1 shows a network example for which this distinction has been made: - vital loads unable to tolerate any power cuts are fed by an uninterruptible power supply - essential loads are re-supplied several seconds after utility network loss once the voltage and frequency of the generator set have been stabilised - priority loads are reconnected once the essential loads have been fully started again (generator set cannot instantaneously accept the whole load) - non-priority loads allow long power cuts and are only re-supplied when the utility network has been restored. Replacement source sizing with respect to operating requirements can be optimised if the right structure and automatic controls are chosen. Dependability studies can be used to determine the "minimum" structure meeting the power supply requirements of critical loads. It must also be remembered that the choice of neutral earthing system is also an important element. Thus, for loads requiring high availability, it is strongly advisable to choose an isolated neutral system (see 2).

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utility supply network

mains /standby can be shed cannot be shed cannot be shed can be shed for several minutes

UPS

. non priority loads . power cut of several hours

. essential loads . power cut of several seconds

. vital loads . no power cut

. priority loads . loads that can be shed for several minutes

Figure 10-1: network with loads classified in relation to their sensitivity to power cuts

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10.1 definition of terms relating to dependability (according to IEC 50 191)

Failure
The terminaiton of the ability of an item to perform a required function. Note: - after failure the item has a fault - "failure" is an event, as distinguished from "fault", which is a state - this concept as defined does not apply to items consisting of software only

Availability
The ability of an item to be in a state to perform a required function under given conditions at a given instant of time or over a given time interval, assuming that the required external resources are provided. Note: - this ability depends on the combined aspects of the reliability performance, the maintainability performance and the maintenance support performance - required external resources, other than maintenance resources, do not affect the availability performance of the item

Reliability (performance)
The ability of an item to perform a required function under given conditions for a given time interval. Note: it is generally assumed that the item is in a state to perform a required function at the beginning of the given time interval

Maintainability (performance)
The ability of an item under given conditions of use to be retained in, or restored to, a state in which it can perform a required function, when maintenance is performed under given conditions and using stated procedures and resources.

Maintenance support performance

The ability of a maintenance organization, under given conditions, to provide upon demand, the resources required to maintain an item, under a given maintenance policy Note: The given conditions are related to the item itself and to the conditions under which the item is used and maintained.

Preventive maintenance
The maintenance carried out at predetermined intervals or according to prescribed criteria and intended to reduce the probability of failure or the degradation of the functioning of an item.

Corrective maintenance
The maintenance carried out after fault recognition and intended to put an item into a state in which it can perform a required function.

Fault
The state of an item characterized by inability to perform a required function, excluding the inability during preventive maintenance or other planned actions, or due to lack of external resources. Note: a fault is often the result of a failure of the item itself, but may exist without prior failure.

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10.2 application areas of dependability studies

The studies can be carried out on all network types and on their control and monitoring system: - single fed network (see fig. 1-17) - dual fed network (see fig. 1-18 and 1-19) - loop network with automatic reconfiguration system (see fig. 1-20a) - double busbar network (see fig. 1-14, 1-15 and 1-16) - network with uninterruptible power supplies (see fig. 1-30, 1-31, 1-32, 1-33, 1-34 and 1-35) - network with automatic changeover systems (see 12.2.1) and load-shedding and restoration systems (see 12.2.3) - ...

They can be customised in relation to the requirements: - detail of the study - types of dependabiltiy criteria to be assessed - type of analysis

n detail of the study (see table 10-1) - a rapid study or pre-study is generally used to make a rapid structure choice - a very detailed study takes into account as many factors as possible; all the operating configurations, detailed analysis of possible faults and their consequences, network model as close as possible to its behaviour during a fault.
Pre-study Detail of hypotheses A single type of fault with average duration and occurrence Detailed study Faults divided into families depending on their effects on the installation The consequences of faults are analysed in detail

Detail of model

The consequences of faults are grouped into large families

Table 10-1: example illustrating the differences between a pre-study and a detailed study

