SEPTEMBER 19, 2019

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DIGITAL SPECIFICATION PROGRAM

Minimizing Total Cost of Ownership

ANSI medium voltage switchgear
Terry Neighbours, Global Product Manager
—
Presenter
MV ANSI air-insulated switchgear

Terry Neighbours
Global Product Manager
Medium voltage ANSI metal-clad switchgear

Slide 2
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Agenda

Introduction
Magnetically actuated circuit breakers
Digital switchgear
Asset health monitoring
Total combined savings
Conclusion

Slide 3
—
Introduction
Key message

Deployment of innovative yet proven technologies can lead to substantial reduction in total cost of
ownership (TCO) of medium voltage switchgear with minimal increase in upfront (capital investment)
costs.

For this webinar we will focus on non-arc-resistant (NAR) switchgear.

Arc-resistant (AR) switchgear will be addressed at a future date.
For AR switchgear there are many more cutting edge technology options to reduce TCO.

Slide 4
—
Introduction
Defining ownership costs

For this webinar ownership costs will include:

– Initial investment costs
• Costs related to the specification, design engineering, procurement, installation and commissioning of ANSI
medium voltage switchgear
– Operating costs
• Costs related to the normal operation of the switchgear
– Maintenance costs
• Costs related to maintaining the switchgear, power circuit breakers, controls and auxiliary units to keep the
equipment operating as originally installed and intended
Other costs may be included in your specific business or applications, but only these are being considered in today’s
session. Does not include upgrade and revised load change costs or any downtime costs.

Slide 5
—
Introduction
Base configuration for sample calculation purposes

15 kV, 3000 A, Main-Tie-Main (MTM) non-arc-resistant switchgear configuration with four feeders for each bus, open delta PTs for each
incoming line and bus, three sets of CTs for each breaker and basic overcurrent protection. Considers three shipping sections of three
frames each.

Slide 6
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Magnetically actuated circuit breakers
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Magnetically actuated power circuit breakers
Savings methods
Breaker failures
All breakers have some level of failure rate.
Spring charge breakers have a higher
failure rate than magnetically charged.
Slide 8
Battery sizing
Significant battery size reductions
No inrush and low current draws allow the
ability to use 48 or 24 VDC battery systems
Additional benefits
Significantly increased personnel safety –
what is the value of human life?
No close, trip coils or spring charge motors
to keep in stock
Maintenance
Five years maintenance free
Reduced maintenance activities
– 5-year maintenance cycles
– Only one moving part in actuator
– Self-monitoring health condition
Cons
Slightly higher initial investment costs
compared to spring charged breakers (some
offset in reduced battery size)
Limited applications in cap switching, 63 kA
and generators
—
Magnetically actuated circuit breakers
Smaller battery systems

Spring charged breakers Magnetically actuated breakers

Spring charged breakers have charge, close or trip coils, which
have large inrush and operating currents, increasing the battery
ratings needed
– Charge current = 8.0 - 10.0 A; Inrush = 56.0 - 80.0 A
– Trip coil current = 2.0 - 3.0 A; Inrush = 12.0 - 24.0 A
– Close coil current = 2.0 - 3.0 A; Inrush = 12.0 - 24.0 A
Most battery systems utilize 125 VDC to keep these large inrush
currents low.
125 VDC Ni-Cd battery system investment cost = $7,820
Magnetically actuated breakers do not have charge close and trip
coils. They use capacitors for storing energy to activate the
magnetic actuators and opto-couplers for closing and tripping.
– Capacitors = 8.80 A to charge; Inrush = 8.80 A
– Trip coupler = 2.75 A to operate; Inrush = 2.75 A
– Close coupler = 2.75 A to operate: Inrush = 2.75 A
Due to decreased loads, battery systems can be 48 VDC, or even
24 VDC
48 VDC Ni-Cd battery system investment cost = $3,400

Substantial decreases in peak and continuous loads allows 48 or 24 VDC systems – costing significantly less than a
125 VDC battery system

Slide 9
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Magnetically actuated circuit breakers
Substantially less maintenance
Spring charged breakers
Estimated labor hours to maintain a spring charged breaker for
normal maintenance requirements is 8.4 hrs per breaker
– Frequency of the maintenance = once every year
– Normal life span of MV switchgear = 30 yrs
– Total number of maintenance operations = 30
– 30 x 8.4 hrs = 252 hrs x $100/hr labor cost = $25,200 per breaker
over the lifetime of the switchgear
– Does not include any costs related to outages due to
maintenance
A savings of $24,180 per breaker can be realized
Slide 10
Magnetically actuated breakers
Estimated labor hours to maintain a magnetically actuated
breaker is 1.7 hrs per breaker
– Frequency of the maintenance = once every 5 years
– Normal life span of MV switchgear = 30 yrs
– Total number of maintenance operations = 6
– 6 x 1.7 hrs = 10.2 hrs x $100/hr labor cost = $1,020 per breaker
over the lifetime of the switchgear
– Does not include any costs related to outages due to
maintenance
—
Magnetically actuated power circuit breakers
Estimated total possible savings
Investment costs
+$3,300 for magnetically
actuated vs spring charged
breaker w/5yr warranty
-$4,420 for battery system size
reduction from 125 VDC to 48
VDC (Ni-Cd)
Total net investment costs
= -$700 (savings)
Slide 11 Considers 30 year life span
Operating costs
Net sum zero
It is considered that the costs
to maintain a 125 VDC vs a 48
VDC system is equal
Operational costs of spring
charged vs magnetically
actuated breakers considered
equal
Maintenance costs
-$254,760 for breaker
maintenance over 30-year life
span for average 11 breakers
per MV switchgear line-up
Total cost savings
$254,060 total cost savings
using magnetically actuated
circuit breakers instead of
spring charged breakers
Considerations:
– Considers normal
maintenance. Further
savings realized if breaker
failures occur
– Considers utilizing smaller 48
VDC battery system in lieu of
125 VDC
—
Digital switchgear
—
Digital switchgear
What is digital switchgear?

61850

An enclosure for circuit switching,

interruption and control devices where
all measurements, device status
information and commands are reliably
transferred on a common
communication [61850] Ethernet bus.

Slide 13
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Digital switchgear
What is digital switchgear?

Digital switchgear Description Main switchgear value

1. Reduced weight
2. Space saving (primarily due to elimination of PT
CTs & PTs replaced with Current & compartments)
Level 1 Voltage Sensors + Asset health 3. Eliminates problems of saturation and
monitors ferroresonance
4. Safety – no possibility of open CT circuits
5. Condition based maintenance
Above + IEC61850-8-1 & GOOSE
Above +
messaging
Level 2 5. Significant reduction in wiring between frames
Ethernet cabling between
6. Late customization
Protective Relays.
Above + Process bus (61850-9-2LE)
Requires use of Merging Units
Above +
(MUs), time synchronization
Level 3 7. Improved flexibility – changes in protection only
devices & Ethernet switches.
require IED level changes.
Fiber optic connection from bay
(switchgear) to substation.

Slide 14
— Voltage sensors

Digital switchgear
What is digital switchgear?

Current sensors

= Conventional

= Digital

Slide 15
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Digital switchgear
Savings analysis

Conventional Digital
Reduction
switchgear switchgear

Length (in.) 324 288 11%

Estimated Weight (lbs.) 33,310 28,638 14%

Wiring (ft.) 2500 289 88%

# of Wire Terminations 910 76 92%

Manufacturing (hrs/fr) 135 75 55%

Slide 16
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Digital switchgear
Estimated total possible savings
Investment costs
-$45,000 – average cost of a
fully equipped non-arc-
resistant auxiliary unit frame (4
sets of PT auxiliary units &
frame structures)
-$16,000 eHouse/building
space savings and installation
commissioning savings
Additional cost benefits:
– No change order costs for
late stage load changes
– Reduced installation costs
due to significant wire
reductions
– Reduce weight = less cost of
structural support
Slide 17 Considers 30-year life span
Operating costs
-$19,200 decreased energy
watt loss. (30 yrs, 160 k KWH @
12c/KWH)
Additional operating benefits:
– Less wiring = higher
reliability
– Safer equipment – failure
modes do not promote
internal arcing faults
Maintenance costs
Net sum zero. In reality there
will be reduced maintenance
costs due to having one less
frame and no CT’s, PT drawers
Additional maintenance
benefits:
– Significant personnel safety
– No open CT secondary issues
– No PT compartments or PT
fuses to maintain or operate
– No ferroresonance in voltage
sensors
Total cost savings
$80,200 total cost savings
using magnetically actuated
circuit breakers instead of
spring charged breakers
Considers normal
maintenance. Further savings
realized if breaker failures
occur
Considers utilizing smaller 48
VDC battery system in lieu of
125 VDC
—
Asset health monitoring
—
Asset health monitoring
What is asset health monitoring (AHM)?

Real time 24x7x365 monitoring of several critical data Sensors

points for determining the health of the switchgear

Humidity Sensor
Breaker characteristics
– Trip/close coil monitoring Antenna for wireless
solutions
– Timing
– Contact wear Data concentrator &
processor
Switchgear condition
Power Supply Unit
– Bolted joint temperatures
– Internal humidity Local HMI

– Partial discharge activity Gateway for remote

connectivity

Slide 19
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Asset health monitoring
What is asset health monitoring?