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n types of dependability criteria to be assessed - the average number of operating hours before the first failure (MTTF: Mean Time To Failure) - the average number of hours between two failures (MTBF: Mean Time Between Failures) - the availability of power supply to a load. This is the probability of correctly supplying a load. This probability takes into account the frequency of faults and the duration of repairs - the average number of faults per year - the average repair time (MTTR: Mean Time To Repair) - the average time during which the system is unavailable during a fault (MDT: Mean Down Time). This includes the fault detection time, the maintenance service travel time, the faulty equipment procurement time and the repair time - the optimum frequency of preventive maintenance operations and the availability of the installation during these operations - the optimisation of replacement sets for maintenance. For example, for the electrical network in figure 10-1, we can calculate: - the probability that the generator set does not start on loss of utility supply - the optimum frequency of generator set tests - the average number of priority load power cut minutes per year - the average number of hours before vital loads undergo a power cut.

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n types of analysis - help with structure design by assessing dependability criteria (see fig. 10-2).
simplest structure

dependability criteria assessment

dependability criteria met yes

no

new structure

chosen structure

Figure 10-2: help with structure design

- comparison of structures (see fig. 10-3)

structure A structure B

dependability criteria assessment

dependability criteria assessment

structure A dependability criteria nearer to objectives

no

structure B chosen

yes

structure A chosen

Figure 10-3: comparison of two structures

- determination and analysis of structure dependability criteria.

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10.3 carrying out a dependability study

Carrying out a study requires a profound knowledge of the dependability area. Abnormal operation analysis software (Adelia, Sofia) and modelling software (Supercat, MOCA-RP) help experts to assess chosen dependability criteria.

10.4 example
A drinking water production plant supplies 100 000 m3 /day at low power 300 days/year and 200 000 m3/day at high power 65 days/year. The water production is ensured by four production sections, each able to supply 100 000 m3/day. Six types of load L1, L2 , L3 , L4 , L5 and L6 (pumps, disinfectors, etc.) which must operate simultaneously to ensure production, are associated with each section. We can thus mark the loads ensuring operation of each section as follows: L1a , ... , L6 a L1b , ... , L6b L1c , ... , L6c L1d , ... , L6d section n 1 section n 2 section n 3 section n 4

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n current network The current wiring diagram of the network supplying the loads used for production is shown in figure 10-4.

Figure 10-4: current wiring diagram of the network supplying the loads used for prodcution

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During normal operation, the switchboard MV1 is fed by "utility 1", the switchboard MV2 by "utility 2". In case of loss of one utility incoming feeder, the other feeder ensures the entire power supply. In case of loss of both utility incoming feeders, the generator sets start and are able to ensure the entire power supply. In case of loss of the transformer T1 , the transformer T2 ensures back-up and vice versa. In case of loss of transformers T 3, T 4 or T5 , the transformer T6 ensures back-up of the nonsupplied busbar. To ensure low power operation (100 000 m3/day), a single section is necessary, and for high power operation (200 000 m3/day), two sections are necessary. The plant has four production sections with numerous redundancies in the electrical supply. It should thus have a sufficient level of availability. Now, electrical installation faults have occurred, causing insufficient production. Indeed, the distribution of load power supply is such that availability is not very good. Thus, a fault on the busbar BB3 puts all L6 and L5 type loads out of service and no production section can operate. Similarly, a fault on busbar BB4 or BB5 puts the entire production system out of service.

n proposed solution To improve availability, we propose to group the loads differently so that the loss of a low voltage busbar only puts one production section out of service. Thus, the solution proposed is the network shown in figure 10-5.

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utility 1

G1

G2

G3

utility 2

switchboard MV1

switchboard MV2

20 kV T1 5.5 kV

20 kV T2 5.5 kV

5.5 kV 400 V section n1 L1a L2a

...

L6a

5.5 kV 400 V section n2 L1b L2b

...

L6b

5.5 kV 400 V section n3 L1c L2c

...

L6c

5.5 kV 400 V section n4 L1d L2d

...

L6d

Figure 10-5: wiring arrangement proposed to supply loads used for production
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However, this requires investment in equipment as eight extra 5.5 kV switches and two extra 5.5 kV circuit-breakers are necessary (6 LV circuit-breakers are taken away). This extra cost will be largely compensated by the very considerable gain in availability, as shown by what follows. The dependability study carried out has allowed us to compare the fault frequency and the availability of the new network and the old network. Furthermore, two specific studies have been carried out on the new network to optimise the frequency of generator set tests and compare the contribution of the MV part and LV part to faults.

o comparison of availabilities and fault frequencies of the two networks

The results are presented in the form of a comparison between the two networks. The old network serves as a reference and the availabilities and fault frequencies associated with it are taken to be equal to 1. The comparison of fault frequencies is shown in table 10-2. Old network Low power op. High power op. In total 1 1 1 New network 1/22 1/21 1/21

Table 10-2: comparison of the fault frequencies of the two networks

Overall, the faults causing insufficient production will be 21 times less frequent with the new network. The comparison of availabilities is shown in table 10-3. Old network Low power op. High power op. In total 1 1 1 New network 110 55 105

Table 10-3: comparison of availabilities of the two networks

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Overall, the availability is 105 times better with the proposed new network. The parameters determining availability are the fault frequency and repair time. A fault causes a reduction in availability which is all the greater the longer the repair time is. Non-availability thus reflects the loss of production. The gains made on availability are much greater than on the fault frequency since: - the fault repair times for the new network are shorter - during preventive maintenance operations on the new network, the availability is less degraded. We can also see that the availability difference is much greater for low power operation than for high power operation as the probability of losing the four sections on the new network is very low. However, the contribution of the low power operation availability is preponderant over the overall result as the plant operates mostly at a low power operation (300 days to 65 days).

o optimisation of generator set testing frequency

This study has only been carried out on the new network The curve in figure 10-6 shows the impact of the generator set testing frequency on the probability that the generator sets are unavailable when they are required. This probability takes into account all of the events which may occur during starting. It has been fixed at random at 1 for a test frequency of one month. The curve in figure 10-6 shows that there is a minimum unavailability point for a test frequency of 6 months. We can see that a higher test frequency does not improve the availability of the sets but, on the contrary, degrades it as, during testing, the generator sets are not available. We can thus advise the customer to carry out tests on the sets every 6 months.

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generator set unavailability probability 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 1 month 1.5 0.9 test frequency 4.9

4.6

6 months

1 year

2 years

5 years

Figure 10-6: probability that the sets are unavailable in relation to the testing frequency

o calculation of the MV part and LV part contribution to fault events

These calculations have only been carried out on the new network. They have shown that the MV part has a much greater contribution than the LV part, roughly 99.9% to 0.1 %, and as much for low power operation as for high power operation. Preventive maintenance must therefore be particularly thorough on the MV part of the network. Finally, it is advisable to implement a control and monitoring system on the MV part in order to monitor the state of the installation and check electrical equipment maintenance.

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CHAPTER 10 BIBLIOGRAPHY

n standards
o

IEC 50 (191) (1990): international electrotechnical vocabulary. Chapter 191: dependability and quality of service IEC 812 (1985): analysis techniques for system reliability - Procedure for failure mode and effects analysis IEC 863 (1986): presentation of reliability, maintainability and availability predictions

n Schneider cahiers techniques

o o

Introduction to dependability design, Cahier Technique n 144, P. Bonnefoi High availability electrical power distribution, Cahier Technique n 148, A. Longchamp,
G. Gatine

o o

Dependability of MV and HV protection devices, Cahier Technique n 175, M. Lemaire Industrial approach to dependability, Cahier Technique n 134, H. Krotoff

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