Sensors for temperature, humidity & partial discharge monitoring

– Wired or wireless
– Preference for battery-less or self-powered sensors

EXAMPLES Temperature Partial Discharge

Conventional RTDs, IR sensors Per IEC 60270 – Coupling

capacitors, RFCTs
Non-conventional Fiber optic sensors Per IEC 62478 – e.g., UHF
Surface Acoustic Wave (SAW) measurements

Diagnostic algorithms – trends or remaining life estimation

Local HMI interface along with remote output to SCADA or other remote monitoring systems
Alarm set points for taking actions as determined by the user, local and/or remote

Slide 20
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Asset health monitoring
Calculated total possible savings
Investment costs
+$30,000 – purchase, install
and commission costs, three
shipping sections (includes
deduction for IR ports on rear
doors)
Slide 21
Operating costs
-$50,000 savings for one
planned outage for
maintenance
Additional operating benefits:
– Significant personnel safety
• 24x7 monitoring by the
system. Personnel do not
need to go to the
switchgear
– Significantly more savings
possible as more than one
planned outage is normally
made in the life span of the
switchgear
Maintenance costs
-$60,000 elimination of
thermography and PD
evaluation every 5 years or bus
joint torque testing
Additional operating benefits:
– Significant personnel safety
• No PD evaluations
• No thermography (no arc-
resistance during
thermography readings)
• No bus torque
measurements
• No need for personnel to
access switchgear
Total cost savings
$80,000 total direct cost
savings using asset health
monitoring
Considerations:
– Considers the savings of only
one planned outage
– Savings from personnel
injured in an arcing fault
during maintenance not
considered
– Does not consider the cost
of an unplanned outage due
to equipment failure that
could be prevented by AHM
—
Total combined savings
—
Total cost of ownership combined savings
TCO = Total Cost of Ownership

Conclusion Savings percentages using all three solutions

50%
TCO can easily be twice the original cost of
conventional switchgear (91% in this example) Savings compared to original switchgear TCO =
Most applications for medium voltage
switchgear can utilize all three of the Savings compared to original cost of switchgear = 94%
technologies presented
– This maximizes the reduction of the total cost Additional initial investment costs = $44.8k = 8.7%
of ownership significantly
– Can mix and match solutions to your Additional benefits
preference
Significant increase in personnel safety – what is the value of human life?
– Asset health monitoring and magnetically
actuated breakers easily retrofitted Reduced downtime, planned and unplanned outages
• Retrofit possible with digital switchgear, Lower operational costs
although more costly to do than other two Increased reliability
options

Slide 23
— Baseline Total Cost of Ownership
Added
Compared to Baseline

TCO savings detail Year

Conventional
($) Comment
initial
TCO Reduction Technology contribution cost ($)
Lifetime cost reduction
potential ($)
1 450,000 Initial cost, ADVANCE, CTs, PTs, ADVAC Mag actuated breakers 8,800
Estimation template 10,000 Transportation cost Mag actuation battery bank saving -4,420
5,500 Additional costs for 5yr warranty Mag actuation includes 5yr warranty -5,500
TEMP/HUM/PD condition monitoring
50,000 Install & commission cost - 5 shipping splits purchase, installation & commission 36,000
No IR ports due to above (=#breakers) -6,000
Digital (one frame less) -45,000
eHouse/building space cost saving
(=(36*95)/(12*12)*250) -6,000
I&C (1 shipping split less + less wiring) -10,000
5 7,000 Thermography & PD Evaluation -7,000
Conventional 10 7,000 Thermography & PD Evaluation -7,000
15 7,000 Thermography & PD Evaluation -7,000
9,000 CT testing (6 CTs/breaker), every 15 yrs? -9,000
20 7,000 Thermography & PD Evaluation -7,000
25 7,000 Thermography & PD Evaluation -7,000
30 7,000 Thermography & PD Evaluation -7,000
Sensors using less energy (30 yrs, 160K
9,000 CT testing (6 CTs/breaker), every 15 yrs? KWH @ 12 c/KWH) -19,200
Magnetically actuated breakers require
Annual spring charged breaker significantly less maintenance and on
277,200 maintenance per mfrs recommendations 5yr periods, not annually -254,760
Saving one planned outage due to CM -50,000
Digital Elimination of bus joint torque testing -18,000
w/AHM and magnetically actuated breakers 852,700 44,800 -469,880
Net -425,080
91% Cost % compared to original switchgear costs Savings % compared to original gear TOC 50%
Savings % compared to original cost of switchgear 94%

Slide 24
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Conclusions
Total cost of ownership minimized

– There are proven technologies available today that can significantly reduce the TCO for MV
switchgear
− In the example of the NAR switchgear shown, a 9% increase in upfront costs(~45KUSD) yields a
50% reduction (~425KUSD) in lifetime costs
– A major additional benefit is that they create a safer work environment
– The technologies covered were:
− Magnetically actuated breakers
− Digital switchgear
− Asset health monitoring

Slide 